property of american airlines · if you have a question if you have any question regarding the...

Lower Deck Loader

CHAMP70W

Maintenance Manual

Docu-No.: 6110825-826_WA_en(us)

For CHAMP70 Service PersonnelPro

perty

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PALLET CONTAINER LOADER CHAMP70

Published by

TREPEL Airport Equipment GmbH

Sales/Marketing

Customer Service

Hagenauer Str. 42

D-65203 Wiesbaden

Telephone: +49 (6 11) 880 88-0

Telefax: +49 (6 11) 880 88-11

E-mail: [email protected]

Internet: http://www.trepel.com

Plant/Purchasing

Administration

Hochhäuser Str. 18

D-97941 Tauberbischofsheim

Telephone: +49 (93 41) 899-0

Telefax: +49 (93 41) 899-339

E-maill: [email protected]

Docu-No.

6110825 - 6110826_WA_en (us)

Date issued

18.05.2015

California Proposition 65 Warning California Proposition 65 Warning

Diesel engine exhaust and some of its consti-tuents are known to state of California to cause cancer, birth defects and other repro-ductive harm.

Battery posts, terminals, and related accesso-ries contain lead and lead compounds, che-micals known to the state of California to cause cancer and reproductive harm. Wash hands after handling.

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Copyright

© 2015 TREPEL Airport Equipment GmbH

This documentation, including all of its parts and chapters is the intellectual property of TREPEL Airport Equipment GmbH and is copyright-protected by national and international laws.

Any use or modification of this documentation or its contents or of parts of the documentation outside of the confines of the copyright law is not permitted without the written approval by TREPEL Airport Equipment GmbH and is liable to prosecution. This is valid in particular for copying, translating, micro-filming, and the storage and processing in electronic systems. All rights reserved. Infringe-ments of these provisions will be prosecuted.

TREPEL Airport Equipment GmbH will not assume liability for damages due to unauthorized use of the contents in the documentation by natural persons or corporate bodies. TREPEL Airport Equip-ment GmbH reserves the right to change this documentation at any time.

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Warranty

(a) With respect to all products provided to American hereunder, Supplier warrants that such pro-ducts will (i) conform in all respects to the applicable specifications and drawings, (ii) be free from all defects, whether patent or latent, in materials, design and workmanship, and (iii) be free and clear of and from all liens, charges and encumbrances of any kind or nature whatsoever caused by or ari-sing by, through or under Supplier. This warranty is valid as to any product or part for the longer of four (4) years or 4500 operating hours, whichever occurs first, after commissioning thereof. The war-ranty will include all rotable parts but not include expendable parts such as filters, tires, etc.

(b) In the event of any breach of the warranty set forth above (a "Defect"), American shall repair the product containing the Defect, all at Supplier's sole cost and expense (including parts). Supplier shall be responsible for the labor expenses incurred by American in the repair of the product at a rate of $35.00 per hour, to be adjusted annually on January 1 of each year commencing from the third year, and for parts used by American for the repair at American's cost. The percentage adjustment to the rate shall correspond to the adjustment to the fully-allocated labor rate published in American's Main-tenance & Engineering Plans Book, the relevant portions of which Supplier will be allowed to review upon request. This reimbursement shall be in the form of a credit or check to American's account and shall be made within thirty (30) days of the notice to Supplier detailing the charges and expen-ses. If the product is not repairable it shall be replaced with a new product.

(c) Supplier shall not be liable under the warranty set forth above for any Defect resulting from a pro-duct having been exposed or subjected, after delivery to American, to:

(i) Any alteration, modification, maintenance, repair, installation, handling, transportation, sto-rage, operation or use that is not in compliance with Supplier's instructions or is otherwise improper, unless caused by Supplier;

(ii) Any accident, contamination, foreign object damage, abuse, neglect or negligence, unless caused by Supplier; or

(iii) Any damage precipitated by any part not supplied by Supplier.

(d) The warranty set forth above shall only apply to products provided by Supplier to American under this Agrement and is in lieu of all other express or implied warranties of Supplier to American with respect to such products, including the implied warranties of merchantability and of fitness for a par-ticular purpose. Without limiting or otherwise adversely affecting Supplier's liability for secondary or resultant damage resulting or arising from adefect or any right or remedy expressly granted or reser-ved to American herein, in no event shall Supplier be liable to American for special or consequential damages sufferedor incurred by American in connection with this Agreement under any contract, tort, strictliability or other theory, excluding gross negligence, recklessness or willful misconduct.

(e) Supplier further warrants that in the 5th year or after the 4500 hours, whichever occurs first, after commissioning of any loader unit (after the warranty has expired), the maximum cost to repair any loader unit will not exceed $2000.00. Should repair of any unit exceed this amount, Supplier will cre-dit American the difference. This includes both parts used and labor expenses as set forth above.

(f) Supplier will invoice American for all warranty replacement parts that are supplied for American installation. American shall be entitled to full or part credit against the cost of such part orther than transportation charges, upon the return of the failed part and determination by the Supplier that such failure is covered by warranty. Such invoice shall be payable in full unless the failed part is returned within thirty (30) days after invoice date.

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IF YOU HAVE A QUESTION

If you have any question regarding the applicable warranty on your Aircraft Ground Support Equip-ment contact:

TREPEL Airport Equipment GmbHHagenauerstraße 4265203 WiesbadenGermany+49 611 880 88-0

Any problems that cannot be resolved by Owner after discussion with the service representative per-forming repairs should be referred to the Managing Director of TREPEL Airport Equipment GmbH, at the above address.

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PUSHBACK TRACTOR CHALLENGER150

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Chapter/Section Page

Maintenance and RepairLOWER DECK LOADER CHAMP 70

TABLE OF CONTENTS

CHAPTER 4MAINTENANCE AND REPAIR

Servicing 4-1 1

1. About this Manual 1A. General 1B. Additional Documents 2C. Characters and Symbols Used 3

2. General Safety Instructions 4A. Intended use 4B. Qualifications for Service Personnel 5C. Safety Gear for Service Personnel 5D. Danger area 6E. Safety regulations 7

3. Maintenance and Repair 16A. Maintenance schedule 16B. Tools and specialized tools 28C. Secure raised platform 30D. Lubricating points 34E. Oil level checks 45F. Maintenance on the motor 55G. Maintenance on Wheels/Axles/Steering/Brakes 60H. Maintenance on the platforms / transport system 76I. Maintenance of the hydraulic system 79J. Maintenance of the electrical system 129

4. Operational Materials 149A. Safety Information 149B. Fuels 151C. Oils for Equipment Units 153D. Lubricating Greases 156

Troubleshooting 4-2 1

1. Troubleshooting 1A. Tasks before troubleshooting 1B. Troubleshooting Table 2

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Page 2(Blank) May 18/154-CONTENTS

Maintenance and Repair LOWER DECK LOADER CHAMP 70

Section 1Servicing

1. About this Manual

Before servicing or repairing the CHAMP 70, please carefully read the relevant sections in this manual.Always observe the safety instructions (see Subsection 2 "General Safety Instructions", page 4).

A. General

This maintenance manual should help you become familiar with the routine maintenance work on the CHAMP 70.

This maintenance manual contains important information on the safe and proper servicing of the CHAMP 70.

This maintenance manual should help you with any repair you may have to perform on the CHAMP 70.

Observe these instructions in order to:

• Avoid dangers.• Reduce repair costs and downtime.• Increase the reliability and operating life of the CHAMP 70.

This manual only describes maintenance and repair work on the CHAMP 70 that may be performed by the operating company's service personnel.

Maintenance and repair work on CHAMP 70 not described in this manual may only be carried out by TREPEL's customer service staff.

A copy of the maintenance manual must be available to the service personnel at all times.

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B. Additional Documents

In addition to this maintenance manual, you also receive the following documents for the CHAMP 70:

• Instruction Manual• Emergency operating measures• Transport instruction manual• Factory settings/production test documents• Hydraulic diagrams• Connection diagrams• Operating manual/spare parts (motor)• Maintenance/spare parts list (front axle)• Manufacturer's information for purchased parts (non-OEM parts).• Spare parts lists

Service address of our customer service:

Hagenauer Str. 42

D-65203 Wiesbaden

Phone: +49 (6 11) 880 88-0

Fax: +49 (6 11) 880 88-11

e-mail: [email protected]

Internet: http://www.trepel.com

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C. Characters and Symbols Used

Pictographs

All of the pictographs used on the CHAMP 70 are based on internationally accepted IATA proposals.

The meanings of the pictographs are explained in the instruction manual.

Symbols

Symbols for the maintenance

Symbol Meaning

Dangers to persons. Non-observance leads to death or serious injury.

Dangers to persons. Non-observance may lead to death or serious injury.

Dangers to persons. Non-observance may lead to injury.

Risks of property damage.

Necessary measures for avoiding a danger.

(1) (2) ...

Step-by-step guide.Please observe the order of the steps to be taken.

INFORMATION Information for better understanding or for optimizing the workflow.

Symbol Meaning

Lubrication of the lubricating nipples with the grease gun.

Lubrication of sliding surfaces with a brush.

Spraying the chains with chain spray.

Oiling of movable components with the oil can.Prope

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2. General Safety Instructions

The following contains a summary of all important safety instructions for repairing and servicing theCHAMP 70.

All personnel who service, repair or work on the CHAMP 70 must read and implement these safetyinstructions.

Furthermore, all other accident prevention regulations in this manual, Occupational Safety und HealthAdministration (OSHA), environmental protection regulations and all other federal, national and regionalregulations and laws that are effective at the place of operation must be observed at all times.

Never operate the CHAMP 70 when under the influence of alcohol, drugs, or medication. Some medica-tions may impair your ability to safely operate the CHAMP 70. Please consult your doctor and inform theshift manager if you are taking medication.

A. Intended use

The CHAMP 70 is intended for loading and unloading cargo from high-capacity aircraft:

• LD containers in lower deck cargo bays• 10-ft units at heights of up to 3.7 m (12 ft).

The CHAMP 70 may be operated at wind speeds of up to 20 m/s (40 knots, 45 mph).

Cargo may be dispatched at a lifting height of up to 3.7 m (12 ft).

The maximum specified container weights may not be exceeded.

Table 1: Container weights

The CHAMP 70 may

• not be driven while loaded with cargo.• not be driven long distances (> 10 km, approx. 6 miles).• not be used for transporting persons.• not be used as a lifting or working platform.• not be used as an elevator for cargo/loading personnel.

Container Max. weight

LD container 1,700 kg (3,752 lb)

10-ft unit 6,800 kg (15,000 lb)

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B. Qualifications for Service Personnel

The CHAMP70 may only be serviced or repaired by personnel qualified and authorized to do so.

Service personnel must

• be at least 18 years of age, as far as no other federal, state or regional laws or any otherapplicable laws dictate a different minimum age.

• Possess the physical and mental capabilities required to drive an automotive vehicle.• Have received instruction in and be able to perform First Aid.• Know the accident prevention regulations and safety instructions of the airport and be able to

apply them.• Know the traffic rules of the airport runways and be able to apply them.• Possess good knowledge regarding the layout of the airport runways.• know the locations of the airport runways and roads as well as the safety areas that the

CHAMP 70 may not drive on.• have received theoretical and practical training on the CHAMP 70.• Be a trained electrician or equivalent.• Understand hydraulic systems, recognize the risks and be able to avert them.• Be a trained industrial mechanic or equivalent.• Understand and be able to use the instruction manual.• Understand and be able to apply the Emergency Operating Measures.

Never operate the CHAMP 70 when under the influence of alcohol, drugs, or medication.

C. Safety Gear for Service Personnel

The CHAMP 70 service employee is obliged to wear the personal safety gear provided by the oper-ating company.

The personal safety gear consists of at least:

• Clearly visible work clothing• Head protection• Hearing protection• Work gloves• Safety boots with steel toes• Safety goggles

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D. Danger area

When servicing or repairing, no other persons should be located within the danger area of the CHAMP 70 apart from service personnel.

No other objects should be located within the danger area of the CHAMP 70 apart from the tools and work implements.

Figure 1: Danger area CHAMP 70

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E. Safety regulations

General

Danger of tipping!

In case of high wind speed and simultaneous raised bridge or elevator there exists the danger of tipping the CHAMP 70.

The CHAMP 70 may be operated at wind speeds of up to 20 m/s (40 knots, 45 mph).

Danger of tipping!

When driving with cargo, the danger exists that the cargo can fall off the platform. Furthermore, there exists the danger of tipping the CHAMP 70 if the cargo on the platform shifts from its intended position.

Do not drive the CHAMP 70 while loaded with cargo.

Danger of explosion and fire!

Fuels are easily inflammable and explosive

Smoking is strictly prohibited in the danger area of the CHAMP 70

No open flames or lights in the danger area of the CHAMP 70.

Falling objects!

Objects loaded on the platforms can fall when raising and lowering the platforms.

No other objects or cargo may be located within the danger area of the CHAMP 70 apart fromthe tools and work implements.

Continued rolling of the CHAMP 70!

If the parking brake is not engaged after shutting off the motor or exiting the driver's stand, the CHAMP 70 can continue rolling unintentionally and roll over persons.

The operator has to engage the parking brake before leaving the driver's stand.

The parking brake has to be engaged whenever the CHAMP 70 is stopped or shut down.

Additionally place blocks under the wheels during maintenance work.Pro

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Untrained personnel!

Uncontrolled movements of the CHAMP 70 as a result of operator errors can lead to life threaten-ing injuries or even death.

The service personnel has to know all of the operating and display elements and be able to operate them.

Disregarding the regulations!

Disregard of the regulations and instructions can lead to life threatening injuries or even death.

Observe all valid accident prevention regulations and instructions.

Observe all valid airport safety regulations and instructions in regard to the runways.

Observe all airport regulations and work instructions.

Observe all of the local airport safety and work regulations applicable to the work places for maintenance and repair activities.

Missing protective clothing!

If the service personnel doesn't wear the mandatory personal protective clothing, this can lead to life threatening injuries or even death.

The service personnel must wear the required safety gear prescribed by law, work regulations or common sense to be protected from predictable injuries.

Consumption of alcohol, drugs, or medication!

The use of alcohol, drugs or medication can severely impair the ability to operate the CHAMP 70.

The use of alcohol, drugs and medications is strictly prohibited at all times.

Property damage!

Due to its low ground clearance, the CHAMP 70 can be damaged if driven on uneven traffic routes.

The CHAMP 70 may only be driven in permitted airport areas and on permitted traffic routes in accordance with local airport regulations.

Other traffic routes may not be used under any circumstances!Prope

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Maintaining the operating safety of the CHAMP 70

Operating safety!

Improper maintenance and repair work can endanger the operating safety and functionality of the CHAMP 70. This can lead to life threatening injuries and even death.

The operator is not to perform any maintenance or repair work.

Maintenance and repair work may only be performed by trained qualified technicians author-ized for this.

All maintenance and repair instructions of the manufacturer or from manufacturers of other components and subassemblies must be strictly adhered to.

Structural changes!

Structural changes can endanger the operating safety and functionality of the CHAMP 70. This can lead to life threatening injuries and even death.

No structural changes may be made to the CHAMP 70.

Only use original spare parts.

Any retrofitting or modification on the CHAMP 70 that was not authorized and not previously permitted in writing by Trepel Airport Equipment GmbH automatically voids all warrantee obli-gations by the manufacturer.

Prior to maintenance work

Danger of tipping!

If the CHAMP 70 is parked on uneven or unsecured surfaces there exists the danger of tipping the CHAMP 70.

Only park the CHAMP 70 on secure and even surfaces.

Inspect the stability of the CHAMP 70 before work or before a shift change.

Safety measures!

Missing safety measures endanger the service personnel during the maintenance work.

Secure the CHAMP 70 from rolling away.

No cargo is located on the platform.

Lower both platforms entirely.

Secure the platform against unintended lowering before working underneath the platform.

Switch off motor.

Switch off main battery switch.

Secure against unintended use.

Attach a "Maintenance Work" warning sign.

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Rolling CHAMP 70!

If the parking brake is not engaged, the CHAMP 70 can roll and run over service personnel.

Ensure that the parking brake is engaged during maintenance work.

Ensure that blocks have additionally been placed under the wheels during maintenance work.

Running over persons!

When the motor is running, the CHAMP 70 can suddenly run over service personnel.

Always engage the parking brake or place blocks under the wheels.

While the engine is running, a person must be present on the driver's stand or at the switch cabinet to monitor the CHAMP 70 and to be able to press the emergency off button in case of an emergency.

Lowering platform!

During work on the CHAMP 70, the platforms can suddenly lower and crush service personnel.

Never work under unsecured platforms.

Lower both platforms completely if you do not have to work beneath them.

Lowering platform!

When working under the raised platform, the service personnel can be crushed by lowering plat-forms.


Secure the raised platforms with maintenance blocks if you have to work under the platform.

Danger of being crushed by platforms!

When securing the platform the service personnel can be crushed by lowering and raising the plat-form.

Always maintain visual and vocal contact to the operator on the driver's stand.

Only position maintenance blocks in the mounting position of the platform once the operator has let go of the control switch/es for raising/lowering and the CHAMP 70 is stationary.

No service personnel may be present in the danger area of the CHAMP 70 during raising or lowering of the platform.

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Danger of poisoning!

In closed rooms the exhausts of the running motors can poison or suffocate the service personnel.

Always ensure good ventilation of the workshop or connect an exhaust hose to the exhaust pipe of the motor.

Spark formation during welding!

Spark formation during welding work can lead to short circuits and trigger fires.

Always switch off the main battery switch before beginning welding work.

Always wait a minimum of 30 minutes before beginning the welding work after the battery loading process.

Tripping danger!

When working on the platform, the service personnel can trip over platform components.

Watch out for parts of the platform that jut out.

Walk carefully.

Wheels and tires

Accident danger!

Negligence and improperly executed work on wheels and tires impair the operating safety of the CHAMP 70 and can lead to severe accidents.

Regularly check wheels and tires for damage and trend thickness.

Defective wheels and wheels with too little tread profile have to be replaced immediately.

Repair work on wheels and tires may only be executed by qualified technicians.

Working on the hydraulic system

Leaking hydraulic oil!

The hydraulic system is under pressure. Suddenly emerging hydraulic oil can squirt into the eyes and injure other body parts.

Depressurize the hydraulic system before performing maintenance on it.

Wear protective goggles when performing any adjustments or inspections.

Regularly check hydraulic lines and hoses for leakage, proper positioning and porosity, repair and replace hydraulic hoses where necessary.

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When connecting the measuring equipment for the pressure reading with a running motor, sud-denly emerging hydraulic oil can squirt into the eyes and injure other body parts.

Switch off the motor before connecting the measuring equipment to the test points of the hydraulic.


Harmful to the environment!

Leaking hydraulic oil pollutes the soil and the ground water.

Close all openings with protective caps or rubber stoppers.

Immediately catch leaking oil and dispose of in accordance with the laws and regulations.

Working on the electrical system

Explosion danger!

Gases escaping from batteries are explosive.

Avoid fire, open light, smoking and sparks near batteries.

Only charge batteries in well-ventilated rooms

Always wait a minimum of 30 minutes after the battery loading process before undertaking any welding work.

Do not place any tools on the battery.

Electric shock!

When working on the electrical system, electric shocks can occur and cause life threatening injuries or even death.

Only let qualified service personnel with extensive electrical knowledge perform maintenance and service work.

Switch off main battery switch and motor before work.

Electric shock!

Damages or defective components in the electrical system can cause electric shocks and lead to life threatening injuries or even death.

Damage to the electrical system must be repaired immediately.

Defective components have to be replaced immediately.

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Fire hazard!

Wrong fuses can lead to short circuits and fires.

Only use fuses with the same ampere rating.

Never override blown fuses.

never exchange blown fuses with fuses with a higher voltage consumption.

Caustic burns from battery acid!

The battery acid contained in batteries cauterize with contact to skin and eyes.

Avoid contact to skin, eyes or clothing.

Avoid breathing in the acidic vapors.

Do not spill acid.

Wear protective clothing, protective gloves and goggles.

Immediately rinse with clear water and consult a doctor.

Fire hazard!

Wrong sequence when connecting and disconnecting the battery terminals leads to short circuits.

Observe the correct sequence when connecting and disconnecting the battery terminals.

When disconnecting the battery, first remove the negative battery pole, then remove the posi-tive battery pole.

When connecting the battery, first connect the positive battery pole, then connect the nega-tive battery pole.

Operating fuels and lubricants

Oils are toxic!

Oils, especially used oil is toxic and carcinogenic. Hot oil can cause injuries.

Do not inhale or swallow oil and avoid extensive contact.

Protective glasses and clothing must be worn when handling oils.

Observe that the oils are not spilled.

Never let the hot oil come in direct contact with the skin.

Thoroughly rinse skin that had contact with oil.

In case of eye contact, rinse out eyes for 10 to 15 minutes with clear water and consult a doc-tor immediately.

Immediately consult a doctor if the oil has been swallowed.

Always store oils in the original container, never refill or store in drinking containers.

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Do not spill acid.



Oils are environmentally hazardous!

Spilled oil pollutes the soil and the ground water.

Only exchange oil in places designed for this purpose.

Dispose of used oils in accordance with your local state laws and regulations.

If in doubt, consult your works personnel or a qualified disposal specialist.






Batteries belong to the waste requiring special supervision.

Batteries may not be disposed of in the regular trash.

Dispose of batteries in accordance with your local state laws and regulations.

If in doubt, consult your works personnel or a qualified disposal specialist or the battery man-ufacturer.

After maintenance work

Operating safety!

Missing safety equipment and an omitted functional test can endanger the operating safety and functionality of the CHAMP 70. This can lead to life threatening injuries and even death.

Connect all coverings and safety equipment.

Check functionality of all operating and safety equipment.

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Documentation

Read and understand documentation!

Service personnel has to be familiar with the contents of this maintenance instruction manual and has to apply its instructions.

A copy of the maintenance and repair manual must be available to every member of the service staff when working on the CHAMP 70.

In addition to the maintenance manual, pay attention to the electrical and hydraulic diagrams, the factory settings, the spare parts lists, and manufacturer's information on purchase parts.

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3. Maintenance and Repair

The following provides support for the maintenance and repair of the CHAMP 70.

Trepel recommends to perform maintenance of the CHAMP 70 in accordance with the maintenance schedule. This maintains the operating safety of the CHAMP 70.

Some maintenance and repair work requires special tools (see Subsection B "Tools and specialized tools", page 28).

A. Maintenance schedule

General remarks

Maintenance plans with the following intervals are applied for every component:

• daily • 250 operating hours• 500 operating hours• yearly

The following applies:

• 250 operating hours require quarterly maintenance• 500 operating hours require biannual maintenance.

INFORMATION

The maintenance plans do not contain the maintenance intervals of the vendor parts, e.g. motor or front axle.

Strictly observe the maintenance intervals and instructions in the documentation of the manufacturer of the vendor parts.

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Screws of supporting parts and flanges

Check all screws of supporting parts and flanges every 250 h for firm fixture.

Table 2: Tightening torque for metric fine thread

Dimensions Tightening torque in Nm (Coefficient of friction = 0,10)

Property class

8.8 10.9 12.9

M8x1 22 32 37

M10x1.25 42 62 72

M12x1.25 75 110 130

M12x1.5 72 105 125

M14x1.5 120 175 200

M16x1.5 180 265 310

M18x1.5 270 385 450

M20x1.5 375 530 620

M22x1.5 500 710 830

M24x2 630 900 1050

M27x2 920 1300 1550

M30x2 1300 1850 2150

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Table 3: Tightening torque for standard metric thread

Dimensions Tightening torque in Nm (Coefficient of friction = 0,10)

Property class

8.8 10.9 12.9

M4x0.7 2.4 3.6 4.2

M5x0.8 4.8 7.1 8.3

M6x1 8.3 12 14

M8x1.25 20 30 35

M10x1.5 40 59 69

M12x1.75 69 100 120

M14x2 110 160 190

M16x2 170 250 290

M18x2.5 245 345 405

M20x2.5 340 490 570

M22x2.5 460 660 770

M24x3 590 840 980

M27x3 870 1250 1450

M30x3.5 1450 1900 1950

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Engine

Table 4: Maintenance schedule for engine

Component Maintenance work Interval

Daily every 250 h

every 500 h

Yearly

Engine oil level Check, refill if necessary. X

Check fuel line and fuel tank

Check for leakage. X

Intake air filter/ dry air filter

Check (according to maintenance display, if present).

X

Speed regulator Check the pilot cylinder setting and look for leaks, clean and lubricate swivel bearing.

X

Engine buffer on chassis

Check functionality and whether securely positioned.

X

Hose lines and con-nections to the fitted hydraulic pumps

Check for leakage and porosity. X

Component units on engine

Check whether securely mounted. X

Exhaust system Check for leakage, firm attachment, and corrosion.

X

Intake air filter/ dry air filter

Check and clean. X

Filter cartridge in dry air filter

Service according to maintenance display, replace if necessary.

Secondary filter element in filter cartridge

Replace after three to five maintenance procedures of the filter cartridge in the dry air filter or not later than after two years.

Engine with attached units

See the engine manufacturer's maintenance manual

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Wheels/axles/steering/brakes


Daily every 250 h

every 500 h

Yearly

Wheels and tires Check for damage. X

Check firm fixture of the rear axle, check profile depth of the tires.

X

Wheel nuts Check tightening torque and tighten; specified tightening torque is 500 Nm (11,870 pdl ft).

X

Wheel nuts after wheel change

Check tightening torque and tighten; recheck torque value after ten hours of operation.

Recheck tightening torque after first ten hours of operation.

Brake/steering sys-tem

Check for leakage; check and adjust the pressure if necessary.

X

Steering cylinder Check for leakage and check cylin-der piston rods for damage.

X

Brake system push buttons

Check for functionality. X

Pressure accumula-tor in the brake sys-tem

Check initial tension, refill if neces-sary. Observe the manufacturer's safety instructions.

X

Fastening nut for hydraulic drive engine on axle drive

Check tightening torque and tighten (specified tightening torque).

X

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Table 5: Maintenance schedule for wheels, axles, steering and brakes

Front axle Lubrication (lubricating points see Subsection D "Lubricating points", page 34).

X

Check oil level of differential gear. X

Check oil level of planetary gear. X

Chassis axle shafts Check that screw connections are firm and secure.

X

Steering unit in driver's stand

Check whether pressure settings are correct.

X

Front axle Oil change axle gears X

Oil change planetary gear X

Front wheel brake See the maintenance manual from the axle manufacturer


Daily every 250 h

every 500 h

Yearly

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Scissor-type jack lifting systems/transport systems/platforms


Daily every 250 h

every 500 h

Yearly

Guide rails Check for functionality and damage. X

All scissor-type jack bearings of the front scissors

Lubrication (lubricating points see Subsection D "Lubricating points", page 34).

X

All scissor-type jack bearings on main scissors


X

Sliding surfaces on lowerable guide rails


X

All cargo stops on front and elevators

Check for functionality and damage; grease lubricating nipples (lubricat-ing points see Subsection D "Lubri-cating points", page 34).

X

Adjustment mecha-nism of the guide rails under the elevator


X

Bridge adapter and its hydraulic cylinder

Check for functionality and damage. Lubricate sliding surfaces (lubricat-ing points see Subsection D "Lubri-cating points", page 34).

X

Gliding surfaces of the restraints between the platforms


X

Lifting chains, eleva-tor lifting system

Only lubricate with chain spray (lubricating points see Subsection D "Lubricating points", page 34).

X

Tracks and rollers on chassis and in plat-form frame

Clean, check rolls for one-sided wear.Caution: Do not lubricate running surfaces!

X

Safety split-pins and locking pins on all bearing pins

Check for damage and functionality. X

Lifting cylinder Check for leakage and damage. X

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Table 6: Maintenance schedule for scissor-type jack lifting systems, transport systems and plat-forms

Hydraulic cylinder of the elevator's lowera-ble guide rails

Check for damage and leakage and replace if necessary.

X

PC drive modules Check for functionality and wear (in particular the roller surface); replace if necessary.

X

Barrel rollers Check whether securely fastened to the respective full-floating axle.

X

Axles of the PC drives Check whether securely fastened (axial).

X

Platform railings Check for smoothness of operation and secure attachment.

X

Coupler between the lateral transport roll-ers

Check for damage, secure attach-ment, and wear and tear; replace if necessary.

X

Transport / ball rollers Check for functionality, damage and corrosion, and lubricate.

X

Friction and ball bear-ings on the scissor track rollers

Check and replace if necessary. X

Lifting chains of the main cylinders

Check whether fastener is firmly positioned, check for damage and wear.

X

Chain tension on the hydraulic drive engine of the longitudinal and PC drives

Check and adjust if necessary. X

Cover plate Check for damage. X

Weld seams on the scissor-type jacks

Check for fissures. X


Daily every 250 h

every 500 h

Yearly

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Driver's stand

Table 7: Maintenance schedule for driver's stand


Daily every 250 h

every 500 h

Yearly

Driver's lumbar sup-ports

Check whether securely fastened. X

Steering, horn, park-ing brake lever

Check for functionality, secure posi-tioning and proper setting.

X

Pedal bearings Lubrication (lubricating points see Subsection D "Lubricating points", page 34).

X

Steering and control elements on the instrument and oper-ating panel

Check for functionality, leakage and proper electrical contact.

X

Instrument and oper-ating panel

Check whether securely fastened. X

Slide-out mechanism of operating stand

Check for functionality and secure handling.

X

Thrust cylinder of the operating stand

Check for leakage and secure attachment.

X

Sliding surfaces on slide-out mechanism for operating stand

Check for wear, lubricate (lubrication points see Subsection D "Lubricat-ing points", page 34).

X

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Hydraulic system


Daily every 250 h

every 500 h

Yearly

Hydraulic oil in hydraulic tank

Check oil level and add oil if neces-sary (do not mix oil types). Oil type see Subsection C "Oils for Equipment Units", page 153 and accompanying vehicle document.

X

All solenoid valves Check for functionality and check lighting display of the plug and socket connections.

X

Pressure control valves

Check pressure settings (see also Subsection J "Maintenance of the electrical system", page 129).

X

Hydraulic emergency operation


Electric emergency operation


Hydraulic lines and hoses

Check for leakage, proper position-ing and porosity; replace if neces-sary. Tighten loose connections.

Replace hydraulic hoses after five years.

Flow control valves, throttle valves

Check for correctly set flow and leakage (see also Subsection J "Maintenance of the electrical sys-tem", page 129).

X

Current dividing coil of the lifting systems

Check for functionality and leakage. X

Entire hydraulic sys-tem

Check for leakage. X

Filter inserts in reverse flow, suction and pressure filters

Replace filter cartridges (service according to maintenance display, if present).

X

Hydraulic fittings Check for leakage, replace if neces-sary.

X

Hydraulic pilot oper-ated return valves and lowering brake valves on lifting cylinder

Check for functionality and adjust if necessary (see also Subsection J "Maintenance of the electrical sys-tem", page 129).

X

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Table 8: Maintenance schedule for hydraulic system

All hydraulic cylinders Check for leakage and whether screw connections are firmly tight-ened, replace if necessary.

X

Hydraulic oil Take oil sample and check for impu-rities.

X

Hydraulic oil Change oil. Oil type see Subsection C "Oils for Equipment Units", page 153.

X

All pumps and hydraulic motors for drive mode

Check and service. See manufacturer's maintenance manual


Daily every 250 h

every 500 h

Yearly

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Electrical systems

Table 9: Maintenance schedule for electrical systems


Daily every 250 h

every 500 h

Yearly

Vehicle lighting Check for functionality and damage, replace defective components.

X

All emergency off but-tons

Check for functionality, damage, and correct attachment; check whether their cable connections are firmly attached.

X

All pilot lamps and warning lights

Check for functionality, replace if nec-essary.

X

Batteries Check battery status. X

Battery acid Check acid concentration and clean-ness (see Subsection "Checking bat-tery status", page 132).

X

Electrical fuses Check for corrosion. X

Electrical limit/proxim-ity switches

Check for functionality, damage, secure attachment, and correct switch-ing distance, and adjust or replace if necessary (see Subsection "Proximity switch", page 145 or Subsection "Set switch distance", page 147).

X

Electrical relays and time lag relays

Check for functionality and corrosion; check whether their cable connections are firmly attached.

X

Electrical time lag relays

Check whether delay is as specified (see Subsection "Setting time lag relay", page 142).

X

Cable connections in the switch cabinets

Check for firm attachment and check connections for corrosion.

X

Cable connections in the terminal boxes

Check for firm attachment and check connections for corrosion.

X

Switch cabinet Check for leakage. X

Electrical compo-nents of the engine (generator, starter, controller)

Check and service. See manufacturer's maintenance manual

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B. Tools and specialized tools

The following provides an overview of the required tools.

Before performing any maintenance work, ensure that the tools can be used safely. Only spe-cially trained service personnel instructed by TREPEL may work with the tools.

Toolse

Most of the maintenance work can be executed with the standard tools for mechanics. Always use tools that are in faultless condition. The workshop should be fitted with at least an assembly pit and a device for the exhaust extraction.

Specialized tools

Special tools are needed for performing specific adjustments.

Working on the mechanical systems

Working on the hydraulic system

Designation Measuring range Type

Torque spanner 30-500 Nm (712-11,870 pdl ft) Commercially availa-ble

Feeler gauge 0-1 mm Commercially availa-ble

Micrometer gauge 0-25 mm Commercially availa-ble

Caliper gauge 0-150 mm Commercially availa-ble

Tools for engine Refer to engine manufacturer documentation

Commercially availa-ble

Designation Connection thread Type

Adapter for manometer R1/4 and M16 MAV 1/4 – MA3

Adapter for manometer R1/2 and M16 MAV1/2 – MA3

Measuring hose for manometer con-nection and adapter

M16 and M16 Hydraulic measuring hose

Oil change adapter hose DIN ISO 228, G1 Accessories if engine is equipped with adapter for oil changes.

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Work on engine oil change

Oil change front axle

Working on the electrical system

Table 10: Specialized tools, adjustment tools

Designation Connection thread

Type

Manometer with glycerine filling R1/4 Up to 400 bar (5,800 psi)



Designation – Measuring range

Speedometer for the speed measurement of the transverse drives

– –

Designation Connection thread

Type

Oil change adapter hose DIN ISO 228, G1

Accessories if engine is equipped with adapter for oil changes.

Designation – Type

Funnel with hose – –

Designation Measuring range

Type

Battery acid spindle – commercially available

Electronic voltmeter (with ohmmeter) –50 V commercially available

Electronic speed gauge – commercially available

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C. Secure raised platform

Some maintenance work must be carried out under the raised platforms. The following describes all measures that must be taken to secure the raised platforms against accidental lowering.

For work carried out underneath the platform, the following applies:

Lowering platform!

When working under the platform the service personnel can be crushed by lowering platforms.

The lowering platform can cause serious injuries or even death to the service personnel.


Secure the raised platforms with maintenance blocks.

Engage parking brake

Rolling CHAMP 70!


A collision with the rolling CHAMP 70 can cause life threatening injuries and even death.


Ensure that blocks have additionally been placed under the wheels during maintenance work.

(1) Park the CHAMP 70 in the workshop.

(2) Keep brake pedal pressed down.

(3) Turn driving direction control switch to the right.

The control switch clicks into position.

Control light parking brake on.

Parking brake is engaged.

(4) Release the brake pedal.

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Secure bridge

Figure 2: Maintenance blocks on the bridge

1 Maintenance block

2 Mounting position

3 Maintenance block placed

4 Storage area


When securing the bridge the service personnel can be crushed by lowering and raising the bridge.



Only position maintenance blocks in the mounting position of the bridge once the operator has let go of the control switch for bridge up/down and the CHAMP 70 is stationary.

No service personnel may be present in the danger area of the CHAMP 70 during raising or lowering of the bridge.

1 2

3 4

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(1) Press both bridge up/down control switches away from operator.

Bridge moves up.

(2) Remove both maintenance blocks from the storage area.

(3) Place the maintenance blocks in the right and left position of the bridge.

(4) Press both bridge up/down control switches towards the operator.

The bridge lowers.

(5) Press both bridge up/down control switches until the maintenance blocks are pressed against the front scissor-type jack.

The maintenance blocks are secured.

The bridge is secured against unintended lowering.

Securing the elevator

Figure 3: Elevator maintenance blocks

1 Storage area

2 Mounting position

1 2

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When securing the elevator, the service personnel can be crushed by lowering and raising the ele-vator.

The lowering elevator can cause serious injuries or even death to the service personnel.


Only position maintenance blocks in the mounting position of the elevator once the operator has let go of the control switch for elevator up/down and the CHAMP 70 is stationary.

No service personnel may be present in the danger area of the CHAMP 70 during raising or lowering of the elevator.

(1) Press elevator up/down control switch away from operator.

The elevator lifts.

(2) Remove both maintenance blocks from the storage area.

(3) Place the maintenance blocks in the right and left position of the elevator.

(4) Press elevator up/down control switch towards operator.

The elevator lowers.

(5) Press elevator up/down control switch until the maintenance blocks are pressed against the lower track roller bearings of the main scissor-type jack.

The maintenance blocks are secured.

The elevator is secured against unintended lowering.

Turning off the motor

(1) Turn starter switch to position "0".

Motor switches off.

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D. Lubricating points

The following describes all important information for lubricating the CHAMP 70.

Lubricate all lubricating points in an interval of 250 operating hours. Here a grease gun is used for the lubricating nipples and a brush for the gliding surfaces.

The lubricating points are protected by a red cap.

As a lubricating grease an all-purpose grease in accordance with DIN 51502/ (identification: KZK, lithium based, drop point above 170°C / 338°F ) is recommended.

The CHAMP 70 has lubricating points above and below the platform.

Lubricating points above the platform

If the lubricating points are above the platform, observe the following safety instruction:

Tripping danger!

When working on the platform, the service personnel can trip over platform components.

The service personnel can easily be injured when tripping.

Watch out for parts of the platform that jut out.

Walk carefully.

Lubricating points below the platform

If the lubricating points are below the platform, observe the following safety instruction:

Lowering platform!





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Lubricate the lubricating points

The two overview drawings show the locations of the lubricating points on the CHAMP 70.

Figure 4: Lubricating points (overview 1)

1 Front scissor-type jack cylinder bearings

2 Upper and lower track roller bearings of the front scissor (floating bearings)

3 Lifting chains, elevator lifting system

4 Upper and lower fixed bearing of the main scissor-type jack

5 Central scissor bearing of the main scissor

6 Upper and lower track roller bearings of the main scissor (floating bearings)

7 Drive axle

8 Central scissor bearing of the main scissor

9 Upper and lower fixed bearing of the front scissor

1

5

2 3 4

6

789

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Figure 5: Lubricating points – other (overview 2)

1 Adapter on the bridge

2 Slide-out tray for driver's stand

3 Pedal bearings

4 Gliding surface of the restraints between the platforms

5 Cargo stops

6 Guide rail adjustment mechanism/sliding surfaces of the guide rails

7 Speed regulator

Lubricating with grease gun

(1) Remove the caps indicated in red from the lubricating nipple.

(2) Position the nozzle of grease gun on the lubricating nipple.

(3) Squeeze trigger 4 - 5 times.

The lubricating point is now greased.

(4) Remove nozzle.

(5) Replace cap on lubricating nipple.

The lubricating nipple is now protected from dirt entering it and the lubrication process is com-pleted.

1

52 3 4 6

7

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Lubrication with brush

(1) Lubricate the gliding surfaces and the restraints between the platforms with the brush.

INFORMATION

Do not lubricate the chain drives with grease. Lubricated chain drives can easily soil.

Lubrication with chain spray

(1) Clean soiled chain drives with degreaser.

(2) Lubricate chain drives with chain spray.

Lubrication regulations front axle

The lubrication regulations for the front axle are not described in this maintenance manual.

(1) Observe the lubrication instructions of the manufacturer for front axles in the appendix of the documentation.

Lubricating points

Figure 6: Sliding surfaces and adjustment mechanism of guide rails (rear guide rail depicted)

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Figure 7: Cargo stops

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Figure 9: Slide-out tray for driver's stand

Figure 10: Bridge adapter

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Figure 11: Movable parts of the speed regulator

Figure 12: Fixed bearing of the front scissor-type jack, inside

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Figure 13: Fixed bearing, front scissor-type jack

Figure 14: Central scissor bearing of the main scissor

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Figure 15: Guide rail adjustment mechanism

Figure 16: Floating bearing of the main scissor-type jack, top

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Figure 17: Floating bearing of the main scissor-type jack, bottom

Figure 18: Fixed bearing of the main scissor-type jack, top

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Figure 19: Fixed bearing of the main scissor-type jack, bottom

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E. Oil level checks

The following describes the procedures for checking engine and hydraulic oil levels. You can also find information on the inspection of the oil levels for the differential and planetary gears of the front axle.

Walk once around the CHAMP 70 daily and inspect for possible oil leakages.

Check the oil levels for the engine and the hydraulic system daily.

Check the transmission oil level in the planetary and differential gears of the front axle every 250 operating hours.

Oil specifications see Subsection 4 "Operational Materials", page 149.

Oils are toxic!

Oils, especially used oil is toxic and carcinogenic. Hot oil can cause injuries.

The improper handling of oils can seriously injure service personnel.

Do not inhale or swallow oil and avoid extensive contact.

Protective glasses and clothing must be worn when handling oils.

Observe that the oils are not spilled.

Never let the hot oil come in direct contact with the skin.

Thoroughly rinse skin that had contact with oil.

In case of eye contact, rinse out eyes for 10 to 15 minutes with clear water and consult a doc-tor immediately.

Immediately consult a doctor if the oil has been swallowed.

Always store oils in the original container, never refill or store in drinking containers.

Oils are environmentally hazardous!

Spilled oil pollutes the soil and the ground water.

Only exchange oil in places designed for this purpose.

Dispose of used oils in accordance with your local state laws and regulations.

If in doubt, consult your works personnel or a qualified disposal specialist.

Engine oil level

Engine damage!

Too high or too low oil level can damage the engine.

Make sure that the oil level never lies above the "HIGH" mark or below the "LOW" mark.

Only use motor oils approved by the engine manufacturer.

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Motor oil level inspection

Figure 20: Oil level check for engine

1 Oil dip stick

2 Oil filler tube

INFORMATION

The CHAMP 70 must be on a horizontal, even surface for the oil level measurement to be correct.

Wait 15 minutes after shutting down the engine before initiating the oil level inspection.

(1) Open engine front door.

(2) Pull oil dip stick.

(3) Clean oil dip stick with a clean, lint-free cloth.

(4) Replace oil dip stick.

(5) Pull out oil dip stick again.

1 2

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Figure 21: Oil dip stick with markings

INFORMATION

The oil level must be between "LOW" mark and the "HIGH" mark.

(6) If the oil level is too low, refill the motor oil using the oil filler tubes.

Engine manufacturer documentation

In the documentation of the engine manufacturer you can find the intervals and procedures for oil change, filling levels and the specifications of the engine oils.

You will find details on the engine oils that are factory-filled in the factory settings record.

HIGH

LOW

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Oil levels front axle

In the front axle, the gear oil levels of both planetary gears and the differential gear should be inspected every 250 operating hours.

MS-E 3060

Figure 22: Front axle: Planetary and differential gears MS-E 3060

1 Filling screw and inspection plug, planetary gear

2 Planetary gear

3 Differential gear, drain screw

4 Differential gear, inspection plug

Oil level inspection planetary gears

(1) Check the oil level of the CHAMP 70 on a level surface.

(2) Always maintain visual and vocal contact to the operator on the driver's stand.

(3) Drive the CHAMP 70 until the checkmark is horizontal to the driving surface (9 o'clock).

(4) Engage parking brake.

(5) Turn off engine.

You may now check the planetary gear's oil level.

1 2

34

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Figure 23: Front axle: Planetary gear MS-E 3060

1 Checkmark

2 Inspection plug, planetary gear

(6) Carefully clean the inspection plug before screwing it off.

(7) Screw off inspection plug.

(8) Check oil level.

The correct level for oil is at the bottom mark of the inspection plug.(9) If the oil level is too low, refill the motor oil.

(10) Check the seals on the inspection plug and replace if necessary.

(11) Screw on inspection plug.

INFORMATION

Use a funnel or hose for refilling the oil into the planetary and differential gear.

Front axle manufacturer documentation

In the documentation of the front axle manufacturer you can find the intervals and procedures for oil change, filling levels and the specifications of the gear oils.

INFORMATION

The vehicle specification sheet has information on which gear oil was filled in at the factory.

2

1

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Oil level inspection differential gear

(1) Park the CHAMP 70 above the assembly pit.


(3) Turn off motor.

You may now check the differential gear's oil level.

Figure 24: Front axle: Differential gear MS-E 3060

1 Differential gear, drain screw

2 Differential gear, inspection plug

(4) Carefully clean the inspection plug before screwing it off.

(5) Screw off inspection plug.

(6) Check oil level.

The correct level for oil is at the bottom mark of the inspection plug.(7) If the oil level is too low, refill the oil.

(8) Check the seals on the inspection plug and replace if necessary.

(9) Screw on inspection plug.


In the documentation of the front axle manufacturer you can find the intervals and procedures for oil change, filling levels and the specifications of the gear oils.

INFORMATION

The vehicle specification sheet has information on which gear oil was filled in at the factory.

1

2

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Hydraulic system

The hydraulic system has to be inspected daily for possible leakages at the beginning of each shift. The level indicator at the mechanical level indicator gauge of the hydraulic tank has to be inspected daily also.

The hydraulic tank is located under the bridge, behind the engine. Multiple level indicator gauges are attached to the hydraulic tank:

• Mechanical level indicator gauge• Electrical level indicator gauge in drive mode• Electrical level indicator gauge in operate mode

Reading the mechanical level indicator gauge

Figure 25: Overview of hydraulic tank

1 Mechanical level indicator gauge

2 Electrical level indicator gauge in drive mode

3 Electrical level indicator gauge in operate mode

(1) Position CHAMP 70 with lowered platforms on a level surface.



(4) Read the hydraulic oil level on the mechanical level indicator gauge.

1 2

3

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Figure 26: Mechanical level indicator of the hydraulic tank

1 Mechanical level indicator gauge

2 Upper marking

3 Hydraulic oil temperature gauge

4 Lower marking

The hydraulic oil level should be in the upper range of the level indicator when the engine is switched off, the platforms are lowered and the stabilizers are retracted.

The oil level may not be above the upper mark.

The oil level may also not be below the lower mark. If the oil level is too low, the cause for the loss of oil has to be found and the error rectified.

Only once the cause for the oil loss has been found and the error rectified can the oil be refilled.

1

2

3

4

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Refill oil

Figure 27: Oil filler tubes closed/opened

(1) Unscrew oil filler tubes.

(2) Refill hydraulic oil.

INFORMATION

Use a hydraulic oil for the hydraulic system that conforms to the specification HLP-ISO-VG. Do not mix hydraulic oils with different specifications.

The vehicle specification sheet has information on which hydraulic oil was filled in at the factory.

(3) Close the tank with the oil filler tube.

Oil level inspection electrical level indicator gauge

Both electrical level indicator gauges are not read at the hydraulic tank. During the operation red con-trol lights illuminate on the instrument panel and the operating panel of the driver's stand in case of too low hydraulic oil levels.

The red engine warning light lights up if the hydraulic level is too low in operate mode.

The red engine warning light lights up if the hydraulic level is too low in drive mode.

If the red engine warning light lights up, do not continue to work with the CHAMP 70. Immediately lower all platforms, shut down the CHAMP 70 and inspect it for the cause of the oil loss.

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Refill oil

(1) Unscrew oil filler tubes.

(2) Refill hydraulic oil.

INFORMATION



(3) Close the tank with the oil filler tube.

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F. Maintenance on the motor

Figure 28: Overview - Motor

1 Speed regulator

2 Dry air filter

3 Motor bearings

Motor damages!

Neglected or improperly carried out maintenance tasks can cause danger to the motor.

The content of the maintenance instructions of the motor manufacturer need to be known to the service personnel and be applied by them.

All maintenance and repair instructions of the motor manufacturer have to be strictly complied with.

Maintenance and repair work is only to be performed by fully trained, qualified, and author-ized service personnel.

2

1

3

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Figure 29: Instruction signs on engine maintenance intervals

Documentation of the motor manufacturer

You will find support to the following maintenance tasks in the documentation of the motor manufac-turer:

• Lubrication system• Fuel system• Cooling system• Dry air filter• Belt drives• Setting tasks• Attached parts• Spare parts

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Checking the speed boost setting

The engine must be running for setting the speed boost. This means that an additional person must be present on the driver's stand to ensure the safety of the person working on the engine.

Strictly observe the following safety instructions:


In closed rooms the exhausts of the running motors can poison or suffocate the service personnel.

Inhalation of noxious exhaust fumes can lead to serious injury and even death.

Always ensure good ventilation of the workshop or connect an exhaust hose to the exhaust pipe of the engine.


When the motor is running, the CHAMP 70 can suddenly run over service personnel.

A collision with the CHAMP 70 can cause life threatening injuries and even death.

Always engage the parking brake or place blocks under the wheels.

While the engine is running, a person must be present on the driver's stand to monitor the CHAMP 70.

Lowering platform!

During work on the CHAMP 70, the platforms can suddenly lower and crush service personnel.

Platforms can suddenly lower and cause serious injury and even death.


Lower the elevator completely.

Secure the raised bridge with maintenance blocks.

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Figure 30: Adjusting the speed boost

1 Counternut

2 Ball head

3 Throttle lever

4 Full load stop

5 Linkage

(1) Engage parking brake and block the wheels.

(2) The first persons starts the engine of the CHAMP 70 and raises the bridge.

(3) The second person secures the bridge using maintenance blocks.

(4) Warm engine to operating temperature.


(6) Loosen ball head retaining ring.

(7) Loosen linkage lock nut.

(8) Remove ball head with linkage from throttle lever.

(9) Start engine.

(10) Person in the driver's stand operates the throttle pedal to full load.

(11) Person at the engine operates the engine throttle lever to full load and checks whether the ball head slides easily onto the throttle lever.


(13) Should this not be the case, the linkage has to be adjusted so that the ball head slides easily over the throttle lever.

(14) Lock the new linkage setting with the counternut.

(15) Install ball head retaining ring.

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Checking the motor bearings

Check the motor bearings annually.

Figure 31: Motor bearings

(1) Carry out a visual inspection of the elastic bearing parts of the motor.

(2) Look for deformation, damages, and cracks.

(3) Check the firm seat of the bearing screws.

INFORMATION

Replace defective bearing parts always in pairs.

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G. Maintenance on Wheels/Axles/Steering/Brakes

The following contains information about maintenance of the wheels, and mounting and dismounting the wheels.

The following gives you a short list of the necessary maintenance work on the front axle.

Wheels and tires

The condition of the wheels and tires is very important for the operating safety of the CHAMP 70.

Accident danger!

Negligence and improperly executed work on wheels and tires impair the operating safety of the CHAMP 70 and can lead to severe accidents.

Accidents due to insufficient maintenance of wheels can lead to severely damaged persons or even death.

Regularly check wheels and tires for damage and trend thickness.

Defective wheels and wheels with too little tread profile have to be replaced immediately.

Repair work on wheely and tires may only be executed by qualified technicians.

Check wheels and tires

Inspect the tires and wheels of the CHAMP 70 before shift change for

• visible damage of tires,• sufficient profile depth,• foreign objects in the tire profile• Damaged wheel rims• Missing or loose wheel bolts/wheel nuts.

Inspecting tightening torques of front wheels

INFORMATION

The tightening torque is 500 Nm (11,865 pdl ft).

(1) Inspect the tightness of the wheel nuts every 250 operating hours.

(2) If the wheels have been newly mounted, check after 10 operating hours.

(3) Use a torque wrench to tighten the wheel nuts. Make sure to use the correct tightening torque.

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Preparations for removing the front wheel

The CHAMP 70 has to be placed onto timber supports for dismounting the front wheels. For this, the CHAMP 70 must be lifted and lowered onto the scantlings.

There are various means of lifting the CHAMP 70, as follows:

• Variant 1: lifting the CHAMP 70 using a crane• Variant 2: lifting the CHAMP 70 using hydraulic jacks with claws• Variant 3: Lifting the CHAMP 70 using pneumatic jacks

Requirements:

• CHAMP 70 stands on an even and firm surface.• Parking brake is engaged.• Stabilizers are extended.• Motor is turned off.

Lifting or placing the CHAMP 70 on support blocks in an improper manner!

The chassis of the CHAMP 70 can bend by lifting or supporting it on one side.

Always lift and support the CHAMP 70 evenly.

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Variant 1: lifting the CHAMP 70 using a crane

Read the transport instruction manual before lifting the CHAMP 70 and strictly follow the instructions.

(1) Lifting the CHAMP 70.

Figure 32: Diagram: Lifting the CHAMP 70 and lowering it on scantlings

1 Scantling 4 000 x 150 x 300 mm (157 ½ x 6 x 11 ¾ inches)

2 Scantling 4 000 x 150 x 190 mm (157 ½ x 6 x 7 ½ inches)

(2) Lower the CHAMP 70 onto the timber supports.

The front wheel can now be dismounted, see Subsection "Dismounting the front wheel", page 68.

ca. 10 500 kg (approx. 23 150 lb) ca. 10 500 kg (approx. 23 150 lb)

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Variant 2: Lifting the CHAMP 70 using hydraulic jacks

To lift the CHAMP 70, two hydraulic jacks with claws each with a lifting capacity of at least 10 000 kg (22,046 lb) must be used.

Impermissible hoists!

If impermissible hoists are used, the chassis can unexpectedly drop down when being placed on support blocks. This can crush persons under the CHAMP 70.

The crush injuries can be life-threatening or even fatal.

Ensure that only lifting equipment with sufficient lifting capacity is used.

Before lifting the CHAMP 70 with lifting equipment, read the manufacturer's documentation and adhere strictly to the instructions.

Two persons are needed for lifting the CHAMP 70.

Figure 33: Diagram: placing hydraulic jacks at one longitudinal side of the chassis

1 Hydraulic jacks with claws with a lifting capacity of at least 10 000 kg (22,046 lb)

(1) Secure the rear wheels with stop blocks.

(2) Place hydraulic jack at the front and the middle of the longitudinal side of the CHAMP 70.

INFORMATION

In each case, a load-bearing part of the chassis must run through the point of support.

The lifting claw must always grip completely below the chassis.

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(3) Using the jacks, lift the CHAMP 70 at the same time and evenly at the front and the middle using two persons.

Figure 34: Diagram: lowering the CHAMP 70 onto supports using hydraulic jacks

1 Hydraulic jack at the longitudinal side, front

2 Support (e.g. scantling, height = 300 mm (11 ¾ inches)

3 Hydraulic jack at the longitudinal side, rear

4 Support (e.g. scantling, height = 190 mm (7 ½ inches)

(4) Underlay the chassis at the support points with suitable supports made from steel or hardwood with a slip-resistant surface.

Support point, front: Support with a height of 300 mm (11 ¾ inches).Support point, rear: Support with a height of 190 mm (7 ½ inches).

(5) Lower the CHAMP 70 evenly onto the supports.


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Variant 3: Lifting the CHAMP 70 using pneumatic jacks

For lifting the CHAMP 70, two pneumatic jacks each with a lifting capacity of at least 8 000 kg (17,640 lb) must be used.




Ensure that only lifting equipment with sufficient lifting capacity is used.

Before lifting the CHAMP 70 with lifting equipment, read the manufacturer's documentation and adhere strictly to the instructions.

Two persons are needed for lifting the CHAMP 70.

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Figure 35: Diagram: lifting the CHAMP 70 using pneumatic jacks

1 Axle connection, left side

2 Axle connection, right side

3 Piston-action pneumatic jack (2 units, minimum lifting capacity per jack 8 000 kg (17,640 lb)

(1) Secure the rear wheels with stop blocks.

(2) Place the piston 3 of the pneumatic jack at the front axle under the middle of the axle connec-tion on the left side 1 and the right side 2 of the CHAMP 70.

(3) In each case, place a slip-resistant mat between the contact surfaces of the axle connection and the piston.

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INFORMATION

The contact surfaces of the axle connection must lie completely on the contact surface of the pis-tons.

(4) Using the jacks, lift the CHAMP 70 at the same time and evenly at the left and the right using two persons.

Figure 36: Diagram: lowering the CHAMP 70 onto supports using pneumatic jacks

1 Support, front support point (e.g. scantling), height = 300 mm (11 ¾ inches)

2 Support, rear support point (e.g. scantling), height = 190 mm (7 ½ inches)

(5) Underlay the chassis at the support points of both longitudinal sides with suitable supports made from steel or hardwood with a slip-resistant surface.

Support points, front: Support with a height of 300 mm (11 ¾ inches).Support points, rear: Support with a height of 190 mm (7 ½ inches).

(6) Lower the CHAMP 70 evenly onto the supports.


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Dismounting the front wheel

Front wheel tips over!

The dismounted front wheel can fall and crush feet.

During the assembly the service personnel can easily be injured by the falling front wheel.

Wear safety boots.

Always exchange front wheels with two persons.

While removing with the fork-lift the second person should hold the front wheel.

Figure 37: Dismount front wheel (ZF MS-E 3060)

1 Wheel nut (x10)

INFORMATION

To dismount the front wheel use a box spanner with the spanner width of 30 mm.

(7) Place box spanner onto the wheel nut.

(8) Turn the box spanner counter clockwise.

Wheel nuts (10 pcs.) unfixed.

(9) Remove wheel nuts and lock washers.

(10) Carefully drive the fork-lift forks under the front wheel.

(11) Lift the front wheel until it is not resting on the wheel hub.

Front wheel is resting on the fork.

(12) Slowly drive the fork-lift with the front wheel on the fork backwards while the second person holds the standing front wheel.

(13) Stop the fork-lift and place the front wheel with two persons horizontally onto the fork.

Front wheel is laying on the fork.

(14) Drive away the fork-lift with the front wheel.

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Mounting the front wheel

(1) Bring the fork-lift with the new or repaired front wheel to the CHAMP 70.

(2) Two persons place the front wheel onto the fork.

(3) One person holds the standing front wheel.

(4) The second person operates the fork-lift and raises the front wheel onto the wheel hub.

INFORMATION

Make sure that the bore holes of the front wheel are aligned with the wheel bolts of the wheel hub. If necessary, turn the front wheel until the bore holes are aligned with the wheel hub.

(5) Push the front wheel with the bore holes carefully onto the wheel bolts.

Front wheel is correctly positioned on the wheel hub.

Property damage!

The wheel bolts can be damaged during the mounting of the front wheel to the wheel hub.

Push the front wheel onto the wheel hub with care.

(6) Push the lock washers onto the wheel bolts.

(7) Screw the wheel nuts manually.

(8) Drive the fork-lift away backwards.

Figure 38: Order for tightening

INFORMATION

The tightening torque is 500 Nm (11,865 pdl ft).

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(9) Use a torque wrench to tighten the wheel nuts. Make sure to tighten the nuts in the correct order and use the correct tightening torque.

The front wheel is now mounted.

(10) Lift the CHAMP 70 with a crane.

(11) Remove planks.

(12) Place the CHAMP 70 onto the ground.

CHAMP 70 is now ready for operation.

INFORMATION

After 10 operating hours the tightening torque of the wheel nuts should be checked with the torque wrench and tightened if necessary.

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Dismounting the rear wheel

To remove the rear wheels, the CHAMP 70 be jacked up. For this, the CHAMP 70 must be lifted using a forklift and placed on support stands.

Requirements:

• CHAMP 70 stands on an even and firm surface.• Parking brake is engaged.• Stabilizers are extended.• Motor is turned off.

Lifting the CHAMP 70 in an improper manner!

If the CHAMP 70 is lifted with the forklift in an improper manner, the chassis can be bent.

Make sure the transverse beam of the chassis is supported on both forks of the forklift.

Securing the CHAMP 70

(1) Start the engine.

(2) Lift the bridge.

(3) Place maintenance stabilizers at the bridge (see Subsection C "Secure raised platform", page 30).

(4) Lift the elevator.

(5) Place maintenance stabilizers at the elevator (see Subsection C "Secure raised platform", page 30).

(6) Turn off the engine and secure the front wheels of the CHAMP 70 with stop blocks.

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Detaching the axle keep plates

Figure 39: Rear wheel axle keep plate

1 Axle holder, inside of wheel

2 Axle holder, outside of wheel

3 Hexagon socket screws (SW19)

(1) Loosen and remove both hexagon socket screws from the two axle keep plates on the inside and the outside of the wheel and remove them.

(2) Remove the axle keep plates on the inside and the outside of the wheel.

Lowering the platforms

(1) Start the engine.

(2) Lift the elevator.

(3) Remove maintenance stabilizers at the elevator.

(4) Lift the bridge.

(5) Remove maintenance stabilizers at the bridge.

(6) Retract the CHAMP 70's stabilizers.

(7) Turn off the engine.

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Lifting the rear of the CHAMP 70

To lift the CHAMP 70, a forklift with a minimum lifting capacity of 11 000 kg (24,250 lb) must be used.




Ensure that only a forklift with the stated lifting capacity is used.

(1) Position the forks of the forklift under the transverse beam at the rear of the CHAMP 70.

Figure 40: Lifting the CHAMP 70

1 Forklift

2 Support stands (2 pieces)

(2) Lift the rear of the CHAMP 70 by approx. 700 mm with the forklift so that the rear wheels and axles can be removed.

(3) Put the support stands in place and lower the CHAMP 70 onto the support stands.

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(4) Remove the rear wheels and axles.

The rear wheels are detached and new wheels can now be attached to the axle.

INFORMATION

The rear wheel must be replaced in the reverse order.

After replacing the wheel, ensure that the screws of the axle keep plate are tightened to the correct torque (see Subsection "Screws of supporting parts and flanges", page 17)

Loosening of wheel nuts!

After a wheel change, the wheel nuts can loosen due to material settling and lead to serious acci-dents.

Persons can be seriously injured or even killed because of serious accidents.

Be sure to retighten all wheel nuts with the specified tightening torque after the wheel exchange.

Retighten the wheel nuts with the prescribed tightening torque again after the first laden jour-ney, at the latest after 24 operating hours.

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Front axle

The front axle contains the brake and steering.


In the documentation of the manufacturer you can find support for the following maintenance work:

• Lubrication regulation• Break wear measurement• Adjustments• Spare parts

Brake and steering pressure adjustments

Maintenance information for brake and steering pressure adjustment see Subsection I "Mainte-nance of the hydraulic system", page 79.

Figure 41: Overview front axle

Pos. Designation Tightening torque

1 Oil drain screw 50 Nm (1,190 pdl ft)

2 Oil drain and oil filler opening bore hole 50 Nm (1,190 pdl ft)

3 Oil filler and oil check bore hole 50 Nm (1,190 pdl ft)

4 Brake connection 20 Nm (475 pdl ft)

5 Brake ventilation valve 20 Nm (475 pdl ft)

6 Lubricating nipple 6 Nm (142 pdl ft)

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H. Maintenance on the platforms / transport system

Pay attention to the general accident prevention regulations when performing maintenance, repair, and adjustment work.

Lowering platform!




Turn off the engine.

Check the cargo safety equipment.


Rolling CHAMP 70!




Ensure that blocks have been placed under the wheels.

Performed work

• Lubrication• Hydraulic/electro-hydraulic checks and adjustments• Visual inspection of mechanical, electrical, and hydraulic components

(1) Lubricate the lubrication points on the platforms and on the transport system (see Subsection D "Lubricating points", page 34).

(2) Perform hydraulic and electro-hydraulic checks and adjustments according to the mainte-nance schedule and Subsection I "Maintenance of the hydraulic system", page 79.

(3) Check that the cargo stops are firmly attached.

(4) Check mobility.

(5) Check cargo stops for damage.

INFORMATION

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Lift chain maintenance

Figure 42: Lift chains (double chain is optional)

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Figure 43: Lift chain tension (double chain is optional)

1 Safety chain

2 Lift chain

3 Jam nut SW 46

4 Adjusting nut SW 46

5 Counter nut SW 46

6 Safety chain fastener (disk spring package)

7 Threaded rod M30

Checking the lift chains

INFORMATION

The lift chains are stretched chains that do not lengthen.

(1) Perform a visual inspection of the chain links for damage.

(2) Check lift chain tension.

(3) Check that the counter nut and jam nut on the threaded rod M30 are securely fastened.

Adjusting the double chain (optional)

(1) Adjust the double chain as per Figure "Lift chains (double chain is optional)".

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I. Maintenance of the hydraulic system

This chapter informs you about the maintenance intervals of the hydraulic system.

You receive information about the inspection and setting work of the flow control valves and the dif-ferent pressures in the hydraulic system.


The hydraulic oil is under pressure. Suddenly emerging hydraulic oil can squirt into the eyes and injure other body parts.

Hydraulic oil emerging under pressure can seriously injure the service personnel.



Regularly check hydraulic lines and hoses for leakage, proper positioning and porosity, repair and replace hydraulic hoses where necessary.





Depressurising the hydraulic system

INFORMATION

The hydraulic system is depressurized by closing the shut-off cock of the hydraulic tank before beginning the maintenance and repair work.

The engine does not start when the shut-off cock is closed.

Requirements

Before you depressurize the hydraulic system, the following conditions need to be met:

• CHAMP 70 stands on an even and firm surface.• Both platforms are lowered.• No cargo is located on the platform.• Parking brake is engaged.• Wheels are blocked by blocks.• Motor is turned off.Pro

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Close the shut-off cock

Figure 44: Shut-off cock hydraulic tank opened

1 Shut-off cock

2 Lock bolt

INFORMATION

To avoid unintended opening and closing of the shut-off cock, it is locked with the lock bolt.

(1) Fasten the lock bolt clockwise by turning it ¼ of a revolution.

Figure 45: Shut-off cock hydraulic tank locked

1 Lock bolt

2 Shut-off cock

(2) Close the shut-off cock.

(3) Turn the lock bolt counter-clockwise by ¼ of a revolution and sink.

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Check hydraulic system

Pump and engine manufacturer documentation

In the maintenance manual for the pump and hydraulic engine you can find the maintenance inter-vals and the procedures for maintenance.

Material damage!

During the maintenance work dirt may inter the hydraulic system and damage the pumps and hydraulic engines.

Thoroughly clean the surrounding area before removing the screws and hoses.


Interval Maintenance work

Daily Perform visual inspection of the hydraulic system for leakages. Also check the contamination indicators of the filters. In case of oil traces on the floor, immediately check the oil level of the hydraulic tank.

Every 250 operating hours Check the hydraulic lines and hoses for leakage, proper posi-tioning and porosity. Remove leakages and replace porous or defect hydraulic hoses. Replace hydraulic hoses no later than every 5 years.

Every 500 operating hours Check the entire hydraulic system for leakages. Check the armatures for leakages and replace defective armatures.

Check hydraulic cylinders for leakages and firm positioning of the screw connections. Replace faulty parts.

At least once a year Perform hydraulic oil change including filter change. Unless the contamination indicator is in the red range, then the filter change and hydraulic oil change is due before the annual inter-val is over.

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Hydraulic oil change

The hydraulic oil needs to be changed at least once a year. Or even earlier if the soiling indicator of the high pressure or return flow filters show that the filters are soiled.

INFORMATION

When changing the hydraulic oil, also exchange the two high pressure and return flow filters.

Requirements

Before you change the hydraulic oil, the following conditions need to be met:

• CHAMP 70 stands on an even and firm surface.• Both platforms are lowered.• No cargo is located on the platform.• Parking brake is engaged.• Wheels are blocked by blocks.• Motor is turned off.• Hydraulic system is depressurized.

Changing hydraulic oil

(1) Place collection container underneath the drain plug of the hydraulic tank.

Figure 46: Oil filler tubes closed/opened

(2) Open oil filler tubes.

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Figure 47: Drain screw

INFORMATION

To unscrew the drain screws use a flat spanner with the spanner width 19 mm.

(3) Unscrew the drain screw with a flat spanner.

(4) Fully drain the oil.

(5) Clean the drain plug with a lint-free cloth.

(6) Put a new seal on the drain plug.

(7) Screw the drain plug back in and screw tight.

(8) Fill with oil.

INFORMATION


INFORMATION


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Figure 48: Mechanical level indicator of the hydraulic tank

1 Upper marking

2 Lower marking

(9) Check the oil level at the mechanical level indicator gauge.

INFORMATION

The hydraulic oil level should be in the upper range of the level indicator when the engine is switched off, the platforms are lowered and the stabilizers are retracted.

Material damage!

A too low oil level can damage the hydraulic pumps and engines.

The oil level should be between the top and bottom marks. It is better when it is in the upper range of the level indicator.

(10) Close the hydraulic tank with the oil filler tubes.

INFORMATION

After the hydraulic oil exchange carry out a function test; check hydraulic system of leaks and oil level.

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High pressure filter

The CHAMP 70 has two high pressure filters. The small high pressure filter is located right next to the hydraulic tank. The big high pressure filter is mounted on the side for the emergency operation. Both high pressure filters feature a contamination indicator.

Figure 49: High pressure filters with contamination indicators

1 Contamination indicator of the small high pressure filter on the hydraulic tank

2 Contamination indicator of the large high pressure filter on the side of the emergency operating equipment

The high pressure filters are replaced once a year along with the hydraulic oil change.

If the contamination indicator shows prematurely that the filter is soiled, the high pressure filter has to be changed before the annual hydraulic oil change.

INFORMATION

When changing the high pressure filter, also exchange the oil and return flow filter.

Checking the contamination indicator

(1) Check the color in the viewing glass.

If the viewing glass shows the color green, then the high pressure filter is in order and does not need to be exchanged.

If the viewing glass shows the color red, then the high pressure filter is soiled and needs to be exchanged.

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Requirements

Before you change the high pressure filter, the following conditions need to be met:


Changing the high pressure filter





(1) Clean the surroundings of the high pressure filter with a clean lint-free cloth.

INFORMATION

To unscrew the lid for a smaller high pressure filter use a flat spanner with the spanner width of 36 mm.

To unscrew the lid for a big high pressure filter use a flat spanner with the spanner width of 32 mm.

(2) Unscrew the lid of the high pressure filter from the flange using a flat spanner.

(3) Take out the filter cartridges.

(4) Clean the lid of the high pressure filter and the flange with a clean lint-free cloth.

(5) Check the cap's seal for cracks and damages and if necessary repeat with new seals.

(6) Insert new filter cartridge into the lid.

(7) Screw the lid with the high pressure filter back on with the flat spanner.

(8) Check the firm seat of the lid before starting up.

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Return flow filter

The return flow filter is located on the hydraulic tank. The return flow filter is replaced once a year along with the hydraulic oil change.

If the contamination indicator shows prematurely that the filter is soiled, the return flow filter has to be changed before the annual hydraulic oil change.

INFORMATION

When changing the return flow filter, also exchange the oil and the two high pressure filters.

Checking the contamination indicator

Figure 50: Contamination indicator, return flow filter

(1) Checking the pointer position of the contamination indicator.

If the pointer is at the color green, then the return flow filter is in order and does not need to be exchanged.

If the pointer is at the color red, then the return flow filter is soiled and needs to be exchanged.

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Requirements

Before you change the high pressure filter, the following conditions need to be met:


Changing the return flow filter





(1) Clean the surroundings of the return flow filter with a clean lint-free cloth.

INFORMATION

To unscrew the lid for the return flow filter use a flat spanner with a spanner width of 17 mm.

(2) Loosen the 4 nuts on the lid of the return flow filter using the flat spanner.

Figure 51: Screws on the return flow filter

(3) Take the lid with the filter insert from the flange housing.

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(4) Take the filter insert completely from the lid.

(5) Clean the flange housing and lid with a clean lint-free cloth.

(6) Remove any metal swarf from the magnetic rod.

(7) Check the seal for cracks and damages; if necessary repeat with new seals.

(8) Place new filter inserts on the lid.

(9) Place the lid with the filter insert by hand on the flange housing. Make sure that the filter car-tridge is not damaged in the process.

(10) Fasten the lid again with the 4 nuts onto the flange housing.

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Pressure readings

Perform pressure readings on the hydraulic system in an interval of every 250 hours or after a part has been replaced.

Make adjustments, if the values do not coincide with the values of the factory preset list anymore or if new parts where fitted.

Information

Information on the test points and prescribed system pressures can be found in the following docu-ments:

• Hydraulic Plan• Factory Preset List

INFORMATION

The test points are indicated with an M and numbered in the hydraulic plan, e.g. M1, M2 etc. Each individual test point in the CHAMP 70 is indicated this way.

Figure 52: Test point

INFORMATION

All test points with the prescribed system pressures are listed in the factory preset list.

INFORMATION

Perform the pressure settings of the flow control valves when the engine is warm.

Preparing the CHAMP 70

(1) Place the CHAMP 70 onto an even surface.

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Rolling CHAMP 70!






(3) Place blocks under the wheels.

CHAMP 70 is secured from rolling away.

Lowering platform!





(4) Raise the bridge.


When securing the platform the service personnel can be crushed by lowering and raising the plat-form.



Only position maintenance blocks in the mounting position of the platforms once the operator has let go of the control switch for bridge up/down or the control switch for elevator up/down and the CHAMP 70 is stationary.




(6) Elevator up.

(7) Place the maintenance blocks in the right and left position of the elevator.



INFORMATION

Ideally, the pressure readings should be performed by two persons. One person performs the pres-sure readings. The second person supports the first person during the pressure readings, e.g. by switching the engine on and off at the switch cabinet or the engine compartment.

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Performing pressure readings

Use the measuring tools consisting of a manometer, connection adapter, measuring hose and union nut for the pressure readings.

Ensure that the screw and hose connections of the measuring equipment are properly attached to the test point.

Select a manometer where the measuring range is 50 % higher than the measuring value of the test point.

Figure 53: Measuring equipment for pressure readings of the hydraulic system

1 Manometer up to 400/200/100 bar (5,800/2,900/1450 psi)

2 Union nut for connection to check point

3 Adapter

4 Measuring hose

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Figure 54: Overview hydraulics test points

1 Test point, front stabilizers

2 Test point brake pressure/steering pressure

3 Test point, driver's stand

4 Test point middle/rear stabilizers

5 Drive valve

6 Central hydraulic control block for high pressure/low pressure/elevator up

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Wear protective goggles when performing the pressure readings.




(1) Select the test point.

(2) Read the system pressure from the factory preset list.

Figure 55: Measuring equipment attached to the CHAMP 70

1 Manometer

2 Test point

3 Union nut

2

3

1

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Figure 56: Union nut attached to the test point

1 Union nut

(3) Unscrew the knurled nut from the test point, turn the knurled nut counter-clockwise for this.

(4) Screw the union nut of the measuring equipment onto the test point, turn the union nut clock-wise for this.

INFORMATION

Leave the engine on for the pressure readings.

(5) Switch the engine in the switch cabinet or engine room on.

(6) Operate the selected valve.

(7) Read the pressure on the manometer.

INFORMATION

If the measured values do not coincide with the values of the factory preset list, adjustments have to be made.


INFORMATION

The adjustment screws for adjusting the pressure and the counternut for securing the pressure set-tings are under the protection cap.

1

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Figure 57: Pressure settings

1 Set screw

2 Counternut

3 Protective cap

(9) Remove the orange protection cap.

(10) Unscrew lock nut.

(11) Set the correct pressure with the adjustment screw.

Turn the adjustment screw to the right = increase pressureTurn the adjustment screw to the left = decrease pressure

(12) Set the pressure settings with the counternut without turning the adjustment screw.

(13) Replace the orange protection cap.

2

3

1

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High pressure settings – set value: 250 bar (3,650 psi)

Requirements

Before you begin the pressure readings and adjustments, the following conditions need to be met:

• Both platforms have to be secured against lowering with maintenance blocks.• No cargo is located on the platform.• Parking brake is engaged.• Wheels are blocked by blocks.• Motor is turned off.

Performing readings and settings

Figure 58: Test point M2 = high pressure

(1) Connect the measuring equipment to the rear of the main control block at test point M2.


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Figure 59: Activate the valve for the high-pressure setting.

1 Valve Y5, not locked

2 Valve Y5, locked

(3) Operate valve Y5.


INFORMATION


(5) Switch off the engine in the switch cabinet or engine room.

INFORMATION

Use the flat spanner with the following spanner widths for the pressure settings: Adjustment screw = spanner width 10 mm Counternut = spanner width 22 mm



(8) Set the pressure to 250 bar (3,650 psi) with the adjustment screw.

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Figure 60: High pressure setting on drive valve

INFORMATION

Once the pressure is set, perform the readings.




INFORMATION

If the measured pressure coincides with the values of the factory preset list, the adjustments can be ended.




(15) Remove the measuring equipment.

(16) Screw knurled nut onto the test point.

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Low pressure setting – set value: 190 bar (2,800 psi)

Figure 61: Test point M1 = low pressure

Requirements




(1) Unscrew the knurled screw of the test point.

(2) Connect the measuring equipment to the rear of the main control block at test point M1.


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Figure 62: Operate the valve for low pressure settings


(5) Read the pressure on the manometer and compare with the values of the factory preset list.

INFORMATION



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Figure 63: Low pressure setting at main control block

INFORMATION

Use the flat spanner with the following spanner widths for the pressure settings: Adjustment screw = spanner width 10 mm Counternut = spanner width 24 mm.


(8) Set the pressure to 190 bar (2800 psi) with the adjustment screw.

INFORMATION





INFORMATION





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Stabilizer pressure setting front stabilizers – set value 15-50 bar (220-730 psi)

There are two test points for setting the stabilizer pressure. There is a test point for the front stabi-lizers and a test point for the centre and rear stabilizers.

Requirements




Figure 64: Test point, front and rear stabilizers M9


(2) Connect measuring equipment to test point M9.

(3) The second person is standing in the driver's stand.

(4) Turn on engine from the driver's stand.

(5) Set "operate/drive mode selector" to operate mode.

The stabilizers extend.

"Stabilizers extended" control light is on.

(6) The first person is at the test point. They measure and set the pressure.


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INFORMATION


(8) The second person switches the engine off.

Figure 65: Pressure setting, front stabilizers

INFORMATION




(11) Set the pressure to 15-50 bar (220-730 psi) with the adjustment screw.

(12) The second person on the driver's stand switches the engine on.




(14) The first person reads the pressure on the manometer.

INFORMATION



(16) The first person sets the pressure settings with the counternut without turning the adjustment screw.

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Stabilizer pressure middle and rear stabilizers – set value: 15-50 bar (220-730 psi)

There are two test points for setting the stabilizer pressure. There is a test point for the front stabi-lizers and a test point for the centre and rear stabilizers.

Requirements




Figure 66: Test point, centre stabilizers M12


(2) Connect measuring equipment to test point.

(3) The second person is standing in the driver's stand.



Stabilizers are still extended.

(5) The first person is at the test point. They measure and set the pressure.


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INFORMATION


(7) The second person on the driver's stand switches the engine off.

Figure 67: Pressure setting, middle and rear stabilizers

INFORMATION




(10) Set the pressure to 15-50 bar (220-730 psi) with the adjustment screw.

INFORMATION





"Stabilizers extended "control light is on.

(13) The first person reads the pressure on the manometer.

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INFORMATION



(15) The first person sets the pressure settings with the counternut without turning the adjustment screw.




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Brake pressure settings for the operating brake – set value for hydraulic, dynamic braking: 60 bar (900 psi)

For the brake pressure setting, one person is in the driver's stand for the pressure setting and the second person is at the test points for pressure readings.

Requirements


• Both platforms are lowered.• No cargo is located on the platform.• Parking brake is engaged.• Wheels are blocked by blocks.• Motor is turned off.


Figure 68: Test point, operating brake M7 and M8

(1) The first person connects the measuring equipment.


(3) Connect measuring equipment to test points M7 and M8.

(4) The second person is on the driver's stand, switches the motor on and sets the pressure at the adjustment screw below the brake pedal.


(6) Press the brake pedal all the way.

(7) The first person at the test point reads the pressure off the manometer and passes the meas-urement on to the second person.

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With faulty brake pressure setting the CHAMP 70 is no longer safe for operation. Persons could be run over by the CHAMP 70.

A CHAMP 70 with faulty brakes can cause serious injuries or death to persons.

Only operate the CHAMP 70 once the brake pressure has been set correctly.

INFORMATION

To set the brake pressure, use a flat spanner with the spanner width 13 mm.

(8) The second person turns the adjustment screw below the brake pedal and presses the brake pedal until the correct pressure is attained.

Unscrew the adjustment screw: Increase pressureScrew in the adjustment screw: Reduce pressure

Figure 69: Adjustment screw operating brake

(9) Turn the adjustment screw below the brake pedal.

(10) Press the brake pedal all the way.

(11) Repeat the procedure until the correct pressure of 60 bar (900 psi) is read.

INFORMATION

Let go of brake pedal – pressure drops to zero Step on brake pedal – set pressure is displayed




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Parking brake release pressure: at least 25 bar (365 psi)

The release pressure of the parking brake can only be checked. Adjustments are not possible.

Requirements

Before you begin the pressure readings, the following conditions need to be met:

• Both platforms are lowered.• No cargo is located on the platform.• Wheels are blocked by blocks.• Motor is turned off.

Performing readings

Figure 70: Test point, parking brake M10





Property damage!

If the release pressure of the parking brake is below 25 bar (365 psi), the parking brake can be damaged.

Immediately shut down the CHAMP 70

Inform the TREPEL customer service.

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With faulty brake pressure setting the CHAMP 70 is no longer safe for operation. Persons could be run over by the CHAMP 70.

A CHAMP 70 with faulty brakes can cause serious injuries or death to persons.

Only operate the CHAMP 70 once the brake pressure has been set correctly.

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Driver's stand pressure setting – set value 25 bar (365 psi)

Requirements




Figure 71: Test point, driver's stand M13






INFORMATION



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Figure 72: Pressure settings driver's stand

INFORMATION





INFORMATION





INFORMATION







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Steering pressure check – set value 175 bar (2,500 psi)

Figure 73: Test points, steering pressure "L" and "R"

Requirements



Test point "L"


(2) Connect measuring equipment to test point "L".






Test point "R"



(3) Connect measuring equipment to test point "R".


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INFORMATION

If the steering pressure is lower than 175 bar (2,500 psi), the CHAMP 70 is hard to steer.

Property damage!

If the steering pressure is a lot higher than 175 bar (2500 psi), hydraulic cylinders can be damaged.

Shut down the CHAMP 70.

Inform the TREPEL customer service.

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Control pressure setting for speed regulator – set value 30 bar (450 psi)

Requirements




Figure 74: Test point, speed regulator M4 (in the front under the engine cover, right-hand side in travelling direction)

Property damage!

If the pressure is greater than 30 bar (450 psi), then the hydraulic servo cylinder mounted to the engine can become damaged.

Set no greater pressure than 30 bar (450 psi) for valve Y39.






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INFORMATION



Figure 75: Pressure setting, speed regulator

INFORMATION





INFORMATION





INFORMATION


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Electrical unit pressure setting nominal value 120 bar (1,750 psi)

Requirements

The following conditions have to be met before beginning with the pressure measurements:

• Both platforms are lowered• No cargo is located on the platforms• Parking brake is engaged• Stop blocks have been placed under the wheels• The engine is turned off

Conducting pressure measurements

Figure 76: Electrical unit test measurement point

1 Electrical unit

2 Setting screw with counter nut under black protective cap

3 Test measurement point M2 (high pressure) with system pressure manometer connected

(1) Unscrew knurled screw of the test measurement point M2.

(2) Connect system pressure manometer to the test measurement point M2.

(3) Switch on the engine at the switch cabinet or in the engine compartment.

(4) Press the "Lower elevator" button on the emergency operation switch cabinet and hold it down.



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INFORMATION

In case the measured values do not match the values in the factory settings record, then re-adjust-ments need to be done.

(6) Release the "Lower elevator" button.

(7) Switch off the engine at the switch cabinet or in the engine compartment.

Adjusting the pressure settings

Use socket wrenches with the following sizes to adjust the pressure:

• Setting screw = wrench size 10 mm• Jam nut = wrench size 24 mm

(1) Pull off the black protective cap.

(2) Loosen the jam nut.

(3) Set the pressure with the setting screw to 120 bar (1,750 psi).

INFORMATION

Once the pressure has been set, conduct a measurement check.

(4) Switch on the engine at the switch cabinet or in the engine compartment.

(5) Press the "Lower elevator" button on the emergency operation switch cabinet and hold it down.



INFORMATION

If the measured pressure matches the values in the factory settings record, the setting work can be ended.

(7) Release the "Lower elevator" button on the switch cabinet.

(8) Switch off the engine at the switch cabinet or in the engine compartment.

(9) Fix the pressure setting with the jam nut.

INFORMATION

Do not turn the setting screw when fixing the jam nut.

(10) Attach the black protective cap.

(11) Remove the measurement tool.

(12) Screw the knurled screw on to the test measurement point.

The measuring process has been completed.

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Flow regulator settings

Check the settings of the flow control valve in an interval of 250 operating hours. The settings are preset correctly ex factory and documented in the factory preset list. Nevertheless, some flow control valve settings can alter with usage of the CHAMP 70.

You can check and correct the speed and time of the following components with the flow control valves:

• Lead time for the extension and retraction of the adapters• Lead time for the extension and retraction of the guide rails

Information

Information on the measuring values can be found in the following documents:

• Hydraulic Plan• Factory Preset List

Preparing the CHAMP 70

(1) Place the CHAMP 70 onto an even surface.

Rolling CHAMP 70!






(3) Place blocks under the wheels.

CHAMP 70 is secured from rolling away.

INFORMATION

The adjustments for the flow control valves are mostly performed under the platform.

Observe the following safety instructions:

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During the flow regulation settings the service personnel can be crushed by lowering and raising the platform.



Only perform settings on the flow control valves after the maintenance blocks have been placed.

Only position maintenance blocks in the mounting position of the platforms once the operator has let go of the control switch for bridge up/down or the control switch for elevator up/down and the CHAMP 70 is stationary.




(5) Elevator up.

(6) Place the maintenance blocks in the right and left mounting positions of the elevator.



Setting flow control valves

INFORMATION

To reduce the speed, turn the flow control valve towards the LARGE NUMBER.

To achieve a low flow speed, turn the flow control valve towards the SMALL NUMBER.

Change the setting of the flow control valve in small steps. Perform speed or time measurements after every change of setting.

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Flow control valves overview

Figure 77: Overview hydraulics flow control valves

1 Flow control valves left/right adapter MD B727 and speed of guide rails

Setting of the flow control valve for adapters

Figure 78: Flow control valves left/right adapter MD B727

1 Flow control valve left adapter

2 Flow control valve right adapter

1

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If the time duration for extending and retracting the adapters is supposed to be checked and set with the flow control valves, the actual time has to be measured first.

There is no existing lead time for the extension and retraction of the adapters in the factory preset list. The times can be adjusted according to the demand.

Requirements

• The CHAMP 70 is secured from rolling away, i.e.– parking brake is engaged – the blocks have been placed under the wheels

• Both platforms are secured against lowering with maintenance blocks.

Procedure


(2) The second person operates the control switch for the respective adapter.

Adapter retracts or extends.

(3) Measure the time with a stop watch.

If the time does not correspond with the intended time, the flow control valve has to be set. (4) The second person switches the engine off.

INFORMATION




(5) Adjust flow control valve.

(6) Move out of the danger area of the CHAMP 70.


(8) The second person operates the control switch for the respective adapter.

Adapter retracts or extends.


INFORMATION

If the measured time still does not correspond with the intended time, the process has to be repeated until there are no more deviations present.

If the measured time corresponds with the intended time, the setting process can be ended.


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Settings, flow control valve guide rail of bridge

Figure 79: Flow control valve guide rails of bridge

The flow control valve of the guide rails is positioned next to the flow control valve of the adapters.

If the extension and retraction speed of the guide rails is supposed to be checked and adjusted, the actual speed has to be measured first.

Requirements

• The CHAMP 70 is secured from rolling away, i.e.– parking brake is engaged – the blocks have been placed under the wheels

• Both platforms are secured against lowering with maintenance blocks.• No cargo is on the platforms.

Procedure


(2) The second person operates the control switch guide rail bridge up/down.

Guide rails extend or retract.


INFORMATION

If the time does not correspond with the intended time, the flow control valve has to be set.


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INFORMATION




(5) Adjust flow control valve.

(6) Move out of the danger area of the CHAMP 70.

The service personnel is outside of the danger area.


(8) The second person operates the control switch guide rail bridge up/down.

Guide rails extend or retract.


INFORMATION

If the measured time still does not correspond with the intended time, the process has to be repeated until there are no more deviations present.

If the measured time corresponds with the intended time, the setting process can be ended.


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J. Maintenance of the electrical system

The following contains all important information on the maintenance of the battery, lighting, exchange of fuses and relays, settings of the time relays and current regulators.

Information

Further information on the maintenance and repair of the electrical system can be found in the fol-lowing documents:

• Electrical Diagram• Spare Parts Lists

Generator

Figure 80: Generator

The CHAMP 70 is equipped with a 24 V DC system. Two batteries save the electrical energy created by the generator of the engine.

The generator is a component of the engine.


In the documentation of the engine manufacturer you can find care and maintenance information on the generator.

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Main battery switch

Electric shock!

When working on the electrical system, electric shocks can occur.

Electric shocks can cause life threatening injuries or even death.

Only let qualified service personnel with extensive electrical knowledge perform maintenance and service work.

Switch off main battery switch and motor before work.

The main battery switch turns the power supply of the CHAMP 70 control system on/off.

Figure 81: Settings of the main battery switch

Table 11: Settings of the main battery switch

Switch positions Description

0 Voltage supply off.

I Voltage supply on.

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Battery

Figure 82: Battery

1 Battery poles under cap

2 Cap, battery (12x)

The batteries are located on the right-hand side of the CHAMP 70 in front of the lifting chain mast.



Acid fumes and spills can cause life threatening injuries or even death.



Do not spill acid.



+–

+ –

24V/DC ----

2

1

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Explosion danger!

Gases escaping from batteries are explosive.

Exploding battery vapors can lead to life threatening injuries or even death.

Avoid fire, open light, smoking and sparks near batteries.

Only charge batteries in well-ventilated rooms

Always wait a minimum of 30 minutes after the battery loading process before undertaking any welding work.

Do not place any tools on the battery.

Fire hazard!

Wrong sequence when connecting and disconnecting the battery terminals leads to short circuits.

Short circuits lead to fires and can cause life threatening injuries or even death.

Observe the correct sequence when connecting and disconnecting the battery terminals.

When disconnecting the battery, first remove the negative battery pole, then remove the posi-tive battery pole.

When connecting the battery, first connect the positive battery pole, then connect the nega-tive battery pole.

Check battery poles and connections

(1) Check battery terminals for corrosion.

(2) Check whether terminals are securely fastened.

(3) Check if the battery poles and terminals are sufficiently lubricated with acid free, acid resistant grease.

(4) Check whether the battery is securely fastened.

Check acid level

(1) Remove protective caps from the battery.

The acid level of the battery should be approx. 10 mm (0.4 inch) above the plate's top edge.(2) If the acid level is too low, carefully top up with distilled water.

(3) Replace the protective caps on the battery.

Checking battery status

The battery status can be determined by the acid concentration of the battery. The acid concentra-tion should be 1.28 g/cm³ (80 Pound per foot3). If the acid concentration is below 1.23 g/cm³ (77 Pound per foot3), the battery needs to be recharged.

INFORMATION

Use a battery acid spindle to determine the acid concentration.

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Charging the battery

(1) Check the battery acid level of the battery.

(2) Loosen and remove the battery terminals.

Observe the sequence - first loosen and remove the negative pole, then the positive pole.(3) Remove protective caps.

(4) Connect battery charging unit.

Observe the sequence - first connect the negative poles of the battery and battery charging unit, and then connect the positive poles.

(5) Switch on the battery charging unit.

(6) Remove the battery charging unit after the charging process.

Observe the sequence - first disconnect the positive poles of the battery and battery charging unit, and then disconnect the negative poles.

(7) Switch off the battery charging unit.

(8) Check battery status again.

INFORMATION

A lowered acid level can indicate a defective cell.

(9) Replace the protective caps on the battery.

(10) Replace defective battery.

INFORMATION

If the battery is functional, then connect the battery terminals and observe the sequence - first the positive pole, then the negative pole.


In the documentation of the engine manufacturer you can find care and maintenance information on the battery.

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Lighting system

Regularly check that the lighting system is operating faultlessly.

(1) Replace defective light bulbs.

(2) Check the diffusing reflector and light panel for chips and tears.

(3) Replace defective diffusing reflectors and light panels.

(4) Check the functionality of the reversing light with the reverse gear set.

Replacing the LED headlights and LED turn signals

INFORMATION

The headlights and the turn signals are cold-light LEDs. A defective headlight or turn signal has to be replaced completely.

Figure 83: LED headlights and LED turn signals

1 LED turn signals

2 LED headlights

2

1

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Replacing headlight lamps (optional)

Figure 84: Fastening screws of the main headlight

INFORMATION

Only turn the screws of the headlight indicated with the arrow.

Do not turn the two diagonally placed screws. They are intended for adjusting the light settings.

(5) Switch off engine and main battery switch.

(6) Remove the screws of the headlight with a crosstip screwdriver.

Figure 85: Remove plug and rubber bushing

(7) Remove headlight from the chassis frame.

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(8) Pull the plug on the back side of the headlight.

(9) Remove rubber bushing.

(10) Remove light bulb from the casing.

INFORMATION

Always replace light bulbs with light bulbs of the same model (type, voltage and power).

The individual types of light bulbs are listed in the spare parts list.

(11) Insert a new light bulb.

(12) Check the bushing for possible damages and replace if necessary.

(13) Replace the rubber bushing on the rear side of the headlight.

(14) Plug in the plug on the back side of the headlight.

(15) Reattach the headlight of the CHAMP 70 with screws.

(16) Switch on the main battery switch.

(17) Perform function test.

Exchanging light bulb, turn signal (optional)

Figure 86: Fastening screw for turn signal


(2) Remove screws from the turn signal with crosstip screwdriver.

(3) Remove the Protective glass.


INFORMATION



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(6) Check the seals for possible damages and replace if necessary.

(7) Replace the protective glass and screw tight.



INFORMATION

If the light bulb does not light up after it has been changed, a relay or fuse might be defective. Check the electrical plan and the label "relay table" in the switch cabinet to locate the correspond-ing relay or fuse. Replace the relay or fuse.

If the light bulb does not light up or lights up only dimly, check that a light bulb with the correct volt-age or rating has been used.

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Replacing the LED headlights

INFORMATION

The headlights are cold-light LEDs. A defective headlight or turn signal has to be replaced com-pletely.

Figure 87: LED headlights

1 Protective grating

2 LED headlights

(1) Release the socket screws (4 used, see arrow) with a socket wrench.

(2) Remove the protective grating 1.

Figure 88: Replacing the rear light

1 Plug

2 Screws (2 pieces)

1 2

1 2

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(3) Pull the plug 1.

(4) Release the screws 2 (2 pieces).

(5) Remove the strip with the rear LED lights.

Replacing warning beacon light bulb

Figure 89: Mounting link for opening the warning beacon


(2) To open the mounting link, press the warning beacon up.

(3) Remove the protective glass of the warning beacon.

INFORMATION

Do not touch the reflector with your bare hands while removing the light bulb.


INFORMATION




(6) Check the seals for possible damages and replace if necessary.

INFORMATION

Make sure that the reflector is not soiled. If the reflector is dirty it has to be replaced.

(7) Replace the protective glass and snap the mounting link closed.



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Working in the switch cabinet

The fuses, relays and current regulator are in the switch cabinet. This chapter describes the exchange of the fuses and relays, setting of the time lag relay and the current regulator.

Replacing fuses


(2) Open the switch cabinet doors.

Figure 90: Fuses and relays

1 Relay

2 Current regulator

3 Fuses

Fire hazard!

Wrong fuses can lead to short circuits.

Short circuits lead to fires and can cause life threatening injuries or even death.

Only use fuses with the same ampere rating.

Never override blown fuses.

never exchange blown fuses with fuses with a higher voltage consumption.

(1) Check which fuse is defective with support from the electrical plan.

(2) Pull defective fuse from its holding device.

(3) Check the electrical contacts for secure attachment and corrosion.

(4) Insert a new fuse with the same amount of Ampere.


2 3

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(6) Turn on engine, if necessary.


(8) Close switch cabinet door.

INFORMATION

Repeated blowing of replaced fuses is an indication that there is a defect within the electrical sys-tem.

Replacing relays


(2) Open switch cabinet.

(3) Check which relay is defective with support from the electrical plan.

(4) Remove defective relay.

(5) Insert new relay.

(6) Check the electrical contacts for secure attachment and corrosion.



(9) Close switch cabinet door.

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Setting time lag relay

Figure 91: Time lag relay

INFORMATION

The electric plan contains the setting data for the time lag relay.

The functions and the displays of the LEDs are described on the side surfaces of the time lag relay.

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Settings at the time lag relay

The time lag relay should, for instance, be set to a response delay of 30 seconds.

Proceed as follows:

(1) Set the function switch to AI ( = response delay – On delay).

(2) Set time switch to "1 min" (1 minute).

(3) Set the multiplier switch for time domain to "5".

(4) If you multiply 1 minute (60 seconds) with 0.5 you receive the result ½ minute or 30 seconds.

The time lag relay is set to 30 seconds.

INFORMATION

If, for instance, the multiplier is set to 10, there is no response delay.

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Setting current regulator

The current regulator adjusts the opening width of the hydraulic valve magnet. This determines the amount and speed of the hydraulic oil throughput.

The throughput amount is set with the maximum current adjustment screw "I max".

Figure 92: Electrical current regulator

1 LED indicator

2 Maximum current

Increasing throughput amount

(1) Turn the adjustment screw "I max" clockwise with a flat headed screw driver.

Reducing throughput amount

(1) Turn the setting screw "I max" counter-clockwise with a flat headed screw driver.

INFORMATION

All other settings of the current regulator are preset from the factory and may not be changed to avoid errors and malfunctions.

The settings may only be changed by the TREPEL service personnel.

2

1

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Proximity switch

This chapter describes the exchange of the proximity switch and the setting of the switch distance.

The CHAMP 70 is equipped with electrical proximity switches. The electrical proximity switches work non-contact, i.e. the switching plate is recognized with a sensor and a signal is created. The signal triggers the switch of the proximity switch.

Requirements

Before you begin to exchange proximity switches or to set the switch distance, the following condi-tions need to be met:

• No cargo is located on the platform.• Parking brake is engaged.• Wheels are blocked by blocks.• Motor is turned off.• The main battery switch is switched off.

Working under raised platforms

While replacing or adjusting the proximity switch you partially work under the platforms.

Observe the following safety instructions for this:

Lowering platform!





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Exchanging the proximity switch

Figure 93: Electrical proximity switch/capacitive proximity switch

1 Capacitive proximity switch

2 Switching plate

3 Sensor button

4 Counternut, spanner width 36x5 mm

5 Adjustment nut, spanner width 36x5 mm

6 Contact terminals

The proximity switch has a connection, i.e. the proximity switch can easily be replaced.

INFORMATION

Measure the switch distance before removing the proximity switch.

(1) Remove defective proximity switch.

(2) Place new proximity switch on the connection.

(3) Set switch distance.

5-10 mm (0.2-0.4 inch)1

5

2

34

6

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Set switch distance

The distance between the switching plate and the sensor surface can be changed with the setting nut. The setting of the switching distance is fixed with the locking nut.

INFORMATION

If the proximity switch reacts to the switching plate, then the switching distance is set correctly.

The optimum switching distance between the sensor surface and the switching plate is 5-10 mm (0.2-0.4 inch).


(2) Turn the setting nut with the screw wrench and set the desired switch distance.

(3) Carry out a functional test.

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4. Operational Materials

This chapter informs you about operational materials that are used for operating the CHAMP 70.

Operational materials are fuels and lubricants, such as engine oils, gear oils, greases, and coolants.

Observe the valid regulations, ordinances, and standards of the country of operation.

Operational material regulations

Be sure to observe the operational material specifications of the manufacturer of the engine, transmission, and axle manufacturers.

Vehicle identification sheet

In the CHAMP 70's vehicle identification sheet, you will find filling amounts and specifications of the oper-ational materials that are factory-filled in the CHAMP 70.

A. Safety Information


Operational materials can contain toxic ingredients.

Touching, swallowing, or inhaling operational materials can lead to poisoning.

When handling operational materials, wear suitable protective clothing and breathing protec-tion.

Do not spill operational materials.

In case of skin contact with operational materials, thoroughly rinse the affected areas of the skin.

In case of eye contact with operational materials, rinse out eyes for 10 to 15 minutes with clear water and consult a doctor.

If operational materials are swallowed, consult a doctor immediately.

Fire hazard!

Operational materials are highly flammable and can lead to fires.

Persons can be seriously injured or even killed because of fires.

When handling operational materials, do not use naked flames, lighting, or tools that generate sparks.

Smoking is prohibited during all service work on the CHAMP 70.

Operational materials are an environmental hazard!

Spilled operational materials contaminate the soil and the groundwater.

Exchange operational materials only in places designated for this task.

Dispose of used oils according to the valid national laws and regulations.

If in doubt, contact your shop or certified disposal company.

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Impermissible fuels!

Using impermissible fuels can damage the fuel system and/or the engine of the CHAMP 70.

Only use fuels that are compliant with the specified standards and the amended national envi-ronmental and low-temperature requirements.

Do not use kerosene, heating oils, or marine diesel fuels.

Do not add normal or premium gasoline to the diesel fuel.

Engine damage!

Sustained use of petroleum mixed with the fuel can lead to engine damage.

Adapt the amount of petroleum added to the engine temperature and keep the amount as low as possible.

Observe the information on the mixing ratio provided in the documentation of the engine man-ufacturer.

Impermissible coolant!

Using impermissible fuel can negatively affect the corrosion protection and damage the engine of the CHAMP 70.

Only use coolants authorized by the engine manufacturer.

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B. Fuels

Cleanliness when refueling

When refueling and when working on the fuel system, cleanliness is important. Dirt or water in the fuel system can damage the fuel pump and the injection system.

Fuel specifications

Only refuel using commercially available diesel fuel with a sulfur content of less than 0.5 %.

INFORMATION

If the diesel fuel has a high sulfur content, operational safety and the long-term durability of the exhaust after-treatment system cannot be guaranteed.

Only use fuels that are compliant with the following standards and the amended national environ-mental and low-temperature requirements:

• EN 590• ASTM D 975 1-D• ASTM D 975 2-D

Impermissible fuels!

Use of fuels that are not permitted can damage the fuel system, the engine and/or the exhaust after-treatment system of the CHAMP 70.

Only use fuels that are compliant with the specified standards and the amended national envi-ronmental and low-temperature requirements.

Do not use kerosene, heating oils, or marine diesel fuels.

INFORMATION

Fuels that do not comply with the standards above require the permission of the manufacturer. Using non-approved fuels voids the warranty.

If you plan to use biodiesel, first consult the engine manufacturer whether the engine of your CHAMP 70 is suitable for operation with biodiesel.

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Operation with diesel fuel during winter

Operation during winter places special demands on low-temperature performance (cold filter plug-ging point). The appropriate fuels are available at gas stations in winter.

For engines with common rail injection, admixtures of petroleum and the addition of extra fluid additives is not permitted.

To avoid malfunctions and clogging in the fuel system, winter diesel fuel has to be used if the ambient temperature is below 0 °C (32°F).

The winter diesel fuel can be used for temperatures down to –20 °C (–4 °F) and is available at fuel stations well in time before the start of the cold months of the year. In the transition period and in individual countries, this might not always be the case.

Impermissible fuel!

Adding normal or premium gasoline can heavily damage the engine.

Do not add normal or premium gasoline to the diesel fuel.

INFORMATION

For arctic regions, special diesel fuels suitable for temperatures down to –44 °C (–47 °F) can be used. See also http://www.deutz.com/service/operating_liquids_brand_additives/fuels.en.html.

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C. Oils for Equipment Units

Engine

Only use HD engine oil with the following specifications (engine type: DEUTZ TD 2011 L04i 53.7 kW / 72 HP):

Table 12: Specification of the engine oils

The following diagram and table show which viscosity classes you can use in the various tempera-ture ranges.

Figure 94: Viscosity classes of engine oils

Designation Standard

CI-4 API (American Petroleum Institute)

E7 ACEA (Association des Constructeurs Européene d’Automobiles)

DQC II or DQC III DEUTZ

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At low temperatures, the viscosity is important for the cold start; at high temperatures, it is important for adequate lubrication during operation under full load.

The temperature values refer to the prevailing ambient temperatures.

In case the CHAMP 70 is used at temperatures below -25 °C (–13°F), special lubricants are neces-sary. Your engine manufacturer will be able to recommend suitable lubricants.

INFORMATION

You can find more information on engine oils in the documentation of the engine manufacturer (DEUTZ) and at http://www.deutz.com/service/operating_liquids_brand_additives/deutz_oils.en.html.

Axle gear oils

The differential and planetary gears of the front axle have been factory-filled with a hypoid bevel gear oil of the quality API GL-5 with SAE 90 viscosity class.

The viscosity class SAE 90 is suitable for a temperature range of -14 °C to +59 °C.

Table 13: Axle gear oils

Type Norm Viscosity class

Hypoid bevel gear oil with Limit-Slip addi-tive (000.291.0026)

API GL-5 MIL-L-2105 B ZF TE-ML 05C ZF TE-ML 12C ZF TE-ML 16E

SAE 90

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Hydraulic oils

Use a hydraulic oil of the specification HLP-ISO-VG for the hydraulic system.

The following diagram shows which viscosity classes you can use in the temperature ranges of out-side air.

Figure 95: Viscosity classes of hydraulic oil

The temperature values refer to the prevailing ambient temperatures.

- 40- 30- 20- 10

+ 10+ 20+ 30+ 40+ 50

- 40- 22- 4

+ 32- 14

+ 50+ 68+ 86+ 104+ 122

11-C00-021-002A-2

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D. Lubricating Greases

The lubricating greases should reduce friction and wear, prevent corrosion, seal lubricating points, and be resistant to occurring operating temperatures.

Consider the operating circumstances, outside influences, lubrication intervals, and especially the performance characteristics of the grease when selecting a suitable lubrication grease.

Table 14: Lubricating greases

Type Standard Viscosity class

Exterior temperature

Chain spray commercially available

– Drop point <170 °C (<338 °F)

Lithium based multi-purpose grease

DIN 51502 – Drop point <170 °C (<338 °F)

Acid-resistant grease for battery terminals

e.g. BOSCH 5700 102025

– –

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Section 2Troubleshooting

1. Troubleshooting

The following provides support for searching for the cause of a malfunction on the CHAMP 70.

Before you start with the troubleshooting, make sure that there were no operator errors or no mechanical damage is present or that lubricants and fuels are lacking.

A. Tasks before troubleshooting

Electrical system

Check the following items before troubleshooting in the electrical system:

• Fixing of screw and weld connections• Function of the control lights and LCDs• working fuses• correct function of battery, generator and their regulators• cabling follows the original circuit diagram• all EMERGENCY OFF buttons unlocked

Have the electrical diagram ready at hand.

Hydraulic system

Check the following items before troubleshooting in the hydraulic system:

• Setpoint setting of all pressure valves • full hydraulic tank• Function of the solenoid valves• Setpoint setting of the flow control valves• Leaks

Have the hydraulic diagram ready at hand.

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B. Troubleshooting Table

Malfunction Possible cause

Remedy

Engine does not start Main battery switch not turned on.

Turn on main battery switch "-S0".

Operate/drive mode selector is not in middle position

Check position of control switch "-S42".

Emergency-off chain active. Emergency off LED is lit

• Check all emergency off buttons.• Check hydraulic oil level "-H21".• Check if shut-off cock hydraulic tank

"-H78" is locked.• Check engine oil pressure "-H8".• Check engine temperature "-H10".• Check fuel level "-P2".• Check emergency stop limit switch for

lift system "-S41".

After changing the fuel filter

• Vent the fuel system by using a hand pump.

• Activate starter for 2 minutes.

The engine does not automatically run at operating speed

Engine components defective

Ask the engine manufacturer.

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CHAMP 70 does not drive

Operate/drive mode selector is not in posi-tion "Drive"

Check position "-S42" and control light "-H19".

Elevator is not down completely

Check lowering limit switch "-B85".

Generator of the engine not operational

Check control light "-H1".

Drive selection switch "2S43" without function

Check electrical connections, terminals and relays.

System pressure in the brake system is too low / no brake pressure "2H20" is lit up

• Check push button "-S9" (802).• Check pressure accumulator (840, 842).

System pressure of the hydraulic system is faulty

• Check pressure settings "Y4-M1", "Y5-M2" (501).

• Check high pressure cartridge (150, 190).


Remedy

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CHAMP 70 drives only slowly

Motor speed too low • Check mechanical connection to engine.

• Check hydraulic valve "Y39-M4" (320, 322) and electrical control.

Hydraulic pump oper-ates only in the small swivel angle

• Bridge is not fully down/limit switch is not connected or is defective (-B82).

• The proximity switch on the gas pedal is always on (-B80).

• Check hydraulic valve "Y3" (310) and the corresponding electrical control.

• Check the correct setting of the main pump/ask the manufacturer.

The gas pedal does not function properly

Check control valve (250).

CHAMP 70 only runs fast

Hydraulic pump oper-ates only in the large swivel angle

• Bridge is not up/limit switch is not con-nected or is defective(-B82).

• The proximity switch on the gas pedal does not switch off (-B80).


• Check the correct setting of the main pump/ask the manufacturer.

Operating brake/brake power is insufficient

Brake pressure is insufficient

• Check M7 + M8. • Check position/limits of the brake pedal.• Check the setting of the brake valve

(800).

Air in brake system Vent the brake system.

Dynamic brake system does not function

Check settings.

Brake linings defective Leak between the planetary gears and the brake system.

Poor brake action of the parking brake

Brake pressure is insufficient

• Check brake linings and brake disk.• Check setting of the spring package.• Check electrical and hydraulic control

(Y30).


Remedy

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Stabilizers do not retract or retract insuffi-ciently

elevator is not lowered completely Limit switch not used or defective


Control switch "-S42" does not function prop-erly


Time lag relay does not function properly or is incorrectly set

Check relay "-K10".

System pressure is insufficient

• Check hydraulic valve "Y4-M1" (501).• Check hydraulic valve "Y16" (204).• Check high pressure cartridge (150/

190).• Check hydraulic valve "Y7-M9", "M12".

Low outside tempera-ture

Warm up CHAMP 70 to operating tempera-ture.

Stabilizers do not extend or extend insuf-ficiently

Parking brake is not engaged

• Check control switch "-S43". • Check control light "-H13".




Check relay "-K9".



190).• Check hydraulic valve "Y8" (520).

Low outside tempera-ture

Warm up CHAMP 70 to operating tempera-ture.


Remedy

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The bridge does not lift. Control switch "-S44"/ "-S44.1" does not func-tion properly




190).• Check hydraulic valve "Y11" (540).• Check flow regulator (373).

Lifting limit switch in use or defective

Check limit switch "-B81".

The bridge does not lower

Control switch "-S44"/ "-S44.1" does not func-tion properly

Electrical connections, terminals and relays

Control pressure is insufficient


190).• Check hydraulic valve "Y12" (540).• Check flow regulator (373).


Remedy

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The elevator does not lift or lifts too slowly

Operate/drive mode selector is not in posi-tion "Extend stabiliz-ers"

• Check control switch "-S43".• Check control light "-H18".


• Check control switch "-S43". • Check control light "-H13".



Proximity switch (auto-matic repeat) is con-nected or defective

Check proximity switch "-B83".

Lowering limit switch in use or defective




190). • Check hydraulic valve "Y12" (540).• Check flow regulator (377).

Proximity switch (auto-matic repeat is occu-pied or defective)

Check proximity switch "-B83".

Lowering limit switch in use or defective


Hydraulic pump oper-ates only in the small swivel angle


• Check the correct setting of the main pump/ask the manufacturer


Check relay "-K35".

Motor speed too low • Check mechanical connection to engine.

• Check hydraulic valve "Y39-M4" (320, 322) and electrical control.


Remedy

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Elevator does not lower or lowers too slowly







Control pressure is insufficient

• Check hydraulic valve "Y4" (M1).• Check hydraulic valve "Y16" (204).• Check high pressure cartridge (150/

1190). • Check hydraulic valve "Y9" (521).• Check flow regulator (522).

PC drives are not work-ing or some sections are not working




• Check control switch "-S43".• Check control light "-H13" .


• Check PC drives of the emergency operating equipment.

• Check hydraulic valve "Y4" (M1).• Check high pressure cartridge (150/

190). • Carry out troubleshooting procedure

using the hydraulic diagram.

Current regulator defective set improp-erly

• Check regulators -A34 to -A37.• Check regulators -A50 to -A55.

Control switch "-S47", "-S49", "-S50" does not function properly



Remedy

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Table 1: Troubleshooting

Adapter not functioning System pressure is insufficient


190).• Check hydraulic valve "Y24/25" (716),

"Y26/27" (1700), "Y41/42" (718) (see also hydraulic diagram).



Bridge is not fully down, switch is not used or is defective


Mechanics are slug-gish

Check the setting screws of the adapter; lubri-cate the movable parts.

Guide rails do not retract



190).• Check hydraulic valve "Y58" (764),

"Y59" (762), "Y60" (766).



Bridge is not down completely/switch (truck loading height) is not used or is defective

Check limit switch "-B85" or "-B87".

The main pump does not function properly (CHAMP 70 drives and lifts only slowly)



• Check the setting of the main pump/ask the manufacturer.


Remedy

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