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SMV 4127-4545 TB
ORIGINAL INSTRUCTIONS
065824en / Revision A / 2014-06-17
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not be reproduced,
disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. 2014 Konecranes Plc. All rights reserved. Konecranes,
Lifting Businesses and C are either registered trademarks or trademarks of Konecranes Plc.Copyright (2014) Konecranes Plc. All rights reserved.
TABLE OF CONTENTS
MAINTENANCE MANUAL
TABLE OF CONTENTS
1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
2.4
2.5
3
3.1
3.2
3.3
3.4
3.5
INTRODUCTION...........................................................................................................
About this manual........................................................................................................
1.1.1
Use of the manual............................................................................................
1.1.2
Copyright notice...............................................................................................
1.1.3
Symbols used in this manual............................................................................
About this product.......................................................................................................
1.2.1
Use of the product............................................................................................
1.2.2
Identification of the product..............................................................................
Standards and directives.............................................................................................
Contact information.....................................................................................................
9
9
9
9
9
10
10
10
10
11
12
12
12
12
16
17
17
17
17
18
19
19
19
19
20
21
21
21
22
22
23
23
23
24
PRODUCT DESCRIPTION............................................................................................
Technical description..................................................................................................
Machine outline............................................................................................................
Controls and indicators in the cabin..........................................................................
Dashboard....................................................................................................................
Display..........................................................................................................................
3.5.1
Home page......................................................................................................
3.5.2
Engine page.....................................................................................................
3.5.3
ECO driving page.............................................................................................
3.5.4
Transmission page...........................................................................................
3.5.5
Hydraulics page...............................................................................................
3.5.6
Attachment page..............................................................................................
3.5.7
Information page..............................................................................................
3.5.8
Main menu.......................................................................................................
3.5.9
Measure page..................................................................................................
25
25
26
27
28
29
29
30
30
31
31
32
32
32
33
3/143
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public,
confidential and proprietary trade secret that may not be reproduced, disclosed to other parties, altered or otherwise employed in any
manner whatsoever without the express written consent of Konecranes Plc. 2014 Konecranes Plc. All rights reserved. Konecranes,
Lifting Businesses and C are either registered trademarks or trademarks of Konecranes Plc.
MAINTENANCE MANUAL
3.6
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
5
5.1
5.2
5.3
TABLE OF CONTENTS
33
34
35
35
35
38
40
OPERATING INSTRUCTIONS......................................................................................
Before driving...............................................................................................................
4.1.1
Daily maintenance before operation.................................................................
4.1.2
Turning on and turning off the battery main switch...........................................
4.1.3
Checking the condition and pressure of the tires..............................................
4.1.4
Checking the engine oil level............................................................................
4.1.5
Checking the transmission oil level..................................................................
4.1.6
Checking the coolant level...............................................................................
4.1.7
Checking the hydraulic oil level........................................................................
4.1.8
Checking the brake cooling oil level.................................................................
4.1.9
Checking the air filter indicator.........................................................................
4.1.10 Cleaning the engine air filter's coarse separator...............................................
4.1.11 Checking the windshield washer level..............................................................
4.1.12 Adding fuel.......................................................................................................
4.1.13 Adjusting the operator's seat............................................................................
4.1.14 Adjusting the steering wheel............................................................................
4.1.15 Using the cabin ventilation...............................................................................
Steering and braking...................................................................................................
4.2.1
Steering...........................................................................................................
4.2.2
Activating the declutch.....................................................................................
4.2.3
Activating the parking brake.............................................................................
4.2.4
Parking.............................................................................................................
Emergency stopping....................................................................................................
Locking the cabin door................................................................................................
Using the rear emergency exit....................................................................................
Running in....................................................................................................................
Operating......................................................................................................................
4.7.1
Starting the engine...........................................................................................
4.7.2
Stopping the engine.........................................................................................
4.7.3
Operating the machine.....................................................................................
4.7.4
Driving forwards...............................................................................................
4.7.5
Stopping the machine......................................................................................
4.7.6
Driving in reverse.............................................................................................
4.7.7
Transport mode................................................................................................
Lifting and driving with a container............................................................................
4.8.1
Before lifting loads...........................................................................................
4.8.2
Lifting a load.....................................................................................................
4.8.3
Transporting a load..........................................................................................
4.8.4
Releasing a container......................................................................................
4.8.5
Overriding the seated signal.............................................................................
4.8.6
Emergency lowering.........................................................................................
4.8.7
Activating the emergency lifting and lowering function.....................................
41
41
41
42
43
44
44
45
46
47
47
48
48
49
50
51
52
52
52
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68
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71
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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public,
confidential and proprietary trade secret that may not be reproduced, disclosed to other parties, altered or otherwise employed in any
manner whatsoever without the express written consent of Konecranes Plc. 2014 Konecranes Plc. All rights reserved. Konecranes,
Lifting Businesses and C are either registered trademarks or trademarks of Konecranes Plc.
TABLE OF CONTENTS
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
MAINTENANCE MANUAL
71
72
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73
73
74
74
74
76
77
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79
79
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100
101
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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public,
confidential and proprietary trade secret that may not be reproduced, disclosed to other parties, altered or otherwise employed in any
manner whatsoever without the express written consent of Konecranes Plc. 2014 Konecranes Plc. All rights reserved. Konecranes,
Lifting Businesses and C are either registered trademarks or trademarks of Konecranes Plc.
MAINTENANCE MANUAL
5.12
5.13
5.14
5.15
5.16
5.17
5.18
6
6.1
6.2
6.3
6.4
6.5
TABLE OF CONTENTS
101
102
103
103
104
104
104
104
105
106
107
107
108
108
109
110
110
111
112
113
113
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116
117
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119
119
120
120
120
121
121
121
122
122
123
123
124
125
126
126
MAINTENANCE SCHEDULE........................................................................................
Commissioning inspection.........................................................................................
Commissioning service...............................................................................................
Daily maintenance before operation...........................................................................
Maintenance points after the first 150 operating hours............................................
Regular service............................................................................................................
127
127
127
128
128
129
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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public,
confidential and proprietary trade secret that may not be reproduced, disclosed to other parties, altered or otherwise employed in any
manner whatsoever without the express written consent of Konecranes Plc. 2014 Konecranes Plc. All rights reserved. Konecranes,
Lifting Businesses and C are either registered trademarks or trademarks of Konecranes Plc.
TABLE OF CONTENTS
6.6
MAINTENANCE MANUAL
134
134
135
135
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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public,
confidential and proprietary trade secret that may not be reproduced, disclosed to other parties, altered or otherwise employed in any
manner whatsoever without the express written consent of Konecranes Plc. 2014 Konecranes Plc. All rights reserved. Konecranes,
Lifting Businesses and C are either registered trademarks or trademarks of Konecranes Plc.
MAINTENANCE MANUAL
TABLE OF CONTENTS
8/143
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public,
confidential and proprietary trade secret that may not be reproduced, disclosed to other parties, altered or otherwise employed in any
manner whatsoever without the express written consent of Konecranes Plc. 2014 Konecranes Plc. All rights reserved. Konecranes,
Lifting Businesses and C are either registered trademarks or trademarks of Konecranes Plc.
MAINTENANCE MANUAL
1 INTRODUCTION
INTRODUCTION
1.1
1.1.1
NOTE
Keep these instructions in a safe, accessible location for future reference by personnel
operating the equipment or exposed to the operating equipment.
The manufacturer makes absolutely no warranty whatsoever regarding the contents of this
manual, express or implied, whether arising by operation of law or otherwise, including, but not
limited to, any implied warranties of merchantability or fitness for a particular purpose.
1.1.2
Copyright notice
This document and the information contained herein, is the exclusive property of Konecranes
Plc and represents a non-public, confidential and proprietary trade secret that may not be
reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever
without the express written consent of Konecranes Plc. Copyright 2014 Konecranes Plc. All
rights reserved. Konecranes, Lifting Businesses and C are either registered trademarks or
trademarks of Konecranes Plc.
1.1.3
Description
Indicates items which require special attention by the reader.
There is no obvious risk of injury that is associated with notes.
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MAINTENANCE MANUAL
1.2
1.2.1
1 INTRODUCTION
The machine is designed to perform lifting and transporting loads within the limits that are
specified in the machine's capacity plate. For more information, see Lifting capacity
plate (page 35).
Contact the manufacturer or manufacturer's representative in case of doubt.
1.2.2
1.3
Attachment number
Lift boom number
Lifting capacity plate
Steer axle number
5.
6.
7.
8.
Engine number
Chassis number
Transmission number
Drive axle number
NOTE
Konecranes reserves the right to modify the design and material specifications without
prior notice.
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1 INTRODUCTION
1.4
MAINTENANCE MANUAL
Contact information
Konecranes Lifttrucks AB
Anders Anderssons vg 13
285 35 Markaryd
Sweden
Tel. +46 433 733 00
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MAINTENANCE MANUAL
2.1
2.1.1
Signal words
The following signal words and symbols are used to identify safety messages in these
instructions.
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious
injury.
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious
injury.
Indicates a potentially hazardous situation that, if not avoided, could result in damage to
property or environment.
2.1.2
Hazard symbols
Hazard symbols are used to indicate the type of the hazard and the potential consequences.
Hazard symbols are indicated by a yellow triangle with black symbols and a black triangle band
that is surrounded by a yellow border. All personnel working on or in proximity of the machine
must understand and follow the information that is given in all hazard symbols.
The general hazard symbol identifies important safety messages in this manual. When you see
this symbol, carefully read and understand the message that follows, and inform other users
when necessary.
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MAINTENANCE MANUAL
Cutting hazard
Entanglement hazard
Hand entanglement
hazard
Forward or backward
tipping hazard
Moving vehicle
hazard
Pressurized gas to
face hazard
Slipping hazard
Falling hazard
Sideways tipping
hazard
Automated startup
hazard
Crushing hazard
Tripping hazard
Electrical hazard
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MAINTENANCE MANUAL
Battery leakage
hazard
Explosion hazard
Environment pollution
hazard
Harmful substance
hazard
Ignition hazard
Oxidizing substance
hazard
Pressurized gas
hazard
Hazardous or
poisonous material
hazard
Explosive
atmosphere hazard
Biohazard
Corrosive chemical
substance hazard
Noise hazard
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MAINTENANCE MANUAL
Radioactive hazard
Laser hazard
Light hazard
Lifting hazard
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MAINTENANCE MANUAL
2.1.3
Wear approved
hearing protectors
Wear approved
protective clothing
Disconnect
equipment from
power source
Use jack
Alarm horn
Use walkway
Wash hands
Read manual
Wear approved
respirator
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MAINTENANCE MANUAL
2.1.4
General prohibition
Access prohibited
Do not climb
Do not smoke
Do not modify
Do not touch
Pacemaker not
allowed
Do not weld
No open fire
Restrict access
2.2
2.2.1
2.2.2
Preventive maintenance
Scheduled inspections and preventive maintenance are essential for keeping the product in
safe working condition. Here are some general guidelines for preventive maintenance.
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MAINTENANCE MANUAL
NOTICE
NOTE
2.2.3
NOTE
This section proposes personal protective equipment to ensure the operator's full safety.
Follow the local regulations and requirements of the working environment. Use only
approved and accepted personal protective equipment that is marked with the CE
symbol.
For safety, the operator or others near the product may be required to wear personal protective
equipment. Various types of personal protective equipment are available and must be selected
according to the requirements of the working environment.
Operators and anyone in the vicinity of the product MUST wear approved personal protective
equipment, which includes but is not limited to:
Hard hat
Eye-protector
Hearing protectors
Safety shoes
Respirator
Safety gloves
Protective clothing
Safety harness when working at heights
High-visibility clothing
Do not wear loose clothing or jewelry that can get caught on controls or pulled into moving parts
of the product.
Tie back long hair. Long hair can get entangled.
Select the appropriate clothing for each task, for example:
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Wear fire-resistant clothing when welding, flame cutting, or using an angle grinder
Tear-resistant clothing must resist damage from sharp edges in the steel structure
Wear anti-static clothing when working on electrical circuits so that components do not get
damaged by a discharge of static electricity
When working with lubricants, clothing must prevent direct skin contact with the lubricant
Choose the clothing with consideration to the temperature at the working site
2.2.4
Incident reporting
Product safety issues that you must report are events in which the manufacturer's product has
been involved in an accident or near-miss incident. Contact your local manufacturer's
representative to report any safety-related feedback, such as unauthorized modifications,
missing manuals and safety labels, neglected maintenance, or misuse. Reporting is mandatory
to ensure safe working conditions for employees, to provide information for the risk assessment
process, and to initiate product improvements. Contact your manufacturer's representative to
report product safety issues.
2.3
2.3.1
For more information, see Lifting capacity plate (page 35). Contact the manufacturer or the
manufacturer's representative in case of doubt.
2.3.2
Inclination angles
WARNING! TIPPING AND COLLISION HAZARD
If you drive on slopes steeper than 15%, the brakes may not stop the machine and
machine may roll. Risk of serious injury and damage to the machine.
Do not drive on slopes steeper than 15%.
NOTE
If you must drive the machine along steeper slopes, contact your Konecranes Lifttrucks
authorized dealer.
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MAINTENANCE MANUAL
<15%
Figure 2. Do not drive on slopes steeper than 15%
2.3.3
WARNING
MACHINE MALFUNCTION HAZARD
Unauthorized changes or modifications to the product could lead to death, severe
injury or property damage.
Always contact the manufacturer to get advance written approval for any product
change or modification.
All modifications and corrections not authorized in the product manuals or which may affect the
maintenance, operation, safety, and availability of the product need to be approved in writing by
the manufacturer before implementation. Approval requires risk assessment taking into
consideration any new risks that the changes and modifications may bring.
Changes and modifications without proper risk assessment, elimination or reduction of risk and
without appropriate safety measures may lead to death, serious personal injuries or damage to
property or environment. Unauthorized modifications will also void the warranty.
If a modification or correction as described above has been implemented without the
manufacturing organizations permission, its effect on warranty liability will be considered caseby-case. Thus, the warranty application may be rejected altogether. Should you consider a
modification or alteration necessary, you must contact the organization that manufactured and
designed the product. No modification is permitted unless you first obtain the written approval of
the manufacturer.
In order to plan and implement the modification you must deliver adequate documentation as
follows.
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2.4
Protective measures
2.4.1
Emergency stopping
MAINTENANCE MANUAL
NOTE
2.4.2
Do not operate the equipment unless you know the location of the emergency stop
button.
NOTE
Do not operate the machine unless you know the location of the battery main switch.
WARNING! ELECTRIC SHOCK HAZARD
Even though the battery main switch is turned off, there may still be voltage present in
some parts of the machine. This could result in exposure to electric shocks, which
could lead to death or serious injury.
Be aware of the battery main switch functionality.
WARNING! TIPPING OVER HAZARD
When turning off the battery main switch while the machine is moving, the machine may
tip over. Risk of serious injury and damage to the machine.
Unless in an emergency situation, do not turn off the battery main switch while the
engine is running.
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MAINTENANCE MANUAL
2.4.3
WARNING
HIGH PRESSURE HAZARD
The hydraulic system contains hydraulic accumulators to maintain the brake function
during a possible engine failure. Risk of serious injury.
Always release the brake pressure before maintaining or servicing the hydraulics of
the machine. Never loosen any hydraulic hoses without ensuring that the brake
pressure is released.
Isolate the machine before performing any maintenance work.
2.4.4
DANGER
HIGH PRESSURE HAZARD
The tires may explode while deflating them. Standing inside the danger zone during a
tire explosion will cause death.
Always stand aside the wheel when deflating or inflating tires, see deflating danger
zone illustration. Use protective eye glasses.
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MAINTENANCE MANUAL
50
120
50
m
120
2.4.5
Fire safety
WARNING
FIRE AND EXPLOSION HAZARD
Ignition sources, such as smoking, open flames, welding work, and sparks, together
with combustible materials, such as fuel, can cause fire and, if not avoided, could lead
to death or severe injury.
Ignition sources are prohibited in the vicinity of the machine.
During maintenance, follow appropriate fire prevention and protection measures,
including but not limited to trained personnel, proper fire extinguishing equipment and
agents. Before starting any maintenance or repairs that require ignition sources, such
as welding or flame cutting, carry out a proper risk assessment to control the risk.
Smoking and open fire are prohibited in the vicinity of the product.
Access to all fire-fighting equipment must be granted at all times, especially during
maintenance and repair works.
All fire-fighting equipment must be inspected and serviced regularly, according to local
regulations.
Damaged fire-fighting equipment and used fire extinguishers must be replaced immediately.
Know the various types of fires and the appropriate fire-fighting methods. Various fires must
not be extinguished with water. In most cases special extinguishing agents, dry powders or
deoxygenating agents are required.
All personnel must be trained regularly in fire-fighting methods, in cooperation with local
authorities and rescue organizations. If there is a fire, the fire alarm must be activated and all
available personnel must help with fire-fighting according to the predetermined fire plan of the
workplace.
2.5
Environmental information
2.5.1
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MAINTENANCE MANUAL
Assembly at site
Use phase, including maintenance and modernization
End-of-life dismantling and recycling of the materials
2.5.2
Energy consumption
Energy consumption during the use phase has the biggest environmental impact. Diesel fuel is
needed for lifting, transporting, lighting, heating, cooling, and other optional components that are
part of the machine.
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3 PRODUCT DESCRIPTION
PRODUCT DESCRIPTION
3.1
Technical description
MAINTENANCE MANUAL
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MAINTENANCE MANUAL
3 PRODUCT DESCRIPTION
Operator's cabin
The operators cabin fulfills international safety standards, and is rubber-mounted to protect the
operator from vibrations. Entrance to the cabin is on the left side using the steps on the
machine.
Hydraulics control levers
All hydraulics control levers for the lifting functions are grouped on the console to the right of the
operators seat. Gear lever, turn signal indicators, and windshield wipers are on the steering
column. Display, warning lights and electrical switches are on the left side of the console.
Electrical system
The electrical system is 24 V.
3.2
Machine outline
4
1
5
5
8
7
3
3
3
6
Figure 5. Machine outline
1.
2.
3.
4.
5.
Lift boom
Attachment
Twistlocks
Damp cylinders (two pieces)
Lift cylinders
6.
7.
8.
9.
Drive axle
Steer axle
Counterweight
Operator's cabin
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3 PRODUCT DESCRIPTION
3.3
20
11
19
9
10
8
7
16
18
17
15
14
13
12
Steering wheel
Wiper front screen
High or low beam
Horn
Function selector
Front windshield washer
Console with switches
Ignition switch
Emergency stop
Joystick
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Position of controls may vary from machine to machine depending on customer order.
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3.4
3 PRODUCT DESCRIPTION
Dashboard
20
14
13
12
18
11
10
15
16
17
19
8
6
5
4
1
Figure 7. Dashboard
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Parking brake
Working lights boom
Working lights attachment
Working lights (optional)
Road lights
Windshield washer
Rear windshield wiper
Roof window wiper
Hazard
Rotating beacon
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Position of controls may vary from machine to machine depending on customer order.
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3 PRODUCT DESCRIPTION
3.5
Display
The purpose of the display is to control the hydraulic system and drive line by using both analog
and digital signals from various sensors. The operator has a complete overview of the activities
during operation.
3.5.1
Home page
4
10
2
1
21
22
14
11
12
20
19
18
17
16
15
13
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Scroll wheel
Previous menu
Engine temperature
Information page
Attachment page
Fuel level
Hydraulics page
Transmission page
Engine page
Engine RPM
Transport mode
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3.5.2
3 PRODUCT DESCRIPTION
Engine page
To go to the Engine page, press F1 in the
Home page.
The Engine page displays the following:
Engine RPM
Engine temperature
Battery voltage
Engine oil pressure
Requested engine RPM
Engine operating hours
3.5.3
Engine type
Scale indicates the fuel consumption
in %
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3 PRODUCT DESCRIPTION
3.5.4
Transmission page
To go to the Transmission page, press F2 in
the Home page.
The Transmission page displays the
following:
Driving speed
Transmission oil temperature
Accelerator pedal position 0%100%
Input transmission RPM
Brake temperature, drive axle
Selected gear, 14
Driving direction F/R
Transmission error code
3.5.5
Hydraulics page
To go to the Hydraulics page, press F3 in the
Home page.
The Hydraulics page displays the following:
Load indicator
R = Pressure right-hand lift cylinder
L = Pressure left-hand lift cylinder
U = pressure piston rod side for both
cylinders
Lift boom angle, "0" = boom is lowered
Weight indicator (optional)
Indicator for regenerative fast lifting
Boom extension, "0" = boom is retracted
Indicator for regenerative fast extension
COG = distance between tire front edge
and center of attachment
Indicator, door switch (hydraulics sliding
cabin, option)
D = regenerative function ON/OFF
Boom
Tele
Door
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3.5.6
3 PRODUCT DESCRIPTION
Attachment page
To go to the Attachment page, press F4 in the
Home page.
The Attachment page displays the following:
Press A to adjust the delay time for
automatic locking of twistlocks. Adjust the
value with the scroll wheel.
Press B to activate or deactivate automatic
locking of twistlocks.
Press C to adjust the slow rotation delay.
Select the required value with the scroll
wheel.
To go to the Main menu, press
3.5.7
Information page
To go to the Information page, press F5 in the
Home page.
The Information page displays the following:
Machine specifications
Container counter
Container trip counter. Press F5 to zero.
Operating hours counter
Operating trip counter. Press F4 to zero.
3.5.8
Main menu
To go to the Main menu, press
Home page.
in the
Main
.
Adjust
Measu re
Settings
Info
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3 PRODUCT DESCRIPTION
3.5.9
Measure page
To go to the Measure page, press F2 in the
Main menu.
To move up and down on the display, turn
the scroll wheel.
To go to the selected page, press the scroll
wheel.
To go to the previous menu, press
.
Figure 16. Measure page
Preferences
.
Figure 17. Preferences page
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3 PRODUCT DESCRIPTION
Display settings:
To select settings, press buttons A-B.
To change settings, turn the scroll wheel.
To save the selected settings, press the
scroll wheel.
To go to the previous menu, press
.
Figure 19. Display settings
Language settings:
To select a language, turn the scroll wheel.
To save the selected language, press the
scroll wheel.
To go to the previous menu, press
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3 PRODUCT DESCRIPTION
MAINTENANCE MANUAL
3.6
Lifting loads
3.6.1
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3 PRODUCT DESCRIPTION
L1
L2
L3
Figure 24. Distance to the load center
The following is an example of values for the main lifting capacity and the alternative lifting
capacities of a machine, which are indicated on the lifting capacity plate.
Main lifting capacity
Lifting capacity is 45 t at lifting height 12,500 mm (492.1 in) and center of load 2,000 mm
(78.7 in).
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3 PRODUCT DESCRIPTION
3.6.2
WARNING
MACHINE MALFUNCTION HAZARD
The lifting of loads may present the risk of serious personal injury or damage to the
vehicle. The use of the machine beyond its designed purposes may cause capacity and
stability to be exceeded.
Use the boom and its attachments only for approved applications. The operator must
be trained to handle the machinery and its equipment.
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3 PRODUCT DESCRIPTION
11
7
8
9
12
14
13
1
15
16
10
17
18
19
20
22
21
23
Boom in
Boom out
Boom down
Boom up
Spreading 20'
Rotation anti-clockwise
Sideshift left
Sideshift right
Rotation clockwise
Vertical lift
Spreading 40'
Twistlock lock/open
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Emergency lowering
Stop 30'
Tilt right/left
Support legs up and down
Clamp open/close
Front legs up/down
Rear legs up/down
Override key
Cabin sliding
Forwards
Backwards
Always maneuver the control gently and slowly. The speed of the hydraulic function depends on
joystick movement. The control automatically slips into its initial position when released. All
hydraulics control levers are positioned on the console to the right of the operators seat.
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3.6.3
3 PRODUCT DESCRIPTION
Attachment light
The following figure shows the indicator light panel for the attachment. The panel is divided into
four groups. Group 1 is common for all TB and CB machines. Group 2, 3 and 4 is for CB
machines only.
1
2.
3.
4.
Group 1: This group of lamps is only used for indicating the functions of the attachment
when top-picking ISO containers. There are three lamps: green (left position) for LOCKED,
yellow (middle position) for SEATED and red (right position) for NOT LOCKED.
Group 2: This group of lamps indicates when all four lift feet are correctly ENGAGED on
the lifting points of a swap body, trailer, or container bottom lift. That is, when the lift feet
have been CLAMPED onto the lifting points (as shown by group 3 lights) and then been
raised so that the lift feet have hooked onto the lifting that is termed as ENGAGED.
Group 3: This group of lamps indicates when the lift feet have been CLAMPED onto the
lifting points. The top light indicates that the right-hand pair of legs is CLAMPED. The
lower light indicates that the left-hand pair of legs is CLAMPED.
Group 4: This group of lamps indicates when the front pair of folding legs (legs furthest to
the operator) is either up or down. When the folding legs are fully up and stowed, the top
lamp switches on. When the folding legs are fully down, the lower light switches on.
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4 OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
4.1
Before driving
4.1.1
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4.1.2
4 OPERATING INSTRUCTIONS
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4 OPERATING INSTRUCTIONS
4.1.3
DRAIN
OIL LEVEL
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4.1.4
4 OPERATING INSTRUCTIONS
NOTE
Make sure that the engine is switched off before checking the engine oil level.
4.1.5
4 OPERATING INSTRUCTIONS
4.1.6
MAINTENANCE MANUAL
NOTE
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4.1.7
4 OPERATING INSTRUCTIONS
High
Low
3. Fill with the recommended hydraulic oil up to the maximum level indicator.
4. Screw the filler cap back on.
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4.1.8
3. Fill with the recommended brake cooling oil up to the maximum level indicator.
4. Screw the breathing filter back on.
4.1.9
1
2
Figure 32. Air filter indicator
1. Check the indicator (1).
2. If the indicator shows RED, reset the indicator by pressing the knob (2) under the unit.
3. Start the engine. If the indicator still shows red, stop the engine and clean or replace the
engine air filter.
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MAINTENANCE MANUAL
NOTE
If air enters the fuel system, the engine stops. To avoid air being sucked into the fuel
system, never run the machine until the fuel tank is empty. Bleed the fuel system if air
enters the fuel system.
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4 OPERATING INSTRUCTIONS
1
2
3
2. Adjust tilting of the seat cushion, by the hand wheel (2).
3. Adjust tilting of the backrest with hand wheel (1).
4. Lift the lever (4), to adjust the seat forward
or backwards.
5
1
4
5. Adjust the lumbar support with hand wheel (5).
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4 OPERATING INSTRUCTIONS
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4 OPERATING INSTRUCTIONS
Heating
Fan
B = AC
1.
2.
3.
4.
Heating
Fan
Recirculation
Air conditioning
C = ACC
1.
2.
3.
4.
Heating
Fan
Recirculation
Air conditioning
4.2
4.2.1
Steering
To minimize unnecessary wear and tear to the tires, turn the steering wheel only when the
machine is moving.
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4 OPERATING INSTRUCTIONS
4.2.2
4.2.3
NOTE
4.2.4
Only use the parking brake to stop the machine in case of emergency. After such a
braking, check and adjust the parking brake. If necessary, replace the pads. Check the
function of the parking brake daily.
Parking
Before parking the machine, check the following:
The boom is lowered.
The boom is retracted.
The extension beams are retracted to 20 position.
The battery main switch is switched off.
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4.3
4 OPERATING INSTRUCTIONS
Emergency stopping
WARNING! FORWARD TIPPING HAZARD
The machine may tip over if the emergency stop is used when the machine is moving.
Risk of serious personal injury and damage to the machine.
Only use the emergency stop in an emergency.
1. To stop the machine in an emergency,
press the emergency stop button (1).
4.4
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4.5
NOTE
1
Figure 40. Rear emergency exit
1. Pull out the lock pin (2).
2. Lift the two handles (1).
3. Push the rear window back and upwards.
4.6
Running in
The machine can be driven at full speed right from the start. However, prolonged maximum
loading of the hydraulic system and transmission must be avoided during the first 50 hours of
operation.
After the first 150 hours, carry out first service. For more information, see Maintenance points
after the first 150 operating hours (page 128).
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4.7
Operating
4.7.1
4 OPERATING INSTRUCTIONS
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4 OPERATING INSTRUCTIONS
4.7.2
NOTE
Use the emergency stop only in an emergency situation. For more information, see
Emergency stopping (page 54).
2
6. Remove the key from the ignition switch when leaving the machine.
7. If you leave the machine unsupervised, turn off the battery main switch.
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4.7.3
4 OPERATING INSTRUCTIONS
NOTE
If you must drive the machine along steeper slopes, contact your Konecranes Lifttrucks
authorized dealer.
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<15%
Figure 45. Do not drive on slopes steeper than 15%
The machine is not intended for off-road driving.
The machine is not equipped with wheel suspension.
Always adjust your method of driving to the condition of the road (bumps, and so on), to
hazards within the working area and the load.
The hill-climbing capacity of the machine indicated in the data sheet is based on the pulling
power of the machine. It applies only to driving over obstacles and minor irregularities in
ground level.
1. Start the engine.
2. Lift the load until visibility is obtained underneath the load.
3. Hold the steering wheel steady. Always use the whole of your hand to hold the wheel knob.
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4.7.4
4 OPERATING INSTRUCTIONS
Driving forwards
1
NOTE
To avoid damage and prevent the transmission from overheating, always start in first
or second gear.
2. Release the parking brake (2).
3. Select forward (1).
4. Release the brake pedal (4).
5. Press the accelerator pedal (3) slowly.
NOTE
When starting uphill, hold the machine still using the brake pedal (4), until you have
sufficient pulling power.
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4.7.5
NOTICE
3. When the machine has stopped, activate the parking brake (2) before releasing the brake
pedal.
4. Select neutral (1).
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4.7.6
4 OPERATING INSTRUCTIONS
Driving in reverse
NOTICE
NOTE
To avoid damage and prevent the transmission from overheating, always start in first
or second gear.
2. Release the parking brake (2).
3. Select reverse (1).
4. Release the brake pedal (4).
5. Press the accelerator pedal (3) slowly.
NOTE
4.7.7
When starting uphill, hold the machine still using the brake pedal (4) until you have
sufficient pulling power.
Transport mode
While driving, the transport mode limits the speed if the boom is not in the correct position. The
speed limit is activated and a warning appears for a few seconds when the boom is in an
incorrect position. The transport mode is activated by default.
MAINTENANCE MANUAL
4 OPERATING INSTRUCTIONS
4.8
4.8.1
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4.8.2
Lifting a load
DANGER
FALLING LOAD HAZARD
Load and attachment may drop, which may cause serious injury or death.
Do not allow anyone to stand or walk under the elevated part of the machine whether it
is empty or loaded.
2. Reverse the machine carefully to a position where the lifted container is clear of the front
face of the container below.
Reverse only as much as needed to ensure clearance between the stack and the lifted
container. B is not more than 2040 cm (7.915.7 in).
3. Stop the machine and remain stationary.
4. Retract the boom as much as possible.
The boom lowers the container. The machine interrupts the retraction of the boom before it
is too far back.
5. Lower the boom.
Be aware of the stack in front as lowering makes the container go forward.
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7. Centralize the load by side shifting until the attachment hangs horizontally level.
4.8.3
Transporting a load
The correct transport position is with the load
as low as possible and as close to the
machine as possible without obstructing
visibility.
The load center must be centered
horizontally.
4.8.4
Releasing a container
1. Drive forward towards the pile.
When approaching the pile, make sure that
the center of the machine is aligned with
the center of the pile.
MAINTENANCE MANUAL
4 OPERATING INSTRUCTIONS
5. Engage the parking brake or keep the machine still using the brake pedal.
6. Maneuver the container into position above
the pile using side shifting, rotating, and
boom in or out.
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4.8.5
4 OPERATING INSTRUCTIONS
NOTE
If one of the corner castings of the container is damaged, the seated pin does not rise. In
this case you cannot lock or unlock the twistlock.
The attachment needs to be correctly seated to lock the twistlock.
4.8.6
Emergency lowering
DANGER
FORWARD TIPPING HAZARD
The emergency lowering overrides the overload system, which can cause a risk for
tipping over, unless a reachstacker or crane takes over the weight of the container and
boom. Risk of personal injury or death.
Ensure that no persons or objects are in the way while lowering.
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4 OPERATING INSTRUCTIONS
4.8.7
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5.1
WARNING
IRRITATING SUBSTANCE HAZARD
The machine contains several chemical substances, which may cause skin irritation
and allergies. Risk of injury when in prolonged contact with skin.
When handling chemical substances such as oils, hydraulic oils, fuel, grease, avoid
direct contact with the skin. Use protective gloves. Immediately wash skin that comes
in contact with chemical substances.
Preventive maintenance and maintenance must be carried out regularly and in accordance with
the regulations supplied in the maintenance schedule.
Maintenance must only be carried out by trained staff or your Konecranes Lifttrucks authorized
dealer in accordance with a service agreement. If you wish to service the machine, carry out the
first three customer service checks in the presence of Konecranes Lifttrucks authorized staff
who can check that you are following the maintenance instructions.
Before any service work, check that:
After every service, carry out a test drive and an operational test on the machine.
NOTICE
5.2
Electric welding
RISK OF DAMAGE TO THE MACHINE
NOTICE
Follow these instructions when doing electric welding on the machine. Disconnect all
battery connection, alternator, and all control units.
1. Remove the battery connections.
2. Remove the connections to the alternator.
3. Disconnect all control units in and on the machine.
4. Connect the welding clamp to the component to be welded and close to the welding point.
Never connect the welding clamp to the engine or in such a manner that the current can
pass over to a bearing.
5. When you have finished welding, connect the alternator and control unit before connecting
the batteries.
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5.3
MAINTENANCE MANUAL
Jump-starting
NOTICE
5.4
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5.4.1
NOTE
Position the cabin to full forward or full backward position. Between these positions, the
lift cylinders obstruct the cabin doors.
5.5
5.5.1
NOTICE
2
Figure 54. Lifting points
1. Attach two lifting hooks to the rear lifting eyes (1) at the counterweight.
2. Attach two lifting hooks to the front lifting eyes (2).
RISK OF DAMAGE TO THE MACHINE
NOTICE When the machine is lifted, the lift slings must not rub against any part of the
machine.
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5.5.2
Towing
WARNING! RUN OVER HAZARD
After releasing the hydraulic parking brake, the machine has no brakes, which may lead
to serious injury and damage to the machine.
As the machine is equipped with a hydraulic brake system, servo-assisted steering
system and a transmission, the engine must be idling when being towed.
If idling is not possible, release the hydraulic parking brake. After releasing the hydraulic parking
brake, the machine has no brakes. A vehicle with sufficient braking capacity to stop both
vehicles must tow the machine. For more information, see Manually releasing the parking
brake (page 112).
1. Remove the propshaft.
2. Use the rear towing peg when fitting a sturdy towing pole on the machine.
5.6
2
1
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5.7
5.7.1
5.7.2
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5.7.3
DANGER
HIGH PRESSURE HAZARD
The tires may explode while deflating them. Standing inside the danger zone during a
tire explosion will cause death.
Always stand aside the wheel when deflating or inflating tires, see deflating danger
zone illustration. Use protective eye glasses.
50
120
50
m
120
NOTICE
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2. Unscrew the valve plug. Ensure that no part of the body is in the possible trajectory of the
valve mechanism.
5.7.4
DANGER
HIGH PRESSURE HAZARD
The tires may explode while inflating them. Standing inside the danger zone during a
tire explosion will cause death.
Always stand aside the wheel when deflating or inflating tires, see danger zone
illustration. Use protective eye glasses.
50
120
50
m
120
MAINTENANCE MANUAL
5.7.5
DANGER
HIGH PRESSURE HAZARD
If you do not release the air from both tires, the wedge band and locking heads may
release and shoot off when the pressure changes. Risk of serious injury and death.
Release the air from both tires.
WARNING! HIGH PRESSURE HAZARD
Fitting tires that are not approved by the manufacturer, may cause the tires to explode,
which may cause serious injury or death.
When changing tires, only use tires which are approved by the manufacturer.
1. Remove all but two of the nuts (2) and
clamp units (3).
3
2
2. Use the support truck to support the weight of the outer wheel (5) on its forks.
3. Remove the two remaining nuts (2) and clamp units (3).
4. Lean the outer wheel (5) against the wheel
support of the support truck (1), and secure
it with a chain (8).
5
5. Reverse the support truck carefully and unload the outer wheel (5).
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5.7.6
7
8
5.7.7
7
6
2. Clean the contact surfaces.
3. Carefully drive the support truck to the required position and place the inner drive wheel (7)
over the drive axle and the hub.
4. Straighten the wheel (7).
5. Lower the forks of the support truck until the inner drive wheel (7) is resting on the hub.
6. Carefully reverse the support truck.
7. Mount the spacer (6).
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5.7.8
5
1
3
2
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5.7.9
DANGER
HIGH AIR PRESSURE
If you do not release the air from both tires, the wedge band and locking heads may
release and shoot off when the pressure changes. Risk of serious injury or death.
Release the air from both tires.
1. Remove all but two of the nuts (9) and
clamp units.
2. To support the weight of the steer wheel (10), use the forks of the support truck.
3. Remove the remaining nuts and clamp units.
4. Lean the steer wheel (10) against the
wheel support (1) and fasten it with a chain
(8).
1
8
10
5. Carefully reverse the support truck and unload the steer wheel (10).
MAINTENANCE MANUAL
5.8
5.8.1
Tightening torque
WARNING! MACHINE MALFUNCTION HAZARD
Failure to check the torque during first service and on regular intervals can result in
death, injury, or damage.
Check the torque of the bolted joints regularly. Check the torque during first service.
WARNING! MACHINE MALFUNCTION HAZARD
Lubricating the bolts before tightening can result in death, injury, or damage.
The torques presented in the table apply only for dry bolts. Do not lubricate the bolts
before tightening.
Inch bolts
10.9
12.9
9.8 Nm
14 Nm
17 Nm
24 Nm
33 Nm
10
47 Nm
12
Thread
UNC
10.9
12.9
1/4
11 Nm
15 Nm
19 Nm
40 Nm
5/16
22 Nm
31 Nm
38 Nm
65 Nm
79 Nm
3/8
38 Nm
54 Nm
68 Nm
81 Nm
114 Nm
136 Nm
7/16
61 Nm
87 Nm
108 Nm
14
128 Nm
181 Nm
217 Nm
1/2
93 Nm
131 Nm
163 Nm
16
197 Nm
277 Nm
333 Nm
9/16
133 Nm
187 Nm
234 Nm
18
275 Nm
386 Nm
463 Nm
5/8
183 Nm
259 Nm
323 Nm
20
385 Nm
541 Nm
649 Nm
3/4
322 Nm
455 Nm
568 Nm
22
518 Nm
728 Nm
874 Nm
7/8
516 Nm
729 Nm
909 Nm
24
665 Nm
935 Nm
1120 Nm
772 Nm
1090 Nm
1360 Nm
27
961 Nm
1350 Nm
1620 Nm
1 1/8
1090 Nm
1550 Nm
1930 Nm
30
1310 Nm
1840 Nm
2210 Nm
1 1/4
1530 Nm
2160 Nm
2690 Nm
33
1770 Nm
2480 Nm
2980 Nm
1 3/8
2020 Nm
2850 Nm
3550 Nm
36
2280 Nm
3210 Nm
3850 Nm
1 1/2
2650 Nm
3750 Nm
4680 Nm
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5.8.2
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5.8.3
Position
Size
Strength class
Torque
Drive axle
M18x2
10.9
Drive axle
M22x1.5
10.9
Steer axle
M22x1.5
8.8
2
1
Strength class
Torque
M14
8.8
M12
8.8
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5.8.4
1
Figure 62. Differential nuts
Table 4. Differential nuts torque
5.8.5
Position
Size
Strength class
Torque
M14
10.9
2
1
Figure 63. Engine mounting (left) and transmission mounting (right)
Table 5. Engine and transmission mounting torque
Position
Size
Strength class
Torque
M20
8.8
M16
8.8
M16
10.9
MAINTENANCE MANUAL
5.8.6
1
Figure 64. Drive axle suspension
There are four bolts on each side of the drive axle suspension. Select the right torque from the
table according to the bolt size.
NOTE
The torque values in this table do not correspond to the standard torque values
presented in the table at the beginning of this chapter.
Table 6. Drive axle suspension torque
Position
Size
Strength class
Torque
M24
10.9
M30
10.9
1,770 Nm
(1,305 lbf ft)
M36
10.9
3,100 Nm
(2,286 lbf ft)
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5.8.7
5.8.8
Position
Size
Strength class
Torque
M12x40
8.8
NOTE
The torque must not be higher than the value that is presented in this table. Otherwise
the suspension ears can be scrunched and damage the mounting brackets. The torque
value does not correspond to the standard torque value presented in the table at the
beginning of the chapter.
Size
Strength class
Torque
M24
8.8
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5.8.9
1
2
Strength class
Torque
M24
8.8
M36
8.8
1
2
Size
Strength class
Torque
M36
8.8
2,280 Nm
(1,682 lbf ft)
M20
8.8
M30
8.8
1,310 Nm
(966.2 lbf ft)
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MAINTENANCE MANUAL
5.9
5.9.1
5.9.2
5.9.3
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5.9.4
3
Figure 70. Lubrication points
1. Remove any old grease and clean the grease nipples.
2. Lubricate the steering links, four points (1) - two points on each steer link.
3. Lubricate the spindle bolts (2), one upper and one lower on each side.
4. Lubricate the wheel bearings (3), one on each side.
Grease penetrates onto the inside.
5.9.5
Lubricating hinges
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5.10
5.10.1 Lubricating the wear pads for main beams and extending beams
There are 24 lubrication points:
Four tracks on the inside of each main beam (1)
Six tracks on each extending beam (2)
Two tracks on the inside of each main beam (3)
3
Figure 72. Lubrication points
2
Figure 73. Lubrication points
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1
Figure 74. Lubrication points
1
2
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1
Figure 78. Lubrication points
5.11
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1
2. Unscrew the drain plug.
WARNING! HOT FLUID HAZARD
Hot engine oil may cause serious personal injury.
To avoid burns, use care in opening the drain plug.
3. Allow the oil to run out.
4. Check that the seal is not damaged.
5. Fit the drain plug.
6. Tighten up the drain plug (1).
7. Remove the filler cap (2).
2
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WARNING
HOT OIL AND HOT SURFACES HAZARD
Risk of personal injury.
Use protective gloves.
1
Figure 80. Changing the engine oil filter
1. Clean the oil filter bracket (2).
2. Remove all oil filters with a suitable oil filter extractor (1).
3. Clean the mating surface of the oil filter bracket.
3.1. Make sure that no remnants of old oil seal are left behind.
3.2. Carefully clean round the inside of the protective rim (2) on the oil filter bracket.
4. Put a thin layer of engine oil on the seals of the new oil filters.
5. Install the new oil filters.
5.1. Tighten the two full-flow filters (on the right of the illustration) 1/23/4 of a turn after
they bottom.
5.2. Tighten the bypass filter 3/41 turn after it bottoms.
6. Top up with engine oil, start the engine, and let it run for 2030 s.
7. Turn off the engine, check the oil level, and top up as required.
8. Check the sealing around the oil filters.
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1
Figure 81. Draining the prefilter
1. Put a receptacle under the fuel prefilter to collect the condensate and fuel.
2. Open the drain valve (1) in the base of the fuel prefilter.
3. Tighten the drain tap (1) when fuel without water starts to run out.
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1
Figure 84. Fuel tank
1. Check the tank for any leaks.
2. Drain the tank of any dirt and water through the drain plug (1).
3. Place a receptacle underneath the drain plug.
4. When clear fuel comes through, refit the drain plug.
5. Check the seal around the fuel cap (2).
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NOTICE
NOTICE
NOTE
NOTE
The filter element is a dry filter element and must not be cleaned with water.
7. After cleaning, write the date of cleaning on the filter element.
8. Discard the filter element:
If it has been cleaned four times
If it is damaged
9. Put back the filter element and close the air filter cover.
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10. Reset the red plunger in the low-pressure indicator by pressing the button.
Never clean the safety cartridge. Do not remove the safety cartridge unnecessarily.
Replace the safety cartridge (1) if there has been any damage to the main filter.
1
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4
3
Figure 88. Cooling system
1. To discover leaks and cracks, check all the hoses by pressing them. When in doubt, replace
the hoses.
2. Check the radiator for damages and leaks, and that there are no deposits.
3. Check the functioning of the cabin heater.
4. Check the coolant in terms of:
Level
Freezing points
Any contaminations
5. Replace the coolant if it is not clean and clear.
6. Check the rubber suspensions (3) in the radiator mounting brackets at the bottom of the
radiator. Replace the rubber mounts as necessary.
7. Ensure that the fixing bolts (4) are tightened.
4
3
2. Refill the expansion tank (2) with coolant.
3. If necessary, replace the coolant.
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Drain the whole system using the drain tap on the side of the radiator when replacing hoses
and components in the system.
4. Switch on the ignition to adjust the temperature for the cabin heater to maximum. After
adjusting the temperature, switch off the ignition.
5. Place a receptacle under the drain valve.
6. Open the drain tap and drain the whole system.
7. Close the tap.
8. Fill through the cap on the expansion tank (1) to the maximum level.
9. Start the engine and run on idle.
10. Observe the level and fill as necessary.
When the operating temperature has
been reached, the level stabilizes.
The level should be at the maximum level
indicator on the side of the expansion
tank (5).
5
11. Refit the filler cap.
NOTICE
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Check the valve clearance when the engine is cold. Follow the instructions in the engine
manufacturers instruction book.
NOTICE
5.12
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1
3. Remove the drain plug and allow the oil to run out.
WARNING! HOT OIL HAZARD
Risk of serious personal injury.
To avoid burns, use care in opening the drain plug.
4. Refit the drain plug (1).
5. Change the transmission oil filter.
For more information, see Changing the transmission oil filter (page 105).
6. Remove the filler cap (2).
1
2
7. Fill with the recommended oil to the maximum level indicator on the dipstick (1).
8. To fill the torque converter and pipes, idle the engine for one minute.
9. Turn on the engine and let it run for one minute.
10. Check the level of the oil while the engine is still running and then fill up with oil to the
minimum indicator.
11. Check the oil level again when the operating temperature has reached 82C...93C
(179.6F...199.4F). Fill to the maximum level indicator.
NOTICE
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1
3. Loosen the filters by hand or with a filter wrench.
4. Remove the filters.
5. Check the new filters and the seals.
6. Lightly lubricate the seals with oil.
7. Screw on the filters until the seal is in contact with the filter housing, tighten the filter one
half turn by hand at the most.
8. Start the engine and check that there are no leaks.
9. Check the oil level with the dipstick.
10. Switch off the engine.
NOTICE
If you use a high-pressure steam cleaner, it may damage the fins of the radiator,
intercooler, and oil coolers.
Use dry, compressed air.
To clean the radiator, intercooler, and oil coolers, use dry compressed air.
1. Blow against the direction of the fan.
The radiator, intercooler, and oil coolers must not be cleaned with high-pressure water. In
extreme cases, solvents or a jet of steam can also be used with great care.
2. Allow the solvent time to penetrate. Rinse off with water.
3. Run the engine warm so that surplus water evaporates and does not cause corrosion.
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.
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8. Make sure that the parking brake is activated and works properly.
9. To apply the service brakes, use the brake pedal in the cabin.
10. Select driving direction forward.
11. Run the engine at maximum RPM.
12. After about 15 s at maximum RPM, select neutral.
13. Continue at maximum RPM.
14. Keep the transmission in neutral at
maximum RPM for another 15 s.
The figure shows the heating cycle for the
transmission.
Engine speed
Full
Idle
Transmission gear
Forward
Neutral
15 sec.
15 sec.
15. Release the speed pedal and allow the engine to slow down to idle.
16. Repeat the procedure from step 3 until the transmission has reached a temperature of
80C...90C (176F...190F).
17. You can now calibrate the transmission.
NOTE
5.13
When the converter output temperature exceeds 120C (248F), the engine is reduced
to half RPM.
4
3. Open the filling and level plugs (2 and 3) and check the oil level.
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If oil comes out of the filling and level plugs, there is enough oil
If oil does not come out of the filling and level plugs, there is not enough oil
4. If there is not enough oil, fill the drive axle
through the filling and level plugs (2 and 3).
5
5. Refit the filling and level plugs (2 and 3).
4
3. Fix the hose in the drain hole while the drain plug is in its uppermost position.
4. Carefully drive the machine forwards or in reverse so that the drain plug returns to its lowest
position.
5. Allow the oil to run out through the hose into a receptacle.
6. Repeat the procedure on the other side.
7. Drain the differential through the drain plug
(5).
Because the oil is of high viscosity, drain
the oil at operating temperature or over
night.
5
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2
7
8
Spring
Lock ring
Locknut
Seal
Piston sealing
6.
7.
8.
9.
Dust cap
Screw cap
Adjusting screw
Bleeder screw
NOTE
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NOTE
The parking brake pressure must be correct and the ignition must be on.
3. Remove the screw cap (7).
4. Loosen the locknut (3). Turn the adjusting screw (8) clockwise until both brake pads contact
the brake disc.
5. Turn the adjusting screw counterclockwise to set the total clearance to 10.5 mm (0.04
0.02 in).
6. Tighten the locknut (3).
7. Recheck the clearance.
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DANGER
RUN OVER HAZARD
If the engine is running, the service break is working. If the engine is not running, only
the parking brake is working. If it is released, there will be no breaks at all. Risk of
serious injury or death.
To prevent the machine from moving, block the wheels.
3
8
7
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5.14
1
Figure 96. Checking the steer axle bearings
1. To lift each side, use a jack.
For more information, see Positioning the jack (page 74).
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2. Check the plays when the wheel rises from the ground.
To lift the wheel and locate the gap, use a crowbar.
3. Check the spindle bearings by lifting the wheel with a crowbar (1).
4. Check the wheel bearings by prying the wheel vertically (2).
5. Check the link bearings by turning the wheels in the steering direction (3).
4
Figure 97. Wheel bearings
1. Remove bearing cover (1).
2. Check that the grease is clean and free from particles.
If it is not, the reason for the play may be a damaged bearing.
3. Loosen the lock washer (2).
4. Tighten the nut (4).
The correct tightening torque is 220 Nm (162.3 lbf ft).
5. Rotate the hub.
The hub should only offer light resistance when rotating. A noise or irregular rotation means
that the bearing is broken. Replace the bearing.
6. Tighten the nut (4) again to 300 Nm (221.3 lbf ft).
7. Check the play.
8. Mount the lock washer (2).
9. Tighten the nut (3).
The correct tightening torque is 220 Nm (162.3 lbf ft).
10. Lock the nut (3) using the lock washer (2).
11. Refit the bearing cover (1).
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3
2
Figure 98. Spindle bearings
3
2
NOTE
The nut (4) is not used to preload the bearing. All bearing preload is adjusted with the
upper nut (3).
7. Tighten the upper nut (3).
The correct torque for KM12 and KM17 is 300 Nm (221.3 lbf ft), and for KM22 is 350 Nm
(258.1 lbf ft).
8. The spindle should only offer light resistance when turning. A noise or irregular resistance.
9. Refit the bearing cover (1).
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5.15
1
Figure 100. Changing the hydraulic oil
1. Drain out the oil through the drain plug (1), using a receptacle.
If the filters have been removed, suck up the oil through the filter housings.
2. Inspect the bottom of the tank for any deposits.
3. Assemble the filters and covers if they have been removed.
4. Fill up the hydraulic oil (2) through the filling cap in the filter cover, thus filtering the oil
through the filters.
To make sure that the oil goes through the filters quickly, connect the oil pump to the filling
cap.
NOTICE
3
Figure 101. Hydraulic pump
1. Disconnect hoses (1) and (2).
2. Unscrew pump plug (3).
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NOTICE
NOTE
MAINTENANCE MANUAL
1
2. Lubricate the rubber seal and fit a new filter.
3. Secure the filter by hand.
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5.15.7 Changing the breathing filter for the brake cooling oil tank
1. Unscrew the breathing filter (1).
5.16
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2
1
6
3
4
5
Figure 105. Guide pads
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5.17
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5.18
MAINTENANCE MANUAL
WARNING
The length of time between cleaning sessions depends on the type of work that the machine
carries out. If the machine is used in aggressive environments where it is exposed to elements
such as salt water, fertilizers, chemicals, or cement, the machine must be thoroughly cleaned
when the work is finished.
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6 MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE
6.1
Commissioning inspection
MAINTENANCE MANUAL
Always perform maintenance, lubrication, inspection, and daily maintenance according to the
instructions in this manual. Before starting up the machine, check the inspection points
according to the warranty commissioning report.
The warranty commissioning report must be filled in and returned to Konecranes Lifttrucks
within one week from starting up the machine to make the warranty valid from the
commissioning date.
If the warranty commissioning report is not returned within one week, the warranty is valid from
the day the machine was delivered by Konecranes Lifttrucks.
6.2
Commissioning service
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
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6.3
6.4
6 MAINTENANCE SCHEDULE
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6 MAINTENANCE SCHEDULE
6.5
Regular service
As necessary
500 h
1000 h
2000 h
4000 h
X
X
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6 MAINTENANCE SCHEDULE
As necessary
1000 h
2000 h
4000 h
500 h
1000 h
2000 h
4000 h
500 h
As necessary
500 h
1000 h
2000 h
4000 h
As necessary
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6 MAINTENANCE SCHEDULE
As necessary
500 h
1000 h
2000 h
4000 h
As necessary
500 h
1000 h
2000 h
4000 h
500 h
1000 h
2000 h
4000 h
As necessary
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6 MAINTENANCE SCHEDULE
500 h
1000 h
2000 h
4000 h
As necessary
X
As necessary
500 h
1000 h
2000 h
4000 h
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6 MAINTENANCE SCHEDULE
6.6
Maintenance data
Unit
Material/oil/lubricant
Volume
Engine
Engine oil
Fuel tank
Diesel
AdBlue tank
AdBlue
Cooling system
Hydraulic oil
Drive axle
Tires
Air
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NOTE
No oil additives should be added to the recommended oils. Using such additives may
invalidate the engine warranty.
Avoid mixing different brands of oil.
The temperature ranges for adjacent SAE classes overlap, so you do not need to replace the oil
when short-term temperature changes occur.
NOTE
To ensure trouble-free cold starts, select the SAE class according to the ambient
temperature.
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NOTE
As the ambient temperature falls, the flow characteristics of the diesel fuel are reduced
and paraffin begins to precipitate. Use the correct diesel quality according to the ambient
temperature.
NOTE
Using additives to improve the flow is not recommended. Additives may reduce the
capacity to start from cold.
Biodiesel (FAME)
Vegetable oil esters (Fatty Acid Methyl Esters, FAME), also called "biodiesel", are increasingly
available as a blending component in diesel fuels.
The engine manufacturer accepts the same FAME content as in major on-road fuels EN590 and
ASTM D975. The maximum FAME content is 7%, without any specific additional service
requirements. Contact the engine manufacturer for further information.
NOTE
Higher FAME blends negatively impact performance, emissions, and fuel consumption. It
also affects negatively the function of the SCR engines exhaust after treatment system.
Transmission oil
ATF Dexron III
Oil change interval
Drain and refill the system every 1000 h for average environmental and duty cycle conditions.
Severe or sustained high operating temperature or dusty environments cause accelerated
deterioration or contamination. Judgment must be used to determine the required change
intervals for extreme conditions.
Drive axle oil
API GL.5 SAE 80 W-140
NOTE
The above are strictly recommendations. If you have any doubts, contact your
Konecranes Lifttrucks authorized dealer for advice.
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Temperature range
SHS 32
-30C...+10C (-22F...+50F)
SHS 46
-20C...+50C (-4F...+122F)
SHS 68
0C...+50C (+32F...+122F)
Grease
Multipurpose type E.P. according to NLGI Grade 2.
Coolant
Use only ethylene glycol-based coolants with an additive that prevents corrosion. Do not mix the
coolant with antifreeze that contains ethanolamine.
WARNING! TOXIC SUBSTANCE HAZARD
It is highly dangerous to drink ethylene glycol. It can cause skin irritation and eye
damage.
Do not drink ethylene glycol and avoid contact with skin.
Liquid antifreeze at the
lowest temperature
Percentage of volume
mixture liquid antifreeze
-12C (10.4F)
25
1:3
-18C (-0.4F)
30
1:2
-25C (-13F)
40
1:1.5
-37C (-34.6F)
50
1:1
-60C (-76F)
66
2:1
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17
25
33
16
24
32
40
Size
Function
F1
10 A
F2
7.5 A
F3
15 A
F4
5A
F5
15 A
F6
7.5 A
F7
7.5 A
F8
10 A
IQAN display
F9
10 A
F10
10 A
MAINTENANCE MANUAL
Number
Size
Function
F11
10 A
F12
7.5 A
F13
7.5 A
F14
15 A
F15
10 A
Entrance lights
F16
10 A
F17
7.5 A
F18
10 A
F19
7.5 A
F20
7.5 A
F21
7.5 A
F22
10 A
F23
15 A
24 V-outlet
F24
3A
F25
3A
F26
3A
F27
7.5 A
F28
7.5 A
F29
7.5 A
F30
7.5 A
F31
10 A
F32
3A
Elme attachment
F33
Extra
F34
Extra
F35
15 A
F36
15 A
F37
10 A
Customer equipment
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Number
Size
Function
F38
10 A
Customer equipment
F39
15 A
F40
3A
Extra
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51
61
71
58
68
78
Size
Function
F51
10 A
F52
Extra
F53
Extra
F54
15 A
Diesel pre-heater
F55
15 A
F56
5A
Transmission ECU
F57
F58
30 A
Electrical oil cooler, Cummins QSB 6.7 (15 A), Scania DC13 (20 A)
F61
30 A
F62
30 A
F63
30 A
F64
30 A
F65
30 A
F66
30 A
F67
30 A
F68
30 A
F71
10 A
Elme attachment
F72
10 A
Elme attachment
F73
10 A
Elme attachment
F74
10 A
Elme attachment
F75
5A
Transmission ECU
F76
10 A
MAINTENANCE MANUAL
Number
Size
Function
F77
10 A
F78
Extra
F80
70 A
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Relays
K1K14 are mounted in the electrical main compartment. K31, K32, K33, K34, and K35 are
mounted next to the main fuses in the battery compartment.
1
14
Function
K1
K2
K3
K4
K5
K6
Extra
K7
K8
K9
K10
K11
K12
K13
Directional lights
K14
Reverse camera
K31
Starter relay: Scania DC9, DI12, DC12, and Volvo TAD 722 VE
K32
Main relay
K33
K35
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www.konecranes.com
Corporate HQ
Region EMEA HQ
Hyvink, Finland
Region Americas HQ
Spring eld, Ohio
Region AP AC HQ
Shanghai, China
This document and the information contained herein, is the exclusive property of Konecranes Plc and
represents a non-public, confidential and proprietary trade secret that may not be reproduced,
disclosed to other parties, altered or otherwise employed in any manner whatsoever without the
express written consent of Konecranes Plc. 2014 Konecranes Plc. All rights reserved. Konecranes,
Lifting Businesses and C are either registered trademarks or trademarks of Konecranes Plc.Copyright
(2014) Konecranes Plc. All rights reserved.