Terex FUCHS MHL340 D User manual

Brand: Terex

Model: FUCHS MHL340 D

Type: User manual

This manual is also suitable for

340210/1350

Service Manual

15.08.08 en

(englisch)

340210 / 1350 >

2006 >

Serial No.

Year of Construction

Edition

Installation

12.65

Generator with wiring

MHL340 D

Contents

1 General......................................................................................................................................3

1.1 Purpose....................................................................................................................................3

1.2 Contents...................................................................................................................................3

1.3 Target group ............................................................................................................................3

1.4 Entire documentation...............................................................................................................3

1.5 In case of questions.................................................................................................................3

2 Safety........................................................................................................................................4

2.1 Requirements for service personnel ........................................................................................4

2.2 General safety notes for service work......................................................................................5

2.3 Special instructions..................................................................................................................6

3 Information for installation .....................................................................................................8

3.1 Assembly overview and working time......................................................................................8

3.2 Lifting equipment and devices .................................................................................................9

3.3 Special tools and aids............................................................................................................10

3.4 Definition of views..................................................................................................................11

4 Preparations...........................................................................................................................12

4.1 Placing the machine in service position.................................................................................12

4.2 Letting off residual pressure in hydraulic system...................................................................12

4.3 Switching off and securing 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 Preparing the generator.........................................................................................................18

5.5 Installing the generator ..........................................................................................................19

5.6 V-belt installation....................................................................................................................22

5.7 Installing and connecting the electrical box and rocker switch...............................................29

5.8 Attaching and connecting the coupler socket.........................................................................35

5.9 Inserting the air hose (13 kW generator only)........................................................................46

5.10 Variations for multi-purpose stick (option)..............................................................................47

5.11 Deviations for "Quick Connect" equipment............................................................................50

5.12 Configuring the electronics ....................................................................................................57

6 Commissioning......................................................................................................................58

6.1 Checks before switching on...................................................................................................58

6.2 Starting operation of magnet system .....................................................................................58

7 Appendix.................................................................................................................................59

7.1 Technical data........................................................................................................................59

12.65-SA10403-en-110808 Version 11.08.2008 1 (60)

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

1 General

1.1 Purpose

These Service Instructions describe the

individual steps to be followed for removing

and installing components. They do not

contain information on troubleshooting and

diagnostics. The service staff must have

comprehensive knowledge of the machine

functions and the interaction of the individual

components and must be knowledgeable of

the national safety regulations applicable to

maintenance work on machines.

The texts, photographs and graphic

depictions have been kept as general as

possible for reasons of clarity.

In your interest, TEREX | Fuchs continues

developing the products further. For this

reason, we reserve the right to implement

technical changes without prior notice that

might deviate from the information contained

in these Service Instructions.

1.2 Contents

These Service Instructions describe the

following service work:

 Installation of a generator with wiring and

control elements up to the coupling box.

The description is valid for the following

machines:

 MHL340 D

as of Vehicle Identity No. 340210 / 1350.

1.3 Target group

These Service Instructions are exclusively

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 Entire documentation

These Service Instructions represent one part

of the entire documentation for the machine.

The entire documentation comprises

 Operating instructions

 Service information

 Service Instructions for the individual

components (if provided).

 Documentation for the various component

manufacturers (if applicable).

NOTICE

The Operating Instructions and

the instructions on the service

work to be carried out must be

read and understood before

beginning with the work.

Depending on the type of service

work, the documentation of the

respective component

manufacturer must also be known.

1.5 In case of questions

These Service Instructions contain basic

information. However, they cannot answer all

questions. Should you have any specific

questions regarding your machine, please

contact the service department that is

responsible for you.

Terex Deutschland GmbH

Geschäftsbereich (division) Terex Fuchs

Industriestrasse 3

D-76669 Bad Schönborn

Phone: +49 (0)7253 84 410

Fax: +49 (0)7253 84 411

USA TCA

8800 Rostin Rd

Southaven, MS38671

Phone: +1 (662) 393 1353

Fax: +1 (662) 393 1729

12.65-SA10403-en-110808 Version 11.08.2008 3 (60)

2 Safety

2.1 Requirements for service personnel

Any service work on the machine requires

comprehensive knowledge of the mode of

operation and dangers of the machine as a

whole and its components.

Therefore, the service staff must have certain

minimum qualifications depending on the

task.

For the required qualification, a distinction is

made between installation/removal of com-

ponents on the one hand and diagnostics on

the other hand.

Activities Qualifications

 Disassembly and installa-

tion of components

 Must be 18 years old (16 years is sufficient for assistant work under

supervision of an authorized service technician).

 Must have the physical and mental abilities to carry out the responsibili-

ties, tasks and actions.

 Must be trained in First Aid and also capable of providing 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-related notes, sources of

danger and safety measures.

 Must have been trained and instructed in rules of conduct in the event

of a fault.

 Must have read and understood the entire documentation, in particular

these Service Instructions, and must be able to apply it.

 Must be qualified to work on the mechanical, electrical, control and hy-

draulic system of loading machines by a corresponding nationally rec-

ognized training for service work and must be up-to-date with the latest

state of knowledge.

 Diagnostic work  Must be able to read and understand circuit diagrams and hydraulic

diagrams.

 Must have attended a work-specific training organized by TEREX |

Fuchs or a person authorized by TEREX | Fuchs for carrying out the

required service work.

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2 Safety

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2.2 General safety notes for service work

Increased danger of injury

Service work always involves a high danger

potential. Serious and permanent injuries

may occur, which might, under extreme cir-

cumstances, even result in death.

Safety through information

Not all dangers can be prevented by design

measures and safety devices. The service

staff must therefore obtain extensive informa-

tion and keep up-to-date with the latest state

of technology.

 National safety regulations and regulations

regarding the protection of the environ-

ment provide basic information on safe

work and environmentally friendly behav-

ior.

 The operating instructions contain detailed

notes on the permissible machine opera-

tion and the correct behavior during ser-

vice work on the machine. The operating

instructions can be found behind the

driver’s seat and must be valid for the ma-

chine.

Safe workplace

The workplace must be selected and occu-

pied carefully.

 Make sure that means of escape exist for

the event of danger.

 Check that stability is sufficient. Clean

slippery areas before beginning with the

work. Remove any obstacles, if possible.

 When climbing on machine parts, always

watch them carefully and make sure that

your hands and feet have safe contact at

least at three points. Do not choose the

shortest, but the safest way.

 Place down parts and components so that

these cannot fall.

 Use a 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 handling of the machine

Safety-aware behavior before, during and

after service work is of vital importance. The

following notes are examples only and not

complete.

 Position the machine at a suitable place.

Consider the condition of the ground and

weather influences. Keep a sufficient

safety distance to overhead electrical lines

and obstacles in the range of travel of ma-

chine parts.

 Operate the parking brake and switch off

the machine prior to any service work.

Remove the ignition key and battery dis-

connect switch. Place a sign with the note

"Service work in progress" in the cab.

 Wear personal protective equipment.

 Safety devices may only be removed dur-

ing standstill and after drive has been se-

cured. Prior to switching on, reattach all

safety devices and check their function.

 Machine parts may move even when

switched off. Secure machine parts using

suitable tools (for example supports). Al-

ways consider the possibility that coupled

machine parts can move.

 Release energies before commencing

work (hydraulics, electricity, tanks with fu-

els, lubricants and coolants, tightening of

machine parts).

 Only seal leakages after the hydraulic

pressure has been relieved. Do not walk

through the jet of hydraulic oil splashing

out. Use tools (for example cardboard)

when searching for leaks. Do not check

the hydraulic components with your hands!

 When switching the machine on, expect

unforeseeable machine behavior. Take

suitable safety measures.

2 Safety

2.3 Special instructions

Safety instructions

Safety instructions that refer to a described

action are indicated at the beginning of such

action or sequence of actions. They explain a

danger and how to avoid it in brief. Their for-

mat makes them stand out from the rest of

the text.

n Signal word

Symbol Information on the source and

the consequences

• Information on how to avoid it

In emergency: Behavior if danger

occurs.

The signal word identifies the danger level.

The following signal words are used:

 DANGER for notes the non compliance

with which will result in death or serious

permanent injuries.

 WARNING for notes the non compliance

with which might result in death or serious

permanent injuries.

 CAUTION for notes the non compliance

with which might result in minor injuries.

Symbols clarify 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.

General notes

Notes the non compliance with which might

result in environmental hazards or machine

damage, that refer to regulations and manu-

facturer's guidelines, or that are particularly

important to ensure that the work to be car-

ried out is successful, are represented as

follows:

NOTICE

Text of a note with or without symbol on the

side.

Used symbols

Symbol Description

General warning of a danger area

or dangerous situation.

Danger because of electric cur-

rent.

Danger because of suspended

loads.

Danger because of fire.

Danger because of hot surfaces.

Danger because of hot liquids.

Danger because of slipping.

Danger because of tripping.

Danger because of falling.

Danger by crushing and strikes on

the entire body.

Danger of crushing and strikes on

body parts.

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2 Safety

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Danger for body parts by 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.

Ecologically harmful substances.

Wear ear and eye protection.

Read safety-relevant information.

3 Information for installation

3.1 Assembly overview 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 additional conversions are

required.

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3 Information for installation

3.2 Lifting equipment and devices

Safety

j WARNING

Risk of bruising when using

incorrect lifting equipment

• Observe component weight.

• Consider auxiliary materials, for

example tank filling.

• Do not route cables over sharp

edges.

• Do not route chains around

corners.

In emergency: Provide first aid.

Consult a doctor immediately.

j WARNING

Risk of bruising due to

incorrect storage places

• Secure components lowered

down against toppling over.

• Provide sufficient free space.

In emergency: Provide first aid.

Consult a doctor immediately.

340-1560-12.65-01

Generator on industrial truck (example)

Installation tool

Suitable industrial truck (3) with which the

generator (1) mounted on the generator plate

(2) can safely be moved up into the machine.

350-1460-12.65-87

340-1560-12.65-87

Lifting equipment for generator

Lifting equipment with lug (1), chain (2), and

load hooks (3). It must be possible to protect

the load hook against slipping out.

h Weight of generator: on page 59

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3 Information for installation

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3.3 Special 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

Loctite 572

1 on page 39

Silicon cartridge with syringe (with "Quick

Connect" only)

1 on page 54

3 Information for installation

3.4 Definition of views

The descriptions include depictions of the

work 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

340-1560-12.65-85

Front

340-1560-12.65-52

Service ladder

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4 Preparations

4.1 Placing the machine in service position

340-1560-12.65-86

Service position

 Unload machine and place it in an even

place that is protected against weather in-

fluences and offers sufficient work area.

 Align the uppercarriage parallel to the un-

dercarriage.

 Lower the dipperstick (1) with the loading

equipment and the 4-point outrigger (2)

down to the ground.

4.2 Letting off residual pressure in hydraulic system

340-1560-12.65-89

Control lever in the cab

 Turn the ignition key to position "1" (igni-

tion on).

 Repeatedly move (min. 5 times) both con-

trol levers (1) and (2) in all directions and

move the toggle switch on the control lever

(2) in both directions (min. 3 times) to re-

lieve the remaining pressure of the hy-

draulic system.

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4 Preparations

4.3 Switching off and securing the machine

340-1560-12.65-52

Battery disconnect switch (view: service ladder)

n DANGER

Electrical shock causing death

• Do not perform any assembly

work while the machine is run-

ning.

• Do not insert the magnet cable

into the generator until the cou-

pler socket is connected.

In emergency: Provide first aid.

Consult a doctor immediately.

 Apply parking brake.

 Switch off the machine.

 Place a sign 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 can easily be found.

4.4 Prior to beginning with the work

Allowing the machine to cool down

j WARNING

• Le

Danger of burning by hot en-

gine parts.

t the machine cool down for a

sufficient time.

• Do not touch hot surfaces.

• Before loosening any connec-

tions, make sure that fuels, lu-

bricants, coolants and fuels con-

tained in these have cooled

down.

In emergency: Provide first aid.

Consult a doctor.

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5 Installation of generator

5.1 Structure of the description

The installation of the generator is described

step by step. The steps are summarized in

groups for purposes of clarity. In the individ-

ual case, a different order might be quicker.

If machine parts must be removed or in-

stalled, the process is described step by step.

Additional notes also appear at the end of the

description of the removal process for later

installation.

5.2 Creating/Closing accesses

340-1560-12.65-46

23 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

Covers (view: service ladder; left)

Remove the service ladder covers

 Remove footplate (1) and plate (2).

 Remove the batteries located under them.

j WARNING

Danger of chemical burns due

to acid; danger of burns due to

electrical shock

• Wear safety goggles and safety

gloves.

• Remove the batteries and keep

it in a safe place.

• Cover the battery poles.

In emergency: Immediately rinse

eyes and affected areas of skin

with clean water and consult a

doctor.

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5 Installation of generato

340-1560-12.65-44

Engine cover (view: starter side)

 Remove the engine cover (1).

340-1560-12.65-61

2 1

Cover plate (view: service ladder; underneath)

 Loosen the fastenings (2) and 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

• Reattach all covers prior to

switching on the machine.

• Hoods and doors must be

closed.

In emergency: Switch off machine.

Provide first aid. Consult a doctor.

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5 Installation of generator

16 (60) Version 11.08.2008 12.65-SA10403-en-110808

5.3 Cleaning the assembly area

j WARNING

Danger of injury to the eyes

from liquid jet and scattering

dirt

• Always wear protective goggles.

No other people may stand

within the area.

In emergency: Rinse eyes with

clean water and consult a doctor

immediately.

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

Holding surfaces for tensioning pulley support (view: starter

side, bottom left)

 Thoroughly clean around the holding sur-

faces for the tensioning pulley support (1)

and (2).

340-1560-12.65-47

Generator plate holding surfaces (view: service ladder; left

from below)

 Also thoroughly clean around the holding

surfaces for the generator plate (1) and

(2).

5 Installation of generato

340-1560-12.65-20

Components in 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) on the engine.

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5 Installation of generator

5.4 Preparing the generator

340-1560-12.65-XX340-1560-12.65-65

8 7

Parts required for generator installation

Have these parts ready:

1) V-belts

2) Tensioning pulley support with fastening

(screws M10×30 mm; D internal of disk =

10.5 mm)

3) Belt tensioners with fastening (screws

M10×30 mm; D internal of disk = 10.5

mm)

4) V-belt pulley for generator with clamping

chuck

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

of disk = 8.4 mm)

9) Cover with sealing profile and fastenings

(screws M8×30 mm; D internal of disk =

8.4 mm)

10) Generator

11) Spiral protector

12) Clamp

13) Measuring instrument for V-belt tension

h More information:

on page 59

340-1560-12.65-24

Connection cable

Inserting the connection cable

 Wrap the connection cable with spiral pro-

tector (1).

 Insert connection plug (2).

18 (60) Version 11.08.2008 12.65-SA10403-en-110808

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Terex FUCHS MHL340 D User manual

Brand: Terex

Model: FUCHS MHL340 D

Type: User manual

This manual is also suitable for

340210/1350

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Terex FUCHS MHL340 D User manual

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