Claas Scorpion Repair Manual For 9040, 7045, 7040, 7030, 6030

SCORPION
9040 (404-03)
7045 (403-03)
7040 (402-03)
7030 (401-03)
6030 (400-01)
Repair Manual
The telehandlers described in this manual are to be used only for agricultural and related applications. This is the designated use they are
to be put to.
If the machine is modified without the prior written consent of CLAAS, or if it used in a way which does not correspond to the designated
use, or if the machine is not driven or serviced correctly, the firm shall not assume any responsibility whatsoever for injuries or damage
(both direct damage and consequential damage).
Strictly observe the procedures regarding operation and maintenance described in this manual.
Moreover, use original CLAAS spare parts only. In the event that no original spare parts are used, the machine guarantee shall be void in
case of damage resulting from failure to use original spare parts.
Exclusively built for CLAAS KGaA mbH by
KRAMER-WERKE GmbH Nussdorfer Str. 50 D-88662 Überlingen/Germany.
Table of contents
Table of contents
Table of contents
Machine specifications: overview 1
Machine outside view .............................................................................................. 1-1
Inside of cab: overview ............................................................................................ 1-2
Instrument panel, multifunctional lever, switch consoles: overview ......................... 1-3
Important information on this manual ...................................................................... 1-4
Abbreviations/symbols ....................................................................................... 1-4
Model and trade names: overview ........................................................................... 1-4
Type labels and component numbers ...................................................................... 1-5
Serial number .................................................................................................... 1-5
Cab number ....................................................................................................... 1-5
Engine number .................................................................................................. 1-5
Hydraulic pump number .................................................................................... 1-6
Variable displacement motor number ................................................................ 1-6
Variable displacement motor number (high speed option) ................................ 1-6
Front and rear axle numbers ............................................................................. 1-6
Frame ...................................................................................................................... 1-8
Engine ...................................................................................................................... 1-8
Oil/water cooling fan ................................................................................................ 1-9
Power train ............................................................................................................... 1-9
Variable displacement pump ............................................................................. 1-9
Variable displacement motor ............................................................................. 1-9
Axles ...................................................................................................................... 1-10
Front axle ......................................................................................................... 1-10
Rear axle ......................................................................................................... 1-10
Service and parking brake ..................................................................................... 1-11
Steering system ..................................................................................................... 1-11
Work hydraulics ..................................................................................................... 1-12
Hydraulic pump ................................................................................................ 1-12
Hydraulic ram protection .................................................................................. 1-12
Lift, tilt and push-out rams: velocity ................................................................. 1-13
Hydraulic pilot control ...................................................................................... 1-13
Additional control circuit (option) ..................................................................... 1-13
Electric system ....................................................................................................... 1-14
Fuses: overview ............................................................................................... 1-14
Electric components ........................................................................................ 1-15
Main fuse box with relays (88 kW diesel engine) ............................................ 1-16
Main fuse box with relays (103 kW diesel engine) .......................................... 1-16
Relays: overview ............................................................................................. 1-17
Tyres for models 400-01/401-03/402-03/403-03 ................................................... 1-18
Tyres for model 404-03 .......................................................................................... 1-18
Weights .................................................................................................................. 1-19
Noise levels ........................................................................................................... 1-19
Vibration ................................................................................................................. 1-19
Coolant compound table ........................................................................................ 1-19
Tightening torques ................................................................................................. 1-20
General tightening torques .............................................................................. 1-20
Specific tightening torques .............................................................................. 1-20
Trailer couplings: trailer weight/drawbar load ........................................................ 1-20
Payload: model 400-01 load diagram .................................................................... 1-21
Payload: models 401-03 load diagram .................................................................. 1-22
Payload: model 402-03 load diagram .................................................................... 1-23
Payloads: model 403 03 load diagram .................................................................. 1-24
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Payloads: model 404 03 load diagram ................................................................... 1-25

Rigid front axle without oscillating axle interlock (rear axle) ............................ 1-25
Rigid front axle with mechanical or hydraulic oscillating axle
interlock (rear axle) .......................................................................................... 1-26
Front axle with frame levelling and without oscillating axle
Front axle with frame levelling and hydraulic oscillating axle
Dimensions with bucket ........................................................................................ 1-29
Dimensions with pallet forks .................................................................................. 1-30
Maintenance and servicing work 3
Explanation of symbols on the maintenance label ................................................... 3-1
Maintenance label .................................................................................................... 3-2
Fluids and lubricants: overview ................................................................................ 3-3
Maintenance plan (overview) ................................................................................... 3-4
Introduction .............................................................................................................. 3-8
Safety prop for telescopic boom .............................................................................. 3-8
Fuel system .............................................................................................................. 3-9
Specific safety instructions ................................................................................ 3-9
Refuelling ........................................................................................................... 3-9
Stationary fuel pumps ........................................................................................ 3-9
Diesel fuel specification ................................................................................... 3-10
Checking/replacing the fuel prefilter (water separator) .................................... 3-10
Replacing the fuel filter .................................................................................... 3-11
Bleeding the fuel system .................................................................................. 3-12
Engine lubrication system: maintenance ............................................................... 3-13
Checking the engine oil level ........................................................................... 3-13
Filling up engine oil .......................................................................................... 3-14
Replacing the engine oil every 500 s/h (service hours) ................................... 3-15
Replacing the engine oil filter cartridge every 500 s/h (service hours) ............ 3-16
Maintenance of the engine and hydraulics cooling system .................................... 3-17
Specific safety instructions .............................................................................. 3-17
Checking the coolant level and quality ............................................................ 3-18
Filling up coolant .............................................................................................. 3-19
Draining coolant ............................................................................................... 3-20
Cleaning the radiator fins ................................................................................. 3-21
Cleaning the radiator with the reversing fan (option) ............................................. 3-22
Air filter maintenance ............................................................................................. 3-23
Checking air filter contamination ...................................................................... 3-23
Replacing the filter cartridge at 500 s/h (service hours) .................................. 3-24
Maintenance: V-belts ............................................................................................. 3-25
Checking V-belt tension ................................................................................... 3-25
Retightening the V-belts .................................................................................. 3-25
Gearbox and axle maintenance ............................................................................. 3-26
Checking the oil level in the gearbox ............................................................... 3-26
Filling up the gearbox oil .................................................................................. 3-26
Changing the gearbox oil ................................................................................. 3-27
Rear axle differential oil level ........................................................................... 3-28
Draining the oil in the rear axle differential ...................................................... 3-28
Front axle differential oil level .......................................................................... 3-29
Draining the oil in the front axle differential ...................................................... 3-29
Planetary drives: checking and filling up the oil level ....................................... 3-30
Changing the oil ............................................................................................... 3-30
Safety instructions regarding the hydraulic system ................................................ 3-31
Monitoring the hydraulic oil and the reflux filter ...................................................... 3-32
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Checking the hydraulic oil level ............................................................................. 3-32

Filling up hydraulic oil ............................................................................................ 3-33
Replacing the reflux filter of the hydraulic system ................................................. 3-33
Replacing the microfilter of the hydraulic system .................................................. 3-33
Replacing hydraulic oil ........................................................................................... 3-34
Important information for the use of biodegradable oil .......................................... 3-35
Checking hydraulic pressure lines ......................................................................... 3-36
Lubrication work ..................................................................................................... 3-37
Central lubrication system (option) .................................................................. 3-37
Lubricating the rear axle oscillation-type bearing ............................................ 3-37
Lubricating the planetary drive bearing ........................................................... 3-37
Lubrication points on the telescopic boom: overview ...................................... 3-38
Lubricating the telescopic boom ...................................................................... 3-38
Checking the slide plates ................................................................................. 3-38
Setting the lubrication and break times ........................................................... 3-39
Filling the central lubrication system ................................................................ 3-39
Maintenance of the brake system .......................................................................... 3-40
Checking/filling up the brake fluid level ........................................................... 3-40
Bleeding the hydraulic powerbrake ........................................................................ 3-41
Replacing/bleeding the service brake fluid with bleed equipment ......................... 3-42
Bleeding the trailer brake valve (option) .......................................................... 3-43
Bleeding the parking brake .............................................................................. 3-43
Maintenance: compressed-air brake system (option) ............................................ 3-44
Checking the compressed-air tank and lines ................................................... 3-44
Checking the compressor attachment and drive ............................................. 3-44
Tyre maintenance .................................................................................................. 3-45
Daily tyre checks ............................................................................................. 3-45
Changing wheels ............................................................................................. 3-46
Heating and ventilation maintenance ..................................................................... 3-47
Cleaning/replacing the fine-dust or active charcoal filter (option) .................... 3-47
Cleaning/replacing the recirculated-air filter .................................................... 3-47
Air conditioning (option): maintenance .................................................................. 3-48
General safety instructions for maintenance of the air conditioning system .... 3-48
Functional and visual check ............................................................................ 3-49
Emptying/filling up the air conditioning system ................................................ 3-50
Replacing the air conditioning compressor ...................................................... 3-50
Maintenance of the electric system ....................................................................... 3-51
Specific safety instructions regarding maintenance and servicing .................. 3-51
Service and maintenance work at regular intervals ......................................... 3-51
Cables, bulbs and fuses .................................................................................. 3-52
Alternator ......................................................................................................... 3-52
Adjusting the headlights when using lightweight material buckets .................. 3-52
Adjusting the headlights .................................................................................. 3-53
Adjusting the headlights when using a lightweight material bucket ................. 3-53
Checking/replacing the battery ........................................................................ 3-54
Maintenance: trailer coupling ................................................................................. 3-55
Rockinger trailer coupling ................................................................................ 3-55
General maintenance work on the machine .......................................................... 3-56
Specific safety instructions regarding maintenance and servicing .................. 3-56
Cleaning inside the cab ......................................................................................... 3-57
Cleaning the seat belt ............................................................................................ 3-57
Cleaning the exterior of the machine ..................................................................... 3-57
Checking screw connections ................................................................................. 3-57
Checking pivots and hinges ................................................................................... 3-57
Cleaning the engine compartment ......................................................................... 3-58
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Maintenance and servicing work “Aggressive Media” ............................................ 3-59

Anticorrosion protection applied in the factory ................................................. 3-59
Safety instructions for maintenance of anticorrosion protection ...................... 3-60
Measures for maintaining anticorrosive protection .......................................... 3-60
Applying the protective anticorrosion coating .................................................. 3-61
Treatment of oxidised surfaces ........................................................................ 3-61
Maintenance and servicing of attachments on the quickhitch ................................ 3-61
Engine 4
Electric system/hydraulics – fan: electric diagram ................................................... 4-1
88 kW diesel engine electric system: electric diagram ............................................ 4-3
103 kW diesel engine electric system: electric diagram .......................................... 4-5
Fuel preheater (option): electric diagram ................................................................. 4-7
Diagnosis wiring diagram ......................................................................................... 4-9
Fan hydraulics diagram designations .............................................................. 4-10
Engine electric diagram designations .............................................................. 4-11
Fan: functional description ..................................................................................... 4-13
Fan control ....................................................................................................... 4-13
Reversing function ........................................................................................... 4-13
Oil supply of the whole system (boost pressure) ............................................. 4-13
Fan connector assignment for models 402, 403, 404 ............................................ 4-14
Diesel engine connector assignment (88 kW) ....................................................... 4-15
Diesel engine connector assignment (103 kW) ..................................................... 4-16
Fuel preheater connector assignment ................................................................... 4-17
Diagnosis connector assignment ........................................................................... 4-18
Engine oil cooler side (88 kW): overview ............................................................... 4-20
Engine drive side (88 kW): overview ...................................................................... 4-21
Engine turbocharger side (88 kW): overview ......................................................... 4-22
Engine oil cooler side (103 kW): overview ............................................................. 4-23
Engine drive side (103 kW): overview .................................................................... 4-24
Engine turbocharger side (103 kW): overview ....................................................... 4-25
Electronics overview (103 kW) ............................................................................... 4-26
Electronic engine revs setting (103 kW): overview ................................................ 4-29
Function: warning telltale in tip switch (103 kW diesel engine) .............................. 4-30
Reading out the flash code .............................................................................. 4-30
Warning limit – coolant temperature ................................................................ 4-30
Warning limit – charge-air temperature ........................................................... 4-31
Warning limit –engine oil pressure ................................................................... 4-31
Overview of flashing codes .............................................................................. 4-32
Engine drive – clutch (88/103 kW): overview ......................................................... 4-35
Fuel system (88/103 kW): overview ....................................................................... 4-36
Bleeding the fuel system (88/103 kW) ................................................................... 4-37
Fan circuit (not in reversing operation) .................................................................. 4-38
Fan circuit with reversing fan ................................................................................. 4-39
Reversing valve block ............................................................................................ 4-40
Revs control ..................................................................................................... 4-40
Setting maximum fan revs (reversing fan) ............................................................. 4-41
Setting maximum fan revs (without reversing fan) ................................................. 4-41
Cleaning the radiator with the reversing fan (option) ............................................. 4-42
Function: reversing fan operation .......................................................................... 4-43
Power train 5
40 kph drive hydraulics diagram for models 400 – 404 ........................................... 5-1
40 kph drive electrics diagram for models 402, 403, 404 ........................................ 5-3
20 kph hydraulic drive diagram for models 400 – 404 ............................................. 5-5
Drive electrics diagram for models 400 – 404 .......................................................... 5-7
Drive hydraulics diagram descriptions ............................................................... 5-8
Electric diagram descriptions ........................................................................... 5-10
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Functional despcription of drive hydraulics and electric system ............................ 5-12

Oil supply via fan pump (10) ............................................................................ 5-12
Boost pressure circuit ...................................................................................... 5-12
Boost pressure relief valve .............................................................................. 5-12
Pump adjustment ............................................................................................. 5-12
Motor adjustment ............................................................................................. 5-13
Drive output regulation .................................................................................... 5-13
Flush feature .................................................................................................... 5-13
Locking driving direction selection ................................................................... 5-13
Holding the signal for the forwards driving direction selection ......................... 5-13
Holding the signal for the reverse driving direction selection .......................... 5-13
Drive speed control .......................................................................................... 5-14
Inching pedal function ...................................................................................... 5-14
Calibrating the inching pedal ........................................................................... 5-14
Crawler gear potentiometer (R3) ..................................................................... 5-14
Drive settings ................................................................................................... 5-14
Troubleshooting (drive) .................................................................................... 5-14
Drive electrics connector assignment for models 400 – 404 ................................. 5-15
Towing and transporting the machine .................................................................... 5-16
Getting ready for towing .................................................................................. 5-16
Towing the machine ........................................................................................ 5-17
Hydraulic pump TMP 89 (models 402, 403, 404) .................................................. 5-18
Hydraulic pump H1 P078 (models 400, 401) ......................................................... 5-19
High speed gearbox (0 – 40 kph) .......................................................................... 5-20
High speed gearbox with auxiliary motor (0 – 40 kph) ........................................... 5-20
Function without auxiliary motor (0 – 40 kph) ........................................................ 5-21
Function with auxiliary motor (0 – 40 kph) ............................................................. 5-21
Gearbox overview (0 – 40 kph) .............................................................................. 5-22
Overview of control cover and gearbox circuit diagram (0 – 40 kph) ..................... 5-23
Control cover component parts for gearbox (0 – 40 kph) ...................................... 5-24
Hydraulic drive circuit (0 – 40 kph) ........................................................................ 5-25
Test report for models 400/401 (0 – 40 kph) ......................................................... 5-26
Error description for test report models 400/401 (0 – 40 kph) ............................... 5-27
Test report for models 402/403/404 (40 kph) ........................................................ 5-28
Error description for test report models 402/403/404 (40 kph) .............................. 5-29
Test report for models 403/404 (30 kph) ............................................................... 5-30
Error description for test report models 403/404 (30 kph) ..................................... 5-31
Checking and setting boost pressure (0 – 40 kph gearbox) .................................. 5-32
Checking high pressure (0 – 40 kph) ..................................................................... 5-33
Checking engine droop (pump) (0 – 40 kph) ......................................................... 5-34
Checking driving direction identification (0 – 40 kph) ............................................ 5-35
Setting engine droop on the gearbox without auxiliary motor (0 – 40 kph) ............ 5-36
Setting engine droop on the gearbox with auxiliary motor (0 – 40 kph) ................. 5-37
Control initiation set screw (0 – 40 kph gearbox) ................................................... 5-38
Checking the cardan shaft speed (0 – 40 kph gearbox) ........................................ 5-39
Troubleshooting diagram (0 – 40 kph) ................................................................... 5-40
Check high pressure (HP valves) .................................................................... 5-41
Check pump engine droop, driving direction identification, differential pressure
measurement ................................................................................................... 5-42
Checking the differential pressure between M4 and M3 (0 – 40 kph) ................... 5-43
Evaluation: differential pressure measurement M4 (0 – 40 kph) ........................... 5-44
Descriptions ..................................................................................................... 5-44
Example: differential pressure measurement M4 (0 – 40 kph) .............................. 5-45
Clean the shuttle throttle .................................................................................. 5-45
Evaluation: differential pressure measurement M3 (0 – 40 kph) ........................... 5-46
Descriptions ..................................................................................................... 5-46
Function ........................................................................................................... 5-46
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Example: differential pressure measurement M3 (0 – 40 kph) .............................. 5-47

Cleaning the pressure relief valve .......................................................................... 5-48
Drive electronics Operator's Manual (SUSMIC) ..................................................... 5-49
Error table .............................................................................................................. 5-50
Checking proportional valve (1) energisation (0 – 40 kph) .................................... 5-51
Table of electric current values of proportional valves ........................................... 5-52
Checking the proportional valves by means of current measurement ................... 5-53
Exchanging proportional valves (0 – 40 kph) ......................................................... 5-54
Interrupting the hydraulic pump/motor circuit (0 – 40 kph) ..................................... 5-54
Separating the consumer circuit from the hydraulic drive ...................................... 5-55
Checking control pressure M4/M5 (0 – 40 kph) ..................................................... 5-56
Variable displacement pump control pressure H1 P078 .................................. 5-56
Variable displacement pump TMP 89 control pressure ................................... 5-56
Checking the control pressure (control piston pressure) ................................. 5-56
Sealing work on the drive shaft (0 – 40 kph gearbox) ............................................ 5-57
Mounting the rotary shaft seal (0 – 40 kph gearbox) ............................................. 5-58
Mounting the drive flange (0 – 40 kph gearbox) .................................................... 5-59
Checking driving direction identification (0 – 40 kph gearbox) ............................... 5-60
Removing driving direction identification (0 – 40 kph gearbox) ............................. 5-61
Variable displacement motor 110 cm3 /rev (20 kph) ............................................... 5-62
Variable displacement motor 110 cm3 /rev (20 kph, seen from the side) ............... 5-63
Variable displacement motor 160 cm3 /rev (20 kph) ............................................... 5-64
Test report for models 400 – 404 (20 kph) ............................................................. 5-65
Error description for test report models 400/401 (20 kph) ..................................... 5-66
Hydraulic circuit: drive with hydraulic pump H1 P078 (20 kph) .............................. 5-67
Hydraulic circuit: drive with hydraulic pump TMP 89 (20 kph) ............................... 5-68
Setting boost pressure (20 kph) ............................................................................. 5-69
Checking high pressure (20 kph) ........................................................................... 5-70
Checking engine droop – variable displacement pump (20 kph) ........................... 5-71
Setting engine droop – hydraulic motor (20 kph) ................................................... 5-72
Setting cardan shaft revs (20 kph) ......................................................................... 5-73
Axles – differential lock 6
Differential lock diagrams (hydraulic/electric) .......................................................... 6-1
Designations: differential lock electric diagram .................................................. 6-2
Designations: differential lock hydraulics diagram ............................................. 6-3
Functional description of differential lock ................................................................. 6-4
Differential lock controls ..................................................................................... 6-4
Differential lock connector assignment .................................................................... 6-5
20 kph gearbox: overview ........................................................................................ 6-6
Removing the 20 kph gearbox ................................................................................. 6-7
Installing the 20 kph gearbox ................................................................................. 6-14
Front and rear axle flanges .................................................................................... 6-22
Type label and oil filler neck: overview .................................................................. 6-24
Conversion table and tightening torques .............................................................. 6-25
Removing the joint housing .................................................................................... 6-26
Installing the joint housing ...................................................................................... 6-28
Removing the double cardan shaft ........................................................................ 6-29
Installing the double cardan shaft .......................................................................... 6-31
Removing the planetary drive ................................................................................ 6-33
Replacing the seals of the planetary drive ............................................................. 6-35
Installing the planetary drive .................................................................................. 6-36
Installing the planetary drive .................................................................................. 6-38
Sealing the front axle differential ............................................................................ 6-40
Removing the front axle differential lock ................................................................ 6-42
Differential lock: overview ................................................................................ 6-44
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Installing the front axle differential lock .................................................................. 6-45

Differential lock: hydraulic circuit ........................................................................... 6-48
Special tools: overview .......................................................................................... 6-49
Brakes 7
Brake (20 kph) diagrams (electric/hydraulic) ........................................................... 7-1
Brake (40 kph) diagrams (electric/hydraulic) ........................................................... 7-3
Hydraulics diagram – trailer brake valve .................................................................. 7-5
Designations: hydraulic brake diagram ............................................................. 7-6
Designations: electric brake diagram ................................................................ 7-7
Functional description of brakes .............................................................................. 7-8
Compressed-air brake lead ............................................................................... 7-8
Releasing the parking brake .............................................................................. 7-8
Starting interlock ................................................................................................ 7-8
Monitoring the parking brake ............................................................................. 7-8
Service brake ..................................................................................................... 7-8
Parking brake .................................................................................................... 7-8
Brakes connector assignment ................................................................................. 7-9
40 kph brake circuit: overview ............................................................................... 7-10
20 kph brake circuit: overview ............................................................................... 7-11
Disabling (releasing) the parking brake in the front axle ........................................ 7-12
Enabling (adjusting) the parking brake in the front axle ......................................... 7-12
Wear check: service brake discs ........................................................................... 7-13
Setting the brake linkage – master brake cylinder ................................................. 7-13
Service and parking brake: overview ..................................................................... 7-14
Removing the brake discs ..................................................................................... 7-15
Removing the brake pistons and the belleville spring washers of the
service brake ................................................................................................... 7-16
Removing the piston and brake linings of the parking brake ........................... 7-17
Brake discs: overview ............................................................................................ 7-18
Installing the the brake pistons of the service and parking brake .......................... 7-19
Installing the belleville spring washers and the brake cylinder housing ................. 7-20
Installing the service brake .................................................................................... 7-22
Setting value for the service brake discs ......................................................... 7-23
Installing the service brake discs ..................................................................... 7-24
Towing and transporting the machine .................................................................... 7-25
Getting ready for towing .................................................................................. 7-25
Towing the machine ........................................................................................ 7-26
Hydraulic trailer brake circuit (option) .................................................................... 7-27
Steering 8
Steering diagrams (electric/hydraulic) ..................................................................... 8-1
Designations: hydraulic steering diagram .......................................................... 8-2
Designations: electric steering diagram ............................................................. 8-3
Functional description of steering system ................................................................ 8-4
Steering system oil supply ................................................................................. 8-4
Priority of steering system oil supply ................................................................. 8-4
Emergency steering function ............................................................................. 8-4
Steering modes ................................................................................................. 8-4
Steering electronics ........................................................................................... 8-4
Brakes connector assignment ................................................................................. 8-5
Work hydraulics 9
Diagram: work hydraulics fixed displacement pump – raising/lowering
the telescopic boom ................................................................................................. 9-1
Diagram: work hydraulics variable displacement pump – raising/lowering
Electric diagram – raising/lowering the telescopic boom, load stabiliser ................. 9-5
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Work hydraulics diagram – extending/retracting the telescopic boom,

fixed displacement pump ......................................................................................... 9-7
Diagram: work hydraulics variable displacement pump – extending/retracting
Electric diagram – extending/retracting the telescopic boom ................................. 9-11
Diagram: work hydraulics fixed displacement pump – dumping in/out .................. 9-13
Diagram: work hydraulics variable displacement pump – dumping in/out ............. 9-15
Electric diagram – dumping in/out .......................................................................... 9-17
Diagram: work hydraulics fixed displacement pump – locking/unlocking .............. 9-19
Diagram: work hydraulics variable displacement pump – locking/unlocking ......... 9-21
Electric diagram – locking/unlocking ...................................................................... 9-23
Diagram: work hydraulics fixed displacement pump – rear additional
control circuit .......................................................................................................... 9-25
Diagram: work hydraulics variable displacement pump – rear additional
control circuit .......................................................................................................... 9-27
control circuit – Autohitch ....................................................................................... 9-29
control circuit, Autohitch ......................................................................................... 9-31
control circuit, Autohitch, tipping trailer .................................................................. 9-33
control circuit, Autohitch, tipping trailer .................................................................. 9-35
control circuit, tipping trailer ................................................................................... 9-37
control circuit, tipping trailer ................................................................................... 9-39
Diagram: work hydraulics fixed displacement pump – Autohitch ........................... 9-41
Diagram: work hydraulics variable displacement pump – Autohitch ...................... 9-43
Diagram: work hydraulics fixed displacement pump – Autohitch, tipping trailer .... 9-45
Diagram: work hydraulics variable displacement pump – Autohitch,
tipping trailer .......................................................................................................... 9-47
Diagram: work hydraulics fixed displacement pump – tipping trailer ..................... 9-49
Diagram: work hydraulics variable displacement pump – tipping trailer ................ 9-51
Diagram: work hydraulics variable displacement pump – additional
control circuit for quick couplers on telescopic boom ............................................. 9-53
Diagram: work hydraulics – safe load indicator ..................................................... 9-55
Electric diagram – front/rear additional control circuit for quick couplers,
Autohitch, tipping trailer, front socket, safe load indicator ...................................... 9-57
Diagram: work hydraulics variable displacement pump – additional
control circuit for quick couplers on quickhitch ....................................................... 9-59
Diagram: work hydraulics variable displacement pump – work platform
with radio control .................................................................................................... 9-61
Work platform with radio control: electric diagram ................................................. 9-63
Tilt ram lock: electric diagram ................................................................................ 9-65
Diagram: work hydraulics variable displacement pump – frame levelling,
oscillating axle interlock ......................................................................................... 9-67
Frame levelling, oscillating axle interlock: electric diagram ................................... 9-69
Work hydraulics diagram: designations ........................................................... 9-70
Electric diagram: designations ......................................................................... 9-73
Functional description of work hydraulics .............................................................. 9-75
Oil supply via fan pump (010) .......................................................................... 9-75
Raising/lowering the telescopic boom ............................................................. 9-75
Parallel lifting and lowering of attachments ..................................................... 9-75
Switching on the load stabiliser ....................................................................... 9-75
Load stabiliser function .................................................................................... 9-76
Retracting and extending the telescopic boom ................................................ 9-76
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Safe load indicator function ............................................................................. 9-77

Overload cutoff (option) ................................................................................... 9-77
Dumping the attachment in and out ................................................................. 9-77
Locking the 3rd control circuit .......................................................................... 9-77
Operating the 3rd control circuit (unlocking/locking the quickhitch) ................. 9-77
Quickhitch lock ................................................................................................ 9-77
Functional description of front socket .............................................................. 9-78
Tilt ram lock ..................................................................................................... 9-78
Remote radio controls ..................................................................................... 9-78
Oscillating axle interlock .................................................................................. 9-78
Work hydraulics connector assignment ................................................................. 9-79
Test report: models 400-01/401-01 ....................................................................... 9-80
Test report: models 402-01/403-01 ....................................................................... 9-81
Work hydraulics test ports .................................................................................... 9-82
Variable displacement pump (hydraulic pump) ...................................................... 9-83
How the pressure regulator works ................................................................... 9-83
How the flow regulator works .......................................................................... 9-84
How the output regulator works ....................................................................... 9-84
Checking and setting the work hydraulics ............................................................. 9-85
Variable displacement pump pressure regulator: settings ............................... 9-85
Control valve (primary pressure): settings ....................................................... 9-85
Flow regulator: settings ................................................................................... 9-86
Work hydraulics circuit (gear pump) ..................................................................... 9-87
Work hydraulics circuit (variable displacement pump LS) .................................... 9-88
Control valve connections (4-fold) ......................................................................... 9-89
Control valve (4-fold): overview ............................................................................. 9-90
Control valve connections (5-fold) ......................................................................... 9-91
Control valve (5-fold): overview ............................................................................. 9-92
Lift ram circuit ....................................................................................................... 9-93
Tilt ram circuit ....................................................................................................... 9-94
Compensating ram circuit ..................................................................................... 9-95
Push-out ram circuit .............................................................................................. 9-96
3rd control circuit .................................................................................................. 9-97
Control valve (4-fold) pilot control circuit ............................................................... 9-98
Valve block connections: overview ........................................................................ 9-99
Pilot control unit, pilot valve ................................................................................. 9-100
Load stabiliser ...................................................................................................... 9-101
Load stabiliser: description ............................................................................ 9-101
Checking and setting the load stabiliser ........................................................ 9-102
Load stabiliser circuit .......................................................................................... 9-103
Changeover valve: Autohitch/tipping trailer connection/additional
control circuit ........................................................................................................ 9-104
Autohitch, rear additional control circuit .............................................................. 9-105
Tipping trailer connection circuit ......................................................................... 9-106
Front additional control circuit ............................................................................. 9-107
Frame levelling with oscillating axle interlock (option) telehandler 404:
overview ............................................................................................................... 9-108
Specific safety instructions ............................................................................ 9-108
Mechanical oscillating axle interlock (rear axle) ............................................ 9-108
Working with the front axle frame levelling (option) ....................................... 9-109
Hydraulic rear oscillating axle interlock (option) ............................................ 9-110
Bleeding the hydraulic ram of the oscillating axle interlock ................................. 9-111
Frame levelling circuit .......................................................................................... 9-112
Frame levelling valve overview ............................................................................ 9-113
Lift ram with hose burst valve: overview .............................................................. 9-114
Tilt ram: overview ................................................................................................. 9-115
Push-out ram with final position damping: overview ............................................ 9-116
000 295 725 0 - RHB SCORPION I-9

Table of contents
Compensating ram: overview .............................................................................. 9-116

Quickhitch ............................................................................................................ 9-117
Installing the telescopic boom .............................................................................. 9-118
Replacing the control valve .................................................................................. 9-127
Replacing the priority valve .................................................................................. 9-127
Replacing the fan pump ....................................................................................... 9-128
Replacing the A 10 work hydraulics pump ........................................................... 9-129
Replacing the pilot valve ...................................................................................... 9-129
Electric systems 10
Machine lights: electric diagram ............................................................................. 10-1
Turn indicators/horn/rotating beacon: electric diagram .......................................... 10-3
Mirror adjustment/heating: electric diagram ........................................................... 10-5
Window wiper/washer, hydraulics monitoring: electric diagram ............................. 10-7
Heating – air conditioning system/air-suspension seat: electric diagram .............. 10-9
Multimedia/cigarette lighter: electric diagram ....................................................... 10-11
Electric diagram designations and positions .................................................. 10-12
Connector positions on machine ................................................................... 10-13
Functional description of hydraulics monitoring ................................................... 10-15
Hydraulic filter monitoring (open bypass): ..................................................... 10-15
Hydraulic oil level monitoring: ........................................................................ 10-15
Hydraulic oil temperature monitoring: ............................................................ 10-15
Hydraulics monitoring connector assigment ........................................................ 10-15
Lights connector assignment ............................................................................... 10-16
Turn indicator/horn connector assignment ........................................................... 10-17
Rotating beacon connector assignment ............................................................... 10-18
Mirror adjustment connector assignment ............................................................. 10-18
Mirror heating connector assignment ................................................................... 10-18
Window wiper/wash connector assignment ......................................................... 10-19
Heating/air conditioning connector assignment ................................................... 10-19
Air-suspension seat connector assignment ......................................................... 10-20
Multimedia connector assignment ....................................................................... 10-20
Cigarette lighter connector assignment ............................................................... 10-20
Ohm's Law (current, voltage, resistance); power ................................................. 10-22
Multifunction measuring device ............................................................................ 10-22
Terminal description ............................................................................................. 10-23
Cable colour coding ............................................................................................. 10-27
Extract from DIN 72551, sheet 4 ................................................................... 10-27
Colour coding ................................................................................................. 10-29
Fuses: overview ................................................................................................... 10-30
Fuses: overview ............................................................................................. 10-30
Electric components ...................................................................................... 10-31
Main fuse box with relays (88 kW diesel engine) ........................................... 10-32
Main fuse box with relays (103 kW diesel engine) ......................................... 10-32
Relays: overview ............................................................................................ 10-33
Electronic components: overview ........................................................................ 10-34
Steering electronics (old) ............................................................................... 10-34
Steering electronics (new) ............................................................................. 10-34
Connector assignment on board .................................................................... 10-35
Functional description of the steering electronics ................................................ 10-36
Changing over from 4 wheel steering to front axle steering .......................... 10-36
Changing over from front axle steering to 4 wheel steering .......................... 10-36
Carrying out synchronisation manually .......................................................... 10-36
Synchronisation requires the following data/prerequisites ............................. 10-36
Possible errors ............................................................................................... 10-36
New steering electronics (17 LEDs): overview .............................................. 10-37
Proportional controls: overview and connections ................................................. 10-38
I-10 000 295 725 0 - RHB SCORPION

Table of contents
Proportional electronics ....................................................................................... 10-39

Hold electronics ................................................................................................... 10-40
Wiring harness 1000103927 (joystick) ................................................................. 10-40
Overview and functional check of safe load indicator .......................................... 10-41
Safe load indicator display (version A) .......................................................... 10-42
Functional check of safe load indicator (version A) ....................................... 10-43
Safe load indicator display (version B) .......................................................... 10-44
Functional check of safe load indicator (version B) ....................................... 10-44
Safety instructions for the safe load indicator ...................................................... 10-45
Setting the safe load indicator (0 % point) ........................................................... 10-46
Setting the 0 % point ..................................................................................... 10-46
Setting the safe load indicator (100 % point stability) .......................................... 10-47
Determining the maximum authorised load (100 % point) ............................. 10-47
Possible errors – safe load indicator .................................................................... 10-48
Retrofitting the front right and rear right working lights ........................................ 10-49
Retrofitting a rotating beacon ............................................................................... 10-50
Retrofitting a radio ............................................................................................... 10-51
Retrofitting the low-speed control ........................................................................ 10-51
Retrofitting the air conditioning system ................................................................ 10-52
Retrofitting a front or rear socket ......................................................................... 10-53
Retrofitting a load stabiliser ................................................................................. 10-53
Wiring harness disconnect (cab – machine frame) .............................................. 10-54
Appendix A
Hydraulics – 4-fold control valve: overall diagram ................................................. A -1
Hydraulic fixed displacement pump – 5-fold control valve: overall diagram .......... A -3
Hydraulic variable displacement pump – 5-fold control valve: overall diagram ..... A -5
Machine components: overview ........................................................................... A -6
000 295 725 0 - RHB SCORPION I-11

Table of contents
I-12 000 295 725 0 - RHB SCORPION

Machine specifications: overview
1 Machine specifications: overview Machine outside view

Models: 400-01, 401-03, 3 4 5 6 7 8 9 2 10 11

402-03, 403-03 1.1 Machine outside view
Telehandler outside views 400-01, 401-03, 402-03, 403-03, 404-03
7
Pos. Description
2 12 1 Lights with turn indicators
2 Rear clearance light

1 13
3 Rearview mirrors
19 4 Boom working light (option)
5 Air filter (preliminary separator option)

14
6 Eye hook1 for installing/removing the cab
7 Working light (standard)

15
8 Rotating beacon (option)
9 Working light (front/rear option)
10 Hydraulic connections (quick couplers, option)
11 Trailer coupling (option)
12 Numberplate fixture (option)

1 18 17 7 16 3
13 Brake, rear and turn indicator lights
14 Door arrester
Models: 404-03 3 4 5 6 7 8 9 23 10 11
15 Rear eye hook for strapping down the machine
16 Handle
7
17 Cab access
1 18 Battery (battery master switch option)
12
19 Front eye hook for towing/strapping down the machine
1 13 20 Right-hand side frame levelling ram on front axle (option) 404-03
21 Boom working light (option) 404-03

14
20
Mechanical oscillating axle interlock with pin (standard)
22
22 Hydraulic oscillating axle interlock (option) 404-03
23 Rearview mirror (rear, option) 404-03
15 1. Eye hooks are for removing the cab only, and may not be used for crane-lifting the machine
19 1 18 17 7 16 3
1-1 000 295 725 0 – RHB SCORPION

1 2 3 4 5 6 1.2 Inside of cab: overview

Cab
1 Front wiper
45 7 2 Storage compartment
3 Front window air vents
6 4 Preheating start switch (ignition lock)
8 5 Steering column adjustment
44 6 Side window air vents
7 Instrument panel
9 8 Safe load indicator
43
9 Fire extinguisher (option)
10 Heating switches
42 0000
00
0h
10 11 Accelerator pedal
12 Control lever (joystick)
41
13 Stop cock – control lever lock for road travel
11
14 Interior light
0
I
II
1 2
40
0
15 Switch panel – side console (right)
3
16 Drink holder
12
39 17 Storage net for
18 Prepared installation for radio (option)
38 19 Loudspeakers (option)
13
20 Air vent – rear window
37 21 Working light (standard on left/option on right)
22 Steering electronics
14
23 Drive electronics (Susmic)
36
24 Central electrics (relays, fuse box etc.)
25 Rear wiper
35 15
26 Rotating beacon
27 Aerial (option)
34 28 Proportional electronics
16
29 Rotary switch – fresh air/recirculated air
33 30 Fresh air filter
17 31 Seat belt
32 32 Hook
33 Brake fluid tank
18 34 Bracket for first aid kit
31
35 Tank – washer system
36 Seat
30
19 37 Roller sun-visor
38 Bracket for side window lock (upper door option)
29 39 Steering system
20 40 Brake/inching pedal
19 41 Lock on cab
42 Inside door lock
20 21 43 Multifunctional lever – turn indicators, headlights, wipers
402 02_0 3_b0 0.iso 44 Switch panel – side console (left)
45 Front working light (option)
21 28 27 26 25 24 23 22
000 295 725 0 – RHB SCORPION 1-2

59 60 61 62 63 64 65 66 67
1.3 Instrument panel, multifunctional lever, switch consoles: overview
51 52 53 68
84 Switch – quickhitch release
50 54 Instrument panel 85 Switch – working light on boom
46 Hour meter 86 Switch – Autohitch trailer coupling (option)
49 55 69
47 Telltale (yellow) – cold starter 87 Switch – front socket for electric attachments (option)
48 Telltale (blue) – high beam 88 Switch – additional rear control circuit (option)
48 56 49 Telltale (red) – coolant level 89 Switch – fuel preheater (option)
00000 00 h
70 77 50 Telltale (red) – hydraulic oil filter 90 Switch – heated rear window (option)
47 57 51 Telltale (yellow) – air filter 91 Switch – rotating beacon (option)
52 Telltale (red) – alternator charge function 92 Switch – rear working light
78
46 58 53 Telltale (red) – parking brake 93 Switch – front working light
54 Telltale (red) – engine oil pressure 94 Pressure gauge – air compressor (option)
79
1 2
55 Telltale (red) – 3rd control circuit continuous operation 95 Switch – machine lights (low beam and rear lights)
56 Telltale (green) – right/left turn indicators for rear attach- 96 Switch with lock – continuous operation of 3rd control circuit
3
Nr_7_2.iso
80 ments (option)
57 Telltale (green) – fuel/water separator 97 Switch – load stabiliser (option)
76 75 74 73 72 71
81 58 Fuel level indicator Right-hand side switch panel
Front instrument panel 98 Switch – diagonal steering (crab steering)
98 59 Telltale (red) – hydraulic system overheating 99 Switch – parking brake
82 83 84 85 86 87 88
60 Telltale (red) – hydraulic oil level 100 Switch – work range/speed range
99 61 Telltale (green) – differential lock 101 Switch with lock – 4 wheel/front axle steering
62 Telltale (green) – right/left turn indicators 102 Tip switch – steering synchronisation
63 Telltale (yellow) – hose burst valve 103 Switch – rear wiper
100
64 Telltale (green) – front axle steering 104 Switch – reversing fan operation (engine)
89
65 Telltale (green) – 4 wheel steering 105 Switch – air conditioning (option)
101 66 Telltale (green) – diagonal steering (crab steering) 106 Switch – hydraulic connection for tipping trailer (option)
67 Telltale (red) – steering synchronisation 107 Tip switch – hydraulically adjustable trailer coupling (Auto-
102 68 Telltale (green) – forwards driving direction hitch) or hydraulic connection for tipping trailer (option)
90
97 69 Telltale (green) – reverse driving direction 108 Switch – additional control circuit (option)
96 103 70 Speedometer (high speed option) 109 Switch – front axle frame levelling
95
71 Temperature indicator – diesel engine (only for telehandler model 404, option)
94 115
93 104 72 Manual throttle potentiometer (option) 110 Tip switch – rear axle hydraulic oscillating axle interlock
92 73 Instrument panel (only for telehandler model 404, option)
91 12 114 111 Switch with lock – disabling/enabling the lock function of the
74 Mark with telltale (red) drive interlock (option)
105 safe load indicator
75 Crawler gear potentiometer (option)
116 113 Control lever (joystick)
76 Tachometer (engine)
106 112 Tip switch – driving direction in neutral
77 Telltale (red) – disabling/enabling the lock function of the
112 safe load indicator 113 Switch – extend/retract telescopic boom
119 118 117 107 Heating switches 114 Not assigned (option)
78 Rotary switch – heating temperature 115 Switch – unlock/lock 3rd control circuit
108 79 Rotary switch – heater fan 116 Tip switch – differential lock
117 Switch – forwards/reverse driving direction
0
80 Switch – tilt ram lock (option)

Nr_9und13_2.iso
Multifunctional lever, switches turn indicators

I
II
109 81 Mirror adjustment switch (option)
118 Rotary switch and tip switch – front wiper, washer pump
110 Left-hand side switch panel 119 Horn tip switch
82 Hazard warning switch
111 83 Switch with lock – lock for 3rd control circuit
1-3 000 295 725 0 – RHB SCORPION

1.4 Important information on this manual

This manual contains important information on how to service your machine safely, cor-
rectly and economically. Therefore, it aims not only at new staff, but it also serves as a ref-
erence 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.
Careful and prudent working is the best way to avoid accidents!
Insist on using original spare parts when carrying out maintenance and repair work. This
ensures operational safety and readiness of your machine, and maintains its value.
If you require more information on the machine, please contact your CLAAS dealer.
Abbreviations/symbols
• This symbol stands for a list
• Subdivision within lists or an activity. Follow the steps in the recommended sequence
☞ This symbol requires you to carry out the activity described
➥ Description of the effects or results of an activity
n. s. = not shown
“Option” = optional equipment
Stated whenever controls or other components of the machine are installed as an option.
This symbol shows the driving direction – for better orientation in figures and
graphics.
1.5 Model and trade names: overview
CLAAS
Telehandler CLAAS model designation
trade name
400-01 K01 6030
401-03 K02 7030
402-03 K04 7040
403-03 K04 7045
404-03 K05 9040
000 295 725 0 – RHB SCORPION 1-4

1.6 Type labels and component numbers

Serial number
The serial number is stamped on the machine frame A (next to the front axle attachment,
on the front right in driving direction). It is also located on the type label.
Type label B is located on the front right on the machine frame in driving direction.
Example:
A Machine model: 400
Version: 402 03
Serial no.: 402 03 0055
Model year: 2005
Front gross axle weight rating: 6500 kg
Rear gross axle weight rating: 6500 kg
Gross weight rating: 10000 kg
Output: 88 kW
B
Fig. 1: Type label: location
Cab number
The type label (arrow) is located in the cab, at the top right in driving direction.
Fig. 2: Cab type label
Engine number
The type label is located on the cylinder-head cover (engine).
Example: Deutz TCD 2012 L04 2V
kW 88
Fig. 3: Diesel engine number
1-5 000 295 725 0 – RHB SCORPION

Hydraulic pump number

The type label (arrow) is located on the hydraulic pump housing (next to where the pump is
installed on the diesel engine)
Fig. 4: Hydraulic pump type label
Variable displacement motor number

The type label (arrow) is located on the housing of the variable displacement motor.
Fig. 5: Variable displacement motor type label
Variable displacement motor number (high speed option)

The type label (arrow) is located on the housing of the variable displacement motor.
Fig. 6: Variable displacement motor type label (option)
Front and rear axle numbers

The type label is located on the differential housing next to the steering ram (arrow).
Fig. 7: Rear axle and gearbox type label
000 295 725 0 – RHB SCORPION 1-6

1-7 000 295 725 0 – RHB SCORPION

1.7 Frame
Sturdy steel sheet frame, rubber-mounted engine
1.8 Engine
Telehandler model 400-01, 401-03, 402-03 403-03/404-03
Type TCD 2012 L04 2V
88 kW 103 kW
Output (as per ISO 9249) at 2400 rpm at 2400 rpm
with charge-air cooler with charge-air cooler
Max. torque 420 Nm 520 Nm
(counterclockwise rotation) 1500 rpm 1500 rpm
Specific minimum fuel con-
215 g/kWh 205 g/kWh
sumption
No. of cylinders 4
Displacement 4038 cm³
Bore and stroke 101 x 126 mm
Compression ratio 1:18
PDL DCR
Fuel injection system
(pump, line, nozzle) (Deutz Common Rail)
Firing order 1-3-4-2
Starting aid Glow plug
Max. lateral left/right inclination: 30° (57 %)
Max. inclined position (engine
Max. uphill/downhill inclination: 30° (57 %)
no longer supplied with oil)
Observe the tilting limit of the machine!
Oil pressure Forced feed lubrication
Intake valve 75°
Valve tip clearance1
Exhaust valve 120°
Control plunger play1 exhaust
Control plunger play 144°
gas recirculation
1. Adjust the play when the engine is cold
000 295 725 0 – RHB SCORPION 1-8

1.9 Oil/water cooling fan

Telehandler model 400-01/401-03/402-03/403-03/404-03
Hydraulic pump Gear pump
Displacement 17 cm³/rev
Fan motor
14 cm³/rev
Capacity
1.10 Power train

Variable displacement pump
Telehandler model 400-01/401-03/402-03/403-03/404-03

Automotive, infinitely variable hydrostatic axial-piston
Design
gearbox
Displacement 0 – 90 cm³/rev
Max. operating pressure 450+30 bar
Starting revs 1050 – 1150 rpm/50 bar HP
2100±100 rpm
Droop
250 bar HP
Boost pump
Design Gear pump
Charging/boost pressure 30 bar at max. rpm
Control Electronic
Driving direction Electrohydraulic control
Inching Electric (potentiometer)
Variable displacement motor
Telehandler 400-01/401-03 402-03/403-03

404-03 (88 kW)
model 402-03/403-03 404-03
Axial piston motor
Design Axial piston motor + fixed displace- Axial piston motor
ment motor
Capacity
233 cm³/rev 233+45 cm³/rev –
(40 kph)
Capacity
– – 233 cm³/rev
(30 kph)
Work range/
Work range: 0 – 7 kph Work range: 0 – 7 kph
drive range
Drive range: 0 – 40 kph Drive range: 0 – 30 kph
forwards/reverse
Traction force1 65 kN 75 kN 65 kN
1. With 17.5LR24 XM37 tyres
1-9 000 295 725 0 – RHB SCORPION

1.11 Axles
Front axle
400-01/401-03/402-03
Telehandler model 404-03
403-03
Planetary steering and drive axle, rigid screw connection
Design
with frame
Differential lock 100 % differential
King-pin inclination 0°
Camber 0°
Steering angle Max. 45° Max. 40°
Toe-in 0 mm
Track width 1920 mm
Rear axle
400-01/401-03/402-03
Telehandler model 404-03
403-03
Planetary steering and drive axle,
Design
oscillating bearing on frame
Differential lock No
King-pin inclination 0°
Camber 0°
Oscillation ±10°
Steering angle Max. 45° Max. 40°
Toe-in 0 mm
Track width 1920 mm
000 295 725 0 – RHB SCORPION 1-10

1.12 Service and parking brake

Service brake
20 kph version
➥ Foot-operated hydraulic multidisc powerbrake
Design 30/40 kph version (option)
➥ Foot-operated dual-circuit hydraulic multidisc power-
brake
20 kph version
➥ Front axle only
Location
30/40 kph version (option)
➥ Front and rear axles
Effect On both axles via cardan shaft
Special hydraulic fluid based on basic mineral oil
Brake fluid – see chapter 3 “Fluids and lubricants: overview” on
page 3-3
Parking brake
Actuated via switch on instrument panel, electrohydraulic
Design1
multidisc spring-loaded brake
1. On left and right between the axle tube and the front axle differential housing
1.13 Steering system

400-01/401-03/402-03
Telehandler model
403-03, 404-03
Design Hydrostatic 4 wheel steering with emergency steering features
Steering mode: 4 wheel steering, front axle steering, optional diagonal
20 kph steering (crab steering)
4 wheel steering, front axle steering, optional diagonal
Steering mode: steering (crab steering)
30/40 kph (option)1 (front axle steering automatically engaged when switching
over to high speed range)
Hydraulic pump, priority valve, servostat with safety valves,
Assemblies
1 steering ram per axle, electronically synchronised
Max. pump pressure2 205 – 235 bar
3
Max. steering pressure 200 bar
1. 30/40 kph version: high speed range only possible with front axle steering!
2. Measured after the pump
3. Measured after the servostat
1-11 000 295 725 0 – RHB SCORPION

1.14 Work hydraulics

Hydraulic pump
Telehandler model 400-01/401-03/402-03 402-03/403-03/404-03
Hydraulic pump 44 cm³/rev 60 cm³/rev
Design Fixed displacement pump
(LS)
Displacement 110 l/min 150 l/min
at 2400 rpm at 2400 rpm
Location on diesel
88 kW 88 kW/103 kW
engine
Control valve 4 – 7-fold pilot control
Hydraulic oil filter Reflux filter
Hydraulic ram protection

Telehandler model 400-01/401-03 402-03/403-03/404-03
Max. service pressure 210 bar 250 bar
Tilt ram
Secondary protection:
Rod side 260 bar 300 bar
Base side 260 bar 300 bar
Lift ram
Push-out ram
Rod side 260 bar 300 bar
Quickhitch ram (3rd
control circuit)
Max. service pressure 210 bar 210 bar
000 295 725 0 – RHB SCORPION 1-12

Lift, tilt and push-out rams: velocity
401-03
Telehandler 400-01 402-03, 403-03 404-03
402-03
Fixed displacement Variable displacement
Hydraulic pump
pump 44 cm³/rev pump 60 cm³/rev
Lift ram
Raise 10.5 sec 9.0 sec 12.5 sec
Lower 6.5 sec 7.0 sec 7.0 sec
Tilt ram
Tilt in 4.5 sec 4.5 sec 5.0 sec
Dump out 4.0 sec 4.0 sec 4.5 sec
Push-out ram
Retract 7.0 sec 9.0 sec 9.0 sec 13.0 sec
Extend 6.0 sec 8.0 sec 8.0 sec 12.0 sec
Hydraulic pilot control

Pilot control pump = boost pump of hydraulic pump
Charging/boost pressure 30 bar at 2400 rpm
Pilot control unit
➥ Four-way lever – control of lift and tilt rams
➥ Push-out ram via potentiometer scroll wheel and
Control lever (joystick)
➥ Lock ram or attachment via potentiometer scroll
wheel (electrohydraulic control)
Lock against unintentional opera-
Stop cock in pilot-control line and switch for 3rd con-
tion (for long-haul travel and
trol circuit lock (electric)
transport)
Additional control circuit (option)

Telehandler model 401-03/402-03/403-03/404-03
Variable displace-
Location Function ment pump
60 cm³/rev
Additional control circuit
Electric control (solenoid
➥ Installed on the left of the
valve) via 3rd control circuit 60 l/min at 250 bar
telescopic boom
80 l/min at 195 bar
Additional control circuit 110 l/min at 75 bar
Electric control (solenoid
➥ Installed at the front and
valve) via 5-fold control valve
rear of the telescopic boom
1-13 000 295 725 0 – RHB SCORPION

1.15 Electric system

Fuses: overview
The fuse board is located underneath the cover behind the seat.
No. (A) Protected circuit

F1 7.5 Brake light
F2 15 Front socket
Mirror adjustment, mirror heating, solenoid valve: additional cir-
F3 10 cuit raise/lower, emergency lowering OFF, lock function of safe
load indicator
F4 15 Proportional electronics
Preheating time control unit, preheating telltale, preheating
F5 10
switching relay, engine electronics
F6 Turn indicators
7.5 Steering electronics, 4 wheel steering/front axle steering/diago-

F7 nal steering solenoid valve, 4 wheel steering/front axle steering/
diagonal steering/synchronism telltale
F8 Susmic (drive electronics)
Solenoid valve: load stabiliser, hose burst valve, reversing fan,
F9
load stabiliser telltale
F10 10 Air-suspension seat (option)
Solenoid valve: additional control circuit, tilt ram lock, bucket
F11 repositioning, quickhitch lock, load stabiliser relay, Autohitch
unlocking
F12 5 Cutoff solenoid
Forwards/reverse driving direction telltale, hold electronics, front
F13 3 socket relay, bucket repositioning relay, parking brake solenoid
valve
Driving direction identification solenoid valve, rear horn, revers-
F14 7.5
ing light, reversing light, float position solenoid valve
Hour meter, telltale: 3rd control circuit, parking brake, air filter,
engine oil pressure, water separator, preheating, hydraulic oil fil-
F15
Fig. 8: Fuse box ter, alternator, hydraulic oil level, hydraulic oil temperature, cool-
3 ant temperature, fuel level indication, speedometer
Front and rear axle sensors, speed sensor, telltale for water in
F16
fuel, level amplifier, reversing fan tip switch, coolant level telltale
F17 30 Window heating
F18 25 Heater fan, magnetic coupling compressor
Main fuse: right/left low beam, right/left high beam, high beam
F19 15
telltale
F20 10 Rear wiper, washer pump
Safe load indicator, window heating time lag relay, window heat-
F21 5 ing switching relay, bucket repositioning sensor, mini switching
relay for lock function of safe load indicator
Switching relay wiper 1st/2nd speed, intermittent wipe relay,
F22 20
front wiper, washer pump, horn
000 295 725 0 – RHB SCORPION 1-14


F23 3 Radio
F24 High beam (right)
F25 High beam (left)
7.5
F26 Low beam (right)
F27 Low beam (left)
Parking light (right), rear light (right), rear clearance light (right),
F28
numberplate lights, switch lights
5
Parking light (left), rear light (left), rear clearance light (left),
F29
instrument lights, light for cigarette lighter
F30 3 High current relay, start switching relay
Main fuse: parking light, rear light, rear socket for additional
F31 lights, front socket for additional lights, switch lights, instrument
15 lights, light for cigarette lighter, interior light
F32 Drive interlock/auxiliary heater
F33 Rotating beacon
F34 Telescopic boom working light
10
F35 Rear working light
F36 Front working light
F37 7.5 Turn indicator relay, turn indicators, radio
F38 15 Socket (cigarette lighter)
Electric components
Description Output
Alternator 12 V 95 A
Starter 12 V 3.0 kW
Battery 12 V/135 Ah
1-15 000 295 725 0 – RHB SCORPION

Main fuse box with relays (88 kW diesel engine)

The main fuse box is located in the engine compartment
K7
Fuse no. Rated current (A) Protected circuit
F39 125 A Preheating/start fuse (starter)

F 40 F 39
F40 100 A Main fuse
K6 K5 K7 Relay no. Protected circuit
F40 F39 K5 Preheating high current relay
K6 Preheating time lag relay
K7 Start high current relay

Fig. 9: Main fuse box (88 kW engine)

K5 K42 K7 F40 F39
F40 100 A Main fuse
F41 25 A Main fuse (engine control unit)
Relay no. Protected circuit

F41
K5 Preheating high current relay
K42 Engine electronics switching relay
000 295 725 0 – RHB SCORPION 1-16

Relays: overview
The relays are located underneath the cover behind the seat.
Switching relay
Protected circuit
no.
K25
K1 High current relay
K23 K2 High current relay
K3 Reverse driving switching relay

K24 K10 Turn indicator relay
K16 Front socket switching relay

K33
K21 Differential lock
K1 K3 K27 K22 Load stabiliser (option)
K23 Wiper switching relay (1st speed)

K2 K24 Wiper switching relay (2nd speed)
K10 K25 Interval relay (wiper)
K27 Time lag relay for rear window heating (option)

K28
K28 Bucket repositioning switching relay (option)
K30 Brake lights switching relay

K22 K36
Fuel preheater switching relay (option, installed in engine compart-
K32 K38 K31
ment)
K16 K37 K32 Reversing fan (option) switching relay
Fig. 11: Relays K30 K35 K33 High current relay for rear window heating (option)
K21 K34 K34 Switching relay for lock function of safe load indicator
Fig. 11: Relays
K35 Switching relay for lock function of safe load indicator
K36 Drive signal switching relay
K38 Switching relay for other options
1-17 000 295 725 0 – RHB SCORPION

1.16 Tyres for models 400-01/401-03/402-03/403-03
Tyre pressure Wheel rims

Tyre size
Front/rear Wheel rim Wheel offset
405/70-20 MPT01 149 B 13 x 20
405/70-24 MPT01 152 B DW13x24
15.5-25 EM60 149 B 12.00/1.3 x 25
17.5LR24 A-570 150 A8 3.0 bar
460/70 R24 159 A8 XMCL

TW14Lx24
17.5L-24 IND 166/155A8 0
TR01 TBL
19.5LR24 A-570 149 A8

3.0 bar DW15Lx24
500/70 R24 164 A8 XMCL
DW16Lx24
500/70 R24 157 A8 2.5 bar
15.5/80 -24 163 A8 TR-01 3.0 bar W13x24
600/50-22.5 16PR 153A8 2.6 bar 22.5x20 TH2 -25
1.17 Tyres for model 404-03

Tyre pressure Wheel rims
Tyre size
Front/rear Wheel rim Wheel offset
405/70-24 MPT01 152 B DW13x24
15.5-25 EM60 TBL 149B 12.00/1.3 x 25
17.5LR24 A-570 150 A8
460/70 R24 159A8 XMCL 3.25 bar TW14Lx24

0
17.5L-24 IND 166/155A8
19.5LR24 A-570 149 A8

W15Lx24
500/70 R24 164A8 XMCL
500/70 R24 IND IT530 TL 2.50 bar DW16Lx24
000 295 725 0 – RHB SCORPION 1-18

1.18 Weights
400-01,
Telehandler 402-03 403-03 404-03
401-03
Kerb weight1 7200 kg 78000 kg 8100 kg 8600 kg
Gross weight rating 10000 kg
Front/rear gross axle weight
6500 kg
rating
Max. authorised load (towing
4000 kg/drawbar load 1000 kg
facility)
1. Without attachment, with driver and full fuel tank
1.19 Noise levels

Diesel engine Sound power level dBA
Measured value 105.6
88 kW
Guaranteed value 106
Measured value 103.8
103 kW
Guaranteed value 104
– Noise level in the cab 78
Important!
Measurement of sound power level according to EC Directive 2005/88 EC. Meas-
urements carried out on asphalted surface.
1.20 Vibration
Vibration
Effective acceleration value for the m
< 2.5 ------
upper extremities of the body s2
Effective acceleration value for the m

< 0.5 ------
body s2
1.21 Coolant compound table

Outside temperature Water1 Antifreeze2
Up to °C % by volume % by volume
4 99 –
- 10 79 20
- 20 65 34
- 25 59 40
- 30 55 45
- 42 50 50
1. Water quality at 20 °C = 6.5 – 8.5 ph/overall hardness 3 – 20 °dGH
2. SeeFluids and lubricants: overview on page 3-3
1-19 000 295 725 0 – RHB SCORPION

1.22 Tightening torques

General tightening torques
Tightening torques in Nm1
Screw dimensions
8.8 10.9 12.9
M4 3 4 5
M5 5.5 8 10
M6 10 14 16
M8 23 34 40
M10 46 67 79
M12 79 115 135
M14 125 185 220
M16 195 290 340
M18 280 400 470
M20 395 560 660
M22 540 760 890
M24 680 970 1150
M27 1000 1450 1700
M30 1350 1950 2300
1. These values are valid for screws with untreated, non-lubricated surfaces
Specific tightening torques

Description Tightening torque
Wheel nut 400 ±20 Nm
Track-rod end (steering ram) 280±10 Nm
Piston rod (steering ram/track rod) 270 ±10 Nm
1.23 Trailer couplings: trailer weight/drawbar load

Gross
Gross braked trailer Gross unbraked
Description drawbar load
weight rating trailer weight rating
rating
Height adjustable trailer
coupling
15000 kg1
Automatic trailer cou- 1000 kg 1000 kg
8000 kg2
pling
Autohitch3
1. With compressed-air brake system
2. With overrun brake in trailer
3. 2000 kg drawbar load from 06/2007, however maximum drawbar load for driving on roads is 1000 kg!
000 295 725 0 – RHB SCORPION 1-20

1.24 Payload: model 400-01 load diagram
Important!
Payload indications with authorised tyres
1-21 000 295 725 0 – RHB SCORPION

1.25 Payload: models 401-03 load diagram
Important!
000 295 725 0 – RHB SCORPION 1-22

1.26 Payload: model 402-03 load diagram
Important!
1-23 000 295 725 0 – RHB SCORPION

1.27 Payloads: model 403 03 load diagram
Important!
000 295 725 0 – RHB SCORPION 1-24

1.28 Payloads: model 404 03 load diagram

Rigid front axle without oscillating axle interlock (rear axle)
Important!
1-25 000 295 725 0 – RHB SCORPION

Rigid front axle with mechanical or hydraulic oscillating axle interlock (rear axle)
Important!
000 295 725 0 – RHB SCORPION 1-26

Front axle with frame levelling and without oscillating axle interlock (rear axle)
Important!
1-27 000 295 725 0 – RHB SCORPION

Front axle with frame levelling and hydraulic oscillating axle interlock (rear axle)
Important!
000 295 725 0 – RHB SCORPION 1-28

1.29 Dimensions with bucket
d
g
f 920
e e
a b c a b c
1710
2450
2650
45°
47 °
430 200
2850 1920
4760 2320
Fig. 12: Machine dimensions
1940 900
5690
Telehandler model 400-01 401-03, 402-03, 403-03 404-03

Overall length 1 (without standard bucket) 5690 mm (4760 mm) 6440 mm (5590 mm)
Overall height 2 2450 mm
Overall height with rotating beacon 2 2650 mm
Overall height of telescopic bearing2 1710 mm 1760 mm
Access height to cab2 2265 mm
Overall width without bucket3 2320 mm
Cab width 920 mm
Bucket pin height 2 retracted 4700 mm 4900 mm 5850 mm
a
extended 6460 mm 7350 mm 9120 mm
Load-over height2, 4 retracted 4410 mm 4600 mm 5555 mm
b
2, 4
Dump height retracted 3680 mm 3920 mm 4810 mm
c
d Dump reach2, 4 extended 320 mm 290 mm 270 mm
2
Length of telescopic extension retracted 4951 mm 5079 mm 5960 mm
e
f Dump-in angle4/dump-out angle4 45°/50° 45°/45° 45°/45°
g Frame levelling – ±10°
Departure angle 47 ° 50°
Transport position 200 mm
Ground clearance underneath axle and gearbox 5 430 mm
Track width, front/rear 1920 mm
Wheelbase: centre 2850 mm 3050 mm
Turning radius: between kerbs 3600 mm 3650 mm
Turning radius: between walls4 4550 mm 5050 mm
Turning radius with frame levelling:
Between kerbs – 3850 mm
Between walls 5250 mm
1. With Autohitch trailer coupling (+ 250 mm)
2. With tyres 405/70-24 MPT01 (with tyres 425/75R20 and 405/70-20 (- 50mm) 17.5LR24, 400/80R24 and 460/70R24 (+ 20 mm), 15.5-25 and 15.5-80-24 (+ 40) 19.5LR24 and 500/70R24 (+ 60)
3. With tyres 460/70 R24 (+ 60 mm), 19.5LR24 A-570 (+ 100 mm), 500/70R24 (+ 90 mm), 17.5LR24 (+ 40 mm)
4. With standard bucket 2400 mm/1.2 m 3
5. Ground clearance 405 mm with cardan shaft guard (option)
1-29 000 295 725 0 – RHB SCORPION

1.30 Dimensions with pallet forks
a b a b
Fig. 13: Machine dimensions
401-03,
Telehandler model 400-01 404-03
402-03, 403-03
Pallet forks pin height1 retracted 4700 mm 4900 mm 5850 mm
a
Pallet height1, 2 retracted 4530 mm 4760 mm 5700 mm
b
c Dump-in angle in transport position 2 20 °
2
d Dump-out angle 75 ° 70 °
2
Turning radius: with forks between walls 4550 mm 5250 mm
Turning radius with frame levelling:
–
With forks between walls2 5300 mm
1. With tyres 405/70-24 MPT01 (with tyres 425/75R20 and 405/70-20 (- 50mm) 17.5LR24,
400/80R24 and 460/70R24 (+ 20 mm), 15.5-25 and 15.5-80-24 (+ 40) 19.5LR24 and 500/70R24 (+ 60)
2. With pallet forks
➥ See page 1-29 for further dimensions
000 295 725 0 – RHB SCORPION 1-30

1-31 000 295 725 0 – RHB SCORPION

Maintenance and servicing work
3 Maintenance and servicing work

3.1 Explanation of symbols on the maintenance label

Affixed on the cab
Symbol Explanation
Before starting maintenance work, follow the safety instructions in the Operator's Manual!
Before starting maintenance work, read the “Maintenance” chapter in the Operator's Manual!
Carry out a functional check of the light system!
Check tyres for damage, pressure and tread depth!
Carry out a functional check and synchronise the steering system!
P Carry out a functional check of the brake system!
Check hydraulic oil level. Fill up if necessary!
Check engine oil level. Fill up if necessary!
Compress the dust valve
Check radiator for engine coolant and hydraulic oil for contamination. Clean if necessary!
Check condition and initial tension of V-belts. Retighten or replace if necessary!
Leakage check:
Check for tightness, leaks and chafing: pipes, flexible lines and screw connections. Rectify if necessary!
Visual check!
Check wear parts and screw connections at regular intervals
Retighten loose connections immediately and replace worn wear parts!
Leakage check:
Check the fuel/water separator. Drain water if necessary!
Lubrication service:
Lubricate the assemblies concerned!
3-1 000 295 725 0 – RHB SCORPION

3.2 Maintenance label
Pflege- und Wartungsarbeiten
1000153091
Service and maintenance work
Travaux de maintenance
Täglich
Daily
Tous les jours
10 h
20 h
Täglich
Daily
Tous les jours
10 h P
20 h
Typ 400/ 401/ 402/ 403/ 404
000 295 725 0 – RHB SCORPION 3-2

3.3 Fluids and lubricants: overview

Engine/machine SAE grade Season/temper-
Component/ application Capacities1
fluid Specification ature
SAE 10W; EO103 Below -5 °C
3
SAE 20W20; EO20 -10 to +10 °C
Diesel engine Engine oil2 with filter SAE 30; EO30 3 5 to 30 °C 12.5 l
3
HD-C 10W-40; EO1040B
Year-round
HD-C 15W-40; EO1540B3
20 kph gearbox 0.8 l
SAE 85 W 90
30/40 kph gearbox (option) 4.0 l
(API GL4 MIL L-2105)
Planetary drives – left and right, Gearbox oil (API GL5 MIL 2105-B) Year-round
0.75 l each
front/rear axle
Front and rear axle differentials SAE 90 LS (hypoid gear oil) 7.1 l each
4
Hydraulic oil HVLPD 46 (HYD0530)
Hydraulic oil tank AVIA Syntofluid 46 Year-round About 100 l5
Biodegradable oil
PANOLIN HLP Synth 46
Grease nipples, telescopic boom Lithium-saponified brand-name
Multipurpose grease Year-round As required
slide plates grease MPG-A3
Battery terminals Acid-proof grease SP-B3 Year-round As required
Optimoly paste “TA”
Mounting of pins, shafts Special grease Year-round As required
White paste
Grade no. 2-D Over 4 °C
Fuel tank Diesel fuel6 About 190 l
Grade no. 1-D Below 4 °C
Brake system Brake fluid7 Agip LHM Super/Shell LHM Year-round 0.5 l
Air conditioning (option)8 Refrigerating agent9 R 134a/DIN 9860 Year-round About 1300 g
Water
Year-round 7.25 l (50 %)
Engine cooling Antifreeze10, 11, 12
MS Frostschutz HAVOLINE XLC
- 40 °C Antifreeze
7.25 l (50 %)
Water
11 1.0 l (33 %)
Washer system Cleaning agent Water + antifreeze Year-round
Antifreeze
2 l (67 %)
1. The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level
2. MIL-L-2104C; API CD/CE/CF4; CCMC-D4
3. Abbreviation for lubricants (Hauptverband der Deutschen Bauindustrie e. V. – German construction engineering association)
4. DIN 51 524
5. Total capacity of hydraulic system about 170 l
6. DIN 51 601, min 45 cetane
7. Do not mix this brake fluid with other brake fluids (standards: B 71 2710 and ISO 7308)
8. Maintenance work must be carried out by trained staff only
9. Bear in mind the safety data sheet during maintenance work
10. SeeCoolant compound table on page 1-19
11. See manufacturer's indications on the packaging and bear in mind the antifreeze compound table
12. Replace the coolant every 2 years!
3-3 000 295 725 0 – RHB SCORPION

3.4 Maintenance plan (overview)
“A”
“B”
“C”
For service and maintenance work on the attachment, please refer to the operation and maintenance manual of the
work
Delivery
at 100 s/h
inspection
attachment manufacturer as well.
once a year
(once a day)
Every 50 s/h
once a week
Maintenance
every 500 s/h2
every 1500 s/h
2nd Inspection
1st Inspection1
Oil and filter changes ( ) (check the oil levels after a test run):
000 295 725 0 – RHB SCORPION

• Engine oil ● ● ●
• Engine oil filter ● ● ●

• Fuel filter (prefilter and main filter) ● ● ●
• Air filter insert 3,4 replace safety cartridge every 3rd time the air filter insert is replaced ● ●
• Gearbox oil in front and rear axle differentials and in rear axle gearbox ● ●
• Gearbox oil in gearbox ● ●
• Gearbox oil in front and rear axle planetary drives (left and right) ● ●
5 ●
• Hydraulic oil
• Hydraulic oil filter insert/reflux filter ● ●
• Line filter (power train) ● ●
• Hydraulic oil tank breather filter 4 ●
• Heating: fine-dust fiter and recirculated-air filter10 ● ●

Inspection work ( ):
• Condition of paint coating ●
• Engine oil (level) ● ● ●
• Hydraulic oil (level) ● ● ● ● ●
• Check the filter insert in the load sensing line (variable displacement pump) for dirt, clean it if necessary ● ● ●
• Gearbox oil in front and rear axle differentials and in rear axle gearbox (level) ● ●
• Gearbox oil in front and rear axle, left and right planetary drives (level) ● ●
6 ● ● ● ● ● ●
• Brake fluid (level)
• Check radiator (engine/hydraulic oil) for dirt, clean if necessary6, 7 ● ● ● ● ●
• Check the charge-air cooler for dirt, clean if necessary and drain condensation water8 ● ● ● ●
• When using biodegradable oil: drain the condensation water in the hydraulic oil tank 5 ● ●
• Clean the dust valve on the air filter3 ● ● ● ● ●

3-4
3-5
“A”
“B”
“C”
work
Delivery
at 100 s/h
inspection
once a year
(once a day)
Every 50 s/h
once a week
Maintenance
every 500 s/h2
every 1500 s/h
1st Inspection1
2nd Inspection
• Clean the dust receptacle on the air filter (option) ● ● ● ● ●
• V-belts: check condition and pre-tension, retighten and replace if necessary9 ● ● ● ● ● ●
• Fuel system ● ● ● ● ● ●
• Check the fuel/water separator. Drain water if necessary ● ● ● ● ●
• Check valve tip clearance (engine timing). Set if necessary ●
• Battery: check charge condition ● ●
• Heating: clean fine-dust filter and recirculated-air filter, replace every 500 s/h if necessary10 ● ●
• Air conditioning (option) check coolant level, clean compressor and evaporator11 ● ● ● ● ● ●
• Check the multidisc brake of the service and parking brake ● ● ● ● ● ●
• Drain the water in the compressed-air tank (compressed-air brake option) ● ● ● ● ● ●
• Tyre check (damage, air pressure, tread depth) ● ● ● ● ● ●
• Trailer coupling (damage, wear) ● ● ● ● ● ●
• Check and readjust slide plates on telescopic boom. Replace if necessary 12 ● ● ● ● ● ●
Check screws and nuts or screw connections for tightness on the following assemblies/components. Retighten if necessary
• Engine and engine bearing ● ● ● ● ●
• Steering system ● ● ● ● ●
• Hydraulic system ● ● ● ● ●
• Telescopic boom (pin locking), quickhitch lock ● ● ● ● ●
• Axle mounting, axle suspension ● ● ● ● ●
• Counterweight (attachment) ● ● ● ● ●
• Fastening screws of cardan shafts ● ● ● ● ●
• Fastening screws of cab ● ● ● ● ●
• Wheel nuts ● ● ● ● ●
• Electric system: check electric and earth connections, chafing on wiring harness, battery terminals ● ● ● ● ●
000 295 725 0 – RHB SCORPION

“A”
“B”
“C”
work
Delivery
at 100 s/h
inspection
once a year
(once a day)
Every 50 s/h
once a week
Maintenance
every 500 s/h2
every 1500 s/h
2nd Inspection
1st Inspection1
Lubrication service13 ( )
000 295 725 0 – RHB SCORPION

• Rear axle oscillating bearing ● ● ● ● ●
• Front and rear axle planetary drive bearings (left and right) ● ● ● ● ●
• Hinges, joints and fittings (e.g. door arrester) ● ● ● ● ● ●
• Trailer coupling (option) ● ● ● ● ● ●
• Telescopic boom – see Lubricating the telescopic boom on page 3-38
• Telescopic boom slide plates ● ● ● ● ● ●
• Compensating ram bearing ● ● ● ● ● ●
• Telescopic ram bearing (push-out ram) ● ● ● ● ● ●
• Boom bearing ● ● ● ● ● ●
• Tilt lever bearing and tilt rod bearing ● ● ● ● ● ●
• Lift ram bearing ● ● ● ● ● ●
• Tilt ram bearing ● ● ● ● ● ●
• Quickhitch: bearing on boom ● ● ● ● ● ●
Functional check ( ):
Check the function of the following assemblies/components. Rectify if necessary:
• Service and parking brake ● ● ● ● ● ●
• Compressed-air brake system (option) ● ● ● ● ● ●
• Steering system: steering column adjustment, synchronous position of wheels ● ● ● ● ● ●
• Lights and electric system ● ● ● ● ● ●
• Drive interlock (option) ● ● ● ● ● ●
• Safe load indicator of telescopic boom ● ● ● ● ● ●
• Seat adjustment, seat belt ● ● ● ● ● ●
• Control lever lock (joystick) for road travel ● ● ● ● ● ●
• Hose burst valve safety feature ● ● ● ● ● ●
• Load stabiliser (option) ● ● ● ● ● ●
• Additional control circuits (option) ● ● ● ● ● ●
3-6
3-7
“A”
“B”
“C”
work
Delivery
at 100 s/h
inspection
once a year
(once a day)
Every 50 s/h
once a week
Maintenance
every 500 s/h2
every 1500 s/h
1st Inspection1
2nd Inspection
Leakage check ( ):
Check for tightness, leaks and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Rectify if necessary:
• Air intake line (air filter, turbocharger, engine charge-air cooler) ● ● ● ● ● ●
• Engine lubrication (engine – filter) ● ● ● ● ● ●
• Fuel lines14 ● ● ● ● ● ●
• Cooling system (engine – hydraulic oil) ● ● ● ● ● ●
• Steering system (flexible lines and rams)15 ● ● ● ● ● ●
• Hydraulic system/telescopic boom (flexible lines and rams)15 ● ● ● ● ● ●

• Additional control circuit quick couplers, 3rd control circuit, tipping trailer connection (option) ● ● ● ● ● ●
• Brake system6 (flexible lines and cylinders, compressed air) ● ● ● ● ● ●
• Air conditioning – flexible lines, compressor, evaporator, attachment (option) ● ● ● ● ● ●
1. Work to be carried out once after the first 100 s/h. This work must be carried out by an authorised workshop for warranty claims to be acknowledged.
2. Work after the first 500 s/h (2nd Inspection) must be carried out by an authorised workshop for warranty claims to be acknowledged
3. Replace filter insert as indicated by the telltale, however at least every 12 months or 1500 s/h.
4. When working in an acidic environment, replace the filter every 300 s/h!
5. When using biodegradable oil: drain the condensation water in the hydraulic oil tank every 500 s/h, in any case before the cold season.
6. Replace the brake oil every 2 years
7. Depending on operation and dust conditions, it may be necessary to clean the radiator more frequently
8. Drain the condensation water every 1500 service hours
9. Replace the V-belts after 2 years at the latest
10. Depending on operation and dust conditions, it may be necessary to replace the dust filter more frequently
11. Replace the dehumidifier every 2 years or after maintenance and repair work on the refrigerating circuit
12. Minimum wear plate thickness (8 mm)
13. Lubricate attachment according to manufacturer's instructions!
14. Replace flexible fuel leak oil lines every 2 years
15. Replace flexible lines every 6 years (UVV, DIN 20066 part 5)
000 295 725 0 – RHB SCORPION

3.5 Introduction
Operational readiness and the service life of the telehandler are heavily dependent on
maintenance.
Maintenance work must be carried out by trained and qualified staff only.
☞ See “Maintenance plan (overview)” on page 3-4
Caution!
Before carrying out service and maintenance work, always read, understand
and follow the instructions given in
☞ chapter 2 “SAFETY INSTRUCTIONS” of this Operator's Manual
☞ the Operator's Manuals of the attachments
☞ Make sure the lift ram of the telescopic boom is secured with a prop so the
telescopic boom cannot be lowered unintentionally if you need to carry out
maintenance work with the telescopic boom raised
3.6 Safety prop for telescopic boom

The safety prop is located
A ➥ on models 400 – 403: on the machine frame at the front right over the axle mounting
➥ on model 404: on the machine frame at the rear right
Model 404
B
Danger!
Do not carry out assembly and maintenance work if the telescopic boom is
raised and not secured –
Danger of crushing and injury!
☞ Fit safety prop A on the extended lift ram and
☞ secure it with pin B (or a screw) (see figure)
Models 400 – 403
000 295 725 0 – RHB SCORPION 3-8

3.7 Fuel system

Specific safety instructions
• Extreme caution is essential when handling fuel – high risk of fire!
• Never carry out work on the fuel system in the vicinity of naked flames or sparks!
• Do not smoke when working on the fuel system or when refuelling!
• Before refuelling, switch off the engine and remove the ignition key!
• Do not refuel in closed rooms!
• Wipe away fuel spills immediately!
• Keep the machine clean to reduce the risk of fire!
Refuelling
Filler inlet A of the fuel tank is located on the left in driving direction, behind the cab
Danger!
A All work involving fuel carries an increased
Danger of fire and poisoning!
☞ Do not refuel in closed rooms
☞ Never carry out work on the fuel system in the vicinity of naked flames or
sparks
Fig. 1: Fuel filler inlet
Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an
environmentally friendly manner!
Stationary fuel pumps

General
wrong ✗ Only refuel from stationary fuel pumps. Fuel from barrels or cans is usually contaminated.
Even the smallest particles of dirt can cause
• Increased engine wear
• Malfunctions in the fuel system and
• Reduced effectiveness of the fuel filters
right ✓ Refuelling from barrels
If refuelling from barrels cannot be avoided, note the following points:
Fig. 2: Refuelling from a barrel • Barrels must neither be rolled nor tilted before refuelling
• Protect the suction pipe opening of the barrel pump with a fine-mesh strainer
• Immerse it down to a max. 15 cm above the floor of the barrel
• Only fill the tank using refuelling aids (funnels or filler pipes) with integral microfilter
• Keep all refuelling containers clean at all times
3-9 000 295 725 0 – RHB SCORPION

Diesel fuel specification

Use only high-grade fuels
Grade Cetane no. Use
No. 2-D according to DIN EN 590 For normal outside temperatures
Min. 45 For outside temperatures below 4 °C or
No. 1-D according to DIN EN 590
for operation above 1500 m altitude
Checking/replacing the fuel prefilter (water separator)

☞ Drain the condensation water in the fuel prefilter every 50 s/h (service hours)
☞ or if the telltale on the instrument panel comes on
Danger!
If the fuel, as it drains, comes into contact with hot engine parts or the exhaust
system, there is an increased
Danger of burns!
☞ Never bleed the fuel system if the engine is hot!
Environment!
☞ Proceed as follows:
• Switch off the engine
• Apply the parking brake with the switch
• Switch off the ignition and remove the ignition key
• Open the engine cover
• Place a container to collect the fuel
A • Remove the cover plate
• Unscrew drain plug B on sight glass A of the fuel prefilter
• Drain the water until the fuel that flows out is clean
B • Tighten drain plug B
Fig. 3: Checking the fuel/water separator • Test run the engine and check for leaks
• Mount the cover plate
Replace the fuel prefilter every 500 s/h (service hours)
• Place a container to collect the fuel
4
• Remove cable 1 from the plug on the water receptacle
• Remove water receptacle 2 (arrow)
3
• Remove filter cartridge 3 with a slight rotation
• Clean filter housing 4
2 • Insert a new filter cartridge 3
• Clean and install water receptacle 2
1 • Install cable 1 on the plug of the water receptacle
• Test run the engine and check for leaks
g. 4: Replacing the fuel/water separator • Mount the cover plate
000 295 725 0 – RHB SCORPION 3-10

Replacing the fuel filter
Danger!
If the fuel, as it drains, comes into contact with hot engine parts or the exhaust
system, there is an increased
A Danger of burns!
☞ Never bleed the fuel system if the engine is hot!
Environment!
Fig. 5: Fuel filter position
• Park the machine on level ground
• Lower the telescopic boom fully
B
A • Switch off the engine
• Place a suitable container underneath the engine to collect the fuel as it drains
• Slacken and unscrew filter cartridge A with a commercially available filter spanner
• Clean the inside of the filter head
A • Apply a thin coat of fuel to rubber seal B of the new filter cartridge
• Tighten the new filter cartridge by hand until the gasket makes contact
Fig. 6: Replacing the fuel filter
• Tighten filter cartridge A by hand by about a further half revolution
• Bleed the fuel system – see Bleeding the fuel system on page 3-12
• Let the engine run and check the filter cartridge for leaks
3-11 000 295 725 0 – RHB SCORPION

Bleeding the fuel system

Bleed the fuel system in the following cases:
• After removing and fitting the fuel filter, prefilter or the fuel lines back on again
• After running the fuel tank empty
• After running the engine again, after it has been out of service for a longer period of
time
☞ Bleed the fuel system as follows:
1 • Switch off the engine
• Fill the fuel tank
• Place the container under the engine
• Slacken bleed screw 1 on the injection pump by a few turns
2 • Press button 2 on the fuel prefilter with your hand (pumping movement) until the fuel
comes out free of air from the slackened bleed screw
• Tighten bleed screw 1
• Start the engine
If the engine runs smoothly for a while, and then stops; or if it does not run smoothly:
• Check once again if there is any air in the fuel system
• Bleed the fuel system again as described above
Fig. 7: Bleeding the fuel system
• Have this checked by authorised staff if necessary
000 295 725 0 – RHB SCORPION 3-12

3.8 Engine lubrication system: maintenance
Caution!
If the engine oil level is too low or if an oil change is overdue, this may cause
☞ Engine damage or loss of output!
☞ Drain the oil
☞ – see Maintenance plan (overview) on page 3-4
Checking the engine oil level
Important!
Check the oil level every 10 service hours or once a day.

We recommend checking it before starting the engine. After switching off a warm
engine, wait at least 5 minutes before checking.
☞ Place the telehandler horizontally

max
☞ Lower the telescopic boom fully
☞ Switch off the engine
min
☞ Switch off the ignition and remove the ignition key

☞ Apply the parking brake with the switch
☞ Open the engine cover
☞ Pull out oil dipstick A
A
➥ Wipe it with a lint-free cloth
➥ Push it back in as far as possible
➥ Withdraw it and read off the oil level
Fig. 8: Checking the oil level
☞ However if necessary, fill up the oil at the latest when the oil reaches the MIN mark on
the oil dipstick A – see Filling up engine oil on page 3-14
3-13 000 295 725 0 – RHB SCORPION

Filling up engine oil
Caution!
Too much or incorrect engine oil may result in engine damage! For this reason:
☞ Do not add engine oil above the MAX mark of oil dipstick A
☞ Use only the specified engine oil
☞ – see Fluids and lubricants: overview on page 3-3
Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in
an environmentally friendly manner!
☞ Clean the area around oil filler cap B with a lint-free cloth
OIL ☞ Open filler cap B
A B ☞ Raise oil dipstick A slightly to allow any trapped air to escape
☞ Fill in engine oil
➥ Wait a moment until all the oil has run into the oil sump
☞ Check the oil level
➥ – see Checking the engine oil level on page 3-13
☞ Fill up if necessary and check the oil level again
☞ Close filler cap B
☞ Push oil dipstick A back in as far as possible
Fig. 9: Filling up engine oil
☞ Completely remove all oil spills from the engine
000 295 725 0 – RHB SCORPION 3-14

Replacing the engine oil every 500 s/h (service hours)
Danger!
Caution when draining hot engine oil –
☞ Danger of burns!
+80 °C ☞ Wear protective gloves
☞ Use suitable tools
OIL Environment!
Fig. 10: Optimum engine oil temperature
Use a suitable container to collect the engine oil as it drains and dispose of it in
•Park the machine on level ground
•Lower the telescopic boom fully
•Apply the parking brake with the switch
•Let the engine run until it reaches its operating temperature (oil temperature
about 70 – 80 °C)
• Remove the cover plate
• Place a container (about 15 l capacity) under the opening to collect the oil as it drains
• Carefully unscrew the oil drain plug on the oil pan
☞ Once the oil is completely drained
• Screw the oil drain plug back onto the oil pan with a new sealing ring
• Replace the engine oil filter
– see Replacing the engine oil filter cartridge every 500 s/h (service hours) on
page 3-16
• Fill in engine oil – see Filling up engine oil on page 3-14
• Check the oil level – see Checking the engine oil level on page 3-13
• Start the engine and let it run briefly at low revs
• Check the engine oil pressure by means of the telltale
• Wait a moment until all the oil has run into the oil sump
• Check the oil level again
• Fill up if necessary and check again
• Completely remove all oil spills from the engine
3-15 000 295 725 0 – RHB SCORPION

Replacing the engine oil filter cartridge every 500 s/h (service hours)
Danger!
Caution when handling hot engine oil –
H
Danger of burns!
☞ Wear protective gloves
Environment!
Fig. 11: Engine oil filter position Collect the drained engine oil in a suitable container. Dispose of used oil and
filters in an environmentally friendly manner!
Engine oil filter H is accessed via the maintenance flap in the rear right wheel well
I
H • Switch off the engine
• Remove the servicing lid
• Place a suitable container underneath the oil filter to collect the oil as it drains
• Slacken and unscrew oil filter cartridge H with a commercially available oil filter
H spanner
• Clean the inside of the filter head
Fig. 12: Replacing the engine oil filter
• Apply fresh engine oil to rubber seal I of the new oil filter cartridge and screw on the
filter cartridge by hand until the seal makes contact
• Tighten the oil filter cartridge to 15 – 17 Nm with a (commercially available) torque
wrench
• Drain the engine oil
– see Replacing the engine oil every 500 s/h (service hours) on page 3-15
000 295 725 0 – RHB SCORPION 3-16

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.
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 mainte-
nance 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 switching off 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 3-3
• Do not use radiator cleaning compounds if an antifreeze compound has been added
to the coolant – otherwise this causes sludge to form, which can damage the engine
Environment!
Use a suitable container to collect the coolant as it drains and dispose of it in
3-17 000 295 725 0 – RHB SCORPION

Checking the coolant level and quality
Important!
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 • Park the machine on level ground
C A • Switch off the engine
MAX
B MIN • 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
Fig. 13: Checking the coolant expansion tank ☞ Check the coolant quality (antifreeze) with suitable testing equipment (antifreeze tester)
➥ – see Fluids and lubricants: overview on page 3-3 and
– see chapter 1 “Coolant compound table” on page 1-19
000 295 725 0 – RHB SCORPION 3-18

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 switching off 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 • Park the machine on level ground
C A • Switch off the ignition and remove the ignition key
MAX
• Allow the engine/cooling system to cool down
MIN
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
Fig. 14: Filling up coolant in the expansion tank • Use brand-name antifreeze compounds with anticorrosion additives – see Fluids and
lubricants: overview on page 3-3
and – see chapter 1 “Coolant compound table” on page 1-19
• Close filler cap D
• Start and warm up the engine, as you do so:
• Open the heating circuit fully (see Operator's Manual)
• 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
3-19 000 295 725 0 – RHB SCORPION

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!
☞ 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:

•Park the machine on level ground
D
•Lower the telescopic boom fully
•Apply the parking brake with the switch
C A •Switch off the engine
MAX
•Switch off the ignition and remove the ignition key
MIN •Set the heating temperature controller to max. temperature in order to drain the
coolant from the heating circuit as well (see Operator's Manual)
• 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
E • 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 3-3
Fig. 15: Draining coolant and – see chapter 1 “Coolant compound table” on page 1-19
• Close filler cap D fully
• Open the heating circuit fully (see Operator's Manual)
• Start and warm up the engine until the thermostat opens
• 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
000 295 725 0 – RHB SCORPION 3-20

Cleaning the radiator fins
Danger!
Warm engine –
Danger of burns!
☞ 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 main-
tenance plan 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
☞ Switch off the engine and let it cool down
☞ Clean the radiator fins by blowing compressed air from the engine side
Caution!
Fig. 16: Cleaning the radiator 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!
3-21 000 295 725 0 – RHB SCORPION

3.10 Cleaning the radiator with the reversing fan (option)

The telehandler is fitted with a reversing fan. Pressing tip switch T reverses the fan's direc-
tion of rotation and cleans the radiator. The radiator can be cleaned at any time with the
T
reversing fan during machine operation and with the diesel engine running.
Caution!
A
B ☞ Check and clean the radiator once a day.

Ar ma_re_02_2.iso ☞ Clean the radiator more frequently in dusty or dirty work conditions
☞ Do not clean in closed premises
Tip switch T for the reversing fan is located on the instrument panel on the right.
☞ Press tip switch T briefly to position B
➥ The fan reverses its direction of rotation,
➥ the fan is in cleaning mode and the
A
➥ dirt is removed from the radiator
➥ This can be seen by the dust A blown out from the intake screen on the engine
cover
➥ The fan automatically switches back to cooling mode after about 1 minute
Fig. 17: Tip switch for reversing fan
Important!
When working in especially dusty environment, clean the radiator repeatedly and
more frequently!
000 295 725 0 – RHB SCORPION 3-22

3.11 Air filter maintenance

Checking air filter contamination
Cleaning the dust valve once a day
51
• 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

Telltale 51 on the instrument panel monitors the filter cartridge.
A ☞ Filter cartridge D must be replaced if:
• Telltale 51 on the instrument panel 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 3-24
D Caution!
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 serv-
34001b520_02.iso ice hours!
F
Fig. 18: Air filter – dust valve
Checking the dust collector (option) once a day

1 • Apply the parking brake with the switch
• Remove cover 1 from the dust collector
2
• Remove and empty the dust container 2
• Insert the dust container and mount the cover
Caution!
Make sure the dust in the container has a minimum distance of 25 mm to the
Fig. 19: Air filter – dust valve cover otherwise the engine is damaged!
3-23 000 295 725 0 – RHB SCORPION

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
H
☞ Replace the filter cartridge when the telltale comes on
☞ Never reuse a damaged filter cartridge
307b0700.ai
☞ Ensure cleanliness when replacing the filter cartridge!
D
307b0710.ai
• Fold both locks G on lower housing section H to the outside
• Remove lower housing section H
D • 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
• Make sure all contamination (dust) inside the upper and lower housing sections has
been removed
H
• Insert a new safety cartridge F into the upper housing section
F • Insert new filter cartridge D into the upper housing section
• Position lower housing section H (make sure it is properly seated)
Fig. 20: Removing the filter element
• Close both locks G
000 295 725 0 – RHB SCORPION 3-24

3.12 Maintenance: V-belts
Danger!
Only check or retighten/replace the V-belts when the engine is switched off –
Danger of personal injury!
☞ Switch off the engine before carrying out 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 it if necessary.
Retighten new V-belts after about 15 minutes of running time.
Check as follows:
Fig. 21: Checking V-belt tension
☞ Remove the V-belt guard
☞ Carefully inspect the V-belts for damage
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 pul-
leys by no more than about 10 mm
☞ Retighten the V-belt if necessary
Retightening the V-belts

Retighten as follows:
A
☞ Apply the parking brake with the switch (99)
☞ 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
☞ Firmly retighten fastening screws 1, 2 + 4 of alternator 5
Fig. 22: Retightening the V-belts ☞ Check V-belt tension again
3-25 000 295 725 0 – RHB SCORPION

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 (overview) on page 3-4
Checking the oil level in the gearbox

• Park the machine on level ground when the gearbox is at operating temperature
• Oil filler and inspection 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 whilst holding a cloth under the opening
• Only use new sealing rings for oil filler and drain plugs.
A
If the oil level is below the opening or if the oil level cannot be seen at all:
• Fill up the oil – see Filling up the gearbox oil on page 3-26
Environment!
Use a suitable container to collect the gearbox oil as it drains and dispose of it
in an environmentally friendly manner!
Fig. 23: Checking the oil level in the gearbox
Filling up the gearbox oil

• Park the machine on level ground when the gearbox is at operating temperature
• oil filler and inspection plug B on 30 kph and 40 kph gearbox (Ecospeed): clean
and unscrew the plug whilst holding a cloth under the opening
A 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
• 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
Fig. 24: Checking the oil level in the gearbox
000 295 725 0 – RHB SCORPION 3-26

Changing the gearbox oil
Danger!
Careful when draining hot gearbox oil –
Danger of burns!
☞ Use suitable tools, e.g. for unscrewing the oil drain plug!
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
• Unscrew oil filler and inspection plug B on the 30 kph or 40 kph gearbox
A (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)
C
Caution!
30 kph or 40 kph Do not unscrew oil drain plug D!
gearbox
☞ It is used for draining the hydraulic oil
• Completely drain the old gearbox oil

• Tighten drain plug C or E with a new sealing ring
B • Fill in oil until it runs out of filler opening A or B – see Filling up the gearbox oil on
page 3-26
Environment!
30 kph or 40 kph Use a suitable container to collect the gearbox oil as it drains and dispose of it
gearbox in an environmentally friendly manner!
Fig. 25: Changing the gearbox oil
3-27 000 295 725 0 – RHB SCORPION

Rear axle differential oil level

Checking the oil
A • 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
• 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
Fig. 26: Oil filler and inspection plug on the differential Filling up oil
• 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
If the oil level in the differential remains constant:
Draining the oil in the rear axle differential
Important!
Drain oil only after running the machine for a longer period of time (operating tem-
perature)!
Danger!
Danger of burns!
• Park the machine on level ground when the differential is at operating temperature
A
• Place an adequately sized container under the differential housing of the rear axle to
B collect the oil
• Clean and unscrew plugs A and B
• Unscrew oil drain plug C
• Completely drain the old gearbox oil
C
• Tighten drain plug C with a new sealing ring to make an oil-tight seal
• Fill in oil through opening A until it runs out of opening B
Fig. 27: Oil drain plug on rear axle differential If the oil level in the differential remains constant:
• Tighten plugs A and B with new sealing rings to make oil-tight seals
After carrying out a test run:
• Check the oil level again after about 5 minutes, and fill up if necessary
000 295 725 0 – RHB SCORPION 3-28

Front axle differential oil level

Checking the oil
• Fill up with oil
A If the oil level is correct:
Fig. 28: Oil filler and inspection plug on the differential Filling up oil
Draining the oil in the front axle differential
Important!
Drain oil only after running the machine for a longer period of time (operating tem-
A B perature)!
Danger!
C
Fig. 29: Oil filler and inspection plug on the differential
Danger of burns!
• Park the machine on level ground when it is at operating temperature
• Clean and unscrew plugs A and B
• Place a container under plug C to collect the oil
• Completely drain the old oil
• Tighten drain plug C with a new sealing ring to make an oil-tight seal
• 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 carrying out a test run:
☞ Check the oil level again after about 5 minutes, and fill up if necessary
3-29 000 295 725 0 – RHB SCORPION

Planetary drives: checking and filling up the oil level
Important!
Drain oil only after running the machine for a longer period of time!
A
☞ 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)
Fig. 30: Oil filler and inspection plug on planetary drive • 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
• Fill up the oil
A ☞ Fill up the oil
• Clean and unscrew plug A (to release possible overpressure)
• Place plug A in the position shown in fig. 31 (filler plug must be horizontal)
Fig. 31: Oil filler and inspection plug on planetary drive
• 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

• Park the machine at operating temperature on level ground and secure it against
rolling away
• Place a suitable container under drain plug A
A
• 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 downwards (plug must be at the bottom)
Fig. 32: Oil drain plug on planetary drive • 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
A • Tighten plug A with a new sealing ring to make an oil-tight seal
Fig. 33: Oil filler and inspection plug on planetary drive
000 295 725 0 – RHB SCORPION 3-30

3.14 Safety instructions regarding the hydraulic system

• Release the pressure in all lines carrying hydraulic oil prior to any maintenance and
repair work. To do this:
• Lower all hydraulically controlled attachments to the ground
• Move all control levers of the hydraulic control valves several times
• Apply the parking brake to prevent the machine from rolling away before you carry out
service and maintenance work
• Hydraulic oil escaping under high pressure can penetrate the skin and cause serious
injuries. Always consult a doctor immediately even if the wound seems insignificant –
otherwise serious infections could set in!
• If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has
penetrated the hydraulic system. This may cause damage to the hydraulic pump!
☞ Contact your CLAAS dealer immediately
Caution!
Contaminated hydraulic oil, lack of oil or wrong hydraulic oil –
Danger of severe damage to the hydraulic system!
☞ Take care to avoid contamination when working!
☞ Always fill in hydraulic oil using the filling screen!
☞ Only use authorised oils of the same type
☞ Always fill in hydraulic oil before the level gets too low
☞ If the hydraulic system is filled with biodegradable oil, then only use biode-
gradable oil of the same type for filling up – observe the sticker on the
hydraulic oil tank
☞ Have the hydraulic oil replaced by an authorised workshop only
Environment!
Collect drained hydraulic oil and biodegradable oil in a suitable container! Dis-
pose of drained oil and used filters by an ecologically safe method.
Always contact the relevant authorities or commercial establishments in
charge of oil disposal before disposing of biodegradable oil.
3-31 000 295 725 0 – RHB SCORPION

3.15 Monitoring the hydraulic oil and the reflux filter

The red telltale 50 on the instrument panel monitors the reflux filter.
50
Caution!
If telltale 50 on the instrument panel comes on when the hydraulic oil is at
operating temperature
☞ Check the hydraulic oil level,
☞ or drain the hydraulic oil
☞ Have hydraulic oil and the filter element replaced by an authorised work-
shop only!
☞ At the latest after 1500 service hours (once a year)
Fig. 34: Telltale for reflux filter
Telltale 50 on the instrument panel can come on in cold weather immediately after starting
the engine. This is caused by increased oil viscosity.
In this case:
☞ Set the engine revs so that telltale 50 (on the instrument panel) goes out
☞ Bear in mind the instructions concerning warmup
3.16 Checking the hydraulic oil level

The oil level sight glass is located on the hydraulic oil tank behind the cab.
• Park the telehandler on level ground
• Retract all hydraulic rams
B
• Check the hydraulic oil level in sight glass A
A ☞ If the oil level is visible in the lower half of the oil level sight glass
➥ OK
☞ If the oil level is not visible in the oil level sight glass (not enough oil)
• Fill up the hydraulic oil
Fig. 35: Oil level sight glass on the hydraulic oil tank
Caution!
Any excess quantity of hydraulic oil in the tank escapes via the breather B as
soon as the temperature rises!
The oil level is no longer visible in the upper half of the oil level sight glass A!
☞ Drain hydraulic oil
000 295 725 0 – RHB SCORPION 3-32

3.17 Filling up hydraulic oil

Do not fill up the hydraulic oil unless the engine is switched off. Otherwise, hydraulic oil will
run out of the filler opening on the hydraulic tank.
☞ Fill up as follows:
• Retract all hydraulic rams
B • Apply the parking brake with the switch
A • Clean the area around the filler and breather filter B with a cloth
• Open breather filter B by hand
With the filter insert in place:
Fig. 36: Hydraulic oil tank • Check the hydraulic oil level on oil level sight glass A
• Fill up if necessary and check again
• Firmly close breather filter B by hand
3.18 Replacing the reflux filter of the hydraulic system

☞ Replace the reflux filter as follows:
C • Retract all hydraulic rams
D • Switch off the engine
B • Apply the parking brake with the switch
A
• Clean the area around the housing of reflux filter A with a cloth
• Open filler cap B
• Remove compression spring C
• Remove reflux filter D and insert a new one
Fig. 37: Reflux filter
• Use a new gasket as you install cap B
3.19 Replacing the microfilter of the hydraulic system

☞ Replace the reflux filter as follows:
A • Switch off the engine
C • Switch off the ignition and remove the ignition key
• Clean the area around the housing of microfilter A with a cloth
B • Unscrew filter housing B
• Remove microfilter C and insert a new one
• Use a new gasket as you install filter housing B
• Tighten the filter housing by hand
Fig. 38: Microfilter
3-33 000 295 725 0 – RHB SCORPION

3.20 Replacing hydraulic oil
Danger!
Caution when draining hot hydraulic oil and removing the filter element –
Danger of burns!
☞ Use an oil drain coupling with a sufficiently long hose
Environment!
Collect drained hydraulic oil and biodegradable oil in a suitable container! Dis-
pose of drained hydraulic oil by an ecologically safe method!
Always contact the relevant authorities or commercial establishments in
charge of oil disposal before disposing of biodegradable oil.
• Retract all hydraulic rams. To do this:
• Lower the telescopic boom completely
• Tilt in the tilt ram fully
A • Switch off the engine and prevent the machine from rolling away
• Unscrew breather filter A to release the pressure in the hydraulic oil tank
– there must be no pressure in the system!
• Place a suitable container under the machine at the rear to collect the oil as it drains
(minimum capacity 110 l)
• Remove filler cap C of oil drain valve D
• Place the end of the hose connected with the oil drain coupling in the container
• Screw the oil drain coupling onto the oil drain valve D
➥ The oil drain valve opens and the oil flows into the container
• See “Checking the hydraulic oil”
D • Unscrew the oil drain coupling from oil drain valve D. Screw on filler cap C of oil drain
C valve D
• Screw on breather filter A. Use a new breather filter depending on the maintenance
interval if necessary
• Bear in mind the maintenance interval for the hydraulic oil filter insert H. Replace the
filter insert if necessary
000 295 725 0 – RHB SCORPION 3-34

3.21 Important information for the use of biodegradable oil

• Use only the tested and approved biodegradable hydraulic fluids
– see Fluids and lubricants: overview on page 3-3. Always contact the manufacturer for
the use of other products which have not been recommended. In addition, ask the oil
supplier for a written declaration of guarantee. This guarantee is applicable to damage
occurring on the hydraulic components, which can be proved to be due to the hydraulic
fluid
• Use only biodegradable oil of the same type for filling up. In order to avoid misunder-
standings, a label providing clear information is located on the hydraulic oil tank (next to
the filler inlet) regarding the type of oil currently used! Replace missing labels!
The joint use of two different biodegradable oils can affect the quality of one of the oil
types. Therefore, make sure the remaining amount of initial hydraulic fluid in the
hydraulic system does not exceed 8 % when changing biodegradable oil (manufacturer
indications)
• Do not fill up with mineral oil – the content of mineral oil should not exceed 2 % in order
to avoid foaming problems and to ensure biological degradability
• When running the machine with biodegradable oil, the same oil and filter replacement
intervals are valid as for mineral oil – see maintenance plans in the appendix
• Have the condensation water in the hydraulic oil tank drained by an authorised
workshop every 500 service hours, in any case before the cold season. The water
content must not exceed 0.1 % by weight
• The instructions in this Operator's Manual concerning environmental protection are also
valid for the use of biodegradable oil
• If additional hydraulic attachments are mounted or operated, use the same type of
biodegradable oil for these attachments to avoid mixtures in the hydraulic system
Subsequent change from mineral oil to biodegradable oil must be carried out by an author-
ised workshop or by your CLAAS partner
3-35 000 295 725 0 – RHB SCORPION

3.22 Checking hydraulic pressure lines

Danger!
Caution when checking hydraulic lines, especially when searching for leaks.
Hydraulic oil escaping under high pressure can penetrate the skin and cause
serious injuries.
☞ Always consult a doctor immediately, even if the wound seems insignificant
– otherwise serious infections could set in!
☞ Always observe the following instructions:
• Retighten leaking screwed fittings and hose connections only when the
system is not under pressure; i.e. release the pressure before working
on pressurised lines!
• Never weld or solder damaged or leaking pressure lines and screw con-
nections. Replace damaged parts with new ones!
• Never search for leaks with your bare hands, but wear protective gloves!
• Use paper or wood to check for minor leaks. Never use an unprotected
light or naked flame!
• Have damaged flexible lines replaced by authorised workshops only!
• Leaks and damaged pressure lines must be immediately repaired or replaced by an

3 Q/07 authorised workshop or after-sales staff.
This not only increases the operating safety of your machine but also helps to protect
the environment
• Replace hydraulic hoses every 6 years from the date of manufacture, even if they do
not seem to be damaged
In this respect, we recommend that you observe all the relevant safety regulations for
hydraulic lines, as well as the safety regulations regarding accident prevention and occu-
pational health and safety in your country. Also observe DIN 20066, part 5.
The date of manufacture (month or quarter and year) is indicated on the flexible line.
Example:
The indication “3 Q/07” means manufactured in the 3rd quarter of 2007.
000 295 725 0 – RHB SCORPION 3-36

3.23 Lubrication work

Lubricate all lubrication points mentioned below with lithium-saponified brand-name
grease – see Fluids and lubricants: overview on page 3-3
Central lubrication system (option)

The telehandler can be equipped with a central lubrication system for lubricating all lubri-
cation points at the same time
➥ Please refer to the instructions supplied with the machine for operating the central lubri-
cation system
Lubricating the rear axle oscillation-type bearing
Important!
A
The machine has an oscillation-type rear axle. Grease the bearing at the latest
after every 20 service hours or once a week.
Both lubrication points A are located on the rear left side of the frame and are
routed to the axle bearing via hoses.
☞ Apply grease to grease nipple A
Fig. 39: Grease nipples for oscillation-type bearing
Lubricating the planetary drive bearing

☞ Lubricate grease nipples B (2x) on each planetary drive bearing every 20 service
hours or once a week
Fig. 40: Grease nipples on planetary drive bearings
3-37 000 295 725 0 – RHB SCORPION

Lubrication points on the telescopic boom: overview
A A
C D B C
Fig. 41: Lubrication points on telescopic boom
Lubricating the telescopic boom

☞ Fully extend the telescopic boom
A
☞ Dump out the quickhitch horizontally
☞ Lubrication points A and B
➥ Apply grease every 20 service hours or once a week
☞ Also apply grease to the slide plates on the inside boom section at regular intervals.
Fig. 42: Lubrication points on quickhitch
Checking the slide plates

Slide plates 57/C are located between the inside and outside boom sections, and slide
plates 57/D are located outside on the telescopic boom.
☞ The wear plates can be readjusted as they wear down – to a minimum thickness of
8 mm only – by means of the set screws.
☞ Replace the slide plates if they are below the minimum thickness!
➥ Slide plate adjustment and replacement must be carried out by an authorised
workshop only.
000 295 725 0 – RHB SCORPION 3-38

Setting the lubrication and break times

Break times and lubrication times are set with the notched switches S and P in the window
of the controls.
Break time ☞ Remove the red frame on the protective motor housing of the pump with a flat screw-
driver to set the time
Lubrication time
☞ Slacken the four cross-slotted screws and remove the transparent cover
☞ Set the break time P and the lubrication time S with a flat screwdriver
Lubrication times (S):
➥ 1 to 16 minutes (16 notches, each 1 minute)
➥ 2 to 32 minutes (16 notches, each 2 minutes)
Break time (P):
➥ 0.5 to 8 h (16 notches, each 0.5 h)
S P L Yellow LED (L)
➥ (B) lubrication system in operation
➥ (A) lubrication under progress: 0.5 seconds LED ON/0.5 seconds LED OFF
B
☞ Install the transparent cover (window) once the settings are carried out
A
Fig. 43: Setting the lubrication times Caution!
Water can penetrate into the controls and damage them if the cover is not
fitted and closed correctly!
Filling the central lubrication system

The lubrication system is filled via conical grease nipple 1 or a fill coupling with a manual or
pneumatic grease gun.
1
Caution!
Use only commercially available greases up to NLGI-Kl. 2 to avoid damage to
the lubrication system and the lubrication points!
Fig. 44: Filling the central lubrication system
3-39 000 295 725 0 – RHB SCORPION

3.24 Maintenance of the brake system
Environment!
Use a suitable container to collect the brake fluid as it drains and dispose of it

• Brakes are crucial to safety. Incorrect work may cause brake failure. Therefore all
maintenance and repair work on the brakes must be carried out by trained staff.
An exception to this is the following work which must be carried out by the driver of the
machine:
• Daily check of the level in the brake fluid tank!
• Damaged brake lines or hoses must immediately be replaced by an authorised
workshop – danger of accidents!
Checking/filling up the brake fluid level

The brake-fluid tank is located inside the cab to the left of the seat.
A Danger!
MAX
MAX An incorrect brake fluid grade or an insufficient brake fluid level may impair the
safety of the brake system –
MIN Danger of accidents!

☞ Check the brake fluid in the tank at regular intervals
☞ The brake fluid must comply with the SAE specification
– see Fluids and lubricants: overview on page 3-3
Fig. 45: Checking the brake fluid level in the tank
☞ Contact an authorised workshop immediately if the brake fluid level is lower
than allowed
☞ The brake fluid must be replaced every 2 years by an authorised workshop
If the fluid level is below the MAX mark:

☞ Clean the area around the cover
☞ Open tank cover A
☞ Fill up brake fluid up to the MAX mark
☞ Close the tank cover
☞ Check the brake system for leaks and correct function
000 295 725 0 – RHB SCORPION 3-40

3.25 Bleeding the hydraulic powerbrake
Danger!
The brake system is under pressure (30 – 35 bar) –
☞ As you bleed the brake system:
• Open bleed valves carefully
Bleed the master brake cylinder as follows:

Main cylinder bleed
☞ Place a container under the master brake cylinder to collect the brake fluid as it drains
screw
☞ Open the bleed screw on the master brake cylinder by one turn
☞ Start the diesel engine
20 kph
☞ Carefully press down the brake pedal
➥ The air is pressed out of the master brake cylinder
30 – 40 kph
☞ Close the bleed screw
3-41 000 295 725 0 – RHB SCORPION

3.26 Replacing/bleeding the service brake fluid with bleed equipment
Danger!
An incorrect brake fluid grade or an insufficient brake fluid level may impair the
safety of the brake system –
Danger of accidents!
☞ Use only LHM brake fluids
☞ Ensure cleanliness when bleeding/replacing the brake fluid
☞ Prevent the machine from rolling away

☞ Connect the bleed equipment onto the expansion tank
Caution!
Do not apply the parking brake when bleeding!
☞ Release the parking brake with the switch (on the right on the instrument
panel)
☞ Order to be followed during bleeding:

• 30, 40 kph (option) machines: on left and right of rear axle
• On the trailer brake valve (option)
• On left and right of the front axle
Caution!
Use only the two outside bleed valves on the front axle (service brake).
☞ Connect the bleed container with the hose onto the bleed valve
☞ Open the bleed valve until you can clearly see that new brake fluid is coming out and
that there are no more air bubbles
☞ Close the bleed valve
☞ Repeat the procedure on all bleed valves in the order mentioned above
☞ Check the brakes for tightness and test the brakes
Environment!
Use a suitable container to collect the brake fluid as it drains and dispose of it
000 295 725 0 – RHB SCORPION 3-42

Bleeding the trailer brake valve (option)

Bleed valve in engine T
compartment
B
N
Connections
• P = pump
• T = tank
• N = reversing fan
• B = quick coupler (mounted at the rear)
• Y = pressure line from the service brake to Y Y P
☞ Bleed as follows:
• Start the diesel engine
• Fit a hose onto the bleed valve and make sure the other end is in the container used
for collecting the brake fluid as it drains
• Open the bleed valve
• Press the brake pedal repeatedly until the oil comes out free of air from the bleed
valve
• Close the bleed valve
• Check the brake system for leaks and correct function
Bleeding the parking brake

The parking brake is located in the front axle
P ☞ Start the engine
Caution!
Do not apply the parking brake when bleeding!
☞ Release the parking brake with the switch (on the right on the instrument
panel)
☞ Fit a hose onto the bleed valve and make sure the other end is in the container used for
collecting the brake fluid as it drains
☞ Carefully open bleed valve P (inside on either side) of the front axle until there is no
more air in the bleed hose
☞ Close bleed valve P
☞ Check the parking brake for correct function
3-43 000 295 725 0 – RHB SCORPION

3.27 Maintenance: compressed-air brake system (option)

Checking the compressed-air tank and lines
☞ Check the system for leaks (sound of escaping air) and damage
➥ Have leaky hose and screw connections repaired
☞ Drain the water in the compressed-air tank (mounted in front of the rear axle)
➥ by actuating the pin in water drain valve A
Fig. 46: Water drain valve of compressed-air tank
Checking the compressor attachment and drive

☞ Remove V-belt cover B
☞ Check the fastening of the compressor console
☞ Check V-belt tension C of the compressor drive by pressing with your thumb to check
whether the V-belt can be deflected between the pulleys by no more than about 10
B mm
Fig. 47: Compressor V-belt tension
000 295 725 0 – RHB SCORPION 3-44

3.28 Tyre maintenance
Danger!
Improper tyre repairs –
☞ All repair work on tyres and rims may only be carried out by authorised
workshops
Important!
Daily inspections of the tyres

• Improve operating safety
• Increase the service life of the tyres
• Reduce machine downtimes
• Refer to the table in chapter “Specifications” on page 1-18 for the authorised tyre
types and the correct tyre pressures. A tyre table sticker is also affixed on the
front window of the machine
Daily tyre checks

☞ Carry out maintenance work once a day:
• Check tyre pressure
• Check tyres and rims for damage (cracks, ageing etc.) – also on the inside
• Remove foreign bodies from the tyre tread
• Remove traces of oil and grease from the tyres
3-45 000 295 725 0 – RHB SCORPION

Changing wheels
Danger!
Use of wrong tyres or wheels –
☞ Use only wheels and tyres authorised for your telehandler – see the Opera-
tor's Manual
☞ Check the wheel nuts for tightness after every wheel or tyre change
Caution!
The wheels are heavy and can damage the threads on the wheel studs if they
are handled incorrectly!
☞ Use suitable assembly tools, such as covering sleeves for the studs, a jack
etc.
Removing the wheels

• Park the telehandler on level and firm ground and prevent it from rolling away
• Slightly loosen the wheel nuts of the wheel you want to remove
• Place a jack under the axle beam, making sure it is standing firmly
• Raise the side of the axle from which you want to remove the wheel
• Secure the machine with a suitable trestle
• Check the machine is standing firmly
• Completely remove the wheel nuts
• Remove the wheel
Fitting the wheels
• Place the wheel onto the wheel studs
• Tighten all wheel nuts part-way
• Lower the raised axle
• Tighten the wheel nuts to the prescribed tightening torque
– see chapter 1 “Specific tightening torques” on page 1-20
000 295 725 0 – RHB SCORPION 3-46

3.29 Heating and ventilation maintenance

The machine's fresh air and heating system is fitted with a recirculated-air filter and a fine-
dust or active charcoal filter (option). Clean the filter elements as required, however
replace them every 500 s/h at the latest.
The volume of warm air flowing out of the air vents decreases as contamination of the filter
elements increases.
Cleaning/replacing the fine-dust or active charcoal filter (option)

The fine-dust or active charcoal filter (option) is located on the outside left of the cab.
Filter replacement every 500 s/h (service hours)
Clean the filter element as follows:
A ☞ Remove the cover
☞ Remove fine-dust filter A or active charcoal filter (option) and check for damage
☞ Knock the filter element on a plate on either side
☞ Blow compressed air from the inside to the outside to clean the filter, or wash it with
water and dry it
➥ Replace the filter element every 500 s/h (service hours) by a new one
➥ Replace the filter more frequently if the machine is used in severe dust conditions
Fig. 48: Fresh-air fine-dust filter
☞ Clean the inside of the filter housing and insert the filter
➥ Make sure it is seated properly
☞ Install the cover
Cleaning/replacing the recirculated-air filter

The recirculated-air filter is located underneath the cover to the left of the seat in the cab.
Filter replacement every 500 s/h (service hours)
B
Clean the filter as follows:
☞ Remove screws B
☞ Remove the cover and recirculated-air filter C
☞ Clean recirculated-air filter C with compressed air or water, replace it with a new one if
necessary
➥ Replace the recirculated-air filter every 500 s/h (service hours) by a new one
➥ Replace the filter more frequently if the machine is used in severe dust conditions
☞ Clean the inside of the filter housing and insert the filter
C ➥ Make sure it is seated properly
☞ Install the cover
Fig. 49: Recirculated-air filter of the heating system
3-47 000 295 725 0 – RHB SCORPION

3.30 Air conditioning (option): maintenance

General safety instructions for maintenance of the air conditioning system
For your own safety, please bear the following instructions in mind:
• Maintenance and repair work may be carried out by trained staff only.
• Careful when carrying out maintenance and repair work – sharp-edged fins on the
condensor and the heat exchanger.
• Wear protective equipment (protective gloves and goggles) during maintenance and
repair work.
• Do not carry out maintenance work unless the heating and air conditioning systems are
switched off.
• Bear in mind the pertinent regulations relevant to accident prevention, other generally
acknowledged regulations regarding safety and occupational medicine.
Danger!
Lines and hoses containing refrigerants and cooling fluids are under pressure
and can be hot!
Danger of burns!
☞ Avoid touching parts containing refrigerants.
☞ Switch off the air conditioning.
Soldering and welding work on the closed system –
Danger of explosion!
☞ Have repair work carried out by an authorised workshop with trained staff
only
000 295 725 0 – RHB SCORPION 3-48

Functional and visual check

The driver must carry out the following visual checks once a day
B
☞ Check for damage of the refrigerating and heating lines
☞ Check the hoses for tightness, leaks and chafing
A ☞ Check the electric connections for correct condition and tightness
☞ Check the level of the refrigerating agent
➥ With the system switched on, the refrigerating agent must be visible and free of air in
sight glass B of dehumidifier A
☞ If there is air in sight glass B
D
➥ The system must be checked for leaks and refilled by an authorised workshop
☞ Clean the dirty condenser C
• Open lock D
• Tilt the condenser forwards
➥ Clean the condensor with compressed air or by spraying water (do not use a high-
C
pressure cleaner)
☞ Tilt back the condenser and safely lock it D once it is clean
☞ Check V-belt tension E and if necessary, retighten the V-belt
➥ Press with your thumb to check whether the V-belt can be deflected between the
pulleys by no more than about 10 mm (arrow)
➥ Have a defective V-belt replaced by an authorised workshop
Caution!
The air conditioning system must be checked and serviced twice a year by
C trained staff in an authorised workshop!
☞ Replace dehumidifier A every two years
Fig. 50: Air conditioning: evaporator, dehumidifier
3-49 000 295 725 0 – RHB SCORPION

Emptying/filling up the air conditioning system

Fill up the air conditioning system as follows:
☞ Remove the lower service plate A of the diesel engine
➥ Compressor B is located to the left of the engine
☞ Empty and refill the air conditioning system with filler inlets C and D
A ➥ Bear in mind the Operator's Manual of the air conditioning service equipment
➥ Bear in mind the safety instructions of the manufacturer of the air conditioning
system
➥ Bear in mind the capacity of the air conditioning system
C
➥ Use refrigerating agent R134a according to DIN 9860 only
➥ Do not allow refrigerating agent to come into contact with the environment
Caution!
D
B Have the air conditioning system serviced
and repaired by authorised staff only!
Fig. 51: Air conditioning compressor
Replacing the air conditioning compressor

Replace the compressor as follows
☞ Remove the lower service plate A of the diesel engine
☞ Emply the air conditioning system
➥ See “Emptying/filling up the air conditioning system”
B ☞ Remove the flexible lines and the device for tightening the V-belts
☞ Remove the compressor
☞ Ensure the correct installation position of the new compressor as you install it again!
➥ The oil filler neck must show upwards!
☞ Install the flexible lines and the device for tightening the V-belts
☞ Fill up the air conditioning system and check for leaks
E
Caution!
Have the air conditioning system serviced
and repaired by authorised staff only!
Fig. 52: Air conditioning compressor
000 295 725 0 – RHB SCORPION 3-50

3.31 Maintenance of the electric system

Specific safety instructions regarding maintenance and servicing
• The battery contains sulphuric acid! This acid must not be allowed to come into contact
with the skin, the eyes, clothing or the machine.
Therefore when recharging or working near the battery:
• Always wear goggles and protective clothing with long sleeves
If acid is spilt:
• Thoroughly rinse all affected surfaces immediately with plenty of water
• Thoroughly wash any part of the body touched by the acid immediately with plenty of
water and seek medical attention at once!
• Especially when charging batteries, as well as during normal operation of batteries, an
oxyhydrogen mixture is formed in the battery cells – danger of explosion!
• Do not attempt to jump-start the machine if the battery is frozen or if the acid level is
low. The battery can rupture or explode!
• Avoid naked flames and sparks and do not smoke in the vicinity of open battery
cells – otherwise the gas produced during normal battery operation may ignite!
• Use only 12 V power sources. Higher voltages will damage the electric components
• When connecting the battery leads, make sure the poles +/– are not inverted, otherwise
sensitive electric components will be damaged
• Do not interrupt voltage-carrying circuits at the battery terminals because of the danger
of sparking!
• Never place tools or other conductive articles on the battery – danger of short circuit!
• Disconnect the negative (–) battery terminal from the battery before starting repair work
on the electric system
• Dispose of used batteries properly
Service and maintenance work at regular intervals

Before driving the machine
☞ Check every time before driving the machine:
• Is the light system OK?
• Is the signalling and warning system OK?
Every week
☞ Check once a week:
• Electric fuses
– see chapter 1 “Fuses: overview” on page 1-14 and
“Main fuse box with relays (88 kW diesel engine)” on page 1-16
• Cable and earth connections
• Charge condition of battery – See Checking/replacing the battery on page 3-54.
• Condition of battery terminals
3-51 000 295 725 0 – RHB SCORPION

Cables, bulbs and fuses

Always observe the following instructions:
• Defective components of the electric system must always be replaced by an authorised
expert. Bulbs and fuses may be changed by unqualified persons
• When carrying out maintenance work on the electric system, pay particular attention to
ensuring good contact in leads and fuses
• Blown fuses indicate overloading or short circuits. The electric system must therefore
be checked before installing the new fuse
• Only use fuses with the specified load capacity (amperage)
– see chapter 1 “Fuses: overview” on page 1-14 and
“Main fuse box with relays (88 kW diesel engine)” on page 1-16
Alternator
Always observe the following instructions:
• Only test run the engine with the battery connected
• When connecting the battery, make sure the poles (+/–) are not inverted
• Always disconnect the battery before carrying out welding work or connecting a quick
battery charger
• Replace defective charge telltales immediately
Adjusting the headlights when using lightweight material buckets
Danger!
If a lightweight or superlightweight material bucket (see table) is fitted onto the
machine, the headlights are covered by the buckets in transport position –
☞ When using a lightweight or superlightweight material bucket on public
roads, the headlight on the right-hand side mirror bracket must be mounted
in a higher position with an extra bracket (order no. ). Also readjust both
headlights
☞ – see Adjusting the headlights when using a lightweight material bucket on
page 3-53
☞ Mounting the headlights in higher positions and readjusting them must be
carried out by an authorised workshop
000 295 725 0 – RHB SCORPION 3-52

Adjusting the headlights

The lights have been adjusted in the factory with the machine equipped with a standard
bucket and standard tyres
The lights can be adjusted with the help of a vertical wall if no equipment for adjusting the
lights is available.
B
A C a b c
☞ Draw the dimensions on a wall as follows

➥ Dimension A standard bucketright and left-hand sidelights = 1446.0 mm1
About 1040 mm About 1040 mm
➥ Dimension B lightweight material bucket right-hand side light = 1634.0 mm1
➥ Dimension C lightweight material bucket left-hand side light = 2103.0 mm1
☞ Lights dimensions on the telehandler
M
➥ Dimension a standard bucket right and left-hand side lights = 1540.0 mm1
C A
➥ Dimension b lightweight material bucket right-hand side light = 1740.0 mm1
A B ➥ Dimension c lightweight material bucket left-hand side light = 2240.0 mm1
☞ Remove the pallet forks or the bucket
☞ Completely retract the telescopic boom and
☞ align the telescopic boom horizontally to the longitudinal axis of the telehandler
☞ Dump out the quickhitch horizontally and
☞ place the telehandler at the centre M against the wall (contact)
☞ Switch off the engine and apply the parking brake
☞ Adjust the lights with the help of the dimensions drawn on the wall (A)
Adjusting the headlights when using a lightweight material bucket

➥ – see Adjusting the headlights on page 3-53
☞ Mount the left c and right-hand side b lights in a higher position
☞ Adjust the lights with the help of the dimensions drawn on the wall (B or C)
1. With tyres 425/75R20 and 405/70-20 (- 50 mm) 17.5LR24, 400/80R24 and 460/70R24 (+ 20 mm),
15.5-25 and 15.5-80-24 (+ 40 mm) 19.5LR24 and 500/70R24 (+ 60 mm)
3-53 000 295 725 0 – RHB SCORPION

Checking/replacing the battery
Danger!
Especially when charging batteries, as well as during normal operation of
batteries, an oxyhydrogen mixture is formed in the battery cells –
Danger of explosion!
☞ Open the caps of the battery openings by half a revolution before recharg-
ing the battery
☞ Avoid naked lights and sparks in the vicinity of the battery and do not
smoke!
☞ Do not attempt to jump-start the machine if the battery is frozen or if the
acid level is low. The battery can rupture or explode!
☞ Always disconnect the negative terminal (–) from the battery before starting
repair work on the electric system!
Battery acid is highly caustic!
Danger of caustic injury!
Therefore when recharging and/or working near the battery:
☞ Always wear goggles and protective clothing with long sleeves
If acid is spilt:
☞ Thoroughly rinse all affected surfaces immediately with plenty of water
☞ Thoroughly wash any part of the body touched by the acid immediately with
plenty of water and seek medical attention at once!
The battery is located underneath the access, on the left in driving direction. The battery is
low in maintenance and no fluid needs to be refilled under normal operating conditions.
However have the battery checked at regular intervals to make sure the electrolyte level is
between the MIN and MAX marks.
+ Always follow the specific battery safety instructions!
-
Replacing the battery
A ☞ Switch off the ignition and remove the ignition key
☞ Remove the key from the battery master switch (option)
☞ Remove the battery lead from the negative terminal (-)
Fig. 53: Battery
☞ Remove the battery lead from the positive terminal (+)
☞ Remove battery brackets A
☞ Replace the battery with a new one
☞ Install the battery in the reverse order
Caution!
When installing the battery leads,
☞ install the positive lead (+) first
☞ and then the negative lead (-)
000 295 725 0 – RHB SCORPION 3-54

3.32 Maintenance: trailer coupling

Rockinger trailer coupling
Maintenance:
☞ Apply tough water-proof grease (EP3) to the coupling pin, the base ring and the draw-
bar eye after heavy use and before taking the coupling into service
☞ Apply tough waterproof grease (EP3) to the lower bearing of the coupling jaw
Caution!
Make sure the coupling pin is engaged in the trailer coupling before cleaning
with high-pressure equipment!
☞ Apply a little more grease to the coupling pin and the base ring once cleaning is over
☞ Apply grease to the grease nipple on the joint
Danger!
Worn coupling pins, too much play in the bearing or a worn base ring –
☞ Check the trailer coupling for wear and play
☞ Apply grease to the base ring
Checking the bearing and longitudinal play A of the coupling head

A 3.0 mm ☞ Move the uncoupled coupling head with force in driving direction
Checking the height-wise play of the coupling head
☞ Open the coupling
☞ Move the coupling head up and down with a suitable tool (mounting lever)
36.5 mm ➥ Play A in the centre axis of the coupling head = max. 3 mm
Checking the coupling pin C/D
2.5 mm
B
☞ Measure wear by means of a slide gauge on the thickest section of the coupling pin C
➥ Diameter C may not drop below 36.5 mm
36.5 mm ➥ Height-wise play B max. 2.5 mm
☞ Otherwise replace the coupling pin
C
☞ Check pin play D in the base ring and thickness E of the base ring
➥ Pin play D max. 2.5 mm
➥ Thickness E of base ring min. 7 mm
2.5 mm
D
Caution!
E
Repair work on the trailer coupling must be carried out by an authorised
workshop only
7 mm
Fig. 54: Rockinger trailer coupling
3-55 000 295 725 0 – RHB SCORPION

3.33 General maintenance work on the machine

Specific safety instructions regarding maintenance and servicing
Cleaning the machine is divided into 3 separate areas:
• Inside the cab
• Exterior of the machine
• Engine compartment
The wrong choice of cleaning equipment and agents can, on the one hand,
• impair the operating safety of the machine and, on the other,
• undermine the health of the persons in charge of cleaning the machine.
Caution!
Therefore always observe the following instructions!
When using washing solvents

• Ensure adequate room ventilation
• Wear suitable protective clothing
• Do not use flammable liquids, such as petrol or diesel
When using compressed air

• Work carefully
• Wear goggles and protective clothing
• Do not aim the compressed air at the skin or at other people
• Do not use compressed air for cleaning your clothing
When using a high-pressure cleaner or steam jet

• Electric components and damping material must be covered and not directly exposed
to the jet
• Cover the vent filter on the hydraulic oil tank and the filler caps for fuel, hydraulic oil etc.
• Protect the following components from moisture:
• Engine
• Electric components such as the alternator etc.
• Control devices and seals
• Air intake filters etc.
When using volatile and easily flammable anticorrosion agents

and sprays
• Ensure adequate room ventilation
• Do not use unprotected lights or naked flames
• Do not smoke!
000 295 725 0 – RHB SCORPION 3-56

3.34 Cleaning inside the cab
Caution!
Never use high-pressure cleaners, steam jets or high-pressure water to clean
inside the cab. Water under high pressure may
• penetrate into the electric system and cause short circuits and
• damage seals and disable the controls!
We recommend using the following aids to clean the cab:

• Broom
• Vacuum cleaner
• Damp cloth
• Bristle brush
• Water with mild soap solution
3.35 Cleaning the seat belt

• Clean the seat belt (which remains fitted in the machine) only with a mild soap solution;
do not use chemical agents as they may destroy the fabric!
Danger!
Soiled automatic seat belts may affect and impair winding –
☞ Only wind the seat belt when it is dry!
3.36 Cleaning the exterior of the machine

The following articles are generally suitable:
• High-pressure cleaner
• Steam jet
3.37 Checking screw connections

All screw connections must be checked regularly, even if they are not listed in the mainte-
nance plans.
Tighten loose connections immediately. Refer to chapter “Specifications” for the tightening
torques.
3.38 Checking pivots and hinges

• All mechanical pivot points on the machine (e.g. door hinges, joints) and fittings (e.g.
door arresters) must be lubricated regularly, even if they are not listed in the lubrication
plan.
3-57 000 295 725 0 – RHB SCORPION

3.39 Cleaning the engine compartment
Danger!
Clean the engine at engine standstill only –
☞ Switch off the engine before cleaning
☞ Remove the ignition key
Caution!
The humidity penetrating the electronics causes it to fail and leads to engine
damage!
When cleaning the engine with a water or steam jet
☞ The engine must be cold
☞ Do not point the jet directly at any of the electric sensors such as tempera-
ture and oil pressure switches or control valves.
☞ Protect all electric parts, such as the alternator, connectors etc. from
humidity
☞ If the water jet is unintentionally pointed at electric components, dry them
with compressed air and apply contact spray to them.
000 295 725 0 – RHB SCORPION 3-58

3.40 Maintenance and servicing work “Aggressive Media”

The machine has been coated in the factory with a special anticorrosive protection.
However, this protective anticorrosion coating is affected by external factors e.g.
dirt, cleaning etc. This is why this protective anticorrosion coating only has ongoing
effect if checked at regular intervals and renewed or reapplied as required.
Anticorrosion protection applied in the factory

The following anticorrosion wax has been applied at the factory:
Designation: ANTICORIT BW 366
Manufacturer: FUCHS MINERALOELWERKE GmbH/Mannheim (Germany)
Complies with specification:TI 8030-015/K 19
MIL-C-16 173 C – grade 4
Components to be coated with anti-

Remarks
corrosive wax
All electric plug-and-socket, earthing • Contact surfaces treated with contact spray
and crimp connections before applying • Plug-and-socket connections established
the wax:
Electric connections of fuel level trans-
mitter
Apply an especially thick coat of wax
Flange surfaces of footholds and trim
panels
Except:
• Piston rods (chromium layer)
• Cab
• Rear light cluster and flaps
• Engine cover
• Counterweight
All other parts of the machine • Brake components
• Radiator and insulating mats
• Wheel discs and rims
• External parts of mudguards and access
• Rubber and plastic parts
• Flange surfaces
•
Parting lines of flange surfaces
1 e.g. axles, engine and

cab bearing:
2 Parting lines sealed after assembly
Wax in parting line
Flange half
1
3-59 000 295 725 0 – RHB SCORPION

Safety instructions for maintenance of anticorrosion protection

• When handling chemical substances of any kind, such as solvents, wax etc., observe
the specific product-related safety regulations (safety data sheet)!
• When using volatile and easily flammable anticorrosive agents and solvents:
• Ensure adequate room ventilation!
• Do not use unprotected lights or naked flames!
• Do not smoke!
• Corrosion on electric connections or components can lead to dangerous operating
malfunctions. Therefore check the electric functions of the machine with special care.
Immediately take the machine out of service if you detect any defects and have defects
rectified immediately.
• Carry out work on the electric system only with the battery disconnected and the engine
switched off!
Measures for maintaining anticorrosive protection

• If the machine is used in corrosive environment over a longer period of time, we
recommend removing the floor mat in the cab to avoid collecting corrosive humidity.
• Thoroughly clean machines that are taken out of service over a longer period of time.
• Clean the machine at least once a week. In particular, remove corrosive deposits (such
as salt crusts) as fast as possible.
Clean the machine with cold running water preferably.
Contrary to the instructions given in Chapter "General maintenance work" in the
Operator's Manual of the machine, neither clean the machine with a bristle brush nor
with a steam jet or a high-pressure cleaner. Otherwise the anticorrosive protection will
be heavily affected.
If cleaning the machine with these means cannot be avoided, check the wax coating
very carefully and have it renewed or reapplied as required.
• As you replace components, bear in mind that they must be specially treated before
assembly.
000 295 725 0 – RHB SCORPION 3-60

Applying the protective anticorrosion coating

Bear in mind the following instructions as you apply the anticorrosive wax:
• ANTICORIT BW 366 can be applied with a brush, by means of immersion or with all
commercially available spray guns.
• ANTICORIT BW 366 protective coating can be removed with petrol, RENOCLEAN E/K
or FUCHS MULTICLEAN as required.
• ANTICORIT BW 366 spots are difficult to remove on clothing. If possible, wear old work
clothes for all repair work. Affix a “Wet paint!” or a similar sign to newly coated
machines.
Treatment of oxidised surfaces

If in spite of all precautionary measures some components should be affected by corrosion
(oxidised), proceed as follows depending on the affected component:
Electric connections
☞ Remove the remaining protective wax in the oxidised area with petrol,
RENOCLEAN E/K or FUCHS MULTICLEAN
☞ Treat all affected parts with an oxide solvent, such as KONTAKT 60
☞ Rinse the area with e.g. KONTAKT WL
☞ Treat the contact surfaces of the connection with e.g. KONTAKTSPRAY WD 40
☞ Establish the connection
☞ Apply/spray anticorrosion wax onto the electric connection from all sides
Sheet-metal parts
☞ Remove the remaining protective wax in the oxidised area with petrol,
RENOCLEAN E/K or FUCHS MULTICLEAN
☞ Remove all remaining corrosion and paint coating from the affected area down to the
bare material, otherwise the paint coating will not adhere properly!
☞ Clean the affected part with a cleaning solvent
☞ Apply a 2-component prime coating to the affected area and then a 2-component paint
coating
☞ Preserve the area with anticorrosion wax
3.41 Maintenance and servicing of attachments on the quickhitch
Important!
Correct maintenance and service is absolutely necessary for smooth and continu-
ous operation, and for an increased service life of the attachments. Please
observe the lubrication and maintenance instructions in the Operator's Manuals of
the attachments!
3-61 000 295 725 0 – RHB SCORPION

Engine
4 Engine Electric system/hydraulics – fan: electric diagram

Engine
4.1 Electric system/hydraulics – fan: electric diagram
4-1 000 295 725 0 – RHB SCORPION

Engine
88 kW diesel engine electric system: electric diagram 88 kW diesel engine electric system: electric diagram
Engine
4.2 88 kW diesel engine electric system: electric diagram
4-3 000 295 725 0 – RHB SCORPION

Engine
103 kW diesel engine electric system: 103 kW diesel engine electric system:
electric diagram electric diagram
Engine
4.3 103 kW diesel engine electric system: electric diagram
Connection from electronics to engine
Connection from electronics to machine
4-5 000 295 725 0 – RHB SCORPION

Engine
Fuel preheater (option): electric diagram Fuel preheater (option): electric diagram
Engine
4.4 Fuel preheater (option): electric diagram
4-7 000 295 725 0 – RHB SCORPION

Engine
Diagnosis wiring diagram Diagnosis wiring diagram

Engine
4.5 Diagnosis wiring diagram
Diagnosis 88 kW Diagnosis 103 kW
4-9 000 295 725 0 – RHB SCORPION

Engine
Engine
Fan hydraulics diagram designations
Fan hydraulics diagram: description Machine position

II Fan motor unit (standard) D6/VI
III Reversing fan unit D6/VI
V Differential/parking brake valve block E4/VII
VI Master brake cylinder with brake servo I6/VIII
VII Drive hydraulics variable displacement pump E7/VIII
VIII Drive hydraulics variable displacement motor E5/VIII
IX Drive hydraulics variable displacement pump E7/VIII
X Drive hydraulics variable displacement motor E5/VIII
XI Joystick pilot control unit G7/VI
XII Solenoid valve pilot control unit E12/VIII
A Consumers port 0
B Consumers port 0
P Pump port 0
T Tank port 0
B15 Coolant level sensor D6/V
B16 Fan control temperature sensor B6/IX
B17 Gearbox input speed transmitter E6/VIII
H34 Coolant level telltale (see “Operation”)
K1 Power supply high current relay (see “Electric system”)
K32 Reversing fan switching relay (see “Electric system”)
N1 Drive electronics (see “Electric system”)
R5 Pull up resistor G9/V
S5 Hydraulic oil dirt pressure switch (see “Operation”)
S6 Hydraulic oil temperature switch (see “Operation”)
S64 Reversing fan tip switch (see “Operation”)
U1 Coolant level sensor level amplifier (see “Electric system”)
Y35 Fan bypass solenoid valve D6/VI
Y37 Reversing fan solenoid valve D6/VI
10 Fan pump D8/VI
13 Fan motor (standard) C6/VI
14 Fan motor (reversing fan) C6/VI
15 Filter E7/VIII
25 Tank H10/V
26 Reflux filter G10/IV
28 Vent filter H10/IV
107 (S5) fouling indicator G10/IV
000 295 725 0 – RHB SCORPION 4-10

Engine
Engine electric diagram designations
Engine electric diagram: description Machine position

B1 Fuel indicator H6/VIII
B6 Engine temperature sensor D7/VI
B14 Engine preheating system temperature sensor (see “Engine/cooling”)
B20 Camshaft revs (see “engine/cooling”)
B21 Charge air cooler (temperature/pressure) (see “engine/cooling”)
B22 Rail/fuel pressure sensor (see “engine/cooling”)
B23 Engine oil pressure sensor (see “engine/cooling”)
B24 Fuel low pressure sensor (see “engine/cooling”)
B25 Crankshaft revs (see “engine/cooling”)
F Fuses (see “Electric system”)
G1 Alternator B8/VI
G2 Battery J5/IX
H2 Preheating telltale (see “Operation”)
H4 Engine oil pressure telltale (see “Operation”)
H5 Alternator charge function telltale (see “Operation”)
H6 Air filter telltale (see “Operation”)
H33 Water separator telltale (see “Operation”)
H44 Engine electronics telltale (see “Operation”)
K5 Preheating high current relay (see “Electric system”)
K7 Start high current relay (see “Electric system”)
K31 Fuel preheater switching relay (see “Electric system”)
K42 Engine electronics switching relay (see “Electric system”)
M1 Starter C6/VII
N3 Preheating time control unit (see “Electric system”)
N5 Engine electronics (see “Electric system”)
P1 Hour meter (see “Electric system”)
P2 Fuel level indication (see “Electric system”)
P3 Engine oil temperature gauge (see “Electric system”)
P7 Tachometer (see “Electric system”)
R1 Glow plug (see “Engine/cooling”)
R9 Fuel preheater (see “Engine/cooling”)
R11 Accelerator pedal (see “Engine/cooling”)
4-11 000 295 725 0 – RHB SCORPION

Engine
Engine electric diagram: description Machine position

R12 Manual throttle (see “Engine/cooling”)
R17 Bus terminating resistance D9/VI
R18 Bus terminating resistance G9/V
S1 Preheating start switch (see “Operation”)
S2 Engine oil pressure switch (see “Operation”)
S4 Air filter pressure switch (see “Operation”)
S8 Battery master switch (see “Operation”)
S58 Water separator switch (see “Operation”)
S61 Fuel preheater switch (see “Operation”)
S65 Parking brake switch (see “Operation”)
S74 Fuel preheater temperature switch (see “Operation”)
S86 Error code call tip switch (see “Operation”)
U1 Coolant level sensor level amplifier (see “Electric system”)
V1 Starting interlock blocking diode (see “Electric system”)
X1 51 pole cab/engine vat disconnect See “Electric system”
X6 6 pole diagnosis connector RS232 to SUSMIC See “Electric system”
X39 8 pole diagnosis connector CAN See “Engine cooling”
X41 22 pole board connection See “Electric system”
X82 94 pole engine electronics connection See “Engine cooling”
X84 12 pole diagnosis connector Deutz Itt-Cannon See “Engine cooling”
Y1 Cutoff solenoid D8/VI
Y30 Multiple quantity valve/minus compensation 0
Y60 Fuel injector (see “Engine/cooling”)
Y76 Rail pressure feed solenoid valve (see “Engine/cooling”)
000 295 725 0 – RHB SCORPION 4-12

Engine
4.6 Fan: functional description

Fan control
The drive electronics module (N1) automatically and continuously controls the fan revs for
cooling the engine.
The fan solenoid valve (Y35) is triggered by the drive electronics module (N1) by means of
a PWM signal.
The banking-up pressure at the fan motor (014) creates a corresponding engine speed.
The fan solenoid valve (Y35) is parallel to the fan motor ( = bypass).
Energised fan solenoid valve (Y35)

• Open bypass
• Low banking-up pressure
• Low fan motor revs (014)
Fan solenoid valve (Y35) without contact

• Closed bypass
• High banking-up pressure
• High fan motor revs (014)
Reversing function
• Switching the reversing fan solenoid valve (Y37) diverts the oil flow.
➥ The fan rotates in the other direction
Oil supply of the whole system (boost pressure)

The reflux oil of the fan motor (014) ensures the supply of the entire low-pressure circuit
(valve units V, VI, Vll, Vlll, lX, X, Xl, Xll) and of the hydrostat.
The reversing function does not affect supply.
4-13 000 295 725 0 – RHB SCORPION

Engine
4.7 Fan connector assignment for models 402, 403, 404

Cab/frame disconnect
Socket housing Pin housing

X1 yellow/X2 green X1 yellow/X2 green
Socket housing X36 (1 pole)
Socket housing X36.1 (1 pole)
Socket housing X36.2 (1 pole)
Socket housing X14 (2 pole) Socket housing X23 (15 pole)
000 295 725 0 – RHB SCORPION 4-14

Engine
4.8 Diesel engine connector assignment (88 kW)


Socket housing X15 (3 pole) Socket housing X23 (15 pole) Socket housing X40 (6 pole)
Socket housing X42 Socket housing X45 Socket housing X48

(14 pole) (12 pole) (9 pole)
Socket housing X41 Socket housing X49 Socket housing X100 Pin housing X100
(22 pole) (14 pole) (1 pole) (1 pole)
4-15 000 295 725 0 – RHB SCORPION

Engine
4.9 Diesel engine connector assignment (103 kW)


Socket housing X15 Socket housing Socket housing Socket housing X42
(3 pole) X23 (15 pole) X40 (6 pole) (14 pole)
Socket housing X41

(22 pole)
Socket housing X45 Socket housing Socket housing X49 Socket housing X79
(12 pole) X48 (9 pole) (14 pole) (6 pole)
Socket housing
X100 (1 pole)
Pin housing
X80 (3 pole)
Socket housing Socket housing Socket housing

X83 (42 pole) X81 (60 pole) X82 (94 pole)
000 295 725 0 – RHB SCORPION 4-16

Engine
4.10 Fuel preheater connector assignment
Disconnect X5 (7 pole)
Socket housing X47 Socket housing X49

(15 pole) (14 pole)
Disconnect X75/X76 (3 pole)
4-17 000 295 725 0 – RHB SCORPION

Engine
4.11 Diagnosis connector assignment


Socket housing X6 (6 pole) Socket housing X39 (8 pole)

For reading the drive electronics in and out Claas CDS diagnosis connector

Deutz Serdia diagnosis connector
in engine vat (next to control valve)
Socket housing X41 Socket housing X47 Socket housing

(22 pole) (15 pole) X82 (94 pole)
000 295 725 0 – RHB SCORPION 4-18

Engine
4-19 000 295 725 0 – RHB SCORPION

Engine
Engine
4.12 Engine oil cooler side (88 kW): overview
Cutoff solenoid R1 heating flange (air-intake

preheating)
Auxiliary output: fan pump
(boost pump) Fuel pump (driven via V-belt)
Oil cooler
Oil pressure switch S2
Auxiliary output: work hydrau- Connection from Connection to sepa- Fuel filter
lics pump separate oil filter rate oil filter
000 295 725 0 – RHB SCORPION 4-20

Engine
4.13 Engine drive side (88 kW): overview
Crankcase breather Multiple-quantity injection dur-

(closed) ing start phase
Temperature sensor B 14 Temperature sensor B 6

(preheating time control) (indication on instrument panel)
4-21 000 295 725 0 – RHB SCORPION

Engine
4.14 Engine turbocharger side (88 kW): overview
Coolant (feed) Coolant (reflux)

Thermostat housing
Heating flange R 1 (air intake)
Connection to expan-
sion tank
Starter 12 V/3.0 kW
Alternator 12 V/95 A Turbocharger
000 295 725 0 – RHB SCORPION 4-22

Engine
4.15 Engine oil cooler side (103 kW): overview
Control valve Housing ventilation
Fan pump auxiliary output Oil cooler Fuel filter
Hydraulic work pump Oil filter Fuel pump
4-23 000 295 725 0 – RHB SCORPION

Engine
4.16 Engine drive side (103 kW): overview
Fuel pump Crankcase revs Alternator

sensor
000 295 725 0 – RHB SCORPION 4-24

Engine
4.17 Engine turbocharger side (103 kW): overview
Thermostat
Alternator Unpressurised charge- Turbocharger

air pressure regulation
4-25 000 295 725 0 – RHB SCORPION

Engine
4.18 Electronics overview (103 kW)

The 103 kW Deutz engine is controlled via an electronic control valve.
Each control valve has been programmed for a specific engine and is therefore delivered
with a serial number.
Important!
Only run the diesel engine of a specific machine with a control valve having the
same serial number as the diesel engine.
Control valves cannot be exchanged without re-programming them.
Fig. 1: Control valve on engine (initial delivery)
In the event of engine damage, the replacement engine is delivered with a new control
X 83 valve which must be installed on the machine instead of the old control valve.
The sensors do not require any calibration.
In case of a guarantee claim, the rejected engine must be shipped together with its control
valve.
X 82 X 81
Fig. 2: Control valve on machine
Revs sensor (camshafts)
Fig. 3: Revs sensor
Oil pressure switch S2
Fig. 4: Oil pressure switch
000 295 725 0 – RHB SCORPION 4-26

Engine
Charge-air pressure sensor
Fig. 5: Charge-air pressure sensor
Engine temperature sensor
Fig. 6: Engine temperature sensor
Rail pressure sensor
Fig. 7: Rail pressure sensor
Fuel metering unit
Fig. 8: Fuel metering unit
Electronically controlled fuel injector
Fig. 9: Fuel injector
4-27 000 295 725 0 – RHB SCORPION

Engine
Fuel line to fuel injector
Fig. 10: Fuel line
Diagnosis connector
1
• Win GPi (1)
• Claas CDS (2)
Fig. 11: Diagnosis connector
000 295 725 0 – RHB SCORPION 4-28

Engine
4.19 Electronic engine revs setting (103 kW): overview

The revs on the 103 kW diesel engine are set by the control valve which receives a signal
from the electronic accelerator pedal or manual throttle.
Electronic accelerator pedal
Fig. 12: Electronic accelerator pedal
Manual throttle
A final resistance is located on the wiring underneath the instrument panel if a machine is
not equipped with a manual throttle.
☞ Remove the final resistance from the wiring harness when retrofitting a manual throttle
☞ Connect the manul throttle regulator onto the wiring harness
Fig. 13: Manual throttle Important!
The accelerator pedal and the manual throttle do not require any re-calibration
when replacing them in the event of damage.
Fig. 14: Final resistance
4-29 000 295 725 0 – RHB SCORPION

Engine
4.20 Function: warning telltale in tip switch (103 kW diesel engine)

Reading out the flash code
The diagnosis switch allows you to read out pending errors as flashing codes.
• Functional check
➥ Telltale comes on about 1 – 2 seconds (ignition ON)
• Telltale comes on continuously
00000 00 h
• Telltale flashes
Diagnosis switch 74 with the integrated telltale is located on the instrument panel. Errors
are indicated by means of a flashing or continuously lit telltale. Detailed information on
pending errors can be read out only at engine standstill by means of these flashing codes.
☞ Press diagnosis switch A about 1 second
74
Nr_7_2.iso ➥ The telltale displays the error by means of the different lengths of the flashing
Fig. 15: Reading out the error code display signals
➥ See Overview of flashing codes on page 4-32.
☞ Error codes are read out as follows
2 3 1
Example:
Flashing code 2-3-1 =>2 short (0.4 sec) – 3 long (0.8 sec) – 1 short (0.4 sec)
➥ Engine oil pressure = not enough or too much oil in the engine
Please contact your dealer if you require more information
Warning limit – coolant temperature
Error display Troubleshooting

☞ Stop the machine as quickly as possible
☞ Read out the error with the ignition switched on
Caution! ➥ – see Overview of flashing codes on page 4-32
Tip switch telltale 74 Coolant temperature 111 °C
☞ Let the diesel engine run briefly at idling speed so it can cool down, then
comes on continu- (see also temperature
switch off the engine
ously indicator 71 on the instru-
ment panel) ☞ Check the coolant level or fill up the coolant
☞ Check the cooling circuit for leaks
☞ Have repair work carried out by an authorised workshop if necessary
☞ Stop the machine immediately and switch off the diesel engine
Danger! ☞ Read out the error with the ignition switched on
Coolant temperature 119 °C
Tip switch telltale 74 ➥ – see Overview of flashing codes on page 4-32
(see also temperature
flashes ☞ Check the coolant level or fill up the coolant
indicator 71 on the instru-
ment panel) ☞ Check the cooling circuit for leaks
Coolant temperature below ☞ Start the diesel engine
Tip switch telltale 74
109 °C ☞ Check the cooling system for leaks and correct function
(see also temperature
goes out
indicator 71 on the instru-
ment panel)
000 295 725 0 – RHB SCORPION 4-30

Engine
Warning limit – charge-air temperature

Dirty radiator
Tip switch telltale 74 Caution! ☞ Read out the error with the ignition switched on
comes on continu- Charge-air temperature ➥ – see Overview of flashing codes on page 4-32
ously 95 °C ☞ Clean the radiator from the engine side with compressed air or with the
reversing fan (option)
Very dirty radiator
Danger! ☞ Read out the error with the ignition switched on
Tip switch telltale 74
Charge-air temperature ➥ – see Overview of flashing codes on page 4-32
flashes
110 °C ☞ Clean the radiator from the engine side with compressed air or with the
reversing fan (option)
Tip switch telltale 74 Charge-air temperature ☞ Start the diesel engine
goes out below 90 °C ☞ Check the cooling system for leaks and correct function
Warning limit –engine oil pressure

☞ Stop the machine as quickly as possible and switch off the diesel
engine
Tip switch telltale 74 ☞ Read out the error with the ignition switched on
Caution!
comes on continu-
Engine oil pressure too low ➥ – see Overview of flashing codes on page 4-32
ously
☞ Fill up engine oil or replace it according to the maintenance plan
☞ Read out the error with the ignition switched on
Tip switch telltale 74 Danger! ➥ – see Overview of flashing codes on page 4-32
flashes No engine oil pressure ☞ Fill up engine oil or replace it according to the maintenance plan
☞ Check the diesel engine for oil loss
Tip switch telltale 74 ☞ Start the diesel engine and check for correct function
goes out
4-31 000 295 725 0 – RHB SCORPION

Engine
Overview of flashing codes
Flash code Component Description
1-2-3 Coolant temperature telltale Open wiring or short circuit
1-2-6 Manual throttle Open wiring or short circuit, signal not plausible
1-2-8 Charge-air temperature sensor Open wiring or short circuit
1-3-3 Customer-specific sensor Open wiring or short circuit (sensor 1)
1-3-3 Customer-specific temperature Not within specified system reaction range (temperature 1)
1-3-4 Rail pressure Positive regulator divergence (speed-sensitive) not within specified range
1-3-5 Fuel metering unit Flow rate not within specified range
1-3-5 Oil pressure telltale Open wiring or short circuit
1-3-6 Air filter Pressure beyond specified system reaction range
1-3-7 Main relay Short circuit (relay 1)
1-4-2 Engine operation telltale Open wiring or internal error of control unit
1-4-3 Multiple position switch Open wiring or short circuit, input voltage not within specificed range (switch 1)
1-4-4 Oil temperature sensor Open wiring or short circuit
1-4-4 Oil temperature Below specified system reaction range
1-4-5 Jumper switch Jammed switch
1-4-6 Rail pressure relief valve Opening error
1-4-7 Rail pressure sensor Open wiring or short circuit
1-4-7 Rail pressure sensor Signal divergence when starting or after run, beyond specified range
1-5-1 Several injectors Short circuit (row of cylinders 1)
1-5-4 Separate injector Short circuit (injector 1)
1-5-4 Separate injector Open wiring (injector 1)
2-1-2 Revs sensor Motor runs only with camshaft revs signal
2-1-2 Revs sensor Bad or missing camshaft revs signal
2-1-2 Revs sensor Bad or missing crankshaft revs signal
2-1-3 Revs sensor Phase displacement of crankshaft and camshaft revs signals
000 295 725 0 – RHB SCORPION 4-32

Engine
2-1-4 Overspeed Overspeed due to error with system reaction
2-1-4 Overspeed Overspeed in overrun (trailing throttle) with system reaction
2-1-6 Fuel low-pressure sensor Open wiring or short circuit
2-1-6 Low fuel pressure Below specified range with system reaction
2-1-9 Engine brake flap (actuator) Engine brake flap (actuator): open wiring or short circuit
2-2-3 Charge-air pressure sensor Open wiring or short circuit
2-2-3 Charge-air pressure Not within specified range with system reaction
2-2-4 Oil pressure sensor Open wiring or short circuit
2-2-5 Coolant temperature sensor Open wiring or short circuit
Drive pedal/analog potentiome-

2-2-6 Open wiring or short circuit, signal not plausible (analog pedal)
ter
2-2-7 Fuel temperature sensor Fuel temperature sensor: open wiring or short circuit
2-2-8 Fuel filter water level Open wiring or short circuit
2-2-8 Water level in fuel filter Beyond specified range
2-3-1 Oil pressure Beyond specified range
2-3-1 Oil pressure Below specified range
2-3-2 Coolant temperature Not within specified range with system reaction
2-3-3 Charge-air temperature Beyond specified system reaction range
2-3-5 Coolant level Not within specified range with system reaction
2-3-7 Fuel temperature Beyond specified system reaction range
2-3-8 Fan actuator Fan actuator: open wiring or short circuit
2-3-8 Fan revs Beyond specified system reaction range
2-4-1 Separate cylinder Misfiring (cylinder 1)
2-4-1 Several cylinders Misfiring
2-4-1 Misfiring Misfiring with system reaction
2-6-1 Misfiring Short circuit against earth or emergency stop (relay 2)
2-6-3 Preheating relay Open wiring or short circuit
2-6-3 Preheating solenoid valve Open wiring or short circuit
2-7-1 CAN bus switched off Open wiring or short circuit, switched off (CAN bus A)
2-9-2 Control unit, internal error Defective environmental pressure sensor
3-1-8 Battery Voltage below specified range
4-33 000 295 725 0 – RHB SCORPION

Engine
3-1-8 Battery voltage Beyond specified system reaction range
3-2-8 Preheating telltale Open wiring or short circuit
3-4-1 Engine stop demand Engine stop demand ignored by operator
4-1-4 EGR positioner (external) Short circuit
5-1-2 Starting relay Starting relay (+ side): short circuit
5-1-3 Diagnostics telltale Open wiring or short circuit, prevented by control unit
5-1-4 Terminal 15 Ignition ON not detected
5-1-5 Terminal 50 Engine start, jammed switch
5-2-1 Machine speed signal Speed over specified range, missing signal or not plausible
5-2-6 CAN message Missing or value over specified range (message “DecV1” = pseudopedal)
5-2-8 Engine brake (internal) Internal engine brake: open wiring or short circuit
5-3-1 Solenoid valve dwell period Not within specified range or missing (cylinder 1)
Engine performance indication

5-5-5 Engine performance indication output: open wiring or short circuit
output
000 295 725 0 – RHB SCORPION 4-34

Engine
4.21 Engine drive – clutch (88/103 kW): overview
Outside plastic part is screwed onto the flywheel

mass of the engine
Inside metal part is located on the drive shaft

(variable displacement pump)
Caution!
Install the longer projecting side of the toothing
towards the flywheel mass of the engine
4-35 000 295 725 0 – RHB SCORPION

Suction pipe with fuel metering device B1 Reflux Fuel pump driven via V-belt
➥ Circulating quantity about 10 l
➥ Fuel is used to cool the pump
and the nozzles
000 295 725 0 – RHB SCORPION

Pressure retaining
valve 5 bar
Fuel filter
4.22 Fuel system (88/103 kW): overview
Manual pump
S 58 water separator sensor

➥ The telltale on the instrument
panel comes on if there is
The fuel tank is located in the access on the left too much water in the
separator
➥ Density is measured
4-36
Engine
Engine
4.23 Bleeding the fuel system (88/103 kW)
1
Reflux line
Suction line
Bleed as follows:
• After removing and fitting the fuel filter, prefilter or the fuel lines back on again
• After running the fuel tank empty
• After running the engine again, after it has been out of service for a longer period of
time
☞ Fill the fuel tank
☞ Place the container under the engine
☞ Slacken flexible line 1 and pump with manual pump 2 until the fuel comes out free of air
☞ Tighten the flexible line.
☞ Open pressure retaining valve 3 and pump with manual pump 2 until the fuel comes out
free of air
☞ Close pressure retaining valve 3
☞ Start the engine and check for leaks
4-37 000 295 725 0 – RHB SCORPION

Oil cooler Radiator Engine
Expansion tank
000 295 725 0 – RHB SCORPION

Suction line
To hydraulic pump
Fan pump on auxiliary

output
4.24 Fan circuit (not in reversing operation)
Temperature sensor for fan speed

control (controlled via Susmic)
Fan motor with integrated valve for

speed control (fan runs at full revs if
disconnected electrically)
1000151975_s.iso
Boost pressure test port
4-38
Engine
4-39
B
Engine
Reversing valve block
Valve for speed control
Reversing valve ➥ Controlled by Susmic
➥ De-energised = full revs
T
A
P
4.25 Fan circuit with reversing fan
Fan pump on auxiliary output

To hydraulic pump
Normal operation = aspiration fan
Reversing operation = pressure
fan
Boost pressure test port Fan motor
Boost pressure filter

Leak oil to manifold block
000 295 725 0 – RHB SCORPION

Engine
4.26 Reversing valve block

Set screw for fan revs
Cable connection from steer-

Valve (speed control) Y35 ing electronics (SUSMIC)
Changeover valve T
A P
Y37
➥ A = to the fan motor

➥ B = to the fan motor
➥ P = connection from the pump
➥ T = to the hydraulic pump via the line filter
Revs control
The temperature sensor of the oil cooler transmits the temperature values to the steering
electronics (Susmic). The revs control valve is energised (580 mA) when the machine is
started with cold oil (below 40 °C), i.e. the fan runs at minimum revs.
➥ at diesel engine idling speed = 500 rpm
➥ at diesel engine maximum speed = 800 rpm
The Susmic system starts controlling the fan revs after about 5 minutes and sends more or
less current to the fan valve depending on the temperature of the oil.
➥ Up to 40 °C = 580 mA low revs
➥ Over 90 °C = 0 mA full revs
000 295 725 0 – RHB SCORPION 4-40

Engine
4.27 Setting maximum fan revs (reversing fan)

The valve block and changeover valve C are screwed onto the engine vat behind the radi-
A ator in the engine compartment.
B At maximum diesel engine revs,
➥ maximum fan revs are 2200 rpm
☞ Set fan revs as follows:
C
• Run the engine until it reaches an oil temperature of 50 °C
• Remove connector B from the solenoid valve
• Run the diesel engine at maximum revs
• Measure the revs of the fan wheel
• Set the revs with set screw A w/f 13/allen key ø 4 mm
➥ Screw in = increases fan revs
➥ Unscrew = reduces fan revs
4.28 Setting maximum fan revs (without reversing fan)
Leak oil to tank
Feed from fan pump
Valve (revs control flanged direct

onto the fan motor)
A Cable connection
from Susmic
☞ Run the engine until it reaches an oil temperature of 50 °C

☞ Remove connector A from the valve
☞ Set the diesel engine to maximum revs
☞ Measure the revs of the fan wheel
➥ Fan revs have a fixed setting currently (revs control via Susmic only)
Manual revs setting starting serial nos.

➥ 40001xxxx, 40101xxxx, 40201xxxx, 40301xxxx
☞ Set the revs with set screw w/f 13/allen key 4 of the solenoid valve
➥ Screw in = increases fan revs
➥ Unscrew = reduces fan revs
4-41 000 295 725 0 – RHB SCORPION

Engine
4.29 Cleaning the radiator with the reversing fan (option)

Pressing tip switch T (on the right in the side console) reverses the fan's direction of rota-
tion and cleans the radiator. The radiator can be cleaned at any time with the reversing fan
T
during machine operation and with the diesel engine running.
Caution!
A
B ☞ Check and clean the radiator.

☞ Clean the radiator more frequently in dusty or dirty work conditions
Arma_re_02_2.is o
☞ Do not clean in closed premises
Tip switch T for the reversing fan is located on the instrument panel on the right.
☞ Press tip switch T briefly to position B
➥ The fan rotates the other way round with a certain delay,
A ➥ 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. 16: Tip switch for reversing fan ➥ The fan automatically switches back to cooling mode after about 1 minute
Important!
When working in especially dusty environment, clean the radiator repeatedly and
more frequently!
000 295 725 0 – RHB SCORPION 4-42

Engine
4.30 Function: reversing fan operation
Fan revs (as a function of

temperature)
Fan in cleaning mode

(valve A (revs control) de-energised) About 0.5 – 1 s
Fan in cooling
Fan in cooling
About 15 s mode
mode
Revs curve
About 40 s Time
Changeover valve C Changeover valve C

energised de-energised
Pressing tip switch T brakes the fan to minimum revs.

A Changeover valve C is energised and the fan runs the other way round, i.e. the fan runs in
B cleaning mode at full revs.
Changeover valve C is de-energised after about 30 – 40 seconds and the fan runs the
other way round for cooling.
C Fan revs are now controlled by the steering electronics (Susmic) depending on tempera-
ture.
Correct reversing operation can be checked by means of the noise produced by the fan
and/or by means of the dust blown out from the intake screen on the engine cover.
4-43 000 295 725 0 – RHB SCORPION

✂
✂
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Werkstatthandbuch
2012
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✂
Workshop Manual
2012
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0312 0361
Werkstatthandbuch
2012
✂
✂
0312 0361
Workshop Manual
2012
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✂
✂
✂
✂
Manuel d’Atelier
2012
✂
✂
Manual de Taller
2012
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✂
0312 0361
Manuel d’Atelier
2012
✂
✂
0312 0361
Manual de Taller
2012
✂
✂
Werkstatthandbuch
Workshop Manual
Manuel d’Atelier
Manual de Taller 2012
0312 0361
Gegenüber Darstellungen und Angaben dieses Werkstatthandbuches sind

technische Änderungen, die zur Verbesserung der Motoren notwendig werden,
vorbehalten. Nachdruck und Vervielfältigung jeglicher Art, auch auszugsweise,
bedarf unserer schriftlichen Genehmigung.
In view of continuous design improvements or changes, the technical data and

illustrations contained in this Workshop Manual are subject to alteration.
Reprinting and reproduction, in part or in whole, are subject to our written
approval.
Sous réserve de modifications techniques nécessaires à l’amélioration des

moteurs présentés par des illustrations et des indications référencées dans ce
Manuel d’atelier. Réimpression et reproduction même partielle, quelle qu’en
soit la nature, interdites sans notre autorisation écrite.
Nos reservamos el derecho a introducir modificaciones técnicas necesarias

para el mejoramiento de los motores, aunque difieran de las ilustraciones
y datos contenidos en este manual de taller. No está permitida la reimpresión
ni la reproducción, parcial o total, en forma alguna, sin nuestro previo
consentimiento por escrito.
© 2003 / 0312 0361

DEUTZ AG
Service-Technik
Instandhaltungstechnik Motoren
Deutz-Mülheimer Straße 147-149
D - 51063 Köln
Phone: ++ 49 (0) 2 21 - 8 22 - 0
Fax: ++ 49 (0) 2 21 - 8 22 - 53 58
Internet: www.deutz.de
Printed in Germany
All rights reserved
3rd Edition, © 06/2004
The engine company. Order No. 0312 0361
VORWORT
Die sachgerechte Ausführung von Reparatur- und Einstellarbeiten ist Voraussetzung für einen
zuverlässigen Motorbetrieb.
In diesem Werkstatthandbuch sind die zweckmäßigen Arbeitsabläufe für anfallende Reparatur-

und Einstellarbeiten an Motor und Motorbauteilen beschrieben. Dabei wird vorausgesetzt, dass
die Arbeiten von qualifiziertem Fachpersonal durchgeführt werden.
Bei der Gestaltung des Werkstatthandbuches wurden im Sinne einer schnellen Erfassung der Inhalte
zusätzlich zu den knapp gehaltenen beschreibenden Texten Bildzeichen gesetzt, die den jeweils
behandelten Arbeitsgang visualisieren.
Betriebs- und Wartungshinweise sind der entsprechenden Betriebsanleitung zu entnehmen.
Zur Ersatzteilbestellung ist die jeweilige Ersatzteilliste zugrunde zu legen.
Das vorliegende Werkstatthandbuch unterliegt keinem Änderungsdienst. Änderungen werden jeweils

bei Neuauflage eingearbeitet.
Beachten Sie bei Reparaturen die Hinweise unserer Technischen Rundschreiben.
Allgemeine Hinweise:
- Lesen und beachten Sie die Informationen dieses Werkstatthandbuches. Sie

vermeiden Unfälle und verfügen über einen funktionstüchtigen und einsatzbereiten
Motor.
- Stellen Sie sicher, dass dieses Werkstatthandbuch jedem an Reparatur- oder

Einstellarbeiten Beteiligten zur Verfügung steht und dass der Inhalt verstanden wird.
- Die Nichtbeachtung dieser Reparaturanleitung kann zu Funktionsstörungen und

Motorschäden sowie Verletzungen von Personen führen, für die vom Hersteller
keine Haftung übernommen wird.
- Die einschlägigen Unfallverhütungsvorschriften sowie die sonstigen allgemeinen

anerkannten sicherheitstechnischen und arbeitsmedizinischen Regeln sind einzu-
halten.
- Voraussetzung für die fachgerechte Reparatur ist die Verfügbarkeit aller erforderli-
chen Ausrüstungen, Hand- und Spezialwerkzeuge, sowie deren einwandfreier
Zustand.
- Höchste Wirtschaftlichkeit, Zuverlässigkeit und lange Lebensdauer ist nur bei Ver-
wendung von Original Teilen der DEUTZ AG sichergestellt.
- Motorteile wie Federn, Klammern, elastische Halteringe etc. beinhalten bei unsach-
gemäßer Behandlung erhöhte Verletzungsgefahr.
- Die Instandsetzung des Motors muss der bestimmungsgemäßen Verwendung -

definiert durch den Gerätehersteller - entsprechen. Bei Umbauten dürfen nur von
der DEUTZ AG für den jeweiligen Verwendungszweck freigegebene Teile eingesetzt
werden.
© 2002 / 0312 0361

FOREWORD
Reliable engine operation is dependent on properly executed repairs as well as adjustment work.
This Workshop Manual describes the appropriate operations for any repair and adjustment work
on the engine and engine components. It is presumed that this work will be carried out by qualified
personnel.
This operation manual has been designed for quick and easy understanding. Therefore the concise
text passages are accompanied by pictographs to illustrate the relevant operation.
Aspects of operation and maintenance are dealt with in the respective Operation Manual.
For spare parts orders the respective spare parts catalogue should be referred to.
This Workshop Manual is not subject to engineering change service and is valid until next issue.
Therefore please refer to the information in our Technical Circulars when carrying out repairs.
General information:
- Please read carefully and observe the instructions given in this Workshop Manual
to avoid accidents and ensure that your engine always functions properly and
reliably.
- Make sure that this Workshop Manual is readily available for all those carrying out
repairs or adjustments and that the contents are well understood.
- Non-compliance with these repair instructions may result in malfunction and engine
damage as well as personal injuries for which the manufacturer shall not accept any
liability.
- The accident prevention regulations and all other generally recognized regulations
on safety and occupational medicine are to be observed.
- A prerequisite for successful repair is that all required equipment, hand and special tools
are available and in perfect working order.
- Optimal operation economy, reliability and durability of the engine can only be ensured
when genuine parts of DEUTZ AG are used.
- Engine components such as springs, clamps, snap rings, etc. may cause injury if not
handled with care.
- Engine repairs must be carried out in accordance with intended use as defined by
the equipment manufacturer. For conversions, only parts approved by DEUTZ AG for
a specific purpose should be used.
© 2002 / 0312 0361

AVANT-PROPOS
Un fonctionnement fiable du moteur implique l’exécution, selon les règles de l’art, des travaux de
réparation et de réglage.
Le présent Manuel d’Atelier décrit les travaux de réparation et de réglage à effectuer sur le moteur
et ses composants. Il est entendu que ces travaux doivent être réalisés par des personnes de métier
et qualifiées.
En vue d’une compréhension rapide du contenu de ce Manuel d’Atelier, les textes descriptifs brefs
sont accompagnés de symboles visualisant l’opération respectivement traitée.
Pour les instructions de service et d’entretien, se reporter au Manuel d’Instructions respectif.
Pour la commande des pièces de rechange, se reporter à la Liste des pièces de rechange respective.
Le présent Manuel d’Atelier n’est soumis à aucun service de mise à jour. Les modifications seront
reportées lors d’une nouvelle édition.
Pour les réparations, reportez-vous à nos Circulaires Techniques.
Instructions générales:
- Lisez attentivement et tenez compte des informations du présent Manuel d’atelier.

Vous éviterez ainsi des accidents et disposerez toujours d’un moteur fonctionnel et
en parfait état de marche.
- Veillez à ce que le présent Manuel d’Atelier soit à la disposition de toute personne

chargée des travaux de réparation et de réglage et que son contenu en soit compris.
- Le non-respect de ces instructions de réparation peut entraîner des incidents de

fonctionnement, des avaries de moteur et des dommages corporels pour lesquels
le constructeur n’assume aucune responsabilité.
- Il y a lieu de respecter les consignes inhérentes de prévention des accidents et les

réglementations générales en matière de sécurité et de médecine du travail.
- Pour une réparation selon les règles de l’art, il est indispensable de disposer de tous
les équipements, outils manuels et spéciaux requis et en parfait état.
- Seul l’emploi de pièces d’origine DEUTZ assure un maximum de rentabilité, de fiabilité

et de durabilité.
- Les éléments de moteurs tels que ressorts, agrafes, bagues élastiques etc. constituent
en cas de maniement incorrect, un danger accru de blessure.
- La remise en état du moteur doit répondre à son usage conforme – défini par le
constructeur du matériel. En cas de transformations, seules doivent être utilisées les
pièces agréées par DEUTZ AG pour l’application respective.
© 2002 / 0312 0361

PROLOGO
Una ejecución competente de trabajos de reparación y ajuste es requisito fundamental para un
funcionamiento seguro del motor.
En el presente manual para talleres han sido descritos los ciclos convenientes de trabajo para
reparaciones y ajustes del motor y de sus componentes. Se presupone, no obstante, que los
trabajos serán realizados por personal técnico especializado.
Con el fin de simplificar la comprensión del contenido del manual para talleres, se han agregado
pictogramas significativos a los textos explicatorios, visualizando así el trabajo a realizar.
Informaciones con respecto al manejo y al servicio de entretenimiento del motor, se encuentran en el

Manual de Instrucciones correspondiente.
Para pedidos de repuestos servirá de base el respectivo catálogo de repuestos.
El presente manual para talleres no está sujeto a un servicio continuado de modificaciones e

innovaciones. Cada nueva edición incluye todas las modificaciones del caso.
Al efectuar reparaciones, aconsejamos asimismo tomar en cuenta las advertencias pertinentes de

nuestras circulares técnicas.
Advertencias generales:
- Le recomendamos la detenida lectura y observancia de las informaciones con-

tenidas en este Manual de taller. Así evitará accidentes y dispondrá de un motor que
funciona perfectamente.
- Haga lo necesario para que este Manual esté a disposición de toda persona que
participe en trabajos de reparación y ajuste, y cuide de que sí comprenda el contenido.
- Al no tenerse en cuenta estas instrucciones de reparación, podrán surgir

perturbaciones en el funcionamiento y averías en el motor así como lesiones de
personas para las cuales el fabricante no asume responsabilidad alguna.
- Se cumplirán las normas aplicables para la prevención de accidentes así como todas
las demás normas de seguridad y medicina laboral generalmente aceptadas.
- Es condición para la correcta reparación que estén disponibles todos los requeridos
equipos, herramientas manuales y especiales en perfecto estado.
- Máxima rentabilidad, fiabilidad y larga duración quedan garantizadas únicamente al

emplearse repuestos originales de DEUTZ AG.
- Piezas del motor, tales como resortes, garras, aros de sujeción elásticos, etc. , aumentan
en caso de tratamiento incorrecto el peligro de lesiones.
- El reacondicionado del motor deberá corresponder al empleo previsto definido por

el fabricante del equipo. En caso de transformaciones, se deberán emplear
únicamente piezas admitidas por DEUTZ AG para el respectivo uso previsto.
© 2002 / 0312 0361

Inhaltsverzeichnis
Table of Contents
Table des matières
Indice
Technische Daten / Bildzeichenerklärung

Specification data / Key to symbols
Caractéristiques techniques / Légende des symboles
Datos técnicos / Leyenda de los pictogramas
1
Prüfen und Einstellen

Control and adjustment
Contrôle et réglage
Verificación y ajustes
2
Repair of
Demontage und Montage, Motor komplett

Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo
Bauteile ab- und anbauen

Removal and re-installation of components
Démontage et remontage des composants
Desmontaje y montaje de componentes
5
Werkzeuge
Tools
Outils
Herramientas
© 2002 / 0312 0361

6
Technische Daten
Specification data
Caractéristiques techniques
Datos técnicos 2012
Hinweis zum Gebrauch des Werkstatthandbuches

In diesem Werkstatthandbuch sind alle technischen Daten, Einstellwerte und
Anziehvorschriften den Stellen zugeordnet, wo sie bei Servicearbeiten, De- und
Montage am Motor benötigt werden.
Notes for the user of this Workshop Manual

In this Workshop Manual all specification data, adjustment values and
tightening specifications are allocated to those parts where they are needed
for service work, disassembly and reassembly on the engine.
Avis aux utilisateurs du Manuel d’Atelier

Dans le présent Manuel d’Atelier, toutes les caractéristiques techniques, valeurs
de réglage et prescriptions de serrage figurent là où elles sont requises
pour la réalisation des travaux de service, de démontage et de remontage
du moteur.
Indicación para el uso del manual de taller

En el presente manual de taller, todos los datos técnicos, valores de ajuste y
prescripciones de apriete están asignados a los puntos donde son necesarios
para la realización de trabajos de servicio, desarmado y ensamblado en el motor.
© 2003 / 0312 0361

Inhaltsverzeichnis Technische Daten
Table of Contents Specification data
Table des matières Caractéristiques techniques
Indice Datos técnicos
Werkstatthandbuch BFM 2012
Deutsch
1. Technische Daten Seite 1

Techn. Daten ______________________________________________________________ 1.00.02 – 1.00.07
Ventilspieleinstellschema _____________________________________________________ 1.00.09
Reihenfolge beim Anziehen der Zylinderkopfschrauben _____________________________ 1.00.11
Förderbeginn ermitteln _______________________________________________________ 1.00.13
Ausgleichscheibendicke für Förderbeginn ermitteln. ________________________________ 1.00.15 – 1.00.15.1
Ausgleichscheibendicke für Förderbeginn ermitteln bei
Einspritzpumpentausch im Servicefall. Grundmaß L0 = 117,5 mm _____________________ 1.00.17
Einspritzpumpentausch im Servicefall. Grundmaß L0 = 111,15 mm ____________________ 1.00.17.1
Korrigiertes Einbaumaß und EP-Code für Einspritzpumpe ermitteln ____________________ 1.00.19
Bildzeichenerklärung ________________________________________________________ 1.00.21
English
1. Specification data Page
Specification data ___________________________________________________________ 1.00.02 – 1.00.07

Schematic for valve clearance adjustment ________________________________________ 1.00.09
Tightening order for cylinder head bolts __________________________________________ 1.00.11
Determining commencement of delivery _________________________________________ 1.00.13
Determining shim thickness for commencement of delivery. __________________________ 1.00.15 – 1.00.15.1
Determining shim thickness for commencement of delivery injection
pump replacement in case of service. Basic dimension L0 = 117.5 mm _________________ 1.00.17
Determining shim thickness for commencement of delivery injection
pump replacement in case of service. Basic dimension L0 = 111.15 mm ________________ 1.00.17.1
Determining corrected installation dimension and EP code for injection pump ____________ 1.00.19
Key to symbols _____________________________________________________________ 1.00.21
© 2002 / 0312 0361

Technische Daten Inhaltsverzeichnis
Specification data Table of Contents
Caractéristiques techniques Table des matières
Datos técnicos Indice
Français
1 1. Caractéristiques techniques Page
Caractéristiques techniques ______________________________________________ 1.00.02 – 1.00.07

Schéma de réglage des soupapes _________________________________________ 1.00.09
Ordre de serrage des boulons de culasse ____________________________________ 1.00.11
Déterminer le début d’injection ____________________________________________ 1.00.13
Déterminer l’épaisseur de cale de réglage pour le début d’injection ______________ 1.00.15 – 1.00.15.1
Déterminer l’épaisseur de cale de réglage pour le début d’injection lors
d’un remplacement de pompe dans le cadre du Service. Cote de base L0 = 117,5 mm 1.00.17
Déterminer l’épaisseur de cale de réglage pour le début d’injection lors
d’un remplacement de pompe dans le cadre du Service. Cote de base L0 = 111,15 mm 1.00.17.1
Déterminer la cote de montage corrigée et le code EP pour pompe d’injection ______ 1.00.19
Légende des symboles ________________________________________________ 1.00.21
Español
1. Datos técnicos Página
Datos técnicos ________________________________________________________ 1.00.02 – 1.00.07

Esquema para el ajuste del juego de válvulas _________________________________ 1.00.09
Orden a seguir para el apriete de los tornillos de culata __________________________ 1.00.11
Determinación del comienzo de alimentación __________________________________ 1.00.13
Determinación del espesor de la arandela de reglaje para el
comienzo de alimentación ______________________________________________ 1.00.15 – 1.00.15.1
comienzo de alimentación, para la sustitución de bombas de
inyección en caso de servicio. Medida básica L0 = 117,5 mm ___________________ 1.00.17
comienzo de alimentación, para la sustitución de bombas de
inyección en caso de servicio. Medida básica L0 = 111,15 mm __________________ 1.00.17.1
Determinación de la medida de montaje corregida
y el código EP para bomba de inyección ___________________________________ 1.00.19
Leyenda de los pictogramas ____________________________________________ 1.00.21
© 2002 / 0312 0361

Technische Daten
Specification data
Datos técnicos
© 2002 / 0312 0361

Technische Daten
Specification data
Datos técnicos
Deutsch English Français Español
Motorgewicht Engine weight Poids du moteur Peso del motor

1 nach DIN 70020 - A acc. to DIN 70020 - A selon DIN 70020 - A según DIN 70020-A
ca. kg approx. kg approx. kg aprox. kg
Gesamthubvolumen Engine swept volume Cylindrée totale Cilindrada total
cm3 cm3 cm3 cm3
Bohrung Bore Alésage Calibre
mm mm mm mm
Hub Stroke Course Carrera
mm mm mm mm
Drehrichtung Direction of rotation Sens de rotation Sentido de rotación
Nenndrehzahl Rated speed Régime nominal Régimen nominal
max. 1/min rpm maxi tr/mn máx. r/min
niedrigste Minimum Ralenti extrême Régimen mín.

Leerlaufdrehzahl idling speed en vacío
1/min rpm tr/mn r/min
Arbeitsweise Working cycle Principe de fonction- Ciclo de trabajo

nement
1.00.02 © 2002 / 0312 0361

Technische Daten
Specification data
Datos técnicos
BF4M 2012 BF4M 2012 C BF6M 2012 C

ohne Kühlsystem ohne Kühlsystem ohne Kühlsystem
w/o cooling system w/o cooling system w/o cooling system
sans système de sans système de sans système de
refroidissement refroidissement refroidissement
sin sistema de sin sistema de sin sistema de
1
refrigeración refrigeración refrigeración
380 380 495
4 040 6 060
101
126
Auf Schwungrad gesehen links

When facing flywheel counter-clockwise
Vu sur le volant, à gauche
Mirándose sobre el volante, a izquierdas
2500
800
Viertakt - Diesel
Four-stroke diesel
Diesel à 4 temps
Diesel de 4 tiempos
© 2002 / 0312 0361 1.00.03

Technische Daten
Specification data
Datos técnicos
Verbrennungs- Combustion Principe de Sistema de

1 verfahren principle combustion combustión
Verdichtungs- Compression Taux de Relación de

verhältnis ratio compression compresión
Kompressionsdruck Compression pressure Compression Presión de

compresión
bar bar bars bar
Zündfolge Firing order Ordre d’allumage Orden de

encendido
Abmessungen des Dimensions of Dimensions du Dimensiones del

Motors mit engine with moteur avec carter motor con
Anschlußgehäuse standard adapter d’adaption standard cárter de adaptación
(normal) housing (normal)
größte Länge Max. length Longueur HT Longitud máx.
mm mm mm mm
größte Breite Max. width Largeur HT Ancho máx.
mm mm mm mm
größte Höhe Max. height Hauteur HT Altura máx.
mm mm mm mm
1.00.04 © 2002 / 0312 0361

Technische Daten
Specification data
Datos técnicos
BF4M 2012 BF4M 2012 C BF6M 2012 C
Direkteinspritzung
Direct injection
1
Injection directe
Inyección directa
19
30 - 38
1-3-4-2 1-5-3-6-2-4
910 921 1038
643 628
771 833 908
© 2002 / 0312 0361 1.00.05

Technische Daten
Specification data
Datos técnicos
Steuerzeiten ohne Valve timing without Calage de la distribution Cotas de reglaje sin
1 Stößel- und Ventilspiel tappet and
valve clearance
sans jeu de poussoirs
et de soupapes
juegos de válvulas y
de empujadores
Einlass öffnet Inlet opens Admission ouvre Admisión abre

vor OT before TDC avant PMH ante PMS
Grad degrees degrés grados
Einlass schließt Inlet closes Admission ferme Admisión cierra

nach UT after BDC après PMB tras PMI
Auslass öffnet Exhaust opens Echappement ouvre Escape abre

vor UT before BDC avant PMB ante PMI
Auslass schließt Exhaust closes Echappement ferme Escape cierra

nach OT after TDC après PMH tras PMS
Absteuerventil Pressurestat Clapet régulateur Válvula reguladora

final final
bar bar bars bar
Schmieröldruck in Lube oil pressure at low Pression d’huile au ralenti Presión de aceite a
niedrigem Leerlauf idling mini température marcha lenta en vacío,
Temperatur ca. 120 °C Temperature approx. environ 120 °C temperatura aprox. 120 °C
Öl SAE 15W/40 120 °C oil SAE 15W/40 huile SAE 15W/40 aceite SAE 15W/40
Minimum bar min. bar mini bar mín. bar
1.00.06 © 2002 / 0312 0361

Technische Daten
Specification data
Datos técnicos
BF4M 2012 BF4M 2012 C BF6M 2012 C
46
56
96
50
4 ± 0,4
0,8
© 2002 / 0312 0361 1.00.07

Technische Daten
Specification data
Datos técnicos
© 2002 / 0312 0361

Ventilspieleinstellschema
Schematic for valve clearance adjustment
Schéma de réglage des soupapes
Esquema para el ajuste del juego de válvulas
1
Kurbelwellenstellung 1 Kurbelwellenstellung 2
Motor bis zum Erreichen der Ventilüber- Motor um eine volle Umdrehung (360°) weiter-
schneidung am Zyl. Nr. 1 durchdrehen. drehen.
nicht einstellbar einstellbar
© 2002 / 0312 0361 1.00.09

English Français Español
1 Crankshaft position 1 Position de vilebrequin 1 Posición del cigüeñal 1

Turn engine until valves of cylinder Virer le moteur jusqu’à ce que les Girar el cigüeñal hasta el cruce de las
No. 1 overlap. soupapes du cyl. n° 1 soient en balance. válvulas en el cilindro No. 1.
Not ready for adjustment. non réglable no ajustable
Crankshaft position 2: Position de vilebrequin 2 Posición del cigüeñal 2
Turn engine further by one complete Virer encore le moteur d’un tour Continuar girando el cigüeñal
revolution (360°). complet (360°). una vuelta entera (360°)
Ready for adjustment. réglable ajustable
1.00.09 © 2002 / 0312 0361

Reihenfolge beim Anziehen der Zylinderkopfschrauben
Tightening order for cylinder head bolts
Ordre de serrage des boulons de culasse
Orden a seguir para el apriete de los tornillos de culata
4-Zylinder 1
4-cylinder
4 cylindres Krümmerseite, elbow side
4 cilindros Côté collecteur, costado codo de escape
14 6 4 12
18 10 2 8 16
17 9 1 7 15
13 5 3 11
6-Zylinder
6-cylinder
6 cylindres Krümmerseite, elbow side
6 cilindros Côté collecteur, costado codo de escape
22 14 6 4 12 20
26 18 10 2 8 16 24
25 17 9 1 7 15 23
21 13 5 3 11 19
© 2002 / 0312 0361 1.00.11

Förderbeginn ermitteln Technische Daten
Determining commencement of delivery Specification data
Déterminer le début d’injection Caractéristiques techniques
Determinación del comienzo de alimentación Datos técnicos
1
7 L
Hinweis:
Auf dem Schriftfeld für den Förderbeginn ist auch der Nockenwellentyp K, L, H, Q oder P angegeben. Dies ist bei der
Grundeinstellung der Einspritzpumpen, siehe Tabelle 1, unbedingt zu berücksichtigen.
Note:
Camshaft type K, L, H, Q or P is also indicated in the inscription field for the commencement of delivery.
It is absolutely necessary to take this into account for the basic setting of the injection pumps, see table 1.
Nota:
Dans la case indiquant le début d’injection figure aussi le type d’arbre à came K, L, H, Q ou P.
Il faut impérativement en tenir compte lors du calage de base de la pompe d’injection, voir tableau 1.
Nota:
En la casilla de inscripción correspondiente al comienzo de alimentación se indica también el tipo de árbol de levas
K , L, H, Q ó P. Es imprescindible considerar este dato para el ajuste básico de las bombas de inyección, ver tabla 1.
© 2002 / 0312 0361 1.00.13

Technische Daten
Specification data
Datos técnicos
© 2002 / 0312 0361

Ausgleichscheibendicke für Förderbeginn ermitteln.
Tabelle 1 Tabelle 2
Motortyp Förderbeginn Nockenwelle Vorhub Vorhub Grundmaß Theor. Dicke Ausgleich- Theor. Dicke Ausgleich-
(FB) (Vh) Korrektur- E-Pumpe „TS“ scheiben- „TS“ scheiben-
Nenn./Tol. Typ Nennwert faktor (L0) dicke „SS“ dicke „SS“
(° kW v. OT) (mm) (mm/° kW) (mm) (mm) (mm) (mm) (mm)
BFM 2012 0,0 K 4,80 0,14 117,5 0,95 - 1,049 1,0 2,45 - 2,549 2,5
BFM 2012 1,0 K 4,62 0,14 117,5 1,05 - 1,149 1,1 2,55 - 2,649 2,6
BFM 2012 2,0 K 4,44 0,14 117,5
1,15 - 1,249 1,2 2,65 - 2,749 2,7 1
BFM 2012 3,0 K 4,27 0,14 117,5
1,25 - 1,349 1,3 2,75 - 2,849 2,8
BFM 2012 4,0 K 4,11 0,14 117,5
BFM 2012 5,0 K 3,95 0,14 117,5 1,35 - 1,449 1,4 2,85 - 2,949 2,9
BFM 2012 2,0 L 5,14 0,14 117,5 1,45 - 1,549 1,5 2,95 - 3,049 3,0
BFM 2012 3,0 L 4,97 0,14 117,5 1,55 - 1,649 1,6 3,05 - 3,149 3,1
BFM 2012 4,0 L 4,80 0,14 117,5 1,65 - 1,749 1,7 3,15 - 3,249 3,2
BFM 2012 5,0 L 4,62 0,14 117,5
1,75 - 1,849 1,8 3,25 - 3,349 3,3
BFM 2012 6,0 L 4,44 0,14 117,5
1,85 - 1,949 1,9 3,35 - 3,449 3,4
BFM 2012 7,0 L 4,26 0,14 117,5
BFM 2012 8,0 L 4,11 0,14 117,5 1,95 - 2,049 2,0 3,45 - 3,549 3,5
BFM 2012 9,0 L 3,95 0,14 117,5 2,05 - 2,149 2,1 3,55 - 3,649 3,6
BFM 2012 1,0 H 5,52 0,14 117,5 2,15 - 2,249 2,2 3,65 - 3,749 3,7
BFM 2012 2,0 H 5,36 0,14 117,5 2,25 - 2,349 2,3
BFM 2012 3,0 H 5,20 0,14 117,5
2,35 - 2,449 2,4
BFM 2012 4,0 H 5,05 0,14 117,5
BFM 2012 5,0 H 4,89 0,14 117,5
BFM 2012 6,0 H 4,73 0,14 117,5
BFM 2012 7,0 H 4,58 0,14 117,5
BFM 2012 8,0 H 4,43 0,14 117,5
BFM 2012 2,0 Q 5,31 0,14 117,5
BFM 2012 3,0 Q 5,14 0,14 117,5
BFM 2012 4,0 Q 4,97 0,14 117,5
BFM 2012 5,0 Q 4,80 0,14 117,5
BFM 2012 6,0 Q 4,62 0,14 117,5
BFM 2012 7,0 Q 4,44 0,14 117,5
BFM 2012 8,0 Q 4,26 0,14 117,5
BFM 2012 9,0 Q 4,11 0,14 117,5
BFM 2012 10,0 Q 3,95 0,14 117,5
BFM 2012 2,0 P 5,23 0,14 117,5
BFM 2012 3,0 P 5,08 0,14 117,5
BFM 2012 4,0 P 4,92 0,14 117,5
BFM 2012 5,0 P 4,76 0,14 117,5
BFM 2012 6,0 P 4,61 0,14 117,5
BFM 2012 7,0 P 4,46 0,14 117,5
BFM 2012 8,0 P 4,31 0,14 117,5
BFM 2012 9,0 P 4,16 0,14 117,5
BFM 2012 10,0 P 4,01 0,14 117,5
© 2002 / 0312 0361 1.00.15

Berechnungsbeispiel: BFM 2012
Zylinder Nr. 0 1 2 3 4 5 6
E - Pumpen Nr. xxx
FB Ist gemessen °kW 8
1 FB Nenn aus Tabelle 1 °kW 7
Vh Korr.faktor aus Tab. 1 mm/°kW 0,14
Vh Nenn aus Tabelle 1 mm 4,26
L0 aus Tabelle 1 mm 117,5
A/100 von E.-Pumpe mm 0,29
L gemessen mm 125,28
E1 = FB Ist - FB Nenn °kW 1

E2 = E1 x Vh Korrekturfaktor mm 0,14
E3 = E2 + Vh Nenn mm 4,40
E4 = E3 + L0 mm 121,90
E5 = E4 + A/100 mm 122,19
TS = L - E5 mm 3,09
„SS“ aus Tabelle 2 mm 3,1
1.00.15 © 2002 / 0312 0361

Determining shim thickness for commencement of delivery.
Table 1 Table 2
Engine type Commencement Camshaft Pre-stroke Pre-stroke Basic Theor. thickness Shim Theor. thickness Shim
of delivery (Vh) correction dimension ”TS“ thickness ”TS“ thickness
nom./tol. type nom. value factor inj. pump ”SS“ ”SS“
(°C/A BTDC) (mm) (mm/°C/A) (L0) (mm) (mm) (mm) (mm) (mm)
BFM 2012 0.0 K 4.80 0.14 117.5 0.95 - 1.049 1.0 2.45 - 2.549 2.5
BFM 2012 1.0 K 4.62 0.14 117.5 1.05 - 1.149 1.1 2.55 - 2.649 2.6
BFM 2012 2.0 K 4.44 0.14 117.5
1.15 - 1.249 1.2 2.65 - 2.749 2.7 1
BFM 2012 3.0 K 4.27 0.14 117.5
1.25 - 1.349 1.3 2.75 - 2.849 2.8
BFM 2012 4.0 K 4.11 0.14 117.5
BFM 2012 5.0 K 3.95 0.14 117.5 1.35 - 1.449 1.4 2.85 - 2.949 2.9
BFM 2012 2.0 L 5.14 0.14 117.5 1.45 - 1.549 1.5 2.95 - 3.049 3.0
BFM 2012 3.0 L 4.97 0.14 117.5 1.55 - 1.649 1.6 3.05 - 3.149 3.1
BFM 2012 4.0 L 4.80 0.14 117.5 1.65 - 1.749 1.7 3.15 - 3.249 3.2
BFM 2012 5.0 L 4.62 0.14 117.5
1.75 - 1.849 1.8 3.25 - 3.349 3.3
BFM 2012 6.0 L 4.44 0.14 117.5
1.85 - 1.949 1.9 3.35 - 3.449 3.4
BFM 2012 7.0 L 4.26 0.14 117.5
BFM 2012 8.0 L 4.11 0.14 117.5 1.95 - 2.049 2.0 3.45 - 3.549 3.5
BFM 2012 9.0 L 3.95 0.14 117.5 2.05 - 2.149 2.1 3.55 - 3.649 3.6
BFM 2012 1.0 H 5.52 0.14 117.5 2.15 - 2.249 2.2 3.65 - 3.749 3.7
BFM 2012 2.0 H 5.36 0.14 117.5 2.25 - 2.349 2.3
BFM 2012 3.0 H 5.20 0.14 117.5
2.35 - 2.449 2.4
BFM 2012 4.0 H 5.05 0.14 117.5
BFM 2012 5.0 H 4.89 0.14 117.5
BFM 2012 6.0 H 4.73 0.14 117.5
BFM 2012 7.0 H 4.58 0.14 117.5
BFM 2012 8.0 H 4.43 0.14 117.5
BFM 2012 2.0 Q 5.31 0,14 117.5
BFM 2012 3.0 Q 5.14 0.14 117.5
BFM 2012 4.0 Q 4.97 0.14 117.5
BFM 2012 5.0 Q 4.80 0.14 117.5
BFM 2012 6.0 Q 4.62 0.14 117.5
BFM 2012 7.0 Q 4.44 0.14 117.5
BFM 2012 8.0 Q 4.26 0.14 117.5
BFM 2012 9.0 Q 4.11 0.14 117.5
BFM 2012 10.0 Q 3.95 0.14 117.5
BFM 2012 2.0 P 5.23 0.14 117.5
BFM 2012 3.0 P 5.08 0.14 117.5
BFM 2012 4.0 P 4.92 0.14 117.5
BFM 2012 5.0 P 4.76 0.14 117.5
BFM 2012 6.0 P 4.61 0.14 117.5
BFM 2012 7.0 P 4.46 0.14 117.5
BFM 2012 8.0 P 4.31 0.14 117.5
BFM 2012 9.0 P 4.16 0.14 117.5
BFM 2012 10.0 P 4.01 0.14 117.5
© 2002 / 0312 0361 1.00.15

Calculation example: BFM 2012
Cylinder No. 0 1 2 3 4 5 6
Injection pump No. xxx
FB measured °C/A 8
1 FB nom. from table 1 °C/A 7
Vh corr. factor from table 1 mm/°C/A 0.14
Vh nom. from table 1 mm 4.26
L0 from table 1 mm 117.5
A/100 of inj. pump mm 0.29
L measured mm 125.28
E1 = FB act. - FB nom. °C/A 1

E2 = E1 x Vh corr. factor mm 0.14
E3 = E2 + Vh nom. mm 4.40
E4 = E3 + L0 mm 121.90
E5 = E4 + A/100 mm 122.19
TS = L - E5 mm 3.09
”SS“ from table 2 mm 3.1
1.00.15 © 2002 / 0312 0361

Déterminer l’épaisseur de cale de réglage pour le début d’injection
Tableau 1 Tableau 2
Type de moteur Début d’injection Arbre à Course à Facteur de Cote de base Epaisseur Epaisseur Epaisseur Epaisseur
(FB) cames débit nul (Vh) correction ppe d’injection théor. cale de théor. cale de
nom./tol. type valeur nom. course à débit nul (L0) ”TS“ réglage ”SS“ ”TS“ réglage ”SS“
(°vil. av. PMH) (mm) (mm/°vil.) (mm) (mm) (mm) (mm) (mm)
BFM 2012 0,0 K 4,80 0,14 117,5 0,95 - 1,049 1,0 2,45 - 2,549 2,5
BFM 2012 1,0 K 4,62 0,14 117,5 1,05 - 1,149 1,1 2,55 - 2,649 2,6
BFM 2012
BFM 2012
2,0
3,0
K
K
4,44
4,27
0,14
0,14
117,5
117,5
1,15 - 1,249 1,2 2,65 - 2,749 2,7 1
1,25 - 1,349 1,3 2,75 - 2,849 2,8
BFM 2012 4,0 K 4,11 0,14 117,5
BFM 2012 5,0 K 3,95 0,14 117,5 1,35 - 1,449 1,4 2,85 - 2,949 2,9
BFM 2012 2,0 L 5,14 0,14 117,5 1,45 - 1,549 1,5 2,95 - 3,049 3,0
BFM 2012 3,0 L 4,97 0,14 117,5 1,55 - 1,649 1,6 3,05 - 3,149 3,1
BFM 2012 4,0 L 4,80 0,14 117,5 1,65 - 1,749 1,7 3,15 - 3,249 3,2
BFM 2012 5,0 L 4,62 0,14 117,5
1,75 - 1,849 1,8 3,25 - 3,349 3,3
BFM 2012 6,0 L 4,44 0,14 117,5
1,85 - 1,949 1,9 3,35 - 3,449 3,4
BFM 2012 7,0 L 4,26 0,14 117,5
BFM 2012 8,0 L 4,11 0,14 117,5 1,95 - 2,049 2,0 3,45 - 3,549 3,5
BFM 2012 9,0 L 3,95 0,14 117,5 2,05 - 2,149 2,1 3,55 - 3,649 3,6
BFM 2012 1,0 H 5,52 0,14 117,5 2,15 - 2,249 2,2 3,65 - 3,749 3,7
BFM 2012 2,0 H 5,36 0,14 117,5 2,25 - 2,349 2,3
BFM 2012 3,0 H 5,20 0,14 117,5
2,35 - 2,449 2,4
BFM 2012 4,0 H 5,05 0,14 117,5
BFM 2012 5,0 H 4,89 0,14 117,5
BFM 2012 6,0 H 4,73 0,14 117,5
BFM 2012 7,0 H 4,58 0,14 117,5
BFM 2012 8,0 H 4,43 0,14 117,5
BFM 2012 2,0 Q 5,31 0,14 117,5
BFM 2012 3,0 Q 5,14 0,14 117,5
BFM 2012 4,0 Q 4,97 0,14 117,5
BFM 2012 5,0 Q 4,80 0,14 117,5
BFM 2012 6,0 Q 4,62 0,14 117,5
BFM 2012 7,0 Q 4,44 0,14 117,5
BFM 2012 8,0 Q 4,26 0,14 117,5
BFM 2012 9,0 Q 4,11 0,14 117,5
BFM 2012 10,0 Q 3,95 0,14 117,5
BFM 2012 2,0 P 5,23 0,14 117,5
BFM 2012 3,0 P 5,08 0,14 117,5
BFM 2012 4,0 P 4,92 0,14 117,5
BFM 2012 5,0 P 4,76 0,14 117,5
BFM 2012 6,0 P 4,61 0,14 117,5
BFM 2012 7,0 P 4,46 0,14 117,5
BFM 2012 8,0 P 4,31 0,14 117,5
BFM 2012 9,0 P 4,16 0,14 117,5
BFM 2012 10,0 P 4,01 0,14 117,5
© 2002 / 0312 0361 1.00.15

Exemple de calcul: BFM 2012
Cylindre n° 0 1 2 3 4 5 6
Pompe d’inj. n° xxx
FB réel mesuré °vil. 8
1 FB nom. selon tableau 1 °vil. 7
Fact. corr. Vh selon tableau 1 mm/°vil. 0,14
Vh nom. selon tableau 1 mm 4,26
L0 selon tableau 1 mm 117,5
A/100 de ppe d’inj. mm 0,29
L mesuré mm 125,28
E1 = FB réel - FB nom. °vil. 1

E2 = E1 x fact. corr. Vh mm 0,14
E3 = E2 + Vh nom. mm 4,40
E4 = E3 + L0 mm 121,90
E5 = E4 + A/100 mm 122,19
TS = L - E5 mm 3,09
”SS“ selon tableau 2 mm 3,1
1.00.15 © 2002 / 0312 0361

Determinación del espesor de la arandela de reglaje para el comienzo de alimentación.
Tabla 1 Tabla 2
Tipo de motor Comienzo Arbol de levas Precurso Factor de Medida básica Espesor teór. Espesor Espesor teór. Espesor
de alimentación Tipo (Vh) corrección Bomba iny. ”TS“ arandela de ”TS“ arandela de
(”FB“, en alemán)
V.nom./tol. Valor nom. precurso (L0) reglaje ”SS“ reglaje ”SS“
(°cig. a. PMS) (mm) (mm/°cig.) (mm) (mm) (mm) (mm) (mm)
BFM 2012 0,0 K 4,80 0,14 117,5 0,95 - 1,049 1,0 2,45 - 2,549 2,5
BFM 2012 1,0 K 4,62 0,14 117,5 1,05 - 1,149 1,1 2,55 - 2,649 2,6
BFM 2012
BFM 2012
2,0
3,0
K
K
4,44
4,27
0,14
0,14
117,5
117,5
1,15 - 1,249 1,2 2,65 - 2,749 2,7 1
1,25 - 1,349 1,3 2,75 - 2,849 2,8
BFM 2012 4,0 K 4,11 0,14 117,5
BFM 2012 5,0 K 3,95 0,14 117,5 1,35 - 1,449 1,4 2,85 - 2,949 2,9
BFM 2012 2,0 L 5,14 0,14 117,5 1,45 - 1,549 1,5 2,95 - 3,049 3,0
BFM 2012 3,0 L 4,97 0,14 117,5 1,55 - 1,649 1,6 3,05 - 3,149 3,1
BFM 2012 4,0 L 4,80 0,14 117,5 1,65 - 1,749 1,7 3,15 - 3,249 3,2
BFM 2012 5,0 L 4,62 0,14 117,5
1,75 - 1,849 1,8 3,25 - 3,349 3,3
BFM 2012 6,0 L 4,44 0,14 117,5
1,85 - 1,949 1,9 3,35 - 3,449 3,4
BFM 2012 7,0 L 4,26 0,14 117,5
BFM 2012 8,0 L 4,11 0,14 117,5 1,95 - 2,049 2,0 3,45 - 3,549 3,5
BFM 2012 9,0 L 3,95 0,14 117,5 2,05 - 2,149 2,1 3,55 - 3,649 3,6
BFM 2012 1,0 H 5,52 0,14 117,5 2,15 - 2,249 2,2 3,65 - 3,749 3,7
BFM 2012 2,0 H 5,36 0,14 117,5 2,25 - 2,349 2,3
BFM 2012 3,0 H 5,20 0,14 117,5
2,35 - 2,449 2,4
BFM 2012 4,0 H 5.05 0,14 117,5
BFM 2012 5,0 H 4,89 0,14 117,5
BFM 2012 6,0 H 4,73 0,14 117,5
BFM 2012 7,0 H 4,58 0,14 117,5
BFM 2012 8,0 H 4,43 0,14 117,5
BFM 2012 2,0 Q 5,31 0,14 117,5
BFM 2012 3,0 Q 5,14 0,14 117,5
BFM 2012 4,0 Q 4,97 0,14 117,5
BFM 2012 5,0 Q 4,80 0,14 117,5
BFM 2012 6,0 Q 4,62 0,14 117,5
BFM 2012 7,0 Q 4,44 0,14 117,5
BFM 2012 8,0 Q 4,26 0,14 117,5
BFM 2012 9,0 Q 4,11 0,14 117,5
BFM 2012 10,0 Q 3,95 0,14 117,5
BFM 2012 2,0 P 5,23 0,14 117,5
BFM 2012 3,0 P 5,08 0,14 117,5
BFM 2012 4,0 P 4,92 0,14 117,5
BFM 2012 5,0 P 4,76 0,14 117,5
BFM 2012 6,0 P 4,61 0,14 117,5
BFM 2012 7,0 P 4,46 0,14 117,5
BFM 2012 8,0 P 4,31 0,14 117,5
BFM 2012 9,0 P 4,16 0,14 117,5
BFM 2012 10,0 P 4,01 0,14 117,5
© 2002 / 0312 0361 1.00.15

Ejemplo de cálculo: BFM 2012
Cilindro No. 0 1 2 3 4 5 6
Bomba de inyección No. xxx
“FB” real, medido °cig. 8
1 “FB” nominal seg. tabla 1 °cig. 7
Factor corr. precurso seg. tabla 1 mm/°cig. 0,14
Precurso nominal seg. tabla 1 mm 4,26
L0 seg. tabla 1 mm 117,5
A/100 de la bomba iny. mm 0,29
L medido mm 125,28
E1 = “FB” real - FB nominal °cig. 1

E2 = E1 x factor corrección precurso mm 0,14
E3 = E2 + precurso nominal mm 4,40
E4 = E3 + L0 mm 121,90
E5 = E4 + A/100 mm 122,19
TS = L - E5 mm 3,09
“SS” seg. tabla 2 mm 3,1
1.00.15 © 2002 / 0312 0361

2012 mit Spritzversteller
Ausgleichscheibendicke für Förderbeginn ermitteln.
Tabelle 1.1 Tabelle 2.1

Motortyp Förderbeginn Nockenwelle Vorhub Vorhub Grundmaß Theor. Dicke Ausgleich- Theor. Dicke Ausgleich-
(FB) (Vh) Korrektur- E-Pumpe „TS“ scheiben- „TS“ scheiben-
Nenn./Tol. Typ Nennwert faktor (L0) dicke „SS“ dicke „SS“
(° KW v. OT) (mm) (mm/° KW) (mm) (mm) (mm) (mm) (mm)
BFM 2012 2,0 Q 5,325 - 111,15 4,625 - 4,6749 4,65 5,575 - 5,6249 5,60
BFM 2012
BFM 2012
3,0
4,0
Q
Q
5,150
4,975
-
-
111,15
111,15
4,675 - 4,7249
4,725 - 4,7749
4,70
4,75
5,625 - 5,6749
5,675 - 5,7249
5,65
5,70
1
4,775 - 4,8249 4,80 5,725 - 5,7749 5,75
BFM 2012 2,0 P 5,231 - 111,15 4,825 - 4,8749 4,85 5,775 - 5,8249 5,80
BFM 2012 3,0 P 5,074 - 111,15 4,875 - 4,9249 4,90 5,825 - 5,8749 5,85
4,925 - 4,9749 4,95 5,875 - 5,9249 5,90
4,975 - 5,0249 5,00 5,925 - 5,9749 5,95
5,025 - 5,0749 5,05 5,975 - 6,0249 6,00
5,075 - 5,1249 5,10 6,025 - 6,0749 6,05
5,125 - 5,1749 5,15 6,075 - 6,1249 6,10
5,175 - 5,2249 5,20 6,125 - 6,1749 6,15
5,225 - 5,2749 5,25 6,175 - 6,2249 6,20
5,275 - 5,3249 5,30 6,225 - 6,2749 6,25
5,325 - 5,3749 5,35 6,275 - 6,3249 6,30
5,375 - 5,4249 5,40 6,325 - 6,3749 6,35
5,425 - 5,4749 5,45 6,375 - 6,4249 6,40
5,475 - 5,5249 5,50
5,525 - 5,5749 5,55
© 2004 / 0312 0361 1.00.15.1

2012 with Injection timer
Determining shim thickness for commencement of delivery.
Table 1.1 Table 2.1

Engine type Commencement Camshaft Pre-stroke Pre-stroke Basic Theor. thickness Shim Theor. thickness Shim
of delivery (Vh) correction dimension ”TS“ thickness ”TS“ thickness
nom./tol. type nom. value factor inj. pump ”SS“ ”SS“
(°C/A BTDC) (mm) (mm/°C/A) (L0) (mm) (mm) (mm) (mm) (mm)
BFM 2012 2,0 Q 5,325 - 111,15 4,625 - 4,6749 4,65 5,575 - 5,6249 5,60
BFM 2012 3,0 Q 5,150 - 111,15 4,675 - 4,7249 4,70 5,625 - 5,6749 5,65 1
BFM 2012 4,0 Q 4,975 - 111,15 4,725 - 4,7749 4,75 5,675 - 5,7249 5,70
4,775 - 4,8249 4,80 5,725 - 5,7749 5,75
BFM 2012 2,0 P 5,231 - 111,15 4,825 - 4,8749 4,85 5,775 - 5,8249 5,80
BFM 2012 3,0 P 5,074 - 111,15 4,875 - 4,9249 4,90 5,825 - 5,8749 5,85
4,925 - 4,9749 4,95 5,875 - 5,9249 5,90
4,975 - 5,0249 5,00 5,925 - 5,9749 5,95
5,025 - 5,0749 5,05 5,975 - 6,0249 6,00
5,075 - 5,1249 5,10 6,025 - 6,0749 6,05
5,125 - 5,1749 5,15 6,075 - 6,1249 6,10
5,175 - 5,2249 5,20 6,125 - 6,1749 6,15
5,225 - 5,2749 5,25 6,175 - 6,2249 6,20
5,275 - 5,3249 5,30 6,225 - 6,2749 6,25
5,325 - 5,3749 5,35 6,275 - 6,3249 6,30
5,375 - 5,4249 5,40 6,325 - 6,3749 6,35
5,425 - 5,4749 5,45 6,375 - 6,4249 6,40
5,475 - 5,5249 5,50
5,525 - 5,5749 5,55
© 2004 / 0312 0361 1.00.15.1

2012 avec L’avance automatique
Tableau 1.1 Tableau 2.1

Type de moteur Début d’injection Arbre à Course à Facteur de Cote de base Epaisseur Epaisseur Epaisseur Epaisseur
(FB) cames débit nul (Vh) correction ppe d’injection théor. cale de théor. cale de
nom./tol. type valeur nom. course à débit nul (L0) ”TS“ réglage ”SS“ ”TS“ réglage ”SS“
(°vil. av. PMH) (mm) (mm/°vil.) (mm) (mm) (mm) (mm) (mm)
BFM 2012 2,0 Q 5,325 - 111,15 4,625 - 4,6749 4,65 5,575 - 5,6249 5,60
BFM 2012
BFM 2012
3,0
4,0
Q
Q
5,150
4,975
-
-
111,15
111,15
4,675 - 4,7249
4,725 - 4,7749
4,70
4,75
5,625 - 5,6749
5,675 - 5,7249
5,65
5,70
1
4,775 - 4,8249 4,80 5,725 - 5,7749 5,75
BFM 2012 2,0 P 5,231 - 111,15 4,825 - 4,8749 4,85 5,775 - 5,8249 5,80
BFM 2012 3,0 P 5,074 - 111,15 4,875 - 4,9249 4,90 5,825 - 5,8749 5,85
4,925 - 4,9749 4,95 5,875 - 5,9249 5,90
4,975 - 5,0249 5,00 5,925 - 5,9749 5,95
5,025 - 5,0749 5,05 5,975 - 6,0249 6,00
5,075 - 5,1249 5,10 6,025 - 6,0749 6,05
5,125 - 5,1749 5,15 6,075 - 6,1249 6,10
5,175 - 5,2249 5,20 6,125 - 6,1749 6,15
5,225 - 5,2749 5,25 6,175 - 6,2249 6,20
5,275 - 5,3249 5,30 6,225 - 6,2749 6,25
5,325 - 5,3749 5,35 6,275 - 6,3249 6,30
5,375 - 5,4249 5,40 6,325 - 6,3749 6,35
5,425 - 5,4749 5,45 6,375 - 6,4249 6,40
5,475 - 5,5249 5,50
5,525 - 5,5749 5,55
© 2004 / 0312 0361 1.00.15.1

2012 con Graduador de avance de inyección
Determinación del espesor de la arandela de reglaje para el comienzo de alimentación.
Tabla 1.1 Tabla 2.1

Tipo de motor Comienzo Arbol de levas Precurso Factor de Medida básica Espesor teór. Espesor Espesor teór. Espesor
de alimentación Tipo (Vh) corrección Bomba iny. ”TS“ arandela de ”TS“ arandela de
(”FB“, en alemán)
V.nom./tol. Valor nom. precurso (L0) reglaje ”SS“ reglaje ”SS“
(°cig. a. PMS) (mm) (mm/°cig.) (mm) (mm) (mm) (mm) (mm)
BFM 2012 2,0 Q 5,325 - 111,15 4,625 - 4,6749 4,65 5,575 - 5,6249 5,60
BFM 2012
BFM 2012
3,0
4,0
Q
Q
5,150
4,975
-
-
111,15
111,15
4,675 - 4,7249
4,725 - 4,7749
4,70
4,75
5,625 - 5,6749
5,675 - 5,7249
5,65
5,70
1
4,775 - 4,8249 4,80 5,725 - 5,7749 5,75
BFM 2012 2,0 P 5,231 - 111,15 4,825 - 4,8749 4,85 5,775 - 5,8249 5,80
BFM 2012 3,0 P 5,074 - 111,15 4,875 - 4,9249 4,90 5,825 - 5,8749 5,85
4,925 - 4,9749 4,95 5,875 - 5,9249 5,90
4,975 - 5,0249 5,00 5,925 - 5,9749 5,95
5,025 - 5,0749 5,05 5,975 - 6,0249 6,00
5,075 - 5,1249 5,10 6,025 - 6,0749 6,05
5,125 - 5,1749 5,15 6,075 - 6,1249 6,10
5,175 - 5,2249 5,20 6,125 - 6,1749 6,15
5,225 - 5,2749 5,25 6,175 - 6,2249 6,20
5,275 - 5,3249 5,30 6,225 - 6,2749 6,25
5,325 - 5,3749 5,35 6,275 - 6,3249 6,30
5,375 - 5,4249 5,40 6,325 - 6,3749 6,35
5,425 - 5,4749 5,45 6,375 - 6,4249 6,40
5,475 - 5,5249 5,50
5,525 - 5,5749 5,55
© 2004 / 0312 0361 1.00.15.1

Ausgleichscheibendicke für Förderbeginn ermitteln
bei Einspritzpumpentausch im Servicefall. Grundmaß L0 = 117,5 mm
Die alte Einspritzpumpe und Ausgleichscheibe ist hierzu nicht erforderlich.
Beispiel: An einem BF6M 2012 ist die Einspritzpumpe von Zylinder 3 zu ersetzen.
Vorgehensweise:
Vom Firmenschild in der Rubrik „EP“ den EP-Code für Zylinder 3 ablesen, z.B. 295.
(Lesefolge: Zeile 1 = Zyl.1, Zeile 2 = Zyl.2, u.s.w.) 1
Korrigiertes Einspritzpumpeneinbaumaß (EK) aus Tabelle 3 entsprechend dem EP-Code entnehmen,

z.B. 120,875 mm.
Tabelle 3
EK EP- EK EP- EK EP- EK EP-

Code Code Code Code
(mm) (mm) (mm) (mm)
119,25 230 119,85 254 120,45 278 121,05 302

119,275 231 119,875 255 120,475 279 121,075 303
119,3 232 119,9 256 120,5 280 121,1 304
119,325 233 119,925 257 120,525 281 121,125 305
119,35 234 119,95 258 120,55 282 121,15 306
119,375 235 119,975 259 120,575 283 121,175 307
119,4 236 120,0 260 120,6 284 121,2 308
119,425 237 120,025 261 120,625 285 121,225 309
119,45 238 120,05 262 120,65 286 121,25 310
119,475 239 120,075 263 120,675 287 121,275 311
119,5 240 120,1 264 120,7 288 121,3 312
119,525 241 120,125 265 120,725 289 121,325 313
119,55 242 120,15 266 120,75 290 121,35 314
119,575 243 120,175 267 120,775 291 121,375 315
119,6 244 120,2 268 120,8 292
119,625 245 120,225 269 120,825 293
119,65 246 120,25 270 120,85 294
119,675 247 120,275 271 120,875 295
119,7 248 120,3 272 120,9 296
119,725 249 120,325 273 120,925 297
119,75 250 120,35 274 120,95 298
119,775 251 120,375 275 120,975 299
119,8 252 120,4 276 121,0 300
119,825 253 120,425 277 121,025 301
Kennzahl für Einspritzpumpenlänge (A) von der neuen Einspritzpumpe ablesen, z.B. 42.
Grundmaß der Einspritzpumpe (L0 ) aus Tabelle 1 entnehmen, z.B. 117,5 mm.
Theoretische Ausgleichscheibendicke (TS) ermitteln.

TS = EK - (L0 + A/100)
TS = 120,875 mm - (117,5 mm + 42/100 mm)
TS = 2,955 mm
Ausgleichscheibendicke (SS) nach Tabelle 2 auswählen.

TS 2,955 mm = SS 3,0 mm
© 2004 / 0312 0361 1.00.17

Determining shim thickness for commencement of delivery
injection pump replacement in case of service. Basic dimension L0 = 117.5 mm
The old injection pump with shim is not required for such purpose.
Example: The injection pump of cylinder 3 is to be replaced on a BF6M 2012.

Procedure: Read off EP code for cylinder 3 from name plate under column ”EP“, e.g. 295
(Reading sequence: line 1 = cyl. 1, line 2 = cyl. 2, etc.)
1
Take corrected injection pump installation dimension (EK) from table 3 according to EP code, e.g. 120.875 mm.
Table 3
EK EP- EK EP- EK EP- EK EP-

Code Code Code Code
(mm) (mm) (mm) (mm)
119.25 230 119.85 254 120.45 278 121.05 302

119.275 231 119.875 255 120.475 279 121.075 303
119.3 232 119.9 256 120.5 280 121.1 304
119.325 233 119.925 257 120.525 281 121.125 305
119.35 234 119.95 258 120.55 282 121.15 306
119.375 235 119.975 259 120.575 283 121.175 307
119.4 236 120.0 260 120.6 284 121.2 308
119.425 237 120.025 261 120.625 285 121.225 309
119.45 238 120.05 262 120.65 286 121.25 310
119.475 239 120.075 263 120.675 287 121.275 311
119.5 240 120.1 264 120.7 288 121.3 312
119.525 241 120.125 265 120.725 289 121.325 313
119.55 242 120.15 266 120.75 290 121.35 314
119.575 243 120.175 267 120.775 291 121.375 315
119.6 244 120.2 268 120.8 292
119.625 245 120.225 269 120.825 293
119.65 246 120.25 270 120.85 294
119.675 247 120.275 271 120.875 295
119.7 248 120.3 272 120.9 296
119.725 249 120.325 273 120.925 297
119.75 250 120.35 274 120.95 298
119.775 251 120.375 275 120.975 299
119.8 252 120.4 276 121.0 300
119.825 253 120.425 277 121.025 301
Read off code for injection pump length (A) from new injection pump, e.g. 42.
Take basic dimension of injection pump (L0 ) from table 1, e.g. 117.5 mm
Determine theoretical shim thickness (TS).

TS = EK - (L0 + A/100)
TS = 120.875 mm - (117.5 mm + 42/100 mm)
TS = 2.955 mm
Select shim thickness (SS) from table 2.

TS 2.955 mm = SS 3.0 mm
1.00.17
© 2004 / 0312 0361
lors d’un remplacement de pompe d’injection dans le cadre du Service.
Cote de base L0 = 117,5 mm
L’ancienne pompe d’injection et cale de réglage n’est pas nécessaire pour cela.
Exemple: Sur un BF6M 2012, il faut remplacer la pompe d’injection du cylindre 3.
Méthode à suivre:
Sur la plaque signalétique relever sous « EP » le code EP pour le cylindre 3, p.ex. 295
(Lire: ligne 1 = cyl. 1, ligne 2 = cyl. 2 etc.) 1
Relever la cote corrigée d’adaptation de pompe d’injection (EK) du tableau 3 selon le code EP;
p.ex. 120,875 mm.
Tableau 3
EK Code EK Code EK Code EK Code

EP EP EP EP
(mm) (mm) (mm) (mm)
119,25 230 119,85 254 120,45 278 121,05 302

119,275 231 119,875 255 120,475 279 121,075 303
119,3 232 119,9 256 120,5 280 121,1 304
119,325 233 119,925 257 120,525 281 121,125 305
119,35 234 119,95 258 120,55 282 121,15 306
119,375 235 119,975 259 120,575 283 121,175 307
119,4 236 120,0 260 120,6 284 121,2 308
119,425 237 120,025 261 120,625 285 121,225 309
119,45 238 120,05 262 120,65 286 121,25 310
119,475 239 120,075 263 120,675 287 121,275 311
119,5 240 120,1 264 120,7 288 121,3 312
119,525 241 120,125 265 120,725 289 121,325 313
119,55 242 120,15 266 120,75 290 121,35 314
119,575 243 120,175 267 120,775 291 121,375 315
119,6 244 120,2 268 120,8 292
119,625 245 120,225 269 120,825 293
119,65 246 120,25 270 120,85 294
119,675 247 120,275 271 120,875 295
119,7 248 120,3 272 120,9 296
119,725 249 120,325 273 120,925 297
119,75 250 120,35 274 120,95 298
119,775 251 120,375 275 120,975 299
119,8 252 120,4 276 121,0 300
119,825 253 120,425 277 121,025 301
Relever la caractéristique de longueur de pompe d’injection (A) pour la nouvelle pompe d’injection, p.ex. 42.
Relever la cote de base de la pompe d’injection (L0 ) du tableau 1, p.ex. 117,5 mm.
Déterminer l’épaisseur théorique de la cale de réglage (TS).

TS = EK - (L0 + A/100)
TS = 120,875 mm - (117,5 mm + 42/100 mm)
TS = 2,955 mm
Choisir l’épaisseur de cale de réglage (SS) selon tableau 2,

TS 2,955 mm = SS 3,0 mm
© 2004 / 0312 0361 1.00.17

Determinación del espesor de la arandela de reglaje para el comienzo de alimentación, para la
sustitución de bombas de inyección en caso de servicio. Medida básica L0 = 117,5 mm
Para ello, no se necesita la antigua bomba de inyección con arandela de reglaje.
Ejemplo: Sustitución de la bomba de inyección del cilindro No. 3 en el BF6M 2012.
Modo de proceder:
Leer de la placa de fabricante, en la columna „EP“, el código EP para el cilindro 3, p.ej. 295.
(Secuencia de lectura: línea 1 = cil. 1, línea 2 = cil. 2, etc.) 1
Tomar de la tabla 3 la medida de montaje corregida (EK) que corresponde al código EP de la bomba de inyección,
p.ej. 120,875 mm.
Tabla 3
EK Código EK Código EK Código EK Código

EP EP EP EP
(mm) (mm) (mm) (mm)
119,25 230 119,85 254 120,45 278 121,05 302

119,275 231 119,875 255 120,475 279 121,075 303
119,3 232 119,9 256 120,5 280 121,1 304
119,325 233 119,925 257 120,525 281 121,125 305
119,35 234 119,95 258 120,55 282 121,15 306
119,375 235 119,975 259 120,575 283 121,175 307
119,4 236 120,0 260 120,6 284 121,2 308
119,425 237 120,025 261 120,625 285 121,225 309
119,45 238 120,05 262 120,65 286 121,25 310
119,475 239 120,075 263 120,675 287 121,275 311
119,5 240 120,1 264 120,7 288 121,3 312
119,525 241 120,125 265 120,725 289 121,325 313
119,55 242 120,15 266 120,75 290 121,35 314
119,575 243 120,175 267 120,775 291 121,375 315
119,6 244 120,2 268 120,8 292
119,625 245 120,225 269 120,825 293
119,65 246 120,25 270 120,85 294
119,675 247 120,275 271 120,875 295
119,7 248 120,3 272 120,9 296
119,725 249 120,325 273 120,925 297
119,75 250 120,35 274 120,95 298
119,775 251 120,375 275 120,975 299
119,8 252 120,4 276 121,0 300
119,825 253 120,425 277 121,025 301
Tomar de la placa de características de la nueva bomba de inyección el código de longitud (A), p.ej. 42.
Tomar de la tabla 1 la medida básica (L0 ) de la bomba de inyección, p.ej. 117,5 mm.
Determinar el espesor teórico (TS) de la arandela de reglaje.

TS = EK - (L0 + A/100)
TS = 120,875 mm - (117,5 mm + 42/100 mm)
TS = 2,955 mm
Elegir el espesor de arandela de reglaje (Ss), según la tabla 2.

TS 2,955 mm = SS 3,0 mm
© 2004 / 0312 0361 1.00.17

Ausgleichscheibendicke für Förderbeginn ermitteln
bei Einspritzpumpentausch im Servicefall. Grundmaß L0 = 111,15 mm
Die alte Einspritzpumpe und Ausgleichscheibe ist hierzu nicht erforderlich.
Beispiel: An einem BF6M 2012 ist die Einspritzpumpe von Zylinder 3 zu ersetzen.
Vorgehensweise:
Vom Firmenschild in der Rubrik „EP“ den EP-Code für Zylinder 3 ablesen, z.B. 665.
(Lesefolge: Zeile 1 = Zyl.1, Zeile 2 = Zyl.2, u.s.w.)
1
Korrigiertes Einspritzpumpeneinbaumaß (EK) aus Tabelle 3.1 entsprechend dem EP-Code entnehmen,
z.B. 117,525 mm.
Tabelle 3.1
EK EP- EK EP- EK EP- EK EP- EK EP-

Code Code Code Code Code
(mm) (mm) (mm) (mm) (mm)
115,9 600 116,5 624 117,1 648 117,7 672 118,3 696
115,925 601 116,525 625 117,125 649 117,725 673 118,325 697
115,95 602 116,55 626 117,15 650 117,75 674 118,35 698
115,975 603 116,575 627 117,175 651 117,775 675 118,375 699
116 604 116,6 628 117,2 652 117,8 676
116,025 605 116,625 629 117,225 653 117,825 677
116,05 606 116,65 630 117,25 654 117,85 678
116,755 607 116,675 631 117,275 655 117,875 679
116,1 608 116,7 632 117,3 656 117,9 680
116,125 609 116,725 633 117,325 657 117,925 681
116,15 610 116,75 634 117,35 658 117,95 682
116,175 611 116,775 635 117,375 659 117,975 683
116,2 612 116,8 636 117,4 660 118 684
116,225 613 116,825 637 117,425 661 118,025 685
116,25 614 116,85 638 117,45 662 118,05 686
116,275 615 116,875 639 117,475 663 118,075 687
116,3 616 116,9 640 117,5 664 118,1 688
116,325 617 116,925 641 117,525 665 118,125 689
116,35 618 116,95 642 117,55 666 118,15 690
116,375 619 116,975 643 117,575 667 118,175 691
116,4 620 117 644 117,6 668 118,2 692
116,425 621 117,025 645 117,625 669 118,225 693
116,45 622 117,05 646 117,65 670 118,25 694
116,475 623 117,075 647 117,675 671 118,275 695
Kennzahl für Einspritzpumpenlänge (A) von der neuen Einspritzpumpe ablesen, z.B. 42.
Grundmaß der Einspritzpumpe (L0 ) aus Tabelle 1.1 entnehmen, z.B. 111,15 mm.
Theoretische Ausgleichscheibendicke (TS) ermitteln.

TS = EK - (L0 + A/100)
TS = 117,525 mm - (111,15 mm + 42/100 mm)
TS = 5,955 mm
Ausgleichscheibendicke (SS) nach Tabelle 2.1 auswählen.

TS 5,955 mm = SS 5,95 mm
© 2004 / 0312 0361 1.00.17.1

2012 with Injection timer
Determining shim thickness for commencement of delivery
injection pump replacement in case of service. Basic dimension L0 = 111.15 mm
The old injection pump with shim is not required for such purpose.
Example: The injection pump of cylinder 3 is to be replaced on a BF6M 2012.
Procedure:
Read off EP code for cylinder 3 from name plate under column ”EP“, e.g. 665.
(Reading sequence: line 1 = cyl. 1, line 2 = cyl. 2, etc.) 1
Take corrected injection pump installation dimension (EK) from table 3.1 according to EP code, e.g. 117.525 mm.
Table 3.1
EK EP- EK EP- EK EP- EK EP- EK EP-

Code Code Code Code Code
115,9 600 116,5 624 117,1 648 117,7 672 118,3 696
115,925 601 116,525 625 117,125 649 117,725 673 118,325 697
115,95 602 116,55 626 117,15 650 117,75 674 118,35 698
115,975 603 116,575 627 117,175 651 117,775 675 118,375 699
116 604 116,6 628 117,2 652 117,8 676
116,025 605 116,625 629 117,225 653 117,825 677
116,05 606 116,65 630 117,25 654 117,85 678
116,755 607 116,675 631 117,275 655 117,875 679
116,1 608 116,7 632 117,3 656 117,9 680
116,125 609 116,725 633 117,325 657 117,925 681
116,15 610 116,75 634 117,35 658 117,95 682
116,175 611 116,775 635 117,375 659 117,975 683
116,2 612 116,8 636 117,4 660 118 684
116,225 613 116,825 637 117,425 661 118,025 685
116,25 614 116,85 638 117,45 662 118,05 686
116,275 615 116,875 639 117,475 663 118,075 687
116,3 616 116,9 640 117,5 664 118,1 688
116,325 617 116,925 641 117,525 665 118,125 689
116,35 618 116,95 642 117,55 666 118,15 690
116,375 619 116,975 643 117,575 667 118,175 691
116,4 620 117 644 117,6 668 118,2 692
116,425 621 117,025 645 117,625 669 118,225 693
116,45 622 117,05 646 117,65 670 118,25 694
116,475 623 117,075 647 117,675 671 118,275 695
Read off code for injection pump length (A) from new injection pump, e.g. 42.
Take basic dimension of injection pump (L0 ) from table 1.1, e.g. 111,15 mm
Determine theoretical shim thickness (TS).

TS = EK - (L0 + A/100)
TS = 117,525 mm - (111,15 mm + 42/100 mm)
TS = 5,955 mm
Select shim thickness (SS) from table 2.1

TS 5,955 mm = SS 5,95 mm
© 2004 / 0312 0361 1.00.17.1

Déterminer l’épaisseur de cale de réglage pour le début d’injection lors d’un remplacement
de pompe d’injection dans le cadre du Service. Cote de base L0 = 111,15 mm
L’ancienne pompe d’injection et cale de réglage n’est pas nécessaire pour cela.
Exemple: Sur un BF6M 2012, il faut remplacer la pompe d’injection du cylindre 3.
Méthode à suivre:
Sur la plaque signalétique relever sous « EP » le code EP pour le cylindre 3, p.ex. 665.
(Lire: ligne 1 = cyl. 1, ligne 2 = cyl. 2 etc.) 1
Relever la cote corrigée d’adaptation de pompe d’injection (EK) du tableau 3.1 selon le code EP;
p.ex. 117,525 mm.
Tableau 3.1
EK Code EK Code EK Code EK Code EK Code

EP EP EP EP EP
115,9 600 116,5 624 117,1 648 117,7 672 118,3 696
115,925 601 116,525 625 117,125 649 117,725 673 118,325 697
115,95 602 116,55 626 117,15 650 117,75 674 118,35 698
115,975 603 116,575 627 117,175 651 117,775 675 118,375 699
116 604 116,6 628 117,2 652 117,8 676
116,025 605 116,625 629 117,225 653 117,825 677
116,05 606 116,65 630 117,25 654 117,85 678
116,755 607 116,675 631 117,275 655 117,875 679
116,1 608 116,7 632 117,3 656 117,9 680
116,125 609 116,725 633 117,325 657 117,925 681
116,15 610 116,75 634 117,35 658 117,95 682
116,175 611 116,775 635 117,375 659 117,975 683
116,2 612 116,8 636 117,4 660 118 684
116,225 613 116,825 637 117,425 661 118,025 685
116,25 614 116,85 638 117,45 662 118,05 686
116,275 615 116,875 639 117,475 663 118,075 687
116,3 616 116,9 640 117,5 664 118,1 688
116,325 617 116,925 641 117,525 665 118,125 689
116,35 618 116,95 642 117,55 666 118,15 690
116,375 619 116,975 643 117,575 667 118,175 691
116,4 620 117 644 117,6 668 118,2 692
116,425 621 117,025 645 117,625 669 118,225 693
116,45 622 117,05 646 117,65 670 118,25 694
116,475 623 117,075 647 117,675 671 118,275 695
Relever la caractéristique de longueur de pompe d’injection (A) pour la nouvelle pompe d’injection, p.ex. 42.
Relever la cote de base de la pompe d’injection (L0 ) du tableau 1.1, p.ex. 111,15 mm.
Déterminer l’épaisseur théorique de la cale de réglage (TS).

TS = EK - (L0 + A/100)
TS = 117,525 mm - (111,15 mm + 42/100 mm)
TS = 5,955 mm
Choisir l’épaisseur de cale de réglage (SS) selon tableau 2.1

TS 5,955 mm = SS 5,95 mm
© 2004 / 0312 0361 1.00.17.1

2012 con Gruaduador de avance de inyección
Determinación del espesor de la arandela de reglaje para el comienzo de alimentación, para la
sustitución de bombas de inyección en caso de servicio. Medida básica L0 = 111,15 mm
Para ello, no se necesita la antigua bomba de inyección con arandela de reglaje.
Ejemplo: Sustitución de la bomba de inyección del cilindro No. 3 en el BF6M 2012.
Modo de proceder:
Leer de la placa de fabricante, en la columna „EP“, el código EP para el cilindro 3, p.ej. 665.
(Secuencia de lectura: línea 1 = cil. 1, línea 2 = cil. 2, etc.) 1
Tomar de la tabla 3.1 la medida de montaje corregida (EK) que corresponde al código EP de la bomba de inyección,
p.ej. 117,525 mm.
Tabla 3.1
EK Código EK Código EK Código EK Código EK Código

EP EP EP EP EP
115,9 600 116,5 624 117,1 648 117,7 672 118,3 696
115,925 601 116,525 625 117,125 649 117,725 673 118,325 697
115,95 602 116,55 626 117,15 650 117,75 674 118,35 698
115,975 603 116,575 627 117,175 651 117,775 675 118,375 699
116 604 116,6 628 117,2 652 117,8 676
116,025 605 116,625 629 117,225 653 117,825 677
116,05 606 116,65 630 117,25 654 117,85 678
116,755 607 116,675 631 117,275 655 117,875 679
116,1 608 116,7 632 117,3 656 117,9 680
116,125 609 116,725 633 117,325 657 117,925 681
116,15 610 116,75 634 117,35 658 117,95 682
116,175 611 116,775 635 117,375 659 117,975 683
116,2 612 116,8 636 117,4 660 118 684
116,225 613 116,825 637 117,425 661 118,025 685
116,25 614 116,85 638 117,45 662 118,05 686
116,275 615 116,875 639 117,475 663 118,075 687
116,3 616 116,9 640 117,5 664 118,1 688
116,325 617 116,925 641 117,525 665 118,125 689
116,35 618 116,95 642 117,55 666 118,15 690
116,375 619 116,975 643 117,575 667 118,175 691
116,4 620 117 644 117,6 668 118,2 692
116,425 621 117,025 645 117,625 669 118,225 693
116,45 622 117,05 646 117,65 670 118,25 694
116,475 623 117,075 647 117,675 671 118,275 695
Tomar de la placa de características de la nueva bomba de inyección el código de longitud (A),

p.ej. 42.
Tomar de la tabla 1.1 la medida básica (L0 ) de la bomba de inyección, p.ej. 111,15 mm.
Determinar el espesor teórico (TS) de la arandela de reglaje.

TS = EK - (L0 + A/100)
TS = 117,525 mm - (111,15 mm + 42/100 mm)
TS = 5,955 mm
Elegir el espesor de arandela de reglaje (Ss), según la tabla 2.1

TS 5,955 mm = SS 5,95 mm
© 2004 / 0312 0361 1.00.17.1

Korrigiertes Einbaumaß und EP-Code für Einspritzpumpe ermitteln.
Bei Austausch von Kurbelgehäuse, Nockenwelle oder Rollenstößel muss das korrigierte Einbaumaß (EK) neu ermittelt und der
dazugehörende EP-Code auf dem Firmenschild geändert werden.
Tabellen siehe Seite 1.00.15. bis 1.00.17.1
1
Berechnungsbeispiel BFM 2012
Zylinder Nr. 0 1 2 3 4 5 6
L0 aus Tabelle 1 mm 117,5
FB Ist gemessen °KW 8
FB Nenn aus Tabelle 1 °KW 7
Vh Korr.faktor aus Tab. 1 mm/°KW -
Vh Nenn aus Tabelle 1 mm 4,26
- -
- -
- -
EK = L - Vh Nenn mm 120,87
EK symmetrisch gerundet mm 120,875
EP-Code aus Tabelle 3 295
© 2004 / 0312 0361 1.00.19

Determining corrected installation dimension and EP code for injection pump.
When replacing crankcase, camshaft or roller tappets, the corrected installation dimension (EK) must be determined once again
and the relevant EP code on the name plate must be changed.
For tables see pages 1.00.15 to 1.00.17.1
1
Cylinder No. 0 1 2 3 4 5 6
L0 from table 1 mm 117,5
FB measured °C/A 8
FB nom. from table 1 °C/A 7
Vh corr. factor from table 1 mm/°C/A -
Vh nom. from table 1 mm 4,26
L measured mm 125,13
- -
- -
- -
EK = L - Vh nom. mm 120,87
EK symm. rounded mm 120,875
EP code from table 3 295
© 2004 / 0312 0361 1.00.19

Déterminer la cote d’adaptation corrigée et le code EP pour la pompe d’injection
En cas de remplacement du bloc-moteur, de l’arbre à cames ou de poussoir à galet, il faut déterminer de nouveau la cote d’adaptation
corrigée (EK) et modifier le code EP correspondant sur la plaque signalétique.
Tableaux, voir pages 1.00.15 - 1.00.17.1
Exemple de calcul: BFM 2012 1

Cylindre n° 0 1 2 3 4 5 6
L0 selon tableau 1 mm 117,5
FB nom. selon tableau 1 °vil 7
Fact. corr. Vh selon tableau 1 mm/°vil -
Vh nom. selon tableau 1 mm 4,26
L mesuré mm 125,13
- -
- - -
- - -
EK = L - Vh nom. mm 120,87
EK symétriquement arrondi mm 120,875
Code EP selon tableau 3 295
© 2004 / 0312 0361 1.00.19

Determinación de la medida de montaje corregida y el código EP
para la bomba de inyección.
Para la sustitución del bloque motor, árbol de levas o empujadores de rodillo es necesario determinar nuevamente la medida
de montaje corregida (EK) y modificar el correspondiente código EP en la placa de fabricante.
Para las tablas, ver págs. 1.00.15 - 1.00.17.1
1
Cilindro No. 0 1 2 3 4 5 6
L0 seg. tabla 1 mm 117,5
“FB” nominal seg. tabla 1 °cig. 7
Factor corr. precurso seg. tabla 1 mm/°cig. -
Precurso nominal seg. tabla 1 mm 4,26
L medido mm 125,13
- -
- -
- -
EK = L - Precurso nominal mm 120,87
EK redondeado simétricamente mm 120,875
Código EP seg. tabla 3 295
© 2004 / 0312 0361 1.00.19

Korrigiertes Einbaumaß und EP-Code für Einspritzpumpe ermitteln.
Bei Austausch von Kurbelgehäuse, Nockenwelle oder Rollenstößel muss das korrigierte Einbaumaß (EK) neu ermittelt und der
dazugehörende EP-Code auf dem Firmenschild geändert werden.
Tabellen siehe Seite 1.00.15. bis 1.00.17.1
1
Berechnungsbeispiel BFM 2012
Zylinder Nr. 0 1 2 3 4 5 6
L0 aus Tabelle 1.1 mm 111.15
FB Ist gemessen °KW 5
FB Nenn aus Tabelle 1.1 °KW 3
Vh Korr.faktor aus Tab. 1.1 mm/°KW -
Vh Nenn aus Tabelle 1.1 mm 5,15
- -
- -
- -
EK = L - Vh Nenn mm 117,52
EK symmetrisch gerundet mm 117,525
EP-Code aus Tabelle 3.1 665
© 2004 / 0312 0361 1.00.19.1

2012 with injection timer
Determining corrected installation dimension and EP code for injection pump.
When replacing crankcase, camshaft or roller tappets, the corrected installation dimension (EK) must be determined once again
and the relevant EP code on the name plate must be changed.
For tables see pages 1.00.15 to 1.00.17.1
1
Cylinder No. 0 1 2 3 4 5 6
L0 from table 1.1 mm 111,15
FB measured °C/A 5
FB nom. from table 1.1 °C/A 3
Vh corr. factor from table 1.1 mm/°C/A -
Vh nom. from table 1.1 mm 5,15
L measured mm 122,67
- -
- -
- -
EK = L - Vh nom. mm 117,52
EK symm. rounded mm 117,525
EP code from table 3.1 665
© 2004 / 0312 0361 1.00.19.1

Déterminer la cote d’adaptation corrigée et le code EP pour la pompe d’injection
En cas de remplacement du bloc-moteur, de l’arbre à cames ou de poussoir à galet, il faut déterminer de nouveau la cote d’adaptation
corrigée (EK) et modifier le code EP correspondant sur la plaque signalétique.
Tableaux, voir pages 1.00.15 - 1.00.17.1
11
Exemple de calcul: BFM 2012
Cylindre n° 0 1 2 3 4 5 6
L0 selon tableau 1.1 mm 111,15
FB nom. selon tableau 1.1 °vil 3
Fact. corr. Vh selon tableau 1.1 mm/°vil -
Vh nom. selon tableau 1.1 mm 5,15
L mesuré mm 122,67
- -
- -
- -
EK = L - Vh nom. mm 117,52
EK symétriquement arrondi mm 117,525
Code EP selon tableau 3.1 665
© 2004 / 0312 0361 1.00.19.1

2012 conGruaduador de avance de inyección
Determinación de la medida de montaje corregida y el código EP
para la bomba de inyección.
Para la sustitución del bloque motor, árbol de levas o empujadores de rodillo es necesario determinar nuevamente la medida
de montaje corregida (EK) y modificar el correspondiente código EP en la placa de fabricante.
Para las tablas, ver págs. 1.00.15 - 1.00.17.1
1
Cilindro No. 0 1 2 3 4 5 6
L0 seg. tabla 1.1 mm 111,15
“FB” nominal seg. tabla 1.1 °cig. 3
Factor corr. precurso seg. tabla 1.1mm/°cig. -
Precurso nominal seg. tabla 1.1 mm 5,15
L medido mm 122,67
- -
- -
- -
EK = L - Precurso nominal mm 117,52
EK redondeado simétricamente mm 117,525
Código EP seg. tabla 3.1 665
© 2004 / 0312 0361 1.00.19.1

Bildzeichenerklärung
© 2003 / 0312 0361 1.00.21

Key to Symbols
© 2002 / 0312 0361 1.00.21

Légende des symboles
© 2002 / 0312 0361 1.00.21

Leyenda de los pictogramas
© 2002 / 0312 0361 1.00.21

Verificación y ajustes 2012
© 2003 / 0312 0361

Inhalts-Verzeichnis Prüfen und Einstellen
Table of Contents Control and adjustment
Table des matières Contrôle et réglage
Indice Verificación y ajustes
Deutsch Werkstatthandbuch BFM 2012
2. Prüfen und Einstellen Seite
Ventilspiel __________________________________________ 2.00.01 – 2.00.02

Einspritzventil __________________________________________ 2.00.03 – 2.00.09
Kompressionsdruck __________________________________________ 2.00.11 – 2.00.12
Thermostat __________________________________________ 2.00.13
English
2. Control and adjustment Page 2

Valve clearance __________________________________________ 2.00.01 – 2.00.02
Injector __________________________________________ 2.00.03 – 2.00.09
Compression pressure __________________________________________ 2.00.11 – 2.00.12
Thermostat __________________________________________ 2.00.13
Français
2. Contrôle et réglage Page
Jeu des soupapes __________________________________________ 2.00.01 – 2.00.02

Injecteur __________________________________________ 2.00.03 – 2.00.09
Pression de compression __________________________________________ 2.00.11 – 2.00.12
Thermostat __________________________________________ 2.00.13
Español
2. Verificación y ajustes Pagina
Juego de válvulas __________________________________________ 2.00.01 – 2.00.02

Inyector __________________________________________ 2.00.03 – 2.00.09
Presión de compresión __________________________________________ 2.00.11 – 2.00.12
Termostato __________________________________________ 2.00.13
© 2002 / 0312 0361

Prüfen und Einstellen Ventilspiel
Control and adjustment Valve clearance
Contrôle et réglage Jeu des soupapes
Verificación y ajustes Juego de válvulas
Special tools: Outillage spécial Herramientas especiales:

Turning gear ________________ 100 320 Vireur ______________________ 100 320 Dispositivo de viraje __________ 100 320
Cranking device _____________ 100 330 Vireur ______________________ 100 330 Dispositivo de viraje __________ 100 330
Valve clearance can be adjusted Le réglage du jeu des soupapes est El ajuste del juego de válvulas es posible:
on the engine in cold or warm condition possible: sur moteur froid ou chaud a motor frío o a motor caliente después
allowing the engine to cool down après une durée de refroidissement de un período de enfriamiento de, por lo
for 0.5 h at a minimum. d’au moins 0,5 h. menos, media hora.
Oil temperature < 80 °C Température d’huile < 80 °C Temperatura del aceite < 80 °C
1. Remove pressure control valve and 1. Démonter la soupape régulatrice de 1. Desmontar la válvula reguladora de
2 inspection cover. pression et le cache-culbuteurs. presión y la tapa de culata.
2. Use cranking device 100 330 for 2. Virer le moteur à l’aide du vireur 2. Sirviéndose del dispositivo de
turning the engine until valves of 100 330 jusqu’à ce que les soupapes viraje 100 330, girar el cigüeñal
cylinder No. 1 overlap. du cyl. n° 1 soient en balance. hasta el cruce de las válvulas
en el cilindro No. 1.
See schematic drawing in Schéma de réglage du jeu des Para el esquema de ajuste del juego
Chapter 1 for carrying out valve soupapes, voir chapitre 1. de válvulas, ver cap. 1.
clearance adjustment.
Note: Valve overlap means: Exhaust Nota: Soupapes en balance signifie: Nota: Cruce de válvulas significa:
valve about to close, inlet valve soupape d’échappement pas la válvula de escape aún no
about to open. encore fermée, soupape está cerrada y la de admisión
d’admission commence à s’ouvrir. comienza a abrirse.
2.1 If engine is not freely accessible at 2.1 Si le moteur n’est pas librement 2.1 A falta de libre acceso al motor en
V-belt pulley , turning gear 100 320 accessible par la poulie à gorges, la polea de la correa trapezoidal
may be used, however, hydraulic il est possible d’utiliser le vireur se puede utilizar el dispositivo de
pump must be removed before. 100 320 après démontage de la viraje 100 320 estando desmontada
pompe hydraulique. la bomba hidráulica.
2.00.01 © 2002 / 0312 0361

Ventilspiel Prüfen und Einstellen
Valve clearance Control and adjustment
Jeu des soupapes Contrôle et réglage
Juego de válvulas Verificación y ajustes
Spezialwerkzeuge:
Durchdrehvorrichtung ________________ 100 320
Durchdrehvorrichtung ________________ 100 330
Die Ventilspieleinstellung ist möglich:

Am kalten oder am warmen Motor nach einer Ab-
kühlzeit von mindestens 0,5 h.
Öltemperatur < 80 °C
1. Druckregelventil und Zylinderkopfhaube ab-

2
bauen. 3
35229 ©
2. Motor mit Durchdrehvorrichtung 100 330 bis

zum Erreichen der Ventilüberschneidung
Zyl. Nr. 1 durchdrehen.
9
Ventilspieleinstellschema siehe Kapitel 1 7
Hinweis: Ventilüberschneidung bedeutet: 5
Auslassventil ist noch nicht geschlossen,
Einlassventil beginnt zu öffnen.
35230 ©
2.1 Ist der Motor an der Keilriemenscheibe nicht frei

zugänglich, kann bei abgebauter Hydraulik-
pumpe die Durchdrehvorrichtung 100 320 ver-
9
wendet werden.
7
35231 ©
© 2002 / 0312 0361 2.00.01

Prüfen und Einstellen Ventilspiel
Control and adjustment Valve clearance
Contrôle et réglage Jeu des soupapes
Verificación y ajustes Juego de válvulas
Werkstatthandbuch BFM 2012 Deutsch
3. Ventilspieleinstellung am entsprechenden Zylin-

6 der mit Fühlerlehrenblatt vornehmen.
5 Einlassventil
Auslassventil
0,3+0,1 mm
0,5+0,1 mm
Hinweis: Wurde die Zylinderkopfdichtung gewech-

selt, ist das Ventilspiel um 0,1 mm zu
erhöhen.
Nach 1500 Bh ist das Standard-Ventil-
spiel einzustellen.
35232 ©
4. Kontermutter festdrehen.
2
4 Anziehvorschrift: 20 ± 2 Nm
6 Ventilspiel nochmals mit Fühlerlehrenblatt über-

prüfen.
35233 ©
5. Dichtung auflegen.
4
0
35234 ©
6. Zylinderkopfhaube und Halteblech anbauen.

4 Schrauben festdrehen. Auf richtigen Sitz der
Dichtgummis in der Zylinderkopfhaube achten.
6 Anziehvorschrift: 11 Nm
Druckregelventil anbauen. Schrauben fest-

drehen.
Anziehvorschrift: 8,5 Nm
35235 ©
2.00.02 © 2002 / 0312 0361

Ventilspiel Prüfen und Einstellen
Valve clearance Control and adjustment
Jeu des soupapes Contrôle et réglage
Juego de válvulas Verificación y ajustes
3. Adjust valve clearance on respective 3. Régler le jeu des soupapes sur le 3. Ajustar el juego de válvulas en el
cylinder using a feeler gauge. cylindre correspondant avec une jauge cilindro correspondiente utilizando la
d’épaisseur. galga de espesores.
Inlet valve: 0.3 mm Soupape d’admission 0,3 mm Válvula de admisión 0,3 mm

Exhaust valve: 0.5 mm Soupape d’échappement 0,5 mm Válvula de escape 0,5 mm
Note: In cases where the cylinder head Nota: En cas de remplacement du joint de Nota: En caso de sustitución de la junta
gasket has been replaced, increase culasse, augmenter le jeu des de culata es necesario aumentar
valve clearance by 0.1 mm. soupapes de 0,1 mm. el juego de válvulas en 0,1 mm.
Standard valve clearance to be set Après 1500 heures, régler le jeu Al cabo de 1500 horas de
after 1500 operating hours. de soupape standard. funcionamiento se ha de ajustar
el juego de válvulas estándar.
4. Tighten locknut. 4. Serrer le contre-écrou. 4. Apretar la contratuerca.

2
Specified tightening torque: 20 ± 2 Nm Prescription de serrage: 20 ± 2 Nm Prescripción de apriete: 20 ± 2 Nm
Check valve clearance with feeler Contrôler encore une fois le jeu des Comprobar otra vez el juego
gauge once again. soupapes avec la jauge d’épaisseur. de válvulas mediante la galga
de espesores.
5. Fit new gasket in place. 5. Poser le joint. 5. Colocar la junta.
6. Fit inspection cover and supporting 6. Remonter le cache-culbuteurs et la 6. Montar la tapa de culata y la chapa
plate. Tighten bolts. Make sure that tôle de retenue. Serrer les vis. Veiller de soporte. Apretar los tornillos.
sealing rubber elements are correctly au bon positionnement des joints en Prestar atención al asiento correcto
installed in inspection cover. caoutchouc dans le cache-culbuteurs. de las obturaciones de goma en la
tapa de culata.
Specified tightening torque: 11 Nm Prescription de serrage: 11 Nm Prescripción de apriete: 11 Nm
Fit pressure control valve. Tighten Monter la soupape régulatrice de Montar la válvula reguladora de
bolts. pression. Serrer les vis. presión. Apretar los tornillos.
Specified tightening torque: 8.5 Nm Prescription de serrage: 8,5 Nm Prescripción de apriete: 8,5 Nm
© 2002 / 0312 0361 2.00.02

Prüfen und Einstellen Einspritzventil
Control and adjustment Injector
Contrôle et réglage Injecteur
Verificación y ajustes Inyector
Commercially available tools: Outillage standard: Herramientas comerciales:

Nozzle tester __________________ 8008 Pompe d’essai des injecteurs _____ 8008 Comprobador de inyectores ______ 8008
Long socket size 15 ____________ 8012 Douille longue de 15 ____________ 8012 Llave de vaso largo de 15 ________ 8012
Claw grip wrench size 17 ________ 8018 Clé à griffes de 17 ______________ 8018 Llave de garra de 17 ____________ 8018
Torx tool kit ___________________ 8189 Jeu d’outils Torx _______________ 8189 Juego de herramientas Torx ______ 8189
Special tools: Outillage spécial: Herramientas especiales:

Dolly for injector _____________ 110 110 Dispositif d’immobilisation Dispositivo de retención
Dolly for injector _____________ 110 110 d’injecteur __________________ 110 110 para inyector ________________ 110 110
Extractor ___________________ 120 680 Extracteur d’injecteur _________ 110 030 Extractor de inyector __________ 110 030
Extractor ___________________ 150 800 Dispositif d’extraction _________ 120 680 Dispositivo de extracción ______ 120 680
Dispositif d’extraction _________ 150 800 Dispositivo de extracción ______ 150 800
Utmost cleanliness required for working Lors de travaux sur le système d’injection, Se cuidará de la máxima limpieza al
2 on the injection unit. Use only pure test veiller à la plus grande propreté. Pour le realizar trabajos en el equipo de
oil to ISO 4113 or clean diesel fuel for contrôle des injecteurs, n’utiliser que du inyección. Para la comprobación de los
injector testing purposes. gasoil d’essai pur selon ISO 4113 ou du inyectores se deberá utilizar tan sólo
combustible diesel propre. aceite de prueba puro según ISO 4113 ó
combustible diesel limpio.
1. Removal of injectors 1. Dépose des injecteurs. 1. Desmontaje de los inyectores.
1.1 Remove pressure control valve and 1.1 Démonter la soupape régulatrice de 1.1 Desmontar la válvula reguladora
inspection cover. Pull cable connector pression et le cache-culbuteurs. de presión y la tapa de culata.
off from cut-off solenoid, governor Débrancher le connecteur de câble Desenchufar los cables del
and temperature sensor. Swivel de l’électroaimant d’arrêt, régulateur, solenoide de parada, regulador y
supporting plate sideways. transmetteur de température. sensores de temperatura. Girar
Basculer la tôle de retenue vers la chapa de soporte hacia el lado.
le côté.
1.2 Remove injection lines. 1.2 Démonter les tuyauteries d’injection. 1.2 Desmontar las tuberías de inyección.
Note: Use claw grip wrench size 8018. Nota: Utiliser la clé à griffes 8018. Nota: Utilizar la llave de garra 8018.
Close connecting points of Obturer les raccords des injecteurs Cerrar con sombreretes protectores
injectors and injection pumps et des pompes d’injection par des las aberturas de los inyectores y
with protective caps. capuchons de protection. bombas de inyección.
1.3 Remove claws and take out injectors. 1.3 Démonter les pattes et sortir 1.3 Desmontar las garras y sacar
les injecteurs. los inyectores.
Note: Use extractor 150 800 in Nota: En cas de blocage, utiliser le Nota: Si los inyectores están fijos, utilizar
combination with extractor dispositif d’extraction 150 800 avec el dispositivo de extracción 150 800
110 030 if jammed. l’extracteur 110 030. con el extractor 110 030.
Use extractor 120 680 for pulling Extraire la bague d’étanchéité avec Quitar el anillo de junta utilizando el
out the sealing ring. le dispositif d’extraction 120 680. dispositivo de extracción 120 680.
2.00.03 © 2002 / 0312 0361

Einspritzventil Prüfen und Einstellen
Injector Control and adjustment
Injecteur Contrôle et réglage
Inyector Verificación y ajustes
Handelsübliche Werkzeuge:
Düsenprüfgerät _______________________ 8008
Lange Stecknuss SW 15 ________________ 8012
Klauenschlüssel SW 17 ________________ 8018
Torx-Werkzeugsatz ____________________ 8189
Spezialwerkzeug:
Halter für Einspritzventil ______________ 110 110
Auszieher für Einspritzventil ___________ 110 030
Ausziehvorrichtung __________________ 120 660
Bei Arbeiten an der Einspritzausrüstung auf größte

2
Sauberkeit achten. Zur Prüfung der Einspritzventile
nur reines Prüföl nach ISO 4113 oder sauberen
3
Dieselkraftstoff verwenden.
1. Einspritzventile ausbauen.
1.1 Druckregelventil und Zylinderkopfhaube abbau-

en. Kabelstecker von Abstellmagnet, Regler
und Temperaturgeber abziehen. Halteblech zur
Seite schwenken. 35236 ©
1.2 Einspritzleitungen abbauen.
Hinweis: Klauenschlüssel 8018 verwenden.

3
Die Anschlüsse an Einspritzventilen und
Einspritzpumpen mit Schutzkappen ver- 5
schließen
35237 ©
1.3 Pratzen abbauen und Einspritzventile heraus-

nehmen. 3
Hinweis: Bei Festsitz Ausziehvorrichtung 150 800
mit Auszieher 110 030 verwenden. 5
Dichtring mit Ausziehvorrichtung 120 660
herausziehen.
35238 ©
© 2003 / 0312 0361 2.00.03

2. Einspritzventile prüfen
Die Einspritzventile sind leckkraftstofflos.

Der anfallende Kraftstoff kann nicht abfließen und
sammelt sich oberhalb der Düsennadel im Feder-
raum des Düsenhalters. Ein Betätigen des Handhe-
bels des Düsenprüfgerätes ist dann nicht mehr mög-
lich.
Damit der Druck im Federraum abgebaut werden
kann, muss vor jeder Prüfung die Spannmutter ge-
löst und wieder nach Anziehvorschrift festgedreht
00000 © werden.
2.1 Spannmutter ca. 180° lösen und wieder fest-

2
1 drehen. Halter 110 110 für Einspritzventil ver-
wenden.
2 Anziehvorschrift: 30 - 40 Nm
7
6
35239 ©
2.2 Einspritzventil an das Düsenprüfgerät 8008

4 anbauen.
e Achtung !
Hände weg vom Düsenstrahl. Der Kraftstoff
dringt tief in das Fleisch ein und kann zur Blut-
vergiftung führen.
35240 ©
2.3 Hebel des Düsenprüfgerätes 8008 bei zu-

geschaltetem Manometer langsam nieder-
6 drücken. Der Druck bei dem der Zeiger
stehen bleibt oder plötzlich abfällt, ist der
e Öffungsdruck.
9 Öffnungsdruck: 220 bar
Hinweis: Nach ca. 3 - 4 Hüben hat sich der Druck

5 im Federraum wieder aufgebaut.
Die Spannmutter muss erneut gelöst und
wieder nach Anziehvorschrift festgedreht
31079 © und die Prüfung wiederholt werden.
2.00.04 © 2002 / 0312 0361

2. Check injectors 2. Contrôle des injecteurs 2. Comprobación de los inyectores.
The injectors are not equipped with bores Les injecteurs sont des injecteurs sans Los inyectores son del tipo sin
for leak –off fuel. fuites. combustible sobrante.
The surplus fuel cannot be discharged Le combustible ne peut donc s’écouler El combustible que se produzca no puede
and accumulates in the space above the et s’amasse au-dessus de l’aiguille de salir y se acumula por encima de la aguja
injector needle in the area of the spring l’injecteur dans la chambre de ressort. Il en la cámara de resorte del portainyector.
of the injector holder. Actuation of the n’est plus alors possible d’actionner Le En tal situación, ya no es posible accionar
manual lever of the injector tester is no levier de la pompe d’essai. la palanca manual del comprobador de
longer possible in this case. Pour pouvoir détendre la pression dans inyectores.
For relieving the pressure in the area la chambre de ressort, il faut, avant Para poder reducir la presión que se ha
of the spring, slacken the tensioning nut chaque contrôle desserrer l’écrou-raccord establecido en la cámara de resorte es
before each test and re-tighten to the et le resserrer ensuite selon prescription necesario, antes de cada comprobación,
specified torque after the test. de serrage. aflojar la tuerca de unión y volver a
apretarla según prescripción.
2
2.1 Slacken tensioning nut by 2.1 Desserrer l’écrou-raccord d’env. 2.1 Aflojar la tuerca de unión girándola
approx. 180° and re-tighten. Use 180° et le resserrer. Utiliser le unos 180° y volver a apretarla.
dolly 110 110 for injector. dispositif d’immobilisation 110 110 Utilizar el dispositivo de retención
pour injecteur. 110 110 para inyector.
Specified tightening Prescription de serrage: 30 – 40 Nm Prescripción de apriete: 30 – 40 Nm

torque: 30 – 40 Nm
2.2 Connect injector to 2.2 Monter l’injecteur sur la pompe 2.2 Montar el inyector en el comprobador
nozzle tester 8008 d’essai 8008. 8008.
Caution: Attention ! Atención

Beware of injection nozzle jet. The Tenir les mains hors du jet des Mantener alejadas las manos del
fuel penetrates deeply into the skin injecteurs. Le combustible pénètre chorro del inyector, pues el com-
and may cause blood poisoning. profondément dans la chair et risque bustible se introduce en la carne y
de provoquer un empoisonnement destruye los tejidos. Si llega a la
du sang. sangre, produce grave intoxicación.
2.3 With pressure gauge switched-on, 2.3 Avec manomètre branché, 2.3 Con el manómetro conectado,
slowly press lever of nozzle tester abaisser lentement le levier de la bajar lentamente la palanca del
8008 down. pompe d’essai 8008. La pression comprobador 8008. La presión a
The pressure at which the gauge à laquelle aiguille s’immobilise ou la que la aguja del manómetro se
pointer stops or suddenly drops is chute brusquement est la pression detenga o caiga repentinamente,
the opening pressure. d’ouverture. es la presión de apertura.
Opening pressure: 220 bar Pression d’ouverture: 220 bars Presión de apertura: 220 bar
Note: The pressure will build-up again in Nota: Après env. 3 à 4 courses, la Nota: Después de accionar unas 3 a 4
the area of the spring after approx. pression s’est à nouveau établie veces la palanca del comprobador,
3 – 4 strokes. Slacken the dans la chambre de ressort. existe de nuevo presión en la
tensioning nut once again, Il faut de nouveau desserrer cámara de resorte. Es necesario
re-tighten to specified tightening l’écrou-raccord et le resserrer aflojar la tuerca de unión, volver a
torque and repeat the test. selon prescriptions de serrage apretarla según prescripción y
puis recommencer l’essai. repetir la comprobación.
© 2002 / 0312 0361 2.00.04

2.4 Measured values are final once 2.4 Si les résultats de mesure de 2.4 Si los valores medidos durante 3
the results of three tests remain 3 essais sont identiques, ils peuvent comprobaciones son idénticos,
constant. être considérés comme valables. pueden ser considerados válidos.
3. Setting of injectors 3. Réglage des injecteurs 3. Ajuste de los inyectores

2
3.1 For a correction of the opening 3.1 Si la pression d’ouverture doit 3.1 Si la presión de apertura deberá
pressure: être corrigée: démonter l’injecteur ser corregida:
Remove injector from nozzle tester de la pompe d’essai 8008. Desmontar el inyector del
8008. Remove tensioning nut and Dévisser l’écrou-raccord, démonter comprobador 8008. Desenroscar la
uninstall all components. Use dolly toutes les pièces. Utiliser le tuerca de unión y desmontar todas
110 110 for the injector. dispositif d’immobilisation 110 110 las piezas. Utilizar el dispositivo
pour injecteur. de retención 110 110 para inyector.
3.2 Sequence of parts disassembly and 3.2 Suite du démontage et du remontage 3.2 Secuencia del despiece:
re-assembly: individuel
1. Tensioning nut 1. Ecrou-raccord 1. Tuerca de unión

2. Nozzle 2. Injecteur 2. Inyector
3. Adapter 3. Pièce intermédiaire 3. Pieza intermedia
4. Thrust pin 4. Poussoir 4. Perno de presión
5. Compression spring 5. Ressort 5. Resorte de presión
6. Shim 6. Cale de réglage 6. Arandela de reglaje
3.3 Adjust opening pressure by selecting 3.3 Régler la pression d’ouverture en 3.3 Ajustar la presión de apertura
appropriate shim. A thicker shim choisissant la cale de réglage eligiendo la arandela adecuada.
will increase the opening pressure. requise. Une cale plus épaisse Una arandela más gruesa
Re-assemble injector. Tighten donne une pression d’ouverture plus aumenta la presión. Ensamblar el
tensioning nut. élevée. Réassembler l’injecteur. inyector. Apretar la tuerca de unión.
Serrer l’écrou-raccord.
Specified tightening
torque: 30 – 40 Nm Prescription de serrage: 30 – 40 Nm Prescripción de apriete: 30 – 40 Nm
Check injector on nozzle tester 8008 Contrôler de nouveau l’injecteur sur Ensayar el inyector de nuevo sobre
once again. la pompe d’essai 8008. el comprobador 8008.
2.00.05 © 2002 / 0312 0361

2.4 Sind die Messwerte von 3 Prüfungen gleich,

können sie als gültig betrachtet werden.
6
9
31079 ©
3. Einspritzventile einstellen
2
3.1 Muss der Öffnungsdruck korrigiert werden:
1
Einspritzventil von Düsenprüfgerät 8008 ab-
bauen. Spannmutter abschrauben, alle Teile 7
ausbauen. Halter 110 110 für Einspritzventil
verwenden.
35241 ©
3.2 Folge der Einzelde- und montage
1. Spannmutter
8
2. Düse
3. Zwischenstück
4. Druckbolzen
5. Druckfeder
6. Ausgleichscheibe
35242 ©
3.3 Durch Auswahl der erforderlichen Ausgleich-

scheibe den Öffnungsdruck einstellen. Stärkere
Ausgleichscheibe ergibt höheren Öffnungs-
2
druck. Einspritzventil zusammenbauen. Spann-
mutter festdrehen. 8
Anziehvorschrift: 30 - 40 Nm 7
Einspritzventil auf dem Düsenprüfgerät 8008
erneut prüfen.
6
35243 ©
© 2002 / 0312 0361 2.00.05

4. Prüfung auf Dichtheit

6 4.1 Düse und Düsenhalter abtrocknen - mit Luft
e trockenblasen.
Handhebel des Prüfgerätes langsam nieder-
drücken, bis ca. 20 bar unterhalb des vorher
abgelesenen Öffnungsdruckes erreicht wer-
den.
31080 ©
4.2 Düse ist dicht, wenn innerhalb 10 Sekunden

2
9 kein Tropfen abfällt.
35244 ©
4.3 Fällt ein Tropfen ab, ist das Einspritzventil zu

9 zerlegen und die Undichtigkeit durch Reinigen
zu beseitigen. Ist das nicht erfolgreich, muss
e die Düse erneuert werden.
Nacharbeit ist nicht zulässig.
35245 ©
2.00.06 © 2002 / 0312 0361

4. Leak test 4. Contrôle d’étanchéité 4. Prueba de estanqueidad
4.1 Dry nozzle and nozzle holder by 4.1 Sécher l’injecteur et le porte-injecteur 4.1 Secar el inyector y el portainyector,
compressed air. Press hand lever of – sécher au jet d’air. soplándolos con aire.
tester slowly down until a pressure Abaisser lentement le levier de la Llevar la palanca manual del com-
of approx. 20 bar below the previous pompe d’essai jusqu’à env. 20 bars probador lentamente hacia abajo
opening pressure reading is attained. au-dessous de la pression hasta alcanzar un valor de aprox.
d’ouverture relevée précédemment. 20 bar por debajo de la presión de
apertura leída previamente.
4.2 The nozzle is leak proof if there is no 4.2 L’injecteur est étanche, si aucune 4.2 El inyector es estanco si después de
dripping within 10 seconds. goutte ne s’écoule plus pendant 10 segundos no sale ni una gota de
2
10 secondes. líquido.
4.3 If there is dripping, dismantle the 4.3 Si une goutte s’écoule, il faut 4.3 Si cae una gota, es necesario des-
injector and clean to remedy the désassembler l’injecteur et éliminer piezar el inyector y limpiarlo para
leak. If this does not work, replace la fuite par nettoyage. Si l’injecteur eliminar la falta de estanqueidad.
the nozzle by a new one. goutte toujours, il doit être remplacé. Si esto no surte el efecto deseado,
el inyector deberá ser sustituido por
otro nuevo.
No reworking allowed! Ne jamais rectifier les injecteurs. No está permitido rectificar el

inyector.
© 2002 / 0312 0361 2.00.06

5. Buzzing and spray pattern test 5. Contrôle du crissement et du jet 5. Comprobación del ronquido y
chorro del inyector
Switch-off pressure gauge of tester. Débrancher le manomètre de la Desconectar el manómetro del

The buzzing test permits audible pompe d’essai. comprobador.
checking for ease of movement of the Le contrôle du crissement est un La comprobación del ronquido
nozzle needle in the nozzle body. contrôle acoustique du déplacement permite controlar acústicamente la
New injectors compared to used ones de l’aiguille dans le corps de facilidad de movimiento de la aguja
have a different buzzing sound. l’injecteur. Les injecteurs neufs dentro del cuerpo del inyector. El
This buzzing sound deteriorates by présentent un comportement comportamiento en el ronquido de
wear in the area of the needle seat. de crissement différent de celui un inyector nuevo es diferente del
If there is no buzzing of a nozzle des injecteurs usagés. de un inyector usado.
despite cleaning, it must be replaced Par suite de l’usure au niveau du Se empeora por el desgaste en la
by a new one. logement de l’aiguille, il se dégrade. zona de asiento de la aguja. Si, tras
A used injector must produce an Si malgré nettoyage un injecteur la limpieza, el inyector no produce
2 audible buzzing sound upon rapid ne crisse plus, il doit être remplacé el ronquido característico, habrá
actuation of the hand lever and par un injecteur neuf. que sustituirlo por otro nuevo.
provide for a well atomised spray Lorsque le levier est actionné Al accionarse rápidamente la
pattern. The spray pattern may differ rapidement, un injecteur usagé doit palanca del comprobador, un inyector
noticeably from that of a new injector. présenter un crissement audible tout usado debe roncar audiblemente y
en pulvérisant bien. La forme du producir un chorro bien pulverizado,
jet peut ici être nettement différente pudiendo diferir la forma de éste
de celle d’un injecteur neuf. notablemente de la que genera un
inyector nuevo.
6. Re-installation of injectors 6. Remontage des injecteurs 6. Montaje de los inyectores
6.1 Place new slightly greased 6.1 Emmancher des bagues d’étanchéité 6.1 Colocar los anillos de junta
sealing rings onto injectors and neuves avec un peu de graisse nuevos con un poco de grasa sobre
install injectors. sur les injecteurs et mettre en place los inyectores e introducir éstos.
les injecteurs.
Note: This notch on the injectors must Nota: Le lamage sur les injecteurs doit se Nota: El rebaje existente en los
face away from the claws. trouver du côté opposé aux pattes. inyectores debe estar orientado
hacia el lado opuesto a las garras.
6.2 Place claws in place and tighten bolts 6.2 Poser les pattes et visser légèrement 6.2 Colocar las garras y enroscar los
hand tight. les vis. tornillos, dejándolos sueltos.
2.00.07 © 2002 / 0312 0361

5. Schnarr- und Strahlprüfung
Manometer des Prüfgerätes abschalten.

9
Die Schnarrprüfung ermöglicht eine hörbare
Prüfung der Leichtgängigkeit der Düsennadel im e
Düsenkörper. Neue Einspritzventile haben ge-
genüber gebrauchten ein geändertes Schnarr-
verhalten.
Durch Verschleiß im Nadelsitzbereich ver-
schlechtert es sich. Schnarrt eine Düse trotz
Reinigung nicht, muß sie durch eine neue er-
setzt werden. 35246 ©
Ein gebrauchtes Einspritzventil muss bei
schneller Hebeltätigkeit hörbar schnarren und
dabei gut zerstäubt abspritzen. Das Strahlbild
kann dabei gegenüber dem eines neuen
2
Einspritzventils deutlich unterschiedlich sein.
6. Einspritzventile einbauen
6.1 Neue Dichtringe mit etwas Fett auf die

4
Einspritzventile aufschieben und Einspritzven-
tile einsetzen. ß
Hinweis: Die Ansenkung auf den Einspritzventilen 8
muss von den Pratzen weg zeigen
5
35247 ©
6.2 Pratzen aufsetzen und Schrauben lose ein-

schrauben. 4
8
35248 ©
© 2002 / 0312 0361 2.00.07

6.3 Neue Einspritzleitungen mit Dichtgummis an-

4 bauen. Überwurfmuttern fingerfest aufschrau-
ben.
ß Hinweis: Bei Montage der Einspritzleitungen müs-

sen die Dichtkonen exakt aufeinander-
5 sitzen.
Ein Nachbiegen ist nicht zulässig.
Die Einspritzleitungen dürfen nicht 2x
verwendet werden.
35249 ©
6.4 Schrauben der Pratzen festdrehen.

2
4 Anziehvorschrift: 16 + 5 Nm
35250 ©
6.5 Überwurfmuttern der Einspritzleitungen an den

4 Einspritzpumpen und Einspritzventilen mit ei-
nem Drehmoment von ca. 5 Nm vorspannen.
6 Danach Überwurfmuttern festdrehen.
Anziehvorschrift: 25 + 3,5 Nm
35251 ©
7. Zylinderkopfhaube aufbauen.
4 7.1 Dichtung auflegen.
0
35252 ©
2.00.08 © 2002 / 0312 0361

6.3 Attach new injection lines with 6.3 Monter de nouvelles tuyauteries 6.3 Montar tuberías de inyección nuevas
sealing rubber elements. Tighten d’injection avec des joints en con las obturaciones de goma.
cap screws finger-tight. caoutchouc. Faire un vissage Enroscar las tuercas de unión con
manuel des écrous-raccord. los dedos.
Note: When installing the injection lines Nota: Lors du montage des tuyauteries Nota: Al hacer el montaje de las
make sure that sealing cones are d’injection, les cônes d’étanchéité tuberías de inyección es
exactly aligned one on top of the doivent coïncider exactement. imprescindible que los conos
other. Un cintrage de rectification n’est de cierre estanco se asienten
Subsequent bending is not pas admissible. Les tuyauteries exactamente uno sobre otro.
allowed. Injection lines must d’injection ne doivent pas être No es admisible curvar
not be re-used. utilisées deux fois. ni reutilizar las tuberías
de inyección.
6.4 Tighten bolts of claws. 6.4 Serrer définitivement les vis 6.4 Apretar los tornillos de
2
des pattes. las garras.
torque: 16 + 5 Nm Prescription de serrage: 16 + 5 Nm Prescripción de apriete: 16 + 5 Nm
6.5 Pre-tension cap nuts of injection 6.5 Préserrer les écrous-raccord des 6.5 Apretar las tuercas de unión de las
lines on injection pumps and injection tuyauteries d’injection sur les tuberías de inyección en las bombas
nozzles to a tightening torque of pompes d’injection et injecteurs de inyección e inyectores inicialmente
approx. 5 Nm. Then tighten cap nuts. avec un couple d’env. 5 Nm. con aprox. 5 Nm. Luego, apretarlas
Ensuite les serrer définitivement. en definitiva.
torque: 25 + 3.5 Nm Prescription de serrage: 25 + 3,5 Nm Prescripción de apriete: 25 + 3,5 Nm
Note: Use claw grip wrench 8018. Nota: Utiliser la clé à griffes 8018. Nota: Utilizar la llave de garra 8018.
7. Mount inspection cover 7. Montage du cache-culbuteurs 7. Montaje de la tapa de culata.
7.1 Install gasket. 7.1 Poser les joints. 7.1 Colocar la junta.
© 2002 / 0312 0361 2.00.08

7.2 Fit inspection cover and 7.2 Monter le cache-culbuteurs et 7.2 Montar la tapa de culata y la chapa
supporting plate. Tighten bolts. la tôle de retenue. Serrer les vis. de soporte. Apretar los tornillos.
Make sure sealing rubber Veiller au bon positionnement Prestar atención al asiento correcto
elements are correctly installed du joint en caoutchouc dans de las obturaciones de goma en la
in inspection cover. le cache-culbuteurs. tapa de culata.
Fit new seal to pressure control Monter la soupape régulatrice de Montar la válvula reguladora de
valve if necessary. Tighten bolts. pression avec un joint neuf. Serrer presión, en su caso, con una junta
les vis. nueva. Apretar los tornillos.
2 7.3 Fit cable connector on cut-off 7.3 Brancher le connecteur de câble sur 7.3 Enchufar los cables en el solenoide
solenoid and governor. l’électroaimant d’arrêt et le régulateur. de parada y el regulador.
7.4 Fit cable connector to temperature 7.4 Brancher le connecteur de câble sur 7.4 Enchufar los cables en los sensores
sensor. la sonde de température. de temperatura.
2.00.09 © 2002 / 0312 0361

7.2 Zylinderkopfhaube und Halteblech anbauen.

Schrauben festdrehen. Auf richtigen Sitz der
Dichtgummis in der Zylinderkopfhaube achten
4
Anziehvorschrift: 11 Nm 6
Druckregelventil ggf. mit neuer Dichtung an-
bauen. Schrauben festdrehen.
0
35253 ©
7.3 Kabelstecker an Abstellmagnet und Regler auf-

2
stecken.
4
35254 ©
7.4 Kabelstecker an Temperaturfühler aufstecken.

4
35255 ©
© 2002 / 0312 0361 2.00.09

00000 ©
© 2002 / 0312 0361

© 2002 / 0312 0361

Prüfen und Einstellen Kompressionsdruck
Control and adjustment Compression pressure
Contrôle et réglage Pression de compression
Verificación y ajustes Presión de compresión

Compression testing device: ______ 8005 Compressiomètre ______________ 8005 Compresímetro ________________ 8005
Torx tool kit: ___________________ 8189 Jeu d’outils Torx _______________ 8189 Juego de herramientas Torx ______ 8189

Adapter: ___________________ 100 110 Elément raccord _____________ 100 110 Pieza de empalme ___________ 100 110
Remove injectors, see Chapter Pour le démontage des injecteurs, voir Desmontar los inyectores, ver apartado
2 “Check of Injectors”. Check and adjust Contrôle des injecteurs. Contrôler le jeu “Inyector”. Verificar y, en su caso,
valve clearance if necessary, see des soupapes, le cas échéant le régler, ajustar el juego de válvulas, ver apartado
Chapter “Valve Clearance Adjustment”. voir Réglage du jeu des soupapes. “Juego de válvulas”.
1. Install connecting piece 100 110 with 1. Insérer l’élément raccord 100 110 1. Meter la pieza de empalme
sealing ring. avec une bague d’étanchéité. 100 110 con un anillo de junta.
2. Fit claws in place. Tighten bolt. 2. Poser la patte. Serrer la vis. 2. Colocar la garra. Apretar el tornillo.
3. Screw on adapter for connecting 3. Visser l’adaptateur pour l’élément 3. Enroscar el adaptador para la pieza
element 100 110. raccord 100 110. de empalme 100 110.
2.00.11 © 2002 / 0312 0361

Kompressionsdruck Prüfen und Einstellen
Compression pressure Control and adjustment
Pression de compression Contrôle et réglage
Presión de compresión Verificación y ajustes
Kompressionsdruckprüfer _______________ 8005
Spezialwerkzeug:
Anschlussstück _____________________ 100 110
Einspritzventile ausbauen, siehe Einspritzventil prü-

2
fen. Ventilspiel kontrollieren ggf. einstellen, siehe
Ventilspiel einstellen.
4
1. Anschlussstück 100 110 mit Dichtring einsetzen. 7
0
35256 ©
2. Pratzen aufsetzen. Schraube festdrehen.

4
35257 ©
3. Adapter für Anschlussstück 100 110 aufschrau-

ben. 4
35258 ©
© 2002 / 0312 0361 2.00.11

Prüfen und Einstellen Kompressionsdruck
Control and adjustment Compression pressure
Contrôle et réglage Pression de compression
Verificación y ajustes Presión de compresión
4. Kompressionsdruckprüfer 8005 anschließen.

4 Motor mit Starter durchdrehen.
35259 ©
5. Kompressionsdruckmessung an jedem Zylinder

2
9 durchführen.
Kompressionsdruck: 30 - 38 bar
Der gemessene Kompressionsdruck ist ab-

hängig von der Anlassdrehzahl während des
Messvorganges und der Höhenlage des
Motoraufstellortes.Grenzwerte sind daher nicht
genau festlegbar.
Empfohlen wird die Kompressionsdruck-
31081 © messung nur als Vergleichsmessung aller Zylin-
der eines Motors untereinander anzusehen.
Sind mehr als 15% Abweichung ermittelt wor-
den, sollte durch die Demontage der betroffenen
Zylindereinheit die Ursache ermittelt werden.
6. Kompressionsdruckprüfer 8005 und Anschluss-

3 stück 100 110 abbauen.
4 Einspritzventile einbauen, sh. Einspritzventile

prüfen.
35260 ©
2.00.12 © 2002 / 0312 0361

Kompressionsdruck Prüfen und Einstellen
Compression pressure Control and adjustment
Pression de compression Contrôle et réglage
Presión de compresión Verificación y ajustes
4. Connect compression gauge 8005. 4. Brancher le compressiomètre 8005. 4. Unir el compresímetro 8005.
Crank engine with starter. Virer le moteur à l’aide du démarreur. Hacer girar el motor con ayuda
del arrancador.
5. Carry out a compression 5. Mesurer la pression de compression 5. Medir la presión de compresión

measurement for each cylinder. sur chaque cylindre. de cada cilindro.
2
Compression: 30 – 38 bar Pression de compression: 30 – 38 bars Presión de compresión: 30 – 38 bar
The measured compression depends La pression de compression mesurée La presión de compresión medida
on the speed of the starter during the dépend de la vitesse de démarrage depende de la velocidad de arranque
measurement and on the altitude durant le relevé et de l’altitude du site durante la medición y de la altitud del
of the site of installation of the engine. d’installation du moteur. Des valeurs lugar de instalación del motor. Por
Limit values cannot be specified exactes ne peuvent donc pas être tanto, no es posible fijar exactamente
exactly therefore. déterminées. valores límite.
A compression measurement Le relevé de la pression de La medición de compresión se
should be considered hence only as compression est uniquement aconseja solamente como una
a comparative measurement of all recommandé comme relevé medida de comparación entre todos
cylinders of an engine. If the comparatif de l’ensemble des los cilindros de un mismo motor.
measurement results in a variation of cylindres d’un moteur. Si l’écart relevé Si se verifican diferencias superiores
more than 15%, trouble shooting est supérieur à 15%, il faut en al 15%, se debería buscar la causa
should take place in form of a complete déterminer la cause par démontage desmontando la unidad de cilindro
disassembly of the cylinder unit. des unités de cylindre en question. afectada.
6. Remove compression tester 8005 and 6. Démonter le compressiomètre 8005 6. Desmontar el compresímetro 8005 y
connecting element 100 110. et l’élément raccord 100 110. la pieza de empalme 100 110.
Install injectors , see Chapter Pour le montage des injecteurs, voir Montar los inyectores, ver apartado
“Check of Injectors”. Contrôle des injecteurs. “Inyector”.
© 2002 / 0312 0361 2.00.12

Prüfen und Einstellen Thermostat
Control and adjustment Thermostat
Contrôle et réglage Thermostat
Verificación y ajustes Termostato
Check thermostat in Contrôle du thermostat à Comprobación del termostato

removed condition l’état démonté. en estado desmontado.
1. Measure dimension “a” on the 1. Relever la cote « A » sur le 1. Medir la distancia „a“ en el
thermostat. thermostat. termostato.
Note: “a” = stroke beginning at approx. Nota: « a » = début de course à Nota: “a” = comienzo del recorrido a
83 ± 2°C (T1) env. 83 ± 2°C (T1) aprox. 83 ± 2 °C (T1)
“b” = stroke ending at « b » = fin de course à “b” = fin del recorrido a
approx. 95°C (T2) env. 95°C (T2) aprox. 95 °C (T2)
2. Heat up thermostat in the 2. Réchauffer le thermostat en 2. Calentar el termostato en el baño

2 water bath. bain d’eau. María o de agua.
For a determination of the exact Pour déterminer le début d’ouverture Con el objeto de determinar el exacto
opening point, the temperature reading précis, le relevé de température est à comienzo de apertura, la medición
should take place as closely as faire le plus près possible du de la temperatura debería efectuarse
possible to the thermostat, however, thermostat, sans le toucher. lo más cerca posible del termostato
without contacting the latter. En vue d’une répartition uniforme de sin tocarlo, removiendo en ello
The water must be continuously la température, il convient d’agiter constantemente el agua para obtener
stirred to arrive at a uniform distribution l’eau en permanence. L’augmentation una distribución uniforme de la
of temperature. The rate of rise of de température ne doit pas dépasser temperatura. La subida de la tempera-
temperature should not exceed 1°C/ 1°C/mn, sinon le début d’ouverture tura no debería ser superior a 1°C
min. at a maximum otherwise opening est retardé d’autant. por minuto; en otro caso, el comienzo
will be delayed correspondingly. de apertura experimentaría el
correspondiente retraso.
3. Measure dimension “b” on the 3. Relever la cote « b » sur le 3. Medir la distancia “b” en
thermostat. thermostat. el termostato.
Stroke length at indicated temperature Course pour la température indiquée Recorrido a la temperatura indicada
(T2) 8 mm at a minimum. (T2) 8 mm mini. (T2): 8 mm como mínimo.
2.00.13 © 2002 / 0312 0361

Thermostat Prüfen und Einstellen
Thermostat Control and adjustment
Thermostat Contrôle et réglage
Termostato Verificación y ajustes
Thermostat prüfen im ausgebauten Zustand.

6
1. Maß "a" am Thermostat messen.
9
Hinweis: "a" = Hubbeginn bei ca. 83 ± 2°C (T1)
"b" = Hubende bei ca. 95 °C (T2) 5
e
31474 ©
2. Thermostat im Wasserbad erwärmen.

2
Zur Ermittlung des genauen Öffnungsbeginn
6
sollte die Temperatur möglichst nah am Thermo-
staten gemessen werden, ohne diesen zu be- 9
rühren.
Das Wasser ist hierbei wegen einer gleichmäßi-
gen Temperaturverteilung ständig umzurühren.
5
Der Temperaturanstieg sollte nicht schneller als
1°C/min erfolgen, andernfalls verzögert sich der
e
Öffnungsbeginn entsprechend.
31475 ©
3. Maß "b" am Thermostat messen.
Hubweg bei angegebener Temperatur (T2) min.

6
8 mm.
9
e
31474 ©
© 2002 / 0312 0361 2.00.13

© 2002 / 0312 0361

Desarmado y ensamblado, motor completo 2012
© 2003 / 0312 0361

Inhalts-Verzeichnis Demontage und Montage, Motor komplett
Table of Contents Disassembly and re-assembly of complete engine
Table des matières Démontage et remontage, moteur complet
Indice Desarmado y ensamblado, motor completo
Deutsch
4. Demontage und Montage, Motor komplett Seite
Motor zerlegen ______________________________________ 4.00.01 – 4.00.13
Motor zusammenbauen:
Ölspritzdüsen ______________________________________ 4.00.15
Stößel/Nockenwelle ______________________________________ 4.00.16
Kurbelwellenlagerung ______________________________________ 4.00.16 – 4.00.19
Massenausgleichswellen ______________________________________ 4.00.20 – 4.00.20.5
Zwischenrad (Regler) ______________________________________ 4.00.20.6
Regelstange ______________________________________ 4.00.20.6
Räderkastendeckel ______________________________________ 4.00.21 – 4.00.23
Vorderer Deckel ______________________________________ 4.00.23
Wellendichtring - vorne ______________________________________ 4.00.23
Wellendichtring - schwungradseitig ______________________________________ 4.00.24
Kolben mit Pleuel ______________________________________ 4.00.24 – 4.00.26
Einspritzpumpen einbauen ______________________________________ 4.00.26 – 4.00.34
Regelstangenweg messen ohne Einspritzpumpen _____________________________ 4.00.26 – 4.00.27
Zünd O.T. des Kolbens ermitteln ______________________________________ 4.00.27 – 4.00.28
Förderbeginn ermitteln ______________________________________ 4.00.29 – 4.00.31
Leichtgängigkeit der Regelstange prüfen _____________________________________ 4.00.34
Regelstangen-Rückstandsmaß messen _____________________________________ 4.00.34
Schwungrad ______________________________________ 4.00.35
Anschlussgehäuse ______________________________________ 4.00.35
Keilrippenscheibe / Drehschwingungsdämpfer ________________________________ 4.00.35 – 4.00.36
Zylinderkopf ______________________________________ 4.00.36 – 4.00.39
Ladeluftleitung ______________________________________ 4.00.39
Abgassammelrohr ______________________________________ 4.00.40
Abgasturbolader ______________________________________ 4.00.40
Ölrücklaufrohr ______________________________________ 4.00.40 – 4.00.41
Starter ______________________________________ 4.00.41 – 4.00.42
Regler ______________________________________ 4.00.42
Einspritzventile / Einspritzleitungen ______________________________________ 4.00.43 – 4.00.44
Motorabstellung ______________________________________ 4.00.44
4
Ölkühlergehäuse ______________________________________ 4.00.44 – 4.00.45
Heizstab-Kühlmittelvorwärmung ______________________________________ 4.00.45
Kraftstofffiltergehäuse ______________________________________ 4.00.45
Wasserkasten ______________________________________ 4.00.45 – 4.00.46
Zylinderkopfhaube ______________________________________ 4.00.46
Steuerleitung ______________________________________ 4.00.47
Druckregelventil ______________________________________ 4.00.47 – 4.00.48
Lüfterkonsole ______________________________________ 4.00.48
Kühlmittelpume ______________________________________ 4.00.49
Konsole / Generator ______________________________________ 4.00.49
Aufhängeblech ______________________________________ 4.00.49
Kraftstoffpumpe ______________________________________ 4.00.49 – 4.00.50
Spannrolle ______________________________________ 4.00.50
Lüfterantrieb ______________________________________ 4.00.50
Keilrippenriemen ______________________________________ 4.00.50 – 4.00.51
Lüfter ______________________________________ 4.00.51
Ölwanne ______________________________________ 4.00.52
© 2002 / 0312 0361

Demontage und Montage, Motor komplett Inhalts-Verzeichnis
Disassembly and re-assembly of complete engine Table of Contents
Démontage et remontage, moteur complet Table des matières
Desarmado y ensamblado, motor completo Indice
English
4. Disassembly and re-assembly of complete engine Page
Disassembly of engine ______________________________________ 4.00.01 – 4.00.13
Re-assembly of engine:
Cooling oil nozzles ______________________________________ 4.00.15
Tappets, camshaft ______________________________________ 4.00.16
Crankshaft bearings ______________________________________ 4.00.16 – 4.00.19
Mass balancing shafts ______________________________________ 4.00.20 – 4.00.20.5
Idler gear (governor) ______________________________________ 4.00.20.6
Control rod ______________________________________ 4.00.20.6
Timing case cover ______________________________________ 4.00.21 – 4.00.23
Front cover ______________________________________ 4.00.23
Shaft sealing insert – front ______________________________________ 4.00.23
Shaft sealing insert – flywheel end ______________________________________ 4.00.24
Piston with connecting rod ______________________________________ 4.00.24 – 4.00.26
Installation of injection pumps ______________________________________ 4.00.26 – 4.00.34
Measurement of control rod travel path without injection pumps ___________________ 4.00.26 – 4.00.27
Determination of piston firing TDC ______________________________________ 4.00.27 – 4.00.28
Determination of the fuel delivery cut-in point _________________________________ 4.00.29 – 4.00.31
Test for ease of movement of the control rod __________________________________ 4.00.34
Measurement of the control rod recess dimension _____________________________ 4.00.34
Flywheel ______________________________________ 4.00.35
Adapter housing ______________________________________ 4.00.35
Ribbed V-belt pulley / torsional vibration damper _______________________________ 4.00.35 – 4.00.36
Cylinder head ______________________________________ 4.00.36 – 4.00.39
Charge air pipe ______________________________________ 4.00.39
Exhaust manifold ______________________________________ 4.00.40
Exhaust turbocharger ______________________________________ 4.00.40
Oil return pipe ______________________________________ 4.00.40 – 4.00.41
Starter ______________________________________ 4.00.41 – 4.00.42
Governor ______________________________________ 4.00.42
Injector nozzles/injector lines ______________________________________ 4.00.43 – 4.00.44
4 Engine stop device ______________________________________ 4.00.44
Oil cooler housing ______________________________________ 4.00.44 – 4.00.45
Coolant preheating by heating rod ______________________________________ 4.00.45
Fuel filter housing ______________________________________ 4.00.45
Water tank ______________________________________ 4.00.45 – 4.00.46
Cylinder head cover ______________________________________ 4.00.46
Control line ______________________________________ 4.00.47
Pressure control valve ______________________________________ 4.00.47 – 4.00.48
Fan bracket ______________________________________ 4.00.48
Coolant pump ______________________________________ 4.00.49
Bracket / generator ______________________________________ 4.00.49
Suspension plate ______________________________________ 4.00.49
Fuel pump ______________________________________ 4.00.49 – 4.00.50
Tension pulley ______________________________________ 4.00.50
Fan drive ______________________________________ 4.00.50
Ribbed V-belt ______________________________________ 4.00.50 – 4.00.51
Fan ______________________________________ 4.00.50 – 4.00.51
Oil pan ______________________________________ 4.00.52
© 2002 / 0312 0361

Inhalts-Verzeichnis Demontage und Montage, Motor komplett
Table of Contents Disassembly and re-assembly of complete engine
Table des matières Démontage et remontage, moteur complet
Indice Desarmado y ensamblado, motor completo
Français
4. Démontage et remontage, moteur complet Page
Démontage du moteur ______________________________________ 4.00.01 – 4.00.13
Remontage du moteur:
Gicleur d’huile ______________________________________ 4.00.15
Poussoirs / arbre à cames ______________________________________ 4.00.16
Paliers de vilebrequin ______________________________________ 4.00.16 – 4.00.19
Arbres à masses d’équilibrage ______________________________________ 4.00.20 – 4.00.20.5
Pignon intermédiaire (régulateur) ______________________________________ 4.00.20.6
Crémaillère ______________________________________ 4.00.20.6
Couvercle de carter de distribution ______________________________________ 4.00.21 – 4.00.23
Couvercle avant ______________________________________ 4.00.23
Joint d’arbre – avant ______________________________________ 4.00.23
Joint d’arbre – côté volant ______________________________________ 4.00.24
Piston avec bielle ______________________________________ 4.00.24 – 4.00.26
Montage des pompes d’injection ______________________________________ 4.00.26 – 4.00.34
Mesurer la course de la crémaillère sans pompes d’injection _____________________ 4.00.26 – 4.00.27
Déterminer le PMH d’allumage du piston _____________________________________ 4.00.27 – 4.00.28
Déterminer le début d’injection ______________________________________ 4.00.29 – 4.00.31
Contrôler le coulissement sans point dur de la crémaillère _______________________ 4.00.34
Mesurer le retrait de la crémaillère ______________________________________ 4.00.34
Volant ______________________________________ 4.00.35
Carter d’adaptation ______________________________________ 4.00.35
Poulie de courroie trapézoïdale nervurée / amortisseur de vibrations torsionnelles ____ 4.00.35 – 4.00.36
Culasse ______________________________________ 4.00.36 – 4.00.39
Collecteur d’admission ______________________________________ 4.00.39
Collecteur d’échappement ______________________________________ 4.00.40
Turbocompresseur à gaz d’échappement ____________________________________ 4.00.40
Conduite de retour d’huile ______________________________________ 4.00.40 – 4.00.41
Démarreur ______________________________________ 4.00.41 – 4.00.42
Régulateur ______________________________________ 4.00.42
Injecteurs / tuyauteries d’injection ______________________________________ 4.00.43 – 4.00.44
Dispositif d’arrêt du moteur ______________________________________ 4.00.44
4
Bloc de refroidisseur d’huile ______________________________________ 4.00.44 – 4.00.45
Canne chauffante de préchauffage de fluide réfrigérant _________________________ 4.00.45
Carter de filtre à combustible ______________________________________ 4.00.45
Caisse d’eau ______________________________________ 4.00.45 – 4.00.46
Cache-culbuteurs ______________________________________ 4.00.46
Conduite pilote ______________________________________ 4.00.47
Soupape régulatrice de pression ______________________________________ 4.00.47 – 4.00.48
Console de ventilateur ______________________________________ 4.00.48
Pompe à fluide réfrigérant ______________________________________ 4.00.49
Console / génératrice ______________________________________ 4.00.49
Tôle de suspension ______________________________________ 4.00.49
Pompe à combustible ______________________________________ 4.00.49 – 4.00.50
Galet tendeur ______________________________________ 4.00.50
Entraînement de ventilateur ______________________________________ 4.00.50
Courroie trapézoïdale nervurée ______________________________________ 4.00.50 – 4.00.51
Ventilateur ______________________________________ 4.00.51
Cuve d’huile ______________________________________ 4.00.52
© 2002 / 0312 0361

Demontage und Montage, Motor komplett Inhalts-Verzeichnis
Disassembly and re-assembly of complete engine Table of Contents
Démontage et remontage, moteur complet Table des matières
Desarmado y ensamblado, motor completo Indice
Español
4. Desarmado y ensamblado, motor completo Página
Desarmado del motor ______________________________________ 4.00.01 - 4.00.13
Ensamblado del motor:

Toberas de aceite para refrigeración de pistón ________________________________ 4.00.15
Empujadores / Arbol de levas ______________________________________ 4.00.16
Apoyos del cigüeñal ______________________________________ 4.00.16 - 4.00.19
Ejes equilibradores ______________________________________ 4.00.20 – 4.00.20.5
Rueda intermedia (regulador) ______________________________________ 4.00.20.6
Cremallera ______________________________________ 4.00.20.6
Tapa del cárter de la distribución ______________________________________ 4.00.21 – 4.00.23
Tapa delantera ______________________________________ 4.00.23
Retén delantero ______________________________________ 4.00.23
Retén en el lado del volante ______________________________________ 4.00.24
Pistón con biela ______________________________________ 4.0024 – 4.00.26
Montaje de las bombas de inyección ______________________________________ 4.00.26 – 4.00.34
Medición del recorrido de la cremallera, sin bombas de inyección _________________ 4.00.26 – 4.00.27
Determinación del PMS de compresión del pistón ______________________________ 4.00.27 – 4.00.28
Determinación del comienzo de alimentación _________________________________ 4.00.29 – 4.00.31
Comprobación de la facilidad de movimiento de la cremallera ____________________ 4.00.34
Medición del retroceso de la cremallera ______________________________________ 4.00.34
Volante ______________________________________ 4.00.35
Cárter de adaptación ______________________________________ 4.00.35
Polea p. correa nervada trap. / amortiguador de vibraciones torsionales ____________ 4.00.35 – 4.00.36
Culata ______________________________________ 4.00.36 – 4.00.39
Tubería de aire de sobrealimentación ______________________________________ 4.00.39
Colector de escape ______________________________________ 4.00.40
Turbocompresor ______________________________________ 4.00.40
Tubo de retorno de aceite ______________________________________ 4.00.40 – 4.00.41
Arrancador ______________________________________ 4.00.41 – 4.00.42
Regulador ______________________________________ 4.00.42
Inyectores / Tuberías de inyección ______________________________________ 4.00.43 – 4.00.44
4 Dispositivo de parada del motor ______________________________________ 4.00.44
Cárter de refrigerador de aceite ______________________________________ 4.00.44 – 4.00.45
Varilla calentadora p. precalentamiento del refrigerante _________________________ 4.00.45
Caja de filtro de combustible ______________________________________ 4.00.45
Caja de agua ______________________________________ 4.00.45 – 4.00.46
Tapa de culata ______________________________________ 4.00.46
Conducto de mando ______________________________________ 4.00.47
Válvula reguladora de presión ______________________________________ 4.00.47 – 4.00.48
Consola para ventilador ______________________________________ 4.00.48
Bomba de refrigerante ______________________________________ 4.00.49
Consola / alternador ______________________________________ 4.00.49
Chapa de suspensión ______________________________________ 4.00.49
Bomba de combustible ______________________________________ 4.00.49 – 4.00.50
Polea tensora ______________________________________ 4.00.50
Accionamiento de ventilador ______________________________________ 4.00.50
Correa nervada trapezoidal ______________________________________ 4.00.50 – 4.00.51
Ventilador ______________________________________ 4.00.51
Cárter de aceite ______________________________________ 4.00.52
© 2002 / 0312 0361

© 2002 / 0312 0361

Dismantling of engine Démontage du moteur Desarmado del motor

Claw grip wrench ______________ 8018 Clé à griffes ___________________ 8018 Llave de garra _________________ 8018
Torx wrench socket E14 _________ 8113 Clé à douille Torx E14 ___________ 8113 Llave de vaso Torx E14 __________ 8113
Spring clamp pliers _____________ 9090 Pince à ressort pour tuyaux ______ 9090 Alicates para abrazaderas elásticas _ 9090

Engine assembly stand __________ 6066 Chevalet de montage moteur _____ 6066 Caballete de montaje para el motor 6066
Angled clamping plate ________ 6066/158 Cornières de fixation __________ 6066/58 Angulares de sujeción ________ 6066/158
Extractor ___________________ 110 030 Extracteur __________________ 110 030 Extractor ___________________ 110 030
Special wrench ______________ 110 500 Clé spéciale ________________ 110 500 Llave especial _______________ 110 500
Extractor ___________________ 120 660 Dispositif d’extraction _________ 120 660 Dispositivo de extracción ______ 120 660
Dolly for torsional Dispositif d’immobilisation / amortisseur Dispositivo de retención / amortiguador
vibration damper _____________ 144 800 de vibrations torsionnelles _____ 144 800 de vibraciones torsionales _____ 144 800
Extractor pulling device ________ 150 800 Dispositif d’extraction _________ 150 800 Dispositivo de extracción ______ 150 800
Dolly for center nut, fan ________ 160 330 Dispositif d’immobilisation Dispositivo de retención
Open jawed wrench __________ 160 340 entraînement de ventilateur ____ 160 330 accionamiento de ventilador ____ 160 330
Embout à mâchoire ___________ 160 340 Boca enchufable para llave
The repair operations described refers dinamométrica ______________ 160 340
to the standard version i.e. components Les opérations de réparation montrées
for customizing the engine are not ne tiennent pas compte des spécifications La secuencia a seguir en los trabajos de
considered. individuelles, c’est-à-dire que les reparación descritos en este capítulo se
composants autres que ceux de la refiere al volumen de suministro estándar,
version standard ne sont pas montrés. o sea, no se muestran los componentes
de adosamiento que difieran del mismo.
1. Mount angled 1. Monter les cornières de 1. Montar los angulares de

clamping plate 6066/158. fixation 6066/158. sujeción 6066/158.
2. Chuck engine in double sided swivel- 2. Placer le moteur dans le chevalet de 2. Alojar el motor en el caballete
type assembly stand 6066 and align. montage pivotant bilatéral 6066 et 6066 orientable de sujeción bilateral y
Tighten bolts. l’aligner. Serrer les vis. alinearlo. Apretar los tornillos.
Drain and collect residual oil and Vidanger l’huile moteur ou l’huile Evacuar el aceite de motor o el
coolant and dispose of properly résiduelle et le fluide réfrigérant, les aceite restante y el líquido
in accordance with anti-pollution recueillir et les éliminer conformément refrigerante, recogerlos y eliminarlos
regulations. aux réglementations antipollution. en forma reglamentaria.
4.00.01 © 2002 / 0312 0361

Motor zerlegen
Klauenschlüssel ______________________ 8018
Torx-Steckschlüssel E14 _______________ 8113
Federklemmenzange __________________ 9090
Spezialwerkzeuge:
Motor-Montagebock ___________________ 6066
Aufspannwinkel ____________________ 6066/158
Auszieher _________________________ 110 030
Spezialschlüssel ____________________ 110 500
Gegenhalter / Drehschwingungsdämfer __ 144 800
Gegenhalter Lüfterantrieb _____________ 160 330
Maul-Steckaufsatz __________________ 160 340
Bei dem gezeigten Reparaturablauf sind unter-

schiedliche Kundenumfänge nicht berücksichtigt,
d. h., von der Standard-Ausführung abweichende
Anbauteile werden nicht gezeigt.
1. Aufspannwinkel 6066/158 anbauen.

s
7
35317 ©
2. Motor in doppelseitigen schwenkbaren Mon-

tagebock 6066 aufnehmen und ausrichten.
Schrauben festdrehen.
s
Motoröl bzw. Restöl und Kühlmittel ablassen,
7
auffangen und vorschriftsmäßig entsorgen.
ü
35318 ©
© 2003 / 0312 0361 4.00.01

Bei Teildemontage und Drehen des Motors um 180°

3 ist die Kurbelgehäuseentlüftung zuerst abzubauen.
Restöl und Kühlmittel auffangen und vorschrifts-
5 mäßig entsorgen.
7
3. Lüfter mit Maulsteckaufsatz 160 340 und Gegen-
halter 160 330 abbauen.
Hinweis: Achtung! Linksgewinde
35320 ©
4. Lüfter senkrecht abstellen.

5 Achtung! Nicht legen.
35321 ©
5. Keilrippenriemen über Spannrolle 1 in Pfeil-

3 richtung entlasten.
5 Hinweis: Keilrippenriemen zuerst über die Rolle 2

abnehmen.
35279 ©
6. Kabelstecker von Generator abziehen und

3 Kabelschuh abschrauben.
35322 ©
4.00.02 © 2002 / 0312 0361

For partial disassembly turn engine by En cas de démontage partiel et de Para el desarmado parcial y el giro del
180° and remove crankcase breather first. virage du moteur de 180°, démonter motor por 180° es necesario desmontar,
Collect residual oil and coolant d’abord l’évent de carter. Recueillir primero, el dispositivo de ventilación del
and dispose of in accordance with l’huile résiduelle et le fluide réfrigérant cárter del cigüeñal. Recoger el aceite
anti-pollution regulations. et les éliminer conformément aux restante y el líquido refrigerante y
réglementations antipollution. eliminarlos en forma reglamentaria.
3. Remove fan using open jaw wrench 3. Démonter le ventilateur à l’aide de 3. Desmontar el ventilador utilizando
160 340 and dolly 160 330. l’embout à mâchoire 160 340 et du la boca enchufable 160 340 y el
dispositif d’immobilisation 160 330. dispositivo de retención 160 330.
Note: Caution: left hand thread! Nota: Attention ! Filetage à gauche. Nota: Atención: Rosca a la izquierda.
4. Place fan down in upright position. 4. Déposer le ventilateur en position 4. Depositar el ventilador de pie,
verticale. en posición vertical.
Caution: Fan must not be placed down in Attention! Ne pas le coucher. Nota: Atención: No tumbarlo.
horizontal position!
5. Relieve pressure of ribbed V-belt via 5. Détendre la courroie trapézoïdale 5. Quitarle la tensión a la correa nervada
pulley 1 in direction of the arrow. nervurée à l’aide du galet tendeur 1 trapezoidal actuando sobre la polea
dans le sens de la flèche. tensora 1 en dirección de la flecha.
Note: Remove ribbed V-belt Nota: Enlever d’abord la courroie Nota: Empezar a retirar la correa nervada
via pulley 2 first. trapézoïdale nervurée du galet 2. trapezoidal de la polea 2.
6. Pull-off cable connector from 6. Débrancher le connecteur de 6. Desenchufar el cable del alternador y
generator set and screw-off câble de la génératrice et dévisser desatornillar el terminal de cable.
terminal end. la cosse de câble.
© 2002 / 0312 0361 4.00.02

7. Remove generator set, fuel line 7. Démonter la génératrice, la 7. Desmontar el alternador, la

and fuel pump. tuyauterie à combustible et la tubería de combustible y la bomba
pompe à combustible. de combustible.
8. Remove fan drive. 8. Démonter l’entraînement de 8. Desmontar el accionamiento

ventilateur. del ventilador.
9. Remove coolant pump 9. Démonter la pompe à fluide 9. Desmontar la bomba de refrigerante.

réfrigérant.
10. Remove tensioning pulley. 10. Démonter le galet tendeur 10. Desmontar la polea tensora.
4.00.03 © 2002 / 0312 0361

7. Generator, Kraftstoffleitung und Kraftstoff-

pumpe abbauen. 3
35323 ©
8. Lüfterantrieb abbauen.
3
35324 ©
9. Kühlmittelpumpe abbauen.
3
35325 ©
10. Spannrolle abbauen.

3
35326 ©
© 2002 / 0312 0361 4.00.03

11. Konsole und Aufhängeblech ausbauen.

3
35327 ©
12. Kraftstoffzulaufleitung ausbauen.

3 Hinweis: Austretenden Kraftstoff auffangen und
5 vorschriftsmäßig entsorgen.
35328 ©
13. Anschlussstutzen und Lüfterkonsole aus-

3 bauen.
5 Hinweis: Anschlussstutzen erneuern.
35329 ©
14. Entlüftungsrohr abbauen.

3 Hierzu Schlauchklemme mit Federklemmen-
zange 9090 lösen.
5 Schmierölleitung, Rücklaufleitung und Abgas-
turbolader abbauen.
Hinweis: Öffnungen von Abgasturbolader ver-

schließen.
35330 ©
4.00.04 © 2002 / 0312 0361

11. Remove bracket and 11. Démonter la console et la tôle 11. Desmontar la consola y la chapa
suspension plate. de suspension. de suspensión.
12. Remove fuel feed line 12. Démonter la tuyauterie d’arrivée 12. Retirar la tubería de llegada de
de combustible. combustible.
Note: Collect escaping fuel and Nota: Recueillir les fuites de combustible Nota: Recoger el combustible que salga y
dispose of in accordance with et les éliminer conformément aux eliminarlo en forma reglamentaria.
anti-pollution regulations. réglementations antipollution.
13. Remove connecting socket and 13. Démonter la tubulure de 13. Desmontar el racor de empalme y la
fan bracket. raccordement et la console de consola del ventilador.
ventilateur.
Note: Replace connecting socket by a Nota: Remplacer la tubulure de Nota: Renovar el racor de empalme.
new one. raccordement.
14. Remove breather pipe. 14. Démonter le tube évent. 14. Desmontar el tubo de ventilación.
Slacken hose collar using spring Pour cela, défaire le collier de Para ello, soltar la abrazadera
clamp pliers 9090 to this end. serrage à l’aide de la pince del tubo flexible mediante los
Remove lube oil pipe, oil return à ressort pour tuyaux 9090. alicates 9090.
pipe and exhaust turbocharger. Démonter les conduites d’huile, Desmontar la tubería de aceite
de retour et le turbocompresseur. lubricante, la tubería de retorno y
el turbocompresor.
Note: Close apertures of Nota: Obturer les orifices du Nota: Cerrar las aberturas del
exhaust turbocharger. turbocompresseur. turbocompresor.
© 2002 / 0312 0361 4.00.04

15. Slacken terminal on starter and 15. Défaire la cosse de câble du 15. Aflojar el terminal de cable del
pull-off. Remove starter. démarreur et l’enlever. Démonter arrancador y retirarlo. Desmontar el
le démarreur. arrancador.
16. Remove exhaust manifold. 16. Démonter le collecteur 16. Desmontar el colector de escape.
d’échappement.
17. Release cable connector and pull 17. Déverrouiller le connecteur de câble 17. Quitar el seguro del conector de
off from temperature sensor. et le tirer de la sonde de température. cable y desenchufar el cable del
Remove fixing clamp. Démonter le collier de fixation. sensor de temperatura.
Quitar la abrazadera de sujeción.
18. Release and pull off cable connector 18. Déverrouiller le connecteur de 18. Quitar el seguro de los conectores
from cut-off solenoid and governor. câble de l’électroaimant d’arrêt de cable del solenoide de parada y
et du régulateur et le tirer. regulador y desenchufar los cables.
Démonter la conduite pilote Desmontar el conducto de mando
du régulateur. del regulador.
4.00.05 © 2002 / 0312 0361

15. Kabelschuh von Starter lösen und abziehen.

Starter abbauen.
3
35331 ©
16. Abgassammelrohr abbauen.

3
35332 ©
17. Kabelstecker entsichern und von Temperatur-

fühler abziehen.
Befestigungsschelle abbauen.
3
35333 ©
18. Kabelstecker von Abstellmagnet und Regler

entsichern und abziehen.
Steuerleitung von Regler abbauen.
3
35334 ©
© 2002 / 0312 0361 4.00.05

19. Steuerleitung abbauen.

3
35335 ©
20. Regler abbauen.

3
35336 ©
21. Druckregelventil ausbauen.

3
35337 ©
22. Abdeckblech, Kabelsatz und Zylinderkopf-

3 haube abbauen.
35338 ©
4.00.06 © 2003 / 0312 0361

19. Remove control line. 19. Démonter la conduite pilote. 19. Retirar el conducto de mando.
20. Remove governor 20. Démonter le régulateur. 20. Desmontar el regulador.
21. Remove pressure control valve. 21. Démonter la soupape régulatrice 21. Desmontar la válvula reguladora
de pression. de presión.
22. Remove cover plate and 22. Démonter la tôle de recouvrement 22. Desmontar la chapa de recubrimiento
inspection cover. et le cache-culbuteurs. y la tapa de culata.
© 2002 / 0312 0361 4.00.06

23. Remove retainer (arrow) and 23. Démonter l’attache (flèche) et le 23. Desmontar el soporte (flecha) y la
charge air pipe. collecteur d’admission. tubería de aire de sobrealimentación.
24. Remove pressure holding valve and 24. Démonter le limiteur de pression et 24. Desmontar la válvula de
fuel line. la tuyauterie à combustible. mantenimiento de presión y la
tubería de combustible.
25. Remove oil dip stick . 25. Retirer la jauge d’huile. 25. Sacar la varilla medidora del nivel
Remove water box and plug-in Démonter la caisse d’eau et de aceite.
element. l’élément raccord. Desmontar la caja de agua y la pieza
de enchufe.
Note: Collect coolant and dispose of Nota: Recueillir le fluide réfrigérant Nota: Recoger el líquido refrigerante y
in accordance with anti-pollution et l’éliminer conformément aux eliminarlo en forma reglamentaria.
regulations. réglementations antipollution.
4
26. Remove fuel filter housing. 26. Démonter le carte de filtre à 26. Desmontar la caja de filtro de
Remove heating rod. combustible. Démonter la canne combustible.
chauffante. Desmontar la varilla calentadora.
Note: Collect fuel and dispose of in Nota: Recueillir le combustible et Nota: Recoger el combustible y eliminarlo
accordance with anti-pollution l’éliminer conformément aux en forma reglamentaria.
4.00.07 © 2002 / 0312 0361

23. Halter (Pfeil) und Ladeluftleitung abbauen.

3
35339 ©
24. Druckhalteventil und Kraftstoffleitung abbauen.

3
35340 ©
25. Ölmessstab herausziehen.

Wasserkasten und Steckstück
abbauen.
3
Hinweis: Kühlmittel auffangen und vorschrifts- 5
mäßig entsorgen.
35341 ©
26. Kraftstofffiltergehäuse abbauen.

Heizstab ausbauen. 3
Hinweis: Kraftstoff auffangen und vorschrifts-
mäßig entsorgen.
5
35342 ©
© 2002 / 0312 0361 4.00.07

27. Ölkühlergehäuse abbauen.

3 Hinweis: Restöl und Kühlmittel auffangen und vor-
5 schriftsmäßig entsorgen.
35343 ©
28. Abstellmagnet ausbauen.

3 Hinweis: Öffnung verschließen.
35344 ©
29. Einspritzleitungen abbauen.

3 Hinweis: Klauenschlüssel 8018 verwenden.
5
7
4
35345 ©
30. Spannpratzen abbauen und Einspritzventile

3 herausnehmen.
5 Hinweis: Bei Festsitz Ausziehvorrichtung 150 800

mit Auszieher 110 030 verwenden.
7
Dichtring mit Ausziehvorrichtung 120 660
herausziehen.
35346 ©
4.00.08 © 2003 / 0312 0361

27. Remove oil cooler housing. 27. Démonter le bloc de refroidisseur 27. Desmontar el cárter del refrigerador
d’huile. de aceite.
Note: Collect residual oil and coolant Nota: Recueillir l’huile résiduelle et le Nota: Recoger el aceite restante y el
and dispose of in accordance with fluide réfrigérant et les éliminer líquido refrigerante y eliminarlos en
anti-pollution regulations. conformément aux réglementations forma reglamentaria.
antipollution.
28. Remove cut-off solenoid. 28. Démonter l’électroaimant d’arrêt. 28. Desmontar el solenoide de parada.
Note: Plug opening. Nota: Obturer l’orifice. Nota: Cerrar la abertura.
29. Remove injection pipes 29. Démonter les tuyauteries d’injection. 29. Desmontar las tuberías de inyección.
30. Remove tensioning claws and take 30. Démonter les pattes de serrage et 30. Desmontar las garras de sujeción y
out injector valves sortir les injecteurs. retirar los inyectores.
Note: Use extractor pulling device Nota: En cas de blocage, utiliser le Nota: Si los inyectores están fijos, utilizar
150 800 in combination with dispositif d’extraction 150 800 el dispositivo de extracción 150 800
tool 110 030 if jammed. avec l’extracteur 110 030. con el extractor 110 030.
Use extractor 120 660 for Extraire la bague d’étanchéité avec Quitar el anillo de junta utilizando el
pulling out the sealing ring. le dispositif d’extraction 120 660. dispositivo de extracción 120 660.
© 2002 / 0312 0361 4.00.08

31. Remove rocker arms and lift 31. Sortir les supports de culbuteurs et 31. Desmontar los soportes de
out pushrods. les tiges de poussoirs. balancines y sacar las varillas
de empuje.
32. Remove cylinder head. 32. Démonter la culasse. 32. Desmontar la culata.
Note: Use Torx wrench socket E14, 8113. Nota: Utiliser la clé à douille Nota: Utilizar la llave de vaso Torx E14,
Torx E14, 8113. 8113.
33. Take out cylinder head gasket. 33. Enlever le joint de culasse. Démonter 33. Quitar la junta de culata.
Remove injection pump flange and la bride de pompe d’injection et Desmontar la brida de las bombas de
pull out injection pumps extraire les pompes d’injection. inyección y sacar éstas.
Note: Plug openings. Nota: Obturer les orifices. Nota: Cerrar las aberturas.
34. Pull out roller tappet together 34. Extraire les poussoirs à galet 34. Sacar los empujadores de rodillo con
with shims. avec cales de réglage. las arandelas de reglaje.
4.00.09 © 2002 / 0312 0361

31. Kipphebelböcke ausbauen und Stoßstangen

herausnehmen.
3
35347 ©
32. Zylinderkopf abbauen.
Hinweis: Torx-Steckschlüssel E14, 8113 verwen-

3
den.
5
35348 ©
33. Zylinderkopfdichtung entnehmen.

Einspritzpumpenflansch abbauen
und Einspritzpumpen herausziehen.
3
Hinweis: Öffnungen verschließen. 5
35349 ©
34. Rollenstößel mit Ausgleichscheiben heraus-

ziehen. 3
35350 ©
© 2002 / 0312 0361 4.00.09

35. Drehschwingungsdämpfer mit Gegenhalter

3 144 800 gegenhalten und abbauen.
5 Hinweis: Torx-Steckschlüssel E20, 8114 verwen-

den.
35351 ©
36. Anschlussgehäuse abbauen.

3 Schwungrad gegenhalten und abbauen.
5 Hinweis: Torx-Steckschlüssel E20, 8114 und E14,

8113 verwenden.
35352 ©
37. Motor um 180° drehen.

3 Ölwanne abbauen.
5 Hinweis: Restöl und Kühlmittel auffangen und

vorschriftsmäßig entsorgen.
35353 ©
38. Vorderen Deckel abbauen.

3
30170 ©
4.00.10 © 2002 / 0312 0361

35. Retain torsional vibration damper with 35. Immobiliser l’amortisseur de 35. Inmovilizar el amortiguador de
dolly 144 800 and remove. vibrations torsionnelles avec le vibraciones torsionales mediante el
dispositif 144 800 et le démonter. dispositivo de retención 144 800 y
desmontarlo.
Note: Use Torx wrench socket E20, 8114 . Nota: Utiliser la clé à douille Nota: Utilizar la llave de vaso Torx E20,
Torx E20, 8114. 8114.
36. Remove adapter housing. 36. Démonter le carter d’adaptation. 36. Desmontar el cárter de adaptación.
Retain flywheel and remove. Immobiliser le volant et le démonter. Retener el volante y desmontar.
Note: Use Torx wrench sockets E20, 8114 Nota: Utiliser les clés à douille Nota: Utilizar las llaves de vaso Torx E20,
and E14, 8113. Torx E20, 8114 et E14, 8113. 8114, y E14, 8113.
37. Turn engine by 180°. 37. Virer le moteur de 180°. Démonter la 37. Girar el motor 180°.
Remove oil pan. cuve d’huile. Desmontar el cárter de aceite.
Note: Collect residual oil and coolant Nota: Recueillir l’huile résiduelle et le Nota: Recoger el aceite restante y el
and dispose of in accordance with fluide réfrigérant et les éliminer líquido refrigerante y eliminarlos en
anti-pollution regulations. conformément aux réglementations forma reglamentaria.
antipollution.
38. Remove front cover. 38. Démonter le couvercle avant. 38. Desmontar la tapa delantera.
© 2002 / 0312 0361 4.00.10

39. Remove timing case cover. 39. Démonter le couvercle du carter 39. Desmontar la tapa del cárter de
de distribution. la distribución.
40. Remove idler gear and guide 40. Démonter le pignon intermédiaire 40. Desmontar la rueda
bushing. Take out control rod. et la douille de guidage. Sortir la intermedia y el casquillo de guía.
crémaillère. Retirar la cremallera.
41. Remove piston together with 41. Démonter les pistons avec bielles. 41. Desmontar los pistones con
connecting rod. las bielas.
42. Remove main bearing cap. Take out 42. Démonter les chapeaux de paliers 42. Desmontar las tapas de los cojinetes
crankshaft together with crankshaft principaux. Sortir le vilebrequin de apoyo. Retirar el cigüeñal con los
bearing and thrust washers. avec les paliers de vilebrequin et cojinetes y arandelas de tope.
les cales latérales.
4.00.11 © 2002 / 0312 0361

39. Räderkastendeckel abbauen.

3
30169 ©
40. Zwischenrad und Führungsbuchse abbauen.

Regelstange herausnehmen.
3
30172 ©
41. Kolben mit Pleuelstangen ausbauen.

3
35173 ©
42. Hauptlagerdeckel ausbauen. Kurbelwelle mit

Kurbelwellenlager und Anlaufscheiben heraus-
nehmen.
3
30174 ©
© 2002 / 0312 0361 4.00.11

43. Falls vorhanden, Antriebsräder für Ausgleich-

3 wellen ausbauen.
30858 ©
44. Falls vorhanden, Anlaufscheiben für Ausgleich-

3 wellen abbauen.
30859 ©
45. Falls vorhanden, Ausgleichwellen heraus-

3 nehmen.
30860 ©
46. Sämtliche Stößel hinunterdrücken. Nocken-

3 welle ausbauen.
5 Hinweis: Für diesen Vorgang den Motor im Mon-

tagebock einseitig abhängen.
30175 ©
4.00.12 © 2002 / 0312 0361

43. Remove drive gears for 43. Le cas échéant, démonter les 43. Si existen, desmontar las
compensation shafts, if any. pignons d’entraînement des arbres ruedas de accionamiento de
à masses d’équilibrage. los ejes equilibradores.
44. Remove thrust covers for 44. Le cas échéant, démonter les 44. Si existen, desmontar las arandelas
compensation shafts, if any. bagues de butée des arbres à de tope de los ejes equilibradores.
masses d’équilibrage.
45. Remove compensation shafts, if any. 45. Le cas échéant, sortir les arbres à 45. Si existen, sacar los ejes
masses d’équilibrage. equilibradores.
46. Press down all tappets. Remove 46. Enfoncer tous les poussoirs . 46. Presionar hacia abajo todos los
camshaft. Démonter l’arbre à cames. empujadores (taqués). Desmontar
el árbol de levas.
Note: Hook up engine on one side in Nota: Pour cette opération, décrocher le Nota: Para esta operación, descolgar
assembly stand for this purpose. moteur d’un côté dans le chevalet el motor en un lado del caballete
de montage. de montaje.
© 2002 / 0312 0361 4.00.12

47. Take out tappets. 47. Sortir les poussoirs. 47. Sacar los empujadores.
48. Turn engine by 180°. 48. Virer le moteur de 180°. 48. Girar el motor 180°.
Press out oil jet nozzles. Chasser les gicleurs d’huile. Desmontar a presión las toberas
Check oil ducts for free passage. Contrôler le libre passage des de aceite para la refrigeración de
canalisations d’huile. los pistones.
Comprobar el libre paso de los
conductos de aceite.
4.00.13 © 2002 / 0312 0361

47. Stößel herausnehmen.

3
30176 ©
48. Motor 180° drehen.
Ölspritzdüsen herausdrücken.
3
Ölkanäle auf freien Durchgang prüfen.
9
30193 ©
© 2002 / 0312 0361 4.00.13

00000 ©
© 2002 / 0312 0361

© 2002 / 0312 0361

Re-assembly of engine Remontage du moteur Ensamblado del motor

External screw type micrometer Micromètre extérieur Micrómetro para exteriores (palmer)
Serrated wrench for turning Clé polygonale pour Llave de giro (poligonal) para
injection pump _________________ 8117 pompe d’injection ______________ 8117 bombas de inyección ___________ 8117
Spring clamp pliers _____________ 9090 Pince à ressort pour tuyaux ______ 9090 Alicates para abrazaderas elásticas 9090

Dial gauge M2T ______________ 100 400 Comparateur M2T ____________ 100 400 Comparador M2T ____________ 100 400
Measuring bar _______________ 100 750 Appareil de mesure ___________ 100 750 Equipo de medición __________ 100 750
Device for measuring and Appareil de mesure / de Equipo de medición y de
locking control rod ____________ 100 800 blocagede la crémaillère _______ 100 800 bloqueo de la cremallera _______ 100 800
Adjusting pin for Pige de réglage pour arbrea Pernos de ajuste para
mass balancing shafts ________ 100 810 à masses d’équilibrage ________ 100 810 ejes equilibradores ___________ 100 810
Measuring device ____________ 100 890 Dispositif de mesure __________ 100 890 Dispositivo de medición _______ 100 890
Graduated disk ______________ 110 020 Disque gradué _______________ 101 020 Disco graduado ______________ 101 020
Adapter for graduated disk _____ 101 030 Adaptateur pour disque gradué _ 101 030 Adaptador para disco graduado _ 101 030
Pointer for graduated disk ______ 101 300 Index ______________________ 101 300 Indicador ___________________ 101 300
Tightening angle dial indicator __ 101 910 Clé de serrage angulaire _______ 101 910 Llave de apriete angular _______ 101 910
Special wrench for injection line _ 110 500 Clé spéciale pour Llave especial para
Piston ring compressor conduite d’injection ___________ 110 500 tuberías de inyección _________ 110 500
dia. 98 mm _________________ 130 660 Collier à segments Ø 98 mm ___ 130 660 Compresor de aros de
Piston ring compressor Collier à segments Ø 101 mm __ 130 670 pistón, Ø 98 mm _____________ 130 660
dia. 101 mm ________________ 130 670 Dispositif de montage arrière ___ 142 660 Compresor de aros de
Piston ring compressor rear ____ 142 660 Dispositif de montage avant ____ 142 670 pistón, Ø 101 mm ____________ 130 670
Piston ring compressor front ____ 142 670 Dispositif d’immobilisation / amortisseur Herramienta de montaje
Dolly for torsional de vibrations torsionnelles _____ 144 800 p. retén trasero ______________ 142 660
vibration damper _____________ 144 800 Dispositif d’immobilisation Herramienta de montaje
Dolly for center nut, fan ________ 160 330 d’entraînement de ventilateur ___ 160 330 p. retén delantero ____________ 142 670
Open jawed wrench __________ 160 340 Embout à mâchoire ___________ 160 340 Dispositivo de retención p. amortiguador
de vibraciones torsionales _____ 144 800
4 Dispositivo de retención
p. accionamiento de ventilador __ 160 330
Boca enchufable _____________ 160 340
Oil injection nozzles Gicleurs d’huile Toberas de aceite para refrigeración

de pistones
1. Press-in oil injection nozzles as 1. Enfoncer les gicleurs d’huile 1. Introducir a presión las toberas
far as they will go. jusqu’en butée. hasta el tope.
4.00.15 © 2002 / 0312 0361

Motor zusammenbauen
Bügelmessschraube
Verdrehschlüssel (Vielzahn)
für E.-Pumpe _________________________ 8117
Federklemmenzange __________________ 9090
Spezialwerkzeuge:
Messuhr M2T ______________________ 100 400
Messgerät _________________________ 100 750
Messgerät / Blockiergerät
für Regelstange _____________________ 100 800
Einstellbolzen für MAG-Wellen _________ 100 810
Messvorrichtung ____________________ 100 890
Gradscheibe _______________________ 101 020
Adapter für Gradscheibe ______________ 101 030
Zeiger ____________________________ 101 300
Winkelanzugschlüssel ________________ 101 910
Hahnenfußschlüssel _________________ 110 500
Kolbenringspannband Ø 98 mm _______ 130 660
Kolbenringspannband Ø 101 mm _______ 130 670
Eindrückvorrichtung hinten ____________ 142 660
Eindrückvorrichtung vorne ____________ 142 670
Gegenhalter / Drehschwingungsdämpfer _ 144 800
Gegenhalter Lüfterantrieb _____________ 160 330
Maul-Steckaufsatz __________________ 160 340
Ölspritzdüsen
1. Ölspritzdüsen bis Anlage eindrücken.

4
30194 ©
© 2002 / 0312 0361 4.00.15

Stößel/Nockenwelle
4 2. Stößel einsetzen.
30195 ©
3. Nockenwelle einsetzen.
4 Hinweis: Gegebenenfalls für diesen Vorgang den
z Motor im Montagebock einseitig abhän-

gen.
30196 ©
6 Kurbelwellenlagerung
4. Innenmeßgerät auf 32,2 mm einstellen.
30198 ©
6 5. Paßlagerbreite der Kurbelwelle messen und

notieren. Maß „a“
Zapfenbreite normal: 32,2 + 0,04 mm

Grenzmaß für
Übermaßstufe: 32,6 + 0,04 mm
30199 ©
4.00.16 © 2003 / 0312 0361

Tappets/camshaft Poussoirs / Arbre à cames Empujadores / Arbol de levas
2. Insert tappets. 2. Mettre en place les poussoirs. 2. Meter los empujadores.
3. Install camshaft 3. Mettre en place l’arbre à cames 3. Introducir el árbol de levas.
Note: Hook up engine on one side in Nota: Pour cette opération décrocher le Nota: Para esta operación, descolgar
assembly stand for this purpose. moteur d’un côté dans le chevalet el motor en un lado del caballete
de montage. de montaje.
Crankshaft bearing Paliers de vilebrequin Apoyos del cigüeñal
4. Set internal dial gauge to 32.2 mm. 4. Ajuster l’appareil de mesure intérieure 4. Ajustar el micrómetro para interiores
sur 32,2 mm a 32,2 mm.
5. Gauge width of crankshaft thrust 5. Mesurer la largeur du palier d’ajustage 5. Medir el ancho del cojinete de
bearing and note down dimension “a”. du vilebrequin et la noter. Cote « a ». empuje del cigüeñal y apuntarlo.
Medida “a”.
Standard journal Largeur de tourillon Ancho de muñón

width: 32.2 + 0.04 mm normale: 32,2 + 0,04 mm normal: 32,2 + 0,04 mm
Valeur limite de cote Límite de
Limit for oversize: 32.6 + 0.04 mm surdimensionnée: 32,6 + 0,04 mm sobremedida: 32,6 + 0,04 mm
© 2002 / 0312 0361 4.00.16

6. Insert bearing shells. 6. Mettre en place les coussinets. 6. Colocar los semicojinetes.
7. Insert bearing shell in main 7. Mettre en place les coussinets dans 7. Colocar los semicojinetes en las
bearing cap. le chapeau de palier principal. tapas de los cojinetes de apoyo.
8. Place half thrust rings on thrust 8. Appliquer les demi-cales latérales 8. Poner las medias arandelas de tope
bearing cap. Gauge and note down sur le chapeau de palier d’ajustage, contra la cara lateral de la tapa del
width. mesurer la largeur et la noter. cojinete de empuje. Medir el ancho y
Dimension “b”. Cote »b ». apuntarlo. Medida “b”.
9. Determine end float. 9. Déterminer le jeu axial. 9. Determinar el juego axial.
Example: Dimension a = 32.23 mm Exemple: Cote a = 32,23 mm Ejemplo: medida a = 32,23 mm

Dimension b = 32.37 mm Cote b = 32,37 mm medida b = 32,37 mm
Dimension a – dimension b = end float Cote a – cote b = jeu axial medida a – medida b = juego axial
= 0.14 mm = 0,14 mm = 0,14 mm
Allowable end float: 0.10 – 0.28 mm Jeu axial admissible: 0,10 – 0,28 mm Juego axial admisible: 0,10 – 0,28 mm
4.00.17 © 2002 / 0312 0361

6. Lagerschalen einsetzen.
4
8
30200 ©
7. Lagerschalen in Hauptlagerdeckel einsetzen.

4
8
30201 ©
8. Anlaufringhälften an Paßlagerdeckel anlegen,

Breite messen und notieren.
Maß „b“.
4
8
6
4
30202 ©
9. Axialspiel ermitteln.
Beispiel: Maß a = 32,23 mm

Maß b = 32,37 mm
Maß a - Maß b = Axialspiel
= 0,14 mm
Zulässiges Axialspiel: 0,10 - 0,28 mm
© 2002 / 0312 0361 4.00.17

10. Kurbelwelle vor Einbau markieren.

i
30203 ©
11. Nockenwelle markieren und positionieren.

i
30204 ©
12. Kurbelwelle einsetzen.

4 Beim Einbau müssen die Markierungen in
Überdeckung stehen.
i
z
4
30205 ©
13. Anlaufringhälften ohne Führungsnase ein-

4 setzen.
5 Hinweis: Anlaufringe müssen mit der Laufschicht-

seite zum Wangenspiegel der Kurbel-
8 welle weisen.
30206 ©
4.00.18 © 2002 / 0312 0361

10. Mark crankshaft prior to installation. 10. Marquer le vilebrequin avant 10. Marcar el cigüeñal antes del montaje.
le montage.
11. Mark and position camshaft. 11. Marquer et positionner l’arbre 11. Marcar el árbol de levas y
à cames. posicionarlo.
12. Introduce crankshaft 12. Mettre en place le vilebrequin. 12. Colocar el cigüeñal en su sitio.
Marks must be exactly in line after Lors du montage, les marquages Las marcas deben coincidir al
installation. doivent coïncider. hacer el montaje.
13. Insert half thrust rings without 13. Monter les demi-cales latérales 13. Colocar las medias arandelas de
guide nose. sans ergot de guidage. tope sin talón de guía.
Note: The overlay sides of the thrust Nota: La surface de frottement des Nota: La cara con la capa de roce de
washers must point towards the cales latérales doit être dirigée las arandelas debe mirar a la cara
cheeck surface of the crankshaft. vers la joue du vilebrequin. de manivela del cigüeñal.
© 2002 / 0312 0361 4.00.18

14. Bond thrust washer halves to the 14. Avec un peu de graisse, coller 14. Pegar con un poco de grasa las
locating bearing cap by means les demi-cales latérales avec medias arandelas de tope con talón
of the guide nose using a small ergot de guidage sur le chapeau de guía a la cara lateral de la tapa
quantity of grease. de palier d’ajustage. del cojinete de empuje.
Note: The overlay sides of the thrust Nota: La surface de frottement des Nota: La cara con la capa de roce de
washers must point towards the cales latérales doit être dirigée las arandelas debe mirar a la cara
check surface of the crankshaft. vers la joue du vilebrequin. de manivela del cigüeñal.
15. Mount thrust bearing cap. 15. Monter le chapeau de palier 15. Montar la tapa del cojinete de
d’ajustage. empuje.
Note: Bearing cap No. 1 at flywheel end. Nota: Le chapeau de palier n° 1 se Nota: La tapa de cojinete No. 1 está en
trouve du côté volant. el lado de volante.
16. Mount main bearing caps paying 16. Monter les chapeaux de paliers 16. Montar las tapas de los cojinetes de
attention to the numbering. principaux en respectant la apoyo ateniéndose a la numeración.
numérotation.
17. Tighten main bearing bolts to the 17. Serrer les vis de paliers principaux 17. Apretar los tornillos de los cojinetes
specified tightening torque: selon prescriptions de serrage. de apoyo según prescripción.
Initial tightening torque: ____ 50 Nm Couple de préserrage ______ 50 Nm Apriete inicial ____________ 50 Nm
1st lock down angle _________ 90° 1er angle de serrage définitif ___ 90° 1er ángulo de reapriete _______ 90°
2nd lock down angle _________ 90° 2e angle de serrage définitif ___ 90° 2° ángulo de reapriete _______ 90°
4.00.19 © 2002 / 0312 0361

14. Anlaufringhälften mit Führungsnase am Pass-

lagerdeckel mit etwas Fett ankleben.
4
Hinweis: Anlaufringe müssen mit der Laufschicht- u
5
seite zum Wangenspiegel der Kurbel-
welle weisen.
8
30207 ©
15. Passlagerdeckel aufbauen

4
Hinweis: Lagerdeckel Nr. 1 ist schwungradseitig.
Neue Schrauben verwenden. 8
5
30208 ©
16. Hauptlagerdeckel entsprechend der Numerie-

4
rung montieren.
9
30209 ©
17. Hauptlagerschrauben nach Anziehvorschrift

4
festdrehen.
6
Vorspannwert ____________________ 50 Nm
1. Nachspannwinkel ________________ 90° 5
2. Nachspannwinkel ________________ 90°
30210 ©
© 2003 / 0312 0361 4.00.19

Massenausgleichswellen BF4M 2012

3 (falls vorhanden)
Motor um 180° drehen.
17.1 Verschlussschrauben herausdrehen.
30989 ©
17.2 Massenausgleichswelle einbauen.

4 Hinweis: Die Gewichtslage muss zur Ölwannen-
z dichtfläche weisen.
30990 ©
17.3 Einstellbolzen 100 810 für Massenausgleichs-

4 welle bis zum Anschlag in das Kurbelgehäuse
einschrauben.
7 Hinweis: Bohrung der Massenausgleichswelle
5
muss mit der Bohrung im Kurbelwellen-
gehäuse in Überdeckung stehen.
30991 ©
17.4 Anlaufscheibe anbauen und zur Wellenachse

4 ausrichten. Schraube festdrehen.
30992 ©
4.00.20 © 2002 / 0312 0361

Mass balancing shafts BF4M 2012 Arbres à masses d’équilibrage Ejes equilibradores BF4M 2012
(if any) BF4M 2012 (le cas échéant) (si existen)
Turn engine by 180°. Virer le moteur de 180°. Girar el motor 180°.
17.1 Turn out plug bolts. 17.1 Dévisser les bouchons filetés. 17.1 Quitar los tapones roscados.
17.2 Fit mass balancing shaft. 17.2 Monter l’arbre à masses 17.2 Montar el eje equilibrador.
d’équilibrage.
Note: The load weight side must point Nota: La position des masses doit être Nota: La masa de equilibrio debe estar
towards the oil pan sealing surface. dirigée vers le plan de joint de la orientada hacia la superficie de
cuve d’huile. asiento y cierre del cárter de aceite.
17.3 Screw adjusting pin 100 810 17.3 Visser la pige de réglage 100 810 17.3 Enroscar uno de los pernos de
for mass balancing shafts into pour arbres à masses d’équilibrage ajuste 100 810 para ejes
crankcase as far as it will go. jusqu’en butée dans le bloc-moteur. equilibradores en el bloque motor,
hasta el tope.
Note: Bore of mass balancing shaft must Nota: L’alésage de l’arbre à masse Nota: Deben coincidir los taladros
be in line with bore on crankshaft d’équilibrage doit coïncider avec existentes en el eje equilibrador y el
housing. l’alésage du bloc-moteur. bloque motor.
4
17.4 Fit thrust washer and align relative 17.4 Monter la bague de butée et l’aligner 17.4 Montar la arandela de tope y
to shaft axis. Tighten bolt. par rapport à l’axe de l’arbre. Serrer alinearla al eje del árbol equilibrador.
la vis. Apretar el tornillo.
© 2002 / 0312 0361 4.00.20

17.5 Set crankshaft cylinder 1 to TDC. 17.5 Placer vilebrequin sur PMH cyl. 1. 17.5 Girar el cigüeñal hasta que el pistón
TDC is reached once the marking Le PMH est atteint lorsque le del cilindro No. 1 esté en su PMS.
on the crankshaft coincides with repérage sur le vilebrequin se trouve Se ha alcanzado el PMS cuando
the connection line of the centre sur la ligne reliant les axes du la marca del cigüeñal se encuentra
points of crankshaft and camshaft. vilebrequin et de l’arbre à cames. sobre la línea que une los centros
del cigüeñal y el árbol de levas.
17.6 Fit idler gear and slightly press into 17.6 Monter le pignon intermédiaire et le 17.6 Poner la rueda intermedia en su sitio
recess of crankshaft gear. presser légèrement en prise dans le y presionarla ligeramente hasta que
pignon du vilebrequin. engrane con la rueda del cigüeñal.
17.7 Mark opposite teeth. 17.7 Repérer les dents opposées. 17.7 Marcar los dientes enfrentados.
17.8 Turn crankshaft clockwise 17.8 Virer le vilebrequin dans le sens 17.8 Girar el cigüeñal en el sentido de
passing 3 teeth. horaire jusqu’à ce que 3 dents soient las agujas del reloj hasta que hayan
surmontées. pasado 3 dientes.
4.00.20.1 © 2002 / 0312 0361

17.5 Kurbelwelle Zyl. 1 auf OT stellen.

OT ist dann erreicht, wenn die Markierung auf
der Kurbelwelle in Verbindungslinie der Mittel-
4
punkte von Kurbelwelle und Nockenwelle liegt.
9
30993 ©
17.6 Zwischenrad einsetzen und leicht in den Eingriff

des Zahnrades der Kurbelwelle drücken. 4
8
30994 ©
17.7 Die gegenüberliegenden Zähne markieren.

i
30995 ©
17.8 Kurbelwelle im Uhrzeigersinn drehen, bis

3 Zähne übergesprungen sind. 9
30996 ©
© 2002 / 0312 0361 4.00.20.1

17.9 Kurbelwelle entgegen dem Uhrzeigersinn

9 drehen, bis Bohrungen in Überdeckung
stehen.
30998 ©
17.10 Lagerzapfen einsetzen.

4 Hinweis: Durch leichtes Hin- und Herdrehen der
z Kurbelwelle prüfen, ob Lagerzapfen in

der Bohrung zentriert ist.
30997 ©
17.11 Neuen Runddichtring aufziehen.

4
ß
30999 ©
17.12 Befestigungsscheibe montieren

4
31000 ©
4.00.20.2 © 2002 / 0312 0361

17.9 Turn crankshaft counter-clockwise 17.9 Virer le vilebrequin dans le 17.9 Girar el cigüeñal en contra del
until bores overlap. sens anti-horaire jusqu’à ce que sentido de las agujas del reloj
les alésages coïncident. hasta que coincidan los taladros.
17.10 Insert bearing journal. 17.10 Insérer le tourillon. 17.10 Introducir el muñón de soporte.
Note: Check centered position of bearing Nota: En virant légèrement le vilebrequin Nota: Girando un poco en vaivén el
journal in bore by alternate dans les deux sens, s’assurer que le cigüeñal comprobar si el muñón
movement of the crankshaft. tourillon est centré dans l’alésage. queda centrado en el taladro.
17.11 Fit new O-ring. 17.11 Emmancher un joint torique neuf. 17.11 Colocar un anillo tórico nuevo.
17.12 Fit mounting disk. 17.12 Monter le disque de fixation. 17.12 Montar la arandela de sujeción.
© 2002 / 0312 0361 4.00.20.2

17.13 Tighten bolt 17.13 Serrer la vis. 17.13 Apretar el tornillo.
17.14 Install second mass 17.14 Monter le second arbre à 17.14 Introducir el segundo eje
balancing shaft masses d’équilibrage. equilibrador.
Note: The load weight side must face the Nota: La position des masses doit être Nota: La masa de equilibrio debe
oil pan sealing surface. dirigée vers le plan de joint de la estar orientada hacia la superficie
cuve d’huile. de asiento del cárter de aceite.
17.15 Screw adjusting pin 100 810 17.15 Visser la pige de réglage 100 810 17.15 Enroscar el segundo perno de
for mass balancing shafts into pour arbre à masses d’équilibrage ajuste 100 810 para ejes
crankcase as far as it will go. jusqu’en butée dans le bloc-moteur. equilibradores en el bloque motor,
hasta el tope.
Note: Bore of mass balancing shaft must Nota: L’alésage de l’arbre à masses Nota: Deben coincidir los taladros
overlap with bore in crankcase. d’équilibrage doit coïncider avec existentes en el eje equilibrador
l’alésage du bloc-moteur. y el bloque motor.
4
17.16 Mount thrust disk and align 17.16 Monter la bague de butée 17.16 Montar la arandela de tope
relative to axis of shaft. et l’aligner par rapport à l’axe y alinearla al eje del árbol
de l’arbre. equilibrador.
4.00.20.3 © 2002 / 0312 0361

17.13 Schraube festdrehen.
Anziehvorschrift: 22 Nm
4
6
31001 ©
17.14 Zweite Massenausgleichswelle einbauen.
Hinweis: Die Gewichtslage muss zur Ölwannen-

4
dichtfläche weisen.
z
5
31002 ©
17.15 Einstellbolzen 100 810 für Massenausgleichs-

welle in das Kurbelgehäuse bis zum An-
schlag einschrauben.
4
Hinweis: Bohrung der Massenausgleichswelle 7
5
muss mit der Bohrung im Kurbelgehäuse
in Überdeckung stehen.
31003 ©
17.16 Anlaufscheibe anbauen und zur Wellen-

achse ausrichten. 4
9
31004 ©
© 2002 / 0312 0361 4.00.20.3


31005 ©
17.18 Zwischenrad so einsetzen, dass Bohrungen

4 in Überdeckung stehen.
8
9
31006 ©
17.19 Lagerzapfen einsetzen.

4
8
z
4
31008 ©
17.20 Befestigungsscheibe montieren.

4
8
31009 ©
4.00.20.4 © 2002 / 0312 0361

17.17 Tighten bolt. 17.17 Serrer la vis 17.17 Apretar el tornillo.
17.18 Insert idler gear so as to make 17.18 Mettre en place le pignon 17.18 Colocar la rueda intermedia, de
bores overlap. intermédiaire de sorte que les modo que coincidan los taladros.
alésages coïncident.
17.19 Insert bearing journals 17.19 Insérer le tourillon. 17.19 Introducir el muñón de soporte.
17.20 Fit mounting disk. 17.20 Monter le disque de fixation. 17.20 Enroscar el tornillo de fijación.
© 2002 / 0312 0361 4.00.20.4

17.21 Tighten bolt 17.21 Serrer la vis 17.21 Apretar el tornillo.
17.22 Remove both adjusting bolts. 17.22 Enlever les deux piges de réglage. 17.22 Retirar ambos pernos de ajuste.
17.23 Turn in screw plugs together with 17.23 Visser les bouchons filetés 17.23 Enroscar los tapones con un
new Cu sealing rings and tighten. avec des bagues d’étanchéité anillo de junta de cobre nuevo
Cu neuves et les serrer. y apretarlos.
torque: 9 + 4 Nm Prescription de serrage: 9 + 4 Nm Prescripción de apriete: 9 + 4 mm
4.00.20.5 © 2002 / 0312 0361

4
6
31010 ©
17.22 Beide Einstellbolzen entfernen.

3
31011 ©
17.23 Verschlussschrauben mit neuen Cu-Dicht-

ringen einschrauben und festdrehen. 4
Anziehvorschrift: 9 + 4 Nm
ß
6
4
31012 ©
© 2002 / 0312 0361 4.00.20.5

Zwischenrad / Regler
4 18. Gewindebohrung der Befestigungsschraube im
5 Kurbelgehäuse mit Sicherungsmasse DEUTZ

DW59 benetzen. Zwischenrad für Regler mit
Lagerzapfen einsetzen.
Hinweis: Lagerstelle des Zwischenrades geringfü-

gig mit Motoröl benetzen. Motoröl darf
nicht mit dem Sicherungsmittel für die
Befestigungssschraube in Verbindung
30211 © kommen.
19. Befestigungsschraube einsetzen und fest-

4 drehen.
6 Anziehvorschrift:
Vorspannwert ________________ 30 Nm
Nachspannwinkel ________________ 90°
30212 ©
Regelstange
4 20. Regelstange mit Führungsbuchse einbauen.
30213 ©
21. Neue selbstsichernde Schraube einsetzen und

4 festdrehen.
w Anziehvorschrift: 10 + 2 Nm
30214 ©
4.00.20.6 © 2003 / 0312 0361

Idler gear / governor Pignon intermédiaire / Régulateur Rueda intermedia / Regulador
18. Wet threaded bore of fastening bolt in 18. Enduire légèrement le taraudage de la 18. Untar con un poco de freno líquido
crankcase with locking compound vis de fixation dans le carter moteur de DEUTZ DW 59 el taladro roscado del
DEUTZ DW 59 59. Insert intermediate produit de freinage DEUTZ DW 59 59. tornillo de fijación en el bloque motor.
gear for governor complete with Insérer le pignon intermédiaire du Colocar en su sitio la rueda
bearing journal. regulateur avec le tourillon. intermedia del regulador con el
muñón de soporte.
Note: Lightly oil bearing point of Nota: Huiler légèrement la portée du Nota: Untar con muy poco aceite el punto
intermediate gear. Oil must not pignon intermédiaire. L ’huile ne doit de apoyo de la rueda intermedia.
come into contact with the locking pas entrer en contact avec le produit El aceite no debe entrar en
compound for the fastening bold. de freinage de la vis de fixation. contacto con el freno líquido del
tornillo de fijación.
19. Insert fastening bolt and tighten. 19. Insérer la vis de fixation et la serrer. 19. Meter el tornillo y apretarlo.
Tightening specification: Prescription de serrage: Prescripción de apriete:

Initial tightening torque ____ 30 Nm Préserrage ______________ 30 Nm Préserrage ______________ 30 Nm
Final tightening angle _____ 90° Serrage définitif __________ 90° Reapriete _______________ 90°
Control rod Crémaillère Cremallera
20. Fit control rod with guide bushing 20. Monter la crémaillère avec la douille 20. Introducir la cremallera con el
de guidage. casquillo de guía.
21. Screw in screw and tighten according 21. Insérer la vis et la serrer 21. Enroscar el tornillo y apretarlo.
to tightening specification. selonprescription de serrage.
Specified tightening Prescription de serrage: 10 + 2 Nm Prescripción de apriete: 10 + 2 Nm

torque: 10 + 2 Nm
© 2003 / 0312 0361 4.00.20.6

Timing case cover Couvercle de carter de distribution Tapa del cárter de la distribución
22. Apply some DEUTZ DW 67 sealing 22. Enduire le plan de joint du couvercle 22. Aplicar sellante DEUTZ DW 67 a
compound to sealing surface of de carter de distribution de produit la superficie de asiento de la tapa
timing case cover. d’étanchéité DEUTZ DW 67. del cárter de la distribución.
23. Fit timing case cover. Tighten bolts 23. Monter le couvercle de carter de 23. Montar la tapa del cárter de la
finger tight and align timing case distribution. Approcher les vis et distribución. Enroscar los tornillos
cover relative to oil pan sealing aligner le couvercle de carter de con la mano y alinear la tapa con
surface. distribution par rapport au plan de respecto a la superficie de asiento
joint de la cuve d’huile. del cárter de aceite.
24. Tighten bolts. 24. Serrer les vis. 24. Apretar los tornillos.
Specified tightening Prescription de serrage: 30 ± 3 Nm Prescripción de apriete: 30 ± 3 Nm

torque: 30 ± 3 Nm
Front cover Couvercle avant Tapa delantera
25. Slightly grease rotors in front cover. 25. Huiler légèrement les rotors dans le 25. Untar con un poco de aceite los
couvercle avant. rotores situados en la tapa delantera.
4.00.21 © 2002 / 0312 0361

Räderkastendeckel
22. Dichtfläche des Räderkastendeckels mit Dicht-

4
mittel DEUTZ DW 67 bestreichen.
w
35354 ©
23. Räderkastendeckel anbauen. Schrauben bei-

drehen und Räderkastendeckel zur Ölwannen-
dichtfläche ausrichten.
4
9
30215 ©
24. Schrauben festdrehen.
Anziehvorschrift: 30 ± 3 Nm
4
6
30216 ©
Vorderer Deckel
25. Rotoren im vorderen Deckel leicht ölen.

4
z
30217 ©
© 2002 / 0312 0361 4.00.21

26. Dichtung für vorderen Deckel mit etwas Fett

4 ankleben.
u
ß
30218 ©
27. Auf Vorhandensein der Spannbuchse achten.

4
9
30219 ©
Motor 180° drehen. Ölwannnendichtfläche muss

4 nach unten weisen.
9 28. Rotor zur Kurbelwelle positionieren.
30220 ©
29. Vorderen Deckel anbauen. Deckel nach oben

4 drücken und zur Ölwannendichtfläche aus-
richten. Schrauben leicht andrehen.
9
30221 ©
4.00.22 © 2002 / 0312 0361

26. Glue on gasket for front cover using 26. Avec un peu de graisse coller le joint 26. Pegar con un poco de grasa la junta
some grease. du couvercle avant. para la tapa delantera.
27. Make sure the tension bush is 27. Veiller à la présence de la douille 27. Prestar atención a la existencia del
in place. de serrage. casquillo de sujeción.
Turn engine by 180°. Sealing surface of Virer le moteur de 180°. Le plan de Girar el motor 180°. La superficie de
oil pan must face downwards. joint de la cuve d’huile doit être dirigé asiento del cárter de aceite debe indicar
vers le bas. hacia abajo.
28. Position rotor relative to crankshaft. 28. Positionner le rotor vers le vilebrequin. 28. Posicionar el rotor con respecto
al cigüeñal.
29. Fit front cover. Press cover upwards 29. Monter le couvercle avant. Pousser 29. Montar la tapa delantera. Presionarla
and align relative to oil pan sealing le couvercle vers le haut et l’aligner hacia arriba y alinearla a la superficie
surface. Start bolts. par rapport au plan de joint de la cuve de asiento del cárter de aceite.
d’huile. Serrer légèrement les vis. Apretar los tornillos ligeramente.
© 2002 / 0312 0361 4.00.22

30. Tighten bolts. 30. Serrer définitivement les vis. 30. Apretar los tornillos.
Shaft oil seal rings Joints d’arbre Retenes del cigüeñal
-front- - avant - - Retén delantero –
31. Fit guide bushing using tool 142 670 31. Monter la douille de guidage 142 670. 31. Montar el manguito de guía 142 670.
32. Slightly oil seal lip. Carefully fit new 32. Huiler légèrement la lèvre d’étanchéité. 32. Untar con un poco de aceite el
shaft seal ring . Add spacer washers Poser le joint d’arbre neuf avec labio de obturación. Colocar el retén
according to mounting depth. précaution. Poser le nombre de nuevo cuidadosamente. Colocar el
bagues entretoise requis suivant la número de arandelas distanciadoras
profondeur d’insertion requise. que corresponda a la profundidad
de montaje.
2 washers ___________ Initial installation 2 bagues ____________ premier montage 2 arandelas ___________ primer montaje
4 1 washer _____ 1st repair mounting depth 1 bague_ 1ere profondeur d’insertion, cote rép. 1 arandela __ profundidad de montaje 1a repar.
without washers __ max. mounting depth sans bague _ profondeur d’insertion maxi. sin arandelas __ profundidad de montaje máx.
33. Fit mounting sleeve and press into 33. Mettre en place la douille de 33. Colocar el manguito de montaje e
device as far as it will go. montage et la presser dans le introducirlo a presión hasta el tope
dispositif jusqu’en butée. en el dispositivo.
Note: Shaft oil seal ring is now in its Nota: Le joint d’arbre se trouve Nota: El retén se encuentra ahora
pre-selected mounting depth. maintenant à la profondeur a su profundidad de montaje
d’insertion voulue. preseleccionada.
4.00.23 © 2002 / 0312 0361

30. Schrauben festdrehen.
4
6
30222 ©
Wellendichtringe
- vorne -
4
31. Führungshülse 142 670 anbauen. 7
30502 ©
32. Dichtlippe leicht einölen. Neuen Wellendicht-

ring vorsichtig auflegen. Anzahl Abstand-
scheiben je nach Einbautiefe auflegen.
4
2 Scheiben ____________ Erstmontage 9
7
1 Scheibe ____________ 1. Rep.-Einbautiefe
ohne Scheiben _________ max. Einbautiefe
ß 4
30504 ©
33. Montagehülse aufsetzen und bis Anlage in der

Vorrichtung eindrücken. 4
Hinweis: Wellendichtring befindet sich jetzt in
seiner vorgewählten Einbautiefe.
7
5
30506 ©
© 2002 / 0312 0361 4.00.23

- schwungradseitig -
4 34. Führungshülse 142 660 anbauen.
30507 ©
35. Dichtlippe leicht einölen. Neuen Wellendicht-

4 ring vorsichtig auflegen. Anzahl Abstand-
scheiben je nach Einbautiefe auflegen.
9 2 Scheiben ____________ Erstmontage
7
1 Scheibe ____________ 1. Rep.-Einbautiefe
ohne Scheiben _________ max. Einbautiefe
ß
30508 ©
36. Montagehülse aufsetzen und bis Anlage in der

4 Vorrichtung eindrücken.
7 Hinweis: Wellendichtring befindet sich jetzt in

seiner vorgewählten Einbautiefe.
5 Auf vorhandensein der Zentierbuchse in der

Kurbelwelle achten, ggf. einsetzen.
4
30509 ©
Kolben mit Pleuel

4 37. Pleuellagerschalen in Pleuelstange einbauen.
8
30229 ©
4.00.24 © 2002 / 0312 0361

- flywheel end - - côté volant - - Reten en el lado de volante –
34. Fit guide bushing using tool 142 660 34. Monter la douille de guidage 142 660. 34. Montar el manguito de guía 142 660.
35. Slightly oil seal lip. Carefully fit new 35. Huiler légèrement la lèvre 35. Untar con un poco de aceite el
shaft seal ring. Add spacer washes d’étanchéité. Poser le joint d’arbre labio de obturación. Colocar el retén
according to mounting depth. neuf avec précaution. Poser le nuevo cuidadosamente. Colocar el
nombre de bagues entretoise número de arandelas distanciadoras
requis suivant la profondeur que corresponda a la profundidad
d’insertion requise. de montaje.
2 washers ___________ Initial installation 2 bagues ____________ premier montage 2 arandelasprimer montaje
1 washer _____ 1st repair mounting depth 1 bague_1ere profondeur d’insertion, cote rép. 1 arandela _ profundidad de montaje 1er repar.
without washers __ max. mounting depth sans bague _ profondeur d’insertion maxi. sin arandelas __ profundidad de montaje máx.
36. Fit mounting sleeve and press into 36. Mettre en place la douille de 36. Colocar el manguito de montaje e
device as far as it will go. montage et la presser dans le introducirlo a presión hasta el tope
dispositif jusqu’en butée. en el dispositivo.
Note: Shaft oil seal ring is now in its pre- Nota: Le joint d’arbre se trouve Nota: El retén se encuentra ahora
selected mounting depth. maintenant à la profondeur a su profundidad de montaje
Make sure the centering bush is in
place, insert as necessary. Veiller à la présence de la douille Prestar atención a la existencia del 4
de centrage dans le vilebrequin, le casquillo de centraje en el cigüeñal;
cas échéant la monter. si no existe, introducirlo.
Piston complete with connecting rod Piston avec bielle Pistón con biela
37. Incorporate big end bearing shells in 37. Monter les coussinets de palier de 37. Colocar los semicojinetes en la biela.
connecting rod. bielle dans la bielle.
© 2002 / 0312 0361 4.00.24

38. Piston ring gaps must be staggered 38. Tiercer les coupes des segments de 38. Situar los cortes de los aros de pistón
by 90 – 120° relative to each other. piston de 90 – 120°. desplazados 90°–120° entre sí.
39. Turn engine by 90°. Introduce piston 39. Virer le moteur de 90°. 39. Girar el motor 90°.
complete with connecting rod into Pousser le piston complet avec Introducir el pistón completo con la
cylinder crankcase. bielle dans le bloc-cylindres. biela en el bloque motor.
Use piston ring compressor size Utiliser un collier à segments adapté Utilizar el compresor de aros que
according to piston diameter. au diamètre de piston. corresponda al diámetro del piston.
Piston ring Collier à Compresor de aros de
compressor _ 98 mm _____ 130 660 segments Ø 98 mm ______ 130 660 pistón Ø 98 mm _________ 130 660
Piston ring Collier à Compresor de aros de
compressor _ 101 mm _____ 130 670 segments Ø 101 mm ______ 130 670 pistón Ø 101 mm _________ 130 670
Note: Flywheel symbol must face Nota: Le symbole du volant doit Nota: El símbolo del volante debe indicar
towards flywheel. être dirigé vers le volant. hacia el volante.
40. Press connecting rod against 40. Pousser la bielle contre le maneton. 40. Presionar la biela contra la
crankpin. Fit pertinent big-end Monter le chapeau de palier de bielle muñequilla.
bearing cap. correspondant. Montar la tapa que corresponda
a la biela.
41. Tighten new connecting rod bolts. 41. Serrer les boulons de bielle neuves. 41. Apretar los tornillos de biela nuevos.
Specified tightening torque: Prescription de serrage: Prescripción de apriete

Initial tightening torque: ____ 30 Nm Couple de préserrage ______ 30 Nm Apriete inicial _____________ 30 Nm
1st lock down angle __________ 60° 1er angle de serrage définitif ___ 60° 1er ángulo de apriete _________ 60°
2nd lock down angle __________ 30° 2e angle de serrage définitif ___ 30° 2° ángulo de apriete _________ 30°
4.00.25 © 2002 / 0312 0361

38. Kolbenringstöße 90-120° zueinander versetzt

anordnen.
9
35355 ©
39. Motor 90° drehen.

Kolben komplett mit Pleuel in das Zylinder-
kurbelgehäuse einschieben.
4
Kolbenringspannband je nach Kolbendurch-
messer verwenden. z
7
Kolbenringspannband Ø 98 mm ___ 130 660
Kolbenringspannband Ø 101 mm ___ 130 670
Hinweis: Schwungradsymbol muss zum Schwung-

rad weisen.
5
30230 ©
40. Pleuelstange gegen den Hubzapfen drücken.

Dazugehörigen Pleuellagerdeckel montieren. 4
z
9
4
30231 ©
41. Neue Pleuelschrauben festdrehen.
Anziehvorschrift:
4
Vorspannwert ____________________ 30 Nm
1. Nachspannwinkel ________________ 60° 6
ß
30232 ©
© 2002 / 0312 0361 4.00.25

42. Pleuelstangen kontrollieren, ob sie sich auf

9 dem Hubzapfen leicht verschieben lassen.
30233 ©
Einspritzpumpen einbauen
4 Regelstangenweg messen ohne Einspritz-
7 pumpen
43. Motor um 90° drehen.

Feststellvorrichtung 100 800 für Regelstange
anbauen.
30234 ©
44. Von Vorrichtung bis zur Stopstellung der

6 Regelstange messen.
30235 ©
44.1 Von Vorrichtung bis zur Startstellung der

9 Differenz zur Stopstellung ergibt Regelstan-

genweg.
Beispiel:
Stopstellung = 30,7 mm
Startstellung = 13,4 mm
Regelstangenweg = 17,3 mm
30236 © Sollmaß = 17,0 mm - 17,5 mm
4.00.26 © 2002 / 0312 0361

42. Make sure that connecting rods 42. Contrôler les bielles, si elles se 42. Controlar si las bielas se pueden
can be easily moved back and forth laisse facilement déplacer sur le desplazar con facilidad sobre las
on the crankpin. maneton. muñequillas.
Install injection pumps Montage des pompes d’injection Montaje de las bombas de inyección
Gauge control rod travel path without Mesurer la course de crémaillère sans Medición del recorrido de la cremallera
injection pumps pompes d’injection. sin las bombas de inyección
43. Turn engine by 90°. 43. Virer le moteur de 90°. 43. Girar el motor 90°.
Fit measuring device 100 800 for Monter le dispositif de blocage Montar el dispositivo de bloqueo
control rod. 100 800 pour la crémaillère. 100 800 para cremallera.
44. Measure distance from device to 44. Mesurer la distance entre le 44. Medir del dispositivo a la posición
stop position of control rod. dispositif et la position stop de la de parada de la cremallera.
crémaillère.
44.1 Measure distance from device to 44.1 Mesurer la distance entre le 44.1 Medir del dispositivo a la posición
start position of control rod. dispositif et la position lancement de arranque de la cremallera.
de la crémaillère.
The difference start- to stop position La différence par rapport à la position La diferencia entre ambos valores
is the control rod travel path. stop donne la course de la crémaillère. da el recorrido de la cremallera.
Example: Exemple: Ejemplo:

Stop position: 30.7 mm position stop = 30,7 mm Posición de parada = 30,7 mm
Start position 13.4 mm position lancement = 13,4 mm Posición de arranque = 13,4 mm
Control rod travel path 17.3 mm course de la crémaillère = 17,3 mm Recorrido de la cremallera = 17,3 mm
Cote de
Specified size: 17.0 mm – 17.5 mm consigne = 17,00 mm – 17,5 mm Valor teórico = 17,0 mm – 17,5 mm
© 2002 / 0312 0361 4.00.26

45. Turn device. Use stop bolt for 45. Tourner le dispositif. Avec la vis 45. Girar el dispositivo. Llevar la
pressing control rod manually into de blocage, pousser manuellement cremallera a la posición de parada
stop position. la crémaillère en position stop. accionando el tornillo de bloqueo
manualmente.
46. Fit graduated disc 101 020 to 46. Monter le disque gradué 101 020 sur 46. Montar el disco graduado 101 020
flywheel flange. la bride de volant. en la brida del volante.
47. Fit pointer 101 300. 47. Monter l’index 101 300. 47. Montar el indicador 101 300.
Determine firing TDC of piston Déterminer le PMH d’allumage Determinación del PMS de compresión
corresponding to the injection pump du piston correspondant à la pompe del pistón que corresponda a la bomba
to be set d’injection à régler. de inyección a ajustar.
48. Position measuring bar 100 750 with 48. Poser la latte de mesure du PMH 48. Colocar la barra de medición de PMS
spacers for gauging TDC and piston 100 750 avec pastilles d’écartement. 100 750 con plaquitas distanciadoras.
projection. Turn crankshaft in the Virer le vilebrequin dans le sens de Girar el cigüeñal en el sentido de
sense of rotation of the engine until rotation du moteur jusqu’à ce que rotación normal del motor hasta que
the pointer of dial gauge 100 400 has l’aiguille du comparateur 100 400 la aguja del comparador 100 400
reached its point of reversal. Set dial ait atteint son point d’inversion. llegue a su punto de inversión.
gauge to “0”. Ajuster le comparateur sur « 0 ». Ajustar el comparador a “0”.
4.00.27 © 2002 / 0312 0361

45. Vorrichtung drehen. Regelstange mit Feststell-

schraube von Hand in Stopstellung drücken.
s
30237 ©
46. Gradscheibe 101 020 an Schwungradflansch

anbauen.
4
7
30238 ©
47. Zeiger 101 300 anbauen.

4
7
30239 ©
Zünd O.T. des Kolbens ermitteln, der zur einzu-

stellenden Einspritzpumpe gehört. 4
48. O.T.-Messbalken 100 750 mit Abstandsplätt-
chen auflegen. Kurbelwelle in Motordreh- 6
7
richtung drehen bis der Zeiger der Messuhr
100 400 seinen Umkehrpunkt erreicht hat.
Messuhr auf „0“ stellen.
30240 ©
© 2002 / 0312 0361 4.00.27

49. Kurbelwelle ca. 90° entgegen der Motordreh-

6 richtung drehen. Danach wieder in Motordreh-
richtung bis 8 mm vor O.T. (Umkehrpunkt der
Messuhr) drehen.
Gradscheibe auf „0“ stellen.
30241 ©
50. Kurbelwelle ca. 90° in Motordrehrichtung

6 drehen. Danach wieder entgegen der Motor-
drehrichtung bis 8 mm vor O.T. (Umkehrpunkt
der Messuhr) drehen. Ermittelten Wert ablesen.
Beispiel: 50°
30242 ©
51. Ermittelten Wert halbieren. Halbierter Wert

9 ist O.T.
Beispiel: = 0°+ 50° = 25° IST

2
Kurbelwelle auf halbierten Wert drehen.
30243 ©
52. Kurbelwelle jetzt nicht mehr verdrehen.

a 2 Rändelschrauben lösen und Gradscheibe
auf „0“ stellen.
6
30244 ©
4.00.28 © 2002 / 0312 0361

49. Turn crankshaft by approx. 90° in 49. Virer le vilebrequin d’env. 90° dans 49. Girar el cigüeñal unos 90° en contra
opposite direction to the sense of le sens inverse du sens de rotation del sentido de rotación del motor. Y,
rotation of the engine. Turn crankshaft du moteur. Le virer ensuite de luego, de nuevo en el sentido de
then again in direction of the sense nouveau dans le sens de rotation du rotación hasta 8 mm antes del PMS
of rotation of the engine until 8 mm moteur jusqu’à 8 mm avant le PMH (punto de inversión del comparador).
before TDC (dial gauge point of (point d’inversion du comparateur). Ajustar el comparador a “0”.
reversal). Ajuster le disque gradué sur « 0 ».
Set graduated disc to “0”.
50. Turn crankshaft by approx. 90° in 50. Virer le vilebrequin d’env. 90° dans le 50. Girar el cigüeñal unos 90° en contra
the sense of rotation of the engine sens de rotation du moteur. Le virer del sentido de rotación del motor. Y,
until 8 mm before TCD (dial gauge ensuite de nouveau dans le sens luego, de nuevo en el sentido de
point of reversal). Read-off indicated inverse du sens de rotation du moteur rotación hasta 8 mm antes del PMS
value. jusqu’à 8 mm avant le PMH (point (punto de inversión del comparador).
d’inversion du comparateur). Relever Leer el valor determinado.
la valeur obtenue.
Example: 50° Exemple: 50°. Ejemplo: 50°
51. Divide indicated value by 2. This 51. Diviser la valeur déterminée par 51. Dividir por dos el valor determinado.
value is the TCD value. deux. Cette valeur est le PMH. Este valor dividido por dos es el PMS.
Example: 0° + 50° = 25° specified Exemple: 0° + 50° = 25° REEL Ejemplo: 0° + 50° = 25° REAL
2 value 2 2
Turn crankshaft to this halved value. Virer le vilebrequin de cette Ajustar girando el cigüeñal al
demi-valeur. valor dividido por dos.
4
52. Crankshaft must not be moved 52. Ne plus modifier maintenant la 52. Hecho esto, no alterar la posición
any longer. position du vilebrequin. del cigüeñal.
Slacken the 2 knurled head screws Desserrer les 2 vis moletées et Aflojar los 2 tornillos moleteados y
and set graduated disc to “0”. ajuster le disque gradué sur « 0 ». ajustar el disco graduado a “0”.
© 2002 / 0312 0361 4.00.28

53. Insert roller tappets. 53. Mettre en place le poussoir à galet. 53. Introducir el empujador de rodillo.
Determine fuel delivery cut-in point – Déterminer le début d’injection Determinación del comienzo de
Bosch injection pump pompe d’injection Bosch alimentación
Bomba de inyección Bosch
The fuel delivery cut-in point and the Le début d’injection et le type El comienzo de alimentación y el tipo
type of camshaft are indicated on the d’arbre à cames figurent sur la plaque del árbol de levas figuran en la placa del
name plate. signalétique. fabricante.
54. Set dial gauge 100 400 in 54. Ajuster le comparateur 100 400 dans 54. Ajustar el comparador 100 400 en el
measuring device 100 890 to O le dispositif de mesure 100 890 avec dispositivo de medición 100 890 con
under pre-tension. précontrainte sur 0. precarga a 0.
Reference dimension: 124 mm Cote de réglage: 124 mm Medida de ajuste: 124 mm
55. Set roller tappets corresponding to 55. Placer le poussoir à galet corres- 55. Colocar el empujador de rodillo de
the injection pump to be adjusted pondant à la pompe d’injection à la bomba de inyección a ajustar,
to base circle measurement. Turn régler sur le cercle de base. Pour sobre el círculo base. Para ello, girar
crankshaft by approx. 90° in opposite cela, virer le vilebrequin d’env. el cigüeñal unos 180° en contra
direction of the engine rotation. 180° dans le sens inverse du sens del sentido de rotación del motor.
de rotation du moteur.
56. Carefully insert measuring device. 56. Insérer avec précaution le dispositif 56. Introducir cuidadosamente el
de mesure. dispositivo de medición.
4.00.29 © 2002 / 0312 0361

53. Rollenstößel einsetzen

4
z
30245 ©
Förderbeginn ermitteln
Bosch-Einspritzpumpe
9
Der Förderbeginn und der Nockenwellentyp sind
auf dem Firmenschild angegeben. 6
54. Messuhr in 100 400 Messvorrichtung
100 890 mit Vorspannung auf 0 stellen.
7
Einstellmaß: 124 mm
30246 ©
55. Rollenstößel der zur einzustellenden Einspritz-

pumpe gehört auf Grundkreis stellen. Hierzu
Kurbelwelle ca. 180° entgegen der Motordreh-
9
richtung drehen.
35356 ©
56. Messvorrichtung vorsichtig einsetzen.

4
7
r
30247 ©
© 2002 / 0312 0361 4.00.29

57. Maß „L“ messen und in

6 Tabelle, siehe Kapitel 1, eintragen.
Beispiel: 125,13 mm
35357 ©
58. Messuhr über den Außenring auf Zeiger-Null-

6 stellung drehen.
5 Hinweis: Bei der Vorhubeinstellung darf die Dreh-

richtung nicht mehr verändert werden.
30248 ©
59. Kurbelwelle in Motordrehrichtung drehen bis

9 Messuhr auf Vorhubmaß anzeigt.
Siehe Tabelle 1.
6 Beispiel: Förderbeginn 9°
Nockenwelle Typ L
Vorhub 3,95 mm
30249 ©
60. Förderbeginn IST ablesen und in Tabelle, siehe

9 Kapitel 1, eintragen.
Beispiel: 8°
30250 ©
4.00.30 © 2002 / 0312 0361

57. Gauge dimension “L” and note down 57. Relever la cote « L » et la noter dans 57. Medir la medida “L” y registrarla en
in the table, see Chapter 1. le tableau, chapitre 1. la tabla, ver capítulo 1.
Example: 125.13 mm Exemple: 125,13 mm Ejemplo: 125,13 mm
58. Turn dial gauge by means of the 58. Tourner le comparateur à l’aide de 58. Girar el comparador a través del aro
external ring to zero position of the l’anneau extérieur en position exterior hasta que la aguja esté en la
pointer. d’aiguille zéro. posición cero.
Note: When the pre-stroke has been set, Nota: Pour le réglage de la course à débit Nota: Durante el ajuste del precurso ya
the sense of rotation may not be nul, le sens de rotation ne doit plus no es admisible cambiar el sentido
changed any longer. être modifié. de giro.
59. Turn crankshaft in direction of 59. Virer le vilebrequin dans le sens de 59. Girar el cigüeñal en el sentido de
rotation of engine until dial gauge rotation du moteur jusqu’à ce que le giro del motor hasta que el
indicates size of pre-stroke. comparateur indique la cote de la comparador marque la medida del
See Table 1. course à débit nul. Voir tableau 1. precurso. Ver tabla 1.
Example:Fuel delivery cut-in point: 9° Exemple: Début d’injection 9° Ejemplo: comienzo de alimentación 9°
Camshaft type L Type d’arbre à cames L árbol de levas tipo L
Pre-stroke 3.95 mm Course à débit nul 3,95 mm precurso 3,95 mm
4
60. Read off ACTUAL fuel delivery 60. Relever le début d’injection REEL 60. Leer el comienzo de alimentación
cut-in point and enter in Table 1, et le reporter dans le tableau, REAL y registrarlo en la tabla,
see Chapter 1. voir chapitre 1. ver capítulo 1.
Example: 8° Exemple: 8° Ejemplo: 8°
© 2002 / 0312 0361 4.00.30

61. Read-off size “A” = index for injection 61. Relever la cote « A » = caractéristique 61. Leer la medida “A” = código de
pump length and enter in Table , see de longueur de pompe d’injection longitud de la bomba de inyección y
Chapter 1. et la reporter dans le tableau, voir registrarla en la tabla, ver capítulo 1.
chapitre 1.
Example: 42 Exemple: 42 Ejemplo: 42
62. Remove measuring device. 62. Démonter l’appareil de mesure. 62. Desmontar el dispositivo de medición.
Determine shim size, see Chapter 1. Déterminer les cales de réglage. Determinar las arandelas de reglaje.
Voir chapitre 1. Ver capítulo 1.
63. Place shim as determined on roller 63. Poser la cale de réglage déterminée 63. Colocar la arandela de reglaje
tappet. sur le poussoir à galet. determinada sobre el empujador
de rodillo.
Note: Measurements described under Nota: Les opérations de mesure des Nota: La operación de medición
items 48 – 63 to be carried out for points 48 à 63 sont à réaliser pour descrita en los puntos 48 a 63
each injection pump. chaque pompe d’injection. ha de repetirse para cada
bomba de inyección.
4
Injection pump Pompe d’injection Bomba de inyección
64. Turn injection pump control lever 64. Tourner le levier articulé de pompe 64. Girar la palanca de mando de
more or less to centre position. d’injection approximativement jusqu’à la bomba de inyección
la position médiane. aproximadamente a la posición
intermedia.
Note: Assembly steps described under Nota: Les opérations de montage des Nota: La operación de montaje
items 64 – 70 to be carried out for points 64 à 70 sont à réaliser pour descrita en los puntos 64 a 70
each injection pump. chaque pompe d’injection. ha de repetirse para cada
bomba de inyección.
4.00.31 © 2002 / 0312 0361

61. Maß „A“ = Kennzahl für Einspritzpumpenlänge

ablesen und in Tabelle, siehe Kapitel 1, ein-
tragen.
9
Beispiel: 42
30095 ©
62. Messgerät abbauen.
Ausgleichsscheiben ermitteln.
3
Siehe Kapitel 1.
9
30252 ©
63. Ermittelte Ausgleichsscheibe auf Rollenstößel

auflegen.
4
Hinweis: Der Messvorgang von Pos. 48 – 63 ist
für jede Einspritzpumpe durchzuführen. 5
30253 ©
Einspritzpumpe
64. Einspritzpumpenlenkhebel auf ca. Mittelstel-

9
lung drehen.
6
5
Hinweis: Der Montagevorgang von Pos. 64 - 70 ist
für jede Einspritzpumpe durchzuführen.
35358 ©
© 2002 / 0312 0361 4.00.31

65. Rollenstößel des jeweiligen Zylinders auf

4 Grundkreis stellen.
Aufnahmebohrung im Kurbelgehäuse und
9 Runddichtringe der Einspritzpumpe

Montagemittel AP 1908 bestreichen.
mit
u
Einspritzpumpenlenkhebel vorsichtig in die
Regelstange einführen.
30254 ©
66. Flansch auflegen.

4 Hinweis: Anfasung muss zum Einspritzpumpen-
5 körper weisen.
30255 ©
67. Schrauben leicht einölen und mit einem Dreh-

4 moment von 5 Nm gleichmäßig festdrehen.
z
6
4
30256 ©
68. Schrauben wieder 60° lösen.

3
6
30257 ©
4.00.32 © 2002 / 0312 0361

65. Place roller tappets of corresponding 65. Placer le poussoir à galet du cylindre 65. Colocar el empujador de rodillo
cylinder on base circle. respectif sur le cercle de base. del respectivo cilindro sobre el
Apply AP 1908 compound to Enduire l’alésage récepteur dans le círculo base.
mounting bore in crankcase and bloc-moteur et les joints toriques de Aplicar deslizante AP 1908 al
O-rings of injection pump. la pompe d’injection de produit de taladro de alojamiento en el bloque
Insert injection pump steering lever montage AP 1908. motor y a los anillos tóricos de la
carefully into control rod. Introduire avec précaution le levier bomba de inyección.
articulé de pompe d’injection dans Introducir la palanca de mando de
la crémaillère. la bomba de inyección cuidadosa-
mente en la cremallera.
66. Fit flange. 66. Poser la bride. 66. Colocar la brida.
Note: Chamfered end must face to Nota: Le lamage doit être dirigé vers le Nota: El bisel debe indicar al cuerpo de
injection pump body. corps de pompe d’injection. la bomba de inyección.
67. Slightly oil bolts and tighten uniformly 67. Huiler légèrement les vis et 67. Untar con un poco de aceite los
to a tightening torque of 5 Nm. les serrer uniformément avec tornillos y apretarlos uniformemente
un couple de 5 Nm. con un par de 5 Nm.
68. Slacken bolts again by 60°. 68. Dévisser à nouveau les vis de 60°. 68. Volver a aflojar los tornillos 60°.
© 2002 / 0312 0361 4.00.32

69. Carefully turn injection pump 69. Avec la clé polygonale tourner 69. Sirviéndose de la llave de giro,
anti-clockwise up to a noticeable doucement la pompe d’injection dans girar la bomba de inyección en
stop using a wrench. le sens anti-horaire jusqu’à ce que la contra del sentido de las agujas
butée se fasse sentir. del reloj cuidadosamente hasta
el tope perceptible.
70. Turn-in bolts again by 60° and 70. Resserrer de nouveau les vis de 60° 70. Apretar los tornillos de nuevo 60° y,
gradually tighten to a tightening et ensuite par passes successives luego, apretarlos en fases de 7 Nm,
torque of 7 Nm, 10 Nm and 30 Nm. avec un couple de 7 Nm, de 10 Nm 10 Nm y 30 Nm.
et de 30 Nm.
Note: Start with the corresponding Nota: Commencer par les vis externes, Nota: Comenzar siempre con el tornillo
external bolt – the one remotest éloignées du volant. exterior, más alejado del volante.
from the flywheel.
Gauge control rod travel path with Mesurer la course de la crémaillère Medición del recorrido de la cremallera
injection pumps avec pompes d’injection con las bombas de inyección puestas
71. Remove retaining bolt from device. 71. Dévisser la vis de blocage du 71. Desenroscar el tornillo de bloqueo
Turn device. dispositif. Tourner le dispositif. del dispositivo. Girar éste.
72. Gauge distance from device to 72. Mesurer la distance entre le 72. Medir del dispositivo a la posición
control rod stop position. dispositif et la position de stop de parada de la cremallera.
4.00.33 © 2002 / 0312 0361

69. Einspritzpumpe mit Verdrehschlüssel gegen

Uhrzeigersinn vorsichtig bis zum fühlbaren
Anschlag drehen.
4
6
30258 ©
70. Schrauben wieder 60° festdrehen und in

Stufen mit einem Drehmoment von 7 Nm,
10 Nm und 30 Nm festdrehen.
4
Hinweis: Mit der jeweils außenliegenden, vom 6
5
Schwungrad entfernteren Schraube be-
ginnen.
30259 ©
Regelstangenweg messen mit Einspritzpumpen
71. Feststellschraube aus Vorrichtung heraus-

3
schrauben. Vorrichtung drehen.
30260 ©
72. Von Vorrichtung bis zur Stopstellung der Regel-

stange messen. 6
30262 ©
© 2002 / 0312 0361 4.00.33

72.1 Von Vorrichtung bis zur Startstellung der

9 Differenz zur Stopstellung ergibt Regel-

stangenweg.
Beispiel:
Stopstellung = 30,5 mm
Startstellung = 13,4 mm
Regelstangenweg = 17,1 mm
30261 © Regelstangenweg mindestens 16,8 mm
Leichtgängigkeit der Regelstange prüfen

9 73. Beim langsamen Hineinschieben der Regel-
stange darf kein ungleichmäßiger Widerstand
auftreten.
Nach dem Loslassen muß die
Regelstange durch die Feder aus jeder Position
in die Ausgangslage zurückgedrückt werden.
30514 ©
74. Feststellvorrichtung, Zeiger und Gradscheibe

3 abbauen.
30263 ©
Regelstangen-Rückstandsmaß messen für

6 Regleranpassung
75. Rückstandsmaß vom Räderkastendeckel bis

zur Stopstellung messen.
Dieses ermittelte Maß ist bei Regleraustausch

oder Reglerreparatur unbedingt anzugeben.
30264 ©
4.00.34 © 2002 / 0312 0361

72.1 Gauge distance from device to 72.1 Mesurer la distance entre le 72.1 Medir del dispositivo a la posición
control rod start position. dispositif et la position lancement de arranque de la cremallera.
The difference between start and La différence par rapport à la La diferencia entre ambos
stop positions is the control rod position stop donne la course de la valores da el recorrido de la
travel path. crémaillère. cremallera.
Example: Exemple: Ejemplo:

Stop position: 30.5 mm position stop = 30,5 mm Posición de parada = 30,5 mm
Start position: 13.4 mm position lancement = 13,4 mm Posición de arranque = 13,4 mm
Control rod travel path 17.1 mm course de la crémaillère = 17,1 mm Recorrido de la cremallera = 17,1 mm
Control rod Recorrido de la
travel path minimum 16.8 mm Cote de consigne minimale 16,8 mm cremallera mínimo 16,8 mm
Check ease of movement of control rod Contrôler la crémaillère quant à Comprobación de la facilidad de
d’éventuels points durs movimiento de la cremallera
73. Slow insertion of the control rod 73. En enfonçant lentement la 73. Al introducir lentamente la
may not give rise to any irregular crémaillère, aucune résistance cremallera no debe sentirse ninguna
resistance. irrégulière ne doit se produire. resistencia desigual.
After release the control rod must Après avoir été lâchée, la crémaillère Después de soltar la cremallera
be pressed back into home position doit être repoussée de toute position debe volver por la acción del
from any other position. dans la position initiale par le ressort. resorte desde cualquier posición a
su posición de partida.
74. Remove retaining device, pointer 74. Démonter le dispositif de blocage, 74. Desmontar el dispositivo de bloqueo,
and graduated disc. l’index et le disque gradué. el indicador y el disco graduado.
Gauge control rod recess dimension Mesurer le retrait de crémaillère pour Medición del retroceso de la cremallera
for governor adjustment l’adaptation au régulateur para la adaptación del regulador
75. Gauge recess dimension timing 75. Mesurer le retrait entre le 75. Medir el retroceso de la tapa del
case cover – stop position. couvercle de carter de distribution cárter de la distribución a la posición
jusqu’à la position stop. de parada.
This dimension must be indicated La cote ainsi déterminée doit En caso de sustitución o reparación
for a replacement or repair of the toujours être indiquée en cas de del reguladur, habrá, imprescindi-
governor. remplacement ou de réparation blemente, que indicar esta medida
du régulateur. determinada.
© 2002 / 0312 0361 4.00.34

Flywheel Volant Volante
76. Fit flywheel, using a self-made 76. Monter le volant en utilisant un 76. Montar el volante utilizando un
guide mandrel. mandrin de guidage confectionné mandril de guía de confección propia.
Retain flywheel. Tighten bolts. sur place. Immobiliser le volant. Retener el volante.
Serrer les vis. Apretar los tornillos.
Specified tightening torque: Prescription de serrage: Prescripción de apriete:

Initial tightening torque: Couple de préserrage Apriete inicial
All bolts: ________________ 30 Nm toutes les vis _____________ 30 Nm Todos los tornillos _________ 30 Nm
1st lock down angle: 1er angle de serrage définitif 1er ángulo de reapriete
All bolts: __________________ 60° toutes les vis _______________ 60° Todos los tornillos ___________ 60°
2nd lock down angle: 2e angle de serrage définitif 2° ángulo de reapriete

Bolts, 30 mm long ___________ 30° vis de 30 mm de long ________ 30° Tornillos de 30 mm de largo ___ 30°
Bolts 35 – 85 mm long _______ 60° vis de 35 – 85 mm de long ____ 60° Tornillos de 35 – 85 mm de largo 60°
Note: Bolts if proven to be fit for use can Nota: A condition de le consigner, Nota: En caso de comprobabilidad, los
be re-used max. 5 times. les vis peuvent être réutilisées tornillos son utilizables 5 veces como
au maximum 5 fois. máximo.
76.1 Knock locking plugs into thread 76.1 Le cas échéant, enfoncer les 76.1 En su caso, introducir golpeando
bores if necessary. bouchons filetés dans les alésages. tapones en los taladros roscados.
Adapter housing Carter d’adaptation Cárter de adaptación
77. Insert tension bushings. 77. Insérer les douilles de serrage. 77. Meter los casquillos de sujeción.
Fit adapter housing and tighten Monter le carter d’adaptation et Montar el cárter de adaptación y
bolts cross-wise. serrer les vis en croix. apretar, alternando en cruz, los
tornillos.
Bolts M12 _______________ 99 Nm Vis M 12 ________________ 99 Nm Tornillos M 12 ____________ 99 Nm
4 Bolts M16 ______________ 243 Nm Vis M 16 _______________ 243 Nm Tornillos M 16 ___________ 243 Nm
Note: Use Torx wrench socket E14, 8113 Nota: Utiliser les clés à douille Torx E14, Nota: Utilizar las llaves de vaso Torx E14,
and E20, 8114. 8113, et E20, 8114. 8113, y E20, 8114.
Ribbed V-belt pulley / torsional Poulie à courroie trapézoïdale Polea para correa nervada
vibration damper nervurée / amortisseur de vibrations trapezoidal / Amortiguador de
torsionnelles vibraciones torsionales
78. Insert tension bushing and tension 78. Le cas échéant, insérer la douille 78. Introducir el casquillo de sujeción y el
pin as necessary. de serrage et la goupille de centrage pasador de sujeción en el cigüeñal, si
dans le vilebrequin. es necesario.
4.00.35 © 2002 / 0312 0361

Schwungrad
76. Schwungrad unter Verwendung eines selbst-

4
gefertigten Führungsdornes anbauen.
Schwungrad gegenhalten. Schrauben fest-
drehen.
Anziehvorschrift:
Vorspannwert
Alle Schrauben __________________ 30 Nm
1. Nachspannwinkel 30266 ©
Alle Schrauben ____________________ 60°
2. Nachspannwinkel
Schrauben 30 mm lang ______________ 30°
Schrauben 35 - 85 mm lang __________ 60°
4
Hinweis: Schrauben können bei Nachweisbarkeit
max. 5x verwendet werden.
76.1 Gegebenenfalls Verschlussstopfen in die Ge-

windebohrungen eintreiben.
31115 ©
Anschlussgehäuse
77. Spannbuchsen einsetzen. Anschlussgehäuse

4
anbauen und Schrauben über kreuz fest-
drehen.
Anziehvorschrift:
Schrauben M 12 _________________ 99 Nm
Schrauben M 16 ________________ 243 Nm 4
Hinweis: Torx-Steckschlüssel E14, 8113 und E20,
8114 verwenden. 35408 ©
Keilrippenscheibe / Drehschwingungsdämpfer
78. Gegebenfalls Spannbuchse und Spannstift in

4
Kurbelwelle einsetzen.
30267 ©
© 2002 / 0312 0361 4.00.35

79. Bei der Montage des Drehschwingungsdämpfers

9 muss die Markierung in der Kurbelwelle und
im Drehschwingungsdämpfer in Überdeckung
stehen.
35280 ©
80. Drehschwingungsdämpfer anbauen und mit

4 Gegenhalter 144 800 gegenhalten.
Schrauben festdrehen.
6 Anziehvorschrift:
5
Vorspannwert ____________________ 30 Nm

den. Schrauben können bei Nachweis-
30268 © barkeit max. 5x verwendet werden.
Zylinderkopf
4 81. Zylinderkopfdichtung bestimmen.
7 81.1 Messbalken mit Abstandsplättchen 100 750
6
auf die Dichtfläche des Zylinderkurbelge-
häuses legen und Messuhr 100 400 auf „0“
stellen.
4
30269 ©
81.2 Messuhr an den Messpunkten auf den Kolben

4 setzen und den größten Kolbenüberstand
ermitteln.
6 Hinweis: Alle Kolben müssen vermessen werden.
30270 ©
4.00.36 © 2002 / 0312 0361

79. When fitting the torsional vibration 79. Lors du montage de l’amortisseur 79. Al hacer el montaje del amortiguador
damper, the markings on crankshaft de vibrations torsionnelles, les de vibraciones torsionales es
and torsional vibration damper must repérages sur le vilebrequin et necesario que las marcas puestas
overlap. l’amortisseur de vibrations doivent en el cigüeñal y el amortiguador de
coïncider. vibraciones torsionales coincidan.
80. Fit torsional vibration damper 80. Monter l’amortisseur de vibrations 80. Montar el amortiguador de
and retain using dolly 144 800. torsionnelles et l’immobiliser avec le vibraciones torsionales y retener
Tighten bolts. dispositif 144 800. Serrer les vis. utilizando el dispositivo 144 800.

Initial tightening torque: ____ 30 Nm Couple de préserrage ______ 30 Nm Apriete inicial ____________ 30 Nm
1st lock down angle __________ 60° 1er angle de serrage définitif __ 60° 1er ángulo de reapriete _______ 60°
Note: Use Torx wrench socket 8114. Nota: Utiliser la clé à douille Torx E20, Nota: Utilizar la llave de vaso Torx E20,
Bolts if proven to be fit for use can 8114. A condition de le consigner, 8114. En caso de comprobabilidad,
be re-used 5 times. les vis peuvent être réutilisées au los tornillos son utilizables 5 veces
maximum 5 fois. como máximo.
Cylinder head Culasse Culata
80. Select cylinder head gasket. 81. Déterminer le joint de culasse. 81. Determinación de la junta de culata.
81.1 Place measuring bar with spacers 81.1 Poser la latte de mesure avec 81.1 Poner la barra de medición
100 750 on sealing surface of pastilles d’écartement 100 750 sur 100 750 con plaquitas distancia-
cylinder crankcase and set dial le plan de joint du bloc-cylindreszet doras sobre la superficie de
gauge 100 400 to “0”. ajuster le comparateur 100 400 asiento del bloque motor y ajustar
sur « 0 ». el comparador 100 400 a “0”. 4
81.2 Place dial gauge on reference 81.2 Placer le comparateur sur le 81.2 Aplicar el comparador al pistón en
points of piston and determine piston aux points de mesure et los puntos de medición y determinar
largest piston projection. déterminer le plus grand el saliente máximo de éste.
dépassement de piston.
Note: All pistons must be gauged. Nota: Le relevé doit être fait sur tous Nota: Se han de medir todos los pistones.
les pistons.
© 2002 / 0312 0361 4.00.36

81.3 Observe reference points. 81.3 Respecter les points de mesure. 81.3 Observar los puntos de medición.
81.4 Compare highest value with that of 81.4 Comparer la plus grande valeur 81.4 Comparar el valor máximo con la
table and select the corresponding avec le tableau et déterminer le joint tabla y determinar la junta de culata
cylinder head gasket. de culasse correspondant. correspondiente.
Piston projection Code on cylinder Dépassement Repérage des Saliente de pistón Identificación de
head gasket de piston joints de culasse la junta de culata
0.33 – 0.55 mm 1 hole 0,33 – 0,55 mm 1 trou 0,33 – 0,55 mm 1 orificio

0.56 – 0.65 mm 2 holes 0,56 – 0,65 mm 2 trous 0,56 – 0,65 mm 2 orificios
0.66 – 0.76 mm 3 holes 0,66 – 0,76 mm 3 trous 0,66 – 0,76 mm 3 orificios
82. Fit new cylinder head gasket. 82. Poser le joint de culasse neuf. 82. Colocar la junta de culata nueva.
Note: Sealing surface of cylinder head Nota: Les plans de pose du joint de Nota: Las superficies de asiento de la
gasket must be clean and free culasse doivent être propres et junta de culata deben estar limpias
from oil. Make sure mounting sans d’huile. Veiller à la présence y exentas de aceite. Prestar
sleeves are fitted. des douilles d’ajustage. atención a los casquillos de ajuste.
83. Mount cylinder head. 83. Monter la culasse. 83. Colocar la culata.
4.00.37 © 2002 / 0312 0361

81.3 Messpunkte beachten.

9
35359 ©
81.4 Größten Wert mit der Tabelle vergleichen und

entsprechende Zylinderkopfdichtung ermitteln. 9
Kolbenüberstand Kennzeichnung der
Zylinderkopfdichtung
0,33 - 0,55 mm 1 Loch

0,56 - 0,65 mm 2 Löcher
0,66 - 0,76 mm 3 Löcher
30271 ©
82. Neue Zylinderkopfdichtung auflegen.
Hinweis: Dichtflächen für Zylinderkopfdichtung

4
müssen sauber und ölfrei sein. Auf
Passhülsen achten. ß
8
5 4
30272 ©
83. Zylinderkopf aufsetzen.

4
35360 ©
© 2002 / 0312 0361 4.00.37

Hinweis: Dichtflächen müssen sauber und ölfrei

4 sein. Auf Vorhandensein der Spannstifte
achten.
z Zylinderkopfschrauben können bei Nach-

weisbarkeit 5x verwendet werden.
5 84. Kurze Zylinderkopfschrauben leicht einölen,

beidrehen und Stoßstangen einsetzen.
30280 ©
85. Kipphebelböcke montieren und zu den Stoß-

4 stangen/Ventilen ausrichten.
35361 ©
86. Lange Zylinderkopfschrauben leicht einölen,

4 beidrehen und Stoßstangen einsetzen. M8
Schrauben einsetzen und beidrehen.
z Hinweis: Zylinderkopfschrauben können bei
5
Nachweisbarkeit max. 5x verwendet
werden.
35362 ©
87. M8 Schrauben mit einem Drehmoment von

4 21 Nm festdrehen.
35363 ©
4.00.38 © 2002 / 0312 0361

Note: Sealing surfaces must be clean Nota: Les plans de joint doivent être Nota: Las superficies de asiento deben
and free from oil. Make sure tension propres et sans d’huile. Veiller estar limpias y exentas de aceite.
pins are fitted. à la présence des goupilles de Prestar atención a los casquillos
Cylinder head screws – if proven centrage. de ajuste.
to be fit for use - can be re-used A condition de le consigner, les En caso de comprobabilidad,
5 times. boulons de culasse peuvent être los tornillos son utilizables 5 veces
réutilisées au maximum 5 fois. como máximo.
84. Slightly oil short cylinder head 84. Huiler légèrement les boulons 84. Untar con un poco de aceite los
screws, tighten finger-tight and de culasse courts, faire un serrage tornillos de culata cortos, enroscarlos
insert thrust rods. d’approche et insérer les tiges con la mano e introducir las varillas
de poussoirs. de empuje.
85. Mount rocker arm brackets and align 85. Monter les supports de culbuteurs 85. Montar los soportes de balancines
relative to thrust rods/ valves. et les aligner par rapport aux tiges y alinearlos a las varillas de empuje /
de poussoir/soupapes. válvulas.
86. Slightly oil long cylinder head screws, 86. Huiler légèrement les boulons de 86. Untar con un poco de aceite los
tighten finger – tight and insert thrust culasse longs, faire un serrage tornillos de culata largos, enroscarlos
rods. Insert M8 screws and tighten. d’approche et insérer les tiges de con la mano e introducir las varillas
poussoirs. Mettre en place les vis de empuje. Meter los tornillos M8 y
M8 et faire un serrage d’approche. enroscarlos con la mano.
Note: Cylinder head screws – if proven Nota: A condition de le consigner, les Nota: En caso de comprobabilidad, los
to be fit for use - can be re-used boulons de culasse peuvent être tornillos de culata son utilizables
5 times. réutilisées au maximum 5 fois. 5 veces como máximo. 4
87. Tighten M8 bolts to a tightening 87. Serrer définitivement les vis M8 87. Apretar los tornillos M8 con un par
torque to 21 Nm. avec un couple de 21 Nm. de 21 Nm.
© 2002 / 0312 0361 4.00.38

88. Tighten cylinder head screws: 88. Serrer définitivement les boulons 88. Apretar los tornillos de culata.
de culasse.

Initital tightening torque: Couple de préserrage Apriete inicial
1st stage _________________ 40 Nm 1ère passe _______________ 40 Nm 1a fase ___________________ 40 Nm
2nd stage ________________ 70 Nm 2ème passe ______________ 70 Nm 2a fase ___________________ 70 Nm
Re-tightening angle _________ 180° angle de serrage définitif _____ 180° Reapriete _________________ 180°
Note: Observe sequence for the Nota: Respecter l’ordre de serrage des Nota: Observar el orden de sucesión al
tightening of the cylinder head boulons de culasse et utiliser la clé apretar los tornillos de culata y
screws and use tightening angle de serrage angulaire 101 910. utilizar la llave de apriete angular
dial indicator 101 910. Voir Caractéristiques techniques – 101 910.
See Technical Data – “Valve « Réglage du jeu des soupapes » Ver “Datos técnicos” – “Ajuste del
clearance setting”, Chapter 2. voir chapitre 2. juego de válvulas”, ver cap. 2.
Charge air pipe Collecteur d’admission Tubería de aire de sobrealimentación
89. Place charge air pipe with sealing 89. Poser le collecteur d’admission avec 89. Depositar la tubería de aire de
surface showing upwards. le plan de joint dirigé vers le haut. sobrealimentación con la superficie
Insert bolts into the charge air pipe Insérer les vis dans le collecteur de cierre indicando hacia arriba.
from below and slide new gaskets d’admission par le bas et pousser des Introducir los tornillos desde abajo en
onto screw thread. joints neufs sur le filetage. la tubería de aire de sobrealimen-
tación y colocar juntas nuevas sobre
la rosca de los tornillos.
Note: Gaskets are kept in place by Nota: Les joints sont retenus par les vis. Nota: Son los tornillos que retienen
the bolts. las juntas.
90. Place charge air pipe 90. Poser le collecteur d’admission avec 90. Colocar la tubería de aire de
together with gaskets onto les joints sur la culasse. sobrealimentación con las juntas
cylinder head. Faire d’abord un serrage d’approche sobre la culata.
de toutes les vis. Apretar, primeramente, con la mano
todos los tornillos.
4
Start all bolts first. Serrage définitif des vis. Luego, apretar los tornillos según
prescripción.
Specified tightening torque: 11 Nm Prescription de serrage: 11 Nm
Prescripción de apriete: 11 Nm
91. Tighten bolt for charge 91. Serrer les vis pour l’attache du 91. Apretar el tornillo para el
air pipe holder. collecteur d’admission. soporte de la tubería de aire
de sobrealimentación.
4.00.39 © 2002 / 0312 0361

88. Zylinderkopfschrauben festdrehen.
Anziehvorschrift:
4
Vorspannwert
1. Stufe ________________________ 30 Nm 6
5
2. Stufe ________________________ 80 Nm
Nachspannen _____________________ 90°
Hinweis: Reihenfolge beim Anziehen der Zylinder-

kopfschrauben beachten und Winkelan-
zugschlüssel 101 910 verwenden.
Siehe Techn. Daten - „Ventilspiel ein- 35364 ©
stellen“ siehe Kap. 2
Ladeluftleitung
4
89. Ladeluftleitung mit Dichtfläche nach oben ß
5
ablegen.
Schrauben von unten in die Ladeluftleitung
einsetzen und neue Dichtungen auf das
Schraubengewinde schieben.
Hinweis: Dichtungen werden von den Schrauben

gehalten. 35365 ©
90. Ladeluftleitung zusammen mit den Dichtungen

auf den Zylinderkopf aufsetzen.
Alle Schrauben zuerst beidrehen.
4
Schrauben festdrehen. 6
35366 ©
91. Schraube für Halter der Ladeluftleitung fest-

drehen. 4
6
35339 ©
© 2003 / 0312 0361 4.00.39

Abgassammelrohr
4 92. Abgassammelrohr mit neuen Dichtungen an-
ß bauen.
6
Hinweis: Sechskantmuttern, beginnend von der
Passlochbohrung (mittig) spiralförmig
nach außen gehend, festdrehen.
5 Sechskantmuttern mit DEUTZ S1
Never Seize Paste bestreichen.
35368 © Anziehvorschrift: 25 Nm
Abgasturbolader
4 93. Abgasturbolader mit neuer Dichtung anbauen.
ß Hinweis: Sechskantmuttern mit DEUTZ S1
6
Never Seize Paste bestreichen
5
35369 ©
Ölrücklaufrohr
4 94. Ölrücklaufrohr-Oberteil mit neuer Dichtung an
ß Abgasturbolader festdrehen
6
35370 ©
95. Neue Runddichtringe auf Ölrücklaufrohrunter-

4 teil aufziehen.
ß Hinweis: Dichtringe mit Montagemittel AP1908 be-

streichen.
u Ölrücklaufrohr-Teile zusammenschieben.
Ölrücklaufrohr-Unterteil in das Kurbel-
gehäuse eindrücken.
5
35371 ©
4.00.40 © 2002 / 0312 0361

Exhaust manifold Collecteur d’échappement Colector de escape
92. Fit exhaust manifold with 92. Monter le collecteur d’échappement 92. Montar el colector de escape con
new gaskets. avec des joints neufs. junta nuevas.
Note: Tighten nuts starting from the Nota: Serrer les écrous en commençant Nota: Apretar las tuercas comenzando
location hole bore (centric) par l’alésage d’ajustage (au centre) por el taladro de ajuste
and proceed in spiral form in et en poursuivant sous forme (central) y avanzando en espiral
outward direction. hélicoïdale vers l’extérieur. hacia el exterior.
Coat nuts with DEUTZ S1 Enduire les écrous de pâte Aplicar a las tuercas pasta
Never Seize Compound. Never Seize DEUTZ S1. Never Seize DEUTZ S1.
Exhaust gas turbocharger Turbocompresseur à gaz Turbocompresor

d’échappement
93. Fit exhaust gas turbocharger 93. Monter le turbocompresseur avec 93. Montar el turbocompresor con una
with new seal. des joints neufs. junta nueva.
Note: Apply DEUTZ S 1 Never Seize Nota: Enduire les écrous de pâte Nota: Aplicar a las tuercas pasta
Compound to nuts. Never Seize DEUTZ S1. Never Seize DEUTZ S1.
Oil return pipe Conduite de retour d’huile Tubo de retorno de aceite
94. Mount upper part of oil return pipe 94. Serrer l’élément supérieur de 94. Unir, provisto de una junta nueva,
with new gasket to turbocharger and conduite de retour d’huile avec un el extremo del tramo superior del
tighten. joint neuf sur le turbocompresseur. tubo de retorno de aceite al
turbocompresor, apretándolo.

4
95. Mount new O-rings to lower part 95. Emmancher des joints toriques 95. Colocar anillos tóricos nuevos
of oil return pipe. neufs sur l’élément inférieur de sobre el tramo inferior del tubo de
conduite de retour d’huile. retorno de aceite.
Note: Apply AP1908 compound to Nota: Enduire les joints de produit Nota: Aplicar deslizante AP 1908 a
O-rings. de montage AP 1908. los anillos tóricos.
Slide oil return pipe components Emmancher les éléments de Unir los tramos del tubo de
together. Press lower part of conduite de retour d’huile les retorno de aceite. Introducir a
oil return pipe into crankcase. uns dans les autres. presión el tramo inferior del
Enfoncer l’élément inférieur tubo en el bloque motor.
de conduite de retour d’huile
dans le bloc-moteur.
© 2002 / 0312 0361 4.00.40

96. Fix lower part of oil return pipe to 96. Visser l’élément inférieur de conduite 96. Atornillar el tramo inferior del tubo
crankcase by use of the mounting de retour d’huile avec l’étrier de de retorno de aceite con el estribo de
bracket. retenue sur le bloc-moteur. sujeción al bloque motor.
97. Fit lube oil pipe. 97. Monter la tuyauterie d’huile de 97. Montar la tubería de aceite lubricante.
graissage.
Note: Pre-oil exhaust gas turbocharger Nota: Prégraisser le turbocompresseur Nota: Preaceitar el turbocompresor
by putting some drops of engine oil par un jet d’huile moteur dans proyectando una gota de aceite de
into the oil feed bore. l’alésage d’arrivée d’huile. motor al interior del conducto de
alimentación de aceite.
Fit hollow screws with new Cu seals. Monter les vis creuses avec des Montar los tornillos racor con anillos
joints Cu neufs. de junta de cobre nuevos.
98. Fix upper part of oil return pipe to 98. Serrer l’élément supérieur de 98. Atornillar el tramo superior del
lower part of oil return pipe and conduite de retour d’huile sur tubo de retorno de aceite al tramo
mount lube oil line to oil return line l’élément inférieur de conduite de inferior y la tubería de aceite
by screwing. retour d’huile et la tuyauterie d’huile lubricante a la tubería de retorno
sur la conduite de retour d’huile. de aceite.
Starter Démarreur Arrancador
99. Mount starter, start and tighten bolts. 99. Présenter le démarreur, insérer les 99. Presentar el arrancador, enroscar
vis et les serrer. y apretar los tornillos.
4.00.41 © 2002 / 0312 0361

96. Ölrücklaufrohr-Unterteil mit Haltebügel an

Kurbelgehäuse festschrauben.
4
6
35372 ©
97. Schmierölleitung anbauen
Hinweis: Abgasturbolader durch einen Spritzer

4
Motoröl in die Ölzulaufbohrung vorölen.
z
5
Hohlschrauben mit neuen Cu-Dichtringen an-
bauen.
0
6 35373 ©
98. Ölrücklaufrohr-Oberteil an Ölrücklaufrohr-Un-

terteil und Schmierölleitung an Ölrücklauf-
leitung festschrauben.
4
35374 ©
Starter
99. Starter ansetzen, Schrauben eindrehen und

4
festdrehen.
6
35375 ©
© 2002 / 0312 0361 4.00.41

100. Kabelstecker (Klemme 50) befestigen.

4 Anziehvorschrift: 1,3 Nm
6 Hinweis: Kabel spannungsfrei verlegen und an
5
den Haltern befestigen.
35376 ©
Regler
4 101. Dichtmittel DEUTZ DW 73 erhaben in die
w Nuten des Räderkastens einfüllen.
5
Hinweis: Dichtfläche muss öl- und fettfrei
sein.
35377 ©
102. Dichtmittel DEUTZ DW 73 auf den Regler auf-

4 tragen. Dichtfadenstärke 1,5 mm.
Hinweis: Dichtfläche muss öl- und fettfrei sein.

Ggf. Reglerzahnrad etwas verdrehen um
ein Einspuren zu ermöglichen.
35378 ©
103. Regler anbauen

4 Hinweis: Beim Austausch des Reglers ist das vor-
6 handene Regelstangenrückstehmaß am
neuen Regler einzustellen.
Anziehvorschrift: 17 ± 1,5 Nm
Anziehreihenfolge der Schrauben
1 - 2 - 3 - 4 - 5.
35379 ©
4.00.42 © 2002 / 0312 0361

100. Fix cable connector 100. Fixer le connecteur de câble 100. Fijar el enchufe de cable
(terminal 50). (borne 50). (borne 50).
Note: Install cable so as to produce no Nota: Poser le câble sans contrainte et Nota: Colocar el cable sin tensión y fijarlo
tensile stress and fix to holders. le fixer sur les attaches. en los sujetadores.
Governor Régulateur Regulador
101. Apply ample quantities of 101. Remplir les rainures du carter de 101. Colmar las ranuras del cárter
DEUTZ DW 73 to timing case distribution de produit d’étanchéité de la distribución con sellante
grooves. DEUTZ DW 73. DEUTZ DW 73.
Note: Sealing surface must be free Nota: Le plan de joint doit être exempt Nota: La superficie de cierre debe estar
from oil and grease. d’huile et de graisse. exenta de aceite y grasa.
102. Apply DEUTZ DW 73 sealing 102. Appliquer le produit d’étanchéité 102. Aplicar sellante DEUTZ DW 73
compound to governor. Thickness DEUTZ DW 73 sur le régulateur. al regulador. Espesor del hilo de
of sealing bead 1.5 mm. Epaisseur du cordon d’étanchéité sellante: 1,5 mm.
1,5 mm.
Note: Sealing surface must be free from Nota: Le plan de joint doit être exempt Nota: La superficie de cierre debe
oil and grease. Slightly turn d’huile et de graisse. Le cas estar exenta de aceite y grasa.
governor gear, if necessary, to échéant, tourner un peu le pignon En su caso, girar algo la rueda
permit meshing. du régulateur pour permettre dentada del regulador para 4
l’engrènement. posibilitar el engrane.
103. Fit governor. 103. Monter le régulateur. 103. Montar el regulador
Note: When replacing the governor, Nota: En cas de remplacement du Nota: En caso de sustitución del
existing dimension of control rod régulateur, ajuster le même retrait regulador es necesario ajustar
recess must be set on the new de crémaillère sur le nouveau en el regulador nuevo la
governor. régulateur. medida de retroceso ya
existente de la cremallera.
Specified tightening Prescription de Prescripción

torque: 17 ± 1.5 Nm serrage: 17 ± 1,5 Nm de apriete: 17 ± 1,5 Nm
Bolt tightening Ordre de serrage Orden de sucesión para el apriete
sequence: 1 - 2 - 3 - 4 - 5. des vis 1 - 2 - 3 - 4 - 5. de los tornillos. 1 - 2 - 3 - 4 - 5.
© 2002 / 0312 0361 4.00.42

Injection valves / injection lines Injecteurs / tuyauteries d’injection Inyectores / Tuberías de inyección
104. Slide new sealing ring to injection 104. Pousser un joint neuf avec un peu 104. Colocar el anillo de junta nuevo con
valve using some grease and insert de graisse sur l’injecteur et insérer un poco de grasa sobre el inyector e
injection valve. l’injecteur. introducir éste.
Note: The notch on the injection valve Nota: Le lamage sur l’injecteur doit Nota: El rebaje existente en el inyector
must face away from the tensioning être dirigé vers le côté opposé à debe estar orientado hacia el lado
claw. la patte. opuesto a la garra.
105. Mount tensioning claw and slightly 105. Poser la patte et la serrer 105. Colocar la garra de sujeción y
screw in. légèrement. enroscar el tornillo, dejándolo suelto.
106. Fit new injection lines with sealing 106. Monter des tuyauteries d’injection 106. Montar las tuberías de inyección
rubber elements. Fit cap screw neuves avec un joint en caoutchouc. nuevas con las obturaciones de
finger-tight. Serrer à la main l’écrou-raccord. goma. Enroscar la tuerca de unión
con los dedos.
Note: Re-bending is not allowed. Nota: Un cintrage de correction n’est Nota: No es admisible curvar
Injection lines must not be pas autorisé. Les tuyauteries ni reutilizar las tuberías
used twice. d’injection ne doivent pas être de inyección.
4 utilisées deux fois.
107. Tighten bolts of claws. 107. Serrer les vis des pattes. 107. Apretar los tornillos en las garras.

torque: 16 + 5 Nm
4.00.43 © 2002 / 0312 0361

Einspritzventile / Einspritzleitungen
104. Neuen Dichtring mit etwas Fett auf das Ein-

4
spritzventil aufschieben und Einspritzventil
einsetzen. ß
Hinweis: Die Ansenkung auf dem Einspritzventil
muss von der Pratze weg zeigen.
8
5
35247 ©
105. Spannpratze aufsetzen und lose einschrau-

ben.
4
8
35248 ©
106. Neue Einspritzleitungen mit Dichtgummi an-

bauen. Überwurfmutter fingerfest aufschrau-
ben.
4
Hinweis: Ein Nachbiegen ist nicht zulässig. 5
Die Einspritzleitungen dürfen nicht
2x verwendet werden.
35249 ©
107. Schrauben der Pratzen festdrehen.
Anziehvorschrift: 16 + 5 Nm
4
6
35250 ©
© 2002 / 0312 0361 4.00.43

108. Überwurfmuttern der Einspritzleitungen an

4 den Einspritzpumpen und Einspritzventilen
mit einem Drehmoment von ca. 5 Nm vor-
6 spannen.
Danach Überwurfmuttern festdrehen.
5 Anziehvorschrift: 25 + 3,5 Nm
35251 ©
Motorabstellung
4 109. Neuen Runddichtring montieren.
ß Hinweis: Runddichtring leicht einölen.
z
5
30291 ©
110. Regelstange mittels Abstellhebel in Stop-

4 stellung drücken und festhalten. Motorab-
stellung einbauen. Schrauben festdrehen.
35296 ©
Ölkühlergehäuse
4 111. Neue Profildichtungen und Formdichtung
ß einsetzen.
35380 ©
4.00.44 © 2002 / 0312 0361

108. Pre-tighten cap nuts of injection 108. Faire un préserrage des 108. Apretar las tuercas de unión
lines on injection pump and écrous-raccord des tuyauteries de las tuberías de inyección en
injection valves to a tightening d’injection sur les pompes las bombas de inyección e
torque of approx. 5 Nm. d’injection et in-jecteurs avec un inyectores previamente con
couple d’env. 5 Nm. aprox. 5 Nm. Luego, apretarlas
Tighten cap nuts now. Ensuite serrer définitivement les en definitiva.
écrous-raccord.
torque: 25 + 3.5 Nm Prescription de serrage: 25 + 3,5 Nm Prescripción de apriete: 25 + 3,5 Nm
Note: Use claw grip wrench 8018 Nota: Utiliser la clé à griffes 8018. Nota: Utilizar la llave de garra 8018.
Engine stop device Dispositif d’arrêt du moteur Dispositivo de parada del motor
109. Mount new O-ring. 109. Monter un joint torique neuf. 109. Montar un anillo tórcio nuevo.
Note: Slightly oil O-ring. Nota: Huiler légèrement le joint torique. Nota: Untar con un poco de aceite
el anillo tórico.
110. Press control rod into stop position 110. A l’aide du levier d’arrêt, pousser la 110. Sirviéndose de la palanca de
using the stop lever and retain. crémaillère en position stop et l’y parada, empujar la cremallera
Install engine stop device. Tighten maintenir. Monter le dispositif d’arrêt a la posicion de parada y mante-
bolts. du moteur. Serrer les vis. nerla en esta posición. Montar el
dispositivo de parada del motor.
Apretar los tornillos.

4
Oil cooler casing Bloc refroidisseur d’huile Cárter de refrigerador de aceite
111. Fit new profiled seals and a 111. Monter des joints profilés et 111. Colocar juntas perfiladas y de
shaped seal. façonnés neufs. forma nuevas.
© 2002 / 0312 0361 4.00.44

112. Mount oil cooler casing. 112. Monter le bloc refroidisseur d’huile. 112. Montar el cárter de refrigerador
de aceite.
Tighten bolts crosswise. Serrer les vis en croix. Apretar, alternando en cruz, los
tornillos.
Specified tightening torque: Prescription de serrage : Prescripción de apriete:
Initial tightening torque: _____ 3 Nm couple de préserrage _______ 3 Nm Apriete inicial _____________ 3 Nm
Final tightening torque: _____ 30 Nm couple de serrage définitif __ 30 Nm Reapriete _______________ 30 Nm
Note: The sealing surface must be clean. Nota: Le plan de joint doit être propre. Nota: La superficie de asiento debe
estar limpia.
Heating rod – coolant preheating Canne chauffante de préchauffage de Varilla calentadora para
fluide réfrigérant precalentamiento del refrigerante.
113. Fit heating rod with new O-ring 113. Monter la canne chauffante avec 113. Introducir la varilla calentadora
and tighten. un joint torique neuf et serrer. provista de un anillo tórico nuevo y
apretarla.
Fuel filter housing Carter de filtre à combustible Caja de filtro de combustible
114. Fit fuel filter housing. 114. Monter le carter de filtre à 114. Montar la caja de filtro de
combustible. combustible.
Water box Caisse d’eau Caja de agua
115. Fit plug-in element with new O-rings. 115. Monter l’élément de raccordement 115. Montar la pieza de enchufe con
avec des joints toriques neufs. anillos tóricos nuevos.
Note: Apply AP 1908 mounting Nota: Enduire les joints toriques de Nota: Aplicar deslizante AP 1908 a
compound to O-rings. produit de montage AP 1908. los anillos tóricos.
Fit oil pressure sensor with new Monter le transmetteur de pression Montar el transmisor de presión de
sealing ring. d’huile avec un joint neuf. aceite con un anillo de junta nuevo.
torque: 34 ± 3 Nm Prescription de serrage: 34 ± 3 Nm Prescripción de apriete: 34 ± 3 Nm
4.00.45 © 2002 / 0312 0361

112. Ölkühlergehäuse anbauen.
Schrauben über kreuz festdrehen.

4
Anziehvorschrift: 6
5
Vorspannwert ____________________ 3 Nm
Nachspannwert _________________ 30 Nm
Hinweis: Die Dichtfläche muss sauber sein.
35381 ©
Heizstab-Kühlmittelvorwärmung
113. Heizstab mit neuem Runddichtring einsetzen

4
und festdrehen.
ß
6
35382 ©
Kraftstofffiltergehäuse
114. Kraftstofffiltergehäuse einbauen

4
Anziehvorschrift: 30 Nm ß
6
4
35383 ©
Wasserkasten
115. Steckstück mit neuen Runddichtringen mon-

4
tieren.
ß
u
Hinweis: Runddichtringe mit Montagemittel
AP 1908 bestreichen.
Öldruckgeber mit neuem Dichtring anbauen. 5

Anziehvorschrift: 34 ± 3 Nm
6 35384 ©
© 2002 / 0312 0361 4.00.45

116. Wasserkasten mit neuer Dichtung auf Steck-

4 stück aufschieben und anbauen.
ß Anziehvorschrift: 30 Nm
35385 ©
117. Kraftstoffleitung und Druckhalteventil mit

4 neuen Cu-Dichtringen einbauen.
ß Anziehvorschrift:
Druckhalteventil _________________ 30 Nm
6
Hohlschraube ___________________ 39 Nm
Rohrschelle an Wasserkasten anbauen.
35386 ©
Zylinderkopfhaube
4 118. Dichtung auflegen und ausrichten.
ß
8
4
35387 ©
119. Zylinderkopfhaube und Abdeckblech an-

4 bauen. Schrauben festdrehen.
5 Hinweis: Auf richtigen Sitz der Dichtgummis in der

Zylinderkopfhaube achten.
8
35388 ©
4.00.46 © 2002 / 0312 0361

116. Slide water box with new seal onto 116. Emmancher la caisse d’eau avec 116. Colocar la caja de agua con
plug-in element and mount. un joint neuf sur l’élément de una junta nueva sobre la pieza
raccordement et la monter. de enchufe y adosarla.
117. Fit fuel line and pressure holding 117. Monter la tuyauterie à combustible 117. Instalar la tubería de combustible y la
valve with new Cu-seals. et le limiteur de pression avec des válvula de mantenimiento de presión
joints Cu neufs. con anillos de junta de cobre nuevos.

Pressure holding valve: ____ 30 Nm limiteur de pression _______ 30 Nm Válvula de mantenimiento
Hollow screw ____________ 39 Nm vis creuse _______________ 39 Nm de presión _______________ 30 Nm
Tornillo racor ____________ 39 Nm
Fit pipe collar to water box. Monter le collier de serrage
sur la caisse d’eau. Montar la abrazadera de tubo
Specified tightening torque: 13 Nm en la caja de agua.
Prescription de serrage: 13 Nm Prescripción de apriete: 13 Nm
Inspection cover Cache-culbuteurs Tapa de culata
118. Fit new gasket and align. 118. Poser le joint et aligner. 118. Colocar la junta y alinearla.
119. Fit inspection cover and cover plate. 119. Monter le cache-culbuteurs et la tôle 119. Montar la tapa de culata y la
Tighten bolts. de recouvrement. Serrer les vis. chapa de recubrimiento. Apretar
los tornillos.
Note: Make sure sealing rubber Nota: Veiller au bon positionnement Nota: Prestar atención a la correcta
elements are properly seated in des joints en ctc dans le cache- colocación de las obturaciones
inspection cover. culbuteurs. de goma en la tapa de culata.
© 2002 / 0312 0361 4.00.46

Control line Conduite pilote Conducto de mando
120. Fit control line. 120. Monter la conduite pilote. 120. Montar el conducto de mando
Specified tightening torque: Prescription de serrage : Prescripción de apriete:

Hollow screw: ____________ 18 Nm vis creuse _______________ 18 Nm Tornillo racor ____________ 18 Nm
Pipe collar _______________ 13 Nm collier de serrage _________ 13 Nm Abrazadera de tubo _______ 13 Nm
Pressure control valve Soupape régulatrice de pression Válvula reguladora de presión
121. Fit pressure control valve with a 121. Monter la soupape régulatrice 121. Montar la válvula reguladora
new O-ring. de pression avec une bague de presión con un anillo de junta
d’étanchéité neuve. nuevo.
122. Fit bleeder hose. 122. Monter le tube évent. 122. Montar el tubo flexible de ventilación.
Note: Use spring clamp pliers 9090 Nota: Utiliser la pince à ressort pour Nota: Utilizar los alicates 9090 para
tuyaux 9090. abrazaderas elásticas.
123. Mount bleeder tube. 123. Fixer le tube évent. 123. Fijar el tubo de ventilación.
4.00.47 © 2002 / 0312 0361

Steuerleitung
120. Steuerleitung anbauen.

4
Anziehvorschrift: 6
0
Hohlschraube ___________________ 18 Nm
Rohrschelle ____________________ 13 Nm
35389 ©
Druckregelventil
121. Druckregelventil mit neuem Dichtring an-

4
bauen.
ß
8
6
35390 ©
122. Entlüftungsschlauch anbauen.
Hinweis: Federklemmenzange 9090 verwenden.

4
7
5
4
35391 ©
123. Entlüftungsrohr befestigen.
4
6
35392 ©
© 2002 / 0312 0361 4.00.47

124. Rohrschelle festdrehen.

35393 ©
Lüfterkonsole
w 125. Dichtmasse DEUTZ DW 67 auftragen.
35394 ©
126. Lüfterkonsole mit neuen Dichtringen anbauen.

ß Hinweis: Dichtflächen vor dem Anbau reinigen und
6 Verschlussstopfen am Kurbelgehäuse auf

Dichtheit prüfen.
4 5
35395 ©
127. Neuen Anschlussstutzen für Kraftstoffzulauf

4 einbauen.
5
Hinweis: Anschlussstutzen komplett erneuern.
35396 ©
4.00.48 © 2002 / 0312 0361

124. Tighten pipe collar. 124. Serrer définitivement le collier 124. Apretar la abrazadera de tubo.
de serrage.
Fan bracket Console de ventilateur Consola del ventilador
125. Apply DEUTZ DW 67 sealing 125. Appliquer la pâte d’étanchéité 125. Aplicar pasta sellante
compound. DEUTZ DW 67. DEUTZ DW 67.
126. Fit fan bracket with new sealing 126. Monter la console de ventilateur 126. Montar la consola del ventilador
rings. avec des joints neufs. con anillos de junta nuevos.
Note: Clean sealing surfaces before Nota: Avant le montage, nettoyer les plans Nota: Limpiar las superficies de asiento
mounting and check locking plug for de joint et contrôler l’étanchéité des antes del montaje y comprobar
tightness. bouchons filetés sur le bloc-moteur. los tapones de cierre en el bloque
motor en cuanto a cierre estanco. 4
127. Install new connecting socket for 127. Monter une nouvelle tubulure 127. Instalar un racor de empalme nuevo
fuel feed line. de raccordement pour l’arrivée para la llegada de combustible.
de combustible.
Note: Provide for a complete new Nota: Remplacer complètement la Nota: Renovar el racor de empalme
connecting socket. tubulure de raccordement. por completo.
© 2002 / 0312 0361 4.00.48

Coolant pump Pompe à fluide réfrigérant Bomba de refrigerante
128. Fit coolant pump with new 128. Monter la pompe à fluide réfrigérant 128. Instalar la bomba de refrigerante
sealing ring. avec un joint neuf. con un anillo tórico nuevo.
Note: Apply AP 1908 mounting Nota: Enduire le joint torique de produit Nota: Aplicar deslizante AP 1908 al
compound to O-ring. Observe de montage AP 1908. Respecter la anillo tórico.
proper position of installation. position de montage. Observar la posición de montaje.
Bracket / generator Console / Génératrice Consola / Alternador
129. Mount bracket, suspension plate 129. Monter la console, la tôle de 129. Montar la consola, la chapa de
and generator. suspension et la génératrice. suspensión y el alternador.
130. Fit flat plug pin and fix cable end ear. 130. Brancher la fiche plate et fixer 130. Meter el enchufe plano y fijar la
l’oeillet de câble. argolla de cable
Fuel pump Pompe à combustible Bomba de combustible
131. Install fuel pump 131. Monter la pompe à combustible. 131. Instalar la bomba de combustible.
4.00.49 © 2002 / 0312 0361

Kühlmittelpumpe
128. Kühlmittelpumpe mit neuem Dichtring ein-

4
bauen.
ß
8
Hinweis: Runddichtring mit Montagemittel
AP 1908 bestreichen.
Einbaulage beachten.
Anziehvorschrift: 30Nm
5
6 35397 ©
Konsole / Generator
129. Konsole, Aufhängeblech und Generator ein-

4
bauen.
6
35398 ©
130. Flachstecker aufstecken und Kabelöse be-

festigen. 4
6
35399 ©
Kraftstoffpumpe
131. Kraftstoffpumpe einbauen.

4
6
35400 ©
© 2002 / 0312 0361 4.00.49

132. Kraftstoffleitung mit neuen Cu-Dichtringen an-

4 bauen.
35401 ©
Spannrolle
4 133. Spannrolle einbauen
35402 ©
Lüfterantrieb
4 134. Lüfterantrieb anbauen.
35403 ©
Keilrippenriemen
s 135. Spannrolle 1 in Pfeilrichtung drücken. Keilrip-
4 penriemen auflegen, dabei auf Rolle 2 zuletzt
auflegen.
Spannrolle entgegen der Pfeilrichtung lösen,

bis Keilrippenriemen gespannt ist.
35297 ©
4.00.50 © 2002 / 0312 0361

132. Fit fuel line with new 132. Monter la tuyauterie à combustible 132. Colocar la tubería de
Cu sealing rings. avec des joints Cu neufs. combustible con anillos de
junta de cobre nuevos.
Tensioning pulley Galet tendeur Polea tensora
133. Install tensioning pulley. 133. Monter le galet tendeur. 133. Montar la polea tensora.
Fan drive Entraînement de ventilateur Accionamiento del ventilador
134. Fit fan drive. 134. Monter l’entraînement de ventilateur. 134. Montar el accionamiento del
ventilador.
Specified tightening torque: 60 Nm Prescription de serrage: 60 Nm
Prescripción de apriete: 60 Nm
Ribbed V-belt Courroie trapézoïdale nervurée Correa nervada trapezoidal
135. Press tensioning pulley 1 in 135. Pousser le galet tendeur 1 dans le 135. Presionar la polea tensora 1 en
direction of the arrow. Mount ribbed sens de la flèche. Poser la courroie dirección de la flecha. Colocar la
V-belt – last on pulley 2. trapézoïdale nervurée en la montant correa nervada trapezoidal, siendo
en dernier lieu sur le galet 2. la polea 2 la última en recibirla.
Release tensioning pulley in Desserrer le galet tendeur dans le Aflojar la polea tensora actuando en
opposite direction of the arrow until sens inverse de celui de la flèche, contra de la dirección en que indica
ribbed V-belt is under tension. jusqu’à ce que la courroie la flecha, hasta que la correa
trapézoïdale nervurée soit tendue. nervada trapezoidal quede tensa.
© 2002 / 0312 0361 4.00.50

136. When re-using ribbed V-belt make 136. En cas de réutilisation de la 136. En caso de reutilización de la correa
sure wear limits are not exceeded. courroie trapézoïdale nervurée, nervada trapezoidal, hay que tener
Gauge distance “a” between the respecter la limite d’usure. en cuenta el límite de desgaste.
nose of the mobile tensioning arm Mesurer la distance « a » entre le Medir la distancia “a” existente entre
and the stop of the stationary talon du bras de tension mobile et el talón del brazo tensor móvil y el
tensioner housing. la butée du carter tendeur fixe. tope de la caja fija del tensor.
If distance “a” is inferior to 3 mm, Si la distance « a » est inférieure Si la distancia “a” es inferior a 3 mm,
replace ribbed V-belt by a new one. à 3 mm, la courroie trapézoïdale es necesario renovar la correa.
nervurée doit être remplacée.
Fan Ventilateur Ventilador
137. Fit fan using open 137. Monter le ventilateur avec l’embout 137. Montar el ventilador utilizando la
jawed wrench 160 340 and à mâchoire 160 340 et le dispositif boca enchufable 160 340 y el
dolly 160 330. d’immobilisation 160 330. dispositivo de retención 160 330.
Note: Caution! Left hand thread – oiled Nota: Attention ! Filetage à Nota: Atención: Rosca a la
gauche – huilé. izquierda – aceitada.
138. Plug cable connector to cut-off 138. Brancher le connecteur de câble 138. Enchufar los cables en el solenoide
solenoid and governor. sur l’électroaimant d’arrêt et le de parada y el regulador.
régulateur.
139. Plug cable connector to 139. Brancher le connecteur de câble 139. Enchufar el cable en los sensores
temperature sensor. sur la sonde de température. de temperatura.
4.00.51 © 2002 / 0312 0361

136. Bei Wiederverwendung des Keilrippenriemens

auf Verschleißgrenze achten.
Den Abstand „a“ zwischen der Nase des be-
s
weglichen Spannarms und dem Anschlag des
festen Spannergehäuses messen. 4
Ist der Abstand „a“ kleiner als 3 mm so ist der
Keilrippenriemen zu erneuern.
35283 ©
Lüfter
137. Lüfter mit Maul-Steckaufsatz 160 340 und

4
Gegenhalter 160 330 anbauen.
7
6
Hinweis: Achtung! Linksgewinde - geölt
5
35320 ©
138. Kabelstecker an Abstellmagnet und Regler

aufstecken. 4
35254 ©
139. Kabelstecker an Temperaturfühler aufstecken.

4
35255 ©
© 2002 / 0312 0361 4.00.51

Ölwanne
4 Motor um 180° drehen
ß 140. Dichtmittel DEUTZ DW 74 auf die Dichtfläche
w
und in die Ausfräsungen auftragen. Dicht-
fadenstärke 3,6 mm
5 Hinweis: Es darf kein Dichtmittel in die Ölsaug-

bohrung gelangen.
35405 ©
141. Je nach Ölwanne eine neue Dichtung aufle-

4 gen und Ölwanne anbauen.
ß Hinweis: Darauf achten, dass der Runddichtring

und der Dichtfaden nicht verschoben
5
werden.
30373 ©
142. Schrauben wechselseitig festdrehen.

30374 ©
4.00.52 © 2002 / 0312 0361

Oil pan Cuve d’huile Cárter de aceite
Turn engine by 180°. Virer le moteur de 180°. Girar el motor 180°.
140. Apply DEUTZ DW 74 sealing 140. Appliquer le produit d’étanchéité 140. Aplicar sellante DEUTZ DW 74
compound to sealing surface and DEUTZ DW 74 sur le plan de joint et a la superficie de asiento y los
notches. Thickness of sealing les fraisages. Epaisseur de cordon puntos fresados. Espesor del hilo
compound bead 3.6 mm d’étanchéité 3,6 mm. de sellante: 3,6 mm.
Note: Sealing compound must not Nota: Le produit d’étanchéité ne doit Nota: No debe llegar sellante alguno al
penetrate into oil suction bore. pas pénétrer dans l’alésage conducto de aspiración de aceite.
d’aspiration d’huile.
141. Place new gasket and fit oil pan. 141. Poser un joint neuf et monter la 141. Poner una junta nueva y montar el
cuve d’huile. cárter de aceite.
Note: Make sure that O-ring and sealing Nota: Veiller à ce que le joint torique Nota: Cuidar de que no se desplace el
bead are not displaced. et le cordon d’étanchéité ne soient anillo tórico ni el hilo de sellante.
pas déplacés.
142. Tighten bolts alternately. 142. Serrer les vis alternativement. 142. Apretar alternativamente los
tornillos.
© 2002 / 0312 0361 4.00.52

© 2002 / 0312 0361

Bauteile ab- und anbauen
Removal and re-installation of components
Démontage et remontage des composants
Desmontaje y montaje de componentes 2012
© 2003 / 0312 0361

Inhaltsverzeichnis Bauteile ab- und anbauen
Table of Contents Removal and re-installation of components
Table des matières Démontage et remontage des composants
Indice Desmontaje y montaje de componentes
5. Bauteile ab- und anbauen am kompletten Motor Seite
Wellendichtringe
- Vorderer Deckel __________________________________________ 5.00.01 – 5.00.05
- schwungradseitig __________________________________________ 5.00.06 – 5.00.08
Einspritzpumpe __________________________________________ 5.00.09 – 5.00.16
Thermostat __________________________________________ 5.00.17
English
5. Removal and re-installation of components on complete engine Page
Shaft seals
- Front cover __________________________________________ 5.00.01 – 5.00.05
- flywheel end __________________________________________ 5.00.06 – 5.00.08
Injection pump __________________________________________ 5.00.09 – 5.00.16
Thermostat __________________________________________ 5.00.17
Français
5. Démontage et remontage des composants sur moteur complet Page
Joints d’arbre
- Couvercle avant __________________________________________ 5.00.01 – 5.00.05
- Côté volant __________________________________________ 5.00.06 – 5.00.08
Pompe d’injection __________________________________________ 5.00.09 – 5.00.16
Thermostat __________________________________________ 5.00.17
Español
5. Desmontaje y montaje de componentes en el motor completo Página
5
Retenes para cigüeñal
- Tapa delantera __________________________________________ 5.00.01 – 5.00.05
- En el lado del volante __________________________________________ 5.00.06 – 5.00.08
Bomba de inyección __________________________________________ 5.00.09 – 5.00.16
Termostato __________________________________________ 5.00.17
© 2002 / 0312 0361

Bauteile ab- und anbauen Wellendichtringe
Removal and re-installation of components Shaft seals
Démontage et remontage des composants Joints d’arbre
Desmontaje y montaje de componentes Retenes para cigüeñal
Replacement of shaft seals on Remplacement des joints d’arbre Sustitución de los retenes en el motor
complete engine sur moteur complet completo
Torx wrench socket E20, Clé à douille Torx E20 ___________ 8114 Llave de vaso Torx E20 __________ 8114
long version ___________________ 8114 Appareil de mesure de la tension __ 8115 Verificador de tensión ___________ 8115
V-belt tension gauge ____________ 8115 Levier de montage des ressorts Palanca de montaje para
Valve spring assembly lever ______ 9017 de soupape ___________________ 9017 resortes de válvula _____________ 9017
Assembly tool for Dispositif de montage arrière ___ 142 830 Herramienta de montaje
rear crankshaft seal __________ 142 830 Dispositif de montage avant ____ 142 670 p. retén trasero ______________ 142 830
Assembly tool for Dispositif d’immobilisation / Herramienta de montaje
front crankshaft seal __________ 142 670 amortisseur de vibrations p. retén delantero ____________ 142 670
Dolly / torsional torsionnelles ________________ 144 800 Dispositivo de retención
vibration damper _____________ 144 800 p. amortiguador
de vibraciones torsionales _____ 144 800
- Front cover - - Couvercle avant - - Tapa delantera –
- V-belt - Courroie trapézoïdale - Correa trapezoidal
1. Remove V-belt. 1. Démonter la courroie trapézoïdale. 1. Desmontaje de las correas

trapezoidales.
V-belt for generator Courroie trapézoïdale de génératrice. Correa trapezoidal para el alternador.
Slacken bolts 1, 2 and 4. Release bolt Défaire les vis 1, 2 et 4. Régler la Aflojar los tornillos 1, 2 y 4. Girar el
3 until V-belt is clear. Remove V-belt. vis 3 jusqu’à ce que la courroie soit tornillo 3 hasta que la correa trape-
libre. Enlever la courroie. zoidal quede libre. Retirar la correa.
2. V-belt for coolant and fuel pumps 2. Courroie trapézoïdale de pompe à 2. Correa trapezoidal para las bombas
Slacken bolts 1 and 2. Press fuel fluide réfrigérant et à combustible. de refrigerante y de combustible.
pump 3 in direction of the arrow Défaire les vis 1 et 2. Pousser la Aflojar los tornillos 1 y 2. Presionar
until V-belt is clear. Remove V-belt. pompe à combustible 3 dans le sens la bomba de combustible 3 en
de la flèche jusqu’à ce que la courroie dirección de la flecha hasta que
soit libre. Enlever la courroie. la correa trapezoidal quede libre.
Retirar la correa.
- Ribbed V-belt - Courroie trapézoïdale nervurée - Correa nervada trapezoidal
3. Press tensioning pulley 1 into 3. Pousser le galet tendeur 1 3. Presionar la polea tensora 1 en
direction of the arrow until ribbed dans le sens de la flèche jusqu’à ce dirección de la flecha hasta
5 V-belt is clear. Remove ribbed que la courroie trapézoïdale que la correa nervada trapezoidal
V-belt – take off on pulley 2 first. nervurée soit libre. Enlever la quede libre. Retirar la correa,
courroie trapézoïdale nervurée primeramente de la polea 2.
en commençant par le galet 2.
5.00.01 © 2002 / 0312 0361

Wellendichtringe Bauteile ab- und anbauen
Shaft seals Removal and re-installation of components
Joints d’arbre Démontage et remontage des composants
Retenes para cigüeñal Desmontaje y montaje de componentes
Austausch der Wellendichtringe am kompletten

Motor.
Spannungsmessgerät __________________ 8115
Ventilfedermontagehebel _______________ 9017
Spezialwerkzeuge:
Eindrückvorrichtung hinten ____________ 142 830
Eindrückvorrichtung vorne ____________ 142 670
Gegenhalter / Drehschwingungsdämpfer _ 144 800
- Vorderer Deckel -
- Keilriemen
s
1. Keilriemen abnehmen. 3
Keilriemen für Generator.
Schrauben 1, 2 und 4 lösen. Schraube 3 ver-
stellen bis Keilriemen frei ist. Keilriemen abneh-
men.
35277 ©
2. Keilriemen für Kühlflüssigkeits- und Kraftstoff-

pumpe.
Schrauben 1 und 2 lösen. Kraftstoffpumpe 3 in
s
Pfeilrichtung drücken bis Keilriemen frei ist.
Keilriemen abnehmen. 3
35278 ©
- Keilrippenriemen
3. Spannrolle 1 in Pfeilrichtung drücken bis Keil-

s
rippenriemen frei ist. Keilrippenriemen abneh-
men, dabei zuerst an der Rolle 2 abnehmen. 3 5
35279 ©
© 2002 / 0312 0361 5.00.01

4. Drehschwingungsdämpfer mit Gegenhalter

3 144 800 gegenhalten und abbauen.
5 Hinweis: Torx-Steckschlüssel E20, 8114 verwen-

den.
30104 ©
5. Blechschraubenloch ca. ø 3 mm vorsichtig in

f den Wellendichtring bohren.
5 Hinweis: Bohrer dick mit Fett bestreichen, damit

keine Bohrspäne ins Kurbelgehäuse
fallen.
30109 ©
6. Entsprechend dicke Blechschraube in das Bohr-

4 loch einschrauben und mit Hilfe eines geeig-
neten Werkzeuges, z. B. Ventilfedermontage-
3 hebel 9017, herausziehen.
5
Hinweis: Eventuell vorhandene Bohrspäne ent-
fernen.
30110 ©
7. Führungshülse anbauen.
4 Montagewerkzeug 142 670 verwenden.
5
7
30111 ©
5.00.02 © 2002 / 0312 0361

4. Retain torsional vibration damper 4. Immobiliser l’amortisseur de 4. Retener el amortiguador de

using dolly 144 800 and remove. vibrations torsionnelles avec le vibraciones torsionales mediante el
dispositif 144 800 et le démonter. dispositivo de retención 144 800 y
desmontarlo.
Note: Use Torx wrench socket E20, 8114. Nota: Utiliser la clé à douille Nota: Utilizar la llave de vaso
Torx E20, 8114. Torx E20, 8114
5. Drill a hole – approx. 3 mm dia. – for a 5. Avec précaution, percer un trou 5. Abrir en el retén cuidadosamente un
self tapping screw into shaft seal ring. de vis à tôle d’env. 3 mm Ø dans le taladro de aprox. 3 mm de diám. para
joint d’arbre. un tornillo autorroscante.
Note: Apply a thick layer of grease to Nota: Enduire le foret d’une épaisse Nota: Aplicar una capa gruesa de
drill to prevent the ingress of chips couche de graisse pour empêcher grasa a la broca para evitar la
into the crankcase. que des copeaux de forage ne caída de virutas al interior del
tombent dans le bloc-moteur. cárter del cigüeñal.
6. Screw a self tapping screw of the 6. Visser des vis à tôle de taille 6. Enroscar un tornillo autorroscante
corresponding size into the bore hole correspondante dans le trou percé de diámetro correspondiente en el
and pull out using a suitable tool such et à l’aide d’un outil approprié, tel taladro y extraer el retén utilizando
as valve spring assembly lever 9017. que levier de montage de ressorts una herramienta adecuada, p.ej. la
de soupapes 9017, extraire. palanca de montaje 9017 para
resortes de válvulva.
Note: Remove chips, if any, left from Nota: Enlever d’éventuels copeaux Nota: Eliminar las virutas que
drilling. de forage. eventualmente queden del
taladrado.
7. Fit guide bushing. 7. Monter la douille de guidage. 7. Montar el manguito de guía.

Use assembly tool 142 670. Utiliser le dispositif de Utilizar la herramienta de
montage 142 670. montaje 142 670.
© 2002 / 0312 0361 5.00.02

8. Slightly oil seal lip. Carefully put on 8. Enduire légèrement d’huile la lèvre 8. Untar con un poco de aceite el labio
new shaft seal. d’étanchéité. Avec précaution, poser de obturación. Colocar el retén nuevo
le joint d’arbre neuf. con todo cuidado.
Note: Sealing lip faces crankshaft. Nota: La lèvre d’étanchéité est dirigée Nota: El labio de obturación debe
vers le vilebrequin. indicar hacia el cigüeñal.
9. Place spacer washers 9. Poser des bagues entretoise. 9. Colocar arandelas distanciadoras.
2 washers _ Initial assembly 2 bagues ______ premier montage 2 arandelas _____ primer montaje
1 washer __ 1st repair mounting depth 1 bague _______ 1ère profondeur 1 arandela ______ profundidad de
0 washers _ max. mounting depth d’insertion, cote rép. montaje 1a repar.
0 bague _______ profondeur sin arandelas ____ profundidad de
d’insertion maxi montaje máx.
10. Mount assembly tool for front 10. Monter la douille de montage 10. Colocar el manguito de montaje
crankshaft seal 142 670 and press 142 670 et la presser dans le 142 670 e introducirlo a presión hasta
into device as far as it will go. dispositif jusqu’en butée. el tope en el dispositivo.
Note: The shaft seal sits now in its Nota: Le joint d’arbre se trouve Nota: El retén se encuentra ahora
pre-selected mounting depth. maintenant à la profondeur a su profundidad de montaje
11. Make sure the centering bush is 11. Veiller à la présence de la douille de 11. Prestar atención a la existencia del
installed in the crankshaft, install as centrage dans le vilebrequin, le cas casquillo de centraje en el cigüeñal;
necessary. échéant la monter. si no existe, introducirlo.
5.00.03 © 2002 / 0312 0361

8. Dichtlippe leicht einölen. Neuen Wellendichtring

vorsichtig auflegen.
4
ß
Hinweis: Dichtlippe weist zur Kurbelwelle
z
8
5 30112 ©
9. Abstandscheiben auflegen.
2 Scheiben ____________ Erstmontage

4
1 Scheibe _____________ 1. Rep.-Einbautiefe
0 Scheiben ____________ max. Einbautiefe 7
9
30504 ©
10. Montagehülse 142 670 aufsetzen und bis Anlage

in der Vorrichtung eindrücken.
4
Hinweis: Wellendichtring ist jetzt in seiner vorge-
wählten Einbautiefe. 7
5
30113 ©
11. Auf Vorhandensein der Zentrierbuchse in der

Kurbelwelle achten, ggf. einsetzen. 9
4 5
30116 ©
© 2002 / 0312 0361 5.00.03

12. Bei der Montage der Keilriemen-/ Keilrippen-

9 scheibe muss die Markierung in der Kurbelwel-
le und in dem Drehschwingungsdämpfer in
Überdeckung stehen.
35280 ©
13. Drehschwingungsdämpfer anbauen und mit

4 Gegenhalter 144 800 gegenhalten. Schrauben
festdrehen.
6 Anziehvorschrift:
5
Vorspannwert ________________ 40 - 50 Nm

den. Schrauben können bei Nachweis-
30114 © barkeit 5x verwendet werden.
14. Keilriemen auflegen und spannen.

s 14.1 Keilriemen für Generator.
4 Generator 5 in Pfeilrichtung durch Drehen der

Schraube 3 verstellen, bis korrekte Keilriemen-
spannung erreicht ist. Schrauben 1, 2 und 4
festdrehen.
Keilriemenspannung:
Erstmontage 450 ± 50 Nm
Nach 15 Minuten Lauf unter Last 300 ± 50 Nm
35281 © Bei Wiederverwendung 300 ± 50 Nm
14.2 Keilriemen für Kühlflüssigkeits- und Kraftstoff-

s pumpe.
Kraftstoffpumpe 3 in Pfeilrichtung drücken, bis
5
4 korrekte Keilriemenspannung erreicht ist.
Schrauben 1 und 2 festdrehen.
Keilriemenspannung:
Erstmontage 450 ± 50 Nm
Nach 15 Minuten Lauf unter Last 300 ± 50 Nm
Bei Wiederverwendung 300 ± 50 Nm
35282 ©
5.00.04 © 2002 / 0312 0361

12. When mounting the V-belt / ribbed 12. Lors du montage de la poulie à 12. Para el montaje de las poleas
V-belt pulley make sure that courroie trapézoïdale / trapézoïdale para las correas trapezoidales /
markings on the crankshaft and nervurée, les repérages sur le correa nervada trapezoidal es
torsional vibration damper overlap. vilebrequin et l’amortisseur de imprescindible la coincidencia
vibrations torsionnelles doivent de las marcas existentes en el
coïncider. cigüeñal y el amortiguador de
vibraciones torsionales.
13. Fit torsional vibration damper 13. Monter l’amortisseur de vibrations 13. Montar el amortiguador de
and retain using dolly 144 800. torsionnelles et l’immobiliser avec le vibraciones torsionales y retenerlo
Tighten bolts. dispositif 144 800. Serrer les vis. mediante el dispositivo de retención
144 800. Apretar los tornillos.

Initial tightening torque: 40 – 50 Nm Couple de préserrage __ 40 – 50 Nm Apriete inicial ________ 40 – 50 Nm
1st lock down angle __________ 60° 1er angle de serrage définitif __ 60° 1er ángulo de reapriete _______ 60°
Note: Use Torx wrench socket E20, Nota: Utiliser la clé à douille Torx E20, Nota: Utilizar la llave de vaso Torx E20,
8114. Bolts – if proven to be fit for 8114. A condition de le consigner, 8114. En caso de comprobabilidad,
use – can be re-used 5 times. les vis peuvent être réutilisées los tornillos son utilizables 5 veces
au maximum 5 fois. como máximo.
14. Mount V-belt and tension V-belt. 14. Poser la courroie trapézoïdale 14. Colocación y tensado de las
et la tendre. correas trapezoidales.
14.1 V-belt for generator 14.1 Courroie trapézoïdale de génératrice. 14.1 Correa trapazoidal para el alternador.
Adjust generator 5 in direction of Déplacer la génératrice 5 dans le Bascular el alternador en dirección
the arrow by turning bolt 3 until the sens de la flèche en tournant la vis 3 de la flecha por giro del tornillo 3
correct V-belt tension has been jusqu’à ce que la tension correcte hasta alcanzar la tensión correcta
achieved. Tighten bolts 1, 2 and 4. de courroie soit obtenue. Serrer les de la correa trapezoidal. Apretar los
vis 1, 2 et 4. tornillos 1, 2 y 4.
V-belt tension: Tension de courroie: Tensión de la correa trapezoidal:

Initial assembly: 450 ± 50 Nm Premier montage 450 ± 50 Nm Primer montaje 450 ± 50 Nm
after 15 minutes operation Après fonctionnement de Tras una marcha de
under load conditions 300 ± 50 Nm 15 minutes sous charge 300 ± 50 Nm 15 minutos bajo carga 300 ± 50 Nm
re-used V-belts 300 ± 50 Nm En cas de réutilisation 300 ± 50 Nm En caso de reutilización 300 ± 50 Nm
14.2 V-belts for coolant and fuel pumps 14.2 Courroie trapézoïdale de pompe à 14.2 Correa trapezoidal para las bombas
Press fuel pump 3 in direction of fluide réfrigérant et à combustible. de refrigerante y de combustible.
the arrow until the correct V-belt Déplacer la pompe à combustible 3 Presionar la bomba de combustible
tension has been achieved. Tighten dans le sens de la flèche jusqu’à ce 3en dirección de la flecha hasta
bolts 1 and 2. que la tension de courroie correcte alcanzar la tensión correcta de la 5
soit obtenue. Serrer les vis 1 et 2 correa. Apretar los tornillos 1 y 2.
V-belt tension: Tension de courroie: Tensión de la correa trapezoidal:

Initial assembly: 450 ± 50 Nm Premier montage 450 ± 50 Nm Primer montaje 450 ± 50 Nm
after 15 minutes operation Après fonctionnement de Tras una marcha de
under load conditions 300 ± 50 Nm 15 minutes sous charge 300 ± 50 Nm 15 minutos bajo carga 300 ± 50 Nm
re-used V-belts 300 ± 50 Nm En cas de réutilisation 300 ± 50 Nm En caso de reutilización 300 ± 50 Nm
© 2002 / 0312 0361 5.00.04

15. Mount ribbed V-belt and tension 15. Poser la courroie trapézoïdale 15. Colocación y tensado de la correa
V-belt. nervurée et la tendre. nervada trapezoidal.
Press tensioning pulley 1 in direction Pousser le galet tendeur 1 dans le Presionar la polea tensora 1 en
of the arrow. Mount ribbed V-belt – sens de la flèche. Monter la courroie dirección de la flecha. Colocar la
last on pulley 2. Release tensioning trapézoïdale nervurée en la posant correa nervada trapezoidal, siendo
pulley in opposite direction of the en dernier lieu sur le galet 2. la polea 2 la última en recibirla.
direction of the arrow until ribbed V- Desserrer le galet tendeur dans le Aflojar la polea tensora actuando
belt is tensioned. sens contraire de la flèche jusqu’à ce en contra de la dirección en que
que la courroie trapézoïdale indica la flecha, hasta que la correa
nervurée soit tendue. nervada trapezoidal quede tensa.
15.1 Make sure that wear limits are 15.1 En cas de réutilisation de la 15.1 En caso de reutilización de la correa
not exceeded when re-using ribbed courroie trapézoïdale nervurée, nervada trapezoidal, hay que tener
V-belts. Guate distance “a” between veiller à la limite d’usure. en cuenta el límite de desgaste.
the nose of the mobile tensioning Mesurer la distance « a » entre le Medir la distancia “a”existente entre
arm and the stop of the stationary talon du bras de tension mobile el talón del brazo tensor móvil y el
tensioner housing. et la butée du carter tendeur fixe. tope de la caja fija del tensor.
If distance “a” is inferior to 3 mm, Si la distance « a » est inférieure Si la distancia “a”es inferior a 3 mm,
replace ribbed V-belt by a new one. à 3 mm, la courroie trapézoïdale es necesario renovar la correa.
nervurée doit être remplacée.
5.00.05 © 2002 / 0312 0361

15. Keilrippenriemen auflegen und spannen.

Spannrolle 1 in Pfeilrichtung drücken. Keilrip-
penriemen auflegen, dabei auf Rolle 2 zuletzt
s
auflegen. Spannrolle entgegen Pfeilrichtung
lösen, bis Keilrippenriemen gespannt ist. 4
35279 ©
15.1 Bei Wiederverwendung des Keilrippenriemens

auf Verschleißgrenze achten.
Den Abstand "a" zwischen der Nase des be-
6
weglichen Spannarms und dem Anschlag des
festen Spannergehäuses messen.
Ist der Abstand "a" kleiner als 3 mm, so ist der
Keilrippenriemen zu erneuern.
35283 ©
© 2002 / 0312 0361 5.00.05

- schwungradseitig -
3 1. Schwungrad gegenhalten und abbauen.
30117 ©
2. Für den Ausbau des schwungradseitigen

3 Wellendichtringes ist das gleiche Verfahren wie
Punkt 5 - 6 anzuwenden.
Ventilfedermontagehebel 9017 verwenden.
30118 ©
3. Führungsbuchse anbauen.
4 Montagewerkzeug 142 830 verwenden.
30119 ©
4. Dichtlippe leicht einölen. Neuen Wellendichtring

4 vorsichtig auflegen.
5
ß Hinweis: Dichtlippe weist zur Kurbelwelle.
z
8
30120 © 5
5.00.06 © 2002 / 0312 0361
- flywheel end - - Côté volant - - En el lado del volante –
1. Retain flywheel and remove. 1. Immobiliser le volant et le démonter. 1. Retener el volante y desmontarlo.
2. Proceed as described under items 2. Pour le démontage du joint d’arbre 2. Para el desmontaje del retén en el
5 – 6 for the removal of the shaft côté volant, procéder comme indiqué lado del volante se procederá de la
sealing ring on the flywheel end. sous points 5 – 6. misma manera que descrita en los
Use valve spring assembly lever 9017. Utiliser le levier de montage de puntos 5 a 6.
ressort de soupape 9017. Utilizar la palanca de montaje 9017
para resortes de válvula.
3. Fit guide bush. 3. Monter la douille de guidage. 3. Montar el manguito de guía.

Use assembly tool for rear Utiliser l’outil de montage 142 830. Utilizar la herramienta de
crankshaft seal 142 830. montaje 142 830.
4. Slightly oil seal lip. Carefully fit new 4. Huiler légèrement la lèvre 4. Untar con un poco de aceite el labio
shaft seal. d’étanchéité. Avec précaution, de obturación. Colocar el retén nuevo
poser le joint d’arbre neuf. con todo cuidado.
Note: Seal lip faces crankshaft. Nota: La lèvre d’étanchéité est dirigée Nota: El labio de obturación debe indicar 5
vers le vilebrequin. hacia el cigüeñal.
© 2002 / 0312 0361 5.00.06

5. Fit spacer washers 5. Poser des bagues entretoises. 5. Colocar arandelas distanciadoras.
2 washers _ Initial assembly 2 bagues ______ premier montage 2 arandelas _____ primer montaje
1 washer __ 1st repair mounting depth 1 bague _______ 1ère profondeur 1 arandela ______ profundidad de
0 washers _ max. mounting depth d’insertion, cote rép. montaje 1a repar.
0 bague _______ profondeur sin arandelas ____ profundidad de
d’insertion maxi montaje máx.
6. Fit assembly tool 142 830 and press 6. Monter la douille de montage 142 830 6. Colocar el manguito de montaje
into device as far as it will go. et la presser dans le dispositif jusqu’en 142 830 e introducirlo a presión
butée. hasta el tope en el dispositivo.
Note: Shaft seal now sits in its Nota: Le joint d’arbre se trouve Nota: El retén se encuentra ahora
pre-selected mounting depth. maintenant dans sa profondeur a su profundidad de montaje
7. Mount flywheel using a self made 7. Monter le volant en utilisant un 7. Colocar el volante, ayudándose de
guide mandrel. Start bolts. mandrin de guidage confectionné un mandril de guía de confección
sur place. Faire un serrage propia. Enroscar los tornillos con
d’approche des vis. la mano.
8. Retain flywheel. Tighten bolts. 8. Immobiliser le volant. Serrer 8. Retener el volante. Apretar los
définitivement les vis. tornillos.

Initial tightening torque: Couple de préserrage Apriete inicial
Bolts 30 – 45 mm long __ 20 – 30 Nm de 30 – 45 mm de long __ 20 – 30 Nm Tornillos de 30 – 45 mm
Bolts 50 – 85 mm long __ 30 – 40 Nm vis de 50 – 85 mm de long 30 – 40 Nm de largo _____________ 20 – 30 mm
Tornillos de 50 – 85 mm
1st lock down angle: 1er angle de serrage définitif:
de largo _____________ 30 – 40 mm
Bolts 30 – 85 mm long ________ 60° vis de 30 – 85 mm de long _____ 60°
1er ángulo de reapriete:
2nd lock down angle: 2e angle de serrage définitif:
Tornillos de 30 – 85 mm de largo _ 60°
5 Bolts 30 mm long ____________ 30° vis de 30 mm de long _________ 30°
Bolts 35 – 85 mm long ________ 60° vis de 35 – 85 mm de long _____ 60° 2° ángulo de reapriete:
Tornillos de 30 mm de largo ____ 30°
Note: Bolts if proven to be fit for use – Nota: A condition de le consigner, Tornillos de 35 – 85 mm de largo 60°
can be re-used 5 times. les vis peuvent être réutilisées
au maximum 5 fois. Nota: En caso de comprobabilidad,
los tornillos son utilizables 5 veces
como máximo.
5.00.07 © 2002 / 0312 0361

5. Abstandscheiben auflegen.
2 Scheiben ____________ Erstmontage 4

7
1 Scheibe _____________ 1. Rep.-Einbautiefe
0 Scheiben ____________ max. Einbautiefe
30508 ©
6. Montagehülse 142 830 aufsetzen und bis An-

lage in der Vorrichtung eindrücken. 4
Hinweis: Wellendichtring ist jetzt in seiner vorge-
wählten Einbautiefe. 7
5
30121 ©
7. Schwungrad unter Verwendung eines selbst-

gefertigten Führungsdornes aufsetzen. Schrau-
ben beidrehen.
4
8. Schwungrad gegenhalten. Schrauben fest-

drehen. 30122 ©
Anziehvorschrift:
Vorspannwert
Schrauben 30 - 45 mm lang _____ 20 - 30 Nm
Schrauben 50 - 85 mm lang _____ 30 - 40 Nm
4
1. Nachspannwinkel:
Schrauben 30 - 85 mm lang ___________ 60°
6 5
2. Nachspannwinkel: 5
Schrauben 30 mm lang _______________ 30°
Schrauben 35 - 85 mm lang ___________ 60°
Hinweis: Schrauben können bei Nachweisbarkeit

5x verwendet werden. 30123 ©
© 2002 / 0312 0361 5.00.07

9. Verschlussstopfen in die Gewindebohrungen bis

4 Anlage eintreiben.
31115 ©
5.00.08 © 2002 / 0312 0361

9. Knock lock plugs into thread bores 9. Enfoncer les bouchons filetés dans 9. Montar golpeando los tapones
as far as they will go. les alésages filetés jusqu’en butée. de cierre en los taladros roscados,
hasta el tope.
© 2002 / 0312 0361 5.00.08

Bauteile ab- und anbauen Einspritzpumpe
Removal and re-installation of components Injection pump
Démontage et remontage des composants Pompe d’injection
Desmontaje y montaje de componentes Bomba de inyección
Replacement of the injection pump Remplacement de la pompe d’injection Sustitución de la bomba de inyección
for service dans le cadre du service en caso de asistencia técnica.
This repair method is intended for a Cette méthode de réparation n’est Este método de reparación está pensado
replacement of the injection pumps only. prévue que pour le seul remplacement para la sustitución de las bombas de
If other components need be replaced des pompes d’injection. Si en plus inyección. Si fuera necesario cambiar
such as roller tappets, governor etc., d’autres pièces devaient être remplacées, otras partes o piezas más, p.ej.
proceed as described under Chapter 4 telles que poussoir à galet, régulateur empujadores de rodillo, regulador, etc.,
“Disassembly and re-assembly of etc., il y a lieu de procéder comme se procederá como descrito en el capítulo
injection pumps”. indiqué au chapitre 4 « Montage des 4 “Montaje de las bombas de inyección.“.
pompes d’injection ».


Press-on device for control rod __ 100 830 Dispositif de montage de Dispositivo de presión para
Extractor pulling device ________ 100 800 la crémaillère ________________ 100 830 cremallera __________________ 100 830
Extractor pulling device for Dispositif d’extraction _________ 150 800 Dispositivo de extracción ______ 150 800
injection valve _______________ 110 030 Extracteur d’injecteur _________ 110 030 Extractor para inyectores ______ 110 030
1. Remove pressure control valve 1. Démonter la soupape régulatrice de 1. Desmontar la válvula reguladora de
and inspection cover. Pull off cable pression et le cache-culbuteurs. presión y la tapa de culata.
connector from cut-off solenoid, Débrancher le connecteur de câble de Desenchufar los cables del solenoide
governor and temperature sensor. l’électroaimant d’arrêt, du régulateur de parada, regulador y sensores
Swivel holding plate sideways. et du transmetteur de température. de temperatura. Girar hacia el lado la
Pivoter la tôle de retenue vers le côté. chapa de soporte.
2. Remove engine cut-off device or 2. Démonter le dispositif d’arrêt du 2. Desmontar del dispositivo de parada
lock cover. moteur ou le couvercle d’obturation. del motor o la tapa de cierre.
3. Press control rod into stop position 3. Pousser la crémaillère à l’aide du 3. Situar la cremallera en la posición
using the stop lever. Insert press-on levier d’arrêt en position stop. de parada mediante la palanca de
device for control rod 100 830 and Mettre en place le dispositif parada. Introducir el dispositivo de
tighten by bolts. d’extraction 100 830 et le visser. presión 100 830 y fijarlo con tornillo.
5
5.00.09 © 2002 / 0312 0361

Einspritzpumpe Bauteile ab- und anbauen
Injection pump Removal and re-installation of components
Pompe d’injection Démontage et remontage des composants
Bomba de inyección Desmontaje y montaje de componentes
Austausch der Einspritzpumpe im Servicefall.
Diese Reparaturmethode ist nur für den Austausch

der Einspritzpumpen gedacht. Sollten zusätzlich
noch andere Teile getauscht werden z. B. Rollen-
stößel, Regler etc.. ist wie in Kapitel 4 „Einspritzpum-
pen einbauen“ zu verfahren“.
Spezialwerkzeug:
Andrückvorrichtung
für Regelstange _____________________ 100 830
Auszieher für Einspritzventil ___________ 110 030 3
1. Druckregelventil und Zylinderkopfhaube abbau-
en. Kabelstecker von Abstellmagnet, Regler und
Temperaturgeber abziehen. Halteblech zur Sei-
te schwenken.
35253 ©
2. Motorabstellung oder Verschlussdeckel ausbau-

en. 3
35284 ©
3. Regelstange mittels Abstellhebel in Stopstellung

drücken. Andrückvorrichtung 100 830 einsetzen
und festschrauben.
4
7 5
35299 ©
© 2002 / 0312 0361 5.00.09

4. Regelstange mit Rändel-Feststellschraube in

s Stopstellung drücken.
Andrückvorrichtung 100 830 für Regelstange-
5 verwenden.
Hinweis: Rändel-Feststellschraube von Hand fest-

drehen.
35285 ©
5. Zylinder der entsprechenden auszubauenden

9 Einspritzpumpe auf Zünd-O.T. stellen.
Kurbelwelle ca. 120° entgegen der Motordreh-
6 richtung drehen.
Hinweis: Darstellung Blickrichtung auf Schwung-

5 rad.
35297 ©
6. Entsprechende Einspritzleitung, Einspritzpumpe

3 und Einspritzventil ausbauen.
5 Hinweis: Für Einspritzleitung Klauenschlüssel

8018 verwenden.
7
Bei Festsitz des Einspritzventils Aus-
ziehvorrichtung 150 800 mit Auszieher
110 030 verwenden.
Ggf. Dichtring mit Ausziehvorrichtung
120 680 herausziehen.
35249 ©
7. Ausgleichscheibe mit Stabmagnet vorsichtig

3 herausziehen.
35288 ©
5.00.10 © 2002 / 0312 0361

4. Press control rod into stop position 4. Pousser la crémaillère à l’aide 4. Sirviéndose del tornillo moleteado
using the knurled lock bolt. de la vis de blocage moletée en de bloqueo, colocar la cremallera
Use press-on device for control rod position stop. en la posición de parada.
100 830. Utiliser le dispositif de montage Utilizar el dispositivo de presión
100 830 pour crémaillère. 100 830 para cremallera.
Note: Tighten knurled lock bolt finger tight. Nota: Serrer la vis de blocage Nota: Apretar con la mano el tornillo
moletée à la main. moleteado de bloqueo.
5. Set cylinder of the injection pump to 5. Placer le cylindre correspondant 5. Poner en el PMS de compresión el
be removed to firing TCD. à la pompe d’injection à démonter pistón del cilindro que corresponda a
Turn crankshaft by approx. 120° sur PMH d’allumage. la bomba de inyección a desmontar.
opposite to the direction of rotation Virer le vilebrequin d’env. 120° Girar el cigüeñal aprox. 120° en
of the engine. dans le sens inverse du sens de contra del sentido de rotación normal
(Zünd OT – firing TCD) rotation du moteur. del motor.
[Zünd OT = PMS de compresión]
Note: as viewed in direction of Nota: Illustration avec vue sur le volant. Nota: Representado con la mirada
the flywheel. puesta en el volante.
6. Remove the corresponding 6. Démonter la tuyauterie d’injection, 6. Desmontar la correspondiente

injection line, injection pump and la pompe d’injection et l’injecteur tubería de inyección, bomba de
injection valve. correspondants. inyección e inyector.
Note: Use claw grip wrench 8018 for Nota: Pour la tuyauterie d’injection, Nota: Utilizar la llave de garra 8018
the injection line. utiliser la clé à griffes 8018. para la tubería de inyección.
Use extractor pulling device En cas de blocage de l’injecteur, Si el inyector está fijo, usar el
150 800 with puller 110 030 for utiliser le dispositif d’extraction dispositivo de extracción 150 800
injection valve if jammed. 150 800 avec l’extracteur 110 030. con el extractor 110 030.
Pull out O-ring if necessary, Le cas échéant, extraire le Extraer, en su caso, el anillo
using extractor 120 680. joint avec le dispositif d’extraction de junta mediante el dispositivo
120 680. de extracción 120 680.
7. Carefully extract shim with bar magnet. 7. Avec précaution sortir la cale de 7. Retirar la arandela de reglaje
réglage avec une barre magnétique. cuidadosamente mediante el
imán de barra.
© 2002 / 0312 0361 5.00.10

8. Read off ID number for injection 8. Relever la caractéristique de 8. Tomar el código de longitud
pump length (dimension A) for the longueur de pompe d’injection (cote (medida A) de la bomba de
new injection pump. A) de la nouvelle pompe d’injection. inyección nueva.
Note: See Chapter 1, page 1.00.17 for Nota: Déterminer la nouvelle cale Nota: Determinar el espesor de la
determining new shim. de réglage, voir chapitre 1, arandela de reglaje nueva,
page 1.00.17. ver cap. 1, pág. 1.00.17.
9. Place newly determined shim on 9. Poser la cale de réglage ainsi 9. Colocar la nueva arandela de
roller tappet. déterminée sur le poussoir à galet. reglaje determinada sobre el
empujador de rodillo.
10. Turn injection pump steering lever to 10. Tourner le levier articulé de 10. Girar la palanca de mando de la
center position more or less. pompe d’injection approx. en bomba de inyección aproximada-
position du milieu. mente a una posición intermedia.
11. Apply AP 1908 compound to location 11. Enduire l’alésage récepteur dans le 11. Aplicar deslizante AP 1908 al taladro
hole in crankcase and to O-rings of bloc-moteur et les joints toriques de de alojamiento en el bloque motor
injection pump. Mount injection pump la pompe d’injection de produit de y a los anillos tóricos de la bomba de
and insert injection pump steering montage AP 1908. Monter la pompe inyección. Montar ésta, introduciendo
5 lever carefully into control rod. d’injection en introduisant avec cuidadosamente la palanca de
précaution le levier articulé de pompe mando en la cremallera.
d’injection dans la crémaillère.
Note: The roller tappet for the respective Nota: Le poussoir à galet de la pompe Nota: El empujador de rodillo
injection pump must be on the base d’injection en question doit se correspondiente a la bomba de
circle of the camshaft. trouver sur le cercle de base de inyección debe encontrarse sobre
l’arbre à cames. el círculo base del árbol de levas.
5.00.11 © 2002 / 0312 0361

8. Kennzahl für Einspritzpumpenlänge (Maß A)

von der neuen Einspritzpumpe ablesen.
9
Hinweis: Neue Ausgleichscheibe ermitteln siehe
Kapitel 1, Seite 1.00.17. 5
30095 ©
9. Neu ermittelte Ausgleichscheibe auf Rollen-

stößel auflegen.
4
35287 ©
10. Einspritzpumpenlenkhebel auf ca. Mittelstel-

lung drehen. 9
35300 ©
11. Aufnahmebohrung im Kurbelgehäuse und

Runddichtringe der Einspritzpumpe mit
Montagemittel AP 1908 bestreichen. Einspritz-
4
pumpe einbauen, dabei Einspritzpumpenlenk-
hebel vorsichtig in die Regelstange einführen. 9 5
Hinweis: Der Rollenstößel für die entsprechende 5
Einspritzpumpe muss auf dem Grund-
kreis der Nockenwelle stehen.
35289 ©
© 2002 / 0312 0361 5.00.11

12. Flansch auflegen.

4 Hinweis: Anfasung muß zum Einspritzpumpen-
5 körper weisen.
35290 ©
13. Schrauben leicht einölen und mit einem Dreh-

4 moment von 5 Nm festdrehen.
z
6
35291 ©
14. Schrauben wieder 60° lösen.

3
6
35292 ©
15. Einspritzpumpe mit Verdrehschlüssel 8117 ge-

4 gen Uhrzeigersinn vorsichtig bis zum fühlbaren
Anschlag drehen.
5
6
35293 ©
5.00.12 © 2002 / 0312 0361

12. Put on flange. 12. Mettre en place la bride. 12. Colocar la brida
Note: Chamfered end must face Nota: Le lamage doit être dirigé vers le Nota: La parte biselada debe indicar
injection pump body. corps de pompe d’injection. hacia el cuerpo de la bomba de
inyección.
13. Slightly oil bolts and tighten to a 13. Huiler légèrement les vis et les serrer 13. Untar con un poco de aceite los
tightening torque of 5 Nm avec un couple de 5 Nm. tornillos y apretarlos con un par
de 5 Nm.
14. Release bolts again by 60°. 14. Desserrer de nouveau les vis de 60°. 14. Volver a aflojar 60° los tornillos.
15. Carefully turn injection pump 15. Avec la clé polygonale 8117 tourner 15. Sirviéndose de la llave de giro
counter clockwise up to a noticeable doucement la pompe d’injection dans 8117, girar la bomba de inyección
stop using serrated wrench 8117. le sens anti-horaire jusqu’à ce que la cuidadosamente en contra del
butée se fasse sentir. sentido de las agujas del reloj,
hasta llegar al tope perceptible. 5
© 2002 / 0312 0361 5.00.12

16. Turn bolts in again by 60° and 16. Resserrer de nouveau les vis de 60° 16. Apretar los tornillos nuevamente 60°
gradually tighten to a tightening et ensuite par passes successives con la mano y, luego, en fases de
torque of 7 Nm, 10 Nm and 30 Nm. avec un couple de 7 Nm, de 10 Nm 7 Nm, 10 Nm y 30 Nm.
et de 30 Nm.
Note: Start with the outer bolt remotest Nota: Commencer par les vis externes, Nota: Comenzar siempre con el tornillo
from flywheel. éloignées du volant. exterior, más alejado del volante.
17. Turn knurled lock bolt back again. 17. Tourner la vis de blocage moletée 17. Girar hacia atrás el tornillo
Remove press on device 100 830. dans le sens inverse. Démonter le moleteado de bloqueo.
(nicht 110 830) dispositif d’extraction 100 830. Desmontar el dispositivo de
presión 100 830.
Note: Check smooth movement of Nota: S’assurer que la crémaillère ne Nota: Comprobar que la cremallera
control rod from stop position présente pas de points durs entre pueda moverse con facilidad de
to start position. Actuate cut-off la position stop et la position la posición de parada a la de
lever to this end. lancement. Pour cela actionner le arranque. Para ello, accionar la
levier d’arrêt. palanca de parada.
18. Mount new O-ring. 18. Monter un joint torique neuf. 18. Montar un anillo tórico nuevo.
Note: Slightly oil O-ring. Nota: Huiler légèrement le joint torique. Nota: Untar con un poco de aceite
el anillo tórico.
19. Press control rod into stop position 19. A l’aide du levier d’arrêt, pousser la 19. Situar la cremallera en la posición
using the cut-off lever and retain. crémaillère en position stop et l’y de parada mediante la palanca
Install engine shut-off device. Tighten maintenir. Monter le dispositif d’arrêt de parada y retenerla en esta
bolts. Plug in cable connector. du moteur. Serrer les vis. Brancher le posición. Montar el dispositivo de
5 connecteur de câble. parada del motor. Apretar los
tornillos. Enchufar el cable.
5.00.13 © 2002 / 0312 0361

16. Schrauben wieder 60° beidrehen und in Stufen

mit einem Drehmoment von 7 Nm, 10 Nm und
30 Nm festdrehen.
4
Hinweis: Mit der jeweils außenliegenden, vom 6
Schwungrad entfernteren Schraube be-
ginnen. 5
35291 ©
17. Rändel-Feststellschraube zurückdrehen.

Andrückvorrichtung 100 830 abbauen. 3
Hinweis: Prüfen ob Regelstange von Stopstellung
zur Startstellung leichtgängig ist. Hierzu 7
5
Abstellhebel betätigen.
35295 ©
18. Neuen Runddichtring montieren.
Hinweis: Runddichtring leicht einölen.

2
ß
5
z
30291 ©
19. Regelstange mittels Abstellhebel in Stop-

stellung drücken und festhalten. Motorab-
stellung einbauen. Schrauben festdrehen.
4
Kabelstecker aufstecken.
6 5
35296 ©
© 2002 / 0312 0361 5.00.13

20. Neuen Dichtring mit etwas Fett auf das

4 Einspritzventil aufschieben und Einspritzventil
einsetzen.
ß Hinweis: Die Ansenkung auf dem Einspritzventil
8
muss von der Pratze weg zeigen. Mar-
kierung zeigt zur Abgasseite.
5
35247 ©
21. Pratzen aufsetzen und Schrauben lose ein-

4 schrauben.
35248 ©
22. Neue Einspritzleitung mit Dichtgummi anbau-

4 en. Überwurfmutter fingerfest aufschrauben.
ß Hinweis: Bei Montage der Einspritzleitung müs-

sen die Dichtkonen exakt aufeinander-
5
sitzen.
Ein Nachbiegen ist nicht zulässig.
Die Einspritzleitung darf nicht 2x ver-
wendet werden.
35249 ©
23. Schraube der Pratzen festdrehen.

4 Anziehvorschrift: 16 + 5 Nm
6
5
35250 ©
5.00.14 © 2002 / 0312 0361

20. Slide sealing ring onto injection 20. Emmancher le joint neuf avec un 20. Colocar, con un poco de grasa,
valve using some grease and insert peu de graisse sur l’injecteur et el anillo de junta nuevo sobre el
injection valve. monter l’injecteur. inyector e introducir éste.
Note: The notch on the injection valve Nota: Le lamage sur l’injecteur doit être Nota: El rebaje existente en el inyector
must face away from the claw. dirigé du côté opposé à la patte. debe estar orientado hacia el lado
Marking faces exhaust gas end. Le marquage est dirigé vers le côté opuesto a las garras. La marca
échappement. está orientada hacia el lado de los
gases de escape.
21. Mount claws and turn in bolts loosely. 21. Mettre en place la patte et serrer 21. Colocar las garras y enroscar los
légèrement les vis. tornillos, dejándolos sueltos.
22. Fit new injection line with sealing 22. Monter une nouvelle tuyauterie 22. Montar la tubería de inyección nueva
rubber. Tighten cap nut finger-tight. d’injection avec un joint en ctc. con la obturación de goma. Enroscar
Faire un vissage manuel de la tuerca de unión con los dedos.
l’écrou-raccord.
Note: Sealing cones must be exactly in Nota: Lors du montage de la tuyauterie Nota: Al hacer el montaje de la tubería
line when mounting the injection d’injection, les cônes d’étanchéité de inyección es imprescindible
line. doivent parfaitement coïncider. que los conos de cierre estanco
Re-bending is not allowed. Un cintrage de correction n’est se asienten exactamente uno
Injection lines must not be pas admissible. sobre otro.
used twice. La tuyauterie d’injection ne doit No es admisible curvar
pas être utilisée 2 fois. ni reutilizar las tuberías de
inyección.
23. Tighten bolt of claws. 23. Serrer la vis de la patte. 23. Apretar el tornillo de las garras.

torque: 16 + 5 Nm
5
© 2002 / 0312 0361 5.00.14

24. Pre-tension cap nuts of injection 24. Préserrer les écrous-raccord de la 24. Apretar las tuercas de unión de la
line on injection pump and injection tuyauterie d’injection sur la pompe tubería de inyección en la bomba de
valve to a tightening torque of d’injection et l’injecteur avec un inyección y en el inyector
approx. 5 Nm. Tighten cap nuts then. couple d’env. 5 Nm. Ensuite, serrer previamente con aprox. 5 Nm. Luego,
définitivement les écrous-raccord. reapretarlas.
Specified tightening torque: Prescription de Prescripción de

25 ± 3.5 Nm serrage: 25 ± 3,5 Nm apriete: 25 ± 3,5 Nm
25. Fit gasket. 25. Poser le joint. 25. Colocar la junta.
26. Fit inspection cover and supporting 26. Monter le cache-culbuteurs et la tôle 26. Montar la tapa de culata y la chapa
plate. Tighten bolts. Make sure de retenue. Serrer les vis. Veiller au de soporte. Apretar los tornillos.
sealing rubbers are correctly seated. bon positionnement des joints ctc. Prestar atención al asiento correcto
de las obturaciones de goma en la
tapa de culata.
Fit pressure control valve Monter la soupape régulatrice de Montar la válvula reguladora de
with a new seal, if necessary. pression avec un joint neuf le cas presión, en su caso, con una junta
Tighten bolts. échéant. Serrer les vis. nueva. Apretar los tornillos.
27. Plug in cable connector on cut-off 27. Brancher le connecteur de 27. Enchufar los cables en el solenoide
solenoid and governor. câble sur l’électroaimant d’arrêt de parada y el regulador.
et le régulateur.
5.00.15 © 2002 / 0312 0361

24. Überwurfmuttern der Einspritzleitung an der

Einspritzpumpe und Einspritzventil mit einem
Drehmoment von ca. 5 Nm vorspannen.
4
Danach Überwurfmuttern festdrehen.
6
Anziehvorschrift: 25 ± 3,5 Nm

5
35251 ©
25. Dichtung auflegen.

4
0
35234 ©
26. Zylinderkopfhaube und Halteblech anbauen.

Schrauben festdrehen. Auf richtigen Sitz der
Dichtgummis achten.
4
Druckregelventil ggf. mit neuer Dichtung an- 0
bauen. Schrauben festdrehen.
35229 ©
27. Kabelstecker an Abstellmagnet und Regler auf-

stecken. 4
5
35254 ©
© 2002 / 0312 0361 5.00.15

28. Kabelstecker an Temperaturfühler aufstecken.

4
35255 ©
5.00.16 © 2002 / 0312 0361

28. Plug in cable connector to 28. Brancher le connecteur de câble sur 28. Enchufar los cables en los sensores
temperature sensor. la sonde de température. de temperatura.
© 2002 / 0312 0361 5.00.16

Bauteile ab- und anbauen Thermostat
Removal and re-installation of components Thermostat
Démontage et remontage des composants Thermostat
Desmontaje y montaje de componentes Termostato
1. Drain coolant, collect and dispose 1. Vidanger le fluide réfrigérant, le 1. Evacuar el refrigerante, recogerlo y
of in accordance with anti-pollution recueillir et l’éliminer conformément eliminarlo en forma reglamentaria.
regulations. aux réglementations antipollution. Desmontar la tubuladura de salida.
Remove outlet connection. Take out Démonter la tubulure de sortie. Retirar el termostato.
thermostat. Sortir le thermostat.
Note: Drain coolant, collect and dispose Nota: Recueillir le fluide réfrigérant et Nota: Recoger el refrigerante y eliminarlo
of in accordance with anti-pollution l’éliminer conformément aux en forma reglamentaria.
2. Fit new sealing ring to thermostat. 2. Placer un joint neuf sur le thermostat. 2. Colocar un anillo de junta nuevo sobre
Mount thermostat together with new Monter le thermostat ensemble avec el termostato. Instalar el termostato
sealing ring. le joint neuf. con el nuevo anillo de junta.
Note: Observe mounting position of Nota: Respecter la position de montage Nota: Observar la posición en que se
thermostat. du thermostat. monte el termotato.
Arrow (bleeder notch) pointing up. La flèche (encoche de purge d’air) La flecha (muesca de purga de
est dirigée vers le haut. aire) indica hacia arriba.
3. Fit outlet connection. 3. Monter la tubulure de sortie. 3. Montar la tubuladura de salida.
5.00.17 © 2002 / 0312 0361

Thermostat Bauteile ab- und anbauen
Thermostat Removal and re-installation of components
Thermostat Démontage et remontage des composants
Termostato Desmontaje y montaje de componentes
1. Kühlmittel ablassen, auffangen und vorschrifts-

mäßig entsorgen.
Austrittsstutzen abbauen. Thermostat heraus-
3
nehmen.
5
Hinweis: Kühlmittel auffangen und vorschrifts-
mäßig entsorgen.
35406 ©
2. Neuen Dichtring auf Thermostat aufsetzen.

Thermostat zusammen mit neuem Dichtring
einsetzen.
4
Hinweis: Einbaulage von Thermostat beachten. ß
8
Pfeil (Entlüftungskerbe) zeigt nach oben.
5
35407 ©
3. Austrittsstutzen anbauen.
4
6
35406 ©
© 2002 / 0312 0361 5.00.17

Bauteile ab- und anbauen Thermostat
Removal and re-installation of components Thermostat
Démontage et remontage des composants Thermostat
Desmontaje y montaje de componentes Termostato
© 2002 / 0312 0361

Werkzeuge
Tools
Outils
Herramientas 2012
© 2003 / 0312 0361

Wir bitten Sie, alle Bestellungen von Spezialwerkzeugen direkt an die
Fa. Wilbär, D-42826 Remscheid, Postfach 14 05 80, Tel 02191 / 93 39 0
Fax 02191 / 93 39 200, e-mail: info@wilbaer.de zu richten.
Please order all your special tools direct from Messrs. Wilbär, D-42826 Remscheid,
Postfach 14 05 80, Tel ++49 (0) 2191 / 93 39 0, Fax ++49 (0) 2191 / 93 39 200, e-mail: info@wilbaer.de
Nous vous prions de passer directement toutes vos commandes d’outillage

spécial auprès de la société: Wilbär, D-42826 Remscheid, Postfach 14 05 80,
Tel ++49 (0) 2191 / 93 39 0, Fax ++49 (0) 2191 / 93 39 200, e-mail: info@wilbaer.de
Rogamos dirigir todos los pedidos de herramientas especiales directamente a la casa Wilbär,
D-42826 Remscheid, Postfach 14 05 80, Tel ++49 (0) 2191 / 93 39 0, Fax ++49 (0) 2191 / 93 39 200,
e-mail: info@wilbaer.de
Handelsübliche Werkzeuge
Commercially available tools
Outils usuels
Herramientas comerciales
Deutsch English Français Español No. Werkstatthandbuch BFM 2012
Druckpumpe für Kühlmitteldichtheitsprüfung 8002
Pressure pump for coolant leakage test.
Pompe refoulante pour contrôle de l’étanchéité du

liquide refroidisseur
Bomba de presión para pruebas de estanqueidad

sistema de líquido refrigerante
35409 ©
Kompressionsdruckprüfer 8005
Compression tester
Compressiomètre
Compresímetro
35410 ©
Düsenprüfgerät 8008
Nozzle tester
Pompe d’essai d’injecteurs
Comprobador para inyectores
35411 ©
Stecknuss SW 15, lange Ausführung für Einspritz- 8012

ventil. (Überwurfmutter)
Socket a/flats 15, long version for injector

(cap nut)
Douille de 15, version longue pour injecteur

(écrou-raccord).
Llave de vaso de 15, versión larga, para inyector

(tuerca de unión)
35412 ©
© 2002 / 0312 0361 6.00.01

6
Outils usuels
Werkstatthandbuch BFM 2012 No. Deutsch English Français Español
8018 Klauenschlüssel SW 17 für Einspritzleitungen
Clay-grip wrench a/flats 17 for injection lines
Cléà griffes de 17 pour tuyauteries d'injection
Llave de garra de 17 para tuberías de inyección
35413 ©
8024 Ventilschaftabdichtungszange
Valve sealing pliers
Pince à joints de queue de soupapa
Alicates para juntas de vástago de válvula
35414 ©
8113 Torx-Steckschlüsseleinsatz E14

Torx wrench sockets E14
Embouts de clé à douille Torx E14
Llave de vaso Torx E14
8114 Torx-Steckschlüsseleinsatz E20, lange Ausführung

Torx wrench sockets E20, long version
Embouts de clé à douille Torx E20, version longue
35415 © Llave de vaso Torx E20, versión larga
8115 Keilriemenspannungsmessgerät
V-belt tension gauge
Appareil de vérification de la tension de la

courroie trapézoïdale
Verificador de tensión para correas

trapezoidales
35416 ©
6.00.02 © 2002 / 0312 0361

6
Outils usuels
Verdrehschlüssel (Vielzahn) für Einspritzpumpe 8117
Serrated wrench for turning injection pump
Clé polygonale pour pompe d’injection
Llave de giro (poligonal) para bomba de inyección
35417 ©
Torx-Werkzeugsatz 8189
Torx tool kit
Jeu d’outils Torx
Juego de herramientas Torx
35418 ©
Ventilfedermontagehebel 9017
Valve spring assembly lever
Levier de montage pour ressort de soupape
Palanca de montaje para resortes de válvula
35419 ©
Federklemmenzange 9090
Spring clamp pliers
Pince à ressort pour tuyaux
Alicates para abrazaderas elásticas
35420 ©
© 2002 / 0312 0361 6.00.03

6
Outils usuels
© 2002 / 0312 0361

6
Spezialwerkzeuge
Special tools
Outils spéciaux
Herramientas especiales
Anschlußstück für Kompressionsdruckprüfer 100 110
Connector for compression tester
Raccord pour compressiomètre
Pieza de empalme para el compresímetro
35421 ©
Durchdrehvorrichtung 100 320
Turning gear
Dispositif vireur
Dispositivo de viraje
35422 ©
Durchdrehvorrichtung 100 330
Turning gear
Dispositif vireur
Dispositivo de viraje
35423 ©
Messuhr M2T mit Feststellring. 100 400
Dial gauge M2T with locking ring
Comparateur M2T avec bague

d’immobilisation
Comparador M2T con anillo exterior

de bloqueo
35424 ©
© 2002 / 0312 0361 6.00.05

56
Spezialwerkzeuge
Special tools
Outils spéciaux
100 750 Messbalken mit Abstandsblättchen zum Messen

des OT und des Kolbenüberstandes.
Measuring bar with spacers for gauging

TDC and piston projection
Barre de mesure avec plaquettes d’écartement

pour mesurer le PMH et la cote de dépassement du
piston
Barra de medición con plaquitas distanciadoras

35425 © para la medición del PMS y saliente de pistón
100 800 Messgerät zum Messen und Blockieren der

Regelstange.
Measuring device for measuring and

locking control rod
Appareil de mesure et de blocage de la

crémaillère.
Equipo de medición y de bloqueo de la cremallera
35426 ©
100 810 Einstellbolzen für MAG-Wellen.
Adjusting pin for mass balancing shafts
Pige de calage pour arbres à masses d’équilibrage

(MAG)
Pernos de ajuste para ejes equilibradores

de masa „MAG".
35427 ©
100 830 Andrückvorrichtung für Regelstange
Press-on device for control rod
Dispositif de montage de cremaillère
Dispositivo de presión para la cremallera
35428 ©
6.00.06 © 2002 / 0312 0361

56
Spezialwerkzeuge
Special tools
Outils spéciaux
Messvorrichtung für Grundkreismessung 100 890

„Einspritzpumpe und Förderbeginn“.
Measuring device for base circle measurement
Dispositif de mesure du cercle de base
Dispositivo de medición del círculo base

“bomba de inyección y comienzo de alimentación“
35429 ©
Gradscheibe 360° mit Befestigung an der 101 020

Schwungscheibe für OT und FB Einstellung.
Graduated disc 360° with device for fastening

to flywheel for TDC and COD setting
Disque gradué 360° avec fixation sur volant moteur

pour réglage du PMH et point de calage du début
d’injection
Disco graduado 360° con fijación en el volante,

para ajuste del PMS y comienzo de alimentación 35430 ©
Adapter für Gradscheibe. 101 030
Adapter for graduated disc
Adaptateur pour disque gradué
Adaptador para el disco graduado
35431 ©
Zeiger für Gradscheibe. 101 300
Pointer for graduated disc
Index pour disque gradué
Indicador para el disco graduado
35432 ©
© 2002 / 0312 0361 6.00.07

56
Spezialwerkzeuge
Special tools
Outils spéciaux
101 910 Drehwinkel-Messgerät. Vorrichtung zum Ablesen

der Winkelgrade beim Anziehen von Hauptlager-,
Pleuel-, Schwungradschrauben usw.
Tightening angle dial indicator for main bearing,
big-end and flywheel bolts, etc.
Appareil de mesure angulaire. Dispositif de lecture
des angles de serrage des vis de palier principal,
de bielle, de volant etc.
Medidor de ángulos de giro. Dispositivo para la
lectura de ángulos de apriete de tornillos de
35456 ©
cojinetes de apoyo, de biela, de volante, etc.
110 030 Auszieher für Einspritzventil in Verbindung

mit 150 800
Extractor for injectors, to be used with tool

150 800
Extracteur d’injecteur en liaison avec 150 800
Extractor para inyector en combinación con

la herramienta 150 800
35433 ©
110 110 Halter für Einspritzventil SW 11
Dolly for injector a/flats 11
Dispositif d’immobilisation d’injecteur de 11
Dispositivo de retención para inyector, de 11
35434 ©
110 470 Montagewerkzeug für Regelstangen-Buchsen.
Assembly tool for control rod sleeves
Outil de montage pour bagues de crémaillère
Herramienta de montaje para casquillos de

cremallera
35435 ©
6.00.08 © 2002 / 0312 0361

56
Spezialwerkzeuge
Special tools
Outils spéciaux
Spezialschlüssel für Einspritzleitung 110 500
Special wrench for injection line
Clé spéciale pour conduite d’injection
Llave especial para tubería de inyección
35436 ©
Ausziehvorrichtung für den Dichtring unter 120 680

dem Einspritzventil.
Extractor for sealing ring beneath injector
Outil d’extraction pour le joint de l’injecteur
Dispositivo de extracción para el anillo de

junta del inyector
35437 ©
Aufspannbock für Zylinderkopf. 120 900
Clamping stand for cylinder head
Chevalet d’ablocage pour culasse
Caballete de sujeción para culata
35438 ©
Aufspannplatte für 120 900. 120 910
Clamping plate for 120 900
Plaque d’ablocage pour 120 900
Placa de sujeción para 120 900
35439 ©
© 2002 / 0312 0361 6.00.09

56
Spezialwerkzeuge
Special tools
Outils spéciaux
121 410 Montagewerkzeug für Ventilschaftabdichtung
Sleeve for fitting valve stem seal
Outil de montage pour joint de tige de soupape
Util de montaje para juntas de vástago de válvula
35440 ©
130 300 Kolbenring-Auflegezange
Piston ring pliers
Pince à monter les segments de piston
Alicates para colocar aros de pistón
35441 ©
130 440 Trapeznut-Verschleißlehre
Trapezoidal groove wear gauge
Jauge d’usure pour gorge trapézoïdale
Calibre de desgaste para ranura trapezoidal
35442 ©
130 660 Kolbenringspannband Ø 98 mm
Piston ring compressor
Collier à segments de piston de Ø 98 mm
Compresor de aros de pistón, Ø 98 mm
35443 ©
6.00.10 © 2002 / 0312 0361

56
Spezialwerkzeuge
Special tools
Outils spéciaux
Kolbenringspannband Ø 101 mm 130 670
Piston ring compressor
Collier à segments de piston de Ø 101 mm
Compresor de aros de pistón, Ø 101 mm
35443 ©
Montagewerkzeug für Kurbelwellendichtring vorn. 142 670
Assembly tool for front crankshaft seal
Outil de montage de bague d’étanchéité de

vilebrequin AV
Herramienta de montaje para el retén delantero del

cigüeñal
35445 ©
Montagewerkzeug für Kurbelwellendichtring hinten. 142 830
Assembly tool for rear crankshaft seal
Outil de montage de bague d’étanchéité de

vilebrequin AR
Herramienta de montaje para el retén trasero del

cigüeñal
35446 ©
Montagewerkzeug für MAG-Buchsen. 143 780
Assembly tool for engine balancer bushes
Outil de montage de douilles d’arbres à masses

d’équilibrage
Herramienta de montaje para casquillos de ejes

equilibradores
35447 ©
© 2002 / 0312 0361 6.00.11

56
Spezialwerkzeuge
Special tools
Outils spéciaux
143 840 Montagewerkzeug für Nockenwellen-Buchsen.
Assembly tool for camshaft sleeves
Outil de montage de douilles d’arbre à cames
Herramienta de montaje para casquillos de árbol

de levas
35448 ©
144 800 Gegenhalter für Drehschwingungsdämpfer
Dolly for torsional vibration damper
Dispositif d’immobilisation de l’amortisseur de

vibrations torsionnelles
Dispositivo de retención para amortiguador de

vibraciones torsionales
35453 ©
150 800 Ausziehvorrichtung, z.B. für Einspritzventil
Extractor pulling device, e.g. for injector
Dispositif extracteur, p. ex. pour injecteur
Dispositivo de extracción, p.ej. para inyector
35449 ©
160 330 Gegenhalter für Zentralmutter, Lüfter
Dolly for center nut, fan
Dispositif d’immobilisation de l’écrou central,

ventilateur
Dispositivo de retención para tuerca central,

ventilador
35454 ©
6.00.12 © 2002 / 0312 0361

56
Spezialwerkzeuge
Special tools
Outils spéciaux
Maul-Steckaufsatz für Drehmomentschlüssel 160 340

(mit großem Vierkant 14 x 18 mm) für Lüfter (Ein- /
Ausbau) - Zentralmutter
Open jawed wrench socket for torque wrench
(large square wrench 14 x 18 mm) for fan
(assembly and removal) – center nut
Embout à mâchoire pour clé dynamométrique
(à grand quatre-pans 14 x 18 mm) pour ventilateur
(démontage/remontage) – écrou central
Boca enchufable para llave dinamométrica
(con macho cuadrado grande 14 x 18 mm) para
(montaje/desmontaje) tuerca central del ventilador 35455 ©
Gegenhalter für Zahnrad Luftpresser 170 630
Dolly for air compressor gear
Dispositif de maintien pour pignon de compresseur

d’air
Dispositivo de retención para rueda dentada

compresor de aire
35450 ©
Motormontagebock für doppelseitige Auf- 6066

spannung
Engine assembly stand for double-sided

chucking
Chevalet de montage moteur avec double

ablocage
Caballete de montaje para sujeción bilateral

del motor
35451 ©
1 Satz Aufspannwinkel für doppelseitige Auf 6066/158

spannung.
1 Set of angled clamping plates for

double-sided chucking
1 jeu d’équerre de fixation pour double ablocage
1 juego de angulares para sujeción bilateral
35452 ©
© 2002 / 0312 0361 6.00.13

56
Spezialwerkzeuge
Special tools
Outils spéciaux
© 2002 / 0312 0361

56
Power train
5 Power train 40 kph drive diagram for models 400 – 404

Power train
5.1 40 kph drive hydraulics diagram for models 400 – 404
Variable displacement pump TMP 89 with ECOSPEED 40 kph and auxiliary motor
(fixed displacement motor)
VIII
5-1 000 295 725 0 – RHB SCORPION

Power train
40 kph drive electrics diagram for models 402, 403, 404 40 kph drive electrics diagram for models 402, 403, 404
Power train
5.2 40 kph drive electrics diagram for models 402, 403, 404
Variable displacement pump TMP 89 with ECOSPEED 40 kph and auxiliary motor
(fixed displacement motor)
5-3 000 295 725 0 – RHB SCORPION

Power train
20 kph drive for models 400 – 404 20 kph hydraulic drive diagram for models 400 – 404
Power train
5.3 20 kph hydraulic drive diagram for models 400 – 404

400 – 401 20 kph 402 – 404 20 kph
VIII.1
5-5 000 295 725 0 – RHB SCORPION

Power train
Drive electrics diagram for models 400 – 404 Drive electrics diagram for models 400 – 404
Power train
5.4 Drive electrics diagram for models 400 – 404
5-7 000 295 725 0 – RHB SCORPION

Power train
Power train
Drive hydraulics diagram descriptions
Hydraulic drive diagram: description Machine position

VII Drive hydraulics variable displacement pump 400/401 E7/VIII
VIII Drive hydraulics variable displacement motor 400/401 E5/VIII
VIII.1 Drive hydraulics variable displacement pump 402/404 E5/VIII
10 Fan pump D8/VI
15 Filter E7/VIII
25 Tank H10/V
27 Oil cooler D6/VI
35 Drive pump E7/VIII
Hydraulic ram drive servo adjustment pump
36 See “Drive”
(non feedback)
37 Boost pressure relief valve (drive) See “Drive”
38 Pressure cut-off valve, reverse (drive) See “Drive”
39 Pressure cut-off valve, forwards (drive) See “Drive”
40 Multifunctional valve, reverse (drive) See “Drive”
41 Multifunctional valve, forwards (drive) See “Drive”
42 Drive variable displacement motor E6/VII
43 Hydraulic ram (drive) servo drive motor See “Drive”
49 Drive pump E7/VIII
50 Hydraulic ram (drive) See “Drive”
52 Pressure relief valve with resuction (reverse driving) See “Drive”
53 Pressure relief valve with resuction (forwards driving) See “Drive”
54 Drive variable displacement motor E6/VII
55 Hydraulic ram (drive) See “Drive”
56 Throttle non-return valve See “Drive”
000 295 725 0 – RHB SCORPION 5-8

Power train
Hydraulic drive diagram: description Machine position

57 (Power valve/control initiation) See “Drive”
58 (driving direction valve) See “Drive”
59 Shuttle valve (drive flushing) See “Drive”
60 Flush pressure relief valve (drive) See “Drive”
61 Fixed displacement motor (drive) See “Drive”
100 (Y02) proportional valve (capacity) See “Drive”
101 (Y04) forwards proportional valve See “Drive”
102 (Y05) reverse proportional valve See “Drive”
103 (Y10) driving direction identification 2/2 directional valve See “Drive”
A Consumers port –
B Consumers port –
M Test port –
L Leak oil port –
S Suction port –
5-9 000 295 725 0 – RHB SCORPION

Power train
Electric diagram descriptions
Drive electrics diagram: description Machine position

B9 Speed sensor E6/VIII
B10 Diesel engine speed (see “Engine/cooling”)
D1 Steering electronics (see “Electric system”)
D2 Hold electronics (see “Electric system”)
H16 Forwards driving telltale (see “Operation”)
H17 Reverse driving telltale (see “Operation”)
K3 Reverse driving switching relay (see “Electric system”)
K30 Brake lights switching relay (see “Electric system”)
K36 Drive signals switching relay (see “Electric system”)
K37 Drive signals switching relay (see “Electric system”)
P5 Speedometer (see “Electric system”)
R2 Inching pedal (see “Electric system”)
R3 Crawler gear potentiometer (see “Electric system”)
S6 Hydraulic oil temperature switch (see “Operation”)
S21 1st/2nd speed switch (see “Operation”)
S22 Steering mode/high speed switch (see “Operation”)
S34 Forwards driving tip switch (see “Operation”)
S35 Reverse driving tip switch (see “Operation”)
S66 Neutral tip switch (see “Operation”)
X1 Engine vat signals See “Electric system” (pages 10 – 31)
X2 Frame signals See “Electric system” (pages 10 – 31)
X7 Hold electronics See “Electric system” (page 10 – end)
X8 Hold electronics See “Electric system” (page 10 – end)
X9 Joystick G6/VI
X11 Armrest/cab disconnect G8/VI
X13 Engine revs signal transmitter See “Engine cooling”
X16 Inching potentiometer See “Drive”
X17 Speed sensor See “Drive”
X20 Steering electronics inputs See “Electric system” (page 10 – end)
X21 Steering electronics outputs See “Electric system” (page 10 – end)
000 295 725 0 – RHB SCORPION 5-10

Power train
Drive electrics diagram: description Machine position

X35 Crawler gear potentiometer G6/V
X37 Driving direction identification See “Drive”
Y2 1st/2nd speed solenoid valve E6/VII
Y4 Reverse driving solenoid valve E7/VII
Y5 Forwards driving solenoid valve E7/VII
Y10 Driving direction identification solenoid valve F6/VIII
5-11 000 295 725 0 – RHB SCORPION

Power train
5.5 Functional despcription of drive hydraulics and electric system

Oil supply via fan pump (10)
The fan pump (010) supplies oil for a range of functions:
• Fan motor (014, 013)
• Drive pump with boost pressure VII
• Drive motor with servopressure
• Brake system with reinforcement pressure VI
• Differential lock and parking brake V
• Solenoid valve pilot control unit with servopressure XII
• Joystick pilot control unit with servopressure XI
Boost pressure circuit

By pumping oil via the filter (015), the fan pump (010) creates and builds up the boost
pressure against the boost pressure relief valve (051). Depending on the spring setting in
the valve (051), the oil flow is put under initial stress and then released to the tank.
The boost pressure is applied to the servo adjustment valve (Y05 and Y04) and the multi-
functional valves (052/053). If the variable displacement pump (VII) is not swivelled out,
the boost pressure is transmitted to either side of the high pressure circuit via the feed
valves in the multifunctional valves (053 – 052).
Boost pressure relief valve

The pressure setting can be corrected after the locknut on the boost pressure relief
valve (051) has been slackened.
Pump adjustment
The spool in the servo adjustment valve is moved proportionally out of the neutral position,
in either direction by means of the solenoid coils (Y04, Y05). Depending on the driving
direction, pressure is applied to one side of the servo cylinder (050), and the other side is
connected with the tank by means of the reflux. The servo cylinder (050) swivels the varia-
ble displacement pump (VII). In doing so, the magnetic force of the solenoid
coils (Y04/Y05) acts against the spring tension of the spool. There is no mechanical feed-
back of the swivel angle to the servo adjustment valve (non feedback system). The swivel
angle is set as a function of the current at the solenoid coils (Y04, Y05). This current is
controlled by the drive electronics (N01).
000 295 725 0 – RHB SCORPION 5-12

Power train
Motor adjustment
The engine has maximum capacity in its base position. In doing so, the highest torque is
created at lowest revs. The motor is adjusted via forwards high pressure. Due to the effect
of the solenoid valve (Y10) for driving direction identification, only high pressure acts on
the drive hydraulic ram
Motor servo adjustment (061). No adjustment takes place when reversing. Machine speed
can be increased by means of the current-regulated solenoid valve for 1st/2nd speed. The
motor is not adjusted in 1st speed. Drive speed is regulated by the pump only. 2nd speed
is used for transport. The current-regulated solenoid valve for 1st/2nd speed of the motor
adjusts the engine to minimum capacity as required by the drive movements of the
machine. In doing so, low torque is created at high revs.
Drive output regulation

Diesel engine revs are picked up by the drive electronics in order to adjust drive output to
the existing diesel engine output. If diesel engine revs drop, the hydraulic motor is regu-
lated to higher capacity. Maximum drive speed is reduced in doing so. Control initiation is
set hydraulically via the valve (output restriction/control initiation 046).
Flush feature
The high-pressure side in the high-pressure circuit switches the shuttle valve (scouring
slide valve 047) in the variable displacement motor (drive hydraulics VIII). In doing so, a
larger amount of oil is replaced in the closed oil circuit.
Locking driving direction selection

Driving direction selection can be locked via the relays by pressing the neutral tip
switch (S66) or by applying the parking brake.
Holding the signal for the forwards driving direction selection

By means of the hold electronics module (D2), an input signal from the forwards tip
switch (S34) is held until the reverse tip switch (S35) or the neutral tip switch (S66) is
pressed, or until the parking brake is applied.
Holding the signal for the reverse driving direction selection

By means of the hold electronics module (D2), an input signal from the reverse tip
switch (S35) is held until the forwards tip switch (S34) or the neutral tip switch (S66) is
pressed, or until the parking brake is applied.
5-13 000 295 725 0 – RHB SCORPION

Power train
Drive speed control

The diesel engine revs (B10) are read into the drive electronics (N1) as rated values. As
the diesel engine revs increase, the drive electronics (N1) proportionally sets the solenoid
valves of the servo adjustment of the variable displacement pump of the drive
hydraulics (VII) and the variable displacement motor of drive hydraulics (VIII) to a higher
drive speed. The drive electronics (N1) captures the actual value via the speed
sensor (B9).
Inching pedal function

The (brake) inching pedal (R2) reduces the rated value for drive speed regulation. The
drive electronics (N1) picks up the voltage from the inching pedal sensor (R2) to this effect.
Calibrating the inching pedal

Calibration must be carried out if the inching pedal sensor (R2) has been replaced or mis-
adjusted.
➥ Calibration is carried out by means of screenshot instructions
Crawler gear potentiometer (R3)

By means of the crawler gear potentiometer (R3), the drive speed can be modulated in
1st speed whilst keeping the diesel engine revs constant. The drive electronics (N1) picks
up the voltage from the crawler gear potentiometer (R3) to this effect.
Drive settings
A range of settings can be carried out if drive output is not optimal. Carrying out all the
measurements, one after another, as specified in the test report is absolutely necessary to
this effect (see page 5-26 and 5-28). The test and adjustment instructions are indicated by
the page numbers in the test report. Follow the instructions carefully. The rated values in
the test report are decisive for the adjustments which must not fall short of or exceed the
values.
Important! File the completed test report for later evidence!
Troubleshooting (drive)
Follow the exact steps shown in the diagram on page 5-40 for carrying out troubleshooting
on the drive. Each step is described separately. All measured values must be entered in
the test report.
Important!
➥ A completed test report must be included in any warranty claim brought forward
➥ Warranty claims cannot be processed without a test report
000 295 725 0 – RHB SCORPION 5-14

Power train
5.6 Drive electrics connector assignment for models 400 – 404


Socket housing Pin housing Socket housing Pin housing Connection Connection Connection
X7/X8/X9 X7/X8/X9 X11 (11 pole) X11 X13 X16 (6 pole) X17
Connection X37
(1 pole)
Steering electronics X20/X21 (12 pole)
Crawler gear potentiometer X35 Connection X40

(3 pole) (6 pole)
Socket housing X41 Socket housing Socket housing X45 Socket housing X48 Socket housing X49
(22 pole) X42 (14 pole) (12 pole) (9 pole) (14 pole)
5-15 000 295 725 0 – RHB SCORPION

Power train
Power train
5.7 Towing and transporting the machine

If the diesel engine and/or the hydraulic drive breaks down, the machine can be towed
under the following conditions.
Getting ready for towing

• Tow the machine with a towing bar only. The brake and steering systems are not
B assisted hydraulically if the diesel engine and/or the hydraulic system break down.
• Make sure no-one is dangerously close to the towing bar!
Caution!
The hydrostatic power train can be damaged when towing the machine!
A
☞ Tow away the machine from the danger area only after you have opened
the HP pressure relief valves and the brake discs
• Towing distance and speed => max 300 m at a max. 8 kph
Fig. 1: Disabling hydraulic pump TMP 89
Mechanically setting the variable displacement pump to neutral

position
A ☞ Switch over HP relief valves B on the hydraulic pump A to towing. To do this:
B ☞ Unscrew the HP valves B 3 – 4 turns with an allen key
Caution!
Fig. 2: Disable hydraulic pump H1 P 078
Reset the variable displacement pump to drive operation once towing the
machine is over!
☞ – see Enabling drive A (hydraulic pump) once towing is over on page 5-17
Mechanically disabling (releasing) the brake discs in the front

Max. 1 turn axle
1
If the diesel engine or the hydraulic pump breaks down, the brake discs in the axle are
automatically enabled (spring-loaded brake system is blocked)!
The spring-loaded brake system must be opened mechanically in order to be able to tow
away the machine.
☞ Slacken lock nut A on set screw 1 (2 on either side of the axle tube) with a hexagon
socket spanner (13 mm) and unscrew by about 8 mm
A ☞ Evenly screw in set screws 1 (2 on either side of the axle tube) until you can feel a
8 mm resistance
Fig. 3: Releasing the parking brake for towing ☞ Evenly screw in set screws 1 (2 on either side of the axle tube) by a max. 1
turn against the pressure of the spring-loaded brake
➥ The parking brake is released
000 295 725 0 – RHB SCORPION 5-16

Power train
Towing the machine
B
Danger!
Careful when towing away the telehandler –
☞ The towing vehicle must have enough tractive power and be fitted with a
A safe brake system
☞ Only tow away with a towing bar
➥ See chapter „Machine specifications: overview“ for the dimensions and
Fig. 4: Disabling hydraulic pump TMP 89 weights!
☞ Eye hooks for towing the machine – see chapter 1 “Machine outside view”
on page 1-1
☞ If possible, run the engine at idling speed when towing the machine
➥ Turning the steering wheel requires greater effort if the diesel engine
and the brakes break down.
A the HP pressure relief valves and the brake discs
B ➥ Towing distance and speed => max 300 m at a max. 8 kph
Fig. 5: Disabling hydraulic pump TMP 89 Enabling drive A (hydraulic pump) once towing is over
☞ Screw in high pressure valves B and tighten them to 85 Nm
Enabling the brake discs in the front axle
1
Danger!
After having been opened mechanically, the brake discs in the axle must be
30 mm
enabled once towing is over! Otherwise –
☞ Unscrew set screws 1 (2 on either side of the axle tube) evenly and alter-
A nately until reaching 30 mm between the end of the screw head and the
contact area (lock nut – axle tube)
Fig. 6: Releasing the parking brake for towing ☞ Secure set screw 1 with lock nut A (2 on either side of the axle tube)
➥ Important! Do not modify the dimension of 30 mm as you secure the
set screw
➥ Parking brake is enabled (blocked)
Once you have enabled the parking brake:

☞ Check the service and parking brake for correct function
5-17 000 295 725 0 – RHB SCORPION

5.8
Only for first fill during
assembly
000 295 725 0 – RHB SCORPION

Distributor
Driving direction identification control

for 20 kph version (models 402 – 404)
Hydraulic pump TMP 89 (models 402, 403, 404)
Y5/forwards WH/VT
High pressure valves for

towing
Do not modifiy the mechani-

cal zero position
Boost pressure Y4/reverse GN/VT

valve
Power train
5-18
Power train
5.9 Hydraulic pump H1 P078 (models 400, 401)
Y5/forwards GN/VT
Y4/reverse WH/VT
Do not modifiy the mechani-

cal zero position
High pressure valves for

towing
Boost pressure valve
5-19 000 295 725 0 – RHB SCORPION

Power train
5.10 High speed gearbox (0 – 40 kph)
5.11 High speed gearbox with auxiliary motor (0 – 40 kph)
Auxiliary motor
000 295 725 0 – RHB SCORPION 5-20

Power train
5.12 Function without auxiliary motor (0 – 40 kph)

Wide-angle technology ensures continous speeds of 0 – 40 kph without interrupting the
tractive force. Pressure control always allows the gearbox to reach max. pushing power
(40 or 20 kph).
A further advantage with regard to a normal gearbox is the fact that the speed can be
reduced via the drive electronics.
5.13 Function with auxiliary motor (0 – 40 kph)

An auxiliary motor (fixed displacement motor) increases efficiency even further when driv-
ing fast. From a certain speed onwards, the auxiliary motor drives the main gearbox.
This means that the main gearbox slews back until efficiency at the output shaft is so small
that no torque is delivered to the output shaft.
The fixed displacement motor (which always is effective on the output shaft with 45°) now
takes over the drive torque on the output shaft and drives the main gearbox.
The transition results from the pressure ratios.
Both drive units are directly driven by the variable displacement pump via the high pres-
sure lines.
5-21 000 295 725 0 – RHB SCORPION

Power train
5.14 Gearbox overview (0 – 40 kph)
Driving direction identifica-

Set screw Qmax – Qmin tion solenoid valve
Control initiation M4 test port Reverse driving energised
Qmin – Qmax
Set screw Qmin – Qmax

Pressure controller
Seal between hydrau-

lic and gearbox part
Control cylin-
der
Rotary shaft lip

seal to rear axle
Rotary shaft lip

seal to front axle
Speed transmitter for speedome-

ter, load stabiliser, overspeed con-
trol
000 295 725 0 – RHB SCORPION 5-22

Power train
5.15 Overview of control cover and gearbox circuit diagram (0 – 40 kph)
4
2
5a
1 5
1 = proportional valve
2
5 2 = wheel revs stroke limitation
3 = flush valve
4 = scouring slide valve
5 = electric driving direction identification sole-
noid valve
8 5a = hydraulic driving direction identification
6 = set screw Qmin – Qmax
7 1
7 = set screw Qmax – Qmin
8 = M4 shuttle throttle
3 4 5a
6
5-23 000 295 725 0 – RHB SCORPION

Power train
5.16 Control cover component parts for gearbox (0 – 40 kph)
000 295 725 0 – RHB SCORPION 5-24

5-25
Cooler outlet
Power train
Cooler inlet
5.17 Hydraulic drive circuit (0 – 40 kph)
From the fan motor Microfilter
Connection for first fill

at the manufacturer's
Non-return valve 2 bar
1000151202_s.iso
000 295 725 0 – RHB SCORPION

Power train
5.18 Test report for models 400/401 (0 – 40 kph)

Rated oil temperature: 50 – 60 °C
Nominal
Page: Test features: Notes: Nominal value value: ✔
(rpm)
Measurement on variable displacement pump
Min. idling speed
870 – 900 rpm
(diesel engine) Measured at the crankshaft
Max. idling speed (diesel engine)/laptop
2520 – 2570 rpm
(diesel engine)
Max. engine revs
– see page 5-32 Boost pressure 30 – 35 bar
(diesel engine)
Against hydraulic resist-
– see page 5-33 High pressure ance at max. revs 460 – 490 bar
(diesel engine)
Engine droop
Measured at the crankshaft
– see page 5-34 Variable displacement 2050 – 2100 rpm
(diesel engine)
pump
Hydraulic motor measurement
Driving direction identi- Y10 energised direct by the Reverse driving ener-
– see page 5-35
fication drive lever gised
Engine droop Full throttle, then brake to
– see page 5-37 2100 + 50 rpm
(hydraulic motor) 22+2 kph
Full diesel engine revs

Cardan shaft revs
– see page 5-39 Front axle steering and 3600 – 3700 rpm
(40 kph)
hare speed range switched
Speed measured with
Front axle steering and hare 36.0 – 36.4 kph
laptop (40 kph)
drive range switched on
Serial no.
Serial no.
variable dis-
placement pump
Serial no.
hydraulic motor
Service hours
000 295 725 0 – RHB SCORPION 5-26

Power train
5.19 Error description for test report models 400/401 (0 – 40 kph)

Which errors occur on the drive?
When or how often does this error occur?
Has the drive been repaired or adjusted before? If yes, what kind
of repairs and adjustments?
Any other errors occurring on the drive?
5-27 000 295 725 0 – RHB SCORPION

Power train
5.20 Test report for models 402/403/404 (40 kph)

L
Nominal
(rpm)
Min. idling speed
870 – 900 rpm
(88 kW diesel engine)
Min. idling speed Measured at the crankshaft
900 – 950 rpm
(103 kW diesel engine) (diesel engine)/laptop
Max. idling speed
2520 – 2570 rpm
(88/103 kW diesel engine)
Max. engine revs
(diesel engine)
(diesel engine)
Engine droop
(diesel engine)
pump (88/103 kW)
Driving direction identifica- Y10 energised direct by the Reverse driving ener-
– see page 5-35
tion drive lever gised
Engine droop
Full throttle, then brake to
– see page 5-37 (hydraulic motor) 2100 + 50 rpm
22+2 kph
(88/103 kW)
Cardan shaft revs
(40 kph)
Speed measured with lap-
Front axle steering and hare 36.0 – 36.4 kph
top (40 kph)
Serial no.
Serial no. varia-
ble displace-
ment pump
Serial no.
hydraulic motor
Service hours
000 295 725 0 – RHB SCORPION 5-28

Power train
5.21 Error description for test report models 402/403/404 (40 kph)
5-29 000 295 725 0 – RHB SCORPION

Power train
5.22 Test report for models 403/404 (30 kph)

L
Nominal
(rpm)
Min. idling speed
870 – 900 rpm
(diesel engine) Measured at the crankshaft
Max. idling speed (diesel engine)/laptop
2520 – 2570 rpm
(diesel engine)
Max. engine revs
(diesel engine)
(diesel engine)
Engine droop
(diesel engine)
pump
Driving direction identi- Y10 energised direct by the Reverse driving ener-
– see page 5-35
fication drive lever gised
– see page 5-37 2100 + 50 rpm

Cardan shaft speed
40 kph
Speed measured with
Front axle steering and 29 – 30 kph
laptop (40 kph)
Serial no.
Serial no.
variable dis-
placement pump
Serial no.
hydraulic motor
Service hours
000 295 725 0 – RHB SCORPION 5-30

Power train
5.23 Error description for test report models 403/404 (30 kph)
5-31 000 295 725 0 – RHB SCORPION

Power train
5.24 Checking and setting boost pressure (0 – 40 kph gearbox)
Variable displace-
ment pump TMP 89
Boost pressure test port Boost pressure valve

on the master brake cylinder
Variable displacement pump H1 P 078
Boost pressure
set screw
Tools required: Check/adjust boost pressure as follows:

• 1x pressure gauge 60 bar ☞ Move the drive lever to neutral
☞ Apply the parking brake
☞ Connect the 60 bar pressure gauge to the test port
☞ Start the diesel engine and set max. revs
➥ Boost pressure at max. engine revs: 30 – 35 bar
If boost pressure is too low:
☞ Screw in the boost pressure valve
If boost pressure is too high:
☞ Unscrew the boost pressure valve
000 295 725 0 – RHB SCORPION 5-32

Power train
5.25 Checking high pressure (0 – 40 kph)
HP forwards test port Inching sensor connector TMP 089 high-pressure valves
(underneath the brake pedal)
H1 P 078 high-pressure valves
Tools required: Check high pressure as follows:

• Pressure gauge (600 bar) ☞ Switch off the ignition
☞ Remove the connector from the inching sensor
Caution!
Disconnecting the inching sensor connector with the
ignition switched on disables the drive electronics
data (SUSMIC), which must be entered again
☞ Connect the pressure gauge

☞ Start the diesel engine and shift to “Turtle”/four wheel drive
(forwards) with the drive lever
☞ Drive the machine against hydraulic resistance
➥ Do not allow the wheels to spin (use the service brake if
required)
☞ Read the pressure gauge
➥ High pressure must be 460 – 490 bar
Important!
It is not possible to adjust the high pressure valves
5-33 000 295 725 0 – RHB SCORPION

Power train
5.26 Checking engine droop (pump) (0 – 40 kph)
HP forwards test port
Inching sensor connector

Pressure controller controlled via SUSMIC
Tools required: ☞ Start the engine

• 600 bar pressure gauge and tachometer/laptop ☞ Shift to “Turtle”/front axle steering (forwards) with the drive
lever
Check as follows ☞ Set the diesel engine to maximum revs and then slowly brake
☞ Safely jack up the machine at the front and rear with the service brake
☞ Switch off the ignition • 40 kph brake to 300 – 350 bar
☞ Remove the connector from the inching sensor • 30 kph brake to 280 – 320 bar
☞ Diesel engine revs must reach 2050 – 2100 rpm and must not
drop below 2050 rpm
Caution!
Disconnecting the inching sensor connector with the Caution!
data (SUSMIC), which must be entered again! If diesel engine revs are below 2050 rpm
☞ Wrong drive electronics (SUSMIC) program has
☞ Connect the pressure gauge to the test port (high pressure for- been installed or
wards) ☞ Diesel engine does not have enough output and
☞ Connect the tachometer must be checked
If diesel engine revs are over 2100 rpm
☞ Wrong drive program for drive electronics (SUS-
MIC) has been installed
If diesel engine revs are over 2100 rpm in spite of
having installed the correct drive program
☞ Make a note in the test report of the value that has
determined since it cannot be modified
000 295 725 0 – RHB SCORPION 5-34

Power train
5.27 Checking driving direction identification (0 – 40 kph)
3
1 proportional valve
2 wheel revs stroke limitation
4 3 flush valve
2 5a 4 scouring slide valve
M4 5
5 electric driving direction identification
1 solenoid valve
5a hydraulic driving direction identification
8 6 set screw Qmin – Qmax
7 set screw Qmax – Qmin
8 M4 shuttle throttle
Connect the 600 bar pressure gauge to the M4 test port

(M4 test port must have high pressure during “Hare”/four wheel drive forwards and reverse driving)
Slightly brake the telehandler with the service brake (forwards and reverse) – see page 5-33
If M4 has only 30 bar during reverse driving
Select reverse driving direction

Solenoid coil 5 must be energised If pressure remains unchanged at only 30 bar
(forwards/reverse)
Check F14 + K3
(difference between M4 and high pressure < 20 bar)
Energisation is OK
M4 always with high M4 has 30 bar when reversing

pressure
Check the 5a driving direction Not OK

identification (spool valve)
– see page 5-61
OK – see page 5-43
5-35 000 295 725 0 – RHB SCORPION

Power train
5.28 Setting engine droop on the gearbox without auxiliary motor (0 – 40 kph)
Set screw
Engine droop
Test port M3
Engine droop
M4 test port
Test port HP/forwards driving
Engine droop must be adjusted on the gearbox in order to droop Carry out the setting as follows:
the engine to maximum output in its revs range. ☞ Safely jack up the machine at the front and rear
In order to do so, jack up the telehandler and brake it at full ☞ Connect a pressure gauge onto test port M3
engine revs from 40 to 22 kph (see test report).
If droop is set too low, the engine runs at revs over its maximum
torque and cannot deliver maximum output. ☞ Shift to “Hare”/front axle steering (forwards)
If the engine droops too much, the engine runs at revs below its ➥ Make sure the steering is synchronised
maximum torque and in addition, unnecessarily converts energy ☞ Set the diesel engine to maximum revs and then brake with
into warmth on account of the high system pressure (droop pres- the service brake at
sure in the gearbox). The drive output of the telehandler is poor. • 40 kph, to 22+2 kph
In order to set the droop as exactly as possible, measure the die- • 30 kph, to 15+2 kph
sel engine revs and use the M 3 pressure only as a reference ➥ Diesel engine revs of 2100 – 2150 rpm must be reached in
value when adusting droop. doing so
Optimally, droop is 50 rpm over pump droop.
➥ Pressure must amount to about 120 – 130 bar on
➥ See test result on page 5-34 test port M3
Setting engine droop: diesel revs too high
Tools required:
☞ Screw in the set screw
• 600 bar pressure gauge
Setting engine droop: diesel revs too low
• Tachometer/laptop
☞ Unscrew the set screw
Caution!
If engine droop cannot be set, or if the drive
behaviour of the machine does not react to the
setting, measure the differential pressure on the
gearbox
☞ – see Checking the differential pressure between
M4 and M3 (0 – 40 kph) on page 5-43
000 295 725 0 – RHB SCORPION 5-36

Power train
5.29 Setting engine droop on the gearbox with auxiliary motor (0 – 40 kph)
Set screw
Engine droop
Test port M3
Engine droop
Test port HP/forwards driving
Engine droop must be adjusted on the gearbox in order to droop Set engine droop as follows:
the engine to maximum output in its revs range. ☞ Safely jack up the machine at the front and rear
In order to do so, jack up the telehandler and brake it at full ☞ Connect a pressure gauge onto test port M3
engine revs from 40 to 20 kph.
If droop is set too low, the engine runs at revs over its maximum
torque and cannot deliver maximum output. ☞ Shift to front axle steering and “Hare”
If the engine droops too much, the engine runs at revs below its ➥ Make sure the steering is synchronised
maximum torque and in addition, unnecessarily converts energy ☞ Set the diesel engine to maximum revs and then brake with
into warmth on account of the high system pressure (droop pres- the service brake at
sure in the gearbox). The drive output of the telehandler is poor. • 40 kph, to 22 +2 kph
In order to set the droop as exactly as possible, measure the die- • 30 kph, to 15 +2 kph
sel engine revs and use the pressure at test port M3 only as a ref- ➥ Diesel engine revs of 2100 – 2150 rpm must be reached in
erence value when adusting droop. doing so
Optimally, droop is 50 rpm over pump droop.
➥ Pressure must amount to about 120 – 130 bar on
➥ See test result on page 5-34 test port M3
Setting: diesel revs too high
Tools required:
• 600 bar pressure gauge
Setting: diesel revs too low
Caution!
If engine droop cannot be set, or if the drive
behaviour of the machine does not react to the
setting, measure the differential pressure on the
gearbox
☞ – see Checking the differential pressure between
M4 and M3 (0 – 40 kph) on page 5-43
5-37 000 295 725 0 – RHB SCORPION

Power train
5.30 Control initiation set screw (0 – 40 kph gearbox)
Start spring (small spring) Qmax – Qmin control initiation set

screw
Caution!
The control initiation set screw is sealed. Do not adjust it!
000 295 725 0 – RHB SCORPION 5-38

Power train
5.31 Checking the cardan shaft speed (0 – 40 kph gearbox)

Tools required:
• Tachometer (infrared)
M3 M4
Label (measure-
ment point)
Set screw for wheel revs
☞ Safely jack up the machine at the front and rear

☞ Diesel engine at full revs
☞ Measure the revs at the cardan shaft
➥ 20 kph 1935 – 2035 rpm
➥ 30 kph 2950 – 3050 rpm
➥ 40 kph 3600 – 3700 rpm
☞ Screw in = less speed
☞ Unscrew = more speed
Caution!
Do not modify the set screw for the wheel revs on the high speed gearbox with
auxiliary motor. The wheel revs are set via the Susmic system.
5-39 000 295 725 0 – RHB SCORPION

Power train
5.32 Troubleshooting diagram (0 – 40 kph)
Lower idling speed

Caution!
Upper idling speed Refer to the test report for the rated boost
pressure value!
Boost pressure
Not OK
OK Adjust Cannot be adjusted
OK Interrupt connec-
Adjust Cannot be adjusted
tion to consumers
– see page 5-55
Check consumers – see page 5-55
OK Adjust Replace the boost pressure valve
Defective boost pressure valve Cannot be adjusted
OK Adjust Disconnect the variable displacement pump from the

hydraulic motor – see page 5-54
Defective hydraulic motor Cannot be adjusted
OK Adjust Replace the pump
Continue checking with high pressure (next page)
000 295 725 0 – RHB SCORPION 5-40

Power train
Check high pressure (HP valves)
Caution!
Refer to the test report for the rated high
Check both high-pressure valves (forwards/reverse) pressure value!
OK Not OK in one direc- Not OK in both Replace the high-pressure OK

tion directions valves – see page 5-33
OK Replace the high- No modification Not OK

pressure valves –
see page 5-33
Defective HP cartridge Check control pressure M4 and M5 (variable

displacement pump) – see page 5-56
Check proportional valve energi- Not OK OK Separate the pump from the
sation – see page 5-53 gearbox – see page 5-54
OK Not OK SUSMIC programming error HP OK HP not OK

- Open wiring
- Short circuit in switching mag-
Exchange proportional valves from net (troubleshoot with laptop)
left to right – see page 5-54
OK Not OK Replace the hydraulic pump Replace the gearbox
OK
OK
OK Replace the hydraulic

pump
OK
Continued on next page

• Pump engine droop
• Driving direction identification
• Engine droop without auxiliary motor (gearbox)
• Engine droop with auxiliary motor (gearbox)
• Differential pressure measurement
5-41 000 295 725 0 – RHB SCORPION

Power train
Check pump engine droop, driving direction identification, differential pressure measurement
Engine droop (pump)

– see page 5-34
Caution!
Refer to the test report for the rated values!
Driving direction identifica-

tion – see page 5-35
Engine droop without aux-

iliary motor (gearbox) – see
page 5-36
Engine droop with auxiliary

motor (gearbox) – see Not OK
page 5-37
Differential pressure
– see page 5-43 and – see page 5-44
OK
000 295 725 0 – RHB SCORPION 5-42

Power train
5.33 Checking the differential pressure between M4 and M3 (0 – 40 kph)
Test port Test port M3

HP/forwards
driving
Inching sensor connec-

tor
M4 test port
(underneath the brake
pedal)
Tools required: ☞ Connect the 600 bar pressure gauge to the HP/forwards test
• 2 pressure gauges 600 bar port (high pressure forwards) M4
• 1 pressure gauge 250 bar ☞ Connect the 250 bar pressure gauge to the M3 test port
Check as follows ☞ Start the diesel engine
☞ Safely jack up the machine at the front and rear ☞ Shift to “Hare”/front axle steering (forwards) with the drive lever
☞ Switch off the ignition ➥ Make sure the steering is synchronised
☞ Remove the connector from the inching sensor ☞ Set and hold the diesel engine at max. revs
☞ Brake the machine to the values indicated below (HP/for-
Caution! wards) with the brake pedal.
➥ Make a note of the M3 and M4 values in the table
Disconnecting the inching sensor connector with the
data (SUSMIC), which must be entered again!
Measurements with HP/forwards 100 bar 150 bar 200 bar 250 bar 300 bar
M3
M4
☞ Remove the machine from the jacks ➥ The wheels must not spin when measuring high pressure
☞ Shift to “Hare”/front axle steering (forwards) with the drive lever ☞ Use the service brake if necessary to achieve full high pres-
➥ Make sure the steering is synchronised sure
☞ With a bucket mounted on the machine, drive the machine ➥ Make a note of the M3 and M4 values in the table
against a hydraulic resistance (wall) to determine high pres-
sure.
Measurements with HP/forwards 460 – 490 bar
M3
M4
5-43 000 295 725 0 – RHB SCORPION

Power train
5.34 Evaluation: differential pressure measurement M4 (0 – 40 kph)

Control pressure M4 is always assigned to the rod side of control cylinder 2 by means of
the driving direction identification. It must always more or less amount to high
pressure (HP).
2
5
8
7 1
3 4 5a
6
Dashed line
➥ Boost pressure
Continuous line
➥ Control pressure (forwards/reverse driving)
Descriptions
1 Proportional valve
2 Control cylinder (wheel revs stroke limitation)
3 Flush valve
4 Scouring slide valve
5 Electric driving direction identification solenoid valve
5a Hydraulic driving direction identification
6 Pressure relief valve (Qmin – Qmax set screw)
7 Qmax – Qmin set screw
8 Shuttle throttle (M4)
Important!
Solenoid valve (5) hydraulically switches driving direction identification (5a) and
assigns the control pressure to M4 (control piston rod side)
000 295 725 0 – RHB SCORPION 5-44

Power train
5.35 Example: differential pressure measurement M4 (0 – 40 kph)

Measurements at high pressure (HP)
100 bar 150 bar 200 bar 250 bar 300 bar
forwards and/or reverse driving
M3
M4 95 145 198 246 297
Result M4 (control piston rod side) OK

M3
M4 30 30 30 30 30
Result 5a Driving direction identification not assigned

M3
M4 100 140 80 80 70
Result 1. Clean the shuttle throttle and measure again
2. Replace the gearbox if there is no change
Clean the shuttle throttle

– see Checking driving direction identification (0 – 40 kph) on page 5-35 (pos. 8)
☞ Remove the plug with an Allen key
☞ Remove the grub screw with the same Allen key
☞ Remove the shuttle throttle with a magnetic lifter
Caution!
The shuttle throttle can fall into the side channel if a magnetic lifter is not used!
☞ The large notch must show inwards when mounting the shuttle throttle
It must be possible to release the control pressure M4 (control piston rod side) again
with high pressure. The shuttle throttle channel 8 is dirty if this is not the case!
5-45 000 295 725 0 – RHB SCORPION

Power train
5.36 Evaluation: differential pressure measurement M3 (0 – 40 kph)

The control pressure M3 is in charge of the progressive adjustment of the gearbox from a
large angle (force) to a small angle (revs).
2
5
8
7 1
3 4 5a
6
Dashed line (bold)

➥ High pressure
Continuous line (bold)
➥ Control pressure
Descriptions
1 Proportional valve
2 Control cylinder (wheel revs stroke limitation)
3 Flush valve
4 Scouring slide valve
5 Electric driving direction identification solenoid valve
5a Hydraulic driving direction identification
6 Pressure relief valve (Qmin – Qmax set screw)
7 Qmax – Qmin set screw
8 Shuttle throttle (M4)
Function
The proportional valve and switching magnet (1) are controlled as a function of engine
revs and drive speed.
Depending on how it is triggered, the proportional valve converts a small amount of oil of
the high-pressure circuit into control pressure M3.
In order to ensure this, the driving direction identification 5a must work correctly.
The maximum M3 pressure (gearbox engine droop) is set by means of the set screw
(pressure relief valve) 6.
Depending on the setting, excess oil flows to the tank against the boost pressure.
000 295 725 0 – RHB SCORPION 5-46

Power train
5.37 Example: differential pressure measurement M3 (0 – 40 kph)

M3 45 70 90 120 120
M4 100 150 200 250 300
Result M3 and M4 OK
Important!
The M3 pressure must be built up evenly up to about 125 bar and must then stay
at this level.
• Gearbox OK
If other values are measured, e.g. ... (see table)

☞ Check the pressure relief valve 6 for dirt
➥ – see Cleaning the pressure relief valve on page 5-48
☞ Check the energisation of the proportional valve
➥ – see Checking proportional valve (1) energisation (0 – 40 kph) on page 5-51
M3 30 20 10 0 0
M4 100 150 200 250 300
or
M3 45 70 30 5 0
M4 100 150 200 250 300
or
M3 45 65 20 90 120
M4 100 150 200 250 300
or
M3 0 5 45 120 120
M4 100 150 200 250 300
or
M3 0 0 0 0 0
M4 100 150 200 250 300
5-47 000 295 725 0 – RHB SCORPION

Power train
5.38 Cleaning the pressure relief valve

Pressure relief valve
6 with Qmin-Qmax set
screw
Orifice M3 (0.6 mm)
☞ Remove the pressure relief valve and the orifice M3 (7)

☞ Clean both parts and mount them back on again
☞ Replace the pressure relief valve if necessary
000 295 725 0 – RHB SCORPION 5-48

Power train
5.39 Drive electronics Operator's Manual (SUSMIC)
12 V supply voltage
5 V supply voltage
Softwareloaded
Software loaded
Error code
The hardware and software of the SAUER-DANFOSS mobile computers of the SUSMIC
series has been designed to enable dialogs for purposes of commissioning, optimisation
and service with a laptop.
5-49 000 295 725 0 – RHB SCORPION

Power train
5.40 Error table

System error
Signal from LED error code DIA 1 error code Troubleshooting:
Sensor voltage -o o o 01 Sensor voltage not in valid range
Sensor error
Signal from LED error code DIA 1 error code Troubleshooting:
Parameter not assigned

Default parameter check sum ---- 17
No software
Inching/brake pedal parameter check
18 Included in error 1
sum
Setup not carried out
Inching/brake pedal sensor -- o o 19 Value to small
Value to high
Revs transmitter
o o - o 20 No rev signal whilst starting the machine
Diesel engine
Proportional valve current
- o - o 21 Short circuit, open wiring
Forwards-reverse control o -- o 22 Forwards and reverse driving short-circuited
Revs transmitter
--- o 23 Rev signal interrupted
Diesel engine
Short circuit
Hydraulic motor current
Open wiring
20 kph valve 1st – 2nd speed o o o - 24
Value too high
Ecospeed proportional
Value to small
Crawler gear parameters
25 Included in error 1
Function only in 1st speed
Crawler gear potentiometer Value too small
- o o - 26
Function only in 1st speed Value too high
Revs transmitter
o o - - 27 Engine speed interrupted
Hydraulic motor/gearbox
Oil temperature sensor for fan
-o-- 28 Value not in valid range
Hydraulic oil
Not used
Wrong Kernel o - o - Kernel software < 2.5
Wrong hardware
--o- Hardware is not S1X-11 G2 AMP
Wrong Susmic
Legend:
0 = short flashing sign

– = long flashing sign
000 295 725 0 – RHB SCORPION 5-50

Power train
5.41 Checking proportional valve (1) energisation (0 – 40 kph)
4
2 5a
1 5
Check with a multimeter, – see page 5-53
Caution!
In order to avoid damage to the multimeter
☞ Switch on ignition only after having connected the multimeter with the mag-
net
☞ Slowly increase drive speed and observe the multimeter

➥ The current should rise up to the maximum value as a function of speed or revs
➥ Refer to the table on page 5-52 for the maximum energisation value
Energisation is OK
☞ Replace the magnet of proportional valve (1)
Energisation not OK
☞ Install new software
☞ Check the wiring harness
☞ Short circuit in switching magnet
☞ Check the electronics module
☞ Then check energisation with the multimeter
☞ Measure the pressure difference again and set the droop, see page 5-45
If droop cannot be set or if the telehandler does not react to the setting
☞ Replace the complete gearbox
5-51 000 295 725 0 – RHB SCORPION

Power train
5.42 Table of electric current values of proportional valves

All measurements at max. diesel engine revs.
Telehandler models 400/401

Diesel engine 88 kW
Pump: 1500 mA
4 wheel steering Front axle steering

Gearbox:
20 kph 40 kph
Intermediate gearbox with 110 cm³ 20 kph 730 mA 730 mA
Intermediate gearbox with 160 cm³ 20 kph
Ecospeed 30 kph
Ecospeed reduced from 40 to 20 kph 1280 mA
Ecospeed 40 kph 1280 mA 1830 mA
Telehandler models 402/403/404

Diesel engine 88/103 kW
Pump: 1500 mA
4 wheel steering Front axle steering

Gearbox:
20 kph 30/40 kph
Intermediate gearbox with 110 cm³ 20 kph – –
Intermediate gearbox with 160 cm³ 20 kph – –
Ecospeed reduced from 40 to 20 kph 1480 mA 1480 mA
000 295 725 0 – RHB SCORPION 5-52

Power train
5.43 Checking the proportional valves by means of current measurement

The electric current at the proportional magnets is checked with an adapter cable and a
multimeter.
Check as follows
Hydraulic pump H1 P078 ☞ Switch off the ignition
☞ Connect connector A of the adapter cable with a proportional magnet M and connect
connector B with the connector that has been removed from the magnet
M M ☞ Connect connector C of the adapter cable with the multimeter
Caution!
Proportional magnets In order to avoid damage to the multimeter:
☞ Connect the multimeter with the magnet first and then switch on ignition
☞ Start the diesel engine and release the parking brake

☞ Select the driving direction and accelerate the diesel engine
Hydraulic pump TMP 89 ☞ Read the value of the electric current off the multimeter
Caution!
Proportional magnets
The value of the electric current must rise slowly as speed increases and must
reach the value indicated in the table for the electric current values – see
page 5-52!
• The electric current value that is measured is the signal that is monitored
M M by the drive electronics
• If the connection between the multimeter and the magnet is inadvert-
ently interrupted during current measurement, the drive electrics detects
an error and interrupts energisation
Adapter cable Energisation is OK

☞ Replace the proportional valves – see page 5-54
Energisation not OK
☞ SUSMIC program error (troubleshooting with laptop)
• Open wiring
• Short circuit in switching magnet
C A B
Resistance
Current is measured in series con-

nection.
➥ Direct voltage at 150 Hz
5-53 000 295 725 0 – RHB SCORPION

Power train
5.44 Exchanging proportional valves (0 – 40 kph)
Caution!
If the energisation of the proportional valves (forwards/reverse) is OK, but high
pressure is applied on only one side, this is a sign of a defective proportional
valve!
☞ Check this by exchanging the proportional valves “reverse/forwards” between each

other
☞ Replace the defective proportional valve
☞ If there is no improvement by exchanging the proportional valves, the hydraulic pump is
defective and must be replaced
5.45 Interrupting the hydraulic pump/motor circuit (0 – 40 kph)

The hydraulic pump or motor are possibly damaged if the high pressure or boost pressure
indicated in the test report cannot be reached.
Detect the damaged component as follows:
☞ Remove the high-pressure hoses A+B from the hydraulic pump
A
B ☞ Cover the outputs on the pump and hoses pressure-tight with dummy covers
☞ Select the “forwards or reverse” driving direction
☞ Run the diesel engine at maximum revs
If the indicated high pressure value is reached:
➥ Defective gearbox (leakage is too high)
If the specified high pressure value is not reached:
➥ Defective hydraulic pump (leakage is too high)
B
A
000 295 725 0 – RHB SCORPION 5-54

Power train
5.46 Separating the consumer circuit from the hydraulic drive

The boost pressure of the drive is also used for a range of other functions. Separate the
specified consumers from boost pressure if the boost pressure cannot be set or checked
as described on page 5-32.
• Negative brake (parking brake)
• Pilot control for boom control valve
• Brake servo (service brake)
• Differential lock
Danger!
Pilot control, brake servo, differential lock are without function and cannot be
operated. The parking brake cannot be released!
☞ Do not drive the machine unless all consumers run perfectly
3
C
1
2
B
A
4
Check as follows
☞ Remove flexible line A from T screw connection B
☞ Remove T screw connection B from elbowed screw connection C
☞ Connect flexible line A pressure-tight with elbowed screw connection C
☞ Check boost pressure as described on page 5-32
Boost pressure not OK
➥ – see Troubleshooting diagram (0 – 40 kph) on page 5-40
Boost pressure OK
☞ Separate the consumers one after another from the boost pressure to detect the pos-
sibly defective component
1 Pilot control unit, brake servo
2 Differential lock, parking brake
3 Pilot valve (at the rear)
4 Hydraulic pump boost pressure
☞ Replace the defective component
5-55 000 295 725 0 – RHB SCORPION

Power train
5.47 Checking control pressure M4/M5 (0 – 40 kph)

Measure the control pressures (control piston pressure) M4 and M5 to check the deflection
of the pump.
Variable displacement pump control pressure H1 P078

Use both test ports (forwards and reverse) for checking (test port threads 7/16 UNF)
☞ Remove the test port caps and connect a pressure gauge (2 x 60 bar)
1 ➥ 1 = forwards control pressure
➥ 2 = reverse control pressure
Variable displacement pump TMP 89 control pressure

Use both test ports (forwards and reverse) for checking
☞ Remove plug 1
1
Caution!
Make sure the zero-position adjustment A of the hydraulic pump is not turned
A when removing the plug!
☞ Install test port (2x) for the pressure gauge (M 12x1.5)

➥ In driving direction: front port = reverse control pressure
➥ In driving direction: rear port = forwards control pressure
Checking the control pressure (control piston pressure)

☞ Connect a 60 bar pressure gauge with each of the forwards/reverse test ports
☞ Start the diesel engine and release the parking brake
☞ Select 1st speed (turtle)
☞ Select “forwards” driving direction
➥ Forwards control pressure must amount to about 20 bar
☞ Select “reverse” driving direction
➥ Reverse control pressure must amount to about 20 bar
Caution!
The forwards/reverse control pressure must rise and drop as a function of
revs!
• The pressure in the control piston that is not triggered during forwards or
reverse driving must not rise over 2 – 3 bar!
000 295 725 0 – RHB SCORPION 5-56

Power train
5.48 Sealing work on the drive shaft (0 – 40 kph gearbox)
Rotary shaft lip seal to rear axle Rotary shaft lip seal to front axle
5-57 000 295 725 0 – RHB SCORPION

Power train
5.49 Mounting the rotary shaft seal (0 – 40 kph gearbox)
Before installing the rotary shaft seal:

Apply rolling bearing grease K2P-30 to
rotary shaft seal
000 295 725 0 – RHB SCORPION 5-58

Power train
5.50 Mounting the drive flange (0 – 40 kph gearbox)
Tightening torque = 50 Nm
5-59 000 295 725 0 – RHB SCORPION

Power train
5.51 Checking driving direction identification (0 – 40 kph gearbox)
Caution!
Make sure there are no foreign bodies in the
bore before assembling
Directional seat valve 12 V Nc
000 295 725 0 – RHB SCORPION 5-60

Power train
5.52 Removing driving direction identification (0 – 40 kph gearbox)
Turn by 180°
Check 0.6 mm bore for

obstructions
5-61 000 295 725 0 – RHB SCORPION

Power train
5.53 Variable displacement motor 110 cm3/rev (20 kph)
Flush valve High pressure forwards
B A
Control initiation test port Y10 driving direction identification

(forwards driving energised)
Set screw for control

initiation Y2 for 1st and 2nd speed
➥ About 40 bar per ➥ 1st speed range energised
revolution ➥ 2nd speed range de-energised
Revs sensor for load stabiliser and

overspeed control
000 295 725 0 – RHB SCORPION 5-62

Power train
5.54 Variable displacement motor 110 cm 3/rev (20 kph, seen from the side)
Y10 electric driving direction identi-

fication
Test port for high pressure forwards
Scouring slide
Set screw for wheel revs

Y2
1st and 2nd speed
(turtle/hare)
Connection to radiator
Connection to variable displacement

pump
5-63 000 295 725 0 – RHB SCORPION

Power train
5.55 Variable displacement motor 160 cm3 /rev (20 kph)
Y2 for 1st and 2nd speed

(turtle/hare)
➥ 1st speed fully energised
Hydraulic driving direction identification
Test port for high pressure forwards
B A
Control initiation test port
Scouring slide
valve
Set screw for control

initiation
Revs sensor for load stabiliser and

overspeed control
000 295 725 0 – RHB SCORPION 5-64

Power train
5.56 Test report for models 400 – 404 (20 kph)

Nominal
(rpm)
Min. idling speed
870 – 900 rpm
(88 kW diesel engine)
Min. idling speed Measured at the crankshaft
900 – 950 rpm
(103 kW diesel engine) (diesel engine)/laptop
Max. idling speed
2520 – 2570 rpm
(88/103 kW diesel engine)
Max. engine revs
(diesel engine)
(diesel engine)
Engine droop Measured at the crankshaft
– see page 5-34 2050 – 2100 rpm
(diesel engine) (diesel engine)
Driving direction identifica- Y10 energised direct by the Reverse driving ener-
tion, models 400, 401 drive lever gised
Driving direction identifica- Measurement on hydraulic Reverse driving ener-
– see page 5-64
tion, models 402, 403, 404 hose gised
– see page 5-37 2100 + 50 rpm
Cardan shaft revs
(20 kph)
Speed measured with lap-
4 wheel steering and hare 19.5 – 20.5 kph
top (20 kph)
Serial no.
Serial no. varia-
ble displace-
ment pump
Serial no.
hydraulic motor
Service hours
5-65 000 295 725 0 – RHB SCORPION

Power train
5.57 Error description for test report models 400/401 (20 kph)
000 295 725 0 – RHB SCORPION 5-66

Power train
5.58 Hydraulic circuit: drive with hydraulic pump H1 P078 (20 kph)

Cooler inlet
Cooler outlet
Microfilter
From the fan motor
5-67 000 295 725 0 – RHB SCORPION

Cooler outlet
000 295 725 0 – RHB SCORPION

Cooler inlet
From the fan motor
Microfilter
5.59 Hydraulic circuit: drive with hydraulic pump TMP 89 (20 kph)
Non-return valve 2 bar

Power train
5-68
Power train
5.60 Setting boost pressure (20 kph)

Tools required:
• 1x pressure gauge 60 bar
Variable displace-
ment pump
Boost pressure test port Boost pressure valve

on the master brake cylinder
H1 P 078
Set screw
Boost pressure
Check/adjust boost pressure as follows:

☞ Move the drive lever to neutral
☞ Connect the 60 bar pressure gauge to the test port
➥ Boost pressure at max. engine revs: 30 – 35 bar
If boost pressure is too low:
☞ Screw in the boost pressure valve
If boost pressure is too high:
☞ Unscrew the boost pressure valve
5-69 000 295 725 0 – RHB SCORPION

Power train
5.61 Checking high pressure (20 kph)

Tools required:
• Pressure gauge (600 bar)
Hydraulic motor 51 D 110, Hydraulic motor 51 D 160,

models 400, 401 models 402, 403, 404
HP forwards Engine droop test HP forwards test Engine droop test Inching sensor connec-
test port port M3 port port M3 tor
Check high pressure as follows:

☞ Switch off the ignition
Caution!
Disconnecting the inching sensor connector with the ignition switched on
disables the drive electronics data (SUSMIC), which must be entered again

☞ Start the diesel engine and shift to “Turtle”/four wheel drive (forwards) with the drive
lever
☞ Drive the machine against hydraulic resistance
➥ Do not allow the wheels to spin (use the service brake if required)
☞ Read the pressure gauge
➥ High pressure must be 460 – 490 bar
Important!
It is not possible to adjust the high pressure valves
000 295 725 0 – RHB SCORPION 5-70

Power train
5.62 Checking engine droop – variable displacement pump (20 kph)

Tools required:
Hydraulic motor 51 D 110, Hydraulic motor 51 D 160,

models 400, 401 models 402, 403, 404
HP forwards Engine droop test HP forwards test Inching sensor connector

test port port M3 port
☞ Check/adjust engine droop as follows:

Caution!
disables the drive electronics data (SUSMIC), which must be entered again!
☞ Connect the pressure gauge to the test port (high pressure forwards)
☞ Connect the tachometer
☞ Start the engine
☞ Shift to “Turtle”/4 wheel with the drive lever
Slowly brake the machine with the service brake to 300 – 350 bar
➥ Diesel engine revs of 2050 – 2100 rpm must be reached in doing so
If diesel engine revs are too low:
☞ Check the diesel engine
If high pressure is too low at prescribed diesel engine revs:
☞ Check the variable displacement pump and the hydraulic motor
5-71 000 295 725 0 – RHB SCORPION

Power train
5.63 Setting engine droop – hydraulic motor (20 kph)

Tools required:
Hydraulic motor Hydraulic motor Set screw

51 D 160 Engine droop
51 D 110
Set screw
Engine droop
HP forwards test Engine droop Inching sensor connector

HP forwards
port test port M3 test port
Check control initiation as follows:

Caution!
disables the drive electronics data (SUSMIC), which must be entered again!
☞ Connect the pressure gauge to the test port (high pressure forwards)
☞ Shift to “Turtle”/front axle steering (forwards) with the drive lever
➥ Make sure the steering is synchronised
Slowly brake the machine with the service brake to 10+2 kph
➥ Diesel engine revs of 2100 – 2150 rpm must be reached in doing so
Setting: diesel revs too high
Setting: diesel revs too low
000 295 725 0 – RHB SCORPION 5-72

Power train
5.64 Setting cardan shaft revs (20 kph)

Tools required:
• Tachometer (infrared)
20 kph version
Label Set screw

(measurement point) Cardan shaft revs
Check/adjust the cardan shaft speed as follows:

☞ Shift to “Hare”/front axle steering (forwards) with the drive lever
➥ Make sure the steering is synchronised
☞ Measure the speed at the cardan shaft with a tachometer
Specified speed
➥ See the test report
Speed too high
Speed too low
5-73 000 295 725 0 – RHB SCORPION

Axles – differential lock
6 Axles – differential lock Differential lock electric diagram

Differential lock hydraulics diagram
6.1 Differential lock diagrams (hydraulic/electric)
45 % automatic
Y09 => differential lock enabled
6-1 000 295 725 0 – RHB SCORPION

Designations: differential lock electric diagram
Description Machine position

H12 Differential lock telltale (see “Operation”)
K21 Differential lock switching relay (see “Electric system”)
N2 Proportional electronics (see “Electric system”)
S25 Differential lock tip switch (see “Operation”)
X2 Frame signals See “Electric system”
X9 Joystick G6/VI
Y9 Differential lock solenoid valve E5/VII
000 295 725 0 – RHB SCORPION 6-2

Designations: differential lock hydraulics diagram

VIII Drive hydraulics variable displacement pump E5/VIII
a Version with/without reversing fan –
10 Fan pump D8/VI
15 Filter E7/VIII
25 Tank H10/V
62 Differential lock (45 % self-locking) E11/VIII
63 Differential lock (100 % hydraulic) E3/VIII
107 Hydraulic oil dirt pressure switch G10/IV
P Pressure supply port (pump) –
T Tank port –
6-3 000 295 725 0 – RHB SCORPION

6.2 Functional description of differential lock

• Fan motor (014, 013)
• Drive motor with servopressure
Differential lock controls

Relay (K30) on module (N1) is enabled when pressing the brake/inching pedal
The differential lock solenoid valve (Y09) is enabled via the proportional electronics
module (N2) when pressing the switch (S25)
000 295 725 0 – RHB SCORPION 6-4

6.3 Differential lock connector assignment


Socket housing Pin housing Socket housing Pin housing

X9 X9 X11 X11
Socket housing X49

(14 pole)
Socket housing X45

(14 pole)
(22 pole) (14 pole)
6-5 000 295 725 0 – RHB SCORPION

6.4 20 kph gearbox: overview
Flanged hydraulic motor
Front axle
Rear axle
000 295 725 0 – RHB SCORPION 6-6

6.5 Removing the 20 kph gearbox

☞ Unscrew fastening screws 21 and 23 from cover 24
Caution!
Different lengths
☞ A flange is installed on either side
☞ Remove cover 24
☞ Slacken the fastening nut on flange 13
☞ Remove nut 11 and O-ring 12
Caution!
A normal flange is installed on the telehandler
6-7 000 295 725 0 – RHB SCORPION

☞ Remove flange 12
☞ Unscrew fastening screws 15 from cover 14
☞ Remove cover 14
☞ Remove spacers 18
☞ Remove sealing ring 17 from cover 14
000 295 725 0 – RHB SCORPION 6-8

☞ Slacken the fastening nut on flange 2
Caution!
☞ Remove nut 11 and O-ring 12
☞ Remove flange 2
☞ Unscrew fastening screws 13 from cover 23
☞ Slacken cover 23
23
6-9 000 295 725 0 – RHB SCORPION

☞ Remove cover 23
23
☞ Lever out sealing ring 17
☞ Remove outer ring 19
☞ Remove shaft 26
☞ Remove shaft 26
26
000 295 725 0 – RHB SCORPION 6-10

☞ Press out bearing 19
☞ Remove gear 37
☞ Remove bearing 19
☞ Expel outer ring 19
☞ Remove fastening screws 27 from cover 29
6-11 000 295 725 0 – RHB SCORPION

☞ Remove cover 29 and washers 18
☞ Unscrew fastening screws 9 from connection housing 5
☞ Remove connection housing 5
☞ Remove bearing 4 from the housing with an extractor
☞ Remove upper shaft 3
000 295 725 0 – RHB SCORPION 6-12

☞ Remove outer ring 4
☞ Position shaft 3 under a press
☞ Press out gear 38 and bearing 19
☞ Press out bearing 4
6-13 000 295 725 0 – RHB SCORPION

6.6 Installing the 20 kph gearbox
86 – 89 Nm
Loctite 510
260 – 280 Nm
86 – 89 Nm
Loctite 242
Loctite 510
S1
35 – 50 Nm
000 295 725 0 – RHB SCORPION 6-14

☞ Install bearing 4 on shaft 3

➥ Heat the bearing to 100 °C
☞ Install gear 13 on shaft 38
☞ Install bearing 19 on shaft 38

➥ Heat the bearing to 100 °C
☞ Install the complete shaft in the housing
☞ Install bearing race 4 in connection housing 5
6-15 000 295 725 0 – RHB SCORPION

☞ Place connection housing 5 on the gearbox housing with Loctite 510
☞ Tighten fastening screws 9 to 140 Nm
☞ Install outer ring 19
☞ Determine measure Y
➥ Outer ring to contact surface
☞ S 1 = X – Y + 0.1 mm
000 295 725 0 – RHB SCORPION 6-16

☞ Install cover 36 and fastening screws 39 with Loctite 510
☞ Tighten screws 39 to 90 Nm
☞ Check bearing for firm position
☞ Position a dial gauge
☞ Check 0.02 mm – 0.05 mm bearing play with a lever
☞ Install gear 37
6-17 000 295 725 0 – RHB SCORPION

☞ Install shaft 26 with a plastic hammer
☞ Heat inner ring 19 and install it onto shaft 26

☞ Turn over the gearbox
☞ Install spacer washers 17
☞ Heat the inner ring of bearing 19 to 100 °C and install it

000 295 725 0 – RHB SCORPION 6-18

☞ Determine measure Y between outer ring 19 and the housing
☞ Determine measure X
☞ S = X – Y + 0.1mm
☞ Install cover 14 with Loctite 510
☞ Tighten fastening screws 15 of cover 14 to 100 Nm
☞ Install flange 13
6-19 000 295 725 0 – RHB SCORPION

☞ Install O-ring 12 and nut 11
☞ Screw in the nut up to the contact surface on the flange
☞ Tighten the nut to 260 – 300 Nm
Caution!
☞ Install flange 2
2
☞ Install O-ring 12 and nut 11
000 295 725 0 – RHB SCORPION 6-20

☞ Place the dial gauge on the flange
☞ Check axial play: 0.02 – 0.05 mm
☞ Apply Loctite 510 to the sealing surfaces
☞ Screw in fastening screws 21/23 (bear in mind the different lengths)
☞ Tighten fastening screws 21/23 to 28 – 25 Nm
6-21 000 295 725 0 – RHB SCORPION

6.7 Front and rear axle flanges
Connection housing
Flanged
hydraulic
motor
Front axle
flange
Rear axle flange
000 295 725 0 – RHB SCORPION 6-22

6-23 000 295 725 0 – RHB SCORPION

6.8 Type label and oil filler neck: overview
Rear axle, on the left in driving direction Rear axle, on the right in driving direction
Front axle, on the right in driving direction Front axle, on the left in driving direction
1 = Type and model with modification index

2 = serial number
3 = oil (designation)
1 = oil filler plug

2 = drain plug
3 = oil fill and check plug
4 = grease nipple
000 295 725 0 – RHB SCORPION 6-24

6.9 Conversion table and tightening torques
Conversion table
Tightening torques
6-25 000 295 725 0 – RHB SCORPION

6.10 Removing the joint housing
19
☞ Raise the planetary drive with lifting gear

☞ Unscrew fastening screws 8 and 15 from the upper and lower pivot pins
☞ Press out the lower pivot pin 19 with a mounting lever
000 295 725 0 – RHB SCORPION 6-26

☞ Press out the upper pivot pin 4 with a mounting lever

☞ Remove sealing ring 9 and spacers 3
☞ Upper pivot pin 4 (cylindrical)

☞ Lower pivot pin 19 (conical)
9
☞ Remove the track rod

☞ Remove the complete planetary drive 1 with lifting gear
6-27 000 295 725 0 – RHB SCORPION

6.11 Installing the joint housing

☞ Apply grease to the bearing and the sealing lip of the cardan shaft
☞ Install the complete planetary drive 1
☞ Place spacers 3 (0.85 mm) under the upper pivot pin 4
☞ Replace sealing ring 9

☞ Insert the upper pivot pin 4 and
☞ tighten fastening screws to 140 Nm
☞ Apply grease to the lower bearing

☞ Replace sealing ring 10
☞ Install the lower pivot pin 19
☞ Tighten fastening screws 15 to 140 Nm
000 295 725 0 – RHB SCORPION 6-28

☞ Check axial play with a mounting lever and a dial gauge

☞ Place spacers depending on the result
Caution!
0 mm
Axial bearings must be set tolerance-free!
☞ Check the rolling resistance of the joint housing once setting is over
➥ Rated rolling resistance = 30 – 60 Nm
6.12 Removing the double cardan shaft

Machines with intermediate gearbox: the front axle is fitted with a service brake and a
parking brake.
Machines with 40 kph gearbox: the rear axle is also fitted with a service brake.
The parking brake is installed in the front axle only
The master brake cylinder hydraulically presses and blocks the brake discs of the service
brake via the belleville spring washers.
The parking brake is actuated electrohydraulically by means of the spring-loaded brake
(switch on instrument panel).
☞ Remove the complete planetary drive
➥ – see Removing the joint housing on page 6-26
Caution!
Block the service brake when removing the double cardan shaft on the rear
axle. If you do not block the brake, this may cause problems during installation
(lamella gearing is no longer lined up).
☞ Apply a pressure of 30 bar to the brake discs with a manual pump
☞ Remove lock nut 2 from centring screw 3
☞ Remove centring screw 3
6-29 000 295 725 0 – RHB SCORPION

☞ Remove double cardan shaft 4 with a mounting lever
☞ Remove spring washer 9 of bushing 13 from the shaft
☞ Use a press to press both bushing 13 and the bearing from shaft 4
☞ Remove circlip 10 from bearing 11

☞ Pull bearing 11 out of bushing 13 with an extractor
☞ Remove sealing ring 12 from bushing 13
000 295 725 0 – RHB SCORPION 6-30

6.13 Installing the double cardan shaft
☞ Use tool T5/T6 to install sealing ring 12 and bearing 11 in bushing 13

➥ Hammer or press
☞ Install circlip 10
Danger!
Careful when heating the bearings –
Danger of burns!
☞ Wear protective gloves!
☞ Heat the bearing to about 100 °C and install it on double cardan shaft 14 together with
bushing 13
6-31 000 295 725 0 – RHB SCORPION

☞ Install circlip 9 on double cardan shaft 4

☞ Insert O-ring 14 on bushing 13
☞ Install the double cardan shaft and screw in securing screw 2

➥ Torque = 15 Nm
Caution!
Make sure the tip is engaged in the centring groove of the bushing as you
install the securing screw 2!
☞ Secure lock nut 3 with Loctite 242

➥ Tighten to 122 Nm torque
000 295 725 0 – RHB SCORPION 6-32

6.14 Removing the planetary drive

☞ Remove the track-rod end from the joint housing
☞ Remove securing screws 1 from the wheel hub
☞ Remove planetary carrier 2 from the wheel hub with a screw driver
☞ Remove planetary carrier 2
☞ Remove fastening screws 4 from the internal-geared wheel 5
☞ Remove tab washer 6
➥ Remove the internal-geared wheel 5 with an extractor
6-33 000 295 725 0 – RHB SCORPION

☞ Slacken wheel hub 7 with a plastic hammer
☞ Remove taper roller bearing 8
☞ Remove wheel hub 7
☞ Remove the upper and lower bearing pins from joint housing 3
➥ – see Removing the joint housing on page 6-26
☞ Remove the joint housing
☞ Remove circlips 9 from the planetary gears
☞ Remove planetary gear 10 with an extractor
000 295 725 0 – RHB SCORPION 6-34

6.15 Replacing the seals of the planetary drive

☞ Remove sealing ring 19 (cartridge ring) from the wheel hub with a mounting lever
☞ Remove taper roller bearing 15 (inner ring)
☞ Remove the outer ring from bearing 15
☞ Remove centering ring 16, sealing ring 17 and bearing 18 from the joint housing with an
extractor
6-35 000 295 725 0 – RHB SCORPION

6.16 Installing the planetary drive
4 planetary gears
☞ Press bushing 18 into joint housing 3 with tool T7
☞ Insert sealing ring 17 and centering ring 16 with tool T8
000 295 725 0 – RHB SCORPION 6-36

☞ Position outer ring 8 of the bearing on tool T9A
☞ Position the wheel hub on outer ring 8 and tool T9A
☞ Press outer ring 8 into the wheel hub with tool T9B and the press
☞ Install bearing 15
☞ Apply Loctite to the outside sealing surface of sealing ring 14

☞ Bear in mind the position in which the sealing ring is installed
☞ Press sealing ring 14 into the wheel hub with tool T10
Caution!
Do not use a hammer to avoid damage to the sealing ring!
☞ Insert the sealing ring with a press
6-37 000 295 725 0 – RHB SCORPION

6.17 Installing the planetary drive

☞ Install planetary gears 10 in the cover with tool T11
☞ Secure planetary gears 10 with circlip 9
☞ Install joint housing 3 onto the axle carrier

➥ – see Installing the joint housing on page 6-28
☞ Carefully insert wheel hub 7 onto the joint housing
☞ Insert bearing 8 as far as it will go
☞ Insert the internal-geared wheel 5 onto joint housing 3
000 295 725 0 – RHB SCORPION 6-38

☞ Apply grease to the tab washer 6 and

☞ insert it onto stud bolts 5 of the joint housing
Caution!
Secure the nuts with Loctite 242
☞ Tighten nuts 4 crosswise with a torque wrench in two passes

➥ 1st pass 120 Nm
➥ 2nd pass 255 – 285 Nm
☞ Install planetary carrier 2 on wheel hub 3
Caution!
Make sure O-ring 20 is positioned correctly!
☞ Install planetary carrier 2 onto wheel hub 7 with fastening screws 1

➥ Torque = 40 – 50 Nm
☞ Fill in oil and check for leaks!
6-39 000 295 725 0 – RHB SCORPION

6.18 Sealing the front axle differential
☞ Remove nut 1 on flange 2
☞ Remove flange 2 with an extractor
000 295 725 0 – RHB SCORPION 6-40

☞ Remove sealing ring 6 with two mounting levers

☞ Clean the sealing surfaces of the housing and the flange
☞ Install sealing ring 6 with tool T27
☞ Install flange 2 with a plastic hammer

☞ Insert O-ring 3
➥ Toothing seal
3
☞ Apply Loctite to nut 1 and tighten to the specified torque
➥ Torque = 280 – 310 Nm
6-41 000 295 725 0 – RHB SCORPION

6.19 Removing the front axle differential lock

☞ Remove the right-hand side half of the axle
☞ Remove the brake piston
➥ – see chapter Removing the brake pistons and the belleville spring washers of the
service brake on page 7-16
☞ Remove upper cover 1 with a drift and a hammer
☞ Unscrew lock nut 4 by about 2 turns
☞ Remove shift fork 5 from the cone of the piston with a drift and a hammer
☞ Hold piston 6 with a key

☞ Remove lock nut 4
000 295 725 0 – RHB SCORPION 6-42

☞ Remove fastening screws 14

☞ Remove intermediate cover 13
☞ Pull shift fork 5 up and at the same time

☞ Remove crown wheel 15 with the differential cage
☞ Remove shift fork 5
☞ Remove circlip 12
☞ Remove piston 6
☞ Remove guide ring 11 and O-ring 10
☞ Remove snap ring 9

☞ Remove washer 8 and spring 7
6-43 000 295 725 0 – RHB SCORPION

☞ Remove bearing 16
☞ Remove thrust washer 18 and sliding sleeve 19 (cone ring)
➥ Mark the installation position of thrust washer 18
☞ Remove balls 20
☞ Remove guide wedges 21
Differential lock: overview
000 295 725 0 – RHB SCORPION 6-44

6.20 Installing the front axle differential lock

☞ Install guide wedge 21
☞ Apply grease to balls 20 and insert them

☞ Install sliding sleeve 19 and thrust washer 18
☞ Install bearing 16 onto differential cage 17 with an adapter
☞ Install O-ring 10 and guide band 11 onto piston 6

☞ Apply grease to the sealing rings and slide tool (sleeve) T29 over them
☞ Place tool (sleeve) T29 and piston 6 on cover 22 and

☞ Press piston 6 into cover 22
6-45 000 295 725 0 – RHB SCORPION

☞ Install spiral spring 7 and washer 8 onto piston 6

☞ Put tool (adapter) T30 in position
☞ Screw in tool (adapter) T30 with lock nut 4 until the groove for the snap ring becomes
visible
☞ Install snap ring 12
☞ Insert shift fork 5 into differential housing 22

☞ Install differential cage 15 with the crown wheel
☞ Install shift fork 5 in sliding sleeve 19 and piston 6
☞ Install intermediate cover 13 with fastening screws 14

➥ Bear in mind O-ring 23 as you do so
➥ Tightening torque = 25 Nm
000 295 725 0 – RHB SCORPION 6-46

☞ Install lock nut 4 and shift fork 5 onto piston 6

➥ Tightening torque = 75 Nm
☞ Install cover 1
☞ Install the brake piston and the axle tube (half)

➥ – see Installing the service brake discs on page 7-24
6-47 000 295 725 0 – RHB SCORPION

000 295 725 0 – RHB SCORPION
Boost pressure 30 – 35 bar
6.21 Differential lock: hydraulic circuit
The differential lock is actuated via tip

switch S 25 on the joystick and sole- Y9
noid valve Y 9 Y43
Front axle
The parking brake is actuated via the

switch on the instrument panel and sole-
noid valve Y 43
Location of solenoid valve:

on the left in driving direction
behind the front axle (engine vat)
6-48
6.22 Special tools: overview
6-49 000 295 725 0 – RHB SCORPION

000 295 725 0 – RHB SCORPION 6-50

6-51 000 295 725 0 – RHB SCORPION

000 295 725 0 – RHB SCORPION 6-52

6-53 000 295 725 0 – RHB SCORPION

000 295 725 0 – RHB SCORPION 6-54

6-55 000 295 725 0 – RHB SCORPION

Brakes
7 Brakes Electric brake diagram (20 kph)

Hydraulic brake diagram (20 kph)
Brakes
7.1 Brake (20 kph) diagrams (electric/hydraulic)
7-1 000 295 725 0 – RHB SCORPION

Brakes
Electric brake diagram (40 kph) Electric brake diagram (40 kph)
Hydraulic brake diagram (40 kph) Hydraulic brake diagram (40 kph)
Brakes
7.2 Brake (40 kph) diagrams (electric/hydraulic)
7-3 000 295 725 0 – RHB SCORPION

Brakes
Hydraulics diagram – trailer brake valve Hydraulics diagram – trailer brake valve
Brakes
7.3 Hydraulics diagram – trailer brake valve
141
Breather
140
7-5 000 295 725 0 – RHB SCORPION

Brakes
Brakes
Designations: hydraulic brake diagram

VIII Drive hydraulics variable displacement pump E5/VIII
L Leak oil port –
N Continuation –
P Pressure supply port –
T Tank port –
Y Control signal –
10 Fan pump D8/VI
15 Filter E7/VIII
29 Expansion tank J7/VII
30 Master brake cylinder (sensor) I6/VIII
31 Left-hand side service/parking brake hydraulic ram (front axle) G3/IX
32 Right-hand side service/parking brake hydraulic ram (front axle) D3/IX
33 Left-hand side service/parking brake hydraulic ram (rear axle) G11/IX
34 Right-hand side service/parking brake hydraulic ram (rear axle) D11/IX
125 (Y43) parking brake E12/VII
140 Trailer brake valve F7/VIII
141 Rear quick coupler See “Operation”
142 Pressure accumulator F7/VIII
000 295 725 0 – RHB SCORPION 7-6

Brakes
Designations: electric brake diagram

H18 Parking brake telltale (see “Operation”)
H19 Brake pressure accumulator telltale (see “Operation”)
H20 Brake lights (see “Operation”)
H21 Brake lights (see “Operation”)
S9 Brake light switch (see “Operation”)
S10 Brake pressure accumulator switch (see “Operation”)
S11 Parking brake pressure switch (see “Operation”)
X2 51 pole cab/frame disconnect See “Electric system”
X3 7 pole cab/sockets disconnect See “Electric system”
X23 15 pole telltale module connection G5/V
X27 7 pole rear socket E13/VI
X42 14 pole drive interlock board connection See “Electric system”
Y9 Differential lock solenoid valve E5/VII
Y43 Parking brake solenoid valve E5/VII
Y50 Compressed-air brake solenoid valve –
7-7 000 295 725 0 – RHB SCORPION

Brakes
7.4 Functional description of brakes

• Fan motor (014, 013)
• Drive pump with boost pressure VII/IX
• Drive motor with servopressure VIII/X
Compressed-air brake lead

The compressed-air brake lead solenoid valve is enabled by the drive electronics N1.
Releasing the parking brake

The parking brake is released via parking brake switch S65, parking brake solenoid
valve (Y43) and the compressed-air brake/parking brake signal solenoid valve (Y49). The
parking brake of the machine is designed as a spring brake actuator system. The parking
brake is applied when there is no oil pressure.
Starting interlock
The machine will not start unless the parking brake is applied. Diode V1 must have a neg-
ative potential so the machine can start.
Monitoring the parking brake

Switch S11 and telltale H18 indicate the parking brake is applied.
Service brake
The brake pedal consists of 3 parts:
• Pedal
• Pressure piston
• Displacement piston
The pedal creates a force on the pressure piston. The connection P pressure (boost pres-
sure) is directed towards the displacement piston due to the movement of the pressure
piston. Moving the displacement piston directs the brake fluid towards the multidisc brake
on the front axle. The pressure piston and the displacement piston have their own oil cir-
cuit.
Parking brake
The multidisc brake is compressed by a spring pile = negative-action brake. Releasing the
multidisc brake requires reducing the load on the spring pile. Servopressure (boost pres-
sure) is not passed on to the spring pile if the parking brake is applied. Servopressure
opens the spring pile of the multidisc brake as soon as the parking brake is released.
000 295 725 0 – RHB SCORPION 7-8

Brakes
7.5 Brakes connector assignment


Socket housing Socket housing

X23 (15 pole) X40 (6 pole)
Socket housing
X27 (9 pole)
Socket housing X41 Socket housing X42 Socket housing X45 Socket housing X49
7-9 000 295 725 0 – RHB SCORPION

7.6
Service brake
Parking brake Brakes
Dr
iv Boost pressure
ing
di r
ec
tio
n
000 295 725 0 – RHB SCORPION

Parking brake telltale
switch
Parking brake solenoid P

Service
valve Y43
brake
Lock Y9 T-fitting (trailer brake
connection)
T
40 kph brake circuit: overview
P
P
P
Brake pedal with
inching sensor
N
R B T
Service brake
➥ 30 and 40 kph
(option)
Expansion tank
➥ Shell LHM Master brake cylinder
➥ Agip LHM Super ➥ Hydraulically assisted
7-10
Brakes
7-11
7.7
Parking brake Service brake
Brakes
Dr
iv ing
di r
ec
tio
Parking brake telltale n
switch
Parking brake solenoid P

valve y43
Service
brake Lock y9
Boost pressure
T
20 kph brake circuit: overview
P
P
Brake pedal with

inching sensor
N
R
B
Expansion tank
➥ Shell LHM Master brake cylinder 1000150883.iso
➥ Agip LHM Super ➥ Hydraulically assisted
000 295 725 0 – RHB SCORPION

Brakes
7.8 Disabling (releasing) the parking brake in the front axle
Danger!
Do not take the machine into service again with mechanically open
brake discs –
☞ Enable the parking brake again once the machine has been repaired or
towed
☞ – see Enabling (adjusting) the parking brake in the front axle on page 7-12
☞ Switch off the engine and prevent the machine from rolling away
Max. 1 turn 31 • Front axle
☞ Slacken and unscrew lock nut 30 on set screw 31 (2 on either side of the axle tube) by
about 8 mm
☞ Evenly screw in set screws 31 (2 on either side of the axle tube) until you can feel a
resistance, then
30 About 8 mm ☞ evenly screw them in against the pressure of the spring brake in small steps by a max.
1 revolution
7.9 Enabling (adjusting) the parking brake in the front axle

☞ Unscrew and clean screws 31
☞ Replace sealing ring 29 and
☞ apply silicone grease (Siliconfett 101) to the screws
☞ Screw in screw 31 up to a spacing of 30 mm
➥ See drawing
☞ Tighten lock nut 30
➥ Important!
Make sure spacing 30 mm between the lock nut and the head of the set screw is
not modified when securing

☞ Check the parking brake for correct function
30 mm
000 295 725 0 – RHB SCORPION 7-12

Brakes
7.10 Wear check: service brake discs

☞ Park the machine and prevent it from rolling away
P ☞ Switch off the engine
☞ Slacken check plug B to release possible internal pressure
☞ Unscrew check plug 1
➥ Left-hand side from the front
B ➥ Right-hand side from the rear
☞ Press the service brake once and with the brake pressed
☞ check the thickness of the brake disc with tool T1 (or feeler gauge)
➥ Wear dimension S (ø 4.5 mm)
Caution!
Replace both brake discs on either side of the axle if they are worn!
1
T1 S
7.11 Setting the brake linkage – master brake cylinder
Caution!
Bear in mind the brake linkage setting described below as you mount/remove
the master brake cylinder.
In addition, bleed the brake system under all circumstances!
☞ – see Bleeding the hydraulic powerbrake on page 3-41
☞ – see Replacing/bleeding the service brake fluid with bleed equipment on
page 3-42

➥ Pressure is applied to the master brake cylinder
☞ Check whether the piston of the master brake cylinder is fully retracted
☞ Set the fork head free of backlash with regard to the bore
☞ Turn back the fork head 1 revolution and mount it with a spring clip pin
☞ Secure the lock nut
➥ There now is a gap of 1.25 mm between the linkage and the piston (master brake
cylinder)
7-13 000 295 725 0 – RHB SCORPION

000 295 725 0 – RHB SCORPION
Pressure plate
7.12 Service and parking brake: overview
Belleville spring
washers
Piston
(parking brake)
Piston
(service brake)
7-14
Brakes
Brakes
7.13 Removing the brake discs

☞ Connect the manual pump to connection P1
☞ Create a pressure of 15 – 30 bar to release the load on the belleville spring washers of
the parking brake
☞ Unhitch track rod ball

☞ Remove fastening screw 17
17 ☞ Remove the axle half with a crane
☞ Remove the axle half with a suitable belt and crane

☞ Remove the inside and outside discs
Caution!
Before you remove any further parts:
☞ Release the pressure in the belleville spring washers
☞ and remove the manual pump
☞ Remove screws 13 with the return springs

13
11
☞ Remove guide screws 18 (automatic readjustment of the pistons)
18
☞ Remove pressure plate 11
Caution!
Make sure they are placed in the correct position!
☞ See DOWN
11
7-15 000 295 725 0 – RHB SCORPION

Brakes
Removing the brake pistons and the belleville spring washers of the service brake
☞ Remove two of the four stud bolts
➥ Block two nuts against each other to remove the stud bolts
➥ Dimension 110 mm for outside stud bolt
Caution!
The brake housing is under pressure due to the two belleville spring washers
☞ Evenly and carefully remove the last two stud bolts
☞ Remove brake cylinder housing 7
7
☞ Remove the two belleville spring washers 2
➥ Bear in mind the installation position for installation
10 Danger!
Removing piston 10 with compressed air –
☞ Turn the brake cylinder housing so that the piston shows downwards
☞ Press out the piston with slight air pressure (low pressure)
☞ Make sure the piston is not ejected suddenly
000 295 725 0 – RHB SCORPION 7-16

Brakes
Removing the piston and brake linings of the parking brake

☞ Mark piston 3 with regard to the brake cylinder housing with a marker
3
Danger!
Removing piston 3 with compressed air –
☞ Turn the brake cylinder housing so that the piston shows downwards
☞ Press out the piston with slight air pressure (low pressure)
☞ Make sure the piston is not ejected suddenly
☞ Remove the inner clutch discs 15 and outer clutch discs 14 from the axle tube
14 ➥ Bear in mind the installation position for installation
15
24 ☞ Remove pressure plate 16 and spacers 24

➥ Bear in mind the installation position for installation
16
7-17 000 295 725 0 – RHB SCORPION

Brakes
7.14 Brake discs: overview
➥ Y = 1.5 mm, 1.25 mm, 1.0 mm, 0.75 mm

➥ – see Setting value for the service brake discs on page 7-23
000 295 725 0 – RHB SCORPION 7-18

Brakes
7.15 Installing the the brake pistons of the service and parking brake
☞ Place O-rings 4/28/27/5/6 on piston 3 of the parking brake

➥ Apply a thin coat of oil to the O-rings
3 ☞ Install brake piston 3 into brake cylinder housing 7
➥ Bear in mind the installation position/the mark
➥ Use a plastic hammer to assemble the brake piston
☞ Install O-ring 9 with prop ring 8 on the piston of service brake 10

☞ Install brake piston into brake cylinder housing 7
9 ➥ Use a plastic hammer to assemble the brake piston
10
10
7-19 000 295 725 0 – RHB SCORPION

Brakes
7.16 Installing the belleville spring washers and the brake cylinder housing
☞ Place belleville spring washer 2 in cylinder 7
2
➥ Apply a little grease
☞ Place belleville spring washer 2 in cylinder 1

1 ➥ Apply a little grease
2
☞ Insert the O-ring in the differential housing
☞ Install brake cylinder housing 7 onto the differential housing
☞ Evenly and alternately tighten the stud bolts
000 295 725 0 – RHB SCORPION 7-20

Brakes
☞ Fill hydraulic oil into the parking brake cylinder (port P1)
P1
P1
☞ Connect a manual pump to port P1 and apply a pressure of 15 – 30 bar

➥ Check the brake housing for leaks
7-21 000 295 725 0 – RHB SCORPION

Brakes
7.17 Installing the service brake

☞ Install clamping sleeve 19 for automatic readjustment flush with the pressure plate 11
19
11
☞ Install pressure plate 11 onto the brake housing

➥ Make sure they are placed in the correct position
11
☞ Install pressure plate 11 with fastening screws 13 and return springs 12

12
13
11
☞ Insert screw 13 with Loctite 270

➥ Torque = 10 – 15 Nm
• Y = brake tolerance
➥ Rear axle = 0.75 mm
➥ Front axle = 1.00 mm
Y 18
☞ Insert the fastening screw with Loctite 270

➥ Torque = 5 – 7 Nm
000 295 725 0 – RHB SCORPION 7-22

Brakes
Setting value for the service brake discs

☞ Connect the manual pump to P1 and apply a pressure of about 30 bar
☞ Determine the valvue X between the pressure plate and the contact surface
➥ Example: 25.4 mm
☞ Place the brake lamellas and discs under a press and apply a force of 1000 kg
☞ Determine the value V
➥ Example: 40 mm
☞ Determine the value between the contact surface of the axle tube and the contact sur-
face of the brake lamellas
➥ Example: 68 mm
☞ Thickness S of spacers 24 of the brake system is calculated as follows:

S 24 • Front axle as an example
➥ S = 68 mm – (X + Y + V)
➥ S = 68 mm – (25.4 mm + 1.0 mm + 40.0 mm) S = 1.6 mm
☞ 1.6 mm spacers have to be used
☞ Place spacers 24 (S= 1.6 mm) in the axle tube under the thrust washer
S 24
7-23 000 295 725 0 – RHB SCORPION

Brakes
Installing the service brake discs

☞ Install brake discs 14 in the axle tube
➥ Apply a thin coat of oil before installation
B
Caution!
14
Make sure bores B coincide in the discs as you install them
☞ Order of installation of the inside and outside lamellas

➥ 1-2-3-4-5-6-7-8
8 7 6 5 4 3 2 1
☞ Install the axle half onto the differential housing with a crane
☞ Tighten the fastening screws crosswise

➥ A = stud bolt nut torque is 200 Nm
A ➥ B = fastening screw torque is 280 Nm
B ☞ Install the track rod into the joint housing
000 295 725 0 – RHB SCORPION 7-24

Brakes
7.18 Towing and transporting the machine

If the diesel engine and/or the hydraulic drive breaks down, the machine can be towed
under the following conditions.
Getting ready for towing

• Tow the machine with a towing bar only. The brake and steering systems are not
B assisted hydraulically if the diesel engine and/or the hydraulic system break down.
• Make sure no-one is dangerously close to the towing bar!
Caution!
The hydrostatic power train can be damaged when towing the machine!
A
the HP pressure relief valves and the brake discs
• Towing distance and speed => max 300 m at a max. 8 kph
Fig. 1: Disabling hydraulic pump TMP 89
Mechanically setting the variable displacement pump to neutral

position
A ☞ Switch over HP relief valves B on the hydraulic pump A to towing. To do this:
B ☞ Unscrew the HP valves B 3 – 4 turns with an allen key
Caution!
Fig. 2: Disable hydraulic pump H1 P 078
Reset the variable displacement pump to drive operation once towing the
machine is over!
☞ – see Enabling drive A (hydraulic pump) once towing is over on page 7-26
Mechanically disabling (releasing) the brake discs in the front

Max. 1 turn axle
1
If the diesel engine or the hydraulic pump breaks down, the brake discs in the axle are
automatically enabled (spring-loaded brake system is blocked)!
The spring-loaded brake system must be opened mechanically in order to be able to tow
away the machine.
☞ Slacken lock nut A on set screw 1 (2 on either side of the axle tube) with a hexagon
socket spanner (13 mm) and unscrew by about 8 mm
A ☞ Evenly screw in set screws 1 (2 on either side of the axle tube) until you can feel a
8 mm resistance
☞ Evenly screw in set screws 1 (2 on either side of the axle tube) by a max. 1
Fig. 3: Releasing the parking brake for towing
turn against the pressure of the spring-loaded brake
7-25 000 295 725 0 – RHB SCORPION

Brakes
Towing the machine
B
Danger!
Careful when towing away the telehandler –
☞ The towing vehicle must have enough tractive power and be fitted with a
A safe brake system
☞ Only tow away with a towing bar
➥ See chapters “Weights” on page 1-19 and “Dimensions with bucket” on
Fig. 4: Disabling hydraulic pump TMP 89 page 1-29 for the machine's dimensions and weights!
☞ Eye hooks for towing the machine – see chapter 1.1 Machine outside view
on page 1-1
☞ If possible, run the engine at idling speed when towing the machine
➥ Turning the steering wheel requires greater effort if the diesel engine
and the brakes break down.
A the HP pressure relief valves and the brake discs
B ➥ Towing distance and speed => max 300 m at a max. 8 kph
Fig. 5: Disable hydraulic pump H1 P 078 Enabling drive A (hydraulic pump) once towing is over
☞ Screw in the high pressure valves B by 3 – 4 turns and tighten them to 85 Nm
Enabling the parking brake in the front axle
1
Danger!
After having been opened mechanically, the brake discs in the axle must be
30 mm
enabled once towing is over! Otherwise –
☞ Unscrew set screws 1 (2 on either side of the axle tube) evenly and alter-
A nately until reaching 30 mm between the end of the screw head and the
contact area (lock nut – axle tube)
Fig. 6: Releasing the parking brake for towing ☞ Secure set screw 1 with lock nut A (2 on either side of the axle tube)
➥ Important!
Make sure spacing 30 mm between the lock nut and the head of the set
screw is not modified when securing
➥ Parking brake is enabled (blocked)

☞ Check the service and parking brake for correct function
000 295 725 0 – RHB SCORPION 7-26

7-27
Pressure line from
Reversing fan valve
Brakes
service brake
Bleed line in engine
compartment
P
N
B 140 bar quick coupler
7.19 Hydraulic trailer brake circuit (option)
for trailer operation

(at rear of telehandler)
T
Trailer brake valve
Hydraulic pump (fan) 1000154130.iso
000 295 725 0 – RHB SCORPION

Work hydraulics
8 Steering Hydraulic steering diagram

Electric steering diagram
Work hydraulics
8.1 Steering diagrams (electric/hydraulic)
8-1 000 295 725 0 – RHB SCORPION

Steering
Steering
Designations: hydraulic steering diagram

IV Steering system valve block E4/VIII
c PFC pump unit version –
d CF pump version –
1 Boost pump (CF) drive (gear pump) D8/VI
3 Flow regulator (PFC) D9/VII
4 Pressure cutoff D9/VII
5 Torque restriction D9/VII
6 Axial-piston variable displacement pump D9/VII
7 Shuttle valve LS pump port D9/VII
8 Priority valve (CF) E10/VII
18 Front axle steering ram E4/VIII
19 Rear axle steering ram E10/VIII
20 Steering ram pressure relief valve H5/VII
21 Rotary spool valve H5/VII
22 Changeover valve (capacity) H5/VII
23 Steering system pressure relief valve H5/VII
24 Steering system check valve H5/VII
25 Tank H10/V
L LEFT –
LS Load sensing port –
P Pressure supply port (pump) –
R RIGHT –
T Tank port –
000 295 725 0 – RHB SCORPION 8-2

Steering
Designations: electric steering diagram

B4 Front axle steering sensor E3/VIII
B5 Rear axle steering sensor E11/VIII
D1 Steering electronics (see “Electric system”)
H13 4 wheel steering LED (see “Operation”)
H14 Front axle steering telltale (see “Operation”)
H15 Synchronism telltale (see “Operation”)
H35 Diagonal steering telltale (see “Operation”)
S21 1st/2nd speed switch (see “Operation”)
S22 Steering mode/high speed switch (see “Operation”)
S23 Synchronism tip switch (see “Operation”)
S73 Diagonal steering mode switch (see “Operation”)
X1 51 pole cab/engine vat disconnect See “Electric system” (pages 10 – 31)
X2 51 pole cab/frame disconnect See “Electric system” (pages 10 – 31)
X18 3 pole steering sensor connection E3/VIII
X19 3 pole steering sensor connection E11/VIII
X20 12 pole steering electronics connection See “Electric system” (page 10 – end)
X21 12 pole steering electronics connection See “Electric system” (page 10 – end)
X77 2 pole connector – 2 steering modes G6/V
X78 2 pole connector – 2 steering modes G8/V
Y6 Front axle steering solenoid valve E4/VIII
Y7 4 wheel steering solenoid valve E4/VIII
Y36 Diagonal steering solenoid valve E4/VIII
Y40 4 wheel steering solenoid valve 2 E4/VIII
8-3 000 295 725 0 – RHB SCORPION

Steering
8.2 Functional description of steering system

Steering system oil supply
Depending on the machine model, a fixed displacement pump or variable displacement
pump supplies the steering system with oil.
Priority of steering system oil supply

The oil pressure supply of the steering system via the priority valve is given first priority.
The work hydraulics is supplied with oil only after the steering system's sufficient supply.
This can mean that a work hydraulics function is carried out with a delay when steering.
Emergency steering function

In the event of an oil supply breakdown, the steering orbitrol is switched to low capacity via
the capacity changeover valve (22). This is necessary in order to steer more easily in man-
ual emergency steering mode.
Steering modes
The steering modes can be selected via the front axle steering (Y6), 4 wheel steering (Y7)
and diagonal steering (Y40 and Y36) solenoid valves.
➥ – see chapter 10.25 Functional description of the steering electronics on page 10-36
Steering electronics
Front axle steering is changed over to 4 wheel steering or diagonal steering (crab steering)
by means of the steering electronics.
Changing over to another steering mode requires setting the axles to the centre position.
The steering electronics (D1) detects the centre position of the axles by means of the
front (B4) and rear axle (B5) steering sensors.
The steering electronics automatically changes over to the preselected steering mode as
soon as the axles reach the centre position. In 4 wheel steering mode, the steering elec-
tronics (D1) sends a signal to the drive electronics (N1).
By means of bridges (X77) and (X78), the steering electronics (D1) is set to the steering
mode “With diagonal steering” or “Without diagonal steering”.
➥ With bridge => diagonal steering OFF
➥ Without bridge => diagonal steering ON
000 295 725 0 – RHB SCORPION 8-4

Steering
8.3 Brakes connector assignment


Pin housing X18 Socket housing Socket housing Pin housing X21 Socket housing
(3 pole) X19 (3 pole) X20 (12 pole) (12 pole) X40 (6 pole)
Socket housing X41 Socket housing X49 Socket housing X77/X78

8-5 000 295 725 0 – RHB SCORPION

Work hydraulics
9 Work hydraulics Diagram: work hydraulics fixed displacement pump

Raising/lowering the telescopic boom
Work hydraulics
9.1 Diagram: work hydraulics fixed displacement pump – raising/lowering the telescopic boom
9-1 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics variable displacement pump Diagram: variable displacement pump – raising/lowering the
Telescopic boom telescopic boom
Work hydraulics
9.2 Diagram: work hydraulics variable displacement pump – raising/lowering the telescopic boom
9-3 000 295 725 0 – RHB SCORPION

Work hydraulics
Electric diagram – raising/lowering the telescopic boom Electric diagram – raising/lowering the telescopic boom, load stabiliser
Load stabiliser
Work hydraulics
9.3 Electric diagram – raising/lowering the telescopic boom, load stabiliser
9-5 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics fixed displacement pump Diagram: fixed displacement pump – extending/retracting the
Extending/retracting the telescopic boom telescopic boom
Work hydraulics
9.4 Work hydraulics diagram – extending/retracting the telescopic boom, fixed displacement pump
9-7 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics variable displacement pump Diagram: variable displacement pump – extending/retracting the
Extending/retracting the telescopic boom telescopic boom
Work hydraulics
9.5 Diagram: work hydraulics variable displacement pump – extending/retracting the telescopic boom
9-9 000 295 725 0 – RHB SCORPION

Work hydraulics
Electric diagram – extending/retracting the telescopic boom Electric diagram – extending/retracting the telescopic boom
Work hydraulics
9.6 Electric diagram – extending/retracting the telescopic boom
9-11 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics fixed displacement pump, dumping in/out Diagram: fixed displacement pump, dumping in/out
Work hydraulics
9.7 Diagram: work hydraulics fixed displacement pump – dumping in/out
9-13 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics variable displacement pump, dumping in/out Diagram: variable displacement pump, dumping in/out
Work hydraulics
9.8 Diagram: work hydraulics variable displacement pump – dumping in/out
9-15 000 295 725 0 – RHB SCORPION

Work hydraulics
Electric diagram: dumping in/out Electric diagram: dumping in/out

Work hydraulics
9.9 Electric diagram – dumping in/out
9-17 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics fixed displacement pump Diagram: fixed displacement pump – locking/unlocking
Locking/unlocking
Work hydraulics
9.10 Diagram: work hydraulics fixed displacement pump – locking/unlocking
9-19 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics variable displacement pump Diagram: variable displacement pump – locking/unlocking
Locking/unlocking
Work hydraulics
9.11 Diagram: work hydraulics variable displacement pump – locking/unlocking
9-21 000 295 725 0 – RHB SCORPION

Work hydraulics
Electric diagram: locking/unlocking Electric diagram: locking/unlocking

Work hydraulics
9.12 Electric diagram – locking/unlocking
9-23 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics fixed displacement pump Diagram: fixed displacement pump – rear additional control circuit
Rear additional control circuit
Work hydraulics
9.13 Diagram: work hydraulics fixed displacement pump – rear additional control circuit
9-25 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics variable displacement pump Diagram: variable displacement pump – rear additional control circuit
Rear additional control circuit
Work hydraulics
9.14 Diagram: work hydraulics variable displacement pump – rear additional control circuit
9-27 000 295 725 0 – RHB SCORPION

Work hydraulics
Rear additional control circuit Autohitch
Autohitch
Work hydraulics
9.15 Diagram: work hydraulics fixed displacement pump – rear additional control circuit – Autohitch
9-29 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics variable displacement pump Diagram: variable displacement pump – rear additional control circuit,
Autohitch
Work hydraulics
9.16 Diagram: work hydraulics variable displacement pump – rear additional control circuit, Autohitch
9-31 000 295 725 0 – RHB SCORPION

Work hydraulics
Autohitch Tipping trailer
Tipping trailer
Work hydraulics
9.17 Diagram: work hydraulics fixed displacement pump – rear additional control circuit, Autohitch, tipping trailer
9-33 000 295 725 0 – RHB SCORPION

Work hydraulics
Autohitch Tipping trailer
Tipping trailer
Work hydraulics
9.18 Diagram: work hydraulics variable displacement pump – rear additional control circuit, Autohitch, tipping trailer
9-35 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics fixed displacement pump Diagram: fixed displacement pump – rear additional control circuit with
Rear additional control circuit with tipping trailer tipping trailer
Work hydraulics
9.19 Diagram: work hydraulics fixed displacement pump – rear additional control circuit, tipping trailer
9-37 000 295 725 0 – RHB SCORPION

Work hydraulics
Rear additional control circuit Tipping trailer
Tipping trailer
Work hydraulics
9.20 Diagram: work hydraulics variable displacement pump – rear additional control circuit, tipping trailer
9-39 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics fixed displacement pump Diagram: fixed displacement pump – Autohitch
Autohitch
Work hydraulics
9.21 Diagram: work hydraulics fixed displacement pump – Autohitch
9-41 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics variable displacement pump Diagram: wariable displacement pump – Autohitch
Autohitch
Work hydraulics
9.22 Diagram: work hydraulics variable displacement pump – Autohitch
9-43 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics fixed displacement pump Diagram: fixed displacement pump – Autohitch, tipping trailer
Autohitch
Tipping trailer
Work hydraulics
9.23 Diagram: work hydraulics fixed displacement pump – Autohitch, tipping trailer
9-45 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics variable displacement pump Diagram: variable displacement pump – Autohitch, tipping trailer
Autohitch
Tipping trailer
Work hydraulics
9.24 Diagram: work hydraulics variable displacement pump – Autohitch, tipping trailer
9-47 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics fixed displacement pump, tipping trailer Diagram: fixed displacement pump, tipping trailer
Work hydraulics
9.25 Diagram: work hydraulics fixed displacement pump – tipping trailer
9-49 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics variable displacement pump – tipping trailer Diagram: variable displacement pump – tipping trailer
Work hydraulics
9.26 Diagram: work hydraulics variable displacement pump – tipping trailer
9-51 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics variable displacement pump Diagram: additional control circuit
Additional control circuit for quick couplers on telescopic boom Quick couplers on telescopic boom
Work hydraulics
9.27 Diagram: work hydraulics variable displacement pump – additional control circuit for quick couplers on telescopic boom
9-53 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics – safe load indicator Safe load indicator diagram
Work hydraulics
9.28 Diagram: work hydraulics – safe load indicator
9-55 000 295 725 0 – RHB SCORPION

Work hydraulics
Electric system – additional functions Electric system – additional functions

Rear additional control circuit Rear additional control circuit
Additional control circuit for quick couplers on telescopic boom Additional control circuit for quick couplers on telescopic boom
Autohitch Autohitch
Tipping trailer Tipping trailer
Front socket Front socket
Safe load indicator Safe load indicator
Work hydraulics
9.29 Electric diagram – front/rear additional control circuit for quick couplers, Autohitch, tipping trailer, front socket, safe load indicator
Additional functions Front socket Safe load indicator
9-57 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics variable displacement pump Diagram: additional control circuit
Additional control circuit for quick couplers on quickhitch Quickcouplers on quickhitch
Work hydraulics
9.30 Diagram: work hydraulics variable displacement pump – additional control circuit for quick couplers on quickhitch
9-59 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics variable displacement pump Diagram: variable displacement pump – work platform with
Work platform with radio control radio control
Work hydraulics
9.31 Diagram: work hydraulics variable displacement pump – work platform with radio control
9-61 000 295 725 0 – RHB SCORPION

Work hydraulics
Work platform with radio control: electric diagram Work platform with radio control: electric diagram
Work hydraulics
9.32 Work platform with radio control: electric diagram
Diesel engine 88 kW With 103 kW common rail diesel engine
9-63 000 295 725 0 – RHB SCORPION

Work hydraulics
Tilt ram lock: electric diagram Tilt ram lock: electric diagram
Work hydraulics
9.33 Tilt ram lock: electric diagram
9-65 000 295 725 0 – RHB SCORPION

Work hydraulics
Diagram: work hydraulics variable displacement pump Diagram: variable displacement pump – frame levelling, oscillating
Frame levelling axle interlock
Oscillating axle interlock
Work hydraulics
9.34 Diagram: work hydraulics variable displacement pump – frame levelling, oscillating axle interlock
Frame levelling Oscillating axle interlock
9-67 000 295 725 0 – RHB SCORPION

Work hydraulics
Frame levelling, oscillating axle interlock: electric diagram Frame levelling, oscillating axle interlock: electric diagram
Work hydraulics
9.35 Frame levelling, oscillating axle interlock: electric diagram
Frame levelling Oscillating axle interlock
9-69 000 295 725 0 – RHB SCORPION

Work hydraulics
Work hydraulics
Work hydraulics diagram: designations
Work hydraulics diagram: description Machine position

I Pump unit PFC D9/VII
IV Steering system valve block E4/VIII
XIII Control block (control valves) E12/VI
XIV Load stabiliser F13/VIII
XV Lift ram load safety valve (with integrated hose burst valve) F9/VII
a Version with/without reversing fan –
1 Boost pump (CF) drive (gear pump) D8/VI
2 PFC pump (cpl) D9/VII
3 Flow regulator (PFC) D9/VII
4 Pressure cutoff D9/VII
5 Torque restriction D9/VII
6 Axial-piston variable displacement pump D9/VII
7 Shuttle valve LS pump port D9/VII
8 Priority valve (CF) E10/VII
10 Fan pump D8/VI
15 Filter E7/VIII
16 RHD check valve E6/VIII
17 Manifold block F8/VIII
25 Tank H10/V
27 Oil cooler D6/VI
64 Joystick valve unit See “Hydraulics”
65 Tilt ram control valve See “Hydraulics”
000 295 725 0 – RHB SCORPION 9-70

Work hydraulics

66 Telescopic boom control valve See “Hydraulics”
67 3rd additional control circuit control valve See “Hydraulics”
68 Lift ram control valve See “Hydraulics”
69 Load retaining valve (secondary protection) See “Hydraulics”
74 LS pressure relief valve See “Hydraulics”
75 Pressure compensator for CF pump See “Hydraulics”
76 Road travel stop cock G8/VI
77 Emergency lowering pressure accumulator D11/VII
78 Pilot pressure insert –
79 Load stabiliser pressure relief valve See “Hydraulics”
80 Load stabiliser pressure accumulator D11/VII
82 Load safety valve with hose burst valve F9/VII
83 Throttle non-return valve F9/VII
84 Hose burst valve pilot spool F9/VII
85 Lift ram E7/VII
86 Compensating ram E7/VII
87 Tilt ram F2/VII
88 Load safety valve with hose burst valve F2/VII
89 Push-out ram (telescopic boom) E11/V
90 Load safety valve with hose burst valve E11/V
91 3rd additional control circuit hydraulic ram G1/IX
92 Autohitch ram See “Hydraulics”
93 Autohitch lock See “Hydraulics”
94 4th additional control circuit valve block See “Hydraulics”
96 Shuttle valve See “Hydraulics”
107 (S5) pressure switch (hydraulic oil contamination) G10/IV
108 (S45) load stabiliser pressure switch F12/VI
110 (Y16) proportional valve/pressure reducing valve (lock) See “Hydraulics”
111 (Y17) proportional valve/pressure reducing valve (unlock) See “Hydraulics”
112 (Y20) load stabiliser See “Hydraulics”
113 (Y21) load stabiliser See “Hydraulics”
114 (Y22) 3/2 directional valve hose burst valve (unlock) See “Hydraulics”
9-71 000 295 725 0 – RHB SCORPION

Work hydraulics

(Y23) proportional valve/pressure reducing valve (retract telescopic
115 See “Hydraulics”
boom)
(Y23) proportional valve/pressure reducing valve (extend telescopic
116 See “Hydraulics”
boom)
126 (Y44) 3/2 directional valve (lower tipping trailer/Autohitch) E12/VII
127 (Y45) 3/2 directional valve (raise tipping trailer/Autohitch) E12/VII
128 (Y46) 6/2 directional valve (tipping trailer/Autohitch changeover) E12/VII
129 (Y47) 3/2 directional valve (unlock Autohitch) E12/VII
130 (Y48) 2/2 directional seat valve (emergency lowering ON) E12/VII
133 (Y51) 2/2 directional seat valve (unlock front quickhitch) G1/IX
ACC Accumulator port –
B Pump pressure line port –
C Consumers port –
CF Orbitrol port –
EF Control valve port –
HP High-pressure circuit –
L Leak oil port –
LP Low-pressure circuit –
LS Load sensing port –
P Pressure supply port –
PFC Axial-piston variable displacement pump –
S Suction port –
T Tank port –
000 295 725 0 – RHB SCORPION 9-72

Work hydraulics
Electric diagram: designations
Electric diagram: description Machine position

B8 Load sensor – strain gauge G11/VIII
H10 Hose burst valve telltale (see “Operation”)
H11 3rd control circuit telltale (see “Operation”)
H43 Telltale hydraulic funtions OFF (overload) (see “Operation”)
K22 Load stabiliser switching relay (see “Electric system”)
K34 Mini switching relay (lock function of safe load indicator) (see “Electric system”)
K35 Switching relay for lock function of safe load indicator (see “Electric system”)
N2 Proportional electronics (see “Electric system”)
P6 Safe load indicator (see “Electric system”)
S27 Front socket/changeover switch (see “Operation”)
S30 “Unlock” tip switch (see “Operation”)
S31 “Lock” tip switch (see “Operation”)
S32 3rd control circuit switch (see “Operation”)
S33 Continuous operation of 3rd control circuit (see “Operation”)
S40 Quickhitch lock tip switch (see “Operation”)
S44 Load stabiliser switch (see “Operation”)
S45 Load stabiliser pressure switch (see “Operation”)
S67 Bucket repositioning/front socket tip switch (see “Operation”)
S84 Switch for switchoff of hydraulic functions (see “Operation”)
V1 Starting interlock blocking diode (see “Electric system”)
V3 Blocking diode (see “Electric system”)
V4 Blocking diode (see “Electric system”)
X1 51 pole cab/engine vat disconnect See “Electric system”
X2 51 pole cab/frame disconnect See “Electric system”
X3 7 pole cab/sockets disconnect See “Electric system”
X9 8 pole joystick disconnect G6/VI
X10 4 pole joystick/additional function disconnect G6/VI
X11 11 pole cab/armrest disconnect G8/VI
X12 Additional function joystick signal G8/VI
9-73 000 295 725 0 – RHB SCORPION

Work hydraulics
Electric diagram: description Machine position

X23 15 pole telltale module connection G5/V
X24 6 pole safe load indicator G6/II
X42 14 pole drive interlock board connection See “Electric system”
000 295 725 0 – RHB SCORPION 9-74

Work hydraulics
9.36 Functional description of work hydraulics

• Fan motor (014, 013)
• Drive motor with servopressure X
Important!
Emergency lowering: with the diesel engine switched OFF, the telescopic boom
can be lowered in an emergency with the joystick. Ignition must be switched on
and bucket unlocking S40 must be enabled for this. See “Unlocking the 3rd control
circuit”
Raising/lowering the telescopic boom

The 4th section in the valve unit of the control valves (XIII) is controlled via the joystick pilot
control unit (X). At the same time as this function is carried out, the load safety valve and
the hose burst valve (XV) are controlled via the shuttle valve (096) when lowering the tele-
scopic boom.
Parallel lifting and lowering of attachments

The compensating ram (086) ensures the preselected tilt angle of the attachment is not
changed when raising or lowering the telescopic boom. When it reaches its mechanical
end position, the tilt ram (087) is hydraulically secured by means of the load retaining
valves (secondary protection) (072) and (073).
Switching on the load stabiliser

This function is available either in speed-sensitive mode or permanently with the load sta-
biliser switch (S44). The drive electronics (N1) switches on the load stabiliser function from
about 7 kph onwards when selecting the speed-sensitive mode.
9-75 000 295 725 0 – RHB SCORPION

Work hydraulics
Load stabiliser function

The load stabiliser avoids peak pressures and dampens oscillating movements if the tele-
scopic boom raised. The load stabiliser pressure accumulator (080) is pres-stressed by
means of the pilot pressure insert (078) as the telescopic boom is raised, in order to pre-
vent the telescopic boom from sagging when switching on the load stabiliser function. A
pressure relief valve (079) integrated in the load stabiliser (XIV) secures the function with
260 bar. The solenoid valves (Y20, Y21 and Y22) are triggered when enabling the load
stabiliser function. This reduces the pressure on the piston rod side of the lift ram (086) to
the tank. This opens the load safety valve and the hose burst valve (XV), and the base
side of the lift ram (085) is connected with the pressure accumulator (080).
The load stabiliser function is automatically switched off if the attachment is tilted in. If the
tilt ram (087) is retracted up to its mechanical end position, an increased hydraulic pres-
sure is built up when lowering the telescopic boom via the compensating ram (086), which
can cause the telescopic boom to rise via the compensating ram (086). In order to prevent
this, the load stabiliser function is switched off at a hydraulic pressure of > 140 bar via the
load stabiliser pressure switch (S45).
Important!
The attachment must not be dumped in up to the mechanical end position in order
to be able to use the load stabiliser function.
Danger!
Prior to carrying out service and maintenance work on the load stabiliser (XIV),
the internal hydraulic pressure must be released by means of the mechanically
operated release valve
(figure with corresponding screw).
Important!
If raising/lowering the telescopic boom does not work correctly, also bear in mind
the safe load indicator or the (optional) lock function of the safe load indicator.
Retracting and extending the telescopic boom

Input signals for these functions are transmitted to the proportional electronics (N2) via the
“Extend telescopic boom/front socket” (S38) and “Retract telescopic boom/Bucket reposi-
tioning” (S39) switches. The proportional electronics (N2) enables the “Retract telescopic
boom” (Y23) and “Extend telescopic boom” (Y24) solenoid valves which hydraulically and
proportionally control the 2nd section in the valve unit of the control valves (XIII).
➥ – see chapter 10.26 Proportional controls: overview and connections on page 10-38
000 295 725 0 – RHB SCORPION 9-76

Work hydraulics
Safe load indicator function

The safe load indicator (P6) indicates the current load status of the machine (see also the
Operator's Manual). Sensor B8 captures the deflection of the rear axle and transmits its
signals to the display.
Overload cutoff (option)

The overload cutoff option switches off the entire pilot controls (with the exception of tele-
scopic boom retraction) of the work hydraulics. The telescopic boom can only be retracted
in case of overload.
• Overload display: X85 connected
• Overload cutoff: X85 connected with X86, K35 can therefore interrupt the pilot control
signal
Dumping the attachment in and out

The joystick pilot control unit (X) actuates the 1st section (dump attachment in/out) in the
valve unit of the control valves (XIII). The attachment remains in its current position by
means of the compensating ram (086) when raising and lowering the telescopic boom.
Locking the 3rd control circuit

The 3rd control circuit (S32) is locked and unlocked by means of the proportional electron-
ics module (N02). The status is displayed by the 3rd control circuit telltale (H11).
Operating the 3rd control circuit (unlocking/locking the quickhitch)

By means of the “Unlock tip switch” (S30) and “Lock tip switch” (S31) switches, input sig-
nals are transmitted to the proportional electronics (N2) which actuates the “Unlock” (Y16)
and “Lock” (Y17) solenoid valves. These solenoid valves hydraulically and proportionally
control the 3rd section in the valve unit of the control valves (XIII).
Quickhitch lock
The “Lock quickhitch” (S40) tip switch triggers the “Lock quickhitch” (Y25) solenoid valve. If
the solenoid valve (Y25) is inoperative, the quickhitch and emergency lowering functions
are hydraulically locked.
9-77 000 295 725 0 – RHB SCORPION

Work hydraulics
Functional description of front socket

By means of the front socket, consumers on attachments can be switched on and off in the
cab, for instance lights for a snow plough. The front socket is required for switching the 3rd
control circuit changeover valve option on and off.
Tilt ram lock

The key-operated switch S47 controls Y26 and Y27 which interrupt the pilot control line for
dumping in and out. The Lock tilt ram option is required for the man basket/remote radio
control option.
Remote radio controls

The remote radio control option controls the raise/lower and extend/retract functions of the
telescopic boom. This is achieved by switching off the joystick pilot controls via Y104, and
by blockinig the tilt ram pilot control by means of the tilt ram lock option.
Oscillating axle interlock

The machine frame suspension on both axles is of an oscillating design and can be set to
a specific angle with respect to the axle by means of a hydraulic ram. As a rule, the rear
axle ram runs freely and can be blocked with switch S24.
000 295 725 0 – RHB SCORPION 9-78

Work hydraulics
9.37 Work hydraulics connector assignment

Socket housing X1 Pin housing

yellow/X2 green X1 yellow/X2 green
Socket X3 Joystick X9 Joystick X10 Socket housing X11

Joystick X12 Telltale X23 Safe load indicator X24 Front socket Board X40
(1 pole) (15 pole) (6 pole) X28 (4 pole) (6 pole)
Socket hous- Board X42 (14 Socket housing Socket housing X47 Socket hous- Board
ing X41 pole) drive inter- X45 (12 pole) (15 pole) ing X49 X50
(22 pole) lock (14 pole) (4 pole)
9-79 000 295 725 0 – RHB SCORPION

Work hydraulics
Work hydraulics
9.38 Test report: models 400-01/401-01
See Test features: Notes: Nominal ✔

page: value:
(rpm)
Min. idling speed Measured on crankshaft 870 – 900 rpm
Max. idling speed Measured on crankshaft 2520 – 2570 rpm
Work hydraulics Max. engine revs 220 – 240 bar
Rod side/base side Minimum idling speed 260 bar

push-out ram
Lift ram (raise, Minimum idling speed 260 bar

secondary pressure)
9-85 Tilt ram (dump out, Minimum idling speed 260 bar
secondary pressure)
Tilt ram (dump in, Minimum idling speed 260 bar

secondary pressure)
Gear pump standby At the measuring point of 15 bar

pressure the pump
Hydraulic tipping trailer At full throttle 220 – 240 bar

connection
Hydraulic trailer brake At idling speed 140 bar
Additional rear circuit At 220 – 240 Q~ 46 – 50 l/min
Steering pressure Max. engine revs 200 – 235 bar
Load stabiliser Minimum idling speed 240 bar
000 295 725 0 – RHB SCORPION 9-80

Work hydraulics
9.39 Test report: models 402-01/403-01
See Test features: Notes: Nominal ✔

page: value:
(rpm)
Min. idling speed Measured on crankshaft 870 – 900 rpm
Max. idling speed Measured on crankshaft 2520 – 2570 rpm
Work hydraulics Max. engine revs 300 bar
Push-out ram rod side Minimum idling speed 300 bar
Push-out ram base side Minimum idling speed 200 bar
Lift ram (secondary Minimum idling speed 300 bar

pressure)
Tilt ram (dump out, Minimum idling speed 300 bar

9-85 secondary pressure)
Tilt ram (dump in, Minimum idling speed 300 bar

secondary pressure)
Gear pump standby At the measuring point of 15 bar

pressure the pump
Control pump standby At the measuring point of 39 bar

pressure the pump
Hydraulic tipping trailer At full throttle 220 – 240 bar

connection
Hydraulic trailer brake At idling speed 140 bar
Additional rear circuit At 220 – 240 Q~ 46 – 50 l/min
Steering pressure Max. engine revs 200 – 235 bar
Load stabiliser Minimum idling speed 240 bar
9-81 000 295 725 0 – RHB SCORPION

Work hydraulics
9.40 Work hydraulics test ports
Work hydraulics
test port
LS pressure test port

Steering
Test port
Pump pressure
LS pressure test port

For work hydraulics
Test port
Pump pressure for fan motor
Test port
Pump pressure
000 295 725 0 – RHB SCORPION 9-82

Work hydraulics
9.41 Variable displacement pump (hydraulic pump)

A10V – swash plate design, adjustable
60 – displacement Vg max (60 cm³/rev) = 140 l/min
How the pressure regulator works

The pressure regulator maintains the pressure within the hydraulic system at a constant
level within the pump's control range. The pump delivers only as much hydraulic oil as
required by the consumers.
LS pressure measuring point
300 bar
300 bar
Pressure controller
☞ Check and set the pressure regulator

➥ – see Test report: models 400-01/401-01 on page 9-80
9-83 000 295 725 0 – RHB SCORPION

Work hydraulics
How the flow regulator works

In addition to the function of the pressure regulator, pump flow can be adjusted via the
consumer's differential pressure.

39 bar
39 bar
Flow regulator
☞ Check and set the flow regulator

➥ – see Test report: models 400-01/401-01 on page 9-80
How the output regulator works

In order to achieve steady drive torque at varying service pressures, the variable angle
and hence the pump's flow are changed in order maintain the product of flow and pressure
at a constant level, and in order not to exceed the specified output value.
Output regulator
☞ The output regulator can only be adjusted on a test bench
000 295 725 0 – RHB SCORPION 9-84

Work hydraulics
9.42 Checking and setting the work hydraulics

Variable displacement pump pressure regulator: settings
• Tools: pressure gauge 600 bar
• Oil temperature: 50 °C
Measurement
☞ Connect pressure gauge (600 bar)
☞ Turn the primary valve on the control valve against hydraulic resistance
☞ Actuate the 3rd control circuit
➥ The measured value is equal to pump pressure
Setting
☞ Screw in the pressure regulator on the pump
Work hydraulics test port ➥ Pressure increase
☞ Unscrew in the pressure regulator on the pump
➥ Pressure reduction
➥ Specified value is 300 bar at full throttle
Pressure controller
Control valve (primary pressure): settings

☞ Use the same measuring point as
Primary valve
➥ see pressure regulator
☞ Actuate the 3rd control circuit
➥ Primary pressure must be 220 – 240 bar (75 kW machine)
➥ Primary pressure must be 260 – 280 bar (90/100 kW machine)
Setting:
☞ Screw in the primary valve on the control valve
➥ Pressure increase
☞ Unscrew in the primary valve on the control valve
9-85 000 295 725 0 – RHB SCORPION

Work hydraulics
Flow regulator: settings

Tools: pressure gauge 60 bar
Oil temperature: 50 °C
Measurement
Caution!
Do not actuate the work hydraulics
Work hydraulics test port ☞ Specified value must be 39 bar
Setting
☞ Screw in the flow regulator on the pump
➥ Pressure increase
☞ Unscrew in the flow regulator on the pump
Flow regulator
000 295 725 0 – RHB SCORPION 9-86

9-87
Test port
Work hydraulics
Work hydraulics
Test port
P1
Pump pressure
T
9.43 Work hydraulics circuit (gear pump)
To steering CF
To steering LS
EF
P
1000153941_s.iso
000 295 725 0 – RHB SCORPION

LS Test port
Work hydraulics
000 295 725 0 – RHB SCORPION

P1 Test port
T Pump pressure
P
Shuttle valve
B
EF S
9.44 Work hydraulics circuit (variable displacement pump LS)
LS
From the steering system

1000153898_s.iso
9-88
Work hydraulics
Work hydraulics
9.45 Control valve connections (4-fold)
LS line only
with LS pump
Secondary valves
P B1 B2 B3 B4
T Pressure compensators
A1 A2 A3 A4
T
Main pressure LS Secondary valves
A 1 => dump out

A 2 => extend
A 3 => unlock
A 4 => lower
B 1 => tilt in
B 2 => retract
B 3 => lock
B 4=> raise
9-89 000 295 725 0 – RHB SCORPION

Pressure compensators
000 295 725 0 – RHB SCORPION

Pressure compensators 1 = tilt ram
2 = push-out ram
Valve for gear pump 3 = 3rd control circuit
4 = lift ram
Anticavitation valve
4
9.46 Control valve (4-fold): overview
P
1000152714_s.iso
Secondary valve
LS pressure relief valve

Tightening torque
33 Nm
9-90
Work hydraulics
Work hydraulics
9.47 Control valve connections (5-fold)
Secondary valves
B1 B2 B3 B4 B5
P
LS line only
with LS pump
A1 A2 A3 A4 A5
T
Secondary valves
Primary pressure LS
A 1 => dump out

A 2 => extend
A 3 => unlock
A 4 => lower
A 5 => open additional control circuit
B 1 => tilt in
B 2 => retract
B 3 => lock
B 4=> raise
B 5 => close additional control circuit
9-91 000 295 725 0 – RHB SCORPION

000 295 725 0 – RHB SCORPION

Pressure compensators 1 = tilt ram
2 = push-out ram
3 = 3rd control circuit
4 = lift ram
5 = additional control circuit
Valve for gear pump
5
4
Anticavitation valve
9.48 Control valve (5-fold): overview
1
P
T Secondary valve
1000155303_s.iso
LS pressure relief valve

Tightening torque
33 Nm
9-92
Work hydraulics
9-93
Work hydraulics
9.49 Lift ram circuit
PIL
PIL
V2 C2
C2
V2
TT
Hose burst valve
T2 Manifold to tank A4
T2 a
B4
b A
B
1000153828_s.iso
000 295 725 0 – RHB SCORPION

A B
000 295 725 0 – RHB SCORPION

9.50 Tilt ram circuit
C2
C2
C1
C1
To compensating ram
V2
V2
V1
V1
Hose burst valve

A1
B1
To compensating ram a
1000153866_s.iso A
b
B
9-94
Work hydraulics
Work hydraulics
9.51 Compensating ram circuit
A
B
A1
B1
To tilt ram
b
1000153759_s.iso
A
B
9-95 000 295 725 0 – RHB SCORPION

Work hydraulics
9.52 Push-out ram circuit
1000153881_s.iso
a
A
B
A2
Hose burst valve
b
B2
000 295 725 0 – RHB SCORPION 9-96

Work hydraulics
9.53 3rd control circuit
A3
B3
9-97 000 295 725 0 – RHB SCORPION

Stop cock for road travel
000 295 725 0 – RHB SCORPION

1 = a4
2 = a1
3 = b4 2 P 4
3 T
B2 4 = b1 1
A2
B3
T
A3 3 4 1
P
2
T
9.54 Control valve (4-fold) pilot control circuit
a1 = tilt in
Orifice 0.8 a4 a2 = extend
a3 = lock
a3 a4 = lower
b3 b1 = dump out
b2 = retract
b3 = unlock
Orifice 0.8 b4 a a2 a1 b4 = raise
b2 b
b1
1000154416_s.iso
9-98
Work hydraulics
Work hydraulics
9.55 Valve block connections: overview

• Y44 – raise tipping trailer/black port
• Y45 – lower tipping trailer/black port
y47 y22 y45 y44
• Y22 – hose burst valve/load stabiliser/black port
y48 • Y47 – Autohitch/black port
y17 y16 y24 y23 • Y23 – proportional valve retract telescopic boom/blue port
• Y24 – proportional valve extend telescopic boom/blue port
• Y16 – lock proportional valve/blue port
Blue valve • Y17 – unlock proportional valve/blue port
• Y48 – emergency lowering OFF
y17 y16 y24 y23 • T1 – from the changeover valve/tipping trailer connection C
• T2 – input from hose burst valve
T1 T2 T3 • T3 – to the tank
• G – steering system reflux oil supply
A3 B3 A2 B2 • F – pressure accumulator
• E – not assigned
Blue valve
• A1 (Y44) – tipping trailer base side (from control valve a5)
• A2 (Y24) – extend telescopic boom (to control valve b2)
y44 y45 y22 y47 • A3 (Y17) – lock 3rd control circuit (to control valve a3)
• A4 (Y22) – hose burst valve/load stabiliser
G E F • A5 – unlock Autohitch
• B2 (Y23) – retract telescopic boom (to control valve a2)
• B3 (Y16) – unlock 3rd control circuit (to control valve b3)
A1 B4 A4 A5
• B4 (Y45) – tipping trailler rod side (to control valve b5)
9-99 000 295 725 0 – RHB SCORPION

Work hydraulics
9.56 Pilot control unit, pilot valve

Connecting plan from pilot control valve to control valve
• Connection 1 to control valve a4 lower
• Connection 2 to control valve a1 tilt in
1 • Connection 3 to control valve b4 raise
• Connection 4 to control valve b1 dump out
2 4
b1 b4
a1 a4
Connecting plan from pilot valve to control valve

• Connection A1 to control valve b5 for 5th control circuit (Autohitch, tipping trailer)
• Connection A2 to control valve b2 for extension
• Connection A3 to control valve b3 for locking or 3rd control circuit
• Connection B2 to control valve a2 for extension
• Connection B3 to control valve a3 for locking or 3rd control circuit
• Connection B4 to control valve a5 for 5th control circuit (Autohitch, tipping trailer)
T1 T2 T3
A3 B3 A2 B2
G E F
A1 B4 A4 A5
000 295 725 0 – RHB SCORPION 9-100

Work hydraulics
9.57 Load stabiliser

Load stabiliser: description
The load stabiliser can be activated by means of two switch positions: continuous opera-
tion or load stabiliser switched on automatically at 15 kph.
Switching on the load stabiliser opens 3 valves
• Solenoid valve Y20 opens the rod side to the tank
• Solenoid valve Y21 opens the base side to the pressure accumulator
• Solenoid valve y22 opens the hose burst valve from the lift ram
A pilot pressure insert applies a pressure of 120 bar to the pressure accumulator of the
load stabiliser. This prevents the telescopic boom from sagging as the load stabiliser is
switched on.
The entire system is protected by a 240 bar pressure relief valve.
Danger!
Work on the hydraulic circuit of the load stabiliser –
☞ Lower the telescopic boom completely
☞ and release system pressure via the release valve
A
F T Release valve
Pressure relief
valve 240 bar Y20
ACC = pressure accumulator connection
F = lift ram base side connection
Pilot pressure in- T = tank connection
ACC sert 120 bar A = lift ram rod side connection
Y21
Y20/21 = both valves are energised as the load sta-
biliser is switched on
9-101 000 295 725 0 – RHB SCORPION

Work hydraulics
Checking and setting the load stabiliser

Tools: pressure gauge 600 bar
Oil temperature: 50 °C
Measurement
☞ Start the engine and set revs to low idling speed (870 – 900 rpm)
☞ Switch the load stabiliser to continuous operation
☞ Raise the telescopic boom as far as it will go
➥ Specified value must be 240 bar
Setting
☞ Screw in the pressure relief valve on the changeover valve
Work hydraulics test port ➥ Pressure increase
☞ Unscrew in the pressure relief valve on the changeover valve
Pressure relief valve 240 bar
000 295 725 0 – RHB SCORPION 9-102

Hose burst valve for lift
9-103
Solenoid valve Y21 Release valve
ram
Solenoid valve Y22
Pilot pressure
Work hydraulics
insert 120 bar

Y22
Pressure switch
The load stabiliser is switched off
at a tilting pressure of 150 bar. F
9.58 Load stabiliser circuit
This prevents the telescopic boom

A4 from being raised by the push-out T
ram with the load stabiliser A
switched on ACC Pressure relief valve
240 bar
B4
A4
Pressure accumulator
a4 25 bar
B1
1000154001_s.iso
000 295 725 0 – RHB SCORPION

Work hydraulics
9.59 Changeover valve: Autohitch/tipping trailer connection/additional control circuit
P1 P2
D
L
C
Y46
A B
A = tipping trailer quick coupler connection

B = tipping trailer quick coupler connection
P1 = oil supply from control valve 5A
P2 = oil supply from control valve 5B
C = Autohitch: ram/base side
C = single-action tipping trailer ram: to the tank
D = Autohitch: ram/rod side
D = single-action tipping trailer ram/base side
L = tank to T1 on pilot valve
000 295 725 0 – RHB SCORPION 9-104

9-105
T1G
A1
Y44
a5 B4
A5
Work hydraulics
54 3 2
1
b5
Y47 Quick coupler (single-action
tipping trailer connection)
Y34
9.60 Autohitch, rear additional control circuit
D
C
P2 Rear additional control circuit
Y46 P1
B A
Lock (Autohitch coupling)
1000154353_s.iso
000 295 725 0 – RHB SCORPION

Work hydraulics
9.61 Tipping trailer connection circuit
A5
B5
A1
a5
B4
b5
To tank
1000154374_s.iso
000 295 725 0 – RHB SCORPION 9-106

Work hydraulics
9.62 Front additional control circuit
Y 51 changeover
(front additional control circuit)
Y51
Quick coupler (addi-
tional control circuit)
9-107 000 295 725 0 – RHB SCORPION

Work hydraulics
9.63 Frame levelling with oscillating axle interlock (option) telehandler 404: overview
• Always lock the control lever for the 3rd control circuit when working with the pallet
forks!
• Always bear in mind the instructions for the safe load indicator.
➥ See Operator's Manual
• Always ensure machine stability
• – see Mechanical oscillating axle interlock (rear axle) on page 9-108
• – see Working with the front axle frame levelling (option) on page 9-109
• Never exceed maximum load!
• Follow the special instructions in the Operator's Manual of the pallet forks!
• Do not lower the extended telescopic boom from a high fork arm position – always
retract the telescopic boom first!
• Approach the material as closely as possible!
• Always approach the material with the machine wheels in straight-ahead position!
• Always load on firm and level ground with sufficient load-bearing capacity only (for a
fully loaded machine)!
• Never raise a load with only one fork arm!
• Maintain a distance of a minimum 6 m between the telescopic boom/load and overhead
lines!
• Before starting work, make sure the fork arms on the fork frame are safely locked!
• Never operate the telescopic boom and the attachments at higher machine speed!
• Never leave the machine with the load raised!
• Always transport the load close to the ground!
Mechanical oscillating axle interlock (rear axle)

During pallet forks/loader operation at greater lift heights, the rear axle can be locked only
on level ground with the oscillating axle interlock located laterally on the frame!
☞ Place the telehandler on level ground
A ☞ Lower the telescopic boom to transport position
☞ Remove pin A from its fixture and
☞ insert it in bracket B of the oscillating axle interlock (see arrow)
☞ Secure the pin with the safety pin
Caution!
In order to avoid damage to the frame and the axle, handle pallets with the
B locked oscillating axle on level ground only!
☞ Unlock the oscillating axle once pallet forks operation is over
000 295 725 0 – RHB SCORPION 9-108

Work hydraulics
Working with the front axle frame levelling (option)

The telehandler can be set horizontally on slopes with the “Frame levelling” option in the
84 108 case of a max. 10° (±) lateral inclination of the longitudinal axis!
A
Danger!
Do not use frame levelling when driving on public roads –
B
Arma_re_05_2.iso Danger of accidents!
☞ Before driving on public roads:
• Set the telehandler horizontally with the level indicator (at the front on
the instrument panel)
Caution!
C
In order to avoid damage to the frame and the axle, disable the hydraulic or
mechanical oscillating axle interlock under all circumstances during frame
levelling operation!
☞ – see Mechanical oscillating axle interlock (rear axle) on page 9-108
☞ – see Hydraulic rear oscillating axle interlock (option) on page 9-110
☞ Stop the telehandler in the required position with the load and the telescopic boom low-
N ered
☞ Press and hold tip switch 84 (to unlock, on the left on the instrument panel), and at the
same time
☞ Press tip switch 108 (frame levelling, on the right on the instrument panel) to
positions A or B
➥ The frame levelling ram C sets the telehandler horizontally in its longitudinal axis to
the right or left
➥ See level indicator N in the cab (at the front on the instrument panel)
☞ Enable rear axle oscillation (option)
➥ During pallet forks/loader operation at greater lift heights, the rear axle can be
locked only on level ground with the oscillating axle interlock located laterally on the
frame
➥ – see Hydraulic rear oscillating axle interlock (option) on page 9-110
☞ Carefully raise and set down the load
9-109 000 295 725 0 – RHB SCORPION

Work hydraulics
Hydraulic rear oscillating axle interlock (option)

We recommend using the oscillating axle interlock when working at greater heights in pal-
let forks/load operation!
N ☞ Slide lock S in the direction of the arrow and at the same time, press switch 109 to posi-
tion B
➥ Rear axle oscillation is locked via the solenoid valve on interlock ram D
☞ Slide lock S in the direction of the arrow and at the same time, press switch 109 to posi-
tion A
K ➥ Rear axle oscillation is unlocked via the solenoid valve on interlock ram D
➥ The red telltale K comes on (next to the level indicator in the cab at the front on the
instrument panel)
Caution!
109 S In order to avoid damage to the frame and the axle, handle pallets/work with
the bucket with the locked oscillating axle on level ground only!
A ☞ Once pallet forks operation is over:
• Disable the hydraulic or mechanical oscillating axle interlock
• Set the telehandler horizontally (see level indicator in the cab)
B
Arma_re_05_2.iso
000 295 725 0 – RHB SCORPION 9-110

Work hydraulics
9.64 Bleeding the hydraulic ram of the oscillating axle interlock
109 S
A
B
B
Arma_re_05_2.iso
Caution!
Bleed the interlock ram B only on level ground!
Environment!
Use a suitable container to collect the oil as it drains and dispose of it in an
☞ Open bleed screw B on the interlock ram 1 revolution

☞ Slide lock S in the direction of the arrow and at the same time, press switch 109 to posi-
tion A
➥ until the oil comes out of the bleed screws without any air bubbles
☞ Close the bleed screw on the interlock ram
9-111 000 295 725 0 – RHB SCORPION

Work hydraulics
9.65 Frame levelling circuit
Reflux line 2 bar
Y 54 check valve. Both

valves are always switched
together
Non-return valve
Shuttle valve for LS controlling

LS signal for control
pump
Control block
T
Hose burst valve

B
A
LS
Priority valve
Solenoid valve Y 52
Levelling ram P
Solenoid valve Y 53
000 295 725 0 – RHB SCORPION 9-112

Work hydraulics
9.66 Frame levelling valve overview
B3 A3
Y 52
T Y 53
LS
P – from priority valve connection EF

T – to tank
LS – signal to variable displacement pump
B3 – frame levelling ram port (rod side)
A3 – frame levelling ram port (base side)
Y 52 – solenoid valve: extend ram
Y 53 – solenoid valve: retract ram
9-113 000 295 725 0 – RHB SCORPION

Work hydraulics
9.67 Lift ram with hose burst valve: overview
Cylinder head 450 – 500 Nm

Scraper Piston 900 Nm Piston seal
Piston rod seal
Threaded pin 20 Nm
O-ring
Guide bands Guide bands
Caution!
Do not carry out any modifications on the
hose burst valve
000 295 725 0 – RHB SCORPION 9-114

Work hydraulics
9.68 Tilt ram: overview

Piston 900 Nm Piston seal
Scraper O-ring
Threaded pin 20 Nm
Piston rod seal
21 mm
9-115 000 295 725 0 – RHB SCORPION

Work hydraulics
9.69 Push-out ram with final position damping: overview

Scraper O-ring
Threaded pin 20 Nm
Piston rod seal
21 mm
9.70 Compensating ram: overview

Scraper O-ring
Threaded pin 20 Nm
Piston rod seal
000 295 725 0 – RHB SCORPION 9-116

Work hydraulics
9.71 Quickhitch
Solenoid valve Y25

(quickhitch lock)
Disassembly and assembly

☞ Release the pressure in the quickhitch ram control circuit
☞ Remove the circlip
☞ Drive out the piston with an impact extractor M 8
☞ Renew the seal between piston rod and guide bushing
➥ Replace complete sealing kit
☞ Assembly in the reverse order
Caution!
Special tools required for sealing the ram
9-117 000 295 725 0 – RHB SCORPION

Work hydraulics
9.72 Installing the telescopic boom

☞ Extend the piston rod (push-out ram) by about 600 mm
☞ Install the slide plate
➥ Allen key 8 mm
826
Fig. 1: Installing the slide plate
☞ Place the push-out ram in the inside boom section
827
Fig. 2: Installing the push-out ram
☞ Fasten the push-out ram at the front

☞ Ensure the level position of the push-out ram with centring pin A
☞ Insert the pin
828
Fig. 3: Fastening the push-out ram
☞ Place the shim onto the pin

☞ Secure the pin with the circlip
829
Fig. 4: Securing the pin
000 295 725 0 – RHB SCORPION 9-118

Work hydraulics
☞ Install the screw connections for the hydraulic lines on the outside boom section
➥ W/F 36 mm
830
Fig. 5: Installing the screw connections
Caution!
Follow the prescribed order for installing the flexible lines!
• Due to different hose lengths and
• to spare part numbers stamped onto the crimped section of the flexible
lines
831 Install as follows on the left in driving direction. The numbers are stamped onto the hose
Fig. 6: Installing the flexible lines
clampings.
☞ Insert flexible line 1000147034 with the elbowed pipe
☞ Connect the hoses with the screw connections on the outside boom section
➥ W/F 32
Caution!
Install the hoses showing to the inside and close to the lower outside boom
section!
☞ See arrow
832
9-119 000 295 725 0 – RHB SCORPION

Work hydraulics
☞ Insert slide plates B loosely from the rear into the outside boom section
A ☞ Insert inside boom section C with slide plate B into the outside boom section
BBB
834
CC
833
Fig. 8: Installing the outside boom section
☞ First install the upper, then the lower slide plates

☞ Adjust the lower slide plates tolerance-free with spacers
➥ W/F 19
835
☞ Install the stud bolts for the clamps
836
Fig. 10: Fastening the flexible lines
000 295 725 0 – RHB SCORPION 9-120

Work hydraulics
☞ Install the hose burst valve on the push-out ram

➥ W/F 27
837
Fig. 11: Installing the hose burst valve
☞ Install the wiring harness in the guide chain

➥ The wiring harness must project 1600 mm beyond the end of the chain
☞ Fasten the wiring harness with tie-wrap.
1600 mm
838
Fig. 12: Installing the wiring harness
☞ Fasten the guide chain onto the push-out ram

➥ Allen key 3 mm
839
Fig. 13: Installing the guide chain
☞ Install the guide chain on the inside boom section

➥ Allen key 3 mm
840
Fig. 14: Installing the guide chain on the inside boom sec-
tion
9-121 000 295 725 0 – RHB SCORPION

Work hydraulics
☞ Route the wiring harness underneath the bracket

➥ See arrow
844
Fig. 15: Wiring harness routing
☞ Slide the wiring harness forwards through the shaft on the left
842
Fig. 16: Installing the wiring harness
☞ Slide the flexible lines forwards

☞ Fasten the flexible lines with the clamps
➥ Do not tighten the clamp so you can adjust the length later on
➥ The inside flexible lines are for the tilt ram
➥ The outside flexible lines are for the 3rd control circuit
843
Fig. 17: Fastening the flexible line
☞ Install the push-out ram on the outside boom section

☞ Compensate the tolerance between the push-out ram and the outside boom section
with spacers.
➥ Max. 1 mm
☞ Secure the pin with a locking screw
➥ W/F 17
844
Fig. 18: Installing the push-out ram
000 295 725 0 – RHB SCORPION 9-122

Work hydraulics
☞ Install the slide plates at the lower rear

➥ W/F 17
846
Fig. 19: Installing the slide plates
☞ Adjust the lower slide plates tolerance-free with spacers

➥ Raise the inside boom section with a mounting lever D
➥ About 8 mm
➥ W/F 19
845
☞ Adjust the lateral slide plates tolerance-free with spacers

➥ About 3 – 4 mm on either side.
➥ W/F 19
847
☞ Install the front lateral slide plates

➥ About 3 – 4 mm lateral tolerance between the outside and the inside boom sections.
849
9-123 000 295 725 0 – RHB SCORPION

Work hydraulics
☞ Insert the wiring harness at the front of the inside boom section
850
Fig. 23: Inside boom section wiring harness
☞ Install the flexible lines for the 3rd control circuit at the front
➥ In driving direction on the right, install the flexible line downwards (the one that is
about 650 mm longer)
➥ In driving direction on the left, install the shorter flexible line upwards
852
☞ Install the tilt ram
Danger!
The tilt ram is very heavy!
Danger of crushing!
☞ Install the tilt ram with appropriate lifting gear only
855
Fig. 25: Installing the tilt ram
☞ Install the mounting pins from the left

☞ Secure the pin with the screw
➥ W/F 19
856
Fig. 26: Tilt ram fastening
000 295 725 0 – RHB SCORPION 9-124

Work hydraulics
Tilt lever installation:

☞ Fully extend the piston rod of the tilt ram
☞ Install the tilt lever
➥ Bear in mind the installation position, see figure.
857
Fig. 27: Fastening the tilt lever
First install the pivotal point of the tilt lever

☞ Centre the tilt lever with spacers as you install it, about 4 mm on either side
➥ Max. 1 mm
☞ Secure the pin with a locking screw
➥ W/F 19
858
Fig. 28: Installing the tilt lever
☞ Install the reversing lever with the tilt lever

☞ Centre the reversing lever with spacers as you install it, about 2 mm on either side
➥ Max. 1 mm
➥ Allen key 10 mm
859
Fig. 29: Installing the reversing lever
☞ Install the hose burst valve on the tilt ram

☞ Route the flexible lines taking care they are not routed over the edge of the ram cylin-
der.
862
9-125 000 295 725 0 – RHB SCORPION

Work hydraulics
☞ Once the tilt ram and the hose burst valve, and the 3rd control circuit have been con-
nected,
➥ install the flexible lines at the rear of the telescopic boom with clamps
863
863
843
000 295 725 0 – RHB SCORPION 9-126

Work hydraulics
9.73 Replacing the control valve

☞ Park the telehandler on level and firm ground with the telescopic boom raised by
about 1.5 m, and prevent it from rolling away.
Danger!
When working under a raised telescopic boom that has not been secured –
☞ Safely secure and support the telescopic boom
☞ Release the pressure in the entire hydraulic system

☞ Remove the battery master switch
☞ Connect a vacuum pump to the hydraulic oil tank
☞ Mark the flexible lines and pilot control lines before removing them
☞ Remove the flexible lines and the pilot control lines
➥ W/F 14, 32, 36, 41
☞ Slacken the fastening screws
➥ W/F 13
0803 ☞ Remove the control valve to the rear
Fig. 32: Removing the flexible lines
After you have installed the control valve
☞ Check and if necessary, adjust the hydraulic pressures according to the test report
☞ Check the hydraulic oil level and fill it up if necessary
9.74 Replacing the priority valve

☞ Park the machine over a pit with the telescopic boom lowered and prevent it from rolling
away.
☞ Remove the flexible lines
➥ W/F 19, 27, 32, 41
☞ Slacken the fastening screws and remove the valve with a downwards movement
0020 ➥ W/F 13
Fig. 33: Removing the priority valve ☞ Check the hydraulic oil level and fill it up if necessary
9-127 000 295 725 0 – RHB SCORPION

Work hydraulics
9.75 Replacing the fan pump

away.
☞ Remove the cover on the opposite of the fan pump
➥ W/F 10
☞ Remove the nut (gear fastening)
➥ W/F 17
Caution!
Caution: When removing the nut on the gear fastening, the nut can fall into the
control cover or into the oil sump
0009
Fig. 34: Removing the cover
☞ Remove the flexible lines on the fan pump

➥ W/F 27, 41
➥ Allen key 10 mm
Caution!
Slacken only the fastening screws of the fan pump
0010
☞ Replace the fan pump with a new one
Fig. 35: Removing the gear pump
After having installed the fan pump:
☞ Check the hydraulic system for leakage
000 295 725 0 – RHB SCORPION 9-128

Work hydraulics
9.76 Replacing the A 10 work hydraulics pump

☞ Park the machine on firm and level with the telescopic boom lowered and prevent it
from rolling away.
☞ Open the engine cover and the lower and lateral maintenance panels.
➥ W/F 17
☞ Remove the fan pump
➥ – see Replacing the fan pump on page 9-128
☞ Remove the flexible lines for the engine oil filter
☞ Remove the leak oil line and the pipe fitting with thread
☞ Remove the LS line
☞ Remove the suction line
☞ Remove the P line
☞ Remove the engine oil filter housing
☞ Remove the variable displacement pump with an upwards movement
☞ Use new O-rings for the suction line and the P line as you install the pump.
☞ Check and if necessary, adjust the pressures according to the test report once the
pump is installed.
9.77 Replacing the pilot valve

away.
☞ Connect the vacuum pump
☞ Mark and remove pilot control line A
➥ W/F 14
☞ Mark and remove the electric connection
☞ Remove pressure line P
➥ W/F 19
☞ Remove reflux line T
➥ W/F 19
A ☞ Remove the pressure accumulator line
0880
➥ W/F 19
Fig. 36: Intermediate ring
☞ Slacken the fastening screws and remove the valve with a downwards movement
➥ Allen key 6
☞ Carry out a functional check after you have installed the pilot control valve
9-129 000 295 725 0 – RHB SCORPION

Electric systems
10 Electric systems Machine lights: electric diagram

Electric systems
10.1 Machine lights: electric diagram
10-1 000 295 725 0 – RHB SCORPION

Electric systems
Turn indicators/horn/rotating beacon: electric diagram Turn indicators/horn/rotating beacon: electric diagram
Electric systems
10.2 Turn indicators/horn/rotating beacon: electric diagram
Turn indicators/horn Rotating beacon
10-3 000 295 725 0 – RHB SCORPION

Electric systems
Mirror adjustment/heating: electric diagram Mirror adjustment/heating: electric diagram

Electric systems
10.3 Mirror adjustment/heating: electric diagram
Mirror adjustment Mirror heating
10-5 000 295 725 0 – RHB SCORPION

Electric systems
Window wiper/washer, hydraulics monitoring: electric diagram Window wiper/washer, hydraulics monitoring: electric diagram
Electric systems
10.4 Window wiper/washer, hydraulics monitoring: electric diagram
Window wiper/washer Hydraulics monitoring
10-7 000 295 725 0 – RHB SCORPION

Electric systems
Heating – air conditioning system/air-suspension seat: Heating – air conditioning system/air-suspension seat:
electric diagram electric diagram
Electric systems
10.5 Heating – air conditioning system/air-suspension seat: electric diagram
Heating – air conditioning system
Air-suspension seat
10-9 000 295 725 0 – RHB SCORPION

Electric systems
Multimedia/cigarette lighter: electric diagram Multimedia/cigarette lighter: electric diagram

Electric systems
10.6 Multimedia/cigarette lighter: electric diagram
Multimedia
Cigarette lighter
10-11 000 295 725 0 – RHB SCORPION

Electric systems
Electric systems
Electric diagram designations and positions
Electric diagram designations and positions Machine position

A1 Radio G8/V
B2 Horn B4/III
B3 Backup warning system F13/VI
B11 Loudspeaker G8/I
B12 Loudspeaker I8/I
D2 Hold electronics (see “Electric system”)
E1 Front right side marker light A4/IV
E2 Rear right light B12/V
E3 Front left side marker light J4/V
E4 Rear left light I12/V
E5 High, low beam (right) A4/IV
E6 High, low beam (left) J4/V
E7 Rear working light J9/I
E8 Rear working light H9/I
E9 Front working light L4/IV
E10 Front working light A4/IV
E12 Frame/boom working light F3/V
E13 Frame/boom working light E3/V
E14 Interior light H8/I
E15 Cigarette lighter G7/V
E17 Clearance lights J4/IV
E18 Clearance lights A4/IV
H1 High beam telltale (see “Operation”)
H7 Hydraulic oil filter telltale (see “Operation”)
H8 Hydraulic oil temperature telltale (see “Operation”)
H22 Machine turn indicator telltale (see “Operation”)
H23 Rear attachment turn indicator telltale (see “Operation”)
H24 Front right turn indicator (see “Operation”)
H25 Rear right turn indicator (see “Operation”)
H26 Front left turn indicator (see “Operation”)
H27 Rear left turn indicator (see “Operation”)
H28 Rotating beacon (see “Operation”)
H30 Reversing light (see “Operation”)
000 295 725 0 – RHB SCORPION 10-12

Electric systems
Connector positions on machine
Connector positions on machine Machine position

X1 Engine vat signals See “Electric system”
X2 Frame signals See “Electric system”
X3 Boom working light/rear socket See “Electric system”
X4 Tilt ram lock/additional control circuit See “Electric system”
X5 Bucket repositioning See “Electric system”
X6 RS232 to Susmic See “Electric system”
X7 Hold electronics See “Electric system”
X8 Hold electronics See “Electric system”
X9 Joystick G6/VI
X10 Additional joystick function G6/VI
X12 Additional function joystick signal G8/VI
X13 Engine revs signal transmitter See “Engine cooling”
X14 Coolant level sensor D7/V
X15 Water separator D4/IX
X16 Inching potentiometer See “Drive”
X17 Speed sensor See “Drive”
X18 Steering sensor E3/VIII
X19 Steering sensor E11/VIII
X20 Steering electronics inputs See “Electric system”
X21 Steering electronics outputs See “Electric system”
X22 Heating H8/VII
X23 Instrument panel G5/V
X24 Safe load indicator G6/II
X25 Hydraulic oil level sensor G9/VI
X26 Safe load indicator sensor G11/VIII
X27 Rear socket E13/VI
X28 Front socket F2/VI
X29 Front wipe/wash pump J8/VII
X30.1 Steering-column control lever I6/V
X30.2 Steering-column control lever I6/V
X31 Radio power G8/V
X32 Radio loudspeaker G8/V
X33 Front wiper I5/V
X34 Rear wipe/wash pump J8/VII
10-13 000 295 725 0 – RHB SCORPION

Electric systems
Connector positions on machine Machine position

X35 Crawler gear potentiometer G6/V
X36 Connection to fan solenoid valve D6/VI
X36.1 Connection to Susmic S1X49 See “Electric system”
X36.2 Connection to earth S1X46 See “Electric system”
X37 Driving direction identification See “Drive”
X39 Diagnosis connector CAN 8 pole “Binder” See “Engine cooling”
X40 Board connection See “Electric system”
X44 Board connection –
X71 Additional control circuit E12/VI
X72 Tipping trailer/Autohitch E12/VI
X75 Bucket repositioning connector –
X76 Bucket repositioning connector –
X77 Steering mode connector G6/V
X78 Steering mode connector G8/V
X79 Accelerator pedal connection See “Engine cooling”
X80 Manual throttle connection See “Engine cooling”
X81 Engine electronics (engine side) See “Engine cooling”
X82 Engine electronics (machine side) See “Engine cooling”
X83 Engine electronics disconnect See “Engine cooling”
X84 Diagnosis plug Deutz Itt-Cannon See “Engine cooling”
X85 Extend telescopic boom disconnect –
X86 Extend telescopic boom relay disconnect –
X87 Front socket telltale disconnect –
X88 Front socket signal disconnect –
X89 Front socket relais signal disconnect –
X100 Cab supply –
000 295 725 0 – RHB SCORPION 10-14

Electric systems
10.7 Functional description of hydraulics monitoring

Hydraulic filter monitoring (open bypass):
A dirty hydraulic filter (hydraulic oil tank reflux) is detected by the hydraulic oil pressure
switch (S05) and is indicated by means of telltale (H07).
Hydraulic oil level monitoring:

The hydraulic oil level is monitored by the switch (hydraulic oil level S07). Telltale (H36)
indicates whether the hydraulic oil level is too low.
Hydraulic oil temperature monitoring:

The hydraulic oil temperature is monitored by the hydraulic oil temperature switch (S06).
Telltale (H8) indicates whether the hydraulic oil temperature is beyond maximum.
10.8 Hydraulics monitoring connector assigment


Socket housing X23 Socket housing X40 Socket

(15 pole) (6 pole) housing X25 (3 pole)
10-15 000 295 725 0 – RHB SCORPION

Electric systems
10.9 Lights connector assignment



Socket housing X23
(15 pole)
Socket housing Socket housing X28

X27 (7 pole) (4 pole)
Socket housing X45

(12 pole)
Socket housing X48

(9 pole)

000 295 725 0 – RHB SCORPION 10-16

Electric systems
10.10 Turn indicator/horn connector assignment



Socket housing X23
(15 pole)
Socket housing
X27 (7 pole)

X30.1 (8 pole) X30.2 (6 pole)
Socket housing X41

(22 pole)

10-17 000 295 725 0 – RHB SCORPION

Electric systems
10.11 Rotating beacon connector assignment

(12 pole) (14 pole)
10.12 Mirror adjustment connector assignment

(15 pole) (14 pole)
10.13 Mirror heating connector assignment
Socket housing X46 Socket housing X47 Socket housing X48 Socket housing X49
000 295 725 0 – RHB SCORPION 10-18

Electric systems
10.14 Window wiper/wash connector assignment
Socket housing
X29/X34
(2 pole)
X30.1 (8 pole) X33 (6 pole)

10.15 Heating/air conditioning connector assignment



10-19 000 295 725 0 – RHB SCORPION

Electric systems
10.16 Air-suspension seat connector assignment
Socket housing X49

(14 pole)
10.17 Multimedia connector assignment

10.18 Cigarette lighter connector assignment

(15 pole) (14 pole)
000 295 725 0 – RHB SCORPION 10-20

Electric systems
10-21 000 295 725 0 – RHB SCORPION

Electric systems
Electric systems
10.19 Ohm's Law (current, voltage, resistance); power

It describes the interrelation between current, voltage and resistance.
Current “I” – Ampere (A)

Voltage “U” – Volt (V)
Resistance “R” – Ohm (Ω)
U Mnemonic:
R I
Output
Power "P" – Watt (W)
P = U x I = R x I² = U²/R
10.20 Multifunction measuring device

• Measurements of values (U, R, I, f)
• Continuity test
• Diode test
Calculate measuring range using known data (P, U, R, I)
and set before measuring!
Observe AC/DC basic setting.
➥ AC = alternating current/voltage;
➥ DC = direct current/voltage
• Measuring current (ignition switched on):

• Black cable in COM socket (earth),
• red cable in A socket or mA socket; connect in series to consumer.
• Measuring voltage (ignition switched on):

• red cable in V socket;
• connect in parallel to consumer.
• Measuring resistance (ignition switched off):
• red cable in Ω socket;
• connect in parallel to consumer (see measuring voltage).
000 295 725 0 – RHB SCORPION 10-22

Electric systems
10.21 Terminal description

(extract from DIN 72 552)
Terminal descriptions and cable descriptions are not identical because equipment with dif-
ferent terminal descriptions can be connected to both ends of a cable. If there are not
enough terminal descriptions (multiple connectors), the terminals are marked with continu-
ous number or letter codes without any standardised function assignment.
Terminal Meaning
Ignition coil, ignition distributor
1 Low voltage
Ignition distributor with two separate electric circuits
1a
to ignition contact breaker I
1b
to ignition contact breaker II
Short-circuit terminal
2
(magneto ignition)
Ignition coil, ignition distributor
4
High voltage
Ignition distributor with two separate electric circuits
4a from ignition coil I, terminal 4
4b from ignition coil II, terminal 4
15 Switched plus behind battery (output ignition [drive] switch)
15a Output at dropping resistor to ignition coil and starter
Preheating start switch
17 Start
19 Preheating
Battery
30 Input from + battery terminal, direct
12/24 V battery changeover relay
30a Input from + terminal of battery II
Return line to battery
31 Minus terminal or earth, direct
Return line to battery
31b Minus terminal or earth, via switch or relay (switched negative)
12/24 V battery changeover relay
31a Return line to minus terminal of battery II
31c Return line to minus terminal of battery I
Electric motors
32 Return line1)
33 Main terminal connection1)
33a Self-parking switch-off
33b Shunt field
33f For second lower speed range
33g For third lower speed range
33h For fourth lower speed range
33L Counterclockwise rotation
33R Clockwise rotation
10-23 000 295 725 0 – RHB SCORPION

Electric systems
Terminal Meaning
Starter
Separate starter relay, output;
45
Starter, input (main current)
Two-starter parallel operation
Starting relay for engagement current
45a Output starter I,
Input starters I and II
45b Output starter II
48 Terminal on starter and on start-repeating relay (to monitor starting)
Turn indicator unit (pulse generator)
49 Input
49a Output
49b Output, 2nd turn indicator circuit
49c Output, 3rd turn indicator circuit
Starter
50 Starter control (direct)
Battery changeover relay
50a Output for starter control
Starter control
50b with parallel operation of 2 starters with sequential control
Starting relay for sequential control of the engagement current during parallel
operation of 2 starters
50c
Input at starting relay for starter I
50d
Input at starting relay for starter II
Start locking relay
50e Input
50f Output
Start repeat relay
50g Input
50 h Output
AC alternator
51 Direct current voltage at rectifier
51e Direct current voltage at rectifier with choke coil for daytime driving
Trailer signals
52 Signals from trailer to towing machine
53 Wiper motor, input (+)
53a Wiper (+), self-parking switch-off
53b Wiper (shunt winding)
53c Electric window washer pump
53e Wiper (brake winding)
53i Wiper motor with permanent magnet and third brush (for higher speed)
Trailer signal
54 For lamp combinations and trailer plug connections
Brake lights
54g Pneumatic valve for additional retarding brake, electromagnetically actuated
55 Fog lights
000 295 725 0 – RHB SCORPION 10-24

Electric systems
Terminal Meaning
56 Headlight
56a High beam and high beam telltale
56b Low beam
56d Headlight flasher contact
57 Side marker light for motorcycles (also for cars, trucks etc. in other countries)
57a Parking light
57L Parking light, left
57R Parking light, right
Side marker, rear, numberplate and instrument panel lights
58
Rear light changeover for single-axle tractors
58b
Trailer plug-and-receptacle assembly for single-conductor rear light cable with
58c
fuse in trailer
58d
Variable-intensity instrument panel lights, side marker and rear light
58L
Left
58R
Right, numberplate light
AC alternator (magneto alternator)
59 Alternating voltage, output, rectifier, input
59a Charging armature, output
59b Rear light armature, output
59c Brake light armature, output
61 Alternator charge telltale
Tone sequence control device
71 Input
71a Output to horns 1 + 2 low
71b Output to horns 1 + 2 high
72 Alarm switch (rotating beacon)
75 Radio, cigarette lighter
76 Loudspeaker
77 Door valve control
Switches (break contact and changeover switches)

Input
81
1st output, break side
81a
2nd output, break side
81b
Make-contact switch
Input
82
1st output
82a
2nd output
82b
1st input
82z
2nd input
82y
Multiple position switch
Input
83
Output, position 1
83a
Output, position 2
83b
Output, left-hand side position
83L
Output, right-hand side position
83R
10-25 000 295 725 0 – RHB SCORPION

Electric systems
Terminal Meaning
Current relay
84a 84b
Input, actuator and relay contact
84
Output, actuator
84a
Output, relay contact
84b 84
Switching relay – output, actuator (end of winding negative or earth)

Input, actuator
85
Start of winding
Start of winding or 1st winding
86
Winding tap or 2nd winding
86a
86 87a 88a 87a 88a 87a 88a
86b 88b
85 87 88 87 87
Relay contact for break and changeover contacts
87 Input
87a 1st output (break side)
87b 2nd output
87c 3rd output
87z 1st input
87y 2nd input
87x 3rd input
Relay contact for make-contact
88 Input
Relay point for make-contact and changeover contacts (make side)
88a 1st output
88b 2nd output
88c 3rd output
Relay contact for make-contact
88z 1st input
88y 2nd input
88x 3rd input
Alternator and governor

B+ Battery positive
B- Battery negative
D+ Dynamo positive
D- Dynamo negative
DF Dynamo field
DF 1 Dynamo field 1
DF 2 Dynamo field 2
U, V, W Three-phase alternator – three-phase terminals
Turn indicators (turn indicator unit)
First telltale
C
Main terminal connection for separate indicator circuits actuated by the turn
C0
indicator switch
C2
Second telltale
C3
Third telltale (e.g. when towing two trailers)
L
Turn indicators (left)
R
Turn indicators (right)
000 295 725 0 – RHB SCORPION 10-26

Electric systems
10.22 Cable colour coding

The cables are colour-coded according to DIN 72551 Part 4. Refer to the 21 pin cab/frame
interface or the explanation in the wiring harness drawings for other colours not listed in
this DIN standard.
Extract from DIN 72551, sheet 4
Line Identification
Basic colour
From to colour
Ignition coil I Ignition distributor (low-voltage ignition lead) Green -
Ignition coil II Ignition distributor (low-voltage ignition lead) Green Red
Battery Starter Black -
Battery Earth (if bare earth lead is not used) Black -
Starter Alternator Red -
Starter Control panel (30) Red -
Light switch (30) Ignition switch (30) Red -
Control panel (30) or light switch (30) Fuse Red -
Fuse Hand lamp, radio, clock etc. Red -
Heater plug and starter switch; heater-plug tell-
Control panel (15/54) Black -
tale
Heater plug and starter switch; heater-plug tell-
Glow plugs Black -
tale
Ignition switch (15/54) Ignition coil Black -
Ignition switch or control panel (54/15/61a) Telltales Black -
Control panel or ignition switch (15/54) Fuse Black -
Fuse box Brake light Black Red
Fuse box Turn indicator switch Black White-green
Turn indicator switch Turn indicators, left Black White
Turn indicator switch Turn indicators, right Black Green
Telltale Turn indicators Light blue -
Fuse Cigarette lighter Black -
Fuse Heated window Black Yellow-red
Fuse 1st horn Black Yellow
Fuse 2nd and 3rd horn Black Yellow-light blue
Horns 1 pole horn pushbutton (earth) Brown -
Fuse Wipers Black Purple
Terminal 61 of alternator or reverse current cut-
Battery charge telltale Light blue -
out
Fuse Main beam telltale Light blue White
Oil pressure gauge (indicator) Oil pressure switch Light blue Green
Fuel level indicator Fuel tank Light blue Black
Tyre-pressure warning device Tyre-pressure drop indicator Light blue Yellow
10-27 000 295 725 0 – RHB SCORPION

Electric systems
Line Identification
Basic colour
From to colour
Control panel bzw. Lichtschalter Low beam switch White Black
Low beam switch (a) Fuse White -
Fuse Main headlight, left White -
Fuse Main headlight, right White -
Low beam switch (b) Fuse Yellow -
Fuse Low beam, left Yellow -
Fuse Low beam, right Yellow -
Control panel or light switch (58) Fuse Grey -
Fuse Rear light, side light and side marker lights left Grey Black
Fuse Numberplate light (combined with rear left light) Grey Black
Fuse Rear light, side light and side marker lights, right Grey Red
Numberplate light (combined with rear right
Fuse Grey Red
light)
Fuse Numberplate light (only if special line is laid) Grey -
Fuse Dome light Red -
Control panel (57) Fuse Grey Green
Control panel bzw. Lichtschalter Instrument panel light Grey Red
All consumers except the battery earth lead if
Earth Brown -
the use of bare lines is not possible
Battery changeover switch (50)/starter pushbut-
Starter Black -
ton or heater plug and starter switch
000 295 725 0 – RHB SCORPION 10-28

Electric systems
Colour coding
Abbreviation Abbreviation
Colour
Old New
Black sw BK
Brown br BN
Red rt RD
Orange or OG
Yellow ge YE
Green gn GN
Blue bl BU
Violet vi VT
Grey gr GY
White ws WH
Pink rs PK
Gold - GD
Turquoise tk TQ
Silver - SR
10-29 000 295 725 0 – RHB SCORPION

Electric systems
10.23 Fuses: overview

Fuses: overview
The fuse board is located underneath the cover behind the seat.

F1 7.5 Brake light
F2 15 Front socket
Mirror adjustment, mirror heating, solenoid valve: additional cir-
F3 10 cuit raise/lower, emergency lowering OFF, lock function of safe
load indicator
F4 15 Proportional electronics
Preheating time control unit, preheating telltale, preheating
F5 10
switching relay, engine electronics
F6 Turn indicators
7.5 Steering electronics, 4 wheel steering/front axle steering/diago-

F7 nal steering solenoid valve, 4 wheel steering/front axle steering/
diagonal steering/synchronism telltale
F8 Susmic (drive electronics)
Solenoid valve: load stabiliser, hose burst valve, reversing fan,
F9
load stabiliser telltale
F10 10 Air-suspension seat (option)
Solenoid valve: additional control circuit, tilt ram lock, bucket
F11 repositioning, quickhitch lock, load stabiliser relay, Autohitch
unlocking
F12 5 Cutoff solenoid
Forwards/reverse driving direction telltale, hold electronics, front
F13 3 socket relay, bucket repositioning relay, parking brake solenoid
valve
Driving direction identification solenoid valve, rear horn, revers-
F14 7.5
ing light, reversing light, float position solenoid valve
Hour meter, telltale: 3rd control circuit, parking brake, air filter,
engine oil pressure, water separator, preheating, hydraulic oil fil-
F15
Fig. 1: Fuse box ter, alternator, hydraulic oil level, hydraulic oil temperature, cool-
3 ant temperature, fuel level indication, speedometer
Front and rear axle sensors, speed sensor, telltale for water in
F16
fuel, level amplifier, reversing fan tip switch, coolant level telltale
F17 30 Window heating
F18 25 Heater fan, magnetic coupling compressor
Main fuse: right/left low beam, right/left high beam, high beam
F19 15
telltale
F20 10 Rear wiper, washer pump
Safe load indicator, window heating time lag relay, window heat-
F21 5 ing switching relay, bucket repositioning sensor, mini switching
relay for lock function of safe load indicator
Switching relay wiper 1st/2nd speed, intermittent wipe relay,
F22 20
front wiper, washer pump, horn
F23 3 Radio
000 295 725 0 – RHB SCORPION 10-30

Electric systems

F24 High beam (right)
F25 High beam (left)
7.5
F26 Low beam (right)
F27 Low beam (left)
Parking light (right), rear light (right), rear clearance light (right),
F28
numberplate lights, switch lights
5
Parking light (left), rear light (left), rear clearance light (left),
F29
instrument lights, light for cigarette lighter
F30 3 High current relay, start switching relay
Main fuse: parking light, rear light, rear socket for additional
F31 lights, front socket for additional lights, switch lights, instrument
15 lights, light for cigarette lighter, interior light
F32 Drive interlock/auxiliary heater
F33 Rotating beacon
F34 Telescopic boom working light
10
F35 Rear working light
F36 Front working light
F37 7.5 Turn indicator relay, turn indicators, radio
F38 15 Socket (cigarette lighter)
Electric components
Description Output
Alternator 12 V 95 A
Starter 12 V 3.0 kW
Battery 12 V/135 Ah
10-31 000 295 725 0 – RHB SCORPION

Electric systems

K7

F 40 F 39
F40 100 A Main fuse
K6 K5 K7 Relay no. Protected circuit
F40 F39 K5 Preheating high current relay
K6 Preheating time lag relay


K5 K42 K7 F40 F39
F40 100 A Main fuse
F41 25 A Main fuse (engine control unit)
Relay no. Protected circuit

F41
K5 Preheating high current relay
K42 Engine electronics switching relay
000 295 725 0 – RHB SCORPION 10-32

Electric systems
Relays: overview
The relays are located underneath the cover behind the seat.
Switching relay
Protected circuit
no.
K25
K1 High current relay
K23 K2 High current relay
K3 Reverse driving switching relay

K24 K10 Turn indicator relay
K16 Front socket switching relay

K33
K21 Differential lock
K1 K3 K27 K22 Load stabiliser (option)
K23 Wiper switching relay (1st speed)

K2 K24 Wiper switching relay (2nd speed)
K10 K25 Interval relay (wiper)
K27 Time lag relay for rear window heating (option)

K28
K28 Bucket repositioning switching relay (option)
K30 Brake lights switching relay

K22 K36
Fuel preheater switching relay (option, installed in engine compart-
K32 K38 K31
ment)
K16 K37 K32 Reversing fan (option) switching relay
Fig. 4: Relays K30 K35 K33 High current relay for rear window heating (option)
K21 K34 K34 Switching relay for lock function of safe load indicator
Fig. 4: Relays
K35 Switching relay for lock function of safe load indicator
K38 Switching relay for other options
10-33 000 295 725 0 – RHB SCORPION

Electric systems
10.24 Electronic components: overview

Steering electronics (old)
Hold electronics (X7+X8) Drive electronics (SUSMIC) Amplifier (coolant Electronics (propor-
level sensor) (U1) tional controls)
Steering electronics (old)

(X20/X21)
Steering electronics (new)
Steering electronics (new)

(X20/X21)
000 295 725 0 – RHB SCORPION 10-34

Electric systems
Connector assignment on board
X46 X40 X49 X41
X47 X48 X42 X45 X43 X44
10-35 000 295 725 0 – RHB SCORPION

Electric systems
10.25 Functional description of the steering electronics

The steering electronics detects the centre position of the wheels to change over the steer-
ing valve to the steering mode that has been selected.
Synchronisation takes place every time the machine is started, but can also be started
manually with the “Tip switch – steering synchronisation 102” on page 1-3.
This means that the steering electonics saves differences (with regard to the centre posi-
tion) between the steering sensors of the front and rear axles. Changing over the steering
valve puts the wheels in centre position, i.e. by turning the steering wheel.
For reasons of safety, synchronisation can be carried out only in 1st speed (turtle) since
you never know the steering mode in which the steering valve actually is.
Changing over from 4 wheel steering to front axle steering
• The steering electronics switches the solenoid valve for front axle steering only after the
wheels of the rear axle are in straight-ahead position.
• The rear axle steering sensor sends a signal to the steering electronics when changing
over from 4 wheel to front axle steering.
Changing over from front axle steering to 4 wheel steering
• The steering electronics switches the solenoid valve for 4 wheel steering only after the
wheels of the front axle are in straight-ahead position.
• The front axle steering sensor sends a signal to the steering electronics when changing
over from front axle to 4 wheel steering.
Carrying out synchronisation manually
• Press “Tip switch – steering synchronisation 102” on page 1-3 briefly to start steering
synchronisation. However, this can be carried out only in 1st speed (turtle) and when
driving.
Synchronisation requires the following data/prerequisites
• 1. First speed for reasons of safety
• 2. 4 wheel steering
• 3. Front axle steering
• 4. Front sensor
• 5. Rear sensor
• 6. Synchronisation
Possible errors
• The steering electronics sounds an alarm:
• A resistance monitors the solenoid valve required for 4 wheel and front axle steering
via the steering electronics. In the case of open wiring or a short circuit, the
resistance changes and the steering electronics sounds an alarm.
• If the signals for 4 wheel and front axle steering coincide (short circuit), the steering
electronics sounds an alarm, too.
• If a steering sensor breaks down, no alarm is given, and changeover to another
steering mode is no longer possible.
• If the steering electronics breaks down, it can be separated from the main wiring
harness and the two connectors can be short-circuited. This makes it possible to
select a steering mode (4 wheel or front axle steering).
Caution!
However, synchronisation must be carried out manually with a visual check of
the position of the wheels.
000 295 725 0 – RHB SCORPION 10-36

Electric systems
New steering electronics (17 LEDs): overview

The diagonal steering function (crab steering) is not functional since no solenoid valve
(crab steering) is installed.
LEDs output LEDs input
1
2
3
4
5
6
LED output Meaning

1Diagonal steering LED (option) Not assigned
2Asynchronism LED Synchronisation LED energised on the instrument panel
31st/2nd speed range solenoid valve Valve for 1st speed range switched
44 wheel steering LED 4 wheel steering LED energised on the instrument panel
5Front axle steering LED Valve for front axle steering energised
64 wheel steering solenoid valve (1) Valve (1) for 4 wheel steering energised
7Front axle steering solenoid valve Valve (1) for front axle steering energised
84 wheel steering solenoid valve (2) Not assigned
9Diagonal steering solenoid valve (option) Not assigned
LED input Meaning

1ON/OFF (12 V power supply) Comes in case of 12V power supply
2Diagonal steering (option) Not assigned
3Synchronisation Comes on when pressing the synchronisation tip switch
4Front axle sensor Comes on when front wheels are in straight-ahead position
54 wheel steering Comes on when pressing the 4 wheel steering tip switch
6Rear axle sensor Comes on when rear wheels are in straight-ahead position
7Front wheel steering Comes on when pressing the front axle steering tip switch
82nd speed range Comes on when pressing the 2nd speed range tip switch
10-37 000 295 725 0 – RHB SCORPION

Electric systems
10.26 Proportional controls: overview and connections

• A1 – not assigned –
• A3 – output differential lock 12V to Y9 – GR/GN
• A5 – input continuous function 3rd control circuit 5V S33 – GN/VT
• A7 – input actuate 3rd control circuit 0V – 5V S30/S31 – BU/RD
• A8 – enables earth for Y16/Y17 (lock/unlock) – BN/BK
• B1 – power supply voltage 12V from F4 – BK/WH
• B2 – not assigned –
• B3 – input switch S25 differential lock – GY
• B4 – input actuate telescopic boom 0V – 5V from S38/39 – YE
• B6 – enables earth for Y23/Y24 (extend/retract telescopic boom) –
BN/YE
• B8 – enables earth for Y9 (differential lock) – BN/GN
• C1 – earth connection control valve – BK
• C2 – 5 V power supply voltage S30/S31 and S38/S39 – RD/GN
• C3 – not assigned –
• C4 – not assigned –
1 • C5 – lock output Y16 – OG
2 • C6 – unlock output Y17 – VT
3 • C7 – extend telescopic boom output Y23 – YE/GN
4 • C8 – retract telescopic boom output Y24 – BN/BU
5 Error code
6 • LED flashes 1x briefly
7 ➥ Joystick not connected
8 ➥ Joystick signal short-circuited against earth
• LED flashes 2x briefly
➥ Joystick is short-circuited
ABC • LED flashes 4x briefly
➥ Y 16/Y 17/Y 24/Y 23 short-circuited
• LED flashes in short intervals
➥ No error (OK).
LED error analysis
000 295 725 0 – RHB SCORPION 10-38

Electric systems
10.27 Proportional electronics

Proportional electronics ensures smooth hydraulic controls. The electronics converts a
continuous input signal of a switch into a certain oil pressure or oil flow of a hydraulic con-
trol valve. Four functions are proportionally controlled in the machine.
➥ Extend the telescopic boom
➥ Retract the telescopic boom
➥ Lock/3rd control circuit
➥ Unlock/3rd control circuit
☞ Press switch A (S38/S39) only slightly towards 1 or 2
➥ The telescopic boom is extended slowly
1
☞ Press switch A (S38/S39) towards 1 or 2 as far as it will go
➥ The telescopic boom is extended at maximum speed
A
☞ The speed with which the telescopic boom is extended can be set continuously with the
2 travel of switch A (S38/S39)
Fig. 5: Joystick A = S38/S39
☞ Press switch B (S30/S31) only slightly towards 1 or 2

➥ Low flow rate of the 3rd control circuit
☞ Press switch B (S30/S31) towards 1 or 2 as far as it will go
1 ➥ Maximum flow rate of the 3rd control circuit
B ☞ The flow rate of the 3rd control circuit can be set continuously with the travel of switch B
(S30/S31)
2
Fig. 6: Joystick B = S30/S31
The control unit for the proportional electronics is located behind the fuse board, behind
the seat. It calculates the input signals of the scroll wheels (continuous switches A and B)
into output signals for the hydraulic proportional valves, thereby controlling them.
Fig. 7: Control valve
10-39 000 295 725 0 – RHB SCORPION

Electric systems
10.28 Hold electronics
Joystick side
Machine side
Signal input reverse WH/VT WH/VT signal output reverse
Signal input neutral GY/GN

BN/BK signal output forwards
Signal input forwards BN/BK Hold electronics
Power supply +12V GN/ GN/VT power supply
VT +12V
BN
VT
GN
RD/WH
10.29 Wiring harness 1000103927 (joystick)

If tip switch S34 is pressed, machine-side PIN2 must have a 12V signal which can switch a
1A current. The 12 V signal must be present until either S35 or S66 is pressed.
If tip switch S35 is pressed, machine-side PIN1 must have a 12V signal which can switch a
1A current. The 12V signal must be present until either S34 or S66 is pressed.
If tip switch S66 is pressed, machine-side PIN1 and PIN2 may have no 12 V signal.
000 295 725 0 – RHB SCORPION 10-40

Electric systems
10.30 Overview and functional check of safe load indicator

The safe load indicator has been installed for pallet forks operation with varying reaches
(telescopic boom according to DIN EN 1459).
The telehandler is equipped with an electronic load indicator for continuously monitoring
weight changes on the rear axle during operation (installed inside the cab at the upper
right).
Visible and acoustic signals warn the operator of critical loads on the telescopic boom that
might cause the machine to tilt to the front.
Critical side loads however are not monitored, i.e. the operator is not warned in this case!
Danger!
A defective safe load indicator or working at more than 100 % of the safe work
load can cause the machine to tilt. Do not rely on the safe load indicator when
working off-road –
Danger of tipping and of accidents!
☞ Work carefully! Adapt your drive speed and loads to the terrain. Refer to the
load diagram for the maximum authorised loads!
☞ Check the safe load indicator once a day!
☞ Loads over 81 % (100 %) – flashing display with uninterrupted sound:
reduce the load
➥ (retract the telescopic boom!
☞ – see Safe load indicator display (version A) on page 10-42
☞ – see Safe load indicator display (version B) on page 10-44
10-41 000 295 725 0 – RHB SCORPION

Electric systems
Safe load indicator display (version A)

The LEDs A, B, C and D indicate the effective load on the telescopic boom – in percent of
the safe work load.
The safe load indicator automatically carries out a self-test as soon as the diesel engine is
started.
Without load, only the lowest green diode E (power) comes on.
The first diode A comes on if the load reaches 40 % of the admissible load. Every other
diode corresponds to a further 10 % of the admissible load.
• A 2 green diodes
➥ Loads between 40 % and 54 % of the safe work load
• B 2 yellow diodes
➥ Loads between 63 % and 72 % of the safe work load
• C 1 yellow diode
A B C D ➥ Loads up to 81 % of the safe work load
• D 1 red diode
➥ Loads up to 90 % of the safe work load
• E green diode (POWER)
➥ “Ready” display
• F tip switch (TEST)
➥ For checking the system
Measures to be taken if ...

• Green diode E (POWER) comes on?
➥ OK; the safe load indicator is ready
E F • Green LEDs A (1 – 2) come on?
➥ OK; load is between 40 and 54 % of the safe work load
Fig. 8: Safe load indicator (version A)
• Yellow LEDs B (4 – 5) come on as well?
➥ Work with caution; the load is between 63 % and 72 % of the safe work load!
• 2 green A, 3 yellow diodes B/C flash and the intermittent alarm sounds?
➥ Work with extreme caution! 81 % of the safe work load is reached according to
the load diagram!
• 2 green A, 3 yellow B/C, the red diode D come and the continuous alarm sounds?
➥ The load is 90 % of the safe work load!
Important!
The green and yellow diodes of the safe load indicator may come on when revers-
ing with the machine, with the wheels steered and with no load on the pallet forks!
This is a normal condition and does not require any action.
000 295 725 0 – RHB SCORPION 10-42

Electric systems
Functional check of safe load indicator (version A)

A B C D
Caution!
Check the safe load indicator once a day!
☞ The check may be carried out at any time, even during operation.
☞ Press tip switch E (TEST)

➥ If all diodes flash and the alarms sounds for 2 seconds:
➥ The safe load indicator is OK
☞ If not all diodes come on:
➥ System error; have the safe load indicator immediately checked and repaired by an
authorised workshop
E F
Fig. 9: Testing the safe load indicator
10-43 000 295 725 0 – RHB SCORPION

Electric systems
Safe load indicator display (version B)

The LEDs a, b and c indicate the load effective on the telescopic boom – in percent of the
safe work load.
a 3 green diodes
➥ Indication of loads between 45 and 85 % of the safe work load
b 1 yellow diode
➥ Indication of loads up to 100 % of the safe work load
c 1 red diode
➥ Indication of loads up to 110 % of the safe work load
d Green LED to signal readiness
e Tip switch (TEST) for checking the system
Measures to be taken if ...

c
• Green LED d comes on?
b ➥ OK; load indicator is ready
a • Green LEDs a (1 – 3) come on?
➥ OK; load is between 45 and 90 % of the safe work load
• Yellow LEDs b (4) come on as well?
d e ➥ Work with caution, the load is between 85 and 100 % of the safe work load
Fig. 10: Safe load indicator (version B) • Green a and yellow LEDs b are flashing, the acoustic signal sounds?
➥ Work with extreme caution! 100 % of the safe work load is reached according to
the load diagram!
• Red LEDs c come on?
➥ DANGER OF OVERTURNING! Retract the telescopic boom immediately to reduce
the load!
➥ The load is between 100 and 110 % of the safe work load!
• The complete indicator is flashing, the acoustic signal is given, although the TEST tip
switch has not been activated?
➥ The safe load indicator is defective, have it immediately checked and repaired by an
expert!
Functional check of safe load indicator (version B)
Important!
The check may be carried out at any time, even during operation.
• Press TEST tip switch e
All LEDs are flashing and the acoustic signal is given:
➥ OK
• If the signal sounds uninterruptedly for 10 seconds and all diodes come on as well:
➥ System error; have the safe load indicator immediately checked and repaired by an
expert with appropriate training!
000 295 725 0 – RHB SCORPION 10-44

Electric systems
10.31 Safety instructions for the safe load indicator

• Never lower the extended telescopic boom from a raised position – danger of
overturning!
• Retract the telescopic boom before lowering it!
• Proceed with extreme care in off-road applications:
always work on firm and solid ground if possible!
• Never drive up to the edge of a pit from outside – danger of cave-in!
• Never undermine the foundations of walls – danger of collapse!
• Operation of the machine by unauthorised staff is prohibited!
• When working with the machine, look out for high-voltage cables, underground cables,
gas and water pipes!
• When using lifting gear such as pallet forks, comply with the load diagrams valid for this
machine.
• The hydraulic system of the machine is still pressurised even when the engine is not
running! Release the pressure in the sections of the system and hydraulic lines which
are to be opened before starting setup or repair work, e.g. fitting/removing an
attachment with hydraulic functions
Danger!
The safe load indicator has been set for industrial applications (S=1.25). Do
not rely on the safe load indicator when working off-road –
☞ Work in rough terrain with even more care than usual!
☞ Adapt your drive speed and the load to the terrain.
➥ Read the authorised loads off the load diagram and adapt them to the
terrain (ideal load = 60 – 70 % of the maximum load indicated)
A defective safe load indicator or working at more than 100 % of the safe work
load can cause the machine to tilt –
Danger of overturning!
☞ Reduce the load under 100 % if the display unit flashes and an acoustic sig-
nal sounds (loads over 100 %)
• Retract the telescopic boom
• Reduce the load
10-45 000 295 725 0 – RHB SCORPION

Electric systems
10.32 Setting the safe load indicator (0 % point)

Adjusting the display unit requires setting two reference points
• the 0 % point, i.e. with no attachments and no load on the telescopic boom on level
ground
• the 100 % point at maximum load on a level surface.
Setting the 0 % point
☞ Place the machine on firm and level ground
c ☞ Retract the telescopic boom as far as it will go
b ☞ Lower the telescopic boom to transport position (250 mm)
☞ Hold adjustment magnet g to the right of the TEST tip switch e on the display and
a
☞ at the same time, press and hold the TEST tip switch e (about 12 seconds) until
➥ the LED c lights up red and an acoustic alarm sounds
g
☞ Remove adjustment magnet g and release the TEST tip switch e
d e
☞ Press the TEST tip switch e again briefly
A ➥ The system confirms the setting with a single beep
➥ The 0 % point is set
Important!
You have 5 minutes for setting the system. An acoustic signal sounds every 5 sec-
onds during setting.
250 mm A If the TEST tip switch and the special magnet are released too early, the setting is
not modified, and the system automatically returns to operation mode and takes
over the old setting!
☞ Set the 100 % point

➥ – see Determining the maximum authorised load (100 % point) on page 10-47
000 295 725 0 – RHB SCORPION 10-46

Electric systems
10.33 Setting the safe load indicator (100 % point stability)
A
c
A
d e
150 mm
30 % Setting dimen-
sion (X)
Extension dimen-
sion (Y)
☞ Pick up pallet forks with the quickhitch frame and lock them safely
☞ Pick up a load of about 2000 – 3000 kg with the forks in a horizontal position
☞ Place the machine on firm and level ground
☞ Raise the telescopic boom to a max. 150 mm (A)
☞ Slowly extend the telescopic boom
Caution!
Extend the telescopic boom only until the machine barely tips forwards!
☞ The wheels of the rear axle must still touch the ground slightly
Determining the maximum authorised load (100 % point)

☞ Slowly extend the telescopic boom to the setting dimension (X)
➥ Setting dimension (X) = extension dimension (Y) – 30 %
➥ e.g. extension (Y) 2100 mm – 30 % (630 mm) = 1470 mm setting dimension (X)
☞ Briefly press TEST tip switch e on the display
➥ The system confirms the setting with a beep
➥ The green LED a and the yellow LED b come on
➥ The 100 % point is set
☞ Check: carefully extend the telescopic boom again until
➥ all LEDs a, b, c flash and an acoustic alarm sounds (danger of tilting!)
10-47 000 295 725 0 – RHB SCORPION

Electric systems
10.34 Possible errors – safe load indicator

The display unit displays four system errors as shown below. In addition, an uninterrupted
alarm sounds at full volume in all four cases for 10 seconds, after which time it stops and
all LEDs on the display unit flash. Briefly press the “TEST” switch to repeat error display.
1 The sensor signal is not within the work range
➥ The red and the first green LEDs come on
2 Setting error: the red and the second green LED comes on.
➥ The signal is too small during calibration between the 0 and 100 % point, it is not
within the admissible range
➥ Cause: sensor mounted in wrong position
3 Instrument error
➥ The red and the second and third green LEDs come on.
➥ Replace the unit
4 Calibration error
➥ The red and the third LEDs come on
➥ No calibration data on the unit
➥ This is the case for units that have not been calibrated
➥ Adjust/calibrate the unit
Remarks
The lowest green LED (d) indicates the display is operational. Do not use it for identifying
the errors sources indicated above.
000 295 725 0 – RHB SCORPION 10-48

Electric systems
10.35 Retrofitting the front right and rear right working lights
These options can be retrofitted on any machine with no additional wiring harness
required.
• Cable A for the additional rear right working light is located in the cab frame, on the
right underneath the roof lining
➥ Cable colour VT/YE earth BK
• Pull cable A outwards through opening B and fit it with a connector to install the
working light
• The cable for the additional front right working light is located in the bracket of the
rearview mirror and must be fitted with a connector
➥ Cable colour VT/WH earth BK
10-49 000 295 725 0 – RHB SCORPION

Electric systems
10.36 Retrofitting a rotating beacon

• Cable A for the rotating beacon is located in the cab frame, over the wiper
➥ Cable colour GN earth BK
• Pull the cable outwards through opening B and fit it with a connector
• Retrofit switch S18 on the switch console on the left

➥ The connector is marked S18 and only needs to be connected
000 295 725 0 – RHB SCORPION 10-50

Electric systems
10.37 Retrofitting a radio

• Connecting cables A for the radio are already installed in the radio bin and only need to
be connected to the radio
A
• Connecting cables B and C for the loudspeakers are located at the top of the cab frame
(over the wiper) and are already fitted with connectors
B ➥ Cable colour BR/WH earth BK
• The machine is not equipped with an aerial cable yet, which must be fitted during retro-
fitting
10.38 Retrofitting the low-speed control

• Remove the instrument panel to install the low-speed control and remove break point A
provided for to this effect
• The connecting cables are located under the instrument panel and are already fitted
with a 3-pole connector
➥ Cable colours RD/ YE, WH, RD/BK
B • The low-speed control must be enabled with a laptop
10-51 000 295 725 0 – RHB SCORPION

Electric systems
10.39 Retrofitting the air conditioning system

• All cables required for retrofitting an air conditioning system are included in the
standard wiring harness
• Connect plug A to the pressure switch
A ➥ Cable colours GN,BR
Caution!
Have the air conditioning system installed, serviced and repaired by specially
trained staff only!
• Connect the compressor to cable B

➥ Cable colour RD
• Connect air conditioning switch S51 on the instrument panel on the right
➥ The connector is marked S51
• Also connect temperature switch S54.
➥ It is located on the evaporator and is supplied with the air conditioning retrofit kit
000 295 725 0 – RHB SCORPION 10-52

Electric systems
10.40 Retrofitting a front or rear socket

Install an additional wiring harness to retrofit the machine with a front or rear socket.
See wiring harness drawing SOCKETS
• Connect the additional wiring harness A (connectors) with X3 and route it to the rear in
the machine frame
• Connect earthing lead B
• Connect the 4 pole connector C (X28) with the 5 or 7 core cable D of the telescopic
D boom
➥ Earth
➥ Parking light (right)
➥ Parking light (left)
➥ Signal line for shuttle valve
• Connector X27 is used for the rear socket
C
• You can now install a socket on the telescopic boom
D ➥ Lights for attachments, e.g. snow plough
➥ Signal for changeover valve
C
10.41 Retrofitting a load stabiliser

• The connecting cables for the load stabiliser are already included in the standard wiring
harness and only require to be connected to the solenoid valves
B • Connectors are marked Y20 A and Y21 B
• Also insert switch S44 in the instrument panel on the left in the cab, the machine is
A already fitted with this connector marked S44
10-53 000 295 725 0 – RHB SCORPION

Electric systems
10.42 Wiring harness disconnect (cab – machine frame)
Disconnect (yellow) for

engine wiring harness
1000148544
X1
Disconnect for wiring Main cab power supply

harness 1000148691 X100 (red)
• Rear 7 pole socket
• Front changeover valve
• Additional control circuit
• Compressed-air brake X3
X100
Disconnect (green)
for frame wiring har-
ness 1000148544
Disconnect (options) X2
• Mirror adjustment
• Fuel preheater Disconnect for wiring
• Bucket repositioning harness 1000148694
(options)
• 5th control circuit
• Tipping trailer connection
• Autohitch/additional
control circuit
X4 • Tilt ram lock
X5 • Additional lights on
telescopic boom
• Unlock Autohitch
000 295 725 0 – RHB SCORPION 10-54

Electric systems
10-55 000 295 725 0 – RHB SCORPION

Appendix
A Appendix 4-fold control valve: overall diagram

Appendix
A .1 Hydraulics – 4-fold control valve: overall diagram
A -1 000 295 725 0 – RHB SCORPION

Appendix
Diagram: hydraulic fixed displacement pump Fixed displacement pump diagram – overall diagram for
Overall diagram for 5-fold control valve 5-fold control valve
Appendix
A .2 Hydraulic fixed displacement pump – 5-fold control valve: overall diagram
A -3 000 295 725 0 – RHB SCORPION

Appendix
Diagram: hydraulic variable displacement pump Variable displacement pump diagram – overall diagram for
Overall diagram for 5-fold control valve 5-fold control valve
Appendix
A .3 Hydraulic variable displacement pump – 5-fold control valve: overall diagram
A -5 000 295 725 0 – RHB SCORPION

Electric systems
Electric systems
A .4 Machine components: overview
000 295 725 0 – RHB SCORPION A -6

Electric systems
A -7 000 295 725 0 – RHB SCORPION

CLAAS KGaA mbH keep abreast of the latest technical develop-
ments and constantly improve their products. For this reason, we
may from time to time need to make changes to diagrams and
descriptions in this documentation which do not reflect products
which have already been delivered and which will not be imple-
mented on these machines.
Technical data, dimensions and weights are given as an indication
only. Responsibility for errors or omissions not accepted.
No reproduction or translation of this publication, in whole or part,
without the written consent of CLAAS KGaA mbH
All rights under the provision of the Copyright Act are reserved.
CLAAS KGaA mbH
33426 HARSEWINKEL
Germany
Our contribution to the environment:

this manual has been printed on 100 % chlorine-free
paper.
CLAAS KGaA mbH
Postfach 1163
33426 Harsewinkel
Tel. +49 (0) 5247 12-0
www.claas.com
000 295 725 0

RHB SCORPION
EN - 12/07
Printed in Germany

Claas Scorpion Repair Manual For 9040, 7045, 7040, 7030, 6030

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SCORPION

000 295 725 0 - RHB SCORPION I-1

Payloads: model 404 03 load diagram ................................................................... 1-25

I-2 000 295 725 0 - RHB SCORPION

Checking the hydraulic oil level ............................................................................. 3-32

000 295 725 0 - RHB SCORPION I-3

Maintenance and servicing work “Aggressive Media” ............................................ 3-59

I-4 000 295 725 0 - RHB SCORPION

Functional despcription of drive hydraulics and electric system ............................ 5-12

000 295 725 0 - RHB SCORPION I-5

Example: differential pressure measurement M3 (0 – 40 kph) .............................. 5-47

I-6 000 295 725 0 - RHB SCORPION

Installing the front axle differential lock .................................................................. 6-45

000 295 725 0 - RHB SCORPION I-7

Work hydraulics diagram – extending/retracting the telescopic boom,

I-8 000 295 725 0 - RHB SCORPION

Safe load indicator function ............................................................................. 9-77

000 295 725 0 - RHB SCORPION I-9

Compensating ram: overview .............................................................................. 9-116

I-10 000 295 725 0 - RHB SCORPION

Proportional electronics ....................................................................................... 10-39

000 295 725 0 - RHB SCORPION I-11

I-12 000 295 725 0 - RHB SCORPION

1 Machine specifications: overview Machine outside view

Models: 400-01, 401-03, 3 4 5 6 7 8 9 2 10 11

2 12 1 Lights with turn indicators

2 Rear clearance light

19 4 Boom working light (option)

5 Air filter (preliminary separator option)

7 Working light (standard)

9 Working light (front/rear option)

10 Hydraulic connections (quick couplers, option)

11 Trailer coupling (option)

12 Numberplate fixture (option)

21 Boom working light (option) 404-03

23 Rearview mirror (rear, option) 404-03

1-1 000 295 725 0 – RHB SCORPION

1 2 3 4 5 6 1.2 Inside of cab: overview

000 295 725 0 – RHB SCORPION 1-2

80 Switch – tilt ram lock (option)

Multifunctional lever, switches turn indicators

1-3 000 295 725 0 – RHB SCORPION

Machine specifications: overview

1.4 Important information on this manual

1.5 Model and trade names: overview

000 295 725 0 – RHB SCORPION 1-4

1.6 Type labels and component numbers

Fig. 1: Type label: location

Fig. 2: Cab type label

Fig. 3: Diesel engine number

1-5 000 295 725 0 – RHB SCORPION

Hydraulic pump number

Fig. 4: Hydraulic pump type label

Variable displacement motor number

Fig. 5: Variable displacement motor type label

Variable displacement motor number (high speed option)

Fig. 6: Variable displacement motor type label (option)

Front and rear axle numbers

Fig. 7: Rear axle and gearbox type label

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Machine specifications: overview

000 295 725 0 – RHB SCORPION 1-8