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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

000 295 725 0 - RHB SCORPION I-1


Table of contents

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
interlock (rear axle) .......................................................................................... 1-27
Front axle with frame levelling and hydraulic oscillating axle
interlock (rear axle) .......................................................................................... 1-28
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
Specific safety instructions .............................................................................. 3-31
Monitoring the hydraulic oil and the reflux filter ...................................................... 3-32

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Table of contents

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
Specific safety instructions .............................................................................. 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
Specific safety instructions .............................................................................. 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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Table of contents

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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Table of contents

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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Table of contents

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
Oil supply via fan pump (010) ............................................................................ 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
Oil supply via fan pump (010) ............................................................................ 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
the telescopic boom ................................................................................................. 9-3
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
the telescopic boom ................................................................................................. 9-9
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
Diagram: work hydraulics fixed displacement pump – rear additional
control circuit – Autohitch ....................................................................................... 9-29
Diagram: work hydraulics variable displacement pump – rear additional
control circuit, Autohitch ......................................................................................... 9-31
Diagram: work hydraulics fixed displacement pump – rear additional
control circuit, Autohitch, tipping trailer .................................................................. 9-33
Diagram: work hydraulics variable displacement pump – rear additional
control circuit, Autohitch, tipping trailer .................................................................. 9-35
Diagram: work hydraulics fixed displacement pump – rear additional
control circuit, tipping trailer ................................................................................... 9-37
Diagram: work hydraulics variable displacement pump – rear additional
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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Table of contents

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

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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


Machine specifications: overview

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


Machine specifications: overview

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


Machine specifications: overview

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


Machine specifications: overview

Machine specifications: overview

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


Machine specifications: overview

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


Machine specifications: overview

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


Machine specifications: overview

1-7 000 295 725 0 – RHB SCORPION


Machine specifications: overview

Machine specifications: overview

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


Machine specifications: overview

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
Displacement 17 cm³/rev
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


Machine specifications: overview

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


Machine specifications: overview

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


Machine specifications: overview

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
Variable displacement pump
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
Secondary protection:
Base side 260 bar 300 bar
Push-out ram
Secondary protection:
Rod side 260 bar 300 bar
Base side 200 bar 200 bar
Quickhitch ram (3rd
control circuit)
Max. service pressure 210 bar 210 bar

000 295 725 0 – RHB SCORPION 1-12


Machine specifications: overview

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
Displacement 17 cm³/rev
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


Machine specifications: overview

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


Machine specifications: overview

No. (A) Protected circuit


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


Machine specifications: overview

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)

Main fuse box with relays (103 kW diesel engine)


The main fuse box is located in the engine compartment
K5 K42 K7 F40 F39
Fuse no. Rated current (A) Protected circuit

F39 125 A Preheating/start fuse (starter)

F40 100 A Main fuse

F41 25 A Main fuse (engine control unit)

Relay no. Protected circuit


F41
K5 Preheating high current relay
Fig. 10: Main fuse box (103 kW engine)
K7 Start high current relay

K42 Engine electronics switching relay

000 295 725 0 – RHB SCORPION 1-16


Machine specifications: overview

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

K37 Drive signal switching relay

K38 Switching relay for other options

1-17 000 295 725 0 – RHB SCORPION


Machine specifications: overview

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


Machine specifications: overview

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


Machine specifications: overview

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


Machine specifications: overview

1.24 Payload: model 400-01 load diagram

Important!
Payload indications with authorised tyres

1-21 000 295 725 0 – RHB SCORPION


Machine specifications: overview

1.25 Payload: models 401-03 load diagram

Important!
Payload indications with authorised tyres

000 295 725 0 – RHB SCORPION 1-22


Machine specifications: overview

1.26 Payload: model 402-03 load diagram

Important!
Payload indications with authorised tyres

1-23 000 295 725 0 – RHB SCORPION


Machine specifications: overview

1.27 Payloads: model 403 03 load diagram

Important!
Payload indications with authorised tyres

000 295 725 0 – RHB SCORPION 1-24


Machine specifications: overview

1.28 Payloads: model 404 03 load diagram


Rigid front axle without oscillating axle interlock (rear axle)

Important!
Payload indications with authorised tyres

1-25 000 295 725 0 – RHB SCORPION


Machine specifications: overview

Rigid front axle with mechanical or hydraulic oscillating axle interlock (rear axle)

Important!
Payload indications with authorised tyres

000 295 725 0 – RHB SCORPION 1-26


Machine specifications: overview

Front axle with frame levelling and without oscillating axle interlock (rear axle)

Important!
Payload indications with authorised tyres

1-27 000 295 725 0 – RHB SCORPION


Machine specifications: overview

Front axle with frame levelling and hydraulic oscillating axle interlock (rear axle)

Important!
Payload indications with authorised tyres

000 295 725 0 – RHB SCORPION 1-28


Machine specifications: overview

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
extended 6180 mm 7050 mm 8825 mm
2, 4
Dump height retracted 3680 mm 3920 mm 4810 mm
c
extended 5480 mm 6370 mm 8080 mm
d Dump reach2, 4 extended 320 mm 290 mm 270 mm
2
Length of telescopic extension retracted 4951 mm 5079 mm 5960 mm
e
extended 6726 mm 7527 mm 9205 mm
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


Machine specifications: overview

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
extended 6460 mm 7350 mm 9120 mm
Pallet height1, 2 retracted 4530 mm 4760 mm 5700 mm
b
extended 6250 mm 7100 mm 8950 mm
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


Machine specifications: overview

1-31 000 295 725 0 – RHB SCORPION


Maintenance and servicing work

3 Maintenance and servicing work


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


Maintenance and servicing work

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


Maintenance and servicing work

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 ● ● ●
Maintenance and servicing work

• 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 ● ● ● ● ●


Maintenance and servicing work

3-4
3-5
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

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 ● ●
Maintenance and servicing work

• 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


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
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) ● ● ● ● ● ●
Maintenance and servicing work

3-6
3-7
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

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) ● ● ● ● ● ●
Maintenance and servicing work

• 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


Maintenance and servicing work
Maintenance and servicing work

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


Maintenance and servicing work

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


Maintenance and servicing work

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

☞ 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)
☞ Proceed as follows:
• 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


Maintenance and servicing work

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

☞ Proceed as follows:
• Park the machine on level ground
• Lower the telescopic boom fully
B
• Apply the parking brake with the switch
A • Switch off the engine
• Switch off the ignition and remove the ignition key
• Open the engine cover
• 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


Maintenance and servicing work

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
• Apply the parking brake with the switch
• Switch off the ignition and remove the ignition key
• Fill the fuel tank
• Place the container under the engine
• Open the engine cover
• 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:
• Switch off the engine
• 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


Maintenance and servicing work

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


Maintenance and servicing work

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


Maintenance and servicing work

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
an environmentally friendly manner!

☞ Proceed as follows:
•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)
• Switch off the engine
• Switch off the ignition and remove the ignition key
• Open the engine cover
• 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
• Switch off the engine
• 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


Maintenance and servicing work

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
☞ Proceed as follows:
• Park the machine on level ground
• Lower the telescopic boom fully
I
• Apply the parking brake with the switch
H • Switch off the engine
• Switch off the ignition and remove the ignition key
• Open the engine cover
• 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


Maintenance and servicing work

3.9 Maintenance of the engine and hydraulics cooling system


The combined engine/hydraulic oil cooler is located in the engine compartment. It cools
the diesel engine, and the hydraulic oil of the drive and work hydraulics.

Specific safety instructions

Danger!
All work involving antifreeze carries an increased
Danger of poisoning and causticisation!
☞ Seek medical attention immediately if antifreeze has been swallowed
☞ Wear protective clothing and gloves
☞ Keep antifreeze out of reach of children

• Dirt on the radiator fins reduces the radiator's heat dissipation capacity! To avoid this:
• Clean the outside of the radiator at regular intervals. Refer to the maintenance plans
for the cleaning intervals
• In dusty or dirty work conditions, clean more frequently than indicated in the 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
an environmentally friendly manner!

3-17 000 295 725 0 – RHB SCORPION


Maintenance and servicing work

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
• 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
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


Maintenance and servicing work

Filling up coolant

Danger!
Never open the coolant tank and never drain coolant if the warm engine is
running since the cooling system is under high pressure –
Danger of burns!
☞ Wait at least 10 minutes after 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
• Lower the telescopic boom fully
• Apply the parking brake with the switch
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)
• Switch off the engine
• Check the cooling system and the heating water circuit for leaks
• If necessary, have leaks immediately repaired by qualified and trained staff
• Check the coolant level again
• If necessary, fill in coolant and repeat the procedure until reaching the correct coolant
level

3-19 000 295 725 0 – RHB SCORPION


Maintenance and servicing work

Draining coolant

Danger!
Never open the coolant tank and never drain coolant if the warm engine is
running since the cooling system is under high pressure –
Danger of burns!
☞ Wait at least 10 minutes after switching off the engine!
☞ Wear protective gloves and clothing
☞ Open filler cap D to the first notch of the expansion tank and release the
pressure

☞ Drain the coolant as follows:


•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)
• Open the engine cover
• Allow the engine/cooling system to cool down
• Place a suitable container underneath the outlet of the radiator to collect the coolant
as it drains
• Release the overpressure in the coolant expansion tank A. To do this:
• Open cap D to the first notch and release the pressure
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
• Switch off the engine
• Check the cooling system and the heating water circuit for leaks
➥ If necessary, have leaks immediately repaired by qualified and trained staff
• Check the coolant level MAX in the expansion tank
• If necessary, fill in coolant and repeat the procedure until reaching the correct coolant
level

000 295 725 0 – RHB SCORPION 3-20


Maintenance and servicing work

Cleaning the radiator fins

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

Caution!
Dirt on the radiator fins reduces the radiator's heat dissipation capacity and
can cause damage to the engine and the hydraulic system!
☞ Check and clean the outside of the radiator once a day. Refer to the 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
☞ Apply the parking brake with the switch
☞ Switch off the engine and let it cool down
☞ Switch off the ignition and remove the ignition key
☞ Open the engine cover
☞ Clean the radiator fins by blowing compressed air from the engine side

Caution!
Fig. 16: Cleaning the radiator 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


Maintenance and servicing work

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

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


Maintenance and servicing work

3.11 Air filter maintenance


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


☞ Proceed as follows:
• Switch off the engine
1 • Apply the parking brake with the switch
• Switch off the ignition and remove the ignition key
• 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


Maintenance and servicing work

Replacing the filter cartridge at 500 s/h (service hours)

Caution!
G The filter cartridge will be damaged if it is washed or brushed out!
Bear in mind the following to avoid premature engine wear!
☞ Do not clean the filter cartridge
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
☞ 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
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


Maintenance and servicing work

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:
☞ Switch off the engine
☞ Apply the parking brake with the switch
☞ Switch off the ignition and remove the ignition key
☞ Open the engine cover
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
☞ Switch off the engine
☞ Apply the parking brake with the switch (99)
☞ Switch off the ignition and remove the ignition key
☞ Open the engine cover
☞ Slacken fastening screws 1, 2 + 4 of alternator 5
☞ Turn screw 3 to move alternator 5 in the direction of arrow A until you reach the correct
V-belt tension
☞ 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


Maintenance and servicing work

3.13 Gearbox and axle maintenance


Maintenance of the axles and the gearbox is limited to checking the oil levels and to
changing the oil at the prescribed intervals.
➥ – see Maintenance plan (overview) on page 3-4

Checking the oil level in the gearbox


☞ Proceed as follows:
• Park the machine on level ground when the gearbox is at operating temperature
• Oil filler and 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


☞ Proceed as follows:
• 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
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
in an environmentally friendly manner!

Fig. 24: Checking the oil level in the gearbox

000 295 725 0 – RHB SCORPION 3-26


Maintenance and servicing work

Changing the gearbox oil

Danger!
Careful when draining hot gearbox oil –
Danger of burns!
☞ Wear protective gloves
☞ Use suitable tools, e.g. for unscrewing the oil drain plug!

☞ Proceed as follows:
20 kph gearbox • Park the machine on level ground when the gearbox is at operating temperature
• Place a suitable container under the rear axle gearbox to collect the oil
• Oil filler and inspection plug A on the 20 kph gearbox, or
• 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


Maintenance and servicing work

Rear axle differential oil level


Checking the oil
☞ Proceed as follows:
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
If the oil level is below the opening or if the oil level cannot be seen at all:
• Fill up the oil
If the oil level is correct:
• Tighten oil filler and inspection plug A with a new sealing ring to make an oil-tight seal
Fig. 26: Oil filler and inspection plug on the differential Filling up oil
☞ Proceed as follows:
• Park the machine on level ground when the differential is at operating temperature
• Clean and unscrew oil filler and inspection plug A on the differential
• Fill in oil until it runs out of the filler opening
If the oil level in the differential remains constant:
• Tighten oil filler and inspection plug A with a new sealing ring to make an oil-tight seal

Draining the oil in the rear axle differential

Important!

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

Danger!
Careful when draining hot gearbox oil –
Danger of burns!
☞ Wear protective gloves
☞ Use suitable tools, e.g. for unscrewing the oil drain plug!

☞ Proceed as follows:
• 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


Maintenance and servicing work

Front axle differential oil level


Checking the oil
☞ Proceed as follows:
• Park the machine on level ground
• Clean and unscrew oil filler and inspection plug A on the differential while holding a
cloth under the opening
If the oil level is below the opening or if the oil level cannot be seen at all:
• Fill up with oil
A 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. 28: Oil filler and inspection plug on the differential Filling up oil
☞ Proceed as follows:
• Park the machine on level ground
• Clean and unscrew oil filler and inspection plug A on the differential while holding a
cloth under the opening
• Fill in oil until it runs out of the filler opening
• Tighten oil filler and inspection plug A with a new sealing ring to make an oil-tight seal

Draining the oil in the front axle differential

Important!

Drain oil only after running the machine for a longer period of time (operating tem-
A B perature)!

Danger!
C
Careful when draining hot gearbox oil –
Fig. 29: Oil filler and inspection plug on the differential
Danger of burns!
☞ Wear protective gloves
☞ Use suitable tools, e.g. for unscrewing the oil drain plug!

☞ Proceed as follows:
• Park the machine on level ground when it is at operating temperature
• Clean and unscrew plugs A and B
• Place a container under 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


Maintenance and servicing work

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


☞ Proceed as follows:
• Park the machine at operating temperature on level ground and secure it against
rolling away
• Place a suitable container under drain plug A
• Place plug A in the position shown in fig. 32 (plug must be at the top)
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


Maintenance and servicing work

3.14 Safety instructions regarding the hydraulic system


Specific safety instructions
• 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
☞ – see Fluids and lubricants: overview on page 3-3
☞ 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


Maintenance and servicing work

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.
☞ Proceed as follows:
• Park the telehandler on level ground
• Retract all hydraulic rams
• Switch off the engine
• Apply the parking brake with the switch
• Switch off the ignition and remove the ignition key
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


Maintenance and servicing work

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:
• Park the telehandler on level ground
• Retract all hydraulic rams
• Switch off the engine
B • Apply the parking brake with the switch
• Switch off the ignition and remove the ignition key
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:
• Fill up the hydraulic oil
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:
• Park the telehandler on level ground
C • Retract all hydraulic rams
D • Switch off the engine
B • Apply the parking brake with the switch
A
• Switch off the ignition and remove the ignition key
• 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
• Check the oil level again after about 5 minutes, and fill up if necessary

3.19 Replacing the microfilter of the hydraulic system


☞ Replace the reflux filter as follows:
• Park the telehandler on level ground
A • Switch off the engine
• Apply the parking brake with the switch
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
• Check the oil level again after about 5 minutes, and fill up if necessary

3-33 000 295 725 0 – RHB SCORPION


Maintenance and servicing work

3.20 Replacing hydraulic oil

Danger!
Caution when draining hot hydraulic oil and removing the filter element –
Danger of burns!
☞ Wear protective gloves
☞ 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.

☞ Proceed as follows:
• Park the machine on level ground
• 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
• Fill up the hydraulic oil
• 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


Maintenance and servicing work

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


Maintenance and servicing work

3.22 Checking hydraulic pressure lines


Specific safety instructions

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.
Danger of personal injury!
☞ 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


Maintenance and servicing work

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


Maintenance and servicing work

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
☞ Switch off the engine
☞ Apply the parking brake with the switch
☞ Switch off the ignition and remove the ignition key
☞ 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


Maintenance and servicing work

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!
☞ – see Fluids and lubricants: overview on page 3-3

Fig. 44: Filling the central lubrication system

3-39 000 295 725 0 – RHB SCORPION


Maintenance and servicing work

3.24 Maintenance of the brake system

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

Specific safety instructions


• 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


Maintenance and servicing work

3.25 Bleeding the hydraulic powerbrake

Danger!
The brake system is under pressure (30 – 35 bar) –
Danger of personal injury!
☞ 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


Maintenance and servicing work

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
☞ – see Fluids and lubricants: overview on page 3-3
☞ Ensure cleanliness when bleeding/replacing the brake fluid

☞ Prevent the machine from rolling away


☞ Connect the bleed equipment onto the expansion tank
☞ Start the diesel engine

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
in an environmentally friendly manner!

000 295 725 0 – RHB SCORPION 3-42


Maintenance and servicing work

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


Maintenance and servicing work

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


Maintenance and servicing work

3.28 Tyre maintenance

Danger!
Improper tyre repairs –
Danger of accidents!
☞ 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


Maintenance and servicing work

Changing wheels

Danger!
Use of wrong tyres or wheels –
Danger of accidents!
☞ 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


☞ Proceed as follows:
• 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
☞ Proceed as follows:
• 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


Maintenance and servicing work

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


Maintenance and servicing work

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


Maintenance and servicing work

Functional and visual check


The driver must carry out the following visual checks once a day
☞ Switch off the engine
B
☞ Apply the parking brake with the switch
☞ Switch off the ignition and remove the ignition key
☞ 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


Maintenance and servicing work

Emptying/filling up the air conditioning system


Fill up the air conditioning system as follows:
☞ Switch off the engine
☞ Apply the parking brake with the switch
☞ Switch off the ignition and remove the ignition key
☞ 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
☞ Switch off the engine
☞ Apply the parking brake with the switch
☞ Switch off the ignition and remove the ignition key
☞ 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


Maintenance and servicing work

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


Maintenance and servicing work

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 –
Danger of accidents!
☞ 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


Maintenance and servicing work

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


Maintenance and servicing work

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
☞ Apply the parking brake with the switch
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


Maintenance and servicing work

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 –
Danger of accidents!
☞ 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


Maintenance and servicing work

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


Maintenance and servicing work

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 –
Danger of personal injury!
☞ 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.

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Maintenance and servicing work

3.39 Cleaning the engine compartment

Danger!
Clean the engine at engine standstill only –
Danger of personal injury!
☞ Switch off the engine before cleaning
☞ Remove the ignition key
☞ Apply the parking brake with the switch
☞ Switch off the ignition and 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


Maintenance and servicing work

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


Maintenance and servicing work

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


Maintenance and servicing work

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”)
K2 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


II Fan motor unit (standard) D6/VI
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”)
K1 Power supply high current relay (see “Electric system”)
K2 Power supply high current relay (see “Electric system”)
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
N1 Drive electronics (see “Electric system”)
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”
X47 15 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”)
Y61 Fuel injector (see “Engine/cooling”)
Y62 Fuel injector (see “Engine/cooling”)
Y63 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)

Socket housing X40 (6 pole)

Socket housing X47 (22 pole)

Socket housing X41 (22 pole)

000 295 725 0 – RHB SCORPION 4-14


Engine

4.8 Diesel engine connector assignment (88 kW)


Cab/frame disconnect

Socket housing Pin housing


X1 yellow/X2 green X1 yellow/X2 green

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)


Cab/frame disconnect

Socket housing Pin housing


X1 yellow/X2 green X1 yellow/X2 green

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
Socket housing X100 (1 pole)
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


Cab/frame disconnect

Socket housing Pin housing


X1 yellow/X2 green X1 yellow/X2 green

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


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

Socket housing X84 (12 pole)


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
☞ Have repair work carried out by an authorised workshop if necessary
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

Error display Troubleshooting


Dirty radiator
☞ Stop the machine immediately and switch off the diesel engine
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)
☞ Have repair work carried out by an authorised workshop if necessary
Very dirty radiator
☞ Stop the machine immediately and switch off the diesel engine
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)
☞ Have repair work carried out by an authorised workshop if necessary
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

Error display Troubleshooting


☞ 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
☞ Have repair work carried out by an authorised workshop if necessary
☞ Stop the machine immediately and switch off the diesel engine
☞ 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
☞ Have repair work carried out by an authorised workshop if necessary
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)

1-5-5 Separate injector Short circuit (injector 2)

1-5-5 Separate injector Open wiring (injector 2)

1-5-6 Separate injector Short circuit (injector 3)

1-5-6 Separate injector Open wiring (injector 3)

1-6-1 Separate injector Short circuit (injector 4)

1-6-1 Separate injector Open wiring (injector 4)

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 Separate cylinder Misfiring (cylinder 2)

2-4-1 Separate cylinder Misfiring (cylinder 3)

2-4-1 Separate cylinder Misfiring (cylinder 4)

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)

5-3-2 Solenoid valve dwell period Not within specified range or missing (cylinder 2)

5-3-3 Solenoid valve dwell period Not within specified range or missing (cylinder 3)

5-3-4 Solenoid valve dwell period Not within specified range or missing (cylinder 4)

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
☞ Apply the parking brake with the switch
☞ Switch off the ignition and remove the ignition key
☞ Fill the fuel tank
☞ Place the container under the engine
☞ Open the engine cover
☞ 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
Dirt on the radiator fins reduces the radiator's heat dissipation capacity and
can cause damage to the engine and the hydraulic system!

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




Werkstatthandbuch
2012



Workshop Manual
2012



0312 0361

Werkstatthandbuch
2012


0312 0361

Workshop Manual
2012




Manuel d’Atelier
2012



Manual de Taller
2012



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

Werkstatthandbuch BFM 2012

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
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 ___________________ 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 = 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
Caractéristiques techniques
Datos técnicos

Werkstatthandbuch BFM 2012

© 2002 / 0312 0361


Technische Daten
Specification data
Caractéristiques techniques
Datos técnicos

Werkstatthandbuch BFM 2012

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
Caractéristiques techniques
Datos técnicos

Werkstatthandbuch BFM 2012

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
Caractéristiques techniques
Datos técnicos

Werkstatthandbuch BFM 2012

Deutsch English Français Español

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
Caractéristiques techniques
Datos técnicos

Werkstatthandbuch BFM 2012

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
Caractéristiques techniques
Datos técnicos

Werkstatthandbuch BFM 2012

Deutsch English Français Español

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

Grad degrees degrés grados

Auslass öffnet Exhaust opens Echappement ouvre Escape abre


vor UT before BDC avant PMB ante PMI

Grad degrees degrés grados

Auslass schließt Exhaust closes Echappement ferme Escape cierra


nach OT after TDC après PMH tras PMS

Grad degrees degrés grados

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
Caractéristiques techniques
Datos técnicos

Werkstatthandbuch BFM 2012

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
Caractéristiques techniques
Datos técnicos

Werkstatthandbuch BFM 2012

© 2002 / 0312 0361


Ventilspieleinstellschema
Schematic for valve clearance adjustment
Schéma de réglage des soupapes
Esquema para el ajuste del juego de válvulas

Werkstatthandbuch BFM 2012

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

Werkstatthandbuch BFM 2012

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

Werkstatthandbuch BFM 2012

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
Caractéristiques techniques
Datos técnicos

Werkstatthandbuch BFM 2012

© 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

Déterminer l’épaisseur de cale de réglage pour le début d’injection

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
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 = 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


2012 mit Spritzversteller
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
(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

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


2012 avec L’avance automatique

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
(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

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
(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

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
L gemessen mm 125,13

- -
- -
- -
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
Calculation example: BFM 2012

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 réel mesuré °vil. 8
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
Ejemplo de cálculo: BFM 2012

Cilindro No. 0 1 2 3 4 5 6
L0 seg. tabla 1 mm 117,5
“FB” real, medido °cig. 8
“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


2012 mit Spritzversteller
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
L gemessen mm 122,67

- -
- -
- -
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
Calculation example: BFM 2012

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


2012 avec L’avance automatique
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 réel mesuré °vil. 5
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
Ejemplo de cálculo: BFM 2012

Cilindro No. 0 1 2 3 4 5 6
L0 seg. tabla 1.1 mm 111,15
“FB” real, medido °cig. 5
“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

Werkstatthandbuch BFM 2012

© 2003 / 0312 0361 1.00.21


Key to Symbols

Werkstatthandbuch BFM 2012

© 2002 / 0312 0361 1.00.21


Légende des symboles

Werkstatthandbuch BFM 2012

© 2002 / 0312 0361 1.00.21


Leyenda de los pictogramas

Werkstatthandbuch BFM 2012

© 2002 / 0312 0361 1.00.21


Prüfen und Einstellen

Control and adjustment

Contrôle et réglage

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

English Français Español

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

Deutsch Werkstatthandbuch BFM 2012

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

English Français Español

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

English Français Español

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

Deutsch Werkstatthandbuch BFM 2012

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
Ausziehvorrichtung __________________ 150 800

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


Prüfen und Einstellen Einspritzventil
Control and adjustment Injector
Contrôle et réglage Injecteur
Verificación y ajustes Inyector

Werkstatthandbuch BFM 2012 Deutsch

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


Einspritzventil Prüfen und Einstellen
Injector Control and adjustment
Injecteur Contrôle et réglage
Inyector Verificación y ajustes

English Français Español

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


Prüfen und Einstellen Einspritzventil
Control and adjustment Injector
Contrôle et réglage Injecteur
Verificación y ajustes Inyector

English Français Español

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


Einspritzventil Prüfen und Einstellen
Injector Control and adjustment
Injecteur Contrôle et réglage
Inyector Verificación y ajustes

Deutsch Werkstatthandbuch BFM 2012

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


Prüfen und Einstellen Einspritzventil
Control and adjustment Injector
Contrôle et réglage Injecteur
Verificación y ajustes Inyector

Werkstatthandbuch BFM 2012 Deutsch

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


Einspritzventil Prüfen und Einstellen
Injector Control and adjustment
Injecteur Contrôle et réglage
Inyector Verificación y ajustes

English Français Español

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


Prüfen und Einstellen Einspritzventil
Control and adjustment Injector
Contrôle et réglage Injecteur
Verificación y ajustes Inyector

English Français Español

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


Einspritzventil Prüfen und Einstellen
Injector Control and adjustment
Injecteur Contrôle et réglage
Inyector Verificación y ajustes

Deutsch Werkstatthandbuch BFM 2012

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


Prüfen und Einstellen Einspritzventil
Control and adjustment Injector
Contrôle et réglage Injecteur
Verificación y ajustes Inyector

Werkstatthandbuch BFM 2012 Deutsch

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

Hinweis: Klauenschlüssel 8018 verwenden.

35251 ©

7. Zylinderkopfhaube aufbauen.
4 7.1 Dichtung auflegen.
0

35252 ©

2.00.08 © 2002 / 0312 0361


Einspritzventil Prüfen und Einstellen
Injector Control and adjustment
Injecteur Contrôle et réglage
Inyector Verificación y ajustes

English Français Español

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.
Specified tightening
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.
Specified tightening
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


Prüfen und Einstellen Einspritzventil
Control and adjustment Injector
Contrôle et réglage Injecteur
Verificación y ajustes Inyector

English Français Español

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.

Specified tightening torque: 11 Nm Prescription de serrage: 11 Nm Prescripción de apriete: 11 Nm

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.

Specified tightening torque: 8.5 Nm Prescription de serrage: 8,5 Nm Prescripción de apriete: 8,5 Nm

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


Einspritzventil Prüfen und Einstellen
Injector Control and adjustment
Injecteur Contrôle et réglage
Inyector Verificación y ajustes

Deutsch Werkstatthandbuch BFM 2012

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
Anziehvorschrift: 8,5 Nm

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


Prüfen und Einstellen
Control and adjustment
Contrôle et réglage
Verificación y ajustes

Werkstatthandbuch BFM 2012 Deutsch

00000 ©

© 2002 / 0312 0361


Prüfen und Einstellen
Control and adjustment
Contrôle et réglage
Verificación y ajustes

English Français Español

© 2002 / 0312 0361


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

English Français Español

Commercially available tools: Outillage standard: Herramientas comerciales:


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

Special tools: Outillage spécial: Herramientas especiales:


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

Deutsch Werkstatthandbuch BFM 2012

Handelsübliche Werkzeuge:
Kompressionsdruckprüfer _______________ 8005
Torx-Werkzeugsatz ____________________ 8189

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

Werkstatthandbuch BFM 2012 Deutsch

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

English Français Español

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

English Français Español

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

Deutsch Werkstatthandbuch BFM 2012

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


Prüfen und Einstellen
Control and adjustment
Contrôle et réglage
Verificación y ajustes

Werkstatthandbuch BFM 2012 Deutsch

© 2002 / 0312 0361


Demontage und Montage, Motor komplett

Disassembly and re-assembly of complete engine

Démontage et remontage, moteur complet

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

Werkstatthandbuch BFM 2012

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

Werkstatthandbuch BFM 2012

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

Werkstatthandbuch BFM 2012

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

Werkstatthandbuch BFM 2012

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

English Français Español

© 2002 / 0312 0361


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

English Français Español

Dismantling of engine Démontage du moteur Desarmado del motor

Commercially available tools: Outillage standard: Herramientas comerciales:


Claw grip wrench ______________ 8018 Clé à griffes ___________________ 8018 Llave de garra _________________ 8018
Torx tool kit ___________________ 8189 Jeu d’outils Torx _______________ 8189 Juego de herramientas Torx ______ 8189
Torx wrench socket E14 _________ 8113 Clé à douille Torx E14 ___________ 8113 Llave de vaso Torx E14 __________ 8113
Torx wrench socket E20 _________ 8114 Clé à douille Torx E20 ___________ 8114 Llave de vaso Torx E20 __________ 8114
Spring clamp pliers _____________ 9090 Pince à ressort pour tuyaux ______ 9090 Alicates para abrazaderas elásticas _ 9090

Special tools: Outillage spécial: Herramientas especiales:


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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

Deutsch Werkstatthandbuch BFM 2012

Motor zerlegen

Handelsübliche Werkzeuge:
Klauenschlüssel ______________________ 8018
Torx-Werkzeugsatz ____________________ 8189
Torx-Steckschlüssel E14 _______________ 8113
Torx-Steckschlüssel E20 _______________ 8114
Federklemmenzange __________________ 9090

Spezialwerkzeuge:
Motor-Montagebock ___________________ 6066
Aufspannwinkel ____________________ 6066/158
Auszieher _________________________ 110 030
Spezialschlüssel ____________________ 110 500
Ausziehvorrichtung __________________ 120 660
Gegenhalter / Drehschwingungsdämfer __ 144 800
Ausziehvorrichtung __________________ 150 800
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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

Werkstatthandbuch BFM 2012 Deutsch

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

English Français Español

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

English Français Español

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

Deutsch Werkstatthandbuch BFM 2012

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

Werkstatthandbuch BFM 2012 Deutsch

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

English Français Español

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

English Français Español

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

Deutsch Werkstatthandbuch BFM 2012

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

Werkstatthandbuch BFM 2012 Deutsch

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

English Français Español

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

English Français Español

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.
regulations. réglementations antipollution.

4.00.07 © 2002 / 0312 0361


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

Deutsch Werkstatthandbuch BFM 2012

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

Werkstatthandbuch BFM 2012 Deutsch

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

English Français Español

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.

Note: Use claw grip wrench 8018. Nota: Utiliser la clé à griffes 8018. Nota: Utilizar la llave de garra 8018.

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

English Français Español

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

Deutsch Werkstatthandbuch BFM 2012

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

Werkstatthandbuch BFM 2012 Deutsch

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

English Français Español

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

English Français Español

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

Deutsch Werkstatthandbuch BFM 2012

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

Werkstatthandbuch BFM 2012 Deutsch

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

English Français Español

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

English Français Español

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

Deutsch Werkstatthandbuch BFM 2012

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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

Werkstatthandbuch BFM 2012 Deutsch

00000 ©

© 2002 / 0312 0361


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

English Français Español

© 2002 / 0312 0361


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

English Français Español

Re-assembly of engine Remontage du moteur Ensamblado del motor

Commercially available tools: Outillage standard: Herramientas comerciales:


External screw type micrometer Micromètre extérieur Micrómetro para exteriores (palmer)
Claw grip wrench ______________ 8018 Clé à griffes ___________________ 8018 Llave de garra _________________ 8018
Torx tool kit ___________________ 8189 Jeu d’outils Torx _______________ 8189 Juego de herramientas Torx ______ 8189
Torx wrench socket E14 _________ 8113 Clé à douille Torx E14 ___________ 8113 Llave de vaso Torx E14 __________ 8113
Torx wrench socket E20 _________ 8114 Clé à douille Torx E20 ___________ 8114 Llave de vaso Torx E20 __________ 8114
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

Special tools: Outillage spécial: Herramientas especiales:


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


Demontage und Montage, Motor komplett
Disassembly and re-assembly of complete engine
Démontage et remontage, moteur complet
Desarmado y ensamblado, motor completo

Deutsch Werkstatthandbuch BFM 2012

Motor zusammenbauen

Handelsübliche Werkzeuge:
Bügelmessschraube
Klauenschlüssel ______________________ 8018
Torx-Werkzeugsatz ____________________ 8189
Torx-Steckschlüssel E14 _______________ 8113
Torx-Steckschlüssel E20 _______________ 8114
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 ____________ 14