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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
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Contents
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7.2 Tightening torques for screw connections..............................................................................59
7.3 Measuring instrument for V-belt tension.................................................................................59
8 Index........................................................................................................................................60
1 General
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
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2 Safety
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 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
1
2
3
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
2
1
3
340-1560-12.65-87
Lifting equipment for generator
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 Preparations
4.1 Placing the machine in service position
340-1560-12.65-86
2
1
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
2
1
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
1
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 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
1
2
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
r
340-1560-12.65-44
1
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
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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
1
2
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
1
2
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
r
340-1560-12.65-20
1
2
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
1
2
4
3
5
6
8 7
10
11
9
12
13
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
2
1
Connection cable
Inserting the connection cable
Wrap the connection cable with spiral pro-
tector (1).
Insert connection plug (2).
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