12.

65

Service Manual

MHL340 D

Installation
Generator with wiring
Serial No.
340210 / 1350 >
Year of Construction
2006 >
Edition
15.08.08 en (englisch)
 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
7.2 Tightening torques for screw connections.............................................................................. 59
7.3 Measuring instrument for V-belt tension................................................................................. 59

8 Index........................................................................................................................................ 60

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 1 General
1 General
1.1 Purpose 1.4 Entire documentation
These Service Instructions describe the These Service Instructions represent one part
individual steps to be followed for removing of the entire documentation for the machine.
and installing components. They do not The entire documentation comprises
contain information on troubleshooting and
ƒ Operating instructions
diagnostics. The service staff must have
comprehensive knowledge of the machine ƒ Service information
functions and the interaction of the individual ƒ Service Instructions for the individual
components and must be knowledgeable of components (if provided).
the national safety regulations applicable to ƒ Documentation for the various component
maintenance work on machines. manufacturers (if applicable).
The texts, photographs and graphic
depictions have been kept as general as NOTICE
possible for reasons of clarity. The Operating Instructions and
the instructions on the service
In your interest, TEREX | Fuchs continues
work to be carried out must be
developing the products further. For this read and understood before
reason, we reserve the right to implement beginning with the work.
technical changes without prior notice that Depending on the type of service
might deviate from the information contained work, the documentation of the
in these Service Instructions. respective component
manufacturer must also be known.
1.2 Contents
These Service Instructions describe the 1.5 In case of questions
following service work:
These Service Instructions contain basic
ƒ Installation of a generator with wiring and information. However, they cannot answer all
control elements up to the coupling box. questions. Should you have any specific
The description is valid for the following questions regarding your machine, please
machines: contact the service department that is
ƒ MHL340 D responsible for you.
as of Vehicle Identity No. 340210 / 1350. Terex Deutschland GmbH
Geschäftsbereich (division) Terex Fuchs
1.3 Target group
Industriestrasse 3
These Service Instructions are exclusively D-76669 Bad Schönborn
intended for authorized service staff of the Phone: +49 (0)7253 84 410
contract dealers and service partners of Fax: +49 (0)7253 84 411
TEREX | Fuchs.
USA TCA
8800 Rostin Rd
NOTICE
Southaven, MS38671
The magnet system must be placed in operation Phone: +1 (662) 393 1353
by an authorized electronics specialist.
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 For the required qualification, a distinction is
comprehensive knowledge of the mode of made between installation/removal of com-
operation and dangers of the machine as a ponents on the one hand and diagnostics on
whole and its components. the other hand.
Therefore, the service staff must have certain
minimum qualifications depending on the
task.

Activities Qualifications

ƒ Disassembly and installa- ƒ Must be 18 years old (16 years is sufficient for assistant work under
tion of components supervision of an authorized service technician).
ƒ Must have the physical and mental abilities to carry out the responsibili-
ties, tasks and actions.
ƒ Must be trained in First Aid and also capable of providing it.
ƒ Must have the respective national permission for operating this loading
machine.
ƒ 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.
ƒ Must have been trained and instructed in rules of conduct in the event
of a fault.
ƒ Must have read and understood the entire documentation, in particular
these Service Instructions, and must be able to apply it.
ƒ 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.

ƒ Diagnostic work ƒ Must be able to read and understand circuit diagrams and hydraulic
diagrams.
ƒ 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
2.2 General safety notes for service work
Increased danger of injury Safe handling of the machine
Service work always involves a high danger Safety-aware behavior before, during and
potential. Serious and permanent injuries after service work is of vital importance. The
may occur, which might, under extreme cir- following notes are examples only and not
cumstances, even result in death. complete.
ƒ Position the machine at a suitable place.
Safety through information Consider the condition of the ground and
Not all dangers can be prevented by design weather influences. Keep a sufficient
measures and safety devices. The service safety distance to overhead electrical lines
staff must therefore obtain extensive informa- and obstacles in the range of travel of ma-
tion and keep up-to-date with the latest state chine parts.
of technology.
ƒ Operate the parking brake and switch off
ƒ National safety regulations and regulations the machine prior to any service work.
regarding the protection of the environ- Remove the ignition key and battery dis-
ment provide basic information on safe connect switch. Place a sign with the note
work and environmentally friendly behav- "Service work in progress" in the cab.
ior.
ƒ Wear personal protective equipment.
ƒ The operating instructions contain detailed
ƒ Safety devices may only be removed dur-
notes on the permissible machine opera-
ing standstill and after drive has been se-
tion and the correct behavior during ser-
cured. Prior to switching on, reattach all
vice work on the machine. The operating
safety devices and check their function.
instructions can be found behind the
driver’s seat and must be valid for the ma- ƒ Machine parts may move even when
chine. switched off. Secure machine parts using
suitable tools (for example supports). Al-
Safe workplace ways consider the possibility that coupled
The workplace must be selected and occu- machine parts can move.
pied carefully. ƒ Release energies before commencing
ƒ Make sure that means of escape exist for work (hydraulics, electricity, tanks with fu-
the event of danger. els, lubricants and coolants, tightening of
machine parts).
ƒ Check that stability is sufficient. Clean
slippery areas before beginning with the ƒ Only seal leakages after the hydraulic
work. Remove any obstacles, if possible. pressure has been relieved. Do not walk
through the jet of hydraulic oil splashing
ƒ When climbing on machine parts, always
out. Use tools (for example cardboard)
watch them carefully and make sure that
when searching for leaks. Do not check
your hands and feet have safe contact at
the hydraulic components with your hands!
least at three points. Do not choose the
ƒ When switching the machine on, expect
shortest, but the safest way. unforeseeable machine behavior. Take
ƒ Place down parts and components so that suitable safety measures.
these cannot fall.
ƒ Use a scaffold when working at high alti-
tudes. If this is not possible, secure your-
self with ropes.
ƒ People wearing medical devices (pace
makers) may not enter machines with in-
stalled magnets (option).

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2 Safety
2.3 Special instructions
Safety instructions Used symbols
Safety instructions that refer to a described
action are indicated at the beginning of such Symbol Description
action or sequence of actions. They explain a General warning of a danger area
danger and how to avoid it in brief. Their for- or dangerous situation.
mat makes them stand out from the rest of
the text.

Danger because of electric cur-

n Signal word rent.
Symbol Information on the source and
the consequences
• Information on how to avoid it
In emergency: Behavior if danger Danger because of suspended
occurs. loads.

The signal word identifies the danger level.

The following signal words are used:
Danger because of fire.
ƒ DANGER for notes the non compliance
with which will result in death or serious
permanent injuries.
ƒ WARNING for notes the non compliance Danger because of hot surfaces.
with which might result in death or serious
permanent injuries.
ƒ CAUTION for notes the non compliance
with which might result in minor injuries. Danger because of hot liquids.
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 because of slipping.
danger in a clear manner.

General notes
Notes the non compliance with which might
Danger because of tripping.
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 Danger because of falling.
follows:

NOTICE
Danger by crushing and strikes on
Text of a note with or without symbol on the
the entire body.
side.

Danger of crushing and strikes on

body parts.

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 2 Safety

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.

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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 j WARNING
Risk of bruising when using Risk of bruising due to
incorrect lifting equipment incorrect storage places
• Observe component weight. • Secure components lowered
• Consider auxiliary materials, for down against toppling over.
example tank filling. • Provide sufficient free space.
• Do not route cables over sharp In emergency: Provide first aid.
edges. Consult a doctor immediately.
• Do not route chains around
corners.
In emergency: Provide first aid.
Consult a doctor immediately.

Installation tool
Suitable industrial truck (3) with which the
1 generator (1) mounted on the generator plate
(2) can safely be moved up into the machine.
2

3
340-1560-12.65-01

Generator on industrial truck (example)

Lifting equipment for generator

1
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
2

350-1460-12.65-87
340-1560-12.65-87

Lifting equipment for generator

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3 Information for installation
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 1 on page 54

Connect" only)

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 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:

340-1560-12.65-59 340-1560-12.65-63

Starter side Fan side

340-1560-12.65-52

Service ladder

340-1560-12.65-85

Front

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4 Preparations
4 Preparations
4.1 Placing the machine in service position

ƒ Unload machine and place it in an even

place that is protected against weather in-
fluences and offers sufficient work area.
ƒ Align the uppercarriage parallel to the un-
dercarriage.
ƒ Lower the dipperstick (1) with the loading
2 equipment and the 4-point outrigger (2)
1 down to the ground.

340-1560-12.65-86

Service position

4.2 Letting off residual pressure in hydraulic system

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

tion on).
ƒ 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.

1 2

340-1560-12.65-89

Control lever in the cab

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 4 Preparations
4.3 Switching off and securing the machine

n DANGER
1 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.

ƒ Apply parking brake.

340-1560-12.65-52 ƒ Switch off the machine.
Battery disconnect switch (view: service ladder) ƒ Place a sign at the machine reading "Re-
pair work".
ƒ Turn the key (1) at the battery disconnect
switch by 90° to the left and pull off.
ƒ 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
Danger of burning by hot en-
gine parts.
• Let 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 If machine parts must be removed or in-
step by step. The steps are summarized in stalled, the process is described step by step.
groups for purposes of clarity. In the individ- Additional notes also appear at the end of the
ual case, a different order might be quicker. description of the removal process for later
installation.

5.2 Creating/Closing accesses

Removing covers at the bottom

ƒ Remove plates (1), (2), and (3).

3 2 1

340-1560-12.65-46

Covers (view: service ladder from the bottom of the uppercar-

riage)

Remove the service ladder covers

ƒ Remove footplate (1) and plate (2).
1
ƒ Remove the batteries located under them.

j WARNING
2
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
340-1560-12.65-17
it in a safe place.
• Cover the battery poles.
Covers (view: service ladder; left)
In emergency: Immediately rinse
eyes and affected areas of skin
with clean water and consult a
doctor.

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 5 Installation of generator

ƒ Remove the engine cover (1).

340-1560-12.65-44

Engine cover (view: starter side)

ƒ Loosen the fastenings (2) and remove the

cover plate (1).

2 1

340-1560-12.65-61

Cover plate (view: service ladder; underneath)

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
5.3 Cleaning the assembly area

j WARNING NOTICE
Danger of injury to the eyes When cleaning with a high-pressure cleaner,
from liquid jet and scattering never direct the jet onto electric components
dirt and connections or the cooler fins.
• Always wear protective goggles. Do not use corrosive cleaning additives!
No other people may stand
within the area.
In emergency: Rinse eyes with
clean water and consult a doctor
immediately.

ƒ Thoroughly clean around the holding sur-

faces for the tensioning pulley support (1)
and (2).
1

340-1560-12.65-19

Holding surfaces for tensioning pulley support (view: starter

side, bottom left)

1 ƒ Also thoroughly clean around the holding

surfaces for the generator plate (1) and
(2).

340-1560-12.65-47

Generator plate holding surfaces (view: service ladder; left

from below)

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 5 Installation of generator

ƒ In the engine compartment, clean the fas-

1 tening and support for the air conditioning
compressor (1) and the area around the V-
belt pulley (2) on the engine.

340-1560-12.65-20

Components in the engine compartment to be cleaned (view:

fan side; from below)

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5 Installation of generator
5.4 Preparing the generator

Have these parts ready:

1 4 5
1) V-belts
2) Tensioning pulley support with fastening
2 (screws M10×30 mm; D internal of disk =
6 10.5 mm)
3) Belt tensioners with fastening (screws
3
M10×30 mm; D internal of disk = 10.5
mm)
8 7 4) V-belt pulley for generator with clamping
9 chuck
5) V-belt pulley for engine
6) Air hose
10
11 7) Generator plate with fastenings (screws
M10×40 mm; D internal of disk = 10.5 mm)
12
8) Shielding plate with sealing profile and
13 fastenings (screws M8×30 mm; D internal
340-1560-12.65-XX
340-1560-12.65-65 of disk = 8.4 mm)
Parts required for generator installation 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

Inserting the connection cable

ƒ Wrap the connection cable with spiral pro-
tector (1).
1
2 ƒ Insert connection plug (2).

340-1560-12.65-24

Connection cable

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 5 Installation of generator
5.5 Installing the generator

Raising the generator

1
j WARNING
2 Risk of crushing by falling
generator
• Only use lifting equipment that is
suitable for the weight (for
information on the lifting
equipment, refer to on page 9).
• Do not step under or put your
hands beneath the generator
when it is raised.
• Set the generator down without
340-1560-12.65-02
delay.
Fixing points for generator
In emergency: Provide first aid.
Consult a doctor immediately.

ƒ Position the lifting device (1) on the

eyebolt (2).

Placing the generator on the generator

plate
ƒ Set the generator plate on the industrial
truck so that the recess (1) is pointing to
2 the right and all elongated holes (4) are
accessible from below.
ƒ Move the generator with drive shaft (2)
1 forward onto the generator plate so that
3
the generator's front fastening holes (3)
4 340-1560-12.65-03
line up with the front elongated holes (4).
Placing the generator on the generator plate

Fastening the generator loosely

ƒ Place the threaded links (1) on the fasten-
2 ing holes of the generator from above.
Screw in the hexagon bolts (3) with wash-
1
3
ers (2) loosely from below.

340-1560-12.65-05

Generator fastenings

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5 Installation of generator

Installing the V-belt pulley

ƒ Clean and degrease all joining points of
the V-belt pulley (1), clamping chuck (2),
and shaft journal (3). Coat the bolts (4)
with a thin film of oil.
ƒ Place the clamping chuck (2) in the V-belt
1 pulley (1) and screw in the bolts (4) lightly.
ƒ Then push it onto the shaft journal (3) until
the V-belt pulley is positioned approxi-
2
mately at the center of the shaft journal.
3
ƒ Tighten the bolts (4). Torque: 31 Nm.
ƒ After placing into operation, check the
4 31 Nm
tightening torque.

340-1560-12.65-06 h For additional information, see the manufac-

turer’s installation instructions
V-belt pulley fastening

Replacing the eyebolt (13 kW generator

1 only)
The eyebolt must be removed for this type of
generator, otherwise the shielding plate to be
assembled later may rest at that point.
ƒ Unscrew the eyebolt.
ƒ To secure the nut, screw in a bolt
M8×12 mm loosely, push to the left (1)
and tighten.

Moving the eyebolt (17 kW generator only)

The eyebolt must be removed for this type of
340-1560-12.65-62
generator, otherwise the shielding plate to be
Moving / replacing the eyebolt
assembled later may rest at that point.
ƒ Loosen the eyebolt, move it to the left (1)
and tighten it.

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 5 Installation of generator

Inserting the generator

1 j WARNING
Risk of crushing by falling
2
generator
• Only use industrial trucks that
are suitable for the weight (for
3 information on the lifting
equipment, refer to on page 9).
• Do not remain under or put your
hands beneath the generator
340-1560-12.65-07 when it is raised.
Inserting the generator (view: service ladder; left) • Fasten the generator plate
without delay.
In emergency: Provide first aid.
Consult a doctor immediately.

ƒ Set the generator plate with the generator

screwed onto it on a suitable industrial
truck so that the fastening points of the
generator plate are accessible from below.
ƒ Move the generator plate into the
machine.
ƒ Screw in all hexagon bolts (2) with wash-
ers (1) into the uppercarriage (3) loosely.

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5 Installation of generator
5.6 V-belt installation

Replacing the V-belt pulley

1
ƒ Loosen the lower fastening (2) on the air
conditioning compressor (1).

340-1560-12.65-14

Loosening the air conditioning compressor (view: fan side)

ƒ Loosen fastenings (1) and (3) on the sup-

port (4) as well.
ƒ Swivel the air conditioning compressor
2 against the engine so that the tension on
1 3
the V-belt (2) is released.
ƒ Remove the V-belt.
4

340-1560-12.65-16

Loosening the air conditioning compressor (view: starter side;

left from above)

1 ƒ Remove the fastening screws (2) on the V-

belt pulley (1) and remove the V-belt pul-
ley.
2 ƒ Clean the mountery surface.

340-1560-12.65-21

Replacing the V-belt pulley (view: fan side; from below)

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 5 Installation of generator

2 ƒ Fasten the new V-belt pulley (1). Torque:

3
125 Nm.
ƒ Set the V-belt in place on the rear diame-
ter of the V-belt pulley (2) and on the air
conditioning compressor (3).
ƒ Tension the V-belt and fasten the air con-
ditioning compressor in place again.

1 h More information: Operating Instructions

Chapter 7
340-1560-12.65-18

Setting the V-belt in place (view: fan side; from below)

Mounting the upper belt tensioner

1 ƒ To prevent lossening, the mounting sur-
face (1) must be clean and shiny. Remove
2 the protection coating without damaging
the mountery surface.
ƒ Set the tensioning pulley support (2) in
place and screw all fastenings (3) in place
loosely.

3
340-1560-12.65-28

Attaching the upper tensioning pulley support (view: fan side;

right)

ƒ Remove the protection coating (2) on the

belt tensioner (1) without damaging the
4 mountery surface.
2
ƒ Loosely screw on the belt tensioner (3) on
1
the tensioning pulley support (4).
3

340-1560-12.65-27

Mounting the upper belt tensioner (view: fan side; right)

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5 Installation of generator

Mounting the lower belt tensioner

ƒ Check the mountery surfaces for even-
2 ness and clean them.
ƒ Fasten the tensioning pulley support (1)
loosely. Make certain the washer (2) is not
resting on the welding seam.

1
340-1560-12.65-25

Mounting the lower tensioning pulley support (view: fan side;

right)

ƒ Remove the belt tensioner of the fastening

4
screw (1).
3
ƒ Remove the protection coating (2) without
damaging the mountery surface.
ƒ Loosely screw on the belt tensioner (3) on
the tensioning pulley support (4).
2

1
340-1560-12.65-26

Mounting the lower belt tensioner (view: fan side; right)

1 Aligning the generator and setting it down

ƒ Align the V-belt pulley of the generator to
the engine. To do this, place the ruler on
the V-belt pulleys (1) and (2).
ƒ Do not tighten the generator plate's fas-
tening screws! Mark the position of the
generator plate so that you will be able to
align it in this position later.
ƒ Tighten all fastening screws of the genera-
tor onto the generator plate enough so that
the generator can no longer slip.
2 ƒ Let down the generator again to attach the
340-1560-12.65-13 shielding plate.
Aligning the generator (view: service ladder; left) For reasons
of clarity, the adjacent components are not shown)

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 5 Installation of generator

1 Attaching the shielding plate

ƒ Apply clamp (4) (only for 13 kW generator).
ƒ Insert the sealing profile (3) on the shielding
plate (1).
3 ƒ Set the shielding plate on the generator
plate (2).

2 4

340-1560-12.65-37

Attaching the shielding plate (attached outside the machine)

ƒ Align the shielding plate with the fastening

holes (1).
ƒ Tighten the shielding plate screws.

340-1560-12.65-38
Attaching the shielding plate (view: from below)

Fastening the generator

1
ƒ Place the generator plate on the industrial
truck with the generator screwed onto it,
observing the safety instructions given on
on page 21 and move it back into the ma-
2 chine.
ƒ Align the generator plate according to the
marks you made before letting it down.
ƒ Tighten all generator plate fastenings (1).
340-1560-12.65-64
340-1560-12.65-XX
Torque: 49 Nm.
Fastening the generator (view: from below)
ƒ Tighten all generator fastenings (2).
Torque: 49 Nm.

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5 Installation of generator

Setting the V-belts in place

1 ƒ Set the V-belt in place on the V-belt pulleys of
the engine (1) and generator (2).

340-1560-12.65-22

Setting the V-belt in place (view: fan side); shielding plate is

not shown for reasons of clarity.

Aligning the upper tensioning pulley and

tightening the bolts
1 ƒ Swivel the upper tensioning pulley in onto
the V-belts.
ƒ Align the tensioning pulley to the engine.
2 To do this, place the long ruler against the
tensioning pulley (2) and V-belt pulley on
3 the engine (1).
ƒ Tighten all fastening screws at the base of
the tensioning pulley support (3).
340-1560-12.65-12

Aligning the upper tensioning pulley (view: fan side; right)

Aligning the lower tensioning pulley and

tightening the bolts
ƒ Swivel the lower tensioning pulley in onto
the V-belts.
ƒ Align the tensioning pulley to the engine.
1 3 To do this, place the short ruler against the
2 tensioning pulley (2) and V-belt pulley on
the engine (1).
ƒ Tighten all fastening screws at the base of
340-1560-12.65-11 the tensioning pulley support (3).
Aligning the lower tensioning pulley (view: fan side; right)

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 5 Installation of generator

Provisionally tightening the upper belt

tensioner
ƒ Swivel the upper belt tensioner until the
scale (1) is opposite the 15° mark on the
3 corner (2).
ƒ Tighten the fastening screw (3). Torque:
1 86 Nm.

340-1560-12.65-29

Provisionally tightening the upper belt tensioner (view: fan

side; right)

Tensioning V-belts
ƒ Check the belt tension (1) with a suitable
measuring device. If necessary, loosen
and adjust the upper belt tensioner.
ƒ Readjust after a short operating time. To
do this, loosen the lower tensioning pulley
1 and turn it away. After the readjustment is
complete, place it lightly against the belt
again.

2 When using the measuring instrument "Op-

340-1560-12.65-75
340-1560-12.65-XX tik1" (2), set the following values:
Measuring belt tension (view: service ladder; left)
Type 13 / 17 kW

Installation 400 N

after 60 min 300 N

h More information: on page 59

Attaching the cover plate

2 ƒ Place the edge guard (2) around the recess
on the cover plate (1).
1
ƒ Insert and fasten the cover plate (3).
3

340-1560-12.65-56

Attaching the cover plate (view: starter side; left)

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5 Installation of generator

Placing the lower tensioning pulley

ƒ Swivel the lower belt tensioner (1) until the
tensioning pulley is resting lightly against
2 1 the belt. Normally, two fingers one laid
over the other will then fit between the two
tensioning pulley (2).

340-1560-12.65-09

Placing the lower belt tensioner (view: fan side; right)

ƒ Tighten the fastening screw (1). Torque:

86 Nm.

340-1560-12.65-10

Tightening the lower belt tensioner (view: fan side; from below,
right)

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 5 Installation of generator
5.7 Installing and connecting the electrical box and rocker switch

Have these parts ready:

1 2 3 1) Connecting cable
2) Electrical box and support
3) Rocker switch
4) Corrugated hose holder
5) Screws
6) Cover for corrugated hose holder
6 5 4

340-1560-12.65-91

Parts required for electrical box

Installing the rocker switch in the operator

panel
3 ƒ Remove the screen (2) on the operator
panel (1).
ƒ Remove the X67 connection cable and
connect to the rocker switch (3).
ƒ Insert the rocker switch (3).

2
1

340-1560-12.65-76

Installing the rocker switch (view of cab)

Attaching the electrical box

ƒ Remove the cover (4) from the MMI elec-
1 trical box (1).
ƒ Align the electrical box with the fastening
holes (3) on the support (5).
2
ƒ Tighten the electrical box from above with
the screws (2) on the support (5).
3 4 ƒ Fasten the cover (4) again.

5 340-1560-12.65-92

Electrical box and support

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5 Installation of generator

ƒ Remove the two lower fastening screws

(3) on the right control lever carrier (1).
ƒ Connect and tighten the support (2) with
these fastening screws.

3
340-1560-12.65-93

Electrical box on the control lever carrier (view: driver's seat;

right)

Laying connecting cable for electrical

box/generator
ƒ Set down the connecting cable on the
2 lever arm (1) and roll it out.
1 ƒ Guide the end of the cable over the lever
arm (1) to the bottom of the cab floor (2).
2
ƒ Lay out the other end of the cable on the
back part of the lever arm (3).

340-1560-12.65-94

Connecting cable to lever arm (view: service ladder; right)

ƒ Guide the connecting cable (2) up through

the access hole (3) in the cab floor.
ƒ Fasten in place later with corrugated hose
holder (1).

1
2

340-1560-12.65-95

Connecting cable in cab (view: below cab)

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 5 Installation of generator

ƒ Remove the cover (1) on the right control

lever carrier.
ƒ Pull out the B55 connection cable (2).
1

340-1560-12.65-96

Connection cable on the control lever carrier (view: driver's

seat; right)

ƒ Guide in the connecting cable (2) from the

5 access hole (1) into the control lever car-
3 4 rier (3).
ƒ Guide the connecting cable out through
the access hole (6).
ƒ Insert the connecting cable plug into the
electrical box (5) and secure it (4).

340-1560-12.65-82

Connecting the connecting cable (view: driver's seat; right)

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5 Installation of generator

1 ƒ Guide the connection cable (3) out through

the access hole (4) as well.
2
ƒ Insert the connecting cable plug (3) into
3 the electrical box (1) and tighten it (2).

340-1560-12.65-97

Connecting the connection cable (view: driver's seat; right)

ƒ Guide the connecting cable (1) over the

lever arm.
ƒ Fasten in place later with corrugated hose
holders (2).

340-1560-12.65-98

Laying the connecting cable on lever arm (view: lever arm;

right)

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 5 Installation of generator

1 ƒ Guide the connection cable (1) down from

the lever arm and to the right to the fasten-
ing console (3).
2
2 ƒ Fasten in place later with corrugated hose
holders (2).
ƒ Guide it down and fasten with corrugated
3
hose holder (4) on the fastening console.
ƒ Guide it through the opening (5) on the
floor in the direction of the drive engine.
5 4

340-1560-12.65-33

Connecting cable from the lever arm (view between hydraulic

oil tank and lever arm)

ƒ Guide the connection cable (1) under the

diesel engine around the batteries.
ƒ Fasten in place later with corrugated hose
holders (2).

2 1

340-1560-12.65-34

Connecting cable around the batteries (view: service ladder;

left)

ƒ Guide the connection cable from the bat-

3 teries (1) down under the service ladder.
4 ƒ Guide the connection cable around the
corner (3).
2
ƒ Fasten in place later with corrugated hose
holders (2) and (4).

340-1560-12.65-35

Connection cable under the service ladder (view: batteries;

right)

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5 Installation of generator

ƒ Guide the connection cable (1) under the

1 service ladder in the direction of the gen-
erator (3).
ƒ Fasten in place later with corrugated hose
holder (2).

3
340-1560-12.65-32

Laying the connecting cable to the generator (view: service

ladder; underneath)

ƒ Lay the connecting cable (1) to the gen-

2 erator.
ƒ Fasten in place with corrugated hose
holder (2).
1

340-1560-12.65-31

Laying the connecting cable to the generator (view: service

ladder; underneath)

ƒ Insert the plug (1) into the generator.

ƒ Secure the plug with safety clip (2).
2 ƒ Close all corrugated hose holders and
fasten the connection cable with cable
ties.
1

340-1560-12.65-30

Connection cable inserted (view: service ladder; underneath))

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 5 Installation of generator
5.8 Attaching and connecting the coupler socket

Have these parts ready:

2 1) Magnet cable
1 2) Coupler socket with screws
3 4 3) Harting connector
4) Corrugated hose holders
5 5) Cable screw connection
6) Screws for corrugated hose holders
6 7
7) Plug inserts
8 9 8) Cover for corrugated hose holders
340-1560-12.65-99
9) Cable ties
Add-on kit for magnet connection

2 1 Laying the magnet cable over the boom to

the coupler socket

j WARNING
3
Danger due to cable ends with
sharp edges
• Tape off the cable end with
insulating tape before laying it.
In emergency: Provide first aid.
Consult a doctor immediately.

ƒ Roll out the magnet cable and lay it on the

340-1560-12.65-88
340-1560-12.65-XX
boom so that the cable end is lying in the
Lay out the magnet cable on the boom (view: service ladder;
right) direction of the generator without contacts
(3).
ƒ Insulate the cable end (3) for your own
safety.
ƒ Align the magnet cable so that the white
mark (1) is located approximately opposite
the fastening for the lubrication lines (2).

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5 Installation of generator

ƒ Open the hose bracket (4) enough to push

4 the magnet cable through.
ƒ Guide the magnet cable (1) onto the
boom.
ƒ Fasten the magnet cable onto the connec-
3
tion bar later with the corrugated hose
holder (2) and onto the hydraulic hose (3)
1 with cable ties.
ƒ Close the hose bracket later.
2
340-1560-12.65-67
340-1560-12.65-XX

Magnet cable to the boom (view: service ladder; right)

ƒ Slightly open the hose bracket (4).

ƒ Guide the magnet cable (1) from the hose
bracket (3) through the hose bracket (4).
4 ƒ Fasten the magnet cable onto the hydraulic
hose later with cable ties (2).
1
2 ƒ Close the hose bracket later.
3

340-1560-12.65-XX
340-1560-12.65-68

Magnet cable to the boom (view: service ladder; right)

4 ƒ Slightly open all hose brackets (2).

ƒ Lay the magnet cable (1) over the boom to
the dipperstick.
ƒ At the transition to the dipperstick, guide
the magnet cable to the center of the stick
(4).
ƒ Fasten the magnet cable on the hydraulic
hose and the line with cable ties (3) later.
ƒ Close the hose bracket later.

3 1

340-1560-12.65-69
340-1560-12.65-XX

Magnet cable over boom (view: service ladder; right)

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 5 Installation of generator

ƒ Slightly open the hose bracket (2).

1 ƒ Lay the magnet cable (1) further to the
2 center on the dipperstick (3).
ƒ Fasten the magnet cable on the hydraulic
hose with cable ties (4) later.
4
ƒ Close the hose bracket later.
3

340-1560-12.65-70
340-1560-12.65-XX

Magnet cable on dipperstick (front view)

ƒ Slightly open the hose bracket (2).

ƒ Lay the magnet cable (1) over the dipper-
stick.
ƒ Fasten the magnet cable on the line (3)
3 with cable ties (4) later.
2
1
ƒ Close the hose bracket later.
4

340-1560-12.65-XX
340-1560-12.65-71

Magnet cable over dipperstick (front view)

ƒ Slightly open the hose bracket (3).

1 ƒ Lay the magnet cable (1) behind the lines
2 (2) in loops so that there is enough length
remaining to connect the coupler socket
later.

340-1560-12.65-100

Magnet cable in the upper dipperstick area (front view)

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5 Installation of generator

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

1 2 perstick (2).
ƒ 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.

340-1560-12.65-101

Magnet cable to the coupler socket (front view)

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 5 Installation of generator

Attaching the coupler socket

3 Depending on the generator type/connection
cable, the cable connection (2) built into the
2 4 coupler socket (1) may have to be converted.
If conversion is required:
5
ƒ Remove the cable connection (2).
ƒ Coat the threading of the reducer (5) with
Loctite 572 (3) and screw it in.
ƒ Coat the threading of the smaller cable
connection (4) with Loctite 572 and screw
it in.
1

340-1560-12.65-102

Preparing the coupler socket

ƒ Fasten the coupler socket (2) onto the

dipperstick (1) with fastening screws (6).
6
ƒ Remove the swivel nut (3) and push it over
5 the magnet cable.
1 2 ƒ Remove the fastening screws (5) from the
4 cover cap (4).
ƒ Remove the cover cap and push it over
the magnet cable.
3

340-1560-12.65-103

Setting the coupler socket in place (front view; right)

ƒ Insert the fastening screw with washer (2)

into the clamping plate (3) and place
2 3 against the cable end (1) as shown here.
Make certain the cable end is resting with
its contact area (4) completely level
4 against the contact place (5).
1

340-1560-12.65-104

Cable end clamping

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5 Installation of generator

ƒ To tighten the cable ends:

(1): Yellow/Green
(2): Black and gray
(3): Brown and blue
2

340-1560-12.65-105

Assignment of cable ends

ƒ Retighten the cover cap (1).

ƒ Retighten the swivel nut (2).

340-1560-12.65-106

Attached coupler socket

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 5 Installation of generator

Laying the magnet cable from the boom to

the generator
ƒ Guide the cable end (1) down between the
connection bar (2) and swivel motor (3).
1
2

3
340-1560-12.65-50

Lay the magnet cable from the boom down (view: service
ladder; right)

ƒ Guide the cable end (1) onto the floor (3)

1 and from there around the swivel motor
(2).

3
340-1560-12.65-49

Magnet cable around the swivel motor (view: service ladder; right)

ƒ Guide the magnet cable (1) coming from

the swivel motor (2) to the access hole (4).
2
ƒ Guide the magnet cable through the ac-
3 cess hole to the bottom of the service lad-
4 der (3).
1

340-1560-12.65-48

Magnet cable into the access hole (view: service ladder; right)

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5 Installation of generator

ƒ Guide the magnet cable coming out of the

2 access hole (1) along under the service
ladder (2).
1

340-1560-12.65-45

Magnet cable coming out of the access hole

ƒ Guide the magnet cable (1) along under

the service ladder.
ƒ Fasten in place with corrugated hose
holders (2) later.
2
1

340-1560-12.65-43

Magnet cable under the service ladder

1 ƒ Guide the magnet cable (1) under the ser-

vice ladder and around the corner in the
direction of the generator (3).
ƒ Fasten in place with corrugated hose
2 holders (2) later.

3
340-1560-12.65-40

Magnet cable under the service ladder to the generator

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 5 Installation of generator

ƒ Guide the magnet cable (1) out of the

opening (2) in the uppercarriage to as-
semble the Harting connector.
1

2
340-1560-12.65-42

Guiding the magnet cable out

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5 Installation of generator

,
Installing the Harting connector
1 2 ƒ Screw the cable screw connection (1) into
the plug housing (2).
ƒ Push the plug inserts (3) into the support
(4).
ƒ Loosen the swivel nut on the cable con-
nection (1) and push it over the magnet
cable.
4 3 ƒ Guide the magnet cable through the cable
connection (1) into the plug housing (2).

340-1560-12.65-107

Harting connector

ƒ Guide the cable ends into the plug inserts.

1 2 (1): Brown
(2): Blue
3 (3): Green/Yellow
(4): Gray
5 4
(5): Black

340-1560-12.65-108

Cable assignment for Harting connector

ƒ Tighten all cable ends.

340-1560-12.65-109

Screwing the cable ends onto the plug insert

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 5 Installation of generator

ƒ Fasten the support (2) in the plug housing

4 1 (1) with the fastening screws (3).
ƒ Tighten the swivel nut (4).

340-1560-12.65-110

Assembled Harting connector

Inserting the Harting connector

2
n DANGER
Electrical shock causing death
1 • Do not insert the magnet cable
until the coupler socket has al-
ready 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
340-1560-12.65-39 immediately.
Laying the magnet cable away from the generator (view: ser-
vice ladder; bottom))
ƒ Insert the plug (1) into the generator.
ƒ Secure the plug with safety clip (2).

ƒ Form the magnet cable into a compensa-

tion loop (1).
ƒ Fasten in place with corrugated hose
holder (2).
2 1
ƒ Fasten with cable ties (3).
ƒ Fasten the magnet cable to the boom with
corrugated hose holders and cable ties.
3

340-1560-12.65-66
340-1560-12.65-XX

Magnet cable with compensation loop (view: service ladder;

underneath)

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5 Installation of generator

Checking the magnet cable

ƒ Check to make certain machine move-
ments could not cause the magnet cable
to come under tension or be squeezed.
ƒ Check whether all hose brackets are
closed and the magnet cable is adequately
fastened with cable ties.

5.9 Inserting the air hose (13 kW generator only)

ƒ If it has not been done, remove the cover

plate.
2 3 h on page 15: cover plate
ƒ Press the air hose (1) together.
ƒ Push the air hose through between the
uppercarriage (2) and generator plate (3).
1

340-1560-12.65-58

Inserting the air hose (view: service ladder; bottom)

ƒ Align the air hose (1) so that it is resting

evenly on the protective grating of the
generator (2).
ƒ Reinstall the cover plate.
2

340-1560-12.65-57

Aligning the air hose (view: service ladder; bottom)

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 5 Installation of generator
5.10 Variations for multi-purpose stick (option)

Laying the magnet cable over the boom to

4 the coupler socket
Cable routing varies somewhat for machines
with an optional multi-purpose stick.
3 ƒ Connect the magnet cable to the genera-
tor as described for standard machine and
lay it to the boom.
h on page 35: Attaching and connecting
2 1 the coupler socket
340-1560-12.65-51 ƒ Open the hose bracket (4) enough to push
Magnet cable to the boom (view: service ladder; right) the magnet cable through.
ƒ Guide the magnet cable (1) onto the
boom.
ƒ Fasten the magnet cable onto the connec-
tion bar later with the corrugated hose
holder (2) and onto the hydraulic hose (3)
with cable ties.
ƒ Close the hose bracket later.

ƒ Slightly open the hose bracket (4).

ƒ Guide the magnet cable (1) from the hose
4 bracket (3) through the hose bracket (4).
ƒ Fasten the magnet cable onto the hydrau-
lic hose later with cable ties (2).
2 1 ƒ Close the hose bracket later.
3

340-1560-12.65-53

Magnet cable to the boom (view: service ladder; right)

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5 Installation of generator

4 ƒ Slightly open all hose brackets (2).

ƒ Lay the magnet cable (1) over the boom to
the dipperstick.
ƒ At the transition to the dipperstick, guide
the magnet cable to the center of the stick
2 (4).
ƒ Fasten the magnet cable on the hydraulic
hose and the line with cable ties (3) later.
ƒ Close the hose bracket later.
3 1

340-1560-12.65-54

Magnet cable over boom (view: service ladder; right)

ƒ Slightly open the hose bracket (2).

ƒ Lay the magnet cable (1) further to the
1
center on the dipperstick (3).
2 ƒ Fasten the magnet cable on the hydraulic
hose with cable ties (4) later.
4 ƒ Close the hose bracket later.
3

340-1560-12.65-XX
340-1560-12.65-72

Magnet cable on dipperstick (front view)

ƒ Slightly open the hose brackets (3) and

5 (5).
1 ƒ Lay the magnet cable (1) behind the lines
4 (4) in loops so that there is enough length
remaining to connect the coupler socket
later.
ƒ Set the hose clamp (2) in place and guide
3 the magnet cable through the hose
2 bracket (3) to the clamp and then further
down.
340-1560-12.65-73
340-1560-12.65-XX
ƒ Fasten the magnet cable with cable ties
Magnet cable in the upper dipperstick area (front view)
later.
ƒ Close the hose bracket later.

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 5 Installation of generator

ƒ Guide the magnet cable (1) to the coupler

1
socket (2).
ƒ After the coupler socket (2) is connected,
2 close all hose brackets and fasten the
magnet cable with cable ties.

340-1560-12.65-74
340-1560-12.65-XX

Magnet cable to the coupler socket (front view)

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5 Installation of generator
5.11 Deviations for "Quick Connect" equipment

For machines with optional "Quick Connect"

1 2
equipment, a magnet plug and magnet
socket must be attached and connected at
the coupling point.
Have these parts ready:
1) Magnet cable for generator
5 4 3 2) Magnet cable for coupler socket
3) Magnet socket with small parts
4) Magnet plug with small parts
5) Counter nut
6 6) Spiral protector
340-1560-12.65-111

Additional parts required for Quick Connect

Laying the magnet cable over the boom to

the coupler socket
4 Cable guiding deviates somewhat for ma-
chines with an optional multi-purpose stick.
ƒ Connect the magnet cable to the genera-
tor as described for standard machine and
lay it to the boom.
3 h on page 35: Attaching and connecting
the coupler socket
ƒ Open the hose bracket (4) enough to push
the magnet cable through.
1
2 ƒ Guide the magnet cable (1) onto the
boom.
ƒ Fasten the magnet cable onto the connec-
340-1560-12.65-XX
340-1560-12.65-77
tion bar later with the corrugated hose
Magnet cable to the boom (view: service ladder; right) holder (2) and onto the hydraulic hose (3)
with cable ties.
ƒ Close the hose bracket later.

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 5 Installation of generator

3 ƒ Open the hose bracket (5) enough to push

the magnet cable through.
2 ƒ Guide the magnet cable (1) under the
safety filters (3).
ƒ Fasten the magnet cable onto the hose
bracket later with a clamp (2) and onto the
hydraulic hose (4) with cable ties.
ƒ Close the hose bracket later.

340-1560-12.65-78
340-1560-12.65-XX

Magnet cable on the boom to the safety filter (view: service

ladder; right)

ƒ Open the hose bracket (2) and (5) enough

5
to push the magnet cable through.
ƒ Guide the magnet cable (1) to the dipper-
4
stick. Lay a loop to compensate for extra
length (3).
ƒ Fasten the magnet cable on the line with
cable ties (4) later.
ƒ Close the hose bracket later.

2
340-1560-12.65-79
340-1560-12.65-XX

Magnet cable to the boom (view: service ladder; right)

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5 Installation of generator

ƒ Open the hose brackets slightly (3) - (4)

and lay the magnet cable (1) to the stick
4 base.
ƒ Fasten the magnet cable onto the hydrau-
lic hose later with cable ties (4).
ƒ Close the hose brackets later.
1

3
340-1560-12.65-XX
340-1560-12.65-80

Magnet cable to the stick base (view: service ladder; right)

1 ƒ Cut through the protective tube on the

5 magnet cable (1) at the height of the
counter nut so that the cable insulation is
2 not damaged and remove it.
ƒ Attach the counter nut (5) on the beam (2).
ƒ Lead the magnet cable through the
counter nut (5).
ƒ Slightly open the hose bracket (3).
ƒ Push the protective tube back onto the
3 magnet cable.
ƒ Lay the magnet cable (1) behind the lines
in a loop towards the opening (4) so that
there is enough length remaining to con-
nect the magnet socket later.
4

340-1560-12.65-112

Magnet cable on the stick base (front view)

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 5 Installation of generator

1 ƒ Lead the magnet cable (1) out of the open-

ing to the hydraulic cylinder unit (2).
ƒ After the magnet socket is connected,
close all hose brackets and fasten the
magnet cable with cable ties.

340-1560-12.65-113

Magnet cable to the hydraulic cylinder unit (front view)

1 Preparations for the magnet socket

The illustration shows the parts for the mag-
net socket. The magnet plug is similar and
2 must be placed ready as well.
3
1) Magnet socket housing
2) Fastening screws for magnet socket on
dipperstick
4 3) Terminal screws for housing
4) Clamping screws and nuts for housing
6 5 5) Cable clamp
6) Contacts (with fastening screws)
340-1560-12.65-114

Parts required for magnet socket

ƒ Screw the cable ends (3) onto the contacts

1
(1) with fastening screws (2).
Make certain while doing this that the ca-
ble end is resting evenly on the contact
2
and that the fastening screw covers the
cable end on all sides.
3

340-1560-12.65-115

Cable end clamping

12.65-SA10403-en-110808 Version 11.08.2008 53 (60)

5 Installation of generator

ƒ Insert the contacts (2) into the housing (1):

1 2 (3): Brown and blue
(4): Yellow/Green
(5): Black and gray
3 4 5 ƒ Press the cable with sealing ring (6) into
the profile in the housing designed for that
7
purpose.
6 ƒ Apply silicon to the connection points of
the housing and around the contacts (7).
ƒ Put the housing together and screw the
340-1560-12.65-81 connections tight.
Assembling the magnet socket

Attaching the magnet socket

ƒ Fasten the magnet socket (1) on the hy-
1 2
draulic cylinder unit (2) of the stick base
(4) with the fastening screws (3).
3

340-1560-12.65-83

Magnet socket on the stick base

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 5 Installation of generator

Laying the magnet cable from the magnet

socket to the coupler socket
ƒ Lay the magnet cable (2) in the stick head
(1) under the hose bracket (3).
4
1 ƒ Guide the magnet cable through the open-
ing out of the stick head (4).

340-1560-12.65-116

Magnet cable to stick head

Attaching the magnet plug

1 3
ƒ Guide the magnet cable from below
through the support (3).
2
ƒ Connect the magnet plug with the magnet
cable as described for the magnet socket.
h on page 53: Preparations for the mag-
net socket
ƒ Fasten the magnet plug (1) with the fas-
tening screws (2).

340-1560-12.65-117

Magnet plug on the stick head

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5 Installation of generator

Attaching the coupling plug

3 ƒ Wrap the cable end from the coupler sock-
et to the stick head with coil (2).
ƒ Attach the coupler socket as described for
the standard version.
h on page 39: Attaching the coupler
socket
1
ƒ Equalize the cable length with a loop un-
der the cover (3).
2

340-1560-12.65-118

Coupler socket on stick head

Fastening the magnet cable

ƒ Close all hose brackets.
ƒ Fasten the magnet cable with cable ties.

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 5 Installation of generator
5.12 Configuring the electronics

ƒ The enable code is indicated with the

scope of parts delivered.
ƒ Enable the option.
h More information: Service documenta-
tion

340-1560-12.65-119

Entering the enable code

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6 Commissioning
6 Commissioning
6.1 Checks before switching on WARNING! Unpredictable movements
are possible.
n DANGER ƒ Increase the load incrementally.
Danger of fatal injuries – electri- ƒ After 30 minutes, switch off the engine and
cal shock allow it to cool off.
• Have the electrical functioning
capability of the magnet system
ƒ Bring the machine to a safe state.
and protective conductor h Preparations: on page 12
checked by an electronics spe-
cialist. ƒ Check the clamping chuck.
In emergency: Provide first aid. h clamping chuck: on page 20
Consult a doctor immediately.
ƒ Adjust the belt tension.
ƒ Check safety devices. h Tensioning V-belts: on page 27

6.2 Starting operation of magnet system ƒ Check the magnet cable and its fastening
for incorrect tension and damage.

j WARNING ƒ Connect the magnet plate and place it in

operation.
Danger of injury by uncon-
trolled machine movements h These Service Instructions do not cover
• Personally make sure that no the magnet tool. Commissioning must be
other people stand in the area. performed as described by the manufac-
• Consider possible collisions. turer.
• Always expect that the machine
operates faulty or incorrectly af-
ter repair work.
• In the event of any abnormal
machine movements, switch off
machine immediately and iden-
tify cause.
In emergency: Provide first aid.
Consult a doctor immediately.

ƒ Close all accesses. Place covers and

plates in place.
ƒ Reinstall battery disconnect switch and
ensure power supply.
ƒ Start engine.
ƒ Turn on the generator.
ƒ After the engine has run for a short time,
turn it off.
ƒ Bring the machine to a safe state.
h Preparations: Preparations on page 12
ƒ Check the V-belt to ensure it is well
seated.
ƒ Switch on the engine again and turn on
the generator.
ƒ Slowly perform the various work move-
ments under low load. Observe the mag-
net cable as you do so.

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

 7 Appendix
7 Appendix
7.1 Technical data

Designation Weight [kg] Remark

Generator

13 kW / 20 kW approx. 130 kg

7.2 Tightening torques for screw connections

Tightening torques TMA [Nm] NOTICE

8.8 10.9 12.9 The specified tightening torques apply for
screwed connections for which no values have
M 4 x 0.7 3.0 4.4 5.1 been indicated in the Service Instructions, Op-
erating Instructions or the documentation of the
M 5 x 0.8 5.9 8.7 10 component manufacturer.
M 6 x 1.0 10 15 18

M 8 x 1.25 25 36 43

M 10 x 1.5 49 72 84

M 12 x 1.75 85 125 145

M 14 x 2.0 135 200 235

M 16 x 2.0 210 310 365

M 18 x 2.5 300 430 500

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

7.3 Measuring instrument for V-belt tension

Measuring instrument "Optik 1" manufactured

by "Optibelt" for measuring V-belt tension.

340-1460-12.65-120

Measuring instrument for V-belt tension

12.65-SA10403-en-110808 Version 11.08.2008 59 (60)

8 Index
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-110808

Hauptverwaltung / Verkauf / Kundendienst
Head Office / Sales / After Sales Service
Sièges Administratif / Vente / Service Après-Vente

Terex Deutschland GmbH

Geschäftsbereich Terex Fuchs
76669 Bad Schönborn
GERMANY

Fon.: ++49 (0) 72 53 / 84-0

Fax: ++49 (0) 72 53 / 84 411
E-Mail: Info@fuchs-terex.de
www.terex-fuchs.de
www.terex.com