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5 Installation of generator

340-1560-12.65-101

2

3

1

Magnet cable to the coupler socket (front view)

Guide the magnet cable (1) out of the dip-

perstick (2).

After the attachment of the coupler socket

(3) described on the following pages is
complete, close all hose brackets and fas-
ten the magnet cable with cable ties.

38 (60)

Version 11.08.2008

12.65-SA10403-en-110808

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Summary of Contents for 340210/1350

Page 1: ...Service Manual 15 08 08 en englisch 340210 1350 2006 Serial No Year of Construction Edition Installation 12 65 Generator with wiring MHL340 D...

Page 2: ......

Page 3: ...the machine 13 4 4 Prior to beginning with the work 13 5 Installation of generator 14 5 1 Structure of the description 14 5 2 Creating Closing accesses 14 5 3 Cleaning the assembly area 16 5 4 Prepar...

Page 4: ...Contents 2 60 Version 11 08 2008 12 65 SA10403 en 110808 7 2 Tightening torques for screw connections 59 7 3 Measuring instrument for V belt tension 59 8 Index 60...

Page 5: ...intended for authorized service staff of the contract dealers and service partners of TEREX Fuchs NOTICE The magnet system must be placed in operation by an authorized electronics specialist 1 4 Entir...

Page 6: ...viding it Must have the respective national permission for operating this loading machine Must know the danger potential of repair work on loading machines Knowledge and understanding of all safety re...

Page 7: ...scaffold when working at high alti tudes If this is not possible secure your self with ropes People wearing medical devices pace makers may not enter machines with in stalled magnets option Safe hand...

Page 8: ...y a danger by a simplified illus tration and are used for severe dangers In this regard the illustration does not depict the actual situation but signalizes the type of danger in a clear manner Genera...

Page 9: ...cutting or separating Danger that objects might be pulled into machine parts Danger because of automatic start Danger because of poisonous substances Danger because of corrosive sub stances Ecological...

Page 10: ...w and working time The following data are based on experiences They might differ depending on the local situation Staff Duration Modifications 10 hours Parts included with delivery are assembled No ad...

Page 11: ...down against toppling over Provide sufficient free space In emergency Provide first aid Consult a doctor immediately 340 1560 12 65 01 1 2 3 Generator on industrial truck example Installation tool Su...

Page 12: ...ecial tools and aids Designation Units Remark Standard equipment Long ruler about 1250 mm 1 on page 26 Short ruler about 600 mm 1 on page 26 Measuring instrument for V belt tension 1 on page 59 Loctit...

Page 13: ...rk steps For orientation purposes the caption of the pictures indicates the viewpoint of the viewer The following designations are used 340 1560 12 65 59 Starter side 340 1560 12 65 63 Fan side 340 15...

Page 14: ...ipperstick 1 with the loading equipment and the 4 point outrigger 2 down to the ground 4 2 Letting off residual pressure in hydraulic system 2 1 340 1560 12 65 89 Control lever in the cab Turn the ign...

Page 15: ...at the machine reading Re pair work Turn the key 1 at the battery disconnect switch by 90 to the left and pull off Keep the key at a safe place where it is protected against unauthorized access but ca...

Page 16: ...g Closing accesses 340 1560 12 65 46 2 3 1 Covers view service ladder from the bottom of the uppercar riage Removing covers at the bottom Remove plates 1 2 and 3 340 1560 12 65 17 1 2 Covers view serv...

Page 17: ...d remove the cover plate 1 Notes on closing the accesses On principle close the accesses in reverse sequence j WARNING Danger of injury because of ro tating parts scattered parts spurting liquids Reat...

Page 18: ...NOTICE When cleaning with a high pressure cleaner never direct the jet onto electric components and connections or the cooler fins Do not use corrosive cleaning additives 340 1560 12 65 19 1 2 Holding...

Page 19: ...the engine compartment to be cleaned view fan side from below In the engine compartment clean the fas tening and support for the air conditioning compressor 1 and the area around the V belt pulley 2...

Page 20: ...k 5 V belt pulley for engine 6 Air hose 7 Generator plate with fastenings screws M10 40 mm D internal of disk 10 5 mm 8 Shielding plate with sealing profile and fastenings screws M8 30 mm D internal o...

Page 21: ...he eyebolt 2 340 1560 12 65 03 1 2 4 3 Placing the generator on the generator plate Placing the generator on the generator plate Set the generator plate on the industrial truck so that the recess 1 is...

Page 22: ...peration check the tightening torque h For additional information see the manufac turer s installation instructions 340 1560 12 65 62 1 Moving replacing the eyebolt Replacing the eyebolt 13 kW generat...

Page 23: ...in under or put your hands beneath the generator when it is raised Fasten the generator plate without delay In emergency Provide first aid Consult a doctor immediately Set the generator plate with the...

Page 24: ...conditioning compressor view starter side left from above Loosen fastenings 1 and 3 on the sup port 4 as well Swivel the air conditioning compressor against the engine so that the tension on the V bel...

Page 25: ...ching the upper tensioning pulley support view fan side right Mounting the upper belt tensioner To prevent lossening the mounting sur face 1 must be clean and shiny Remove the protection coating witho...

Page 26: ...on the belt tensioner 3 on the tensioning pulley support 4 340 1560 12 65 13 1 2 Aligning the generator view service ladder left For reasons of clarity the adjacent components are not shown Aligning t...

Page 27: ...te with the fastening holes 1 Tighten the shielding plate screws 340 1560 12 65 XX 340 1560 12 65 64 2 1 Fastening the generator view from below Fastening the generator Place the generator plate on th...

Page 28: ...oning pulley to the engine To do this place the long ruler against the tensioning pulley 2 and V belt pulley on the engine 1 Tighten all fastening screws at the base of the tensioning pulley support 3...

Page 29: ...le measuring device If necessary loosen and adjust the upper belt tensioner Readjust after a short operating time To do this loosen the lower tensioning pulley and turn it away After the readjustment...

Page 30: ...belt tensioner 1 until the tensioning pulley is resting lightly against the belt Normally two fingers one laid over the other will then fit between the two tensioning pulley 2 340 1560 12 65 10 1 Tig...

Page 31: ...r switch view of cab Installing the rocker switch in the operator panel Remove the screen 2 on the operator panel 1 Remove the X67 connection cable and connect to the rocker switch 3 Insert the rocker...

Page 32: ...ice ladder right Laying connecting cable for electrical box generator Set down the connecting cable on the lever arm 1 and roll it out Guide the end of the cable over the lever arm 1 to the bottom of...

Page 33: ...the B55 connection cable 2 340 1560 12 65 82 1 3 6 5 2 4 Connecting the connecting cable view driver s seat right Guide in the connecting cable 2 from the access hole 1 into the control lever car rier...

Page 34: ...hrough the access hole 4 as well Insert the connecting cable plug 3 into the electrical box 1 and tighten it 2 340 1560 12 65 98 2 1 Laying the connecting cable on lever arm view lever arm right Guide...

Page 35: ...pening 5 on the floor in the direction of the drive engine 340 1560 12 65 34 1 2 Connecting cable around the batteries view service ladder left Guide the connection cable 1 under the diesel engine aro...

Page 36: ...340 1560 12 65 31 2 1 Laying the connecting cable to the generator view service ladder underneath Lay the connecting cable 1 to the gen erator Fasten in place with corrugated hose holder 2 340 1560 12...

Page 37: ...1560 12 65 XX 340 1560 12 65 88 1 3 2 Lay out the magnet cable on the boom view service ladder right Laying the magnet cable over the boom to the coupler socket j WARNING Danger due to cable ends wit...

Page 38: ...service ladder right Slightly open the hose bracket 4 Guide the magnet cable 1 from the hose bracket 3 through the hose bracket 4 Fasten the magnet cable onto the hydraulic hose later with cable ties...

Page 39: ...340 1560 12 65 71 1 2 3 4 Magnet cable over dipperstick front view Slightly open the hose bracket 2 Lay the magnet cable 1 over the dipper stick Fasten the magnet cable on the line 3 with cable ties...

Page 40: ...r socket front view Guide the magnet cable 1 out of the dip perstick 2 After the attachment of the coupler socket 3 described on the following pages is complete close all hose brackets and fas ten the...

Page 41: ...w it in 340 1560 12 65 103 3 1 5 6 2 4 Setting the coupler socket in place front view right Fasten the coupler socket 2 onto the dipperstick 1 with fastening screws 6 Remove the swivel nut 3 and push...

Page 42: ...1 Assignment of cable ends To tighten the cable ends 1 Yellow Green 2 Black and gray 3 Brown and blue 340 1560 12 65 106 1 2 Attached coupler socket Retighten the cover cap 1 Retighten the swivel nut...

Page 43: ...12 65 49 2 3 1 Magnet cable around the swivel motor view service ladder right Guide the cable end 1 onto the floor 3 and from there around the swivel motor 2 340 1560 12 65 48 4 3 2 1 Magnet cable int...

Page 44: ...r the service ladder Guide the magnet cable 1 along under the service ladder Fasten in place with corrugated hose holders 2 later 340 1560 12 65 40 1 3 2 Magnet cable under the service ladder to the g...

Page 45: ...of generator 340 1560 12 65 42 1 2 Guiding the magnet cable out Guide the magnet cable 1 out of the opening 2 in the uppercarriage to as semble the Harting connector 12 65 SA10403 en 110808 Version 11...

Page 46: ...on the cable con nection 1 and push it over the magnet cable Guide the magnet cable through the cable connection 1 into the plug housing 2 340 1560 12 65 108 2 3 4 1 5 Cable assignment for Harting con...

Page 47: ...eady been connected Failure to observe this instruction places the other cable end under cur rent if the machine is acciden tally turned on In emergency Consult a doctor immediately Insert the plug 1...

Page 48: ...erator only 340 1560 12 65 58 1 3 2 Inserting the air hose view service ladder bottom If it has not been done remove the cover plate h on page 15 cover plate Press the air hose 1 together Push the air...

Page 49: ...ing the coupler socket Open the hose bracket 4 enough to push the magnet cable through Guide the magnet cable 1 onto the boom Fasten the magnet cable onto the connec tion bar later with the corrugated...

Page 50: ...cable on dipperstick front view Slightly open the hose bracket 2 Lay the magnet cable 1 further to the center on the dipperstick 3 Fasten the magnet cable on the hydraulic hose with cable ties 4 late...

Page 51: ...74 2 1 Magnet cable to the coupler socket front view Guide the magnet cable 1 to the coupler socket 2 After the coupler socket 2 is connected close all hose brackets and fasten the magnet cable with...

Page 52: ...1560 12 65 77 1 2 3 4 Magnet cable to the boom view service ladder right Laying the magnet cable over the boom to the coupler socket Cable guiding deviates somewhat for ma chines with an optional mult...

Page 53: ...bracket later with a clamp 2 and onto the hydraulic hose 4 with cable ties Close the hose bracket later 340 1560 12 65 XX 340 1560 12 65 79 5 2 1 4 3 Magnet cable to the boom view service ladder righ...

Page 54: ...cable on the stick base front view Cut through the protective tube on the magnet cable 1 at the height of the counter nut so that the cable insulation is not damaged and remove it Attach the counter n...

Page 55: ...ion shows the parts for the mag net socket The magnet plug is similar and must be placed ready as well 1 Magnet socket housing 2 Fastening screws for magnet socket on dipperstick 3 Terminal screws for...

Page 56: ...file in the housing designed for that purpose Apply silicon to the connection points of the housing and around the contacts 7 Put the housing together and screw the connections tight 340 1560 12 65 83...

Page 57: ...magnet cable through the open ing out of the stick head 4 340 1560 12 65 117 1 2 3 Magnet plug on the stick head Attaching the magnet plug Guide the magnet cable from below through the support 3 Conn...

Page 58: ...er sock et to the stick head with coil 2 Attach the coupler socket as described for the standard version h on page 39 Attaching the coupler socket Equalize the cable length with a loop un der the cove...

Page 59: ...guring the electronics 340 1560 12 65 119 Entering the enable code The enable code is indicated with the scope of parts delivered Enable the option h More information Service documenta tion 12 65 SA10...

Page 60: ...esses Place covers and plates in place Reinstall battery disconnect switch and ensure power supply Start engine Turn on the generator After the engine has run for a short time turn it off Bring the ma...

Page 61: ...30 500 M 20 x 2 5 425 610 710 M 22 x 2 5 580 830 970 M 24 x 3 0 730 1050 1220 M 27 x 3 0 1100 1550 1800 M 30 x 3 2 1450 2100 2450 NOTICE The specified tightening torques apply for screwed connections...

Page 62: ...dex 8 Index References to service documentation Enabling options 57 References to the operating instructions V belt tension air conditioning compressor 23 60 60 Version 11 08 2008 12 65 SA10403 en 110...

Page 63: ......

Page 64: ...es After Sales Service Si ges Administratif Vente Service Apr s Vente Terex Deutschland GmbH Gesch ftsbereich Terex Fuchs 76669 Bad Sch nborn GERMANY Fon 49 0 72 53 84 0 Fax 49 0 72 53 84 411 E Mail I...

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