Manual de Operador

MODEL RANGE REACHSTACKER
SMV 108 TB
Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01 1

Your SMV Reachstacker
This user manual provides you with the information you When ordering spares, it is important to indicate the
need to know about starting, driving, servicing and item number found in the spare part list as well as the
maintaining your SMV Reachstacker. following information:
Using and attending to the machine properly will pre- Model:
serve Serial number/year of manufacture:
its qualities for a long and profitable working life, and Delivery date:
will make full use of its applications.
The expressions ”front”, ”back”, ”right” and ”left” indicate When ordering spares for the following units, you
the position in which the relevant component is in- must indicate their individual manufacturing num-
stalled in the Reachstacker as seen from the driving bers:
compartment. Engine no.:
Follow all instructions in the manual on using the Reach- Boom no.:
stacker and carry out maintenance and inspection as Lift height of the boom:
described in the maintenance table on a regular basis Hydraulic pump no.:
and at the correct time, using the specified lubricant. Transmission no.:
Drive axle no.:
Maintenance must be carried out only by qualified staff.
When the Reachstacker is delivered, the details on the
Above all, we would like to emphasise the importance type plate should be written in this user manual.
of following both the general traffic regulations and the
guidelines in force for the use of the machine and the Delivery inspection
prevention of accidents at work.
Each Reachstacker from Konecranes Lifttrucks is carefully
The regulations in force for normal and regular use of inspected before it leaves the factory to ensure that it is
commercial trucks must be strictly adhered to by man- fully in order and is fully equipped in accordance with the
agement, commercial operators and service staff. order. Authorised Konecranes Lifttrucks dealers are then
required to re-inspect the truck before it is delivered to the
The user, not Konecranes Lifttrucks, is responsible for customer.
any dangers that may arise when the truck is being used
In order to avoid later complaints and problems, the
for applications not approved by the manufacturer.
customer also should check that the Reachstacker is
Reachstackers from Konecranes Lifttrucks are designed in full working order and is fully equipped when it is
for the transport and lifting of loads indicated on the delivered, with a receipt of the acceptance/hand over
load-bearing capacity plate. No alterations and, above of the Reachstacker from the dealer.
all, no additions or conversions may be made to the Always perform Lubrication, Checking, Maintenance
Reachstacker without the permission of the manufac- and Daily Maintenance according to the instructions
turer. in this book.
The user instructions for additional parts issued by the Prior to start-up of the Reachstacker the check points
manufacturer apply to those additional parts. according to the Warranty/Delivery report are to be
checked.
Technical remark
The Warranty/Delivery report must be filled in and re-
Konecranes Lifttrucks is constantly developing both the turned to Konecranes Lifttrucks within one week after
design and manufacture of its products. Illustrations and start-up thus to be considered as first day of Warranty.
technical details concerning the design, parts and per-
If the Warranty/Delivery report is not returned within
formance of the Reachstacker are subject to alteration one week from start-up, delivery date will count as
as a result of this technological development. first warranty date.
Konecranes Lifttrucks therefore assumes no responsibil- The following technical manuals accompany every
truck:
ity on the basis of those specifications, illustrations and
descriptions found in the user manual. 1 Spares catalogue for the Reachstacker
1 User manual for the Reachstacker
If you have any questions concerning Reachstackers 1 Machine card
from Konecranes Lifttrucks and ordering spares, contact
your nearest authorised dealer. Take care to supply the When contacting your authorised dealer, always
correct address for delivery. indicate:
1. Reachstacker model designation
If any repairs are needed, use only Konecranes Lifttrucks 2. Reachstacker serial number
original spares. This is necessary in order for your 3. Year of manufacture.
Reachstacker from Konecranes Lifttrucks to retain its
original technical standard.
2 Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01

Contents
Your SMV Reachstacker .........................................................2 Assembling, disassembling the steer wheels............................51
Technical remark, Delivery inspection .....................................2
Tightening bolted joints .......................................................52
Safety regulations....................................................................4 Tightening the wheel nuts .....................................................52
Warnings and important information ......................................5 Tightening torque .................................................................53
Before operation, Prevention of accidents, Norms ...................6 Drive shaft, Differential nuts .................................................53
Engine, Transmission mountings ...........................................54
Outline picture of the reachstacker.........................................7
Drive axle suspension, Hydraulic pumps,
ID-plates and serial numbers ..................................................8 Cab suspension .....................................................................55
Counterweights, Steer axle ....................................................56
Technical description ..............................................................9
Lubrication/maintenance points...........................................57
Controls and indicators in the cab .......................................10
General rules which apply to lubrication ...............................58
Display for electronic systems ..............................................11 Lubricating the damping cylinders, attachment suspension,
boom suspension ...................................................................60
Before driving .......................................................................12 Wear pads for main beams and extending beams ...................61
Daily maintenance and service before operation ....................12 End beams and twist locks.....................................................61
Check the screen washer tank ................................................12 Extention cylinder support wear pads and tracks ...................61
Checking the coolant of the radiator .....................................12 Stop cylinders, Side shift slider pads ......................................62
Checking the oil level in the engine, gearbox .........................13 Slewing ring bearing and gear ................................................62
Air filter indicator..................................................................13 Side shift cylinder bearings, Slewing gearbox (only 1 unit) ....63
Cleaning the air cleaner coarse cleaner ...................................14 Lubricating the steer axle .......................................................64
Hydraulic system, Checking the hydraulic oil level ................14 Lubricating the hinges of the battery comp. and doors .........64
Topping up the hydraulic oil .................................................14
Checking, topping up the brake cooling oil ...........................15 Changing oil and filters ........................................................65
Filling with fuel .....................................................................15 Draining the engine oil .........................................................65
Main circuit switch................................................................16 Cleaning the engine oil filter, Filling up the engine oil...........65
Checking the condition and pressure of the tires ..................16 Changing the oil in the transmission .....................................66
Adjusting the driver’s seat ......................................................17 Changing the transmission oil filter .......................................66
Adjustment lever of steering wheel ........................................18 Filling up the transmission oil ...............................................66
Description of the EMC drive monitor type IQAN .........19-25 Changing of transmission breathing filter ..............................67
Checking, Changing the oil in the drive axle .........................67
Operating .............................................................................26 Changing the return filter, hydraulic oil ................................68
Starting, stopping the engine .................................................26 Changing of hydraulic tank breathing filter, Changing the
Operating ..............................................................................27 hydraulic oil ..........................................................................68
Driving forwards ...................................................................28 Start of hydraulic pumps .......................................................69
Stopping the machine............................................................29 Changing the cooling oil filter, cooling oil breathing filter .....70
Driving backwards ................................................................29 Changing fuel filters, Water separating filter,
Steering and braking.............................................................30 Bleeding the fuel system ........................................................71
The parking brake switch, steering, disengaging switch .........30 Checking and other maintenance .........................................72
Emergency stop ...................................................................31 Cleaning/changing the air filter
Cleaning the coarse filter .......................................................72
Sliding cabin .........................................................................32 Cleaning/changing the main filter element,
Manually sliding cab, hydraulically sliding cabin (option) .....32 Safety cartridge .....................................................................73
Rear emergency exit ..............................................................32 Checking the air intake system ..............................................74
Ventilation and cab filter ......................................................33 Checking the battery .............................................................74
Changing the windscreen wipers ...........................................75
Lifting of loads .....................................................................34 Checking the cooling system ............................................75-76
Before lifting loads, Capacity plate, Lifting of loads ..........34-35 Replacing the coolant ............................................................76
Maneuvring the boom and spreader ......................................36 Checking the exhaust system for leaks ...................................76
Maneuvring the joystick, Operating ......................................36 Valve clearance, Checking the fuel system and injectors.........77
Spreader lights ......................................................................37 Checking the fuel tank ..........................................................78
Checking of poly-v belts ........................................................78
Lifting and driving with container .......................................38 Boom wear pads ....................................................................79
Before lifting loads ................................................................38 Main pads, Side guide pads, Boom ........................................80
Lifting and driving with container .........................................39 Sliding pads, Twist lock .........................................................81
Before releasing the container ................................................41 Checking weld constructions .................................................82
Safety override, Emergency lowering .....................................42 Checking of the steer axle bearings ........................................82
Service and maintenance ......................................................43 Adjusting wheel bearings, spindle bearings .......................82-83
Electric welding, Jump-starts .................................................44 Parking brake, Brake adjustment ...........................................84
Running in/servicing after the first 150 hours of Parking brake emergency release ............................................85
operation ...............................................................................44
Delivery / start-up service.....................................................86
Transport/towing..................................................................45
Cleaning ...............................................................................46 Checking and Maintenance schedule ..............................87-89
Changing a wheel .................................................................47 Engine service schedule ........................................................90
Pressure release ......................................................................47 Maintenance data .................................................................91
Positioning of the jack ...........................................................47
Specifications for drive axle and steer axle tires ......................47 Fuel and oil recommendations ........................................92-93
Specifications for rims, Other type of tires .............................47 Electrical system ..............................................................94-96
Deflating, Inflating the tire ....................................................49
Dismantling the drive wheel, Outer, Inner drive wheel, Notes ...............................................................................97-98
Mounting the drive wheels ....................................................50

Safety regulations
SAFETY REGULATIONS
* Follow national safety regulations * Lifting a person or persons is forbidden unless

the machine is equipped with an approved lift
* The machine must only be driven by those age for this purpose.
trained to do so and who have the permission of
the management * Never exceed the lifting capacity of the machine -
see type plate and load diagram
* Remember: The national and state laws on driv-
ing licences and driving regulations always apply! * The load should always be transported in a
lowered position
* Before starting up, ensure that no person(s) or
other obstacles are in the way of the machine or * Always report damage and wear and tear
its equipment. affecting the safety/function and life of the ma-
chine.
* Do not block doors and/or emergency exits.
* The hydraulics of the machine are equipped
* The machine must not be used if it has faulty with a high-pressure hydraulic accumulator.
brakes, steering, lifting or other important func- Take great care when working with the hydraulic
tions system. Only service staff with knowledge of the
hydraulics may intervene here.
* Passengers are not allowed
* Use protective equipment – breathing protection,
helmet, gloves, eye- and ear protection when
working on the Reachstacker.

Safety regulations
WARNINGS AND IMPORTANT INFORMATION
In the instruction book there are three types of warning Important information is indicated by the indicator word
texts. These are divided into different levels of hazardous NOTE. The information is not necessarily safety related; it
situations. Warning texts are preceded by a warning symbol. can also touch on issues that will facilitate handling, or clarify
information.
This symbol indicates a potential personal
injury hazard. Whenever you see this NOTE
symbol, take care to read the following Used to draw attention to important information that facili-
instructions: tates work processes or handling.
Read the instruction book carefully before

you start using the machine.
DANGER
Incorrect handling may cause serious
Indicates an immediately hazardous situa-
injury or damage to persons, products, or
tion which, if not avoided, will result in
property.
death or serious injury.
The instruction book contains important
information on handling and safety and should always be
available in the machine. Never use a machine that does not
have an instruction book.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, may result in minor
or moderate injury.
Always read the instructions that follow the safety alert

symbol or the signal word.

Safety regulations
BEFORE OPERATION
Persons responsible, particularly drivers and service staff, Consider the following impact on the environ-
must be instructed on the regulations for normal and safe ment:
use of the rechstacker which accompany this manual.
1. Driving
Exhaust emissions, noise, leakage (oil, fuel, fluids) are
Follow the guidelines and safety regulations applicable
influenced negatively by incorrect driving and handling of
to:
the Reachstacker.
- use of the reachstacker
- roads and work sites 2. Service
- drivers (rights, obligations and regulations for imple- Oil, fuel, filters and filter deposit, cleaning fluids have to
mentation) be disposed of or recovered according to local legislation.
- any extra equipment
- different types of drive trains 3. Repairs
- service (maintenance and inspection) Metal, batteries, electronics, rubber (tires, hoses, seals),
- annual inspection for the prevention of accidents. solutions, chemicals have to be disposed of or recovered
according to local legislation.
The driver (/owner) or other persons in positions of re-
sponsibility must ensure that the above guidelines and
safety regulations are adhered to. Norms
When a trained driver is about to operate the truck,
instruct him on: This reachstacker is built regarding the following norms
- special functions of the SMV-machine according to
- extra equipment Health and safety 2006/42/EC
- special operating applications. EN 1459
Noise 2005/88/EC
Driving, manoeuvring and steering should be practised Vibrations EN 13059
until the driver is fully acquainted with all these opera- Emissions 2004/26/EC
tions. Only after that stage can training in stacking EMC 2004/108/EC
manoeuvres begin.
The stability of the reachstacker in the working area can
only be guaranteed if the correct procedures are fol-
lowed. Should the truck start to roll due to unapproved
manoeuvres or incorrect driving, the full instructions
supplied must be followed.
Prevention of accidents
In some countries, reachstackers must be inspected once a
year by trained staff in accordance with the prevention of
accidents regulations. Authorised Konecranes Lifttrucks
dealers can supply information on these.
We reserve the right to modify our design and material

specifications without prior notice.

Outline picture of the reachstacker
DESCRIPTION
1. Lift boom 4. Damping cylinders 2 pcs 8. Counterweight

2. Attachment 5. Lifting cylinders 9. Driver’s cab
3. Twistlocks 6. Drive axle
7. Steer axle
9
2
5 8
6
3

ID-plates and serial numbers
DESCRIPTION
1. Attachment 4. Steer axle number 7. Transmission number

2. Boom number 5. Engine number 8. Drive axle number
3. Load capacity plate 6. Chassis number
3
2
7
8
6 4
5

Technical description
TECHNICAL DESCRIPTION
Specification SMV 4531 CBX5 means: The hydraulic system comprises five hydraulic pumps.
SMV = Product name Four of the hydraulic pumps are mounted on the trans-
45 = 45 tons lift capacity in first row mission and one is mounted on the engine. The hydrau-
31 = 31 tons lift capacity in second row lic system is divided into five circuits: Boom, attachment,
T = Top attachmant steering, brake pressure and brake cooling. The relief
C = Combi attachment valves in the hydraulic circuits are preset to prevent the
B = B-model system from overloading.
X = Support legs
5 = Stacking height, No. of containers The steering is fully servo-assisted. If the engine should
stall, it is still possible to steer the truck without servo
The engine is a water-cooled, turbo-charged 6-cylinder assistance, although it is heavy going.
diesel engine. The engine drives a three or four speed
transmission using a torque converter. The gear selec- A control valve, mounted on the chassis, is controlled
tion is electrical with three or four gears for driving from the cab by a servo-assisted joystick to the right of
front/back. The torque converter is equipped with an oil the driver. The joystick regulates the functions for lifting,
cooler which lies underneath the radiator. lowering, boom in/out and the spreader.
The transmission has a disengaging valve controlled by
the brake pedal in the cab. This valve disengages the The driver’s cab fulfils international safety standards, and
transmission so that the operator can control the brakes is rubber mounted to protect the driver from vibrations.
whilst maintaining a high engine speed during stacking Entrance to the cab is on the left side via the steps on
maneuvers. the machine.
The front axle is driven by the transmission via an uni- All hydraulic controls for the lifting functions are
versally jointed drive shaft. grouped on the console to the right of the driver’s seat.
The axle is of the heavy duty double reduction type. The Gear selector, direction indicators and windscreen
primary reduction is through the hypoid crown wheel wipers are located on the steer wheel column. Display,
and pinion gear set. The secondary reduction is achieved warning lights and electrical switches are located on the
by a planetary gear set within the wheel hub. The wheel left side of the instrument panel.
hubs are carried on taper roller bearings.
The electrical system is 24 V and has two serial-connect-
The steer axle is mounted in ”sphere elastic” bushes ed 140 Ah heavy duty batteries.
which allow sufficient wheel movements for stability on
uneven ground. The parallel tie-rods are between the
steering cylinder and the wheel axles.
The brakes are operated by an oil-cooled wet disc-brak-

ing system. The service brakes are controlled by the foot
brake valve which activates the drive axle. The parking
brake is controlled electrically and activates a hydraulic
cylinder which acts on a brake disk mounted between
the drive axle and the drive shaft.

Controls and indicators in the cab
9 20 2 3 4 10
19 5 6
8
11
18
16
14 12
17 15 13
DESCRIPTION
1. Steering wheel 11. Adjustment steering wheel
2. Wiper front screen 12. Accelerator
3. High/low beam 13. Brake pedal
4. Horn 14. Declutch switch
5. Directional switch 15. Air condition
6. Front screen washer 16. Fan
7. Instrument panel with switches 17. Recirculation
8. Ignition switch 18. Heater
9. Emergency stop 19. Display for EMC
10. Joystick 20. Direction and gear selector
Position of controls may vary from reachstacker to reachstacker depending on customer order.

Display for electronic system
20
14
15
12 13
11
16
10
17 9
8
18
19
1 3
2
1. Parking brake 11. Joystick steering (optional)

2. Working lights boom 12. Central lubrication attachment (optional)
3. Working lights attachment 13. Central lubrication chassis (optional)
4. Working lights (optional) 14. Warning light EMC
5. Road lights 15. High beam indicator
6. Screen washer 16. Direction indicator
7. Rear windscreen wiper/interval 17. Engine pre-heater
8. Roof window wiper/interval 18. Emergency switch
9. Hazard 19. Ignition switch
10. Rotating beacon 20. Display electronic system EMC
Position of controls may vary from reachstacker to reachstacker depending on customer order.

Before driving
DAILY MAINTENANCE AND SERVICE BEFORE START-UP
Check points:
- Washer level
- Water level of the radiator
- Oil level of the engine
- Oil level of transmission
- Air filter indicator (engine air filter)
- Air filter
- Oil level of the hydraulic system
- Oil level of the brake cooling oil
- Fuel level
- Tire pressure, condition and wheel nuts
- Main circuit switch
- Function of brake system
- Function of steering system
- Function of hydraulic system
- Lighting and horn
Check the screen washer tank

1
The washer tank (1) is placed behind the cab.
Fill when necessary.
Check the coolant of the radiator
- Open the cap of the expansion tank (1).

1 First a quarter of a turn to ensure that the system is under no
pressure.
- The level should be up to the MAX-mark of the expansion tank.
NOTE
- Do not refill through or open the cap of the radiator.

Before driving
Checking the engine oil level
- Lift the engine casing.

- The dip stick (1) is on the right-hand side of the engine.
1 - Remove the dip stick (1) completely and dry it off with a
clean cloth.
- Dip the stick back in fully and remove again.
2 - The oil level should be between the minimum and maxi-
mum level indicators.
- If necessary, remove the filler cap (2) and top up the oil.
- Fill with oil to the maximum level indicator on the dip stick.
1 See maintenance data for volume.
H1666
Checking the oil level in the gearbox
- Start the engine and run until the oil has reached operating
temperature.
1 - Remove the dip stick (1) and dry it off with a clean cloth.
- Dip the stick back in fully and remove again.
- The oil level should be between the minimum and maxi-
2 mum level indicators.
- If necessary, remove the filler cap (2) and top up the oil.
- Fill with oil to the maximum level indicator on the dip stick.
- Turn off the engine.
See maintenance data for volume.
H1667
Air filter indicator
- Check the indicator (1).

- If the indicator shows RED, reset the indicator by pressing
the knob (2) under the unit.
- Start the engine. If the indicator still shows red, stop the
engine and clean or replace the air filter.
1
H1794

Before driving
Cleaning the air cleaner coarse cleaner

1
- Remove the cover (1) from the coarse cleaner.
- Remove the conical coarse separator. Empty from particles
and dry out with a cloth.
- Refit the coarse separator and screw the cover in place.
H1791
HYDRAULIC SYSTEM
Checking the hydraulic oil level
- Check that the oil level is between the MIN and MAX marks
on the indicator at the side of the hydraulic oil tank (the boom
should be lowered & fully retracted).
H1664
Topping up the hydraulic oil
WARNING
Hot hydraulic oil may spray from the oil refill.
Risk of serious injury.
Do not open the oil cap whilst the engine is run-
ning.
- Unscrew the oil cap.

- Fill with hydraulic oil up to the upper mark on the indicator.
- Screw the cap back on.
H1665

Before driving
Checking the brake cooling oil (Option with separate

brake cooling)
- Check that the brake fluid level is between the MIN and
MAX marks on the indicator at the side of the brake fluid
tank.
H1668
Topping up the brake cooling oil (Option with sepa-

rate brake cooling)
- Unscrew the breathing filter (1).

- Fill with brake fluid up to the upper mark on the indicator.
1
- Screw the breathing filter back on.
H1699
Filling with fuel
- Open the tank cap located on the left-hand side of the

machine and fill with the recommended fuel.
- Screw on the cap.
See Maintenance data for volume.
CAUTION
To avoid air being sucked into the fuel injection
system, the fuel tank should never be run com-
pletely empty. If air enters the fuel system, the
engine will stop and the system must be deaired.

Before driving
Checking the condition and pressure of the tires
Drive axle (illustration No. H1670)

Steer axle (illustration No. H1671)
- Check that the tires have not been damaged or become

too worn
- Remove any foreign objects from the tread
DRAIN - Check that the tires have the correct pressure according to the
manufacturers recommendations.
- Pump the tires according to the relevant regulations.
- Check the wheel nuts.
H1670
Main circuit switch
WARNING
H1671
The main disconnect does not cut the power to
the alternator. Always disconnect the ground
(minus) cable at the battery when working near
or on the alternator.
To reduce the risks of electrical shock and personal injury
1
always remove jewelry and conductive material prior to
working on the electrical system.
Unless in an emergency situation, do not turn off the main
cicuit switch while the engine is running.
Beware of short-circuiting the battery, which may cause fire or
explosion.
Risk for serious injury or death.
The battery contains corrosive acid. Always use the necessary
protective equipment.
Batteries generate explosive hydrogen when charged. Ensure
that there is good ventilation and avoid sparking.
- The main circuit switch (1) is located on the right-hand side of

the machine.
- Turn the main circuit switch clockwise to turn it on.
H1669 - Turn the switch anti-clockwise to turn it off and remove the key.

Before driving
Adjusting the driver’s seat
- To elevate the seat, turn the hand wheel (3) clockwise.

Weight adjustment is automatic.
- Adjust tilting of the seat cushion, by the hand wheel (2).
- Adjust tilting of the backrest with hand wheel (1).
- Lift the clamp (4), to adjust the seat forward/backwards.

- Adjust the lumbar support with hand wheel (5).
- Rotate the seat by pressing pedal (6) Option.
- Adjust the height stroke limiter with handle (7).

Lever to the right - full stroke.
Lever one step to left - stroke limited partially.
Lever to the left - stroke fully limited.
- Adjust the armrest with the hand wheel (8).
- To remove seat press pedal (9) Option.
- Fasten the safety belt before driving.
WARNING
Never operate a machine without having faste-
ned the seat belt properly.
Risk of serious injury or death.
The safety belt should always be used when
driving.
WARNING
Never drive the truck unless the seat is locked
in position.
A seat that is not locked in position may cause
the driver to make uncontrolled movements,
which may cause the machine to be handled
incorrectly.

Before driving
Adjustment lever of steering wheel
When positioning the steering wheel:
- Pull lever (1) upwards to adjust the height.

- Pull lever (1) downwards to adjust the tilt.

Before driving
DESCRIPTION OF THE EMC DRIVE MONITOR TYPE IQAN

The drive monitor’s purpose is to efficiently control the reach stacker’s hydraulic system and drive line by utilising both analog
and digital information from various sensors. This will give the driver a complete overview of the reachstacker’s activities during
operation.
START-UP MENU
7 8
3 4 6 9
2 5 10
1
21
11
12
19 17 13
20 18 15
16 14
Description of the keys The scroller knob
1. Regenerated fast hoist 11. Measure and adjustment menus By turning the scroller knob you
2. Joystick steering activated 12. Scroller and select can step up/down in the menu.
3. Gear position 13. Previous menu The selected function is lightend
4. Warning, low fuel level 14. Engine temperature up in green. By pressing the scrol-
5. Alternator 15. Information page ler knob the selected function will
6. Oil pressure, engine 16. Attachment page be activated.
7. Parking brake 17. Fuel level
8. Low brake pressure 18. Hydraulics page
9. Twistlock indication 19. Transmision page
10.Load indicator 20. Engine page
21. Engine RPM

Before driving
Engine page
- Press button F1 on the main menu.
The engine page displays:
- current engine RPM
- current engine temperature
- battery voltage
- engine oil pressure
- transmission required engine RPM
- required engine RPM in percent of E-gas max.value
- engine operating hours
- engine diagnostics, warning and indicator lamp.
Stop the engine by pressing button F4.
Error codes are displayed when pressing
button F5.
Button takes you to the Adjust & measure menu.
- Press button F1 to return to the Start-up menu.
Transmission page
- Press button F2 on the Start-up menu.
The transmission page displays:
- driving speed
- transmission (gear box) temperature
- accelerator position (angle)
- input transmission RPM
- brake temperature, drive axle
- currently selected gear, 0-4th
- driving direction F/R
- transmission diagnostics, warning and error code ”0”
or error code missing = no error detected
Button C activates manual gear shifting. Default: auto-
matic gear shifting.
- Press button D for start in 1st gear. Default: 2nd
gear.

Before driving
Hydraulics page
- Press F3 in Start-up menu.
The Hydraulics page displays:
- load indicator
- R = pressure (bar) right-hand lifting cylinder
- L = pressure (bar) left-hand lifting cylinder
- U = pressure (bar) piston rod side
- lift boom angle
- load scale
- indicator, regenerative fast hoist
Boom Tele Door
- Boom out, ”0” = boom totaly retracted
- indicator, regenerative boom out
- distance between tire front edge and center of attach-
ment
- indicator, door switch (hydraulic sliding cab, option)

Before driving
Attachment page
This menu is an option for attachment with CANBUS.
- Press button F4 in the start-up menu.
- Press button A for adjustment of delay time for auto-
matic locking of twistlocks.
- Press button B for activating/non-activating automa-
tic locking of twistlocks.
- Press button C for adjustment of slow rotation value.
Select the required value by means of the scroller
wheel.
Information page
- Press button F5 in the start-up menu.
The Information page displays:

- Machine specifications
- container main counter. Can not be zeroed.
- operating hour main counter. Can not be zeroed.
- container sub-counter. Press the F5-button to zero.
- operating hours sub-counter. Press the F4-button to
zero.
Button takes you to the Adjust & measure page.

Adjust & measure page

- Press button in start-up menu.
- Press button F1 to go to sub-menu Adjust
Main - Press button F2 to go to sub-menu Measure
- Press button F3 to go to sub-menu Settings
- Press button F4 to go to sub-menu Info
- Press button to return to the Start-up menu.
Adjust Measure Settings Info
H1626

Before driving
Measure page
- Turn and press the scroller knob to select an option.
- Press the to return to the previous menu.

- Press button F1 to return to Adjust & measure main menu.
H1627
Settings page
- Press button F3 in the main menu Adjust & measure.
- Press button A to set Date/time.

- Press button B to select Display settings.
- Press button C to select Language.

- Press button F1 to return to Adjust & measure main menu.
H1629

Before driving
Date / time-setting page
- Press button A to set date.

- Press button B to set time.
- Select the required value by turning the scroller knob.

- Save the value by pressing the scroller knob.

- Press button F1 to return to Adjust & measure page.
H1630
Display-setting page
- Select settings by pressing buttons A-D.

- Change settings by turning the scroller knob.
- Save settings by pressing the scroller knob.
- Press the to return to the previous page.

- Press button F1 to return to Adjust & measure page
Language-setting page
- Select a language by turning the scroller knob.

- Save settings by pressing the scroller knob.

- Press button F1 to return to Adjust & measure page.
H2123

Before driving BEFORE DRIVING
Error code display
This message is displayed if an input value, that is not

within the preset limits, is registered.
The message will inform you about the digital input,

error code and pin number. ”Input high” or ”Input
low” is also displayed.
- Press F2 to acknowledge the message.

The message will disappear from the display.
- Press F3 to display more than one error code.
H1633
Alarm display
The alarm message, due to anything abnormal, informs

you about
- cause of alarm
- digital input causing the alarm
- pin number.
- Press F2 to acknowledge the message.

The message will disappear from the display.
- Press F3 to display more than one error code.
H1634

Operating
Starting the engine
WARNING
Exhaust fumes are harmful. Never run the engine
in unventilated places.
Use fume extraction.
Before starting up the engine, the driving direction control on the

left-hand side of the steering column must be in neutral.
On starting up:
- Position yourself in the driver’s seat

- Insert the ignition key into the ignition switch, position (0)
- Turn the key into position (1). The electrical system is now
turned on. Check that the display is lit.
- Turn the key to position (III). Release the key as soon as the
engine has started up.
Stopping the engine
- Release the accelerator (3).

- Apply the brakes in a controlled manner (4).
- Engage the parking brake (2).
- Put the driving direction control (1) into neutral.
CAUTION
Allow the engine to idle for a few minutes if it
has constantly been run hard this is to avoid any
1
2
turbo damages or overheating.
The current must not be interrupted before the engine has stopped
- Turn the ignition key to position ”0”.
- Remove the key from the ignition switch when leaving the ma-
chine.
- Turn the electricity off as well at the main circuit switch if the
machine is being left unsupervised.
NOTE
- Use the emergency stop only in an emergency situation,
see page 31.
4 3 - If the engine is not allowed to cool down before being turned
off, there is a risk of turbo damage and overheating.

Operating
Operating
WARNING
Driving on uneven terrain may cause damage to
the machine.
Driving on surfaces with not enough support
may cause the machine to roll or sink.
Risk of serious injury and damage to vehicle.
The truck is not intended for off-road driving. The truck is
not equipped with wheel suspension and should therefore only
be driven on level ground intended for the total weight and
surface pressure of the truck.
WARNING
Risk of the brakes not stopping the machine.
Risk of the machine rolling.
Driving on slopes steeper than 15% is not permitted as a rule

because of the minimum regulations for braking and the
stabilising capabilities of the truck. If the truck has to be
driven along steeper slopes, you should contact your SMV
dealer. The hill-climbing capacity of the truck indicated in the
data sheet is based on the pulling power of the truck, and
applies only to driving over obstacles and minor irregularities
in ground level.
WARNING
Always adjust your method of driving to the
condition of the road (undulations, etc.), to
hazards within the working area and the load.
- Start the engine

- Lift the boom until visibility is obtained underneath the
spreader.
- Hold the steering wheel steady. Always use the whole of your
hand to hold the wheel knob.
WARNING
The working range of the machine is large and
visibility from the driver’s cab is limited.
Before you start to move the truck, check that
the road ahead is free and that you have a clear
view.
WARNING
Avoid driving on slopes or uneven ground when
transporting a container. Never cross or turn on
a slope.

Operating
Driving forwards
1
- Press brake pedal (4).
NOTE
Always start in first or second gear to avoid damage and prevent
the gearbox from overheating.
- Release the parking brake (2).

- Push the driving direction control (1) forward.
- Release the brake pedal (4).
- Depress the accelerator (3) slowly so that the truck starts off
gently.
NOTE
When starting up-hill, hold the machine still using the brake
pedal (4), until you have sufficient pulling power.
4 3

Operating
Stopping the machine
- Take your foot off the accelerator (3).

1 - Press the brake pedal (4) and stop the truck in a gentle,
2 controlled manner.
WARNING
Sudden braking and acceleration may cause the
machine to roll or tip.
Avoid violent acceleration and braking.
CAUTION
Do not use the gearbox as a brake.
4 3
- When the truck has stopped completely, engage the parking
brake (2) before releasing the brake pedal.
- Put the driving direction control (1) into neutral.
Driving backwards
Changing the direction of driving

1
CAUTION
The truck must be completely stopped before
changing the direction of driving.
Serious damage may be inflicted on the gear box
and drive axel.
- Release the parking brake (2).

- Pull the driving direction control (1) backwards.
- Depress the accelerator (3) slowly so that the truck starts gently.
NOTE
2
When starting uphill, hold the machine stationary with
brake pedal (4) until you have obtained sufficient pulling power.
Always start in the lowest gear.
4 3

Steering and braking
Steering
Very little effort is needed to turn the steering wheel thanks to the
servo-assisted steering system.
To minimise unnecessary wear and tear to the tires, the steering

wheel should, if possible, be turned only when the machine is
moving.
The disengaging switch
- Release the accelerator (3).

- Activate the clutch using the disengaging switch (5).
- If the disengager is pressed at the same time as the brake
pedal (4), the brakes are applied.
- When braking using only the brake pedal (4), the disengaging
function is not activated.
4 5 3
The parking brake switch
- The parking brake (2) is to the left of the steering wheel.

- The parking brake should not be used to bring the truck to a
halt unless in an emergency.
If the driver is leaving the seat with parking brake
2 not activated, an audio signal is sounding.
NOTE.
The brake is a pure parking brake and should
be used as such - to keep the machine stationary.
Due to the gear ratio through the drive axle, the
brake is very powerful, however if the brake is
used to stop the machine it will wear the pads
rapidly.
Only use the parking brake to stop the machine in case of
emergency. After such a braking the brake should be checked,
adjusted and if necessary pads replaced. Being an emergency
brake, the function of it has to be checked daily by the opera-
tor.

Emergency stop
Emergency stop
1
- When using the emergency stop (press button (1) down-
wards), all functions are cut out, the parking brake is activa-
ted and the engine stops.
WARNING
There is a risk of tipping over if the emergency
stop is used when the truck is moving.
Parking
Before parking the machine make sure that:

- The boom is fully lowered.
- The boom is fully retracted.
- The spreader beams are fully closed to 20’ position.
- The main circuit switch is switched off.

Sliding cabin
Manually sliding cab

1
All standard machines are equipped with manual sliding cabin in
order to give access to the engine.
- Lift up the handles (1) at the side of the cabin.

- Push the cabin forward by hand.
WARNING
The manually slided cabin should always be
locked in its rear position while operating the
machine. The doors may be blocked.
H1690
Hydraulically sliding cabin (optional)
- Operate the cab motion forward / backwards with the lever (1)
to required position.
CAUTION
Preferable is to position the cabin to full for-
ward or full backward position. Between these
positions the normal entrance doors are obstruc-
ted by the lift cylinders.
The engine has to be running in order to move the cabin.
Rear emergency exit
Machines equipped with hydraulically sliding cabin are also

equipped with a rear emergency exit due to the doors are
blocked between the lift cylinders when the cabin is in travel.
WARNING
2 Do not block emergency exits.
In an emergency:
1
- Lift up the two handles (1).
- Pull out the lock pin (2).
- Push the glass pane back / upwards.
H1867

Ventilation and cab filter
Ventilation
1 2
A = Heating; B = AC; C = ACC;
- (1) heating - (1) heating - (1) heating
- (2) fan - (2) fan - (2) fan (variable)
- (3) recirkulation - (3) recirkulation
- (4) cooling - (4) cooling
Settings for different weather conditions

1 2 1 2 Hot weather and normal atmospheric humidity
- Open the fresh air intake.
- Turn off the heating.
- Turn on the cooling system and set the cooling thermostat
at desired temperature.
Very hot weather and high atmospheric humidity

3 4 3 4 - Close the fresh air intake.
- Turn off the heating.
- Turn on the cooling system and set the cooling thermostat
at desired temperature.
Fall or early winter and high atmospheric humidity

caused by rain and sleet; steamy windows
- Turn on the cooling system.
- Open the fresh air intake.
- Open a window to provide air ciculation.
Decrease heat if necessary.
Cold weather during winter time

- Open the fresh air intake, turn off the cooling system.
- Set the temperature as desired.
Very cold weather and low atmospheric humidity

- Close the fresh air intake.
- Turn off the cooling system.
- Adjust the temperature.
Cold and dry periods during winter time and

little usage
- Turn on the cooling system, operate the compressor for a few
1 2 minutes, so that couplings, gaskets etc are lubricated.
1
1
Cab filter
3 A filter for cab air intake is located on the right hand dashboard.
- loosen the screws (1)

- disassamble the cover (2)
- pull up the filter cassette (3) gentle to avoid dust in the climate
unit and cabin.
Replace the filter insert, Part No. 2050000143.

Lifting of loads
BEFORE LIFTING LOADS
Capacity plate
Before lifting a load, read the lifting capacity plate on the left
side of the cabin.
If an accessory has been fitted, read the capacity plate for
this.
The values indicated on the capacity plate are valid for
SMV 108 TB6 compact and regular loads, and if they are exceeded, there is
M8340 a risk to the stability of the machine and the tensile strength
of the boom/lifting attachment.
2011 Maximum capacity depends on the height of the lift and
the distance to the centre of the load, i e. load center (”L1”,
16 200 mm ”L2” and ”L3”).
3 900 mm ”L1”, ”L2” and ”L3” is the distance between the front of the
drive wheels and the gravity center of the load.
40 360 kg
Read the capacity plate according to the following example;
5 000 kg 16 200 mm 2 700 mm

Main lifting capacity
10 000 kg 13 700 mm 2 700 mm Lifting capacity is 45 000 kg at lifting height 12 500 mm

and center of load 2000 mm (related to model).
8 000 kg 11 000 mm 3 850 mm
5 000 kg 11 000 mm 6 350 mm
Alternative lifting capacities
Lifting capacity is decreased by prolonged load center or

lifting height according to the following examples;
Lifting capacity is 31 000 kg at lifting height 10 200 mm

and center of load 3850 mm.
Lifting capacity is 16 000 kg at lifting height 5700 mm and

center of load 6350 mm.

Lifting of loads
L 1 = 1st row
L 2 = 2nd row
L 3 = 3rd row

Operating
MANEUVRING THE BOOM AND SPREADER
Maneuvring the joystick
WARNING
The lifting of loads may present the risk of serious
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 driver must be trained to handle the machinery
and its equipment.
Always maneuver the control gently and slowly. The speed of the
hydraulic function depends on position of the control. The control
automatically slips into its initial position when released. All hydraulic
controls are positioned on the console to the right of the driver’s seat.
SIDESHIFT RIGHT
SIDESHIFT LEFT SPREADING 40'
ROTATION CLOCK WISE
BOOM
DOWN BOOM
OUT
ROTATION ANTI CLOCK WISE TWISTLOCK LOCK/OPEN

EMERGENCY LOWERING
BOOM STOP 30'
IN BOOM TILT RIGHT/LEFT
UP
SUPPORT LEGS UP/DOWN
VERTICAL
LIFT
CLAMP OPEN/CLOSE
SPREADING 20'
FRONT LEGS UP/DOWN
REAR LEGS UP/DOWN
SAFETY OVERRIDE
FORWARD
BACKWARDS
CABIN

Spreader lights
Group 1 Group 2 Group 3 Group 4
Spreader lights
The picture above shows the indicator light panel for the spreader.
The panel is divided up into four groups. Group 1 is common for all spreaders TB and CB-versions.
Group 2, 3 and 4 is for CB-versions only (Bottom pick).
Group 1.
This group of lamps is solely used for indicating the functions of the spreader when top
picking ISO containers.
There are three lamps, the green one (left position) for LOCKED, the yellow one (middle position)
for SEATED and the red one (right position for NOT LOCKED.
Group 2.
This group of lamps indicates when all four feet are correctly “ENGAGED” on the lifting
points of a swap body, trailer or container bottom lift. I.e. when the feet have been
“CLAMPED” onto the lifting points (as shown by group 3 lights) and then been raised so that
the feet have hooked onto the lifting termed as “ENGAGED”.
Group 3.
This group of lamps indicates when the feet have been “CLAMPED” onto the lifting points .
The top light indicates that the right hand pair of legs is “CLAMPED” and the lower light
That the left-hand pair of legs is “CLAMPED”.
Group 4.
This group of lamps indicates when the front pair of legs (legs furthest to the driver)is
either up or down. During the legs up sequence, when the second leg is fully up and
stowed the top lamp will switch on. During the down sequence when the second leg is fully
down the lower light will switch on.

Lifting and driving with container
Before lifting loads
- Drive forward towards the pile.

- Endcavour to move the center of the machine
towards the center of the container.
- Lift the spreader until it is above the container.
- The right-hand lamp (red) indicates open twist lock.
- Drive the machine forward as close to the pile as

possible.
- Engage the parking brake if desired, or keep the
machine still using the brake pedal.
- Maneuver the spreader into position over the
container using side shifting, turning and boom in/out.
- The right-hand light (red) indicates open twist lock.
- Lower the spreader on the container.

- The middle light (yellow) is lit when all four corners are cor-
rectly aligned.
- Use the switch to lock the twist lock (if it is not locked
automatically).

- Right-hand light (red) goes out when the locking moment

starts.
- The lifting function is interupted whilst either the right-
hand (red) or the left-hand light (green) are off.
- Left-hand light (green) lights up when the locking moment
has been completed.
- Ready to lift load.
- As soon as the load is lifted the middle light (yellow) goes

out and twist lock function is interrupted.
- Lift up only as much as needed to ensure clearance from
the container below. (”A” approx. 20 to 40 cm)
- 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 bet-
ween the stack and the lifted container. “B” not more than
20 to 40 cm. Then stop the machine and remain stationary.
- Retract the boom as much as possible, which lowers the
container down, the EMC will warn and interrupt the re-
traction of the boom when it is too far back, at this position
lower the boom. Be aware of the stack in front as lowering
down will make container to go forward.
- Continue, altering the retraction and lowering until the safe
transport position is obtained.
DANGER
Load and attachment my drop down.
Do not allow anyone to stand or walk
under the elevated portion of the truck
whether it is empty or loaded.

- Retract the boom all the way back.

- Lower the load as much as possible without obstructing
the visibility I.E. not below “C”.
- Centralize the load by side shifting until the spreader
hangs level, horizontally.
WARNING
Avoid driving on slopes or uneven ground
when transporting a container. Never cross or
turn on a slope.
- The correct transport position is with the load as low and as

close to the vehicle as possible without obstructing
visibility.
- The center of gravity of the load must be centred
horizontally.
H1648

Before releasing the container
- Drive forward towards the pile.

- Endeavour to center the load above the pile.
H1649
- Lift the load above the pile.

- Drive as close to the pile as possible.
- Engage the parking brake if desired or keep the machine
still using the brake pedal.
- Maneuver the load into position above the pile
using sideshifting, turning and boom in/out.
H1650
- Lower the load.

- The middle light (yellow) comes on when the correct posi-
tion is reached.
- The twist lock can now be opened.
- The left-hand light (green) goes out when the unlocking
moment starts.
- The right-hand light (red) only lights up when the twist lock
is fully open.
- The machine can now begin a new work function.
WARNING
The lifting of loads may present the risk of
serious injury or damage to the vehicle.
Never lift during the locking moment.
This may prevent the twist lock from fastening
properly.

Safety override
The safety override key (1) is used to simulate alignment. I.E.

yellow light lits up.
This can be used to open or close twist locks if alignment has not
been achived normally. (Defect corner castings or safety system).
Key should only be used by service personel.
WARNING
The safety override key is used to simulate align-
ment and may cause uncontrolled release of the
container.
Risk of serious injury and damage to the vehicle.
The key should only be used by service person-
nel.
Emergency lowering
Should a fault arise that makes the release of the container from
the twist locks impossible or when overloading, the load may be
lowered by using the emergency lowering function (1).
This should only be done with the greatest of care.
This lowering is very slow. Only the boom angle is decreased, the
boom is not retracted.
1
If the container is more than 0.5 m above ground or the con-
tainer stacked below, another reachstacker or crane must hold the
container weight during the entire emergency lowering. Fastenings
used for external lifting equipment is to be found on the front part
of the inner boom and on the attachment/spreader.
DANGER
Danger to life and property.
Ensure that no persons or objects are in the way
when lowering is being executed.
The emergency lowering is overriding the over-
load system which can cause a risk for tilting
over unless the container weight is taken over by
another reachstacker or crane.

Service and maintenance
General information
WARNING
The machine contains several chemical sub-
stances, which may cause skin irritation and
allergies.
Risk of personal injury when in prolonged contact with skin!
When handling chemical substances such as oils, hydraulic
oils, fuel, grease etc. 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 inspection table so that the truck will work as well as
possible.
Maintenance must only be carried out by trained staff or an

authorised Konecranes Lifttrucks-dealer in accordance with a
service agreement. If you wish to service the machine yourself, we
recommend that you carry out the first three customer service
checks in the presence of Konecranes Lifttrucks’ authorised staff
who can check that you are following the maintenance instruc-
tions.
Before any service work, check that:
- the machine is parked on firm, level ground.

- the machine is blocked so that it cannot roll.
- the engine is turned off and the ignition key removed.
- the boom and attachment have been secured if they are in the
raised position.
- the machine is firmly chocked if work is to be carried out un-
derneath when the machine is lifted up.
After every service, carry out a test drive and an operational

test on the truck.
CAUTION
If the machine is used in extremely warm, cold
or dusty environments or in other unfavorable
conditions, the service should be carried out
more frequently compared to the check- and
maintenance schedule.
Clean the area around each component before lubricating,
changing filters or repairing the hydraulic system. Use only
clean containers when topping up lubricants.

Service and maintenance
Electric welding
CAUTION
It is important to follow these instructions
when electric-welding on the machine. Risk
of serious damage to the machine. Bat-
tery cabling and all control units must be
disconnected.
1. Remove the battery leads and the leads to the alternator.
2. Important! Disconnect all control units in and on the

machine.
3. Connect the weld clamp to the component to be welded

and close to the welding point, never to the engine or in
such a manner that the current can pass over to a bearing.
When you have finished welding, connect the leads to the

alternator and control unit before connecting the batteries.
Jump-starts
CAUTION
It is forbidden to jump-start the machine
by means of a quick-charger, a booster, a
power-pack or similar. It can cause current-
rushing and serious damage to the control
units.
1. Connect the first cable from the + contact of the auxiliary
battery to the + contact of the starter motor.
2. Then connect the second cable from the contact of the

fully charged battery to the chassis, e.g. the starter motor
fixing bolt, or a nearby side-member.
3. When the engine starts, remove the cables in the reverse

order.
Running in/servicing after the first 150 hours of

operation
The machine may be driven at full speed right from the start.
However, prolonged maximum loading of the hydraulic
system and transmission should be avoided during the first
50 hours of operation.
After the first 150 hours, carry out first service according to
Maintenance Table.

Transport / towing
Lifting the machine
CAUTION
3 4
Use only lifting equipment and cranes
which have sufficient lifting capacity. See the
manufacturer’s type plate for the weight of the
truck.
1 - Attach two lift hooks to the rear lifting eyes (1), located above on
the counterweight.
- Attach two lift hooks to the front lifting eyes (2).
- Attach the lift chains to the lift hook of the crane (3).
2
CAUTION
After attaching the lift slings to the lift hook,
the safety lock (4) must be closed. When the
H1651 truck is lifted, the lift slings must not rub
against any part of the truck.
Towing
1
CAUTION
As the truck is equipped with a hydraulic
braking system, servo-assisted steering and a
hydraulic gearbox, the engine must be idling
when being towed.
If this is not possible, the hydraulic parking brake (1) must be

released, see page 84.
Remove the drive shaft, when towing longer distance.
WARNING
The machine will now have no brakes and
must only be towed by a vehicle which has
sufficient braking capacity to stop both
vehicles.
Risk of serious injury and damage to the
vehicle.

Cleaning
Cleaning the machine
The length of time between cleaning sessions depends on the

type of work carried out by the machine. If it is used in extremely
aggressive environments where it is exposed to elements like salt
water, fertilisers, chemicals, cement, etc., it should be thoroughly
cleaned when the work is finished.
WARNING
Hot steam or aggressive degreasing agents
should be used with great care. Protective clo-
thing and eye protection must be worn.
- Protect all electrical components and the air intake filter from
steam, water, etc., during cleaning.
- Clean particularly the areas around the oil top-up and lubrica-
tion places before servicing.
H1870
- If a degreasing agent is used in cleaning, allow sufficient time
for it to penetrate and then rinse with a powerful jet of water.
- After cleaning the engine, it should be run warm so that it dries
and to check that no water that has penetrated has caused any
faults.
- All materials used in cleaning should be disposed of in an envi-
ronmentally-friendly manner.
- Always lubricate the machine after steam clening.
See chapter Lubrication
Cleaning the radiator
CAUTION
The cooler must only be cleaned when the
engine has been turned off and cooled down.
Do not use high pressure steam cleaner as it
may damage the radiator fins.
- The most suitable way of cleaning the cooler is with dry com-
pressed air.
- Blow against the direction of the fan.
- The cooler must not be cleaned with high-pressure water.
- In extreme cases, solvents or a jet of steam can also be used with
great care.
- Allow the solvent time to penetrate. Rinse off with water.
- Run the engine warm so that surplus water evaporates and does
not cause corrosion.

Changing a wheel
HYDRAULICS PRESSURE RELEASE
WARNING
2 The hydraulic system contains high pressure
accumulators to maintain the brake function
during a possible engine failure.
1
Always release the brake pressure before maintaining or servic-
ing the hydraulics of the truck.
Never loosen any hydraulic hoses without ensuring that the
brake pressure is released.
- Loosen lock nut using a 11/16” ring spanner (1).

- Loosen drain screw using an 3/16” Allen-key (2).
CHANGING A WHEEL
Positioning of the jack
WARNING
Observe the following regulations before lifting
the machine.
Use only a jack that has sufficient lifting capacity.
See technical data sheet for axle pressure.
1
- To lift the machine drive axle, position the jack underneath
the drive axle (1) and block the steer axle wheels.
- To lift the steer axle of the machine, position the jack un
derneath the main plate of the steer axle (2) and block the
drive axle wheels.
- When working underneath the machine, support the under
2 side of the chassis with suitable material. Do NOT simply
H1931
rely on the jack.
Changing a wheel is a two-man operation.

- An ancillary truck fitted with an attachment for the wheel (1)
facilitates the work.
- Position the machine on even ground.
- Lift the side of the machine and support the underside
of the chassis in accordance with recommendations
1
Specifications for drive axle and steer axle tires
See machine card.
Specifications for rims

Use only rims that are approved by the manufacturer of the ma-
chine.
Other type of tires

The machine is designed to use pneumatic tires.
Solid/cushion tires are used only in consultation with the manufac-
turer of the truck.

Changing a wheel
Changing a wheel
DANGER
High-pressure tires!
To avoid accidents - always follow these
instructions when deflating or inflating tires.
DANGER
Always stand aside the wheel when deflating or
inflating tires.
DANGER
Forbidden area when deflating or inflating tires.

Changing a wheel
DEFLATING THE TIRE
WARNING
The valve can get damaged or plugged with ice
when deflating the tire. If air cannot be deflated
through the valve or if there is any doubt on
valve function a hole has to be drilled into the
tread.
DANGER
High-pressure tires.
inflating tires.
Deflate as follows
- use protective eye glasses
H2203 - unscrew the valve cap
- unscrew the valve cone. Ensure that no part of the body is in the
possible trajectory of the valve mechanism.
INFLATING THE TIRE

DANGER
High-pressure tire.
inflating tires.
- Never hit a tire or rim which is fully or partly inflated.
The tire must not be inflated until all parts are assembled.
- Rim components must never be assembled by means of ham
mer blows during inflating.
- Disassemble the tire and check the rim for damage if the tire
was deflated.
- It is important that all rim components are certified.
- Check that all components are in place when bead seating
pressure is achieved.
- Final inflation adjustment to service pressure is performed
with the wheel mounted to the truck or in a safety cage.
- If a safety cage is used the tire can be inflated to full service
pressure. Otherwise the tire shall be inflated to a setting
pressure according to the manufacturer’s instructions.
- The maximum inflation pressures specified by the tire manu
facturer must never be exceeded. If another rim or tire than
recommended is used, other pressure values might be valid.
Get in contact with Konecranes Lifttrucks for advice.
Inflate the tire as follows:
- Use a filter and dehumidifier (or dryer) on the compressed air
line in order to prevent the entry of humidity which will lead to
corrosion.
- Check that locking rings and split rim fittings are in place be-
fore stating inflation.
- Connect the compressed air line to the tire air nipple.
- Always stand aside the wheel until the setting pressure has been
achieved.
- Check that all components are in place when bead seating pres
sure is achieved.
- Mount the tire to the truck according to instructions.
- Inflate the tire to the he maximum pressures specified by the tire
manufacturer.

Changing a wheel
DISMANTLING THE DRIVE WHEEL

22 Outer drive wheels
DANGER
High pressure tires.
Risk of serious injury and death.
Release the air from both tires.
If you do not, the conical ring and locking heads may release
and shoot off when the pressure changes.
WARNING
When changing tires, use only tires which are
approved by the manufacturer.
H2111
- Remove all but two of the nuts (2) and clips (3)
- Use the ancillary truck to support the weight of the outer
wheel (5) on its forks
- Remove the two remaining nuts (2) and clips (3)
- Lean the outer wheel (5) against the ancillary truck’s wheel sup
port and secure it with a chain.
- Reverse the ancillary truck carefully and unload the outer
wheel (5).
Inner drive wheel

- Remove the outer drive wheel.
- Remove the spacer (6).
- Use the forks of the ancillary truck to support the weight of the
inner wheel (7).
- Lean the inner wheel (7) against the wheel support (1) and se-
cure it with a chain (8).
- Carefully reverse the ancillary truck and unload the
inner wheel (7).
MOUNTING THE DRIVE WHEELS
The inner drive wheels
- Load the inner wheel (7) onto the ancillary truck and fasten it to
7
the support.
- Clean the application surfaces.
- Carefully drive the ancillary truck to the required position and
place the inner wheel (7) over the drive axle and the hub.
- Remove the fastening device from the wheel support (1) and the
inner wheel (7) and straighten the wheel (7).
- Lower the forks of the ancillary truck until the inner wheel (7) is
resting on the hub.
- Carefully reverse the ancillary truck.
6 - Mount the spacer (6).

Changing a wheel
Outer drive wheel
- Load the outer wheel (5) onto the ancillary truck and secure it to
5 the wheel support. Carefully drive the ancillary truck into posi-
tion and place the outer wheel (5) over the hub.
1
- Remove the fastening device from the wheel support (1) and the
outer wheel (5) and straighten the wheel (5).
- Fasten two clips (3) and two nuts (2) placed diagonally to each
other in order to keep the rim in place.
- Fasten the remaining nuts (2) and tighten the wheel nuts cross
wise using a torque stated under Tightening bolted joints.
- Pump the tires according to manufacturers recommendations.
Disassembling the steer wheels

DANGER
1 Tires with high air pressure.
Never stand square with the wheel when
emptying and pumping air.
Release the air from the tires. If you do not, the conical ring
and clips may release and shoot off when the pressure changes.
Note that the valves may be damaged or that a valve may
become plugged with ice when the air is released. If the air can-
not be released through the valve it may be necessary to drill a
hole in the tread.
- Remove all but two of the wheel nuts (9).
- Use the ancillary truck forks to support the weight of the steer-
10
wheel (10).
- Remove the remaining nuts and clips.
- Lean the steer wheel (10) against the wheel support (1) and
fasten it with a chain (8).
- Carefully reverse the ancillary truck and unload the
steer wheel (10).
9 ASSEMBLING THE STEERING WHEELS

- Load the steer wheel (10) onto the ancillary truck and fasten it
onto the support.
- Clean the application surfaces.
- Carefully drive the ancillary truck into position and place the
steer wheel (10) against the hub.
- Use the forks of the ancillary truck to support the weight of the
steer wheel.
- Fix and tighten two of the clips and nuts (9) diagonal to each
other.
- Remove the fork support.
- Fasten and tighten the remaining clips and nuts crosswise using a
torque stated under Tightening bolted joints.
H2112 - Pump the tires according to manufacturers recommendations.

Tightening bolted joints
Tightening torque
Information on friction ratio is needed in order to select the

exact tightening torque.
WARNING
It is important that the torque of the bolted
joints is checked regularly. It is especially im-
portant in connection with the ”first servicing”.
WARNING
The wheel nuts torque must be checked daily
for 14 days or, until the rim, clamps and nuts
have settled in and there is no more tightening
obtained. This must be done:
- After a new delivery of machine.
- After the truck has been taken into use.
- After a wheel has been removed or replaced.
The following pages describe how bolted joints should be tight-
ened using a torque key.
Tightening the wheel nuts
WARNING
The wheel nuts torque must be checked daily
for 14 days or, until the rim, clamps and nuts
have settled in and there is no more tightening
obtained. This must be done:
- After a new delivery of machine.
- After the truck has been taken into use.
- After a wheel has been removed or replaced.
Tighten the nuts crosswise according to the table below.
Wheel nuts, drive axle

- Drive shaft M22 x 1.5 10.9 650 Nm
Wheel nuts, steer axle

- Steer axle M22 x 1,5 8.8 400 Nm

The tables below specify the torque for ”lightly greased” bolts.
Millimeter screws Inch screws
Tensile strength class Tensile strength class
Thread 8.8 10.9 12.9 Thread 8.8 10.9 12.9
M Nm Nm Nm UNC Nm Nm Nm
6 9,8 14 17 1/4” 11 15 19
8 24 33 40 5/16” 22 31 38
10 47 65 79 3/8” 38 54 68
12 81 114 136 7/16” 61 87 108
14 128 181 217 1/2” 93 131 163
16 197 277 333 9/16” 133 187 234
18 275 386 463 5/8” 183 259 323
20 385 541 649 3/4” 322 455 568
22 518 728 874 7/8” 516 729 909
24 665 935 1120 1” 772 1090 1360
27 961 1350 1620 1 1/8” 1090 1550 1930
30 1310 1840 2210 1 1/4” 1530 2160 2690
33 1770 2480 2980 1 3/8” 2020 2850 3550
36 2280 3210 3850 1 1/2” 2650 3750 4680
Drive shaft
To the gearbox (1) M12 8.8 81 Nm

To the drive axle (2) M12 8.8 81 Nm
Differential nuts
- (1) M14 10.9 181 Nm

The engine mountings
Check the condition of the rubber suspensions.

3 If any wear and tear is discovered, replace the damaged parts.
The engine mountings are accessible from the engine compart-
ment, one on each side of the rear part of the engine.
1
- (1) M20 8.8 385 Nm
- (2) M16 8.8 197 Nm
- (3) M16 10.9 277 Nm
H2005
The transmission mountings
Check the condition of the mountings and the rubber suspension.

Replace the worn parts if you discover any wear and tear.
The mountings are accessible from the engine compartment, one
1 on each side of the gearbox.
- (1) M20 8.8 385 Nm

- (2) M16 8.8 197 Nm
- (3) M20 8.8 385 Nm
2

Drive axle suspension
- (1) M30 8.8 1310 Nm
Hydraulic pumps
- (1) M12 8,8 81 Nm

- (2) M10 10,9 65 Nm
Cab suspension
- (1) M 24 8.8 245 Nm
NOTE
The torque must not increase the specified above. The suspension
ears can be scrunched and damage the mounting brackets.
1

Counter weights
- (1) M24 8.8 665 Nm

- (2) M24 8.8 665 Nm
1
2
Steer axle
- (1) M30x2 1310 Nm

- (2) M30 8.8 1310 Nm
H1896

Lubrication points
15
H 2096
6
4 7
11
9
17
14 16
13 10
1
5
8
H2097 12

Lubrication table
Pos.No Description Illustration Page no.
1. Steer axle H2092 64

2. Boom, lifting cylinders H2075 60
3. Attachment, damping cylinders, H1658, H1659, 59
attachment suspension H2083 60
4. Oil plug, engine H1872 65
5. Filler cap, engine oil H1838 65
6. Oil filter H1839 65
7. Oil plug, transmission H1846 66
8. Filler cap, transmission H1847 66
9. Oil filter, transmission H1880 66
10. Breather filter, transmission H1840 67
11. Drive axle H2115 67
12. Hydraulic oil filter H1700 68
13. Fuel filter H1893 71
14. Engine air filter H1790+H1792 72
15. Cab filter H1077 33
16. Brake cooling oil filter H1694 70
17. Water separator H1894 71
General rules which apply to lubrication
- Clean off old grease and clean nipples.

- Lubricate until fresh grease penetrates.
- Use only recommended grease.
- All slide bearings must be free of pressure for the grease to be
able to penetrate.
- Slide bearings require frequent lubrication with a small amount
of grease. Roller bearings require more grease less often.
- Also check the function and bearing slackness when lubricating.
- Specified lubrication periods apply in favorable conditions.
More frequent lubrication is recommended in more demanding
conditions, particularly of the slide bearings.

Lubrication / maintenance points
8
6
4
1 4
1
5 5
7
H1658
2 7 2
5 5
3
3 5
5
7
H1659 2
2
Pos.No Description Illustration Page no.
1. Slider pads extension H 1799 61

2. Twist locks H 1800 61
3. Extension cylinder H 1798 61
4. Stops H 1801 62
5. Slider pads side shift H 1802 62
6. Slewing ring bearing and gear H 1796 62
7. Side shift cylinders H 1533 63
8. Slew gearbox H 1797 63

Lubricating the damping cylinders
- No. Of grease points 4.

- Points - one grease nipple at each end of the cylinder (1).
H2083
Lubricating the attachment suspension
- No. of grease points 2.

- Points - one grease nipple at each side of the boom (1).
H2083
Lubricating the boom suspension
- Unload the boom using a container according to the picture.

- Clean the nipples before lubricating.
1 - Lubricate the grease nipples - 4 grease points (1).

Wear pads for main beams and extending beams

2
1
- 6 tracks on each extending beam (2).
- 6 tracks on the inside of each main beam (1).
1
H1799
2
1
End beams and twist locks

- 1 grease nipples in each end box (1).
- Inside end box on top of twist lock support bracket,
see pos (2).
1
2
H1800
Extention cylinder support wear pads and tracks

- 2 tracks in each extention beam.
H1798

Stop cylinders

1
- 1 grease nipple (1) on each cylinder.
H1801
Side shift slider pads

- 2 tracks on each side of the spreader pos (1) and (2).
H1802
Slewing ring bearing and gear
1 - No. of grease points 6.

- 4 grease nipples position (1) mounted at one central point
on the upper rotator frame plate for greasing the bearing.
- 2 holes at position (2) in the stop blocks for lubricating the
gear ring.
H1796

Side shift cylinder bearings

1
- 1 grease nipples on each cylinder tube bearing, position (1).
1
Slewing gearbox (only 1 unit)
- Check oil level at each service occasion.

- Fill up with oil; filler and level plug (1).
- Change oil each 2000 operating hours; drain plug (2).
- Use drive axle oil according to recommendations.
H1797

Lubricating the steer axle

2
- Clean of old grease and clean nipples.
- Lubricate the parallel tie-rods, four points (1) - 2 points on each
parallel tie rod.
- Lubricate the spindle bolts (2), one upper and one lower on
each side.
- Lubricate the hub bearings (3), one on each side. Grease pen-
etrates onto the inside.
1
H2092
Lubricating the door hinges
- Inspect and clean the hinges of the cabin door and emergency
exit.
- Lubricate the hinges (1) and open and close the doors in order
to check that all parts of the hinges have been lubricated.
Lubricating the hinges of the battery compartment
- Inspect and clean the hinges of the battery compartment.

- Lubricate the hinges (1) and open and close the door in order
to check that all parts of the hinges have been lubricated.

Changing oil and filters
Draining the engine oil
Drain oil when the engine is at operational temperature.

The oil should be replaced once a year.
- Place a suitable container underneath the drain plug (1).
- Unscrew the drain plug.
- Allow the oil to run out.
- Check that the seal is not damaged. Renew if necessary.
- Fit the drain plug.
- Tighten up the drain plug.
WARNING
Engine oil may be hot.
1 Use care in opening the cap to avoid burns.
Changing the engine oil filter
- Remove and dispose of the old filter (1).

- Lubricate the rubber seal and fit a new original filter.
- Secure the filter by hand.
1
- Never use tools. The filter could be damaged and the circula-
tion obstructed.
- Start up the engine and check whether the filter is secure.
Filling up the engine oil
- Remove the oil filler cap (2).

- Pour oil through the opening.
- Check the oil level using the dipstick (1). Fill up to the max-
mum indicator level.
- Refit the cap (2).
- Close the engine cover.
NOTE
1 When test running after changing the oil and
filter, observe the oil pressure indicator and the
warning light on the instrument panel. Also
check that there are no leaks from the drain plug
2 or the oil filter.
In order to check the oil level carefully, particularly when the
oil filter is replaced, turn off the engine and check the oil level
after around one minute.

Changing the oil in the transmission
Drain the transmission oil
The transmission must be at operating temperature when the oil is

replaced.
- Clean around the drain plug.

- Place a suitable container underneath the drain plug (1).
- Remove the drain plug and allow the oil to run out.
- Remount the drain plug (1).
WARNING
Transmission oil may be hot.
Use care in opening the cap to avoid burns.
1
Change the transmission oil filter
- Clean the outside of the filter unit (2).

- Place a suitable container underneath the filter unit.
- Loosen the filter unit with a filter wrench and dispose according
to environmental legislation.
- Oil the gasket lightly.
- Screw on the filter by hand until the gasket seals.
NOTE! Do not overtighten!
- Start the engine and check for leaks
Filling up transmission oil
- Remove the oil cap (3).

4 - Fill the transmission with oil to the maximum mark on the
dipstick (4).
3 - Run the engine at idling speed for one minute to fill the torque
converter and pipes.
- Check the level of the oil when the engine has been running for
one minute and then fill up with oil to the minimum mark.
- Check the oil level again when the operating temperature has
reached 82 - 93° C. Fill to the maximum level mark.
- Refit the dipstick (4) and the oil cap (3).
See Maintenance Data regarding the oil level in the gearbox.
WARNING
Transmission oil may be hot.
Use care in opening the cap to avoid burns.

Changing of transmission breathing filter

1
- Unscrew the breathing filter (1).
- Replace with new
Checking the oil in the drive axle

NOTE
Both hubs and the differential casing to be checked
- Park the machine on level ground.
- Place the machine so that the hub level mark (1) is horizontal.
- Carefully unscrew the filling/level plug (2) and check the oil level.
- If oil runs out from the plug, screw it back in.
- If no oil runs out, fill up with oil until it begins to seep out from
2 - the filling/level plug (2).
- Repeat the procedure for the other hub.
- Check the level in the banjo cap by unscrewing the filling/level
plug (3).
- If oil runs out of the plug, screw it back in.
- If no oil runs out, fill it with oil until it begins to seep out.
1 NOTE
Overpressure can occur.
4
H2111 Changing the oil in the drive axle
NOTE
Both hubs and the diff casing to be replaced
- Park the machine on level ground.
- Make a drainage hose using a thread which fit through the drain
ing hole (4).
- Fix the hose in the drain hole whilst it is in its uppermost posi
tion.
- Carefully drive the machine forwards/backwards so that the drain
hole returns to its lowest position.
- Allow the oil to run out through the hose into a suitable vessel.
3 - Repeat the procedure on the other side.
- Drain the diff casing through the drain plug (5).
Note! The oil must have operational temperature.
- Refit all drain plugs (4 and 5).
- Place the machine so that the hub level mark (1) is horizontal.
- Fill the drive axle trough the filling/level holes (2 and 3).
H2115
5 - Replace the filling/level plugs (2 and 3).

Changing the return filter, hydraulic oil

4
The return filters are situated on the right-hand side of the
hydraulic tank by the filling cap.
3 CAUTION
Follow these instructions. Otherwise you may
risk damaging the hydraulic system.
- Clean carefully around the filter cap (1).

1
- Remove the filter cap.
- Loosen the four screws of the filter housing in the return
2 chamber.
- Lift up the filter housing (2) and the filter element (3).
NOTE
H1700
Do not disassemble the filters and the housing in the tank.
- Remove the element by pressing and turning the bypass

valve (4).
- Check that the valve is closed.
- If the tank is empty: Also check the bottom of the tank for
any impurities.
- Clean the filter housing.
- Fit new filters and close with the bypass valve (4).
Press and turn to the correct position.
1 - Fit the filter housing in the tank.
- Fill with oil if it has been drained.
- Fit the filter cap.
- Start the engine and check for leakage.
- Turn off the engine and check the level.
Changing of hydraulic tank breathing filter
- Unscrew the breathing filters (1).

H1684 - Replace with new.
Changing the hydraulic oil
Recommended oil filter change intervals may vary due to

environment and operation.
2
- Drain the oil out through the drain plug (1), using a suitable
vessel. See oil volume, Maintenance data.
- Alternatively, the oil can be sucked up through the filter
housings if the filters have been removed.
- Inspect the bottom of the tank for any impurities.
- Assemble the filters and caps as above.
- Fill with hydraulic oil (2).
- It is advisable for the oil to be filled under some pressure.
H1685 1

Start of hydraulic pumps
1 The Reachstacker is equipped with three variable pumps.

After servicing pumps or other parts of the hydraulic system the
pumps are started as follows:
CAUTION
3 Extensive damage to the hydraulic system may
be caused by air in the system.
Never start the truck if the pumps are not air-
bled
- Loosen hoses (1) and (2).

2 - Unscrew plug (3).
- Fill the pump housings with hydraulic oil.
H1869
- Refit the the hoses (1), (2) and the plug (3).
- Start the engine and lift the boom.
Any noise should have disappeared after a few seconds. If not

- stop the engine and check the hydraulic system.

Changing the cooling oil filter (Option with separate

brake cooling)
- Remove and dispose of the old filter (1).

- Lubricate the rubber seal and fit a new original filter.
- Secure the filter by hand.
2
Changing the cooling oil tank breathing filter (Option
with separate brake cooling)
- Unscrew the brathing filter (2).

- Replace with new.
H1701

Changing the fuel filter
- Open the engine casing.

- Clean the outside of the filter unit carefully.
- Place a container underneath the fuel filter (1) to catch any
spilled fuel.
- Loosen the fuel filter with a filter key.
- Unscrew and remove the filter by hand.
- Inspect the new filter and check that the covers are in good
condition.
- Lightly lubricate the new seals with fuel.
- Screw in the new filters by hand until the seals are in contact
with the cap.
- Turn the filters a half circle by hand.
- Bleed the fuel system.
1 - Close the engine housing.
- After a test run, check that there are no leakages.
CAUTION
Never use a sealant or lubricant. Never use tools
to tighten the filter. Always use original spares
when changing filters.
Water separating filter
Drainage must be carried out when filling fuel. The filter must be
2 changed according to section ’Check and maintenance schedule’.
- Close the drain tap (1) before the filter.

- Unscrew the container and drain valve (4).
3 - Unscrew and change the filter (3). Lubricate the seal before
tightening the new filter by hand.
- Screw the container and drain valve into position.
- Open the drain tap (1).
4 - Bleed the fuel system.
Bleeding the fuel system
Air can penetrate the fuel system when:

- the fuel tank runs completely empty.
- the fuel pipes are disconnected.
- the fuel filter is replaced.
Do as follows in order to bleed the fuel system:

- Remove the fuel return line from the pipe. Connect a hose to the
pipe. Place the other end of the hose into a vessel half filled with
fuel.
- Run the engine at 800-1000 rpm. Single bubbles can appear. If
the amount of bubbles increases or foam is built up there is air in
the system.
- Remedy by tightening all connections.
CAUTION
A leaking seal will disrupt fuel flow from the
tank to the metering pump as it will enable air to
enter the system.

Checking and other maintenance
Cleaning/changing the air filter
4 WARNING
The air filter contains a significant amount of
1 dust particles.
Danger of respiratory distress!
A protective mask must always be worn when servicing the air
intake system. Do not inhale the dust particles.
Consider the environment when carrying out this work.
Majorrisk of engine damage if the filter element is damaged.
CAUTION
H1790 3 Cleaning the element always entails a risk of
5 damaging it. It should only be cleaned four tmes
2 a year at most. After cleaning it has poorer dust
capacity than a new element.
CAUTION
Do not clean the inside of the filter casing with
compressed air. All maintenance on the air in-
take system must be carried out while the engine
is turned off. This is a dry filter element and
must not be cleaned with water.
Cleaning the coarse filter
This type of engine is equipped with a coarse cleaner (4).

Clean daily or when necessary.
- Remove the cover from the coarse separator..

- Remove the conical coarse separator. Empty out the partic-
les of dirt and clean it.
- Refit the coarse separator and screw the cover in place.

Cleaning/changing the main filter element
Clean or change the filter element if the low pressure indicator

shows red.
- Open all of the clips (1) and remove the cap (2).
- Empty out the dust which has collected in the cap and dry the
cap using a damp cloth.
- Remove the element carefully (5).
- Clean the inside of the filter casing (3) clean using a damp cloth.
- Insert a torch into the filter element and check from the outside
that there are no holes or cracks in the filter paper.
NOTE
Do not clean the inside of the filter casing with compressed air.
Use a damp cloth.
H1792 - Carefully blow dry compressed air over the filter element to
clean it, a maximum of 5 bar, from the inside until no more dust
comes out.
- Mark the filter element when it has been cleaned.
NOTE
This is a dry filter element and must not be cleaned with water.
6 NOTE
Discard the filter element:
- if it has been cleaned 5 times.
- if it is the slightest damaged.
- after 1 000 hours of use.
- after 12 months of use, maximum.
Record each service carried out on the filter element.
- Assemble the air cleaner in reverse order.

H1793 - Reset the red plunger in the low pressure indicator by pressing in
the button.
Safety cartridge
NOTE
Never clean the safety cartridge.
Do not remove the safety cartridge unnecessarily.
- The safety cartridge (6) is normally replaced after around

4 000 hours of use, or if there has been any damage to the
main filter.
- Disassemble the filter lining as above.
- Fit in a new safety cartridge.

Checking the air intake system
It is of paramount importance for the air intake system to be

intact. Broken and leaking pipes can drastically shorten the
life of the engine.
Check the system regularly.
2 - Check the hoses (1) for fissures and damage. If necessary,
replace them.
- Ensure that all hose clips (2) are tightened and fit snugly.
- Check that the filter container is intact.
1
2
H034
Checking the battery
WARNING
The battery contains corrosive acid. Always use
the necessary protective equipment.
Batteries generate explosive hydrogen when
charged. Ensure that there is good ventilation
and avoid sparking.
The main disconnect does not cut the power to the alternator.
Always disconnect the ground (minus) cable at the battery
when working near or on the alternator.
To reduce the risks of electrical shock and personal injury al-
ways remove jewelry and conductive material prior to working
on the electrical system.
cicuit switch while the engine is running.
Beware of short-circuiting the battery, which may cause fire or
explosion.
The batteries are located in the compartment on the right hand

side of the machine.
The batteries are maintenance free.
- Keep the batteries clean.

- Remove corrosion from the battery connections and check that
the cable connections are tightened.
- Lubricate the battery terminals using acid-free grease.

Changing the windscreen wipers
- Remove the bolt (1).

- Remove the blade (2) from the arm (3).
- Insert the new blade (2) into the arm (3).
- Replace the bolt.
- Lower the wiper back onto the windscreen.
3
Checking the cooling system
- Check all hoses by pressing them to find any fissures andle-

aks. If in doubt, replace them.
- Check the radiator for damage, leaks and blockages. See
section ’Cleaning’.
- Check the function of the cab heater.
- Check the level of the coolant: see below, glycol content, see
Maintenance Table, and for any impurities.
- Replace the coolant if it is not clean and clear.

Checking the cooling system

2
- Check the rubber pads in the radiator fittings (6) on the
bottom of the radiator and the upper bracing (7) - replace if
1 3 necessary.
7 - Check that the nuts (8) are tight.
Replacing the coolant
WARNING
The coolant may be pressurized and hot.
4 Risk of serious injury.
The system may be pressurised, even if it is
6 not the pressure type.
8 - Open the cap of the expansion tank (1) with care - first turn
it 1/4 of a turn to ensure that the system is not under pressure
when the cap has been removed.
- It can only be refilled through an expansion vessel (2). The
cap of the cooler (3) is only used for filling when the system
has been completely drained.
- Drain the whole system through the tap (4) when replacing
the hoses and system components.
- Turn the cab heater control to maximum. Place a suitable
container underneath the drainage tap.
- Open the tap and drain the system fully.
- Turn off the tap.
- Fill the system through the radiator filler cap (3).
- Screw on the cap.
- Fill up through the expansion tank (1) to the maximum
level.
- Start the engine and let it idle.
- Observe the level during this period and top up if neces-
sary.
- When the operating temperature is reached, the level
should have stabilised.
- The level should be between MIN- and MAX-marks.
Checking the exhaust system for leaks
WARNING
The exhaust system may be hot.
Risk of burns!
Wait until the exhaust system has cooled before
starting work.
- Check the overall condition of the exhaust system, replace

pipes or the silencer if they are leaking due to corrosion.
- Check all joints and screw joints.
- Check the exhaust manifold.
- Check the rubber silencer suspension. Replace if necessary.
- Start the engine.
- Check for any leaks in the exhaust system.

Valve clearance
NOTE
The valve clearance should be checked when the engine is cold.
Follow the instructions in the engine manufacturer’s instruction
book.
H1680
Checking the fuel system and injectors
- Check the fuel system for leakage.
CAUTION
The injectors must be checked and adjusted by
an authorised dealer who has the necessary spe-
cial equipment.
H1681

Checking the fuel tank
- Check the tank for any leaks.

- Drain the tank of any grime and water through the
drain plug (1).
- Place a suitable vessel underneath the end plug.
- When clear fuel comes through, replace the drain plug.
- Check the seal around the fuel cap (2).
Checking of poly-v belts
If the poly-v-belt (2) is worn or damaged, it should be

2 replaced.
Check also the automatic belt tensioner (1) for function.
1
H1682

Boom wear pads
Pads and wearing surfaces are maintenance free. Check pads and
retainers for wear and damages at each service. Excessive wear or
damaged retainers or pads may cause severe damage to the cor-
responding wearing surfaces. These surfaces are threated with a
special graphite paint and should under no circumstances make
metal to metal contact.
The main pads (1) are located at front bottom and rear top. Total
four.
The guide pads (2) are located at front, two on each side and at the
rear two at bottom and one on each side. Total eight.

Main pads
The main pads (1) are not adjustable and are fixated by a bolted
bracket (2). Original thickness of pads is 20 mm.
Thickness of bracket is 12 mm. Minimum allowable thickness of
pad is 14-15 mm. I.E pad should be at least 2-3 mm higher than
bracket (3). Worn pads must be replaced.
Side guide pads
The guide pads are adjustable by shims (1). Before opening

the cover (6) make sure that pads are unloaded. Front pads
should be adjusted while the innerboom is completly
retracted. Rear pads should be adjusted with the boom exten-
ded until the lower pads are unloaded.
Add shims in order to get pads tighter. Side play (3) in boom
should be kept between minimum 0-1 mm and maximum 4 mm.
Original thickness of pad (4) is 40 mm. Minimum thickness
20 mm or when there is only 10 mm left to the bracket. When
shimming pads make sure that the innerboom lines up ”center to
center” with the outer boom.
I.E (5) should be equal right side and left side.
Boom
- Use a claw wrench or crowbar to check the room between

inner and outer boom.
If there is a gap of more than 5 mm, contact your local

Konecranes Lifttrucks-dealer.

ATTACHMENT
Sliding pads
Check that the thickness of the sliding pads does not go below
18 mm (1). Change the sliding pads when required. The change
1 can be performed with standard tools and without disassembling
the attachment beams.
- Check the sliding pads on the underside of the extension cylin-

der.
- Check the sliding pads of the side shift cylinders.
H2069
Twist lock
Change the twist locks if the measurement (1) is less than 25 mm if

the worn part exceeds the marked area (2).
The twit locks must be changed after 5000 operating hours.
Other maintenance of the attachment
- If the attachment is equipped with stop cylinders, check that all

screws are properly tightened and check the cylinder for leakage.
- Inspect all major parts of the attachment for cracks or other dam-
age.
1 2 - Check that the signal systems works properly.
- Check the hydraulic pressure regularly.
H2070
- Check the hydraulic cylinders for leakage. Change seals when
required.
- Check the hydraulic hoses for leakage or damage. Change if
required.

Checking weld constructions
Check the boom, spreader, chassis and all welded parts to see if
there are any visible signs of damage, deformation, metal fatigue,
etc. This should be done at least once a year, more often if the
machine does shift work. If there are any doubts, contact the
Konecranes Lifttrucks-dealer.
H1683
32 Checking of the steer axle bearings

3
Check the wheel and spindel bearings regulary and always
when the tires are replaced. Inportant during the running in
period. As these bearings are exposed to high loads and chocks it is
of greatest importance that is no play whatsoever in these bearings.
Any play will result soner or later in bearing breakedown. Bearings
are adjustable, see next page. Play in link bearings are acceptable to
1-2 mm per each bearing, this is however not adjustable.
1 Any gap can be checked when the wheel rises from the
ground. Use a crowbar to lift the wheel and locate the gap.
Use a jack to lift up each side (see Changing a Wheel) and check as
follows:
- Check the spindle bearings by lifting the wheel with a
prybar (1).
- Check the hub bearings by prying the wheel
vertically (2).
- Check the link bearings by turning the wheels in the
steering direction (3).
Adjusting wheel bearings
- Undo the cap (1).

- Check that the bearing grease is clean and free from
particles. If not, the reason for the gap may be a damaged
bearing.
- Turn up the lock washer (2).
- Tighten the nut (3);
the correct tightening torque is 245 – 294 Nm.
- Rotate the hub. This should only offer light resistance.
A noise or irregular rotation signifies a broken down
bearing. Replace the bearing.
- Check the gap.
- Lock the nut (3) using the lock washer (2).
- Fit the cap (1).
H105

Adjusting the spindle bearings
- Remove the steering link.

1 - Remove the cap (1).
- Check the grease.
- Turn down the lock washer (2).
- Unscrew the nut (3) a few turns.
- Check that the lower nut (4) is tightened; the correct torque is
3
2 around 980 Nm.
- NOTE The nut (4) is not used to preload the bearing. All bea-
ring preload is adjusted with the upper nut (3).
- Tighten the upper nut (3) to around 245 – 294 Nm.
- Check that there is no gap and that the spindle can easily be
turned without it making a noise or offering irregular resistane.
- Remount the caps (1).
1 3

Parking brake
9 1
WARNING
2 The brake is a pure parking brake and
should be used as such - to keep the
machine stationary.
7
Due to the gear ratio through the drive axle, the brake
is verypowerful, however if the brake is used to stop the
machine it will wear the pads rapidly .
Use the parking brake to stop the machine with only
in emergency. After such a braking the brake should be
8 checked, adjusted and if necessary pads replaced.
As being an emergency brake, the function of it has to
6 be checked daily by the operator. To ensure the func-
3 tion and to make the following adjusting procedures to
go easy , it’s necessary to keep the calliper well lubri-
5 4 cated and all parts in good condition. In case of any
doubts, dismantle, clean and lubricate.
1. Spring Brake adjustment

2. Lock ring
3. Lock nut Brake adjustment is required after installing new brake
4. Seal ring pads or brake discs, after all repairs, and to improve
5. Piston sealing braking performance. Adjust the brakes when the brake
6. Dust cap is cold. The park brake must be in the released condition
7. Screw cap during the adjustment procedure.
8. Adjusting screw
9. Bleeder - Park the vehicle on a level surface.
NOTE.
Block the wheels to prevent the vehicle from moving.
- Apply hydraulic pressure by releasing the parking brake.
CAUTION
Make sure that the parking brake pres-
sure is correct. See below.
- Remove the screw cap (7).

- Loosen the lock nut (3). Turn the adjusting screw (8)
clockwise until both brake pads contact the brake disc.
- Turn the adjusting screw counterclockwise to set the
1
total clearance to 1 mm - 0,5 mm.
- Tight Lock nut (3).
- Recheck the clearence.
Measuring parking brake pressure
- Connect a pressure gauge (300 bar) to the metering

outlet (1) marked PRM on the accumulator block.
- Start the engine and let it idle.
- Read the pressure. Check according to machine card.

Parking brake emergency release

3
DANGER
When the parking brake is released, the
9
vehicle does not have any park brake
function.
You must block the wheels to prevent the vehicle from
moving.
If hydraulic pressure is not available, the parking brake can

be manually released using the following procedure.
- Block the wheels to prevent the vehicle from moving.
- Remove the screw cap (7).
8 - Loosen the lock nut (3).
- Turn the adjusting screw (8) counterclockwise until the
H1672 7 brake is released.
- Tighten the lock nut (3). Install and hand-tighten the
screw cap.
- Before you return the vehicle to service, adjust the brake
using the procedure in this section.
Bleeding the parking brake
When you loosen any brake system hydraulic connection,

you must bleed the brake to remove all air from the system.
The brake cylinder must be filled with hydraulic fluid, so
no air can be pulled into the system.
- Attach a clear tube to the bleeder screw (9). Submerge
the other end of the tube in a clear container filled with
hydraulic fluid.
- Slowly apply hydraulic pressure to the brake.
- Loosen the bleeder screw (9).
- Continue to apply pressure until no air bubbles appear
in the container of fluid.
- Tighten the bleeder screw and release the pressure.

Delivery / start-up service
DELIVERY INSPECTION AND INITIAL START-UP
Always perform maintenance, lubrication, inspection and daily maintenance according to the instructions in this book. Before
commissioning of the reachstacker, inspection points according to the guarantee/delivery report.
The guarantee/delivery report must be filled in and returned to Konecranes Lifttrucks within one week from commissioning the
reachstacker in order to make the guarantee value from commissioning date.
If the guarantee/delivery report is not returned within one week, the guarantee is value as from the day the reachstacker was
delivered by Konecranes Lifttrucks.
DELIVERY/COMMISSIONING SERVICE
Pos. Inspection points to check or maintain Activity

1 Clean the truck X
2 Tighten the wheel nuts according to torque X
3 Check tire pressure and condition X
4 Check fluid level/fill up the washing fluid container X
5 Check fuel level X
6 Check cooling fluid level X
7 Check gear box oil level X
8 Check engine oil level X
9 Check oil level of the hydraulic system X
10 Check function of service and parking brake X
11 Check function of steering system X
12 Lubricate according to lubrication chart X
13 Check function/condition of electrical system, lighting, instruments, switches and safety system X
14 Check function of hydraulic system X
15 Check oil level of the drive axle X
16 Check condition of batteries X
17 Check safety and condition of driver’s cab, fuel and oil tanks, chassis, counter weights, lifting equipment X
and attachment
18 Check condition of painting and windows X
19 Compare specifications with customer’s acceptance of order X
20 Check ID and warning signs X
21 Check that the proper driver’s service book is delivered with the reachstacker X

Checking and Maintenance schedule
DAILY MAINTENANCE AND SERVICE BEFORE START-UP
Pos. Service points to check or maintain Activity
1 Check washer level X
3 Check engine oil level X
4 Check transmission oil level X
5 Check air filter indicator X
6 Clean engine air filter coarse cleaner X
7 Check hydraulic oil level X
8 Check brake cooling oil level X
9 Check fuel level X
10 Check tire pressure, condition and wheel nuts X
11 Check the main circuit switch X
12 Check brake system for function X
13 Check steering system for function X
14 Check hydraulic system for function X
15 Check lights and horn X
SERVICE POINTS AFTER THE FIRST 150 OPERATING HOURS
Pos. Service points to check or maintain At 150
hours
1 Change engine oil X
2 Change engine turbo filter/oil filter X
3 Change transmission oil X
4 Change transmission oil filter X
5 Change oil in attachment slew gears X
6 Lubricate machine according to lubrication schedule X
7 Check oil level in drive axle X
9 Check cooling freezing point X
10 Check engine drive belt X
11 Check hydraulic oil level X
12 Check brake cooling oil level X
13 Check battery condition X
14 Check exhaust system X
15 Check (clean if necessary) air filter and air intake X
16 Check sliding pads of boom and attachment X
17 Check tire pressure and condition X
18 Tighten wheel nuts to proper torque X
19 Check steer axle bearings X
20 Check/tighten bolt joints X
21 Check condition and function of electrical system, lighting, instrumentation, switches and safety system. X
22 Check safety and condition of cab, tanks, chassis, counter weights, lifting equipment and attachments X
23 Check condition of painting and windows X
24 Check function of service and parking brake X
25 Check function of steering system X
26 Check function of hydraulic system X
27 Check function of attachment
NOTE! Extra service after 500 hours on Scania engines
28 Check/adjust valve clearance 1) X
29 Check/adjust PDE-injector rocker lever 1) X
NOTE!
1) See manufacturers instruction handbook

REGULAR SERVICE
Pos. Service points to maintain When 500 h- 1000 h- 2000 h- 4000 h-
necessary service service service service
1 Clean the machine X
2 Clean the radiator X
Filter- and liquid change
3 Lubricate according to Lubrication schedule X X X X
4 Change engine oil 1) X X X X
5 Clean engine oil filter 1) 2) X X X X
6 Change turbo filter/engine oil filter X X X X
7 Change fuel filter X X X
8 Change fuel/water separator filter element X X X
9 Change/clean engine air filter X X X X
10 Change transmission oil X X X
11 Change transmission oil filter X X X
12 Change cab filter X X X X
13 Change hydraulic oil filter X X
14 Change oil in attachment slew gears X X
15 Change hydraulic oil X X
16 Change brake cooling oil filter X X
17 Change brake cooling oil X X
18 Change hydraulic oil tank breathing filter X X
19 Change brake cooling oil tank breathing filter X X
20 Change drive axle oil X
21 Change engine air filter safety cartridge X
NOTE!
1) Change intervals for oil and filters is dependent on sulphur content of the fuel and operation conditions
2) SCANIA engines only

REGULAR SERVICE
Pos. Service points to maintain When 500 h- 1000 h- 2000 h- 4000 h-
necessary service service service service
Checking and cleaning
22 Clean engine air filter safety cartridge X X X X X
23 Drain fuel filter water saparator X X X X X
24 Check tire pressure and condition X X X X X
25 Tighten wheel nuts to proper torque X X X X X
26 Check/tighten bolted joints X X X X X
27 Check cooling level X X X X X
28 Check oil level in drive axle X X X X
29 Check battery condition X X X X
30 Check engine drive belts X X X X
31 Check exhaust system X X X X
32 Check adjustment of parking brake X X X X
33 Check condition of painting and windows X X X X
34 Check safety and condition of cab, tanks, chassis, counter X X X X
weights, lifting equipment and attachments
35 Check ID-plates and warning signs X X X X
36 Check electric system for function X X X X
37 Check service and parking brake for function X X X X
38 Check steering system for function X X X X
39 Check hydraulic system for function X X X X
40 Check attachment for function X X X X
41 Check/adjust valve clearance See engine service schedule
42 Check/adjust injectors 3) 4) See engine service schedule
43 Check/adjust fuel injector rocker levers See engine service schedule
44 Check attachment twist locks X X X X
45 Check steer axle bearings X X X X
46 Check sliding pads of boom and attachment X X X
47 Check cooling freezing point and anticorrosion X X X
48 Check welding constructions X X
49 Clean/drain fuel tank X X
Calibration
50 Calibration of transmission X X X X
NOTE!
3) See engine service schedule, page 89, for service intervals.
4) Only Volvo 6-7 liter engines

Engine service schedule
VOLVO TAD 620VE AND TAD 722VE, VOLVO TAD 660VE AND TAD 762VE
First service at 150 hours
Check/adjust valve play 1)
Tighten injectors 50 Nm 1)
Check point every 1500 hours


Check injectors 1)
SCANIA DC9
First service at 500 hours
Check/adjust PDE-injector rocker levers 1)

Check/adjust PDE-injector rocker levers 1)
CUMMINS QSB6,7
1) Note! See engine manufacturer’s manual for instructions.

Maintenance data
No. Unit Material/oil/lubricant
1 Engine Engine oil Volvo
TAD 620 VE, oil and filter change 16 l (4,2 US Gal)

TAD 722 VE, oil and filter change 23 l (6,1 US Gal)
TAD 660 VE, oil and filter change 15,5 l (4,1 US Gal)
TAD 760 VE, oil and filter change 21,5 l (5,7 US Gal)
Scania
DC9, oil and filter change 37 l (9,8 US Gal)
Cummins
QSB 6,7, oil and filter change 16,7 l (4,4 US Gal)
2 Air filter Air pressure -

max. 5 bar (cleaning)
3 Fuel tank Diesel SMV 108 TB 430 l (114 US Gal)
4 Cooling system Glycol / water mixture 50 l (13,2 US Gal)
5 Hydraulic oil system Hydraulic oil SMV 108 TB 600 l (159 US Gal)
(total volume)
6 Drive axle Drive axle oil D81 PL475 1,5 l (0,4 US Gal) 38 l (10 US Gal)
D81 PL488 2 l (0,5 US Gal) 45 l (11,9 US Gal)
7 Transmission ATF Dexron III DANA TE17 25-30 l (6,6-7,9 US Gal)
8 Tires Air See manufacturer’s manual
9 All lubrication points Grease When required
10 Valve clearance - See manufacturer’ instruction book.

(engine)
11 Fuel inj. Diesel See manufacturer’ instruction book.

Fuel and oil recommendations
Quality of the engine oil
The engine oil must comply with one of below classifica- Changing the oil due to a change in season may be avoided
tions for oil: by using what are known as multi-grade oils. Specified inter-
- ACEA E3, E4, or E5 vals for changing the oil also apply to multi-grade oils.
- TBN-value should at least be 12-13 (ASTM 2896)
Check with your oil supplier that your oil meets these NOTE
demands. No oil additives of any sort should be added to those oils
recommended! Using such additives could invalidate the
The recommended oil change intervals are valid if the sulp- engine warranty.
hur content of the fuel is below 0.3%.
If the sulphur content is higher than 0.3%, the oil change Mixing different brands of oil should be avoided.
intervals must be divided in half (250 h).
Since the temperature ranges for adjacent SAE classes over-
When the engine is in use, some of the oil which serves lap, the oil does not need to be replaced when short-term
as a lubricant will be burned (used) prior to reaching the temperature replaces occur.
pistons. The combustion products in combination with the
high temperatures lead to ”oil wear”, particularly for the
chemical additives. Extended oil change interval
Since this oil wear depends on operating conditions, the Extended oil service life may result when using synthetic flu-
quality of the oil (the productivity of the oil) and the fuel ids. Appropriate change intervals should be determined for
used, the intervals between changing the oil may vary in each transmission by measuring oil oxidation and wear me-
length. tals over time, to determine a baseline. Wear metals analysis
can provide useful information but a transmission should
The longest possible time before the engine lubricating oil not be removed from service based solely on this analysis.
is replaced is one year, i.e. the oil should be replaced after a
maximum of one year’s operation.
Since the viscosity of the oil varies according to tempera-

ture, the temperature in the place where the
truck is being used is vital to the choice of the engine oil
viscosity range (see diagram).

Fuel and oil recommendations
RECOMMENDED FUELS , HYDRAULIC OILS AND TRANSMISSION OIL
Diesel Hydraulic oil

Use only fuel in accordance with DIN 51601 with a cetane Universal Traktor Transmission Oil (UTTO)
rating not below 45.
The oil must comply with one of the following classifica-
The diesel sulphur content should not exceed 0.3 %. If the tions:
sulphur content lies over 0.3 % the oil changing intervals in
- John Deere JD20C
the maintenance table must be halved.
- Massey Ferguson MF1141/MF1135/ MF1143
If the values are higher, contact the manufacturer of the - ZF TE-ML 03E/TE-ML 05F/TE-ML 06K
fork-lift truck or the lubricant.
It is also possible to use an hydraulic oil according to specifi-
NOTE cation below in addition with 1.5 % Lubrizol.
As the surrounding temperature falls, the flow characteristics
of the diesel are reduced to a point where paraffin begins to
precipitate. If ”summer quality” diesel is used, this may cause
trouble in operation. For this reason, ”winter quality” diesel
DIN 51524 Part 2 HLP and Part 3 HVLP
should be used during the cold part of the year, as it operates
in the cold better and functions reliably at -15 °C.
Use hydraulic oil from a well-known oil company for mo-
Using additives to improve the flow is not recommended. bile applications.
They may reduce the capacity to start from cold.
Viscosity Temperature range
Converter/transmission oil SHS 32 -30 °C – +10 °C
ATF Dexron III
SHS 46 -20 °C – +50 °C
Oil change interval SHS 68 ±0 °C – +50 °C

Drain and refill system every 1000 hrs for average environ-
mental and duty cycle conditions. Severe or sustained high
operating temperature or very dusty atmospheric conditions Grease
will result in accelerated detioration or contamination. Multipurpose type E.P. according to NLGI Grade 2.
Judgement must be used to determine the required change
intervals for extreme conditions.
Coolant
Use only monoethylene glycol-based coolants with an ad-
Drive axle oil ditive to prevent corrosion.
API GL.5 SAE 80 W-140 Do not mix with anti-freeze liquid containing ethanola-
mine.
NOTE
The above are strictly recommendations. When ever hesita-
ting contact the SMV-dealer for advice.
Liquid anti-freeze % volume mixture Mixture of

at the lowest liquid anti-freeze anti-freeze and
temperature °C water
-12 25 1:3
-18 30 1:2
-25 40 1:1,5
-37 50 1:1
-60 66 2:1

Electrical system
Fuses
Fuses are located to the left below the instrument panel and in
the battery compartment on the right side of the machine.
Italic = optional.
Fuse Size Function

no.
F1 10 A Ignition voltage engine box D+ voltage
supply, relays working lights
F2 7,5 A Brake light, side marker lights, dome lamp.
switch illumination
F3 15 A HVAC
F4 5A Fuel shut-off valve, central lubr. pump, seat
buzzer
F5 15 A Condenser fan motor
F6 7,5 A Road lights, high beam
F7 7,5 A Road lights, low beam
F8 10 A IQAN-MDL
F9 10 A IQAN-XA2-A0
F10 10 A IQAN-XA2-B1
F11 10 A IQAN-XA2-B2
F12 7,5 A Hazard and HVAC
F13 7,5 A Power supply, ignition lock, pre-heater
F14 15 A Road lights, relay
F15 7,5 A Entrance lights
F16 10 A Wiper, washer and horn
F17 7,5 A Directionals, seat heater
F18 10 A Seat suspension air compressor
F19 7,5 A Extra
F20 7,5 A Beacon, rear view mirror heater, map light
and search light
F21 7,5 A backup lights, backup alarm
F22 7,5 A Converter 24/12 for radio, comm.radio
F23 15 A 24 V-outlet 8roof )
F24 3A IQAN-MDL (+RTC), timer for diesel pre-heater
F25 3A Left marker light
F26 3A Right marker light
F27 7,5 A Working light boom, right
F28 7,5 A Working light boom left
F29 5A Working light chassis front
F30 7,5 A Working light chassis front
F31 10 A IQAN-XA2-A3 (Option for Elme 857)
F32 3A Attachment
F33 - Extra
F34 - Extra
F35 15 A Power supply for:
Scania DC9, DI12 and DC12 EMS S6
Cummins QSM 11
Volvo TAD 760 VE EMS 2
Diagnostics outlet in cab for:
Cummins QSB 6,7 and QSM 11
F36 15 A Power supply for:
Cummins QSM 11
F37 10 A Computer/customer equipment
F40 3A Backup camera 12 V

Electrical system
Fuses and relays in the battery compartment.
WARNING
Beware of short-circuiting the battery, which
may cause fire or explosion.
The battery contains corrosive acid. Always use the necessary
protective equipment.
Batteries generate explosive hydrogen when charged. Ensure
that there is good ventilation and avoid sparking.
The main disconnect does not cut the power to the alterna-
tor. Always disconnect the ground (minus) cable at the battery
when working near or on the alternator.
To reduce the risks of electrical shock and personal injury al-
ways remove jewelry and conductive material prior to working
on the electrical system.
circuit switch while the engine is running.
Fuses F51-F68 and F71-F78 are situated in the battery compart-

ment on the right side of the machine.
1. Fuse 51-75
2. Relay K32
3. Relay K33-34
4. Relay K31
Italic = Option.
Fuse Size Function

no.
F51 10 A Main fuse for fuses F12 and F24
F52 Extra
F53 Extra
F54 15 A Extra
F55 15 A Extra
F56 5A APC200
F57 15 A Extra/Cummins QSB 6,7
F58 15 A Extra/Cummins QSB 6,7
F61 30 A Main fuse F1, F3, F4, and F5
F62 30 A Main fuse for fuses F8, F9, F10, F11 and
F34
F63 30 A Main fuse for fuses F16, F17, F18, F21,
F31, F32 and F39
F64 30 A Main fuse for fuses F2, F13, F27, F28 and
F33
F65 30 A Main fuse for fuses F14, F15, F29 and F30
F66 30 A Main fuse for fuses F20, F22, F37 and F38
F67 30 A Main fuse for fuses F23, F35 and F36
F68 30 A Starter relay:
Scania DI12, DC12
Volvo TAD722 VE
F71 10 A Elme Attachment
F75 5A APC200
F76 10 A Volvo TAD 722 VE
F80 70 A Cummins supply starter relay

Electrical system
RELAYS
K1 - K14 are mounted in the electrical main box. K31, K32, K33,
K34 och K35 are mounted next to the main fuses in the battery
compartment. Italic = optional.
Relay no. Relay function

K1 *) Automatic shut-off of 65 000-supply
K2 *) Automatic shut-off of 64 000-matning
K3 *) Automatic shut-off of of ignition voltage
K4 Working lights boom
K5 Working lights chassis front
K6 Extra
K7 backup light/warning
K8 Interlocking direction selector (joystick steering)
K9 Rear view mirror heater, short-stop heater
K10 Interval wiper rear
K11 Interval wiper roof
K12 Interval wiper front
K13 Directionals
K14 Backup camera
K16 Horn
K31 Starter relay: Scania DC9, DI12, DC12 and
Volvo TAD 722 VE
K32 Main relay
K33 Earth relay for K31 at start-up
K34 Shut-off relay APC200, Scania DI12, DC12
K35 Starter relay Cummins QSB 6,7 and QSM 11
Automatic shut-off earlier versions Volvo TAD1240,
1250 VE
TMR1 *) Time relay, bridging of relay K3
*) = used only in combination with automatic light shut-off

Notes

Notes

Manual de Operador

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual de Operador

Uploaded by

Copyright:

Available Formats

MODEL RANGE REACHSTACKER

Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01 1

2 Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01

Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01 3

* Follow national safety regulations * Lifting a person or persons is forbidden unless

4 Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01

WARNINGS AND IMPORTANT INFORMATION

Read the instruction book carefully before

Always read the instructions that follow the safety alert

Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01 5

We reserve the right to modify our design and material

6 Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01

1. Lift boom 4. Damping cylinders 2 pcs 8. Counterweight

Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01 7

1. Attachment 4. Steer axle number 7. Transmission number

8 Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01

The brakes are operated by an oil-cooled wet disc-brak-

Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01 9

10 Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01

1. Parking brake 11. Joystick steering (optional)

Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01 11

DAILY MAINTENANCE AND SERVICE BEFORE START-UP

Check the screen washer tank

Check the coolant of the radiator

- Open the cap of the expansion tank (1).

12 Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01

Checking the engine oil level

- Lift the engine casing.

1 See maintenance data for volume.

Checking the oil level in the gearbox

See maintenance data for volume.

Air filter indicator

- Check the indicator (1).

Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01 13

Cleaning the air cleaner coarse cleaner

Checking the hydraulic oil level

Topping up the hydraulic oil

- Unscrew the oil cap.

14 Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01

Checking the brake cooling oil (Option with separate

Topping up the brake cooling oil (Option with sepa-

- Unscrew the breathing filter (1).

Filling with fuel

- Open the tank cap located on the left-hand side of the

See Maintenance data for volume.

Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01 15

Checking the condition and pressure of the tires

Drive axle (illustration No. H1670)

- Check that the tires have not been damaged or become

Main circuit switch

- The main circuit switch (1) is located on the right-hand side of

16 Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01

Adjusting the driver’s seat

- To elevate the seat, turn the hand wheel (3) clockwise.

- Lift the clamp (4), to adjust the seat forward/backwards.

- Adjust the height stroke limiter with handle (7).

Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01 17

Adjustment lever of steering wheel

When positioning the steering wheel:

- Pull lever (1) upwards to adjust the height.

18 Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01

DESCRIPTION OF THE EMC DRIVE MONITOR TYPE IQAN

Description of the keys The scroller knob

Service Instruction Book SMV 108 TB Publ.No: 6196.090 1124, Version 01 19