1. Delivery The TSP 6000 will be delivered in 3 parts 1.1. Power Unit
1.2. Mast with Cabin
1.3. Load Handler
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2. Equipment Required The country specific Health and Safety Rules must be observed 2.1. Personnel 2 Technicians
2.2. Lifting Equipment
1 mobile crane with 2 hooks, capacity of minimum 8 t. 1 fork lift with a capacity of 1.5 t and a lift height of 3.5 m.
or alternatively
1 fork lift with a capacity of 5.0 t and a lift height of 3.5 m.
1 fork lift with a capacity of 2.5 t and a lift height of 1 m more than the collapsed height of the TSP.
1 round sling (blue) with 8 t capacity, 6 m perimeter
2 round sling (green) with 2 t capacity, 4 m perimeter
2 high strength shackle bolts with a capacity of 9500 kg.
4 chain shackle bolts with a capacity of 3250 kg.
2.1. Tools 1 set wrenches metric up to size 32 mm 1 set sockets metric like above 1 set wrenches imperial up to 1 ½“ Allan keys size 2 - 12 mm Metal-Scissor, cutter knife ¾ inch ratchet Torque wrench 435 Nm
2.3. Further equipment
1 pc square wooden block 60 x 60 mm, 1,5 m long 1 Oil sump flat 1 Pallet 1 crane attachment for fork lift with a capacity of 3 t 1 working platform or 1 truck with cabin and a lift height to reach the top of the TSP mast
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3. Assembly 3.1. Hook on mast and cabin
The TSP is delivered on a lorry. It’s possible to unload the trailer via a ramp directly into a warehouse or sideward. If this way is chosen you have to jack up the transportation pallet on wooden blocks to gain access for the forks.
After unloading the TSP fit the blue rope at the bracket on top of the mast. Use therefore the high strength shackle.
The bracket doesn’t allow to fit the shackle from outside. Due to the sharp corners of the bracket the rope will be disturbed. So the pin of the bracket has to be removed and put trough the eye of the shackle.
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3.2. Transport of the components
If you unload the truck via a loading dock the components are lift able and moveable by using a WP or PTH.
Shown in the picture below is the transport with two forklifts. During transportation in length direction the mast side of the transport palette also can be guided from a WP or PTH.
Now unwrap the components but don’t cut the tapes. They secure the components during up righting and installation.
3.3. Uprighting the mast
For up righting the mast use the lifting blocks delivered in a separate box. The box is inside the battery compartment of the power unit. Fit the blocks at the bottom side of the mast unit by using the special drillings.
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The drillings have a bigger diameter then the normal mounting drills. They are located between the drillings of the normal fitting bolts.
If the mast unit will be align with 2 forklifts the forks of the 5t truck need to be removed. They would demage components on the mast unit.
Now route the 2 small ropes around the fork carriage of the 5t truck and fit them with a shackle to the blocks on the mast unit. So the ropes secures themselves. Cut all securing tapes except the tapes around the platform and the gates. Revision GB 2-2 10.05.06 -6- Service Department Munich
Lift the mast unit free and remove the transportation pallet. Now prepare a normal pallet to secure the cabin during the last phase of uprigthing.
After the mast unit exceeds the tilt point put a square wooden block 60 x 60 mm underneath the mast. This wooden block allows the mast unit to
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be at the right height during the power unit installation. Chock the brakeless load wheels.
3.4. Power Unit assembly
To improve the handling remove all side covers. Lift up the power unit by routing the small slings around the top braces inside the battery compartment. Related to the battery compartment size the position of the ropes may varies a bit.
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Shown in the pictures above is the position on a power unit with an AA
battery compartment. Lift up the power unit with 2.5t truck and make sure that the unit is horizontally lifted.
Now gently guide the pin of the power unit into the drilling of the mast unit.
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Further on assemble the mounting bolts. Fit the 6 bolts on the bottom side and the 2 long bolts on the top. The “washers” delivered with the 2 long bolds are used as spacer. They keep the power unit and mast unit vertically aligned. So the lean back of the mast unit is set in the factory. If these spacers are required it’s decided during the final assembly at the factory. If this spacers are present they have to be put between the mast and power unit. If you don’t use them, the stability of the truck is in compromise.
To fit the rear bolts the battery rollers have to be taken out. Fit the threaded side of the bolts inwards into the battery compartment. So you are able to check the torque of the nuts during a maintenance from outside.
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3.5. Tighten the mounting bolds
Now the bolts need to be tighten in 3 steps. Refer to the sequence shown in the picture below. Tighten the bolts in the first step with 305 Nm. Increase the torque in a second step to 435 Nm. Check the torque of 435 Nm in the third and last step.
To finish this work step now cut and remove the tapes strapping the cabin and doors down. Take out wooden block underneath the mast and the wooden lath of the mast profile. Last of all disassemble the bracket on top of the mast. The cabin must not be lifted before bracket removal. The cylinders will be damaged.
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3.6. Battery assembly
Put back the rear battery rollers.
Assemble the battery but don’t switch on the truck yet.
Install the battery retainer on the inner side of the bottom battery cover. To adjust the distance you need a ¾ “ ratchet. Secure the retainer by fitting the securing screw above the buffer. The buffer is protecting the thread of the retainer.
The retainer is supplied in two different length.
Depending on the size of the battery it may be necessary to fit a Spacer
Kit. This Spacer Kit consists out of two iron bars. These bars have to be screwed into the battery compartment as required. The drilling s are prepared. So the movement of the battery will be minimized.
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3.7. Connections between Power Unit and Mast
For the initiation of the truck you have to assemble the following connections: Motor cable U, V and W at the terminal board of the pump motor. Plug in CA 412, CA 413, CA 414, CA 415 and CA 416.
Fit and adjust the steel cable of the emergency lower valve.
Only on trucks with EAC or / and Wire Guidance:
Route the cable coming from the mast unit across the battery compartment wall and plug in CA 602 at the Access 6 module.
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Only trucks with Wire Guidance:
Remove the skirt across the drive wheel by using a 12 mm Allen key. Fit the Sub-Min D plug CA 603 on the wire guidance sensor. Assemble the sensor with a clearance of 82 – 86 mm to the floor.
3.8. Tank breather
For transportation the tank is closed and sealed. This cover has to be removed prior to the first movement of the truck (danger of vacuum inside the tank). Replace it with supplied breather. Make sure that no part of the silicon sealent drops into the tank.
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3.9. Load Handler Assembly
First of all remove all left hand side covers at the cabin. Remove the top left stop block.
Loosen the hose bundle underneath the cabin floor. Remove the bottom covers of the load handle and secure the control cable. Lift up the load handler together with the transportation pallet with the 2.5t forklift. Secure the lifting sling with a second one to the fork carriage. After the load handler is aligned cut the straps and remove the pallet. Don’t cut the tapes around the forks. These tapes will make it possible to drop the mast without tipping the load handler.
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3.10. Load Handler connections
Loosen the hose bundle totally from the platform floor.
Remove the bottom cover and fit the hoses.
On the load handler side one hose is marked with 1.
On the platform side the elbow terminals are marked with 1 and 2.
In case a movement of the truck is necessary there is a bridge on PC 701.
Remove and keep this bridge in case of disassembly of the truck. The bridge is located between pin 7 and 8 (brown and yellow cable).
Align the load handler as far as possible to the teeth bars and keep it there. Switch on the truck and operate traverse to the right. Instantly after driving in the load handler fit all stops and bottom covers of the cabin. Now drive the load handler into the left stop and check the vertically position by counting the remaining teethes. The number of teethes must be equal top and bottom. If necessary correct the position. Afterwards cut the remaining tapes around the fork carriage.
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Fit the angle bracket on the load handler bottom. Reassemble the cover left, right and bottom side. Assemble the hose protection guard at the cabin floor. Watch for the screw position. In case you mount them opposite to the shown position the load handle will be damaged.
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3.11. Transportation lock
New on TSP 6000 trucks is a transportation lock for the mast. This lock prevent the mast stages against totally collapsing during transport. To remove the lock lift up the cabin. If the truck is equipped with a TF mast you must lift the mast above staging.
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3.12. Initiation of the truck
Put all covers back in position. Fit all accessories to the operator compartment (mirror, paper clamp, scanner gun holder, etc) Place the operator egress system in the storage area behind the operator seat. Calibrate all handles, lift heights, lift / lower stops. Check and set all parameters. Perform a pre delivery inspection, make a function check and finally lubricate the truck.
