Hankeleping

PAKKUMUS HINDAMISKRITEERIUMID JA HINNATAVAD NÄITAJAD Viitenumber: 305669 Hankija: Riigi Kaitseinvesteeringute Keskus (70009764) Hange: Tõstukid ja käsikahvelkärud Pakkumus: 616886 Ettevõtja: Willenbrock Baltic OÜ (11341282), roll: peapakkuja OSA 1 – RASKETÕSTUK 25T Pakkumuse maksumust hinnatakse - Ilma maksudeta 1. Pakkumuse kogumaksumus Pakkumuse kogumaksumus ilma käibemaksuta. Pakkumuse kogumaksumus peab sisaldama kõiki tarnega seotud kulusid. Tüüp ja hindamismeetod: Maksumus, vähim on parim Osakaal: 100% Hindamismetoodika kirjeldus: Madalaima väärtusega pakkumus saab maksimaalse arvu punkte. Teised pakkumused saavad punkte arvutades valemiga: "osakaal" - ("pakkumuse väärtus" - madalaim väärtus") / "suurim väärtus" * "osakaal". a. Rasketõstuk 25T Tehniline kirjeldus alusdokumentide juures. Tõstuki(te) tarne Eesti Vabariigi piires vastavalt etteantud tellimusaadressile. Kogus Ühik Ühiku hind Maksumus KM% Maksumus KM-ga Märkused 2 tk 419581,000 839162,000 24 1040560,880 Osa maksumus kokku KM-ta: 839162,000 Osa maksumus kokku KM-ga: 1040560,880 OSA 2 – KÄSIKAHVELKÄRU 1200MM KAHVLITEGA, KAALUGA Pakkumuse maksumust hinnatakse - Ilma maksudeta 1. Pakkumuse kogumaksumus Koostatud 13.03.2026 11:52:04 1/2 https://riigihanked.riik.ee/rhr-web/#/procurement/ 9878684/general-info  Pakkumuse kogumaksumus ilma käibemaksuta. Pakkumuse kogumaksumus peab sisaldama kõiki tarnega seotud kulusid. Tüüp ja hindamismeetod: Maksumus, vähim on parim Osakaal: 100% Hindamismetoodika kirjeldus: Madalaima väärtusega pakkumus saab maksimaalse arvu punkte. Teised pakkumused saavad punkte arvutades valemiga: "osakaal" - ("pakkumuse väärtus" - madalaim väärtus") / "suurim väärtus" * "osakaal". a. Käsikahvelkäru 1200mm kahvlitega, kaaluga Tehniline kirjeldus alusdokumentide juures. Tarneaeg max 90 päeva. Kogus Ühik Ühiku hind Maksumus KM% Maksumus KM-ga Märkused 25 tk 1595,000 39875,000 24 49445,000 Osa maksumus kokku KM-ta: 39875,000 Osa maksumus kokku KM-ga: 49445,000 Pakkumuse maksumus kokku Maksumus kokku KM-ta: 879037,000 Maksumus kokku KM-ga: 1090005,880 Koostatud 13.03.2026 11:52:04 2/2 https://riigihanked.riik.ee/rhr-web/#/procurement/ 9878684/general-info  1/4 PAKKUMUS VASTAVUSTINGIMUSED Viitenumber: 305669 Hankija: Riigi Kaitseinvesteeringute Keskus (70009764) Hange: Tõstukid ja käsikahvelkärud Pakkumus: 616886 Ettevõtja: Willenbrock Baltic OÜ (11341282), roll: peapakkuja OSA 1: RASKETÕSTUK 25T PAKKUMUSE ESITAMINE Pakkumuse esitamisega kinnitab pakkuja kõigi riigihanke alusdokumentides esitatud tingimuste ülevõtmist. Pakkumus peab vastama riigihanke „Tõstukite ostmine, rentimine, hooldus ja remont" (viitenumber 274884), selle tulemusena sõlmitud raamlepingu ja minikonkursi (305669) tingimustele. Tingimusliku pakkumuse esitamine ei ole lubatud. Kõik täiendavad dokumendid pakkumuses, mida hankija riigihanke alusdokumentides ei ole nõudnud, on informatiivsed lisamaterjalid, mida hankija ei ole kohustatud arvestama pakkumuste menetlemisel. Ettevõtjalt oodatavad vastused: 1. Kas pakkuja kinnitab, et pakkumus vastab riigihanke „Tõstukite ostmine, rentimine, hooldus ja remont" (viitenumber 274884) raamlepingu ja antud minikonkursi tingimustele? (Raadionupp valikutega "Jah/Ei") Vastus: Jah TEHNILINE KIRJELDUS Ettevõtjalt oodatavad vastused: 1. Kinnitan, et pakkuja poolt täidetud tehniline kirjeldus ja selles nõutavad dokumendid on lisatud pakkumusele. (Raadionupp valikutega "Jah/Ei") Vastus: Jah PAKUTAV TOODE Lisada pakkumise juurde foto või link pakutavast tootest Ettevõtjalt oodatavad vastused: 1. Pakkuja kinnitab, et on lisanud pakkumise juurde foto või lingi tootest (Raadionupp valikutega "Jah/Ei") Vastus: Jah PAKKUMUSE MAKSUMUS Pakkumuse maksumus tuleb esitada töölehel "Hindamiskriteeriumid ja hinnatavad näitajad" toodud struktuuri kohaselt. Koostatud 13.03.2026 11:52:04 https://riigihanked.riik.ee/rhr-web/#/procurement/9878684/general-info  2/4 Ettevõtjalt oodatavad vastused: 1. Kas pakkuja kinnitab, et täidab pakkumuse lehe "Hindamiskriteeriumid ja hinnatavad näitajad" lehel ette antud struktuuri kohaselt? (Raadionupp valikutega "Jah/Ei") Vastus: Jah ÄRISALADUS Pakkuja märgib pakkumuses, milline teave on pakkuja ärisaladus ning põhjendab teabe määramist ärisaladuseks. Teabe ärisaladuseks määramisel lähtutakse ebaausa konkurentsi takistamise ja ärisaladuse kaitse seaduse § 5 lõikes 2 sätestatust. Pakkuja ei või ärisaladusena märkida: 1) pakkumuse maksumust ega osamaksumusi; 2) teenuste hankelepingute puhul lisaks punktis 1 nimetatule muid pakkumuste hindamise kriteeriumidele vastavaid pakkumust iseloomustavaid numbrilisi näitajaid; 3) asjade ja ehitustööde hankelepingute puhul lisaks punktis 1 nimetatule muid pakkumuste hindamise kriteeriumidele vastavaid pakkumust iseloomustavaid näitajaid (RHS § 46 (1)). Ettevõtjalt oodatavad vastused: 1. Kirjeldage lühidalt pakkumuses sisalduvat ärisaladust ja lisage selle määramise põhjendus või märkige, et pakkumus ei sisalda ärisaladust. (Suur sisestusala (max pikkus 4000 tähemärki)) Vastus: ei sisalda ärisaladust EL NÕUKOGU SANKTSIOON. ALLTÖÖVÕTJAD JA TARNIJAD. Pakkuja kinnitab, et ta ei kaasa üle 10% hankelepingu maksumusest hankelepingu täitmisele alltöövõtjaid ega tarnijaid, kes on: 1. Vene Föderatsiooni kodanik, resident või Vene Föderatsioonis asutatud ettevõtja, sh füüsilisest isikust ettevõtja, juriidiline isik, asutus või muu üksus; 2. rohkem kui 50% ulatuses otseselt või kaudselt punktis 1 nimetatud isiku, asutuse või muu üksuse omandis; 3. punktis 1 või 2 nimetatud isiku, asutuse või muu üksuse esindaja või tegutseb sellise isiku juhiste alusel. Hankija lükkab tagasi pakkumuse, mille alusel sõlmitav hankeleping oleks RSanS § 7 lg 1 alusel tühine. Määrust kohaldatakse riigihangetele alates rahvusvahelisest piirmäärast. NÕUKOGU MÄÄRUS (EL) 2022/576, 8. aprill 2022, millega muudetakse määrust (EL) nr 833/2014, mis käsitleb piiravaid meetmeid seoses Venemaa tegevusega, mis destabiliseerib olukorda Ukrainas. Ettevõtjalt oodatavad vastused: 1. Pakkuja kinnitab, et ta ei kaasa üle 10% hankelepingu maksumusest hankelepingu täitmisele alltöövõtjaid ega tarnijaid, kes on: 1. Vene Föderatsiooni kodanik, resident või Vene Föderatsioonis asutatud ettevõtja, sh füüsilisest isikust ettevõtja, juriidiline isik, asutus või muu üksus; 2. rohkem kui 50% ulatuses otseselt või kaudselt punktis 1 nimetatud isiku, asutuse või muu üksuse omandis; 3. punktis 1 või 2 nimetatud isiku, asutuse või muu üksuse esindaja või tegutseb sellise isiku juhiste alusel. (Raadionupp valikutega "Jah/Ei") Vastus: Jah RAHVUSVAHELISE SANKTSIOONI OBJEKT Pakkuja kinnitab, et pakutav kaup ei ole rahvusvahelise sanktsiooni objektiks või pärit sanktsiooni all olevatest piirkondadest. Hankija lükkab tagasi pakkumuse, mille alusel sõlmitav hankeleping oleks RSanS § 7 lg 1 alusel tühine. Ettevõtjalt oodatavad vastused: 1. Pakkuja kinnitab, et pakutav kaup ei ole rahvusvahelise sanktsiooni objektiks ega pärit sanktsiooni all olevatest piirkondadest. (Raadionupp valikutega "Jah/Ei") Vastus: Jah Koostatud 13.03.2026 11:52:04 https://riigihanked.riik.ee/rhr-web/#/procurement/9878684/general-info  3/4 OSA 2: KÄSIKAHVELKÄRU 1200MM KAHVLITEGA, KAALUGA PAKKUMUSE ESITAMINE Pakkumuse esitamisega kinnitab pakkuja kõigi riigihanke alusdokumentides esitatud tingimuste ülevõtmist. Pakkumus peab vastama riigihanke „Tõstukite ostmine, rentimine, hooldus ja remont" (viitenumber 274884), selle tulemusena sõlmitud raamlepingu ja minikonkursi (305669) tingimustele. Tingimusliku pakkumuse esitamine ei ole lubatud. Kõik täiendavad dokumendid pakkumuses, mida hankija riigihanke alusdokumentides ei ole nõudnud, on informatiivsed lisamaterjalid, mida hankija ei ole kohustatud arvestama pakkumuste menetlemisel. Ettevõtjalt oodatavad vastused: 1. Kas pakkuja kinnitab, et pakkumus vastab riigihanke „Tõstukite ostmine, rentimine, hooldus ja remont" (viitenumber 274884) raamlepingu ja antud minikonkursi tingimustele? (Raadionupp valikutega "Jah/Ei") Vastus: Jah TEHNILINE KIRJELDUS Ettevõtjalt oodatavad vastused: 1. Kinnitan, et pakkuja pakutav toode vastab tehnilisele kirjeldusele. (Raadionupp valikutega "Jah/ Ei") Vastus: Jah PAKUTAV TOODE Lisada pakkumise juurde foto või link pakutavast tootest Ettevõtjalt oodatavad vastused: 1. Pakkuja kinnitab, et on lisanud pakkumise juurde foto või lingi tootest (Raadionupp valikutega "Jah/Ei") Vastus: Jah PAKKUMUSE MAKSUMUS Pakkumuse maksumus tuleb esitada töölehel "Hindamiskriteeriumid ja hinnatavad näitajad" toodud struktuuri kohaselt. Ettevõtjalt oodatavad vastused: 1. Kas pakkuja kinnitab, et täidab pakkumuse lehe "Hindamiskriteeriumid ja hinnatavad näitajad" lehel ette antud struktuuri kohaselt? (Raadionupp valikutega "Jah/Ei") Vastus: Jah ÄRISALADUS Pakkuja märgib pakkumuses, milline teave on pakkuja ärisaladus ning põhjendab teabe määramist ärisaladuseks. Teabe ärisaladuseks määramisel lähtutakse ebaausa konkurentsi takistamise ja ärisaladuse kaitse seaduse § 5 lõikes 2 sätestatust. Pakkuja ei või ärisaladusena märkida: 1) pakkumuse maksumust ega osamaksumusi; 2) teenuste hankelepingute puhul lisaks punktis 1 nimetatule muid pakkumuste hindamise Koostatud 13.03.2026 11:52:04 https://riigihanked.riik.ee/rhr-web/#/procurement/9878684/general-info  4/4 kriteeriumidele vastavaid pakkumust iseloomustavaid numbrilisi näitajaid; 3) asjade ja ehitustööde hankelepingute puhul lisaks punktis 1 nimetatule muid pakkumuste hindamise kriteeriumidele vastavaid pakkumust iseloomustavaid näitajaid (RHS § 46 (1)). Ettevõtjalt oodatavad vastused: 1. Kirjeldage lühidalt pakkumuses sisalduvat ärisaladust ja lisage selle määramise põhjendus või märkige, et pakkumus ei sisalda ärisaladust. (Suur sisestusala (max pikkus 4000 tähemärki)) Vastus: ei sisalda ärisaladust EL NÕUKOGU SANKTSIOON. ALLTÖÖVÕTJAD JA TARNIJAD. Pakkuja kinnitab, et ta ei kaasa üle 10% hankelepingu maksumusest hankelepingu täitmisele alltöövõtjaid ega tarnijaid, kes on: 1. Vene Föderatsiooni kodanik, resident või Vene Föderatsioonis asutatud ettevõtja, sh füüsilisest isikust ettevõtja, juriidiline isik, asutus või muu üksus; 2. rohkem kui 50% ulatuses otseselt või kaudselt punktis 1 nimetatud isiku, asutuse või muu üksuse omandis; 3. punktis 1 või 2 nimetatud isiku, asutuse või muu üksuse esindaja või tegutseb sellise isiku juhiste alusel. Hankija lükkab tagasi pakkumuse, mille alusel sõlmitav hankeleping oleks RSanS § 7 lg 1 alusel tühine. Määrust kohaldatakse riigihangetele alates rahvusvahelisest piirmäärast. NÕUKOGU MÄÄRUS (EL) 2022/576, 8. aprill 2022, millega muudetakse määrust (EL) nr 833/2014, mis käsitleb piiravaid meetmeid seoses Venemaa tegevusega, mis destabiliseerib olukorda Ukrainas. Ettevõtjalt oodatavad vastused: 1. Pakkuja kinnitab, et ta ei kaasa üle 10% hankelepingu maksumusest hankelepingu täitmisele alltöövõtjaid ega tarnijaid, kes on: 1. Vene Föderatsiooni kodanik, resident või Vene Föderatsioonis asutatud ettevõtja, sh füüsilisest isikust ettevõtja, juriidiline isik, asutus või muu üksus; 2. rohkem kui 50% ulatuses otseselt või kaudselt punktis 1 nimetatud isiku, asutuse või muu üksuse omandis; 3. punktis 1 või 2 nimetatud isiku, asutuse või muu üksuse esindaja või tegutseb sellise isiku juhiste alusel. (Raadionupp valikutega "Jah/Ei") Vastus: Jah RAHVUSVAHELISE SANKTSIOONI OBJEKT Pakkuja kinnitab, et pakutav kaup ei ole rahvusvahelise sanktsiooni objektiks või pärit sanktsiooni all olevatest piirkondadest. Hankija lükkab tagasi pakkumuse, mille alusel sõlmitav hankeleping oleks RSanS § 7 lg 1 alusel tühine. Ettevõtjalt oodatavad vastused: 1. Pakkuja kinnitab, et pakutav kaup ei ole rahvusvahelise sanktsiooni objektiks ega pärit sanktsiooni all olevatest piirkondadest. (Raadionupp valikutega "Jah/Ei") Vastus: Jah Koostatud 13.03.2026 11:52:04 https://riigihanked.riik.ee/rhr-web/#/procurement/9878684/general-info  1/1 PAKKUMUS KÕRVALDAMISE ALUSED JA KVALIFITSEERIMISTINGIMUSED Viitenumber: 305669 Hankija: Riigi Kaitseinvesteeringute Keskus (70009764) Hange: Tõstukid ja käsikahvelkärud Pakkumus: 616886 Ettevõtja: Willenbrock Baltic OÜ (11341282), roll: peapakkuja KÕRVALDAMISE ALUSED KÕRVALDAMISE ALUSED Hankija ei sõlmi hankelepingut pakkujaga ja kõrvaldab pakkuja, kellel esinevad riigihangete seaduse (RHS) § 95 lg 1 ja lg 4 välja toodud kõrvaldamise alused. Hankija kontrollib edukal pakkujal kõrvaldamise aluste puudumist avalikest registritest Kehtib: Kogu hanke kohta Ettevõtjalt oodatavad vastused: 1. Kas pakkuja kinnitab, et tal puuduvad kõrvaldamise alused? Vastus: Jah Kokkuvõtlikud kinnitused Ettevõtja kinnitab, et esitatud teave on täpne ja õige ning et ta on teadlik valeandmete esitamise tagajärgedest. Ettevõtja kinnitab, et tal on võimalik vajaduse korral viivitamata tema kinnitustele vastavad dokumendid hankijale esitada. Ettevõtja kinnitab, et ta on nõus oma kinnitustele vastavate andmete väljastamisega hankijale, kui need andmed on avalike andmete põhjal hankijale oluliste kulutusteta elektroonilisest andmekogust kättesaadavad. Kinnituse andja nimi: Marek Ploom Koostatud 13.03.2026 09:00:50 https://riigihanked.riik.ee/rhr-web/#/procurement/9878684/general-info  Calculationnumber:..........SMV4535TB5Volvo1171 Creator/Version:................KLSDSJ/2.54.11 7(&+1,&$/'$7$609͈& Machinetype SMV25Ͳ1200C LOADHANDLINGDATA Liftingcapacity/Loadcenter kg/mm 25000/1200 Maximumliftingspeed,unloaded/at70%ofratedload m/s 0,32/0,30 Maximumloweringspeed,unloaded/atratedload m/s 0,38/0,40 DRIVINGDATA Drivespeedforward,unloaded/atratedload km/h 26/25 Drivespeedreverse,unloaded/atratedload km/h 26/25 Incline(drivingability)atratedloadat0km/h/at2km/h % 38/27 Towing(powerability)atratedloadat0km/h/at2km/h kN 218/164 SERVICEWEIGHT/AXLELOADS Serviceweight kg 34100 Axleloadfront,unloaded/atratedload kg 16700/55100 Axleloadrear,unloaded/atratedload kg 17400/4000 ENGINE Enginemake,modelname VolvoTAD851ͲVE EmissionapprovalEU/US StageIIIA/Tier3 Monitoring/emissioncontrolled/CanBus  Yes/yes/yes Fuel/typeofengine Diesel/4ͲstrokeCI RatedpowerISO3046/maxspeed kW/rpm 185/2200 RatedtorqueISO3046/atspeed Nm/rpm 1160/1350 Displacement/No.ofcylinders/configuration L// 7,7/6/Inline Fuelconsumption,normaloperations L/h 8Ͳ12 Alternator,type/power/amperage W/Amp AC/3080/110 Startingbattery,voltage/capacity V/Ah 2x12/140 TRANSMISSION Transmissionmake,modelname DANATEͲ17 Monitoring/reverseprotection/CanBus Yes/yes/yes Clutch,type Torqueconverter Transmissiontype/typeofshiftgear Softshift–Powershift/Automatic No.ofgears,forward/reverse 3/3 DRIVEAXLE&STEERSYSTEM Driveaxlemake,modelname KesslerD91 Driveaxletype Differential+hubreduction Servicebrake,type/affectedwheels OilcooledWetDiscBrakes/drivewheels Parkingbrake,type/affectedwheels Drydiscbrake/springapplied/drivewheels STEERAXLE&STEERSYSTEM Steeraxlemake/type Konecranes/doubleactingsinglecylinder Steeringsystem Hydraulicservoassisted/powersteering WHEELS Numberofwheels,front+rear/Type(*driven)  4*+2/pneumatic Tirepressurefront/rear MPa 1,0/1,0 Tiredimensions(Plyrating)front/rear Inch(No) 14.00x24"(PR24)/14.00x24"(PR24) Rimdimensionfront/rear Inch 10.00x24"/10.00x24" HYDRAULICSYSTEM Hydraulicpumpmake,modelname ParkerP2Ͳseries Hydraulicsystem/pumptype Loadsensingsystem/variableaxialpistonpump PowerͲonͲdemand/Lowenergy  Yes/yes Hydraulicoilpressuremast MPa 24,0 TANKVOLUMES Fueltankvolume L 336 Hydraulictankvolume L 312 LIFTINGEQUIPMENT Liftmastmodel/masttype/design Konecranesduplexstandard/2Ͳstage/freevisibility Carriagemake/model Konecranes/Hydraulicintegralrollertype Forkmake/Model Konecranes/Rollertype OTHERS Noiselevel(insideCab/Lm)DIN45635 dB(A) 67 Noiselevel(insideCab/LpAZ)EN12053(EU+EFTAonly) dB(A) 73 Maximumnoiselevel(outsideLwa)2000/14/EC(EU+EFTAonly) LWA 107 NORMS&STANDARDS StabilityofIndustrialTrucksISO22915Ͳ2 Yes SafetyofIndustrialTrucksENISO3691Ͳ1 Yes .21(&5$1(6/,)7758&.6$% ZZZNFOLIWWUXFNVFRP %R[6(0DUNDU\G6:('(1 3KRQH 'DWDLQWKLVGRFXPHQWLVEDVHGRQDVWDQGDUGPDFKLQHLPSDFWIURPPRGLILFDWLRQVRUFXVWRPL]DWLRQVDUHQRWFRYHUHG .RQHFUDQHV/LIWWUXFNVUHVHUYHWKHULJKWWRDOWHUGHVLJQDQGVSHFLILFDWLRQZLWKRXWSULRUQRWLFH 7(&+1,&$/'$7$609͈&         .21(&5$1(6/,)7758&.6$% ZZZNFOLIWWUXFNVFRP %R[6(0DUNDU\G6:('(1 3KRQH 'DWDLQWKLVGRFXPHQWLVEDVHGRQDVWDQGDUGPDFKLQHLPSDFWIURPPRGLILFDWLRQVRUFXVWRPL]DWLRQVDUHQRWFRYHUHG .RQHFUDQHV/LIWWUXFNVUHVHUYHWKHULJKWWRDOWHUGHVLJQDQGVSHFLILFDWLRQZLWKRXWSULRUQRWLFH  Tõstuki operaatorite koolituse kava Eesmärk: Koolituse eesmärk on pakkuda tõstukite operaatoritele vajalikke teadmisi ja oskusi, mis tagavad masina ohutu ja tõhusa kasutamise, vähendades vigade ja ohtude riski. Kava teemad ja järjestus: Ohutuse põhimõtted Tõstukite kasutamise üldine ohutus. Tööohutuse reeglid töökeskkonnas. A kude laadimis ega seotud ohutusnõuded Kaitsevarustuse kasutamine ja ohutustsoonide määratlemine. Masina kasutamise üldised põhimõtted Tõstukite töökeskkonna ja tööülesannete mõistmine. Nõuded masina eelkontrolliks enne töö alustamist. Mida järgida tõstuki kasutamise ajal. Masina kasutamise spetsiifilised teadmised Konkreetse tõstuki mudeli tehnilised omadused. Spetsiaalsed funktsioonid ja lisaseadmete kasutamine. Connecti kasutamine Digitaalse süsteemi Connect kasutamise tutvustus. Andmete sisestamine, ülevaatamine ja aruannete koostamine. Kaugjuhtimise ja diagnostika võimalused. Lihtsamate vigade tuvastamine ja kõrvaldamine Tõstuki rutiinne hooldus ja lihtsate probleemide lahendamine. Tüüpilised vead ja nende ennetamine. Veakoodide ja märgutulede selgitus Veakoodide tähenduse mõistmine ja kasutusjuhendi järgimine. Märgutulede roll ja tähtsus masina töös. Lisamärkused: Koolitus peaks sisaldama nii teoreetilist osa kui ka praktilist harjutamist. Oluline on kohandada kava vastavalt kasutatavate tõstukite tüübile ja ettevõtte vajadustele. Koolituse lõpuks peaksid osalejad suutma iseseisvalt tõstukit opereerida ja järgida ohutusnõudeid. C&D RANGER 6TAGM BATTERY With over 5.5 million batteries sold yearly in over 120 countries, C&D Technologies is a world leader in energy storage solutions. The Ranger 6TAGM battery delivers high performance and reliability for military-style and power sports vehicles. BENEFITS HIGH-STARTING POWER: Powerful cold UNMATCHED RELIABILITY: Our batteries are cranking amps significantly reduce engine designed for durability in extreme temperatures start-up wear and tear and improve engine and demanding environments. efficiency and lifespan. MAINTENANCE-FREE​: AGM/VRLA technology LONG SHELF LIFE: Even when not in use, requires no service and comes with safety expect the longest battery life and, therefore, features like a flame arrestor and leak-proof reduced lifetime replacement costs thanks all-welded construction for longer life. to AGM/VRLA technology. FEATURES • 6T NATO-Size Battery • 120 Ah C20 Battery • 24-Month Shelf Life @ 77˚F (25˚C) • 1100 Cold Cranking Amps • 230 Min Reserve Capacity • 90 lb (40kg) Weight • Non-Spillable Transport-Class C&D RANGER 6TAGM BATTERY SPECIFICATIONS RANGER 6TAGM BATTERY SIZE 6T CHEMISTRY / BATTERY TYPE AGM / VRLA NOMINAL VOLTAGE 12-volt NOMINAL CAPACITY 120Ah (C/20: 6A to 1.75VPC, 27°C) COLD CRANKING AMPS 1100 amps RESERVE CAPACITY 230 minutes (25A to 1.75VPC, 27°C) DIMENSIONS IN [MM] See figure WEIGHT (LB / KG) 90 lb (40.75 kg) TERMINAL TYPE AP TERMINAL TORQUE 50-70 in.lb ©2025 C&D Technologies Inc. Any data, descriptions or specifications presented herein are subject to revision by C&D RANGER 6TAGM DATASHEET REV 02/21/2025 C&D Technologies, Inc. without notice. While such information is believed to be accurate as indicated herein, C&D Technologies, Inc. makes no warranty and hereby disclaims all warranties, express or implied, with regard to the accuracy or completeness of such information. Further, because the product(s) featured herein may be used under conditions beyond its control, C&D Technologies, Inc. hereby disclaims all warranties, either express or implied, concerning the fitness or suitability of such product(s) for any particular use or in any specific application or arising from any course of dealing or usage of trade. The user is solely responsible for determining the suitability of the product(s) featured herein for user’s intended purpose and in user’s specific application. 200 Precision Road, Horsham, Pennsylvania 19044 USA | www.cdtechno.com   Your trusted business partner for independent testing and certification of agricultural machinery Prüfbericht Test report Industrial trucks - Overhead guards - Specification and testing Berichts-Nr. 2411-0007 Report no. Prüfgrundlage ISO 6055:2023 Test standard Prüfobjekt Optima cab Test item Auftraggeber FRITZMEIER Systems GmbH Applicant FO-DLGTS_PrüfberichtVL_DE-EN_DAkkS_2024_V00 DLG TestService GmbH Geschäftsführer: Rudolf Hepp, Christian Grachtrup Max-Eyth-Weg 1 Sitz der Organisation: Gau-Bickelheim D-64823 Groß-Umstadt Amtsgericht Mainz HRB 40800 USt-IdNr.: DE114139855 Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 2 von / of 14 Prüfobjekt / Test item Optima cab I Allgemein General Auftraggeber (Name und Adresse) FRITZMEIER Systems GmbH Applicant (Name and address) Großhelfendorf, Forststraße 2 D-85653 Aying Hersteller (Name und Adresse) FRITZMEIER Systems GmbH Manufacturer (Name and address) Großhelfendorf, Forststraße 2 D-85653 Aying II Anhänge Annexes Anhang A Prüfprotokoll - ISO 6055:2023 Test record - ISO 6055:2023 III Anlagen Enclosures Anlage A Darstellung der Kabine Description of cab Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 3 von / of 14 Prüfobjekt / Test item Optima cab IV Zusammenfassung Summary Das Prüfobjekt erfüllt vollumfänglich die Anforderungen der Prüfgrundlage ISO 6055:2023. Alle Ergebnisse beziehen sich nur auf die geprüften Muster. Bei Konformitätsentscheidungen wurde die Messunsicherheit gemäß der Norm angewendet. Es wurden keine anderen Messungen als die beschriebenen durchgeführt. Dieser Bericht darf nur vom Auftraggeber und nur in vollem Wortlaut vervielfältigt und weitergegeben werden. Eine auszugsweise Vervielfältigung und Veröffentlichung des Berichtes ist nur nach schriftlicher Genehmigung zulässig. The test object is in full compliance with the test standard ISO 6055:2023. All results refer only to the tested object. In conformity decisions, the measurement uncertainty was applied according to the standard. No other measurements than those described were carried out. This report may only be reproduced and passed on by the client and only in full. Reproduction and publication of extracts of the report is only permitted with written consent. Unterschriftsberechtigter Interne Qualitätskontrolle Authorised signatory Internal Quality Check M.Sc. Dubielski Dipl.-Ing. (FH) Keunecke Groß-Umstadt, 15.11.2024 Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 4 von / of 14 Prüfobjekt / Test item Optima cab Anhang A Annex A Prüfprotokoll ISO 6055:2023 Test record 0 Vorbemerkungen Die Festigkeitsüberprüfungen wurden für 2 Remarks Kabinenvarianten, Standard- und Hochkabine, durchgeführt. The strength tests were performed on 2 cab options, standard and high cab. 1 Prüfgrundlagen ISO 6055:2023 Test standard 2 Prüfbedingungen Test conditions 2.1 Prüfobjekt Kabine Test object cab 2.2 Mess- und Prüfeinrichtungen Prüfstand Nr. 2.58 Equipment for measuring and testing test rig no. 2.3 Prüfortparameter 20°C Parameter of the test area 3 Prüfergebnisse Gliederung in Klammern gemäß Test results Prüfgrundlage Structure in brackets according to test standard (A.1) Kennzeichnung Identification (A.1.1) Fahrzeug Machine Bauart: Gabelstapler, Leercontainerstapler, Type Teleskopstapler Forklift truck, Empty container handler, Reach stacker Hersteller: Konecranes Lifttrucks AB Manufacturer Anders Anderssons väg 13 285 23 Markaryd / Sweden Typ Bezeichnung: SMV 10-100, SMV 28-52G, SMV EC, Model number SMV RS Serien Nummer: -n/a- Serial number Maschinen-Rahmen-Nummer: -n/a- Machine frame part number Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 5 von / of 14 Prüfobjekt / Test item Optima cab (A.1.2) Schutzdach Overhead guard Hersteller: FRITZMEIER Systems GmbH Manufacturer Großhelfendorf, Forststraße 2 D-85653 Aying Typ: Optima cab Model Serien Nummer: -n/a- Serial number Bauteil-Nr.: Standardkabine / standard cab Part number Konecranes: 6211.001, 6211.040 Fritzmeier: 826380, 833620 Hochkabine / high cab Konecranes: 6211.151, 6238.180 Fritzmeier: 859355, 859377 (A.2) Informationen der Prüfeinrichtung Information supplied by test facility (A.2.1) Beschreibung der Fallprüfkörper Test object description (A.2.1.1) Dynamische Prüfung & Schutz der Beine und Füße des Bedieners Dynamic test & Operators' legs and feet protection test Genormter Fallprüfkörper mit einer quadratischen Eichenholzgrundplatte und einer Kantenlänge von 300 mm. Standard laboratory drop test object with a square striking face made of oak wood and side dimension of 300 mm. Masse: 45,00 kg Mass Fallhöhe bei der Prüfung: 1,50 m Drop height in the test Anzahl der dyn. Belastungen: 10 Number of drops (A.2.1.2) Aufprallprüfung Impact drop test Die Prüflast besteht aus einem Stapel normalem Bauholzes mit dem Querschnitt 50 mm x 100 mm. Der Holzstapel ist 3600 mm lang, 1000 mm breit und hat eine Höhe von 700 mm. Die einzelnen Hölzer sind mit der 100 mm Abmessung in horizontaler Richtung angeordnet. Zusammengehalten werden die einzelnen Hölzer über einen Spanngurt in der Mitte und zweien jeweils 900 mm von jedem Ende entfernt. The test load is composed of 50 mm x 100 mm nominal construction timber boards. The stack of wood has a length of 3600 mm, a width of 1000 mm and has a height of 700 mm. The timber is placed with the 100 mm nominal dimension of the cross section Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 6 von / of 14 Prüfobjekt / Test item Optima cab horizontal. The timbers are bound together with one tension belt in the centre and two tension belts 900 mm from each end. Masse: 1340 kg Mass Fallhöhe bei der Prüfung: 3,72 m Drop height in the test (A.3) Informationen vom Hersteller Information supplied by manufacturer Tragfähigkeit der Maschine: * > 10000 kg Truck rated capacity Lagebestimmung des SIP: Auf der Längsmittelebene der Kabine und Location of SIP 477 mm vor der Rückwand. On longitudinal median plane of the cab and 477 mm in front of rear wall. (A.4) Fotos Photographs (A.4.1) Dynamische Prüfung Dynamic test Bild / Picture 1: Oberseite vor dem Test / Top surface before the test Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 7 von / of 14 Prüfobjekt / Test item Optima cab Bild / Picture 2: Zweiter Fall bei -20°C / Second drop at -20°C Bild / Picture 3: Zehnter Fall bei -20°C / Tenth drop at -20°C Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 8 von / of 14 Prüfobjekt / Test item Optima cab Bild / Picture 4: Oberseite nach der Prüfung bei -20°C / Top surface after the test at -20°C Bild / Picture 5: Zweiter Fall bei 40°C / Second drop at 40°C Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 9 von / of 14 Prüfobjekt / Test item Optima cab Bild / Picture 6: Zehnter Fall bei 40°C / Tenth drop at 40°C Bild / Picture 7: Oberseite nach der Prüfung bei 40°C / Top surface after the test at 40°C (A.4.2) Schutz der Beine und Füße des Bedieners Operators' legs and feet protection test -n/a- (A.4.3) Aufprallprüfung Impact drop test Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 10 von / of 14 Prüfobjekt / Test item Optima cab Bild / Picture 8: Vor der Prüfung, Hochkabine / Before the test, high cab Bild / Picture 9: Aufschlag der Prüflast, Hochkabine / Impact of test load, high cab Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 11 von / of 14 Prüfobjekt / Test item Optima cab Bild / Picture 10: Nach dem Aufschlag der Prüflast, Hochkabine / After impact of test load, high cab Bild / Picture 11: Vor der Prüfung, Standardkabine / Before the test, standard cab Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 12 von / of 14 Prüfobjekt / Test item Optima cab Bild / Picture 12: Nach dem Aufschlag der Prüflast, Standardkabine / After impact of test load, standard cab (A.5) Prüfergebnisse Test results (A.5.1) Dynamische Prüfung Dynamic test Standardkabine bei -20°C / standard cab at -20°C: Die gesamte vertikale Verformung des Schutzdachs nach der dynamischen 5 mm Prüfung beträgt: The total vertical deformation of the overhead guard after the dynamic test was Standardkabine bei 40°C / standard cab at 40°C: Die gesamte vertikale Verformung des Schutzdachs nach der dynamischen 7 mm Prüfung beträgt: The total vertical deformation of the overhead guard after the dynamic test was (A.5.2) Schutz der Beine und Füße des Bedieners Operators' legs and feet protection test Die gesamte vertikale Verformung der Schutzstruktur für Beine und Füße -n/a- des Bedieners beträgt: The total vertical deformation of the operators' legs and feet protection structure after the test was (A.5.3) Aufprallprüfung Impact drop test Standardkabine / standard cab: Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 13 von / of 14 Prüfobjekt / Test item Optima cab Die vom Fallprüfkörper (Prüflast) aufgebrachte Energie, ohne dass 48,96 kJ irgendein Aufbauteil in den Verformungsgrenzbereich noch der Fallprüfkörper in den Schutzaufbau eingedrungen ist, beträgt: The energy applied to the protective structure by the drop test object (test load) without intrusion of any structural members into the deflection-limiting volume was Die gesamte vertikale Verformung des Schutzaufbaus nach der 110 mm Aufprallprüfung beträgt: The total vertical deformation of the protective structure after the impact drop test was Hochkabine / high cab: Die vom Fallprüfkörper (Prüflast) aufgebrachte Energie, ohne dass 48,96 kJ irgendein Aufbauteil in den Verformungsgrenzbereich noch der Fallprüfkörper in den Schutzaufbau eingedrungen ist, beträgt: The energy applied to the protective structure by the drop test object (test load) without intrusion of any structural members into the deflection-limiting volume was Die gesamte vertikale Verformung des Schutzaufbaus nach der 270 mm Aufprallprüfung beträgt: The total vertical deformation of the protective structure after the impact drop test was (A.5.4) Transparente Materialien Transparent material Transparente Materialien, die zur Überbrückung von Öffnungen in der Oberseite der Schutzstruktur verwendet werden, die nicht ISO 6055:2023; 4.3.1 entsprechen, gelten als Bauteile der Schutzstruktur, und die transparenten Materialien müssen mindestens die Anforderungen der ISO 16936-1:2020, P4A erfüllen. Die Prüfung ist gemäß ISO 16936-1:2020 bei Temperaturen von -20°C und +60°C durchzuführen. Transparent material(s) used to bridge openings in the top of the overhead guard structure not conforming to ISO 6055:2023; 4.3.1 shall be considered as structural parts and the transparent material(s) shall fulfil at least the requirements of ISO 16936-1:2020, P4A. The test shall be performed according to ISO 16936-1:2020 at temperatures of -20°C and +60°C. erfüllt / fulfilled Siehe Prüfbericht 2405-0023 nicht erfüllt / not fulfilled See test report 2405-0023 -n/a- (A.6) Werkstoff, Temperatur Material, temperature Die Prüfungen wurde bei Umgebungstemperatur, -20°C und 40°C durchgeführt. The strength tests were performed at ambient temperature, -20°C and 40°C. Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 14 von / of 14 Prüfobjekt / Test item Optima cab (A.7) Prüfbescheinigung Attestation statement Mindestleistungsanforderungen nach ISO 6055:2023 wurden bei dieser Prüfung erfüllt. The minimum performance requirements of ISO 6055:2023 were met in this test. Anmerkungen: - Keine - Remarks - None - 4 Datum der Prüfung 11./12.02.2014, Date of test 28.04.2022, 26./28.09.2022 Name und Anschrift der DLG TestService GmbH Prüfstelle Max-Eyth-Weg 1 Name and address of test D-64823 Groß-Umstadt facility Prüfer M.Sc. Dubielski Tester *Angaben gemäß Hersteller Information according to manufacturer Ende des Berichts End of Report  Anlage A zu 2411-0007 Seite 1 von 4 Standardkabine / standard cab: 6211.001, 826380 6211.040, 833620  Anlage A zu 2411-0007 Seite 2 von 4 Teil Material B-Säule Blech EN10130-DC01-A-m-2,99 C-Säule Karosserieprof. 89x68x4, EN1049-S355MC Profilrohr Rahmenprofil 43x25x1,6, EN10025-S235JRG2C Rechteckrohr 50x50x4 CFRHS EN10219-S355J2H- 50x50x4 Rechteckrohr 50x50x3 Ro EN10305-5-E275+CR1 Rechteckrohr 50x40x3 Ro EN10305-5-E275+CR1 Rechteckrohr 30x30x3 Ro EN10305-5-E275+CR1 Rundrohr 30x1,5 Ro EN10305-1-E235+N Blech 10mm Blech EN10149-S355MC-10A Blech 8mm Blech EN10149-S355MC- 8A Blech 6mm Blech EN10149-S355MC- 6A Blech 5mm Blech EN10149-S355MC- 5A Blech 4mm Blech EN10149-S355MC- 4A Blech 3mm Blech EN10149-S355MC- 3A Blech 2.99mm Blech EN10130-DC01-A-m-2,99 Blech 2mm Blech EN10130-DC05-A-m-2,00 Blech 2mm Blech EN10130-DC01-A-m-2,00 Blech 1mm Blech EN10130-DC01-A-m-1,00  Anlage A zu 2411-0007 Seite 3 von 4 Hochkabine / high cab: 6211.151, 859355 6238.180, 859377  Anlage A zu 2411-0007 Seite 4 von 4 Teil Material B-Säule Karprof-S355MC- 70.8x49.1x3 C-Säule Karosserieprof. 89x68x4, EN1049-S355MC Profilrohr Rahmenprofil 43x25x1,6, EN10025-S235JRG2C Rechteckrohr 50x50x4 CFRHS EN10219-S355J2H- 50x50x4 Rechteckrohr 50x50x3 Ro EN10305-5-E275+CR1 Rechteckrohr 50x40x3 Ro EN10305-5-E275+CR1 Rechteckrohr 30x30x3 Ro EN10305-5-E275+CR1 Rundrohr 30x1,5 Ro EN10305-1-E235+N Blech 10mm Blech EN10149-S355MC-10A Blech 8mm Blech EN10149-S355MC- 8A Blech 6mm Blech EN10149-S355MC- 6A Blech 5mm Blech EN10149-S355MC- 5A Blech 4mm Blech EN10149-S355MC- 4A Blech 3mm Blech EN10149-S355MC- 3A Blech 2.99mm Blech EN10130-DC01-A-m-2,99 Blech 2.49mm Blech EN10130-DC01-A-m-2,49 Blech 2mm Blech EN10130-DC05-A-m-2,00 Blech 2mm Blech EN10130-DC01-A-m-2,00 Blech 1mm Blech EN10130-DC01-A-m-1,00  NATO riigid kus kaitsevägi kasutab Konecranes -i tõstetehnikat Leedu Saksamaa Iirimaa Kütusekulu arvutus SMV25-1200 kütusepaagi maht on 336 liitrit Masina kütusekulu Volvo TAD851-VE tase3 mootoriga on normaaltingimustes 8-12 liitrit tunnis. Seega tuleb tööaeg ühe paagitäiega 42-28h 4575 Built in battery charger Stationary battery charger in the machine for charging the batteries at parking . C an also be in combination with additional heaters. Offer QUO0000040508 2026-03-13 Offer revision 0 Offer 26001672 Forklift truck SMV 25-1200 C for Riigi Kaitseivesteeringute Keskus  Offer QUO0000040508 2026-03-13 Offer revision 0 WILLENBROCK BALTIC OÜ 2026-03-13 Dear, Thank you for the opportunity to offer the SMV 25-1200 to your company site in Estonia. Konecranes is the world’s leading manufacturer in the material lifting business. We have delivered more than 10,000 Lift Trucks all over the world. The Medium Forklift Truck we are offering you today is designed to meet the toughest demands and is built according to your specific requirements. That is what we call ‘Built for your World’. It has been purchased by some of the world’s leading industrial companies due to its high productivity, high reliability, and low total cost of ownership. I look forward to discussing this offer with you in detail. Please find our offer on the subsequent pages. Marek Ploom Willenbrock Baltic OÜ Mobile Email [email protected] 5 reasons to choose Konecranes +600 Global footprint Optima – The best Smart Lower total cost Lifetime Advantage Operations at over 600 cabin on the Connected Lift of ownership Experience locations. in more than Years of experience Far more than just after 120 countries worldwide market Trucks Every detail has been Remote monitoring is has proven that the sales-service. Our and served by a broad combination of high extensive resources are distributor network. carefully designed for a key toward a more comfort and safety. productive, efficient quality components available to you for the Controls, displays, and safe workplace. and cutting edge entire life cycle of your ventilation and seating With TRUCONNECT technology together Konecranes lift trucks. We work to boost driver you get more out of with low running costs will always be at your productivity. Excellent your lift trucks. results in a lower total side. visibility in all directions. cost of ownership (TCO). Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 SMV 25-1200 C - Medium Forklift Truck DESCRIPTION OF STANDARD FEATURES AND OPTIONS INCLUDED IN THIS OFFER 00. GENERAL INFORMATION, STANDARDS & NORMS The fork lift truck is designed and built in accordance with the current legislations and norms, which are described below: 2006 / 42 / EC ................................................................... Machinery Directive ISO 22915 series ............................................................... Stability for Industrial Trucks EN ISO 3691-1 .................................................................. Safety for Industrial Trucks ISO 3046 ........................................................................... Engine power, torque, fuel & emission norm EN 12895 .......................................................................... Electro Magnetic Compatibility approvals (EMC) EN 16842 series ............................................................... Visibility norm for driver EN 13059 .......................................................................... Vibration norm for driver EN 12053 .......................................................................... Noise level norm (DIN 45635 inside cab) 01. TRUCK MISCELLANEOUS INFO Standard • Included options • Compliance EN 1175:2020 10. CHASSIS “BOX-TYPE” The chassis is made with long life time, low concentration of stress, and a high torsion strength in mind. This is possible through the high-strength rectangular design that is built from 2 longitudinal welded box sections with powerful cross members. The front end of the chassis is made even stronger by reinforcements with thick steel plates, support plates and brackets, and the fork lift trucks gets additional safety and strength from reinforced tilt cylinder fixations. All fixation points for vital main components, including drive axle, steer axle and lift mast, have very powerful fixation points which together with the design gives a durable and rigid chassis. Chassis components in this offer Standard • Box type chassis, bolted tanks, mudguards front & rear • 2+2 lifting ears (front in mast & rear in steer axle stops) • Access steps, hand rails upto cabin on chassis sides (left & right) Included options • License plate holder with light on top counter weight • Electric heated external mirror (mudguard) • Strainer on Fuel Filler • Galvanized storage box on left bottom step + lock (Appr. 40 Lit) Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 20-30. DRIVE LINE (ENGINE, TRANSMISSION, DRIVE / STEER AXLES) The engine is certified low-emission CanBus diesel, with turbo charger, air-to-air intercooler, fuel injection, common rails technology with high capacity cooling system. The automatic transmission is bolted directly to the engines and connected via flexible steel plates. Automatic gear shifting with hydraulic operation and electronic controls, the softshift type gives safe and smooth driving performance. The Kessler axle has a two-stage reductions and integral “Wet Disc Brakes”. The two-stage reduction reduces stresses in the axle transmission system. The “Wet Disc Brakes” system for service brakes are mounted in each hub with multiple brake discs. Strong welded steer axle of sandwich design in wide version, mounted in two (2) long life bushings between chassis and axle. Mechanical side stops between axle and chassis for best side stability. Hydrostatic powersteering with double acting single cylinder. Drive Line components in this offer Standard • Engine air filter standard, 2-stage filtration • Kessler D91 Wet Disc Brakes • Volvo TAD-851-VE + TE-17312 (185 kW, 1060 Nm, 2200 rpm, 7.7 L, 6-cyl / EU Stage 3a) • DANA TE-17312, Automatic Transmission (3+3 gear, CanBus) • External fuel water separator Included options • Mechanical wheelnut indicators front- indicators on the bolts • Mechanical wheelnut indicators rear - indicators on the bolts • Engine heater 220V (electric) 40. LOAD SENSING HYDRAULIC SYSTEM (LOW-ENERGY) Low energy consumption is reached with the “power-on-demand” function that builds up Konecranes load sensing hydraulic system. The system is designed to work together as one unit and we use the same components in all our trucks and stackers. This means that all of them includes powerful and silent running variable piston pumps, accurate proportional valves, efficient valve regulators and electronic controls. These very efficient and proven hydraulic systems are the most powerful on the market, with the key features being lowest power and fuel consumption, extended service intervals, reduced wear on components and oil, lower heat generation, fingertip precision and safety for the driver. Hydraulic components in this offer Standard • Load-sensing hydraulic system (variable piston pumps), return filter (10 µm) • Four hydraulic functions (lift-tilt-sideshift-fork positioning), 4 electronic servo levers, power steering Included options • Extra hydraulic function Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 45. ELECTRICAL SYSTEM The 24V electrical system is designed and EMC-approved according to EN 12895. Electrical components in this offer Standard • Electrical system 24V with monitoring system, CanBus, MD4 controls, 7" colour touch display (Compliance: Machinery Directive 2006/14/EC) • Road light Kit, LED lights (position-brake-tail-blinkers), LED working lights (mast-reverse-front) • Transmission in neutral when seat switch is not activated Included options • 6 extra working lights LED (3000 Lum) on light console, 4 pointing forward, 2 reverse • Light console on cab roof (for extra lights & warning beacon) • Reverse alarm (acoustic signal when reversing) • Warning beacon LED (on counter weight) • NATO electric starting aid connection (power supply) • Built in battery charger 20A • One (1) power connection 230V/16A/1-phase for electric engine & cab heater, right side (incl starting locking device) 49. ELECTRONIC MACHINE CONTROL (EMC) Electronic Overload, Control & Monitoring System The truck is equipped with electronic control & monitoring system to optimize performance and efficiency of the truck. This gives the operator a unique possibility to control and monitor the performance of the truck or truck fleet. EMC components in this offer Standard • EMC Master incl. MD4-controller with 7" colour touch display • EMC Chassis G • EMC 106 Monitoring (engine, transmission, hydraulics, levers & service) • EMC 107 Electronic weight scale (resolution 0,1 tons) • EMC 114 Electronic servo levers (incl. auto accelerator/power control) • EMC 123 ECO Drive module (fuel measure functions & settings) • EMC 124 Driver login module (max 40 logins) • EMC 125 Data logger module (alarms + errors) • EMC 129 Productivity Hour Counter (idle-neutral-driving) • EMC 134 TRUCONNECT - Basic HW (Incl. TRUCONNECT Essentials feature pack & CheckApp) Included options • Reverse alarm on/off switch Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 50. OPTIMA – DRIVERS CABIN Remarkable visibility Visibility is very difficult to measure objectively: you just know it when you see it. When you sit down in OPTIMA, you will see what visibility from a lift truck really means. The remarkable visibility is made possible by very large, lowered windows with no corner posts, thin but very strong roof cross member, and curved panes. New EMC Master with MD4 7” touch screen enables a more spacious cabin with its integrated solutions. There is also more space for operating the foot pedals. The positioning of the instrumentation improves operating ergonomics and is located to the right-hand side of the operator´s seat, easily accessible from the right hand side arm rest. OPTIMA is customizable for your exact operational needs. You can select levers or joystick, mini-wheel steering, the driver’s seat and precisely the instrumentation you need. Optima Cabin features in this offer Standard • Cabin Optima (L x W x H = 1605 x 1480 x 1620 mm) • Seat BEGE 9230 Mechanical spring (4 settings, high back, 2-p belt black) • El. connection 24V / 7.5A / 12.5mm plug front of dashboard right side Included options • Electrical pump for powered cabin tilting • DAB / Analog Radio incl. Bluetooth, MP3, AUX, USB-A, 2 speakers • Interval wiper speed switch front / roof / rear window • ACC Switch off when doors are open • Climate control unit (ACC) • El. connection 12V / 10A / 21.4mm plug cabin roof right side • Diesel powered cabin & engine water heater • Laminated glass front & side windows • Assembly of customers com.radio/door opener/computer etc. (data sheet/drawing needed at order date) 60-75. LIFT MAST, CARRIAGE AND FORKS The Konecranes lift mast is designed for maximum strength and stability. The heavy-duty lift mast is of 2-stage design and the structures welded in high quality steel, with large cross section areas and strong profiles. Cross members of thick profiles and support plates sits between the mast channels, and strong roller bearings and side roller bearings are located between the outer and inner mast, and between the inner mast and the carriage. The fork carriage is designed for high strength, durability and good visibility, and is made of high quality steel with large cross section areas. The carriage has hydraulic powered sideshift and fork positioning of the two (2) integral forks, by means of 2 hydraulic cylinders. Lift mast, carriage and forks in this offer Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 Standard • Tilt angle 10° rear / 5° front (15º) • Full cylinder stroke in carriage (longer SS/FP) • Fork dimension 2400 x 250 x 110 • Tapering STD (full thickness 0-600 mm, tapering 600-2400 mm, tip 25 mm) Included options • Triplex Freelift, Lift Height max=4500, Mast Height min-max=3310-6310, Freelift Height =1500 mm • Reinforced top beam, outer mast • Wider carriage 3500 mm • Center levelling carriage ±3,5 deg (excl. hyd func) • Assembly kit for spreaders (Control unit, cables, hoses, couplings) Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 80. EXTRA EQUIPMENT Extra equipment consists of factory mounted accessories that help improve productivity and safety in the daily operation of Konecranes lift trucks. Extra Equipment in this offer Included options • Protection greasing container • Central greasing "Lincoln Auto-Lube" basic truck (steer axle, mast fix, tilt, carriage mast wheels & rollers) • Reverse camera (1) colour monitor integrated in MD4 85. WHEELS, TIRES & RIMS Standard Included options • Solid Conti SC15/SC20 14.00x24"/PR24 (6x) Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 90. COLOUR & PAINTING Standard • Black (Cabin) RAL 7021 • Seagreen (Engine hood) TVT 553S • Seagreen (Chassis, Tanks, mudguards, counter weights) TVT 553S • Black (Mast, carriage, forks) RAL 7021 • Black (Axles) RAL 7021 • Lift lever / Joystick function sticker (A5-size, transparent, on right window) 95. DOCUMENTATION The standard package includes the following: Operator’s Manual, Maintenance Manual, Spare Parts Catalogue, Machine Card, Warranty/Start-up Protocol, Engine Operator’s Manual. Documents in this offer Standard • Operators Manual • Doc set on OneDrive - Maintenance Instructions & Operating Instructions • Doc set on OneDrive - Spare Part Catalogue Included options • Doc set on OneDrive - Technical Instructions • Doc set on OneDrive - Transmission & drive axle manual • Doc set hardcopy - Maintenance Instructions & Operating Instructions • Doc set hardcopy - Spare Part Catalogue • Doc set hardcopy - Technical Instructions • Doc set hardcopy - Transmission & drive axle manuals 98. SPARE PART KIT Spare part kit in this offer Included options • Tool kit according to separate list 100. WARRANTY Warranty according to Konecranes standard or extended warranty conditions. For further information see warranty documentation. Included in this offer Standard Included options • Warranty 30 months / 5000 hours (whichever comes first) Month 13 up to month 30 or 2001 – 5000 hours according to extended warranty terms Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 LOCAL OPTIONS Included in this offer • Fuel separatorfilter with heating • Coolant heater in engine block at 230V • Fire extinguisher with pressure gauge 12 kg 2 pcs • Safety vest XXL • Medical first aid kit • Universal mount for weapons: AK4, Galil, R20 • Starting cable NATO Stanang 4074 type 1 • Fork extensions 3200 mm • Lifting chains 4m with capacity 8t/pc Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 COMMERCIAL TERMS 1. DELIVERY SCHEDULE Approx. 40 weeks Ex. works after fully clarified order. 2. DELIVERY TERMS Seller shall deliver the Equipment on the delivery terms: DDP Delivered Duty Paid (INCOTERMS 2020) 3. PAYMENT TERMS 4. GENERAL TERMS AND CONDITIONS This offer shall be subject to Seller’s General Terms and Conditions attached hereto and available upon request and incorporated as if fully rewritten herein: General Terms and Conditions of Sale (KC LT December 2017). 5. VALIDITY OF OFFER This offer is valid until 2026-04-03. 6. WARRANTY Warranty 30 months / 5000 hours (whichever comes first) Month 13 up to month 30 or 2001 – 5000 hours according to extended warranty terms 7. CURRENCY CLAUSE Prices are based on a fixed currency (USD/EUR). If the currency exchange rate is changed more than 2%, we reserve the right to adjust the prices. 8. FREIGHT COST CLAUSE The freight pricing is based on a rate of 10 000 eur. If, at the date of actual shipment, the shipping rate quoted by us differs from the contractual rate of by more than 5 percent, we reserve the right to adjust the freight pricing accordingly. PRICE 419 581 EUR OFFER is valid only after final confirmation from Swedesh Goverment export authorities The Parties understand and acknowledge the current global component shortages may and will cause direct and/or indirect adverse effect or effects and/or hardship to the Seller. To the extent such effect or effects and/or hardship is/are caused, in Seller’s reasonable opinion, by component shortage, the Seller is entitled at its sole discretion and without any liability or liquidated damages/penalties to withhold or postpone the performance of any and/or all of its obligations under this Agreement. Any relevant deadline, delivery milestone or other agreed timeline shall be adjusted accordingly. The Seller shall inform the Buyer of any such withholding or postponement and its practical consequences as soon as practically possible. Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 RECOMMENDED OPTIONS (NOT INCLUDED IN THIS OFFER) Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 GENERAL TERMS AND CONDITIONS OF SALE -LIFT TRUCKS 1. APPLICATION OF THESE TERMS reimburse the Seller for the payment. If the Seller so demands, the Buyer shall furnish the Seller with documentation on its domicile, These Terms and Conditions of Sale ("Terms") shall apply to any residence and other necessary certificates, documentation and/or tender and any contract of sale ("Agreement"), unless the parties information required by taxing authority for tax purposes. agree otherwise in writing. The parties object to any other or different terms and conditions than these even if they or one of them have not made an express objection. In the event of any inconsistency between the Agreement and these Terms, the Agreement shall 6. TERMS OF PAYMENT govern. 6.1. The payments shall be made in accordance with the 2. SCOPE OF DELIVERY payment schedule specified in the Agreement. 2.1. The delivery of the equipment ("Equipment") includes all 6.2. Whenever any part of the payment is to be made by means components, materials and services expressly specified in the of a Documentary Credit, Section 23. shall apply. Agreement. 6.3. If the Buyer delays making any payment or in the 2.2. The delivery includes Seller's standard technical establishment of the Documentary Credit or if it becomes evident that documents, such as spare part lists, operating manuals, erection the Buyer will not fulfil his contractual obligations, the Seller may instructions (if the erection is not included in the scope of delivery) and postpone the fulfilment of its obligations until such a payment is made main dimension drawings in English. The Seller shall not be obliged to or the Documentary Credit is established. provide manufacturing drawings for the Equipment or spare parts. 6.4. The Seller shall be entitled to charge interest from the 2.3. Design, work at site, erection, supervision of erection, Buyer, if payment to the Seller is past due. The rate of the interest is training services, start-up assistance and materials other than the highest rate permissible under the applicable law. The interest components are included to the extent they are expressly specified in shall be counted from the due date until the actual date of the the Agreement. payment. The Buyer shall pay such interest within thirty (30) days from the date of the respective invoice. 3. INTELLECTUAL PROPERTY RIGHTS AND CONFIDENTIALITY If the Buyer has not paid the amount due within three months, the Seller shall be entitled to terminate the Agreement by notice in writing 3.1. The Seller shall have all rights, title and interest including to the Buyer and to claim compensation for the loss it has incurred. ownership right, copyright and other intellectual and industrial property rights to documents, drawings, software, reports, technical 7. STANDARDS OF MANUFACTURING AND DESIGN information, definitions, descriptions, manuals and any other The Equipment supplied and the work carried out shall be in intellectual property that the Seller has or creates and to Equipment accordance with the technical standards commonly used in Seller’s Usage Data as well as to the data and reports made available in the country. If the Equipment shall be operated outside of Seller`s country, Portal or data or reports created by the Seller. the scope of the work agreed in the Agreement shall prevail. The 3.2. Documents, drawings, software, reports, technical Seller shall not take into consideration laws and regulations prevailing information, definitions, descriptions, manuals and any other at the place of operation, if they are not agreed in the Agreement. The intellectual property received by the Buyer shall not, without the Buyer shall inform the Seller of the applicable safety regulations. Any consent of the Seller, be used for any other purpose than for the costs in excess of the costs of compliance with European standards erection, commissioning, operation or maintenance of the Equipment. resulting from mandatory local laws and regulations shall be added to They may not otherwise be used or copied, reproduced, transmitted or the price and paid by the Buyer. communicated to a third party. The Buyer may, however, transmit the 8. INSPECTIONS DURING MANUFACTURING documents or software to a third party that the Buyer sells the Equipment to. The Buyer has the right at its own expense, subject to the Agreement with the Seller as to the time and place, to inspect the progress of 3.3. The Buyer shall keep confidential and shall not disclose to manufacture and the quality of the Equipment. The inspections of the any third parties, or use for any other purposes than those of the Equipment shall be carried out at Seller's works or at the place of Agreement, any information regarding Agreement, Seller’s business, manufacturing. Inspection carried out by the Buyer is not a Equipment Usage Data, reports and/or data in Apps and/or Portal precondition to the delivery of the Equipment. provided or made available to the Buyer. This obligation of confidentiality shall survive the termination of the Agreement. 9. DELIVERY TERM AND PASSING OF THE RISK 4. PACKING AND MARKING 9.1. Any agreed delivery term shall be construed in accordance with INCOTERMS 2020. If no delivery term is specifically agreed, the The Equipment shall be packed in accordance with Seller's standard delivery term shall be Ex Works Seller's manufacturing plant (EXW). packing procedures as required for transportation under normal transportation conditions. The Equipment shall be clearly marked and 9.2. The risk of loss of or damage to the Equipment shall pass carry the necessary information concerning Buyer's identification and from the Seller to the Buyer in accordance with the agreed delivery place of destination. term. If no delivery term is set forth in the Agreement, the risk of loss shall pass to the Buyer Ex Works Seller's manufacturing plant. 5. PRICE 10. DELIVERY TIME 5.1. In addition to the price set forth in the Agreement, the Buyer shall be responsible for additional charges as set forth in these Terms. 10.1. The delivery time shall start to run on the latest of 5.2. If any part of the delivery of the Equipment is delayed due (a) the date of execution of the Agreement by the Seller; to reasons caused by the Buyer or any third party under the control of the Buyer, the Buyer shall compensate any additional expenses (b) the date of receipt by the Seller of the agreed down incurred by the Seller due to the late delivery. payment as set forth in the Agreement; or; 5.3. Prices do not include any stamp duty, turnover or value- (c) the date of receipt by the Seller of all agreed information added tax, bank charges or any other similar taxes, duties, tariffs or and approval by the Buyer of the general arrangement drawings. charges payable in the country into which the Equipment is to be 10.2. The Seller shall be entitled to a reasonable extension of the imported and where the installation is to be carried out. In the event delivery time (which shall not be less than the length of the delay), if the Seller is required to pay any such tax or charge, the tax or charge the delivery is delayed due to the Buyer's actions or actions by a third will be added to the invoice as a separate charge and the Buyer shall party under the control of the Buyer such as modifications requested Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 by the Buyer, delay in the approval of the relevant drawings, delay in 14.2. These warranty conditions apply to the Equipment named the preparing work at the erection site and delay in payments or it in this Agreement. The warranty applies for the original Buyer and for becomes evident that the Buyer will not fulfil his contractual later owners who have acquired the Equipment within 6 months from obligations. the delivery date to the Buyer. 11. TRANSFER OF PROPERTY 14.3. The period of the warranty for any part of the Equipment is the earliest of 11.1. Notwithstanding Section 9.1, the Equipment shall remain Seller's property until the total purchase price has been paid. In the (i) twelve (12) months from the date of the delivery event the applicable laws do not permit the Seller to retain title, the of the Equipment in accordance with applicable delivery Seller shall be entitled to a security interest or charge in the property. term or The Buyer shall give the Seller every assistance in securing an interest in the property or taking any measure required to protect (ii) 2000 operating hours whichever occurs earlier. Seller's title or such other rights. The retention of title, security interest 14.4. The warranty period for replaced or repaired parts is twelve or charge shall not affect the passing of risk of loss under Section 9. (12) months from the date of repair or replacement. However, no 11.2. The Seller shall retain title to any software and warranty for any parts shall apply after twenty-four (24) months from documentation. To the extent that such software and documentation the delivery of the Equipment. are included in the scope of delivery, the Buyer shall receive a royalty- 14.5. The Seller provides a warranty on genuine spare parts for free, non-exclusive and non-transferable license to use such software 12 months or 2000 hours, whichever occurs earlier, counted from the and documentation only in connection with the Equipment and for no date of delivery. The Seller does not reimburse labor costs or other other purpose whatsoever. costs referable to the replacement or repair of a defected spare part. 12. ACCEPTANCE TESTS Otherwise, the same warranty conditions apply in applicable parts as for new Equipment. 12.1. Should the Agreement require separate acceptance tests, the tests shall be carried out in accordance with the Agreement. If the 14.6. Should defects occur during the period of this warranty, the Agreement does not specify the requirements, the tests shall be Seller or its authorized dealer will, at its option, either repair the carried out in accordance with general practice in the industry in the defects or supply the correct parts free of charge. The defected parts country of manufacture. of the Equipment shall on request of the Seller be sent to the Seller together with a claim report according to Section 14.7 below. In case 12.2. The Seller shall notify the Buyer of the tests on sufficient the parts have not been defected, the Buyer will cover all the costs time to permit the Buyer to be represented. If the Buyer is not including, but not limited to repair, replacement and/or sending costs. represented, the test report shall be sent to the Buyer and shall be deemed accepted as accurate. 14.7. Claims must be reported in writing to the Seller within 45 days after the alleged fault has been discovered. Claims must always 12.3. If the tests show the Equipment not to be in accordance include information concerning Equipment’s serial number, type with the Agreement, the Seller shall without delay remedy any designation, and date of delivery and total hours of operation. In deficiencies in order to ensure that the Equipment complies with the addition, a complete description of the nature of the fault must be Agreement. New tests shall then be carried out at Buyer's request, given. unless the deficiency was insignificant. 14.8. This warranty is given on the condition that the Equipment 12.4. The Seller shall bear its own costs for tests carried out at is in all respects operated, handled, serviced and maintained properly, the place of manufacture. the Buyer shall bear all its own costs, in accordance with Seller's instructions and under specified operating including but not limited to travelling and living expenses for Buyer's conditions. Excluded from the warranty are those parts including spare representatives in connection with such tests. parts 13. FINAL ACCEPTANCE (a) To which repair or replacement becomes necessary due to normal wear, tear and corrosion; 13.1. Should the Agreement require separate acceptance, the Equipment is deemed to be finally accepted when acceptance tests (b) To which repair or replacement becomes necessary due to the have been carried out and the Equipment is found to be in accordance overloading of the Equipment with the Agreement. Minor defects do not prevent the acceptance of the Equipment. Such defects shall be listed and the Seller shall (c) Which are used for purposes other than for those intended by remedy any listed deficiencies without delay. If acceptance tests are the Seller and have not otherwise been used in an appropriate not to be carried out, the Equipment is deemed to be delivered and manner, taken over when delivered in accordance with the delivery term (d) Which are exhaustible items, including but not limited to such specified in Section 9. items as bulbs and fuses; 13.2. If the acceptance has been agreed, the acceptance is to be (e) Which are not approved by the Seller made without delay after the notification of readiness for acceptance. If the acceptance is not carried out in due time or completely, the (f) On which repairs, alterations or adjustments have been Equipment is deemed to be finally accepted seven (7) days after the performed or begun by the Buyer or any third party without the notification of readiness for acceptance. Seller's previous consent; 13.3. The Buyer is not entitled to take the Equipment into use (g) Which failures are not promptly reported to the Seller within the before final acceptance. If the Buyer takes the Equipment into use warranty period above; before final acceptance without Seller's consent, the Equipment is deemed to be finally accepted. (h) Which failures or damage are due to negligence other than that of the Seller, included but not limited to accident, abuse, 13.4. In the cases specified in Section 13.2 and 13.3, the Seller is improper installation (other than installations made by the entitled to invoice the Equipment from the Buyer and the period of Seller), improper operation, or abnormal conditions of warranty shall start to run. temperature, moisture, dirt, corrosive matter, dust or other similar type of reason; 14. WARRANTY (i) Which have been damaged otherwise without the fault of the 14.1. The Seller warrants that to the best of its knowledge the Seller. Equipment is free from defects caused by faulty design, materials or workmanship, which would prevent the electrical or mechanical functioning of the Equipment. The cost of disassembling and installing a repaired or replaced part furnished under this warranty is excluded. The delivery inspection and warranty service specified in the service manual are to be carried out by the Seller or by a dealer or service Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 workshop authorized by the Seller. If the Buyer and Seller have The clauses 18.3 – 18.9 only apply to an Agreement in case the EU agreed on a longer warranty period (called also extended warranty) Data Act (2023/2854) is applicable. such an extended warranty is subject to these Terms and additionally: 18.3. “Raw Product Data” shall mean raw and pre-processed (a) The extended warranty covers only the main components data collected from the Equipment, if any, limited to product data and including engine, transmission, drive axle, hydraulic pumps, related service data, including the relevant metadata necessary to valves and cylinders, electric control units and structural parts interpret and use those data, that the Seller as data holder has obligation to share or provide access to under EU Data Act (b) It is to be noted that the extended warranty does not cover on (2023/2854). bolded items, for example, turbo alternator, starter, water pump, sensors, hydraulic hoses, connections, seals, solenoids, 18.4. The Seller shall, when acting as data holder, be entitled to electrical cabling, plugs, switches, fan and wiper motors. use, share and transfer to third parties Raw Product Data, product data and related service data for the purposes of (i) performance of 14.9. THIS IS THE SOLE AND EXCLUSIVE WARRANTY GIVEN the Agreement and related arrangements, including but not limited to BY THE SELLER TO THE BUYER WITH RESPECT TO THE delivering and monitoring the Equipment, and services, service level EQUIPMENT AND IS IN LIEU OF AND EXCLUDES ALL OTHER agreements, remote connections and troubleshooting, (ii) improving WARRANTIES, EXPRESS OR IMPLIED ARISING BY OPERATION the functioning of connected products and/or related services, OF LAW OR OTHERWISE, INCLUDING, BUT NOT LIMITED TO ANY research and development, development of new products or services IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR and (iii) development and use, as applicable, of algorithms, A PARTICULAR PURPOSE. simulations, machine learning, artificial intelligence, statistics and 15. FORCE MAJEURE indexes, and more generally aggregating data with the aim of making available the resulting derived data to the Seller and third parties for Either party shall be entitled to suspend performance of its obligations commercial and non-commercial use, provided that such derived data under the Agreement to the extent that such performance is impeded do not allow the identification of specific data transmitted to the data by circumstances beyond the control of the party, including but not holder from the connected product, or allow a third party to derive limited to war (whether declared or not), revolution, strikes, failure of those data from the dataset. supplies of power, fuel, transport, equipment or other goods or services, natural disasters, unacceptable weather conditions, acts of 18.5. The Seller shall, when acting as data holder, provide the government, traffic accidents, export or import prohibitions, fire, Buyer and third-party recipients access to Raw Product Data, in case explosions, floods, accidents, sabotage, civil commotions, riots, and the Buyer makes a request, in accordance with EU Data Act. Such breakage or loss during transportation or storage as well as delays of request shall include purpose for which the data is being used by the deliveries by the subcontractors (when caused by Force Majeure as third-party. The Seller shall provide access to the data on as is and as herein defined). available basis without undue delay. The Buyer warrants that it is entitled to make such request as user and that the scope of request 16. LIQUIDATED DAMAGES OF DELAY OF THE SELLER does not exceed the mandatory requirements set forth in the EU Data Act. In case the Buyer has authorized a representative to make such The Buyer is entitled to liquidated damages for delay from the date on request, the Buyer shall provide the Seller with necessary information which the delivery should have taken place in case the delivery is for the purpose of verifying such authorization. The third-party shall delayed due to Seller's fault. The liquidated damages shall be 0,5 per pay compensation to the Seller. Seller is entitled to define such cent of the price of the delayed portion of the Equipment for each compensation provided that it meets the statutory requirements of the complete week of delay. In no event shall the liquidated damages for EU Data Act. The Seller shall provide access to third parties as may delay exceed 5 % of the price of the delayed portion of the Equipment. be designated by the Buyer only provided that (i) such request does The Buyer shall forfeit his right to liquidated damages if the Buyer fails not exceed the scope of the statutory requirement, (ii) third-party pays to claim liquidated damages by written notice within one (1) month compensation to the Seller and (iii) the Buyer and third party comply after the date when the delivery took place. The liquidated damages with the EU Data Act. referenced in this Section shall be the sole and exclusive remedy for such delay. The parties agree that such liquidated damages are a 18.6. In case the Raw Product Data includes personal data, the reasonable estimate of the damages the Buyer is likely to incur as a Buyer shall instruct the Seller of the transfer of such personal data result of such delay. expressly in writing. In case the transfer is to a third party, the instructions shall include necessary details in order to conduct the 17. LIQUIDATED DAMAGES OF DELAY OF THE BUYER transfer including but not limited to details of the third party recipient. The Buyer shall be responsible that it has the right to instruct the Seller If any part of the delivery or the acceptance of the Equipment is in such a manner and that the instruction and transfer complies with delayed due to reasons not caused by the Seller, the risk of loss the applicable personal data legislation. In no event shall the Seller be passes to the Buyer and the Buyer pays the liquidated damages in the liable for any costs or damages related to the transfer conducted by amount of 0.5% of price of the delayed portion of the Equipment for the Seller in accordance with the instructions from the Buyer and the each complete week of delay, starting 14 days after notification of the Buyer indemnifies and holds the Seller harmless for any claims, costs readiness for shipment or acceptance, where the liquidated damages and damages thereto. are limited to 5% of the price of the delayed portion of the Equipment, unless higher costs or damages can be proven by the Seller. The 18.7. In case the Raw Product Data includes Seller’s trade Buyer shall compensate any additional expenses incurred by the secrets, the Seller shall identify such trade secrets appropriately and Seller due to delay. agree the terms of disclosure in accordance with the EU Data Act. The Seller is entitled to, prior to any disclosure, to require users and third 18. REPORTING parties to preserve the confidentiality and secrecy of such trade 18.1. If separately agreed, the Seller may deliver reporting secrets encumbered data by agreeing to and implementing services to the Buyer including also remote Data Connection reporting safeguards necessary to that end. The Seller is further entitled to services using distribution channel of its choice without being withhold or suspend the sharing of trade secrets if no agreement is responsible or liable for the selected channel. The Buyer may prohibit reached, if the user or third party does not implement the agreed the collection of data at any time. Despite of such prohibition the Buyer measures, or if the confidentiality of the trade secrets is undermined. is obliged to pay the agreed charges till the end of contract period. 18.8. The Buyer shall indemnify and hold the Seller harmless 18.2. The Seller is entitled, at its sole discretion and without any against any costs, losses or claims incurred by the Seller (including liability, to suspend and/or to cancel the remote Data Connection directors and employees), or its affiliates (including directors and service at any time. The Seller reserves the right to use and develop employees) in connection with any breach by the Buyer of its the Equipment Usage Data for its general research and development obligations under this Section 17. of equipment, for delivering services, for other services and products, 18.9. If and to the extent applicable (i) the Seller shall comply for marketing them and for other purposes. with laws regarding cyber and IT security, including but not limited to the EU Cyber Resilience Act (2024/2847), to the extent they are applicable to the products and/or services the Seller shall deliver to Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 the Buyer and provided that the Buyer's use of the Equipment and/or act in violation of his/her or its lawful duties or proper services complies with this Agreement; and (ii) the Seller shall inform performance of functions); or the Buyer of actively exploited vulnerabilities or severe incidents having an impact on the security of the product and, where (ii,) obtain or retain business or an improper advantage for the necessary, of risk mitigation and corrective measures to deploy to Buyer or any of its business partner or a third-party mitigate the impact of that vulnerability or incident, where appropriate intermediary. in a machine-readable, easily processable format. (b) Neither the Buyer nor any of its Representative is a public 18.10. The Seller shall keep confidential and not disclose official who may have responsibility for or oversight of any Equipment Usage Data to any third parties in such manner that the business activities of the Buyer, other than any relationships or identity of the Buyer or its customers would remain recognizable but associations that have been disclosed in writing to the Seller. may otherwise use the said Equipment Usage Data without restriction. 20.5. To ensure full compliance with Trade Laws, prior to any use 18.11. The Buyer accepts and agrees that the Seller is not or transfer of the Sold Items to a third party the Buyer shall in responsible to monitor, inspect or otherwise follow any Equipment, particular ensure that: Equipment Usage Data, report including Equipment Usage Data or (a) The use and/or transfer of the Sold Items does not infringe other information that is generated by using CMS Unit, Data the Trade Laws, also considering the prohibitions of by-passing those Connection and/or otherwise. Any such Equipment Usage Data, report embargos; and and/or other data shall be created and provided to the Buyer on “as is” and as available basis and without warranties of any kind either (b) If the Sold Items are intended for use in connection with express or implied made in relation to the correctness, accuracy or armaments, nuclear technology or weapons, all required reliability of such Equipment Usage Data, report and/or other data. authorizations have been obtained. The Buyer is obliged to inform the Seller about such use or possible use immediately after such use or 18.12. The Words have the following definitions: possible use has been identified. "Data Connection" means any data connection (including but not limited to machine to machine connection) to be used for transferring information between the Seller and the Buyer from and to the 20.6. In case of conflicting Trade Laws or differences in Trade Equipment. Laws resulting in ambiguity over applicability of different Trade Laws, “Equipment Usage Data” means any data relating to the Equipment the Buyer shall contact the Seller for Seller’s final decision. The Buyer and/or its usage collected and/or processed by the Seller in will accept Seller’s decision without any further claims or demands. connection with remote services, remote reporting or by other means. 20.7. The Buyer shall maintain all documentation required by the 19. LIMITATION OF LIABILITY Trade Laws and shall provide the same to the Seller without delay at Seller’s reasonable request. This recordkeeping obligation of the SELLER'S LIABILITY UNDER THE AGREEMENT SHALL BE Buyer shall continue for five (5) years from the final acceptance of the LIMITED TO THE AMOUNT OF THE ACTUAL DIRECT DAMAGES Sold Items. INCURRED BY THE BUYER OR TO 40 % OF THE PRICE PAID BY THE BUYER TO THE SELLER FOR THE EQUIPMENT OR TO THE 20.8. The Buyer shall at its own expense apply for, obtain and REPLACEMENT OF THE EQUIPMENT, WHICHEVER IS THE have renewed all permits, authorizations and licences, including LOWEST. THE BUYER SHALL BE ENTITLED TO NO OTHER export control authorizations, required for its activity or needed to REMEDY REGARDLESS OF THE FORM OF CLAIM OR CAUSE OF perform its obligations pursuant this Agreement. ACTION, WHETHER BASED IN AGREEMENT, NEGLIGENCE, TORT, LAW, STRICT LIABILITY OF OTHERWISE. 20.9. If the Buyer learns or has a reason to believe that there has been any violation of Laws or Regulations, especially relating to Trade Laws or Anti-Corruption Laws, or violations of the Seller’s Code of Conduct by the Buyer or any of its Representatives, it shall IN NO EVENT SHALL THE SELLER BE LIABLE FOR ANY SPECIAL, immediately notify the Compliance and Ethics Officer of the Seller. In PUNITIVE, INCIDENTAL, INDIRECT OR CONSEQUENTIAL such case the Buyer agrees to undertake all actions reasonably DAMAGES LOSS OF PRODUCTION, LOSS OF PROFIT, LOSS OF requested by the Seller, including investigative and remedial actions. USE, LOSS OF REPUTATION OR LOSS OF AGREEMENTS. 20.10. The Buyer shall assist and cooperate fully with the Seller’s 20. COMPLIANCE AND EXPORT LAWS AND efforts to comply with Laws and Regulations. Upon request the Buyer REGULATIONS shall provide the Seller with all information and documents necessary 20.1. The Buyer undertakes to comply with these terms, the to verify the Buyer’s compliance with its obligations under the Agreement; all Laws and Regulations, including but not limited to Agreement. The Seller may also audit the premises, books and Trade Laws in relation to the Sold Items, Anti-Corruption Laws, records and other documents of the Buyer which reasonably relate to competition laws and ethical business practices. the performance of its obligations under this Section 20, not only Any breach of this Section 20 is deemed to be a material breach of during the continuance of this Agreement, but for seven (7) years after this Agreement. its expiry or termination. The Seller shall provide at least 15 days prior written notice of the audit. The Seller has the right to make copies of 20.2. The Buyer understands that the Laws and Regulations documents audited. change over time and may vary depending on, for example, the product, software, documentation, and technical data. The Buyer 20.11. If required by applicable competition laws, the above audit undertakes to know about and comply with such changes. right and collection and review of information provided by the Buyer shall be exercised through a third party auditor selected by the Seller 20.3. The Buyer confirms that it has sufficient and effective to ensure that no commercially sensitive information is disclosed or internal controls, ethics and compliance programs or measures for exchanged between the Seller and the Buyer. preventing and detecting any violations of Section 20.1 above. The Buyer’s Representatives are to Buyer’s best knowledge in compliance 20.12. The Seller hereby informs the Buyer that certain personal with all Laws and Regulations and ethical business practices. data relating to the Buyer and its customers may and will be collected by the Seller as data controller for the purpose of executing the 20.4. The Buyer represents and warrants that: Agreement, of complying with the applicable laws and regulations, including tax and accounting laws as well as for other purposes in (a) The Buyer or any of its Representatives will neither solicit or accordance with Konecranes personal data processing information at accept nor give, offer or promise to give anything of value, http://www.konecranes.com/data-protection. For special purposes the directly or indirectly, to any private individual or organization, or Seller may also act as a data processor. public official in an effort to: 20.13. The Buyer accepts and agrees with the foregoing and (i,) improperly influence any act or decision by the above confirms that providing the data is necessary for executing the mentioned parties (including a decision to do or omit to do any Agreement and managing the contractual relationship and accepts an Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 obligation to inform its customers (if applicable), employees and other 24. PORTAL representatives about the handing of personal data by the Seller as part of the Agreement. 24.1. The Seller may provide the Buyer with an access to a portal and/or app. The Buyer undertakes to act in strict compliance with the 20.14. The words have the following definitions: applicable portal and/or app terms of use that are applicable from time to time. Such terms shall be available in the portal and/or in the app (a) “Anti-Corruption Laws” means Laws and Regulations and shall also be provided to the Buyer upon written request. relating to anti-bribery and anti-corruption, always including the US Foreign Corrupt Practices Act and the UK Bribery Act 2010, money 24.2. The Buyer expressly accepts and agrees that if not laundering and extortion. otherwise agreed the use of the portal and/or app, its content and any services or items obtained through the portal and/or app are at Buyer’s (b) “Laws and Regulations” means all international, country own risk, on “as is” and “as available basis, without any warranties of specific, federal, state and local laws, rules and regulations applicable any kind, either express or implied. The Buyer further accepts that the to either party, as amended from time to time. Seller does not make any warranty or representation with respect to (c) "Representatives" means a party’s partners, officers, the completeness, security, reliability, quality, accuracy or availability directors, employees, agents and anyone acting on its behalf or for its of the portal and/or app without limiting the foregoing and if not benefit. otherwise agreed, the Seller does not represent or warrant that the portal and/or app, its content or any services or items obtained (d) “Sold Items” means the Equipment, spare parts and through the portal and/or app will be accurate, error-free or services and all related software. uninterrupted, that defects will be corrected, that the portal and/or app are free of viruses or other harmful components or that the portal (e) “Trade Laws” means Laws and Regulations relating to and/or app meet Buyer’s expectations. The Seller reserves the right to export control, trade sanctions, re-export and trade, normally including revise portal and/or app or withdraw access to them at any time. the Trade Laws of the United Nations, European Union and the United States of America. 25. NO WAIVER 21. APPLICABLE LAW AND SETTLEMENT OF DISPUTES No course of dealing between either party, no failure or delay on the part of either party in exercising any right or remedy under the 21.1. The Agreement shall be governed by and construed in Agreement or no single or partial exercise of any other right or remedy accordance with the laws of Seller's place of incorporation. of either party shall operate as a waiver of any such right or remedy. 21.2. All disputes arising out of or in connection with the present 26. SEPARABILITY; REFORMATION AND AMENDMENTS Agreement shall be finally settled under the Rules of the Arbitration Institute of the Stockholm Chamber of Commerce by one or more 26.1. The invalidity or enforceability of any provisions of the arbitrators appointed in accordance with the said Rules. The Agreement shall not impair the validity or enforceability of any other arbitration shall take place in Stockholm, Sweden. The language of the provisions; provided, however, that the Agreement shall be reformed arbitration proceedings shall be English. to the maximum extent permitted by law to carry out the parties’ original intention. 21.3. Notwithstanding the above, The Seller shall be entitled to take action for collecting its receivables from The Buyer at the courts 26.2. The Agreement may be amended only in writing signed by of the Buyer's place of domicile. both parties. 22. LANGUAGE KC 1 July 2025 All documents and correspondence between The Seller and The Buyer shall be in English. 23. LETTER OF CREDIT (DOCUMENTARY CREDIT) 23.1. The Documentary Credit shall be irrevocable and transferable, it shall allow partial shipments, loading on deck, charter party Bill of Lading, shipment on barge and transhipments. 23.2. The Documentary Credit shall be established in a form acceptable to the Seller not later than 30 days from the date on which the Agreement is executed by the Seller and it shall remain valid for a period of at least 30 days after the date of last shipment. 23.3. The Documentary Credit shall be confirmed by a first class international bank acceptable to the Seller and it shall be payable at sight at the counters of a bank nominated by the Seller against presentation of a commercial invoice and/or other documents specified in the Agreement. 23.4. Regardless of any other section or term of these Terms, if any, if the Seller is unable to ship the goods due to any reason outside of its control, the Documentary Credit shall be payable against the forwarding agent's receipt, or, should The Buyer fail to name the forwarding agent, against the warehouse receipt. 23.5. The Documentary Credit shall provide that the rules in the "Uniform Customs and Practice for Documentary Credits (2007 Revision) ICC Publication No. 600" are applicable to the Documentary Credit. 23.6. All charges and expenses, related to the fulfilment of this Contract of Buyer’s Bank including opening and extension of Documentary Credit and confirmation commission of the same in the Seller’s Bank shall be borne by the Buyer. The charges and expenses of Seller’s bank, except the confirmation commissioning of Documentary Credit, shall be borne by the Seller. Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 EXTENDED WARRANTY REGULATIONS FOR NEW KONECRANES LIFT TRUCKS (KCLT) 1. SCOPE b. To which repair or replacement becomes necessary due to the overloading of the Machine These warranty conditions apply to the machine (Machine) named in this warranty certificate and/or specified as agreed in the purchasing c. Which are used for purposes other than for those intended by agreement. The original warranty period applies for the original Buyer KCLT and has not otherwise been used in an appropriate and for later owners. manner, d. Which are exhaustible items, including but not limited to such items as bulbs and fuses; 2. WARRANTY PERIOD e. Which are not approved by KCLT Warranty time is 12 months or 2.000 running hours from date of signing the “Warranty start up report”, or as latest 15 months from f. On which repairs, alterations or adjustments have been KLFT invoice date, whichever comes first performed or begun by the Buyer or any third party without KCLT previous consent The Extended Warranty time is limited to following components: g. Which failures are not promptly reported to KCLT within the Including major components such as; warranty period above - Engine. h. Which failures or damage are due to negligence other than that of KCLT, including but not limited to accident, abuse, improper - Transmission. installation (other than installation by KCLT), improper - Drive axle. operation, or abnormal conditions of temperature, moisture, dirt, corrosive matter, dust or other similar type of reason. - Hydraulic pumps, valves and cylinders. i. Which have been damaged otherwise without the fault of KCLT. - Electric control units. - Structural parts. Further, this warranty is given on the condition that, Excluding on-bolted items such as; The delivery inspection, warranty service and other in Service manual - Turbo, alternator, starter, water pump, sensors, specified services have been carried out by KCLT or by a KCLT authorised dealer or service workshop - Engine after treatment systems, - Hydraulic hoses, connections, seals, solenoids, 6. LIMITATION OF LIABILITY - Electrical cabling, plugs, connections, switches, fan and wiper motors. This is the sole and exclusive warranty given by KCLT to the Buyer with respect to the equipment and is in lieu of and excludes all other The warranty period for replaced or repaired parts during the warranty warranties, express or implied, arising by operation of law or period is limited to the machine warranty. otherwise, including but not limited to, any implied warranties of merchantability or fitness for particular purpose. 3. WARRANTY OBLIGATIONS Should defects occur during the period of this warranty, KCLT or its 7. E-VER BATTERY & SPARE PARTS WARRANTY authorized dealer will, at its option, either repair the defects or supply See separate terms and conditions. the correct parts free of charge. The defective parts of the Machine shall on request of KCLT be sent to KCLT together with a claim report according to clause 4 below. In case the parts are not defective, the Buyer will cover all the costs including, but not limited to, repair, replacement and/or shipping costs. 4. CLAIMS Claims must be reported in writing or via Konecranes Warranty On- Line (WOL) system to KCLT within 45 days of discovery of the alleged fault. Claims must always include information concerning the machine’s serial number, type designation, and date of delivery and total hours of operation. In addition, a complete description of the nature of the fault must be given. 5. FAULTS This warranty is given on the condition that the Machine is in all respects operated, handled, serviced and maintained properly, in accordance with KCLT instructions and under specified operating conditions. Excluded from the warranty are those parts including spare parts, to which repair or replacement becomes necessary due to: a. Normal wear, tear and corrosion, tyre equipment, batteries, fuses, light bulbs or LED’s or other wear parts of the machine. It does neither cover fluids, filters and unspecified material such as grease, oil, cleaning material. Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 We thank you for your interest Konecranes in a snapshot History and experience Global market leader Growing Maintenance Going back to the 1930s in lifting equipment and steadily contracts service and financially solid covering over 400,000 items of lifting equipment of different makes © 2025 Konecranes. All rights reserved. “Konecranes”, “Moves what matters” and are either registered trademarks or trademarks of Konecranes Global Corporation. Konecranes Li,trucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN, Finland. Tel +46 433 733 00, Fax +46 433 733 10 VAT: SE556142496001, E-mail: info.li,[email protected], www.kcli,trucks.com  Tehniline kirjeldus Tehnikavahendi nimetus: rasketõstuk (Edaspidi „Masin“) Pakutava tehnika mark ja mudel: Konecranes SMV 25-1200 Pakkumus peab vastama tehnilises kirjelduses esitatud miinimumnõuetele. Alternatiivsete pakkumuste esitamine ei ole lubatud. Hangitav masin on mõeldud mitmesugusteks tõstetöödeks. Masin on mõeldud töötama kõikides ilmastiku- ja valgustustingimustes keskmise ning kõva pinnasega tööplatsidel, kus tööplatside vahemaad on kuni üks kilomeeter. Suuremate vahemaade korral kasutatakse transportimiseks treilereid. Hankija soovib osta Eesti Kaitseväele kaks tõstukit, mis vastavad käesolevas dokumendis toodud nõuetele. V ajadusel võib hankija tellitavat kogust suurendada kuni kahe ühiku võrra . Lühendid RKIK Riigi K aitseinvesteeringute K eskus STANAG NATO standardiseerimise kokkulepe (Standardization Agreement) Ed. Edition (Dokumendi versioon) Normatiivid Pakkuja peab tundma ja täitma alljärgnevaid normatiive. EN 590 Mootorikütused. Diislikütus. Nõuded ja katsemeetodid. STANAG 7090 Ed. 7 NATO maismaasõidukitel kasutavate kütuste miinimumnõuded. STANAG 4015 Ed. 3 Käivitusakude akukastid kasutamiseks taktikalistel maismaasõidukitel. STANAG 4074 Ed.3 Käivitusabi pistikud kasutamiseks taktikalistel maismaasõidukitel. ISO 12117-2-2008 Ümbermineku kaitsekonstruktsioonide karakteristika RT I, 10.02.2023, 32 Seadme ohutuse seadus 2006/42/EÜ EUROOPA PARLAMENDI JA NÕUKOGU DIREKTIIV Kui nõutud standardil on järelliide „või samaväärne”, võib selle nõude täita, täites mõne muu samaväärse standardi nõudeid. Lisaks kohustuslikule vastusele peab pakkuja nimetama samaväärse standardi ja selgitama, kuidas alternatiivne standard täidab mainitud/nõutud standardis esitatud nõudeid, ning vajadusel esitama vastava dokumendi. Seotud dokumendid Nõuetes viidatud dokumendid on antud tehnilise kirjelduse osa. Nõuded, mis esinevad viidatud dokumentides, on antud tehnilise kirjelduse osad ja kuuluvad täitmisele, välja arvatud juhul, kui tehnilises kirjelduses on eraldi välja toodud eri- või lisatingimused. Juhul, kui viidatud dokument viitab edasi teistele dokumentidele, kuuluvad ka need täitmisele, välja arvatud juhul, kui need ei rakendu hankeobjekti kohta või hankedokumentides ei ole sätestatud teisiti. Juhul, kui ei ole sätestatud teisiti, kuuluvad täitmisele dokumentide kõige uuemad versioonid, sh standardi muudatused, tehnilised parandused ja muud seotud muudatused ja teatised. Dokumente, millele on viidatud tehnilises kirjelduses, kuid mis ei ole RKIK-i poolt loodud, RKIK ei edastada. Nimetud dokumendid (STANAG, ISO jne) on leitavad näiteks www.nato.int või www.iso.org . Tingimused pakkumusele Nõuded antud tehnilises kirjelduses on miinimumnõuded, mis on kohustuslikuks täitmiseks Pakkujale. Pakkuja peab täitama kollase taustaga väljad tulbas „TÄIDAB PAKKUJA“ järgmises peatükis olevas tabelis. Hankija loeb pakkumuse mittevastavaks, kui Pakkuja on jätnud väljad täitmata või on esitanud muu sinna mittekuuluva info. Pakkuja ei pea täitma väljasid, mis on Hankija poolt täidetud musta taustaga. Tulpa „JAH“ tuleb sisestada sõna „JAH“. Sisestades sõna „JAH“ Pakkuja kinnitab, et on üheselt aru saanud nõudest ja suudab ning kohustub seda nõuet täitma. Tulpa „Esitada dokumendi ja peatüki nimi/number“ tuleb sisestada dokumendi nimi ja peatüki nimi/number selles dokumendis , kus nõude täitmine on tõendatud/kirjeldatud. Juhul, kui on lisatud täpsustav nõue „#“, tuleb esitada dokument vähemalt nõutud sisuga. Tulpa ei tohi kirjutada mitte midagi muud, isegi mitte ühesõnalist ja/või numbrilist vastust! Tulpa „Esitada viide“ sisestatud dokumendi nimi ja peatüki nimi/number peavad ühtima pakkumuses esitatud dokumendi nimega ja peatüki nime/numbriga selles dokumendis. Pakkuja peab hoiduma mittevajalike turunduslike materjalide kasutamisest. Esitatud dokumendid peavad andma selge vastuse/kirjelduse sellest, kuidas Pakkuja nõuet täitma hakkab. Pakkuja ei tohi muuta dokumendi struktuuri ja sõnastust. Tolerantsid käesolevas tehnilises kirjelduses on ± 1% Rasketõstuk, diiselmootoriga, tõstejõuga vähemalt 25 tonni 1200 mm raskuskeskme korral. Nr Tehniline nõue TÄIDAB PAKKUJA 1 JAH Si sestada dokumendi number ja pea tüki nimi /number 1.1 Tõstuk on uus (kasutamata), tootmisaasta vähemalt 202 5 Jah Offer 26001672 1.2 Tõstuki nõutav töökeskkonna temperatuurivahemik - 3 2 °C kuni +4 9 °C . Masin, kõik selle komponendid ning tehnilised vedelikud peavad vastama nõudele. Jah User manual 1.3 Pakutava tõstuki mark ja mudel SMV 25-1200 Offer 26001672 1.4 Tõstevõime vähemalt 25 000 kg / 1200 mm Jah Offer 26001672 1.5 Tõstekõrgus vähemalt 4 000 mm Kolme osaline mast Masina maksimaalne ehituslik kõrgus kuni 3300mm Jah Offer 26001672 1.6 Masti kallutus ette ja taha vähemalt 5 °/ 5 ° Jah Offer 26001672 1.7 Vabatõste kõrgus vähemalt 15 00 mm Jah Offer 26001672 2 Mootor 2.1 Diiselmootor (Vähemalt EURO 3 heitmenormile vastav) 2.1.1 Mootori võimsus peab tagama koos maksimum koormaga startida 20% kallakust üles. Jah 2.1.2 Masin peab olema võimeline töötama, kasutades kütusena EN 590 vastavat diislikütust ja NATO STANAG 7090 vastavat F-63 kütust ilma ümberehituseta; AdBlue süsteemi peab saama välja lülitada ilma erivahenditeta ja/või AdBlue vedeliku otsasaamine ei tohi mõjutada masina opereerimisvõimet , kui AdBlue süsteem on paigaldatud . # Esitada mootori või masinatootja kinnitus ja ekspluatatsiooni tingimused F-63 kütuse kasutamise korral. Jah Confi r mation AN 06-03-2026 2.1.3 Heitgaasi järeltöötlussüsteemi olemasolul ( nt DPF, SCR) korral peab olema tagatud masina täielik töövõime juhtudel , kui nimetatud seadmed ei tööta või esinevad rikked / tõrked . Masina töövõimet ei tohi seeläbi piirata ka elektroonselt . Jah 2.1.4 Kütuse veeseparaator filter koos kütuse elektrilise eelsoojendiga. Jah 2.1.5 Jahutusvedeliku soojendiga integreeritud 230V töötav akulaadija , mis on varustatud automaatse ülelaadimise kaitsefunktsiooniga . #Esitada tõendus , et laadija on sobilik masinale paigaldatud akude laadimiseks välitingimustel . Jahutusvedeliku soojendi mootoriplokis, mis töötab 230V pingel; seadet peab olema võimalik kasutada ilma ajalise piiranguta 24/7. Jah 2.1.6 Kütusepaagi maht peab tagama vähemalt 8 h katkematut tööaega. Jah Technical data 2.1.7 Masinale peab olema paigaldatud autonoomne diislikütusel töötav soojendussüsteem vähemalt kabiini ja mootori veesärgi soojendamiseks. Jah Offer 26001672 2.2 Masin peab olema varustatud automaatse kesk määrdesüsteemiga , määrdeaine mahuti peab olema kaitstud metallist või tugevast plastikust kaanega, et vältida mehaanilisi kahjustusi. Määrdeaine mahuti peab olema kaitstud niiskuse eest, nt survepesu ajal ei tohi niiskus määrdeaine mahutisse sattuda. Masti määrimiseks on lubatud keskmäärde süsteem käsitsi määrimiseks (st määrdeliinide väljavõte) Jah 3 Ülekanne 3.1 Piduri- ja hüdraulikasüsteem peavad võimaldama avariiteisaldamist juhul kui mootor ei tööta või akud on tühjad Jah 3.2 Veoskeem 4x2 või 4x4 Jah Tech nical data 3.3 Esi- ja tagateljel peavad olema elastikrehvid. Jah 3.4 Minimaalne liikumiskiirus vähemalt 15 km/h koormatult ja koormamata Jah Technical data 3.5 Mehaaniline seisupidur , sõidupidur mehaaniline või hü d r auliline Jah 4 Juhtimine 4.1 Tööorgani juhtimine kabiinist Jah 4.2 K ahvlite külgnihe Jah 4.3 K ahvli käppade pikkus vähemalt 2000 mm Jah 4.4 Sõidusuuna, masti tööoperatsioone ja lisaseadmete juhtimine elektriliselt juhtkangilt (elektriliselt juhitav hüdrojagaja ). Jah Offer 26001672 4.5 Roolivõimendi Jah 4.6 Tõstukiga peab olema võimalik töötada 5 tundi järjest ilma pausideta Jah 4.7 Reguleeritav roolisammas. Jah 4.8 Vajalik operaatori tuvastamise süsteem tööoperatsioonide teostamiseks. Jah 4.9 Reverseerimise alarm väljalülitamise võimalusega Jah 5 Kabiin Cabin 5.1 ISO 3471 ROPS – Roll Over Protective Structure 5.2 ISO 3449 FOPS – Falling Object Protective Structure Jah PM-FM Konecranes 5.3 Kabiini õhuvõtusüsteem peab olema varustatud tolmufiltriga (salongifilter). Jah 5.4 Mehaaniliselt kiige süsteemiga või õhkvedrustusega reguleeritav juhiiste koos turvavööga . Jah 5.5 Elektrilise soojendusega välised tahavaatepeeglid ja vähemalt üks sisepeegel . Jah 5.6 Esi- ja tagaklaasi pesur ja kojamees. Jah 5.7 Mehaaniline või elektriliselt lülitatav massilüliti, mis võimaldab kogu elektrisüsteemi väljalülitamist. Jah 5.8 Kabiini soojendus- ja jahutussüsteem koos konditsioneeriga Jah 5.9 Kabiin peab hoolduste teostamiseks olema elektriliselt või elektrohüdrauliliselt kallutatav. Jah 6 Elektrisüsteem 6.1 Põhi- ja töötuled, täielikult väljalülitatavad 6.1.1 kaks vähemalt 24W LED töötuld katuse esi - ja kaks vähemalt 24 W LED töötuld katuse tagaservas , mõlemal masina küljel vähemalt üks vähemalt 24W LED töötuli, vähemalt kaks töötuld masina taga, vähemalt kaks töötuld mastil Jah 6.1.2 töötulede valgustussuund peab olema reguleeritav; Jah 6.1.3 Sõidu- ja pidurituled Jah 7 Muu varustus 7.1 Ettenähtud tehasepoolne tööriistakomplekt kasutajatasandi hooldus- ja remonttööde teostamiseks ning hüdraulikasüsteemi mutrite pingutamiseks. Mehaaniliste määrdepunktide olemasolul peab olema tööriistakomplektis määrdetuubiga täidetav määrdeprits. Komplekt peab asuma selleks ettenähtud veekindlast kastis või sahtlis. Jah Offer 26001672 7.2 Masinas kasutuses olevad õlid peavad tagama aastaringse kasutamise, arvestades nõutavat töökeskkonna temperatuurivahemikku Jah 7.3 Manomeetriga tulekustuti d, 2 tk, kokku vähemalt 12 kg kustutusainega, kinnitatuna, kaitstud mehaaniliste vigastuste eest Jah 7.4 Ohutusvest XXL suuruses. Jah 7.5 Meditsiinilise esmaabi komplekt, kinnitatult ning komplekteeritud vastavalt kehtivale seadusandlusele. Jah 7.6 Akende, peeglite, tulede katted, mis peavad olema pakendatud veekindlalt . 8 Üldine 8.1 Tarneaeg mitte üle 12 kuu pärast hankelepingu sõlmimist . Jah 8.2 Tõstuki(te) tarne Eesti Vabariigi piires vastavalt etteantud tellimusaadressile. Jah 8.3 Garantii vähemalt 2 aastat või 5 000 h Jah 8.4 Vähemalt inglis keelne varuosade kataloog ning hüdraulika- ja elektrisüsteemide diagrammid paberkandjal ja digitaalselt. Jah 8.5 Ho olduse ja remondi teostaja(d), h oolduskeskus( ed ) Eesti Vabariigis Jah 8.6 Hooldusvälp mitte vähem kui 500 töötundi. Jah 8.7 CE sertifikaat Jah Offer 26001672 8.8 Pakkuja peab tagama mehaaniku ja operaatori kasutajataseme väljaõppe oma kuludega 4-6 Eesti Kaitseväe isikule. Koolitus peab toimuma 14 päeva jooksul pärast esimeste masinate tarnimist. Jah 9 Lisanõuded 9.1 Masin ja lisaseadmed peavad vastama direktiivi „EUROOPA PARLAMENDI JA NÕUKOGU DIREKTIIV 2006/42/EÜ“ nõuetele. Jah 9.2 Masin ja lisaseadmed peavad vastama Eesti ja Euroopa kehtivatele nõuetele. Jah Offer 26001672 9.3 Pakutava masinaga sama marki üle 10t tõstejõuga masinad peavad olema kasutusel vähemalt kolme NATO riigi relvajõudude poolt. (esitada nimekiri) 9.4 Masin peab olema varustatud vähemalt masina laiuse kahvliraamiga . 20’ konteinerit peab olema võimalik liigutada külgnihkega külgsuunas standardsetest tõstekohtadest tõstes , vähemalt 800mm . Jah 9.4.1 Masinal peab olema nn viies sektsioon kahvliraami kallutamiseks pikitelje suhtes ( kallutav kahvliraam ). Kahvliraam peab kallutama vähemalt 3 ° mõlemale poole Jah 9.4.2 Masinale peab olema võimalik kinnitada ja kasutada konteinerite tõstmiseks üla ja külg spreederit . Jah 9.5 Masina ja lisaseadmete värvus tehase standard, masin peab olema värvitud valmistajatehase poolt Jah 9.6 Masinal ei tohi olla kroomitud või nikeldatud vms läikivaid kere detaile ( v.a peeglid , klaasid ning hüdraulika silindrite tööpinnad ). Jah 9.7 Masinal ei tohi olla andmeside monitooringut masina töö - ja veainfo kuvamiseks , millel on GPS positsioneerimise või muud sarnane sidesüsteemi ( Julgeolek ). Jah 9.8 Kütusepaak ( või - paagid ) korrosioonikindlast materjalist ja lukustatav (ad). Jah 9.9 Kütusepaagi maht peab tagama vähemalt 8 h katkematut tööd keskmise kütusekulu järgi . #Esitada arvutus , mille alusel on saadud kriteeriumile vastavuse andmed . Jah 9.10 Süsteem peab olema 24V, et saaks käivitusabiks ühendada Eesti Kaitseväe teiste sõidukitega . Jah 9.11 Akuruum , akude kinnitus , klemmide mõõtmed ja asukohad peavad vastama STANAG 4015 Ed.3 nõuetele . # Esitada nõutele vastav akukastide joonis koos klemmide asetusega . Jah 9.12 Akud peavad olema hooldusvabad ja vastama STANAG 4015 Ed.3 nõuetele mõõtmete ja ühendusklemmide asetuse suhtes . #Esitada paigaldatavate akude andmeleht . Jah 9.13 Masin on varustatud NATO STANAG 4074 tüüp 1 -le vastava stardiabi pistikuga , paigaldatuna kergesti ligipääsetavasse kohta . Jah 9.14 Töötuled peavad olema LED- tüüpi . Jah 9.15 Masina tööala peab olema valgustatud ümber masina 360 kraadi . Iga töötuli peab olema vähemalt 24W. Jah Töö- ja parkimistuled peavad olema kaitstud mehaaniliste kahjustuste eest. Jah 9.16 Masinal peab olema registreerimismärgi alus koos valgustusega . Jah 9.17 Sõidualarm ( liikumise helisignaal ); peab olema väljalülitatav . Jah 9.18 Masin peab olema varustatud kollase LED vilkuriga . Vilkur peab olema kabiinist lülitatav ja lihtsasti eemaldatav . Jah 9.19 Peab olema varustatud FM- raadio , kõlarite ja antenniga . Jah 9.20 Iste peab olema reguleeritav vähemalt edasi-tagasi suunal , istmepadi pikikalde osas ning seljatoe nurk istmepadja suhtes . Jah 9.21 Istme amortisatsioon peab olema reguleeritav vastavalt operaatori kehakaalule . Jah 9.22 Istmekate peab olema valmistatud kulumis - ja määrdumiskindlast materjalist . Ei tohi olla nahast . Jah 9.23 Töötuledel peab olema soojendus lume sulatamiseks tule klaasidelt Jah 9.24 Kabiini ventilatsioonisüsteem peab olema varustatud välisõhu filtri ( te )ga. Jah 9.25 Klaasid peavad olema kaetud päikesekaitsekilega (UV kaitse , läbipaistvus vähemalt 75%) . Jah 9.26 Masinas peab olema DIN1 pesa raadiojaama paigaldamiseks , raadiojaama tarnib hankija , raadiojaama ühendused , antenni - ja toitekaablid peavad olema paigaldatud ja ühendatud Jah 9.27 Kabiinis peab olema koht, kuhu kinnitada relv masinaga opereerimise ajaks; kinnitus peab olema universaalne ja sobima relvadele: AK4, GALIL, R20. Jah 9.28 Küljepeegli kinnitused peavad olema valmistatud löögijõudu neelavast materjalist või varustatud vedrusüsteemiga , et vältida nende küljest murdumist või deformeerumist valise jõu rakendumisel . Jah 9.29 Küljepeeglid peavad purunemise vältimiseks olema kokku lükatavad või - klapitavad . Jah 9.30 Masina rehvid peavad võimaldama liikumist nii kõvakattega teedel kui ka pinnasel . Rehvi muster peab olema sobilik pinnasel töötamiseks . Jah 9.31 Kabiinis peab asetsema mõõteseadmete paneel , millel asuvad vähemalt : 9.31.1 töötunnilugeja Jah Offer 26001672 9.31.2 mootori jahutusvedeliku temperatuurinäidik ; Jah Offer 26001672 9.31.3 kütusepaagi taseme näidik; Jah Offer 26001672 9.31.4 audio-visuaalne hoiatussüsteem elektrisüsteemi rikete, jahutusvedeliku, mootori ja tööhüdraulika õlisurve, õhufiltri ummistumise, ülekuumenemise jne vigadest alarmeerimiseks; Jah Offer 26001672 9.31.5 Sees oleva käigu indikaator Jah Offer 26001672 9.31.6 Lasti kaal koos hoiatussüsteemiga ülekoormuse osas Jah Offer 26001672 9.32 Kabiini uks peab olema fikseeritav avatud ja suletud asendis Jah 9.33 Juhul, kui masinal on T ahavaate / külgvaate kaamerad , siis peavad need olema kaitstud mehaaniliste vigastuste eest . Jah 9.33.1 Masinal peab olema vähemalt tahavaate kaamera Jah 9.34 Hüdraulikasüsteem peab võimaldama proportsionaalset ehk tööorgani liigutuste sujuvat juhtimist. Jah 9.35 Peab võimaldama avariiteisaldamist juhul, kui mootor ei tööta (st peab olema võimalik tööorganeid alla lasta või tõsta abivahendite abil). Jah 9.36 Tööriistakomplekt, mis on vajalik kasutajatasandi hooldus- ja remonttööde läbiviimiseks ja hüdroliinide kinni-lahti keeramiseks. Tööriistkomplekt peab asuma selleks ette nähtud ilmastikukindlas kastis või sahtlis. Jah 9.37 V ähemalt 6 m pikkune käivitusvoolu ülekandekaabel , varustatud mõlemas otsas NATO STANAG 4074 tüüp 1 -le vastava stardiabi pistikuga koos üleminekuga Type 2 ühendusele . Jah 9.38 Masinaga koos tarnitakse kahvlipikendused pikkusega vähemalt 1,5 masina kahvlite pikkust Jah 9.39 Masina tõstekahvlid peavad võimaldama kauba tõstmist tõstekettidega . Ketid peavad olema masinaga kaasas . Kettide pikkus minimaalselt 4m. Tõstekettide nominaalne tõstejõud peab olema vähemalt 8 t/ tk Jah 10. Dokumentatsioon ja muud tingimused 10.1 Varuosade kataloog , hüdro - ja elektriskeemid vähemalt inglise keeles . Jah 10.2 Kasutamisjuhend (paberkandjal ning elektrooniliselt eesti keeles ja elektrooniliselt inglise keeles). #Esitada kasutusjuhend inglise või eesti keeles. Jah 10.3 Mehaaniku ja operaatori koolitus (kasutajatasemel) 4-6 kaitseväelasele. Väljaõpe peab olema läbi viidud mitte hiljem kui kaks nädalat pärast esimese masina üleandmist. Mehaanikutele on nõutud lihtsamate hooldustööde ja ekspluatatsioonimaterjalide (töövedelikud, filtrid, tihendid, rihmad jne) vahetamise koolitus. #Esitada koolituskava, ajakava (üldine) ja koolituse sisu ülevaatus. Sammuti eeldused personali varasema pädevuse osas. Esitada muud koolitusega seotud olulised kommentaarid. Jah 10.4 Pakkujapoolne vea määratlemine tõstuki juures tööpäevadel hiljemalt 24 h jooksul ja nädalavahetustel ning riiklikel pühadel hiljemalt 72 h jooksul Eesti Vabariigi piires alates rikke teatamisest. Jah 10.5 Kuluvaruosade tarneaeg maksimaalselt 7 päeva . Jah Operating Instructions Forklift SMV 10-65, Gen C OIFLTC_RevE Original Instructions 24 May 2024 Document ID: DOC2730881A / en-US This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Internal reference: X101986 en-US / E Contact information Contact the manufacturer’s local representative or Konecranes Lifttrucks AB Anders Anderssons väg 13 285 35 Markaryd SWEDEN Tel. +46 433 733 00 For UK, contact: Konecranes Demag UK Ltd Coalfield Way LE65 1NF Asby De La Zouch UNITED KINGDOM www.kclifttrucks.com Table of contents Operating Instructions TABLE OF CONTENTS 1 INTRODUCTION.............................................................................................................7 1.1 About this document.................................................................................................... 7 1.1.1 Use of the document......................................................................................... 7 1.1.2 Terminology.......................................................................................................7 1.1.3 Abbreviations.................................................................................................... 8 1.1.4 Copyright notice................................................................................................ 9 1.1.5 Available technical documents.......................................................................... 9 1.1.6 Feedback on documents................................................................................... 9 1.2 About this product........................................................................................................ 9 1.2.1 Use of the product ............................................................................................9 1.2.2 Conditions of warranty.................................................................................... 10 1.2.3 Identification of the product............................................................................. 11 1.2.4 Standards and directives.................................................................................12 1.2.5 Declaration of conformity.................................................................................13 2 SAFETY AND ENVIRONMENT.................................................................................... 15 2.1 Safety messages and symbols.................................................................................. 15 2.1.1 Signal words................................................................................................... 15 2.1.2 Hazard symbols.............................................................................................. 15 2.1.3 Mandatory action symbols...............................................................................18 2.1.4 Prohibited action symbols............................................................................... 19 2.1.5 Safety and information labels on the product...................................................19 2.1.6 Location of the safety and information labels...................................................20 2.2 Responsibilities of the operational manager............................................................ 26 2.2.1 Preventing work-related hazards.....................................................................26 2.2.2 Personal protective equipment........................................................................ 26 2.2.3 Incident reporting............................................................................................ 27 2.3 Limitations of the product.......................................................................................... 27 2.3.1 Operating conditions....................................................................................... 27 2.3.2 Inclination angles............................................................................................ 27 2.3.3 Lift truck danger zones, general...................................................................... 29 2.3.4 Tire explosion danger zone............................................................................. 29 2.3.5 Prohibited use................................................................................................. 31 2.3.6 Changes to the product................................................................................... 31 2.4 Emissions.................................................................................................................... 32 2.4.1 Noise...............................................................................................................33 2.4.2 Vibration .........................................................................................................33 2.5 Protective measures................................................................................................... 34 2.5.1 Emergency stopping....................................................................................... 34 2.5.2 Battery main switch......................................................................................... 35 2.5.3 Releasing the hydraulic pressure ................................................................... 37 2.5.4 Fire safety....................................................................................................... 37 2.5.5 Emergency exits..............................................................................................38 2.5.6 Mounting, and dismounting the machine......................................................... 39 2.5.7 Locking the cabin door in open position.......................................................... 39 2.5.8 Personnel requirements.................................................................................. 40 2.6 Environmental information.........................................................................................41 2.6.1 Energy consumption....................................................................................... 41 2.6.2 Product lifecycle stages...................................................................................41 2.6.2.1 Production of materials and components.................................................... 42 2.6.2.2 Equipment manufacturing and assembly.....................................................42 2.6.2.3 Use phase, including maintenance and modernization................................43 2.6.2.4 Dismantling and handling waste material.................................................... 43 3/184 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Operating Instructions Table of contents 2.6.2.5 Deliveries between each stage....................................................................44 2.6.3 Notice on the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH)....................................................................................... 45 2.7 Storage information.................................................................................................... 45 2.7.1 Storage........................................................................................................... 45 2.7.2 Alternative storage, up to two months............................................................. 46 2.7.3 Alternative storage, longer than two months....................................................47 3 PRODUCT DESCRIPTION........................................................................................... 49 3.1 Technical description .................................................................................................49 3.2 Machine outline, forklift.............................................................................................. 51 3.3 Controls and indicators in cabin with lever control .................................................52 3.4 Controls and indicators in cabin with joystick (option)........................................... 53 3.5 Keypad.........................................................................................................................54 3.6 MD4 display................................................................................................................. 55 3.6.1 User interface..................................................................................................56 3.6.1.1 Introduction to MD4 pages.......................................................................... 56 3.6.2 MD4 display frame ......................................................................................... 56 3.6.3 MD4 pages......................................................................................................60 3.6.3.1 Start-up page.............................................................................................. 60 3.6.3.2 Home page (weight page)........................................................................... 61 3.6.3.3 Date and time page.....................................................................................62 3.6.3.4 ECO-driving page........................................................................................63 3.6.3.5 Operator page ............................................................................................64 3.6.3.6 Machine overview page...............................................................................65 3.6.3.7 Information page......................................................................................... 73 3.6.4 Preferences.....................................................................................................74 3.6.4.1 Setting the display backlight and screen saver............................................74 3.6.4.2 Setting the date...........................................................................................75 3.6.4.3 Setting the time........................................................................................... 75 3.7 Lifting loads.................................................................................................................76 3.7.1 Lifting capacity plate........................................................................................76 3.7.2 Maneuvering the mast with levers................................................................... 78 3.7.3 Maneuvering the mast with joystick (option).................................................... 79 3.7.4 Mast and attachment symbols.........................................................................80 4 OPERATING INSTRUCTIONS..................................................................................... 84 4.1 Daily maintenance before operation..........................................................................84 4.2 Daily maintenance checks .........................................................................................86 4.2.1 Turning on and turning off the battery main switch.......................................... 86 4.2.2 Checking the condition and pressure of the tires............................................. 88 4.2.3 Checking the engine oil level...........................................................................90 4.2.4 Checking the DANA transmission oil level ......................................................92 4.2.5 Checking the ZF transmission oil level............................................................ 93 4.2.6 Checking the coolant level, Volvo engines...................................................... 94 4.2.7 Checking the coolant level, Cummins..............................................................95 4.2.8 Checking the hydraulic oil level....................................................................... 96 4.2.9 Checking the brake cooling oil level (option)................................................... 97 4.2.10 Checking the engine air filter, Volvo engines .................................................. 97 4.2.11 Checking the windshield washer level............................................................. 98 4.2.12 Checking the fuel level.................................................................................... 99 4.2.13 Checking the AdBlue level............................................................................ 100 4.2.14 Check the soot level......................................................................................102 4.2.15 Adjusting the operator's seat......................................................................... 102 4.2.15.1 Adjusting the BE-GE operator's seat......................................................... 103 4.2.15.2 Adjusting the Isringhausen operator's seat................................................106 4/184 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Table of contents Operating Instructions 4.2.15.3 Adjusting the Grammer operator's seat..................................................... 107 4.2.16 Adjusting the steering wheel..........................................................................108 4.3 Hydraulic long life (HLL) filter (option).................................................................... 108 4.3.1 Placement of the hydraulic long life (HLL) filter............................................. 108 4.3.2 Checking the HLL filter.................................................................................. 109 4.4 Engine After-treatment System (EATS) - Volvo stage V......................................... 109 4.4.1 Selective catalyst reduction (SCR) - Volvo stage V........................................ 111 4.4.2 Diesel Particulate Filter (DPF) - Volvo stage V...............................................112 4.4.3 Parked regeneration - Volvo stage V............................................................. 113 4.5 Engine aftertreatment System - Cummins engines................................................ 115 4.5.1 Selective catalyst reduction (SCR) - Cummins engines................................. 116 4.5.2 Diesel Particulate Filter (DPF) - Cummins engines........................................118 4.5.3 Parked regeneration - Cummins engines.......................................................119 4.5.4 Diesel Oxidation Catalyst (DOC) - Cummins engines....................................121 4.6 Using the cabin heating and ventilation.................................................................. 122 4.7 Using the cabin ventilation (option).........................................................................123 4.8 Driver login (option).................................................................................................. 123 4.9 Changing the operator..............................................................................................124 4.10 Break-in period..........................................................................................................126 4.11 Steering and braking.................................................................................................126 4.11.1 Steering........................................................................................................ 126 4.11.2 Using the electrical mini-wheel steering (option)............................................127 4.11.3 Force neutral when braking...........................................................................130 4.11.4 Activating the declutch.................................................................................. 131 4.11.5 Activating the declutch, with pressure switch (option)....................................132 4.11.6 Activating the inching function (option).......................................................... 132 4.11.7 Parking..........................................................................................................133 4.11.8 Activating the parking brake.......................................................................... 134 4.11.9 Automatically applied parking brake (option)................................................. 134 4.11.10 Differential lock function (option)................................................................... 135 4.12 Sideways sliding cabin............................................................................................. 136 4.13 Using the 180° rotating seat (option)....................................................................... 139 4.14 Operating................................................................................................................... 141 4.14.1 Daily inspection before operation (option)..................................................... 141 4.14.2 Operating - general information.....................................................................141 4.14.3 Starting the engine ....................................................................................... 142 4.14.4 Starting the engine, with RFID tag (option)....................................................144 4.14.5 Stopping the engine...................................................................................... 145 4.14.6 Stopping the engine, with RFID tag (option).................................................. 146 4.14.7 Operating the machine ................................................................................. 148 4.14.8 Driving forwards............................................................................................ 150 4.14.9 Stopping the machine....................................................................................152 4.14.10 Driving in reverse ......................................................................................... 154 4.15 Mounting the attachment - ELME 815......................................................................156 4.15.1 Parts of the attachment................................................................................. 156 4.15.2 Mounting the attachment - forks in standard position.................................... 156 4.15.3 Mounting the attachment - forks in inverted position......................................158 4.15.4 Connecting the hydraulic quick couplings......................................................159 4.15.5 Connecting the electric contact..................................................................... 160 4.16 Lifting and driving with a load..................................................................................161 4.16.1 Lifting a load..................................................................................................161 4.16.2 Transporting a load....................................................................................... 163 4.16.3 Unloading a load........................................................................................... 165 4.17 Emergency lowering, general...................................................................................167 5/184 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Operating Instructions Table of contents 4.17.1 Emergency lowering for SMV 10-16 - L90 main valve................................... 167 4.17.2 Emergency lowering for SMV 18-60 - K220/L90 main valve..........................168 4.18 Towing........................................................................................................................169 APPENDIX I: FUEL AND OIL RECOMMENDATIONS........................................................... 171 Quality of the engine oil...............................................................................................171 Extended oil change interval....................................................................................... 172 Recommended fluids and lubricants............................................................................172 APPENDIX II: FUSES AND RELAYS..................................................................................... 177 Fuses.......................................................................................................................... 177 Relays.........................................................................................................................182 6/184 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. 1 Introduction Operating Instructions 1 INTRODUCTION 1.1 About this document This operating instruction offers guidance to enable safe and efficient operation of the equipment. Taking the time to read this document helps to prevent damage to the equipment, and, most importantly, keep the personnel safe. The equipment is safe when used correctly. However, there are many potential hazards that are associated with incorrect operation. These hazards can be avoided with knowledge about how to recognize and anticipate them. This document increases the awareness of the responsibilities regarding the equipment. Following the content of this document will ensure that the equipment is kept in a safe operating condition throughout its lifetime. This document is not intended as a substitute for proper training but provides recommendations and methods for safe and efficient operation and maintenance. The operational manager must ensure that operators are properly trained before operation. They must always comply with all the applicable and prevailing safety, as well as other standards, rules, and regulations. 1.1.1 Use of the document Every person that is exposed to the equipment must, before operating, servicing and maintaining such products, read, and understand the contents of this document. Also to strictly adhere and conform their conduct with and to the information, recommendations, and warnings that are provided in this document. NOTE Keep the operating instructions in the cabin of the machine for future reference. WARNING IGNORING INSTRUCTIONS HAZARD Failure to follow the given instructions could cause death or serious injury. Read and understand the contents of this document before operating, servicing, and maintaining the equipment. The manufacturer makes absolutely no warranty whatsoever regarding the contents of this document, express or implied, whether arising by operation of law or otherwise. This includes, but are not limited to, any implied warranties of merchantability or fitness for a particular purpose. 1.1.2 Terminology All brand names, product names, and trademarks that are used in this document are registered trademarks of their respective owners. The following terms and definitions may have been used in this document: 7/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 1 Introduction Authorized dealer Company, or person authorized by Konecranes Lifttrucks AB to carry out service actions, and represent the manufacturer. Authorized Persons who have the necessary training and who are authorized by personnel Konecranes Lifttrucks AB or their representative to carry out operation, or service actions. Manufacturer Refers to Konecranes Lifttrucks AB, or supplier of part when otherwise specificed. Operational Person, or persons, with different areas of responsibility at the working manager site where the machine is used. The areas of responsibility include, but are not limited to risk assessments, daily operations and maintenance tasks. Battery A compartment containing the 24V batteries and fuses, which are compartment found on the right side of the machine. CE marking The CE marking of the machine is displayed on the lifting capacity plate. The symbol indicates that the machine complies with the appropriate CE regulations. Check A visual and functional assessment (not a test) of the machine without dismantling it. Touch screen A touch screen where the user receives information, and enter display commands by touching designated areas on the screen. TRUCONNECT® TRUCONNECT® is a suite of remote service products and applications to support maintenance operations and drive improvements in safety and productivity. The collected data from the machines can be viewed at yourKONECRANES customer portal. 1.1.3 Abbreviations The following abbreviations and shortenings can occur in this document: Abbreviation Description Abbreviation Description Automated determination of the filling paramaters AEB LV Low Voltage (Automatisiertes Ermitteln der Befüllparameter) COG Center Of Gravity NCD Nox Control Diagnostics DEF Diesel Exhaust Fluid PCB Printed Circuit Board DOC Diesel Oxidation Catalyst PCD Particle Control Diagnostics Personal Protective DPF Diesel Particulate Filter PPE Equipment Engine After-treatment EATS PPS Power Pile Slope System Radio Frequency ECM Engine Control Module RFID Identification Electric Magnetic EMC SCR Selective Catalyst Reduction Compatibility FGO Function Group Output SWL Safe Working Load 8/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 1 Introduction Operating Instructions Abbreviation Description Abbreviation Description Tire Pressure Monitoring HLL Hydraulic Long-Life TPMS System Heating, ventilation, and air HVAC ULSD Ultra-Low Sulphur Diesel conditioning International Organization for ISO VCU Vehicle Control Unit Standardization LC Load Center 1.1.4 Copyright notice This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Konecranes © 2024. All rights reserved. 1.1.5 Available technical documents For this equipment, there are technical documents that serve different purposes and audiences. Contact your supplier if you require any of the documents that are listed here. Operating instructions Describes the responsibilities of the operator and the operating instructions, along with some mandatory daily maintenance tasks and safety information. The operating instruction must be stored in the cabin of the truck. Maintenance instructions Describes maintenance tasks such as lubrication and oil change and the recommended safety instructions. Technical instructions Describes in greater detail the hydraulic and electrical systems, vehicle control unit, and other components of the machine and its software. Spare part catalogue Includes part numbers of all components for the supplied parts, drawings, and exploded views. Supplier documentation Describes components that are assembled on the machine, and provided by approved suppliers to the manufacturer. This includes component-specific documents, for example, for installation, operation, and maintenance. NOTE Store documents in a safe, dry place where they can be easily located when required. 1.1.6 Feedback on documents As the goal is constant improvement, this document may be updated or revised to provide operational managers and operators with the most accurate information currently available. Current versions of instructions can be found at document portal www.kclifttrucks.com. To communicate any inaccuracies or omissions, or to provide general feedback or suggestions regarding the quality of this document, send an email to [email protected]. 1.2 About this product 1.2.1 Use of the product The machine is designed to perform lifting and transporting of loads within the limits that are specified in the machine's lifting capacity plate. For more information, see Lifting capacity plate (page 76) in front of the left side cabin door. 9/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 1 Introduction Contact the manufacturer or manufacturer's representative in case of doubt. 1.2.2 Conditions of warranty The terms under which seller's equipment and/or services are warranted are defined pursuant to the warranty set forth in the contract between seller and customer for seller's products and/or services and, if not so set forth, the warranty for seller's products and/or services is seller's standard warranty in effect at the time of sale, a copy of which is available from seller upon request. THE FOREGOING REPRESENTS THE SOLE AND EXCLUSIVE WARRANTY GIVEN BY SELLER AND IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, ARISING BY OPERATION OF LAW OR OTHERWISE, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Seller provides no warranties for products manufactured or services provided by parties other than seller ("Third Party Products"). Third Party Products may be warranted separately by their respective manufacturers or such other parties from whom seller purchases such Third Party Products and seller shall, to the extent possible, assign to you whatever rights seller may obtain under any such warranties. Modifying any seller product or incorporating any Third Party Product into any seller product or service without the seller's approval invalidates the warranty. Seller does not accept, shall not have any responsibility and disclaims any liability for accidents, injury or physical or property damage arising as a consequence of such unauthorized modifications and/or incorporation of Third Party Products. Further, each of the following invalidates any warranty of seller and relieves seller from any responsibility to repair or replace any seller product due to a failure to operate and/or maintain seller products in accordance with the applicable manuals, instructions, guides, recommendations, and any other manuals, guidelines or recommendations of seller concerning the maintenance and operation of seller products that may be communicated to you from time to time; damage or defects caused by side-pulling of load, shock loading, excessive jogging, eccentric loading or overloading, accidental occurrence, improper repair, improper handling or storage of products, chemical exposure, abnormal operating conditions, or any other cause that in seller's sole discretion is not attributable to defects in the material and workmanship of seller’s product. The applicable seller manuals, instructions, guidelines, and recommendations must be strictly complied with by customer which may include, by way of example and not by limitation, installation and commissioning instructions, owner's manuals, operator's/user’s manuals, operating and maintenance instructions and user's guides. SELLER SHALL HAVE NO LIABILITY TO YOU OR ANY END USER OF PRODUCTS FOR LOST PROFITS OR FOR INDIRECT, SPECIAL, CONSEQUENTIAL, EXEMPLARY OR INCIDENTAL DAMAGES OF ANY KIND WHETHER ARISING IN, CONTRACT, TORT, PRODUCT LIABILITY, STRICT LIABILITY OR OTHERWISE, EVEN IF SELLER WAS ADVISED OF THE POSSIBILITY OF SUCH LOST PROFITS OR DAMAGES. SELLER’S LIABILITY IS LIMITED TO THE AMOUNT OF YOUR DIRECT DAMAGES UP TO THE AMOUNT OF THE CONTRACT PRICE AND IN NO EVENT SHALL SELLER BE LIABLE TO YOU FOR ANY DAMAGES WHATSOEVER IN EXCESS OF THE TOTAL PRICE PAID BY YOU FOR THE APPLICABLE SELLER PRODUCTS. YOU HEREBY WAIVE ANY CLAIM THAT THE EXCLUSIONS OR LIMITATIONS IDENTIFIED HEREIN DEPRIVE YOU OF AN ADEQUATE REMEDY OR CAUSES YOUR AGREEMENT WITH SELLER TO FAIL OF ITS ESSENTIAL PURPOSE. YOU SHALL BE ENTITLED TO NO OTHER REMEDY OTHER THAN THOSE IDENTIFIED IN THE CONTRACT BETWEEN YOU AND SELLER OR SELLER’S STANDARD WARRANTY, WHICHEVER IS APPLICABLE, WITH RESPECT TO THE PROVISION OF PRODUCTS BY SELLER REGARDLESS OF THE FORM OF CLAIM OR CAUSE OF ACTION, WHETHER BASED IN AGREEMENT, NEGLIGENCE, STRICT LIABILITY OR OTHERWISE. UNLESS OTHERWISE REQUIRED BY MANDATORY LAW, SELLER DISCLAIMS ALL WARRANTIES RELATING TO THE CONTENTS OF THIS DOCUMENT, EXPRESS OR IMPLIED, ARISING BY OPERATION OF LAW OR OTHERWISE. 10/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 1 Introduction Operating Instructions 1.2.3 Identification of the product 1 2 3 4 5 6 7 8 Figure 1. Plates and serial numbers 1. Mast serial number 6. Transmission serial number 2. Lifting capacity plate 7. Engine serial number 3. Fork carriage number 8. Steer axle serial number 4. Drive axle serial number 5. Chassis serial number (punched into the frame) NOTE The appearance may deviate from the delivered product depending on model size. 11/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 1 Introduction 1.2.4 Standards and directives This product has been designed and manufactured to conform to the following standards and directives: • Health and safety: EU: Machinery directive 2006/42/EC UK: Supply of Machinery (Safety) Regulations 2008 S.I. 2008:1597 ◦ EN ISO 3691-1:2015/A1:2020. "Industrial trucks – Safety requirements and verification - Part 1: Self-propelled industrial trucks, other than driverless trucks, variable-reach trucks, and burden-carrier trucks". ◦ ISO/TS 3691-8:2012,IDT. Industrial trucks – Safety requirements and verification. Regional requirements for countries outside the EC. ◦ EN 16307-1:2013+A1:2015. "Safety requirements and verification. Supplementary requirements for self-propelled industrial trucks, other than driverless trucks, variable-reach trucks, and burden-carrier trucks" (EU/EFTA market). ◦ EN 13059+A1:2008. "Safety of industrial trucks. Test methods for measuring vibration" (EU/EFTA market). ◦ EN 12053+A1: 2008. "Safety of industrial trucks. Test methods for noise emission" (EU/ EFTA market). ◦ EN 1175-2+A1:2010 “Safety of industrial trucks – Electrical Requirements - Part 2: General requirements of internal combustion engine powered trucks“. • EMC: EU: 2014/30/EU UK: Electromagnetic Compatibility Regulations 2016 S.I. 2016:1091 ◦ EN 12895:2015+A1:2019. Industrial trucks - Electromagnetic compatibility. • Emissions: EU: 2016/1628/EC (EU/EFTA market, stage 4, and 5 engines). UK: The Non-Road Mobile Machinery (Type-Approval and Emission of Gaseous and Particulate Pollutants) Regulations 2018 2018 No. 764 • 2016/1628/EU “REGULATION (EU) 2016/1628 OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 14 September 2016 on requirements relating to gaseous and particulate pollutant emission limits and type-approval for internal combustion engines for non-road mobile machinery, amending Regulations (EU) No 1024/2012 and (EU) No 167/2013, and amending and repealing Directive 97/68/EC" Declaration of conformity and other certificates are included in the delivery package. Manufacturer reserves the right to modify the design and material specifications without NOTE prior notice. Applicable sections of EN13155 are used for all lifting ears on the machine. 12/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 1 Introduction Operating Instructions 1.2.5 Declaration of conformity EC DECLARATION OF CONFORMITY OF THE MACHINERY (Machinery Directive 2006/42/EC, Annex II, sub. A) Manufacturer: Konecranes Lifttrucks AB Anders Anderssons väg 13, P.O. Box 103 SE-28523 MARKARYD SE Name and address of the person authorised to compile the technical file: XXXXX XXXXX Anders Anderssons väg 13, P.O. Box 103 SE-28523 MARKARYD SE The manufacturer declares that Description: Forklift Model: XXXXX Serial number: XXXXX • Is in conformity with the relevant provisions of the DIRECTIVES OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL: - of May 17, 2006, "relating to machinery" 2006/42/EC - of February 26, 2014, "relating to electromagnetic compatibility" 2014/30/EU - Directive 2000/14/EC as amended by Directive 2005/88/EC on the noise emission in the environment by equipment for use outdoors and fulfils the requirements of the following harmonised standards: • regarding Machinery Directive: EN ISO 3691-1 • regarding EMC Directive: EN 12895 Place and date of issue MARKARYD DD.MM.YYYY Signature: Anders Nilsson Technical Director Konecranes Lift trucks Figure 2. EC Declaration of conformity of the machinery (template) 13/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 1 Introduction UK DECLARATION OF CONFORMITY OF THE MACHINERY (Supply of Machinery (Safety) Regulations 2008, Annex II, sub. A) Manufacturer: Konecranes Lifttrucks AB Anders Anderssons väg 13, P.O. Box 103 SE-28523 MARKARYD SE Name and address of the person authorised to compile the technical file: XXXXX XXXXX Coalfield Way LE65 1NF Ashby De La Zouch UK The manufacturer declares that Description: Forklift Model: XXXXX Serial number: XXXXX • is in conformity with the relevant provisions of statutory instruments - Supply of Machinery (Safety) Regulations 2008 No.1597 - Electromagnetic Compatibility Regulations 2016 No.1091 - Noise emission in the environment by Equipment for use Outdoors Regulations 2001 No.1071 and fulfils the requirements of the following designated standards: • regarding 2008 No. 1597: EN ISO 3691-1 • regarding 2016 No. 1091: EN 12895 Place and date of issue MARKARYD DD.MM.YYYY Signature: Anders Nilsson Technical Director Konecranes Lift trucks Figure 3. UK Declaration of conformity of the machinery (template) 14/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions 2 SAFETY AND ENVIRONMENT 2.1 Safety messages and symbols 2.1.1 Signal words The following signal words and symbols are used to identify safety messages in these instructions. Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation that, if not avoided, could result in damage to property or environment. 2.1.2 Hazard symbols Hazard symbols are used to indicate the type of the hazard and the potential consequences. Hazard symbols are indicated by a yellow triangle with black symbols and a black triangle band. All personnel working on or in proximity of the machine must understand and follow the information that is given in all hazard symbols. General hazard symbol General hazard The general hazard symbol identifies important safety messages in this document. When you see this symbol, carefully read and understand the message that follows, and inform other users when necessary. 15/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment Mechanical hazard symbols Moving vehicle Sideways tipping Forward or backward Run over hazard hazard hazard tipping hazard Moving parts hazard Falling load hazard Slipping hazard Hanging load hazard Crushing hazard Crushing hand Flying objects to face Flying objects hazard hazard hazard Skin injection hazard Electrical hazard symbols Electrical hazard Material hazard symbols Hot liquid hazard Explosion hazard Harmful substance High-pressure hazard hazard Ignition hazard Corrosive chemical Pressurized gas Hazardous or substance hazard hazard poisonous material hazard 16/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions Thermal hazard symbols Hot surface hazard Slippery when frozen hazard Noise hazard symbols Noise hazard Laser hazard symbols Laser hazard Ergonomic hazard symbols Lifting hazard 17/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment 2.1.3 Mandatory action symbols Mandatory action symbols specify actions to be taken to avoid a hazard. Mandatory actions are indicated by blue circle with white symbols. All personnel working on or in proximity of the machine must understand and follow the information that is given in all mandatory action symbols. Wear approved safety Wear approved Wear approved Wear approved safety gloves hearing protectors protective clothing shoes Wear approved safety Wear approved hard Wear approved high Wear approved eye harness hat visibility clothing protector Disconnect Apply indicator for Use jack Alarm horn equipment from pin-hole leak test power source Read instructions Two persons for Wear approved Use seat belt handling respirator 18/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions 2.1.4 Prohibited action symbols Prohibited action symbols indicate actions that are prohibited in order to avoid a hazard. Prohibited actions are indicated by a red circle with a red diagonal line across the circle. The action that is prohibited is always in black. All personnel working on or in proximity of the machine must understand and follow the information that is given in all prohibited action symbols. General prohibition Do not walk or stand Do not weld No open fire here Do not smoke Do not modify Do not test for leak Do not touch with hands Restrict access 2.1.5 Safety and information labels on the product The safety and information labels communicate the following: • Level of risk that is based on the signal word Danger, Warning, or Notice • Type of hazard, such as cutting parts, hanging load, hot surface, live parts • Consequence of hazard, such as cutting, injection, crushing, burn, electric shock • How to avoid the hazard Always keep safety and information labels visible, and check the condition of the labels daily. Before operating the machine, replace labels that are damaged, have come loose, NOTE or do not meet the readability requirements for safe viewing distance. New safety and information labels can be ordered from the manufacturer of the machine. 19/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment 2.1.6 Location of the safety and information labels 1 5 6 7 4 8 10 3 1 9 1 12 2 26 25 11 12 1 13 13 21 20 19 18 15 14 22 16 23 17 24 Figure 4. Location of the safety and information labels 1. Lifting point 14. Accumulator pressure 2. Engine oil 15. Hydraulic oil 3. Transmission oil 16. Diesel fuel 4. Fuses and relays, PCB 17. Brake cooling oil 5. Emergency exit only 18. Do not step here 6. Seat belt 19. Remove pressure before demounting tire 7. In case of rollover 20. Read operating instructions first 8. Working zone 21. Battery main switch 9. Crush injury risk 22. Cab tilting 10. Injection hazard 23. Fuses and relays, battery compartment 11. Do not stand under or on lifted load 24. Warning-Acid and explosion risk 12. Tire pressure 10 bar (1.0 MPa)*) 25. Crushing risk by tire 13. Tie down point when transporting the 26. Machine working zone machine *) Sign present above all tires. 20/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions Table 1. Labels 1. Lifting point 2. Engine oil 3. Transmission oil 4. Fuses and relays, PCB 5. Emergency exit only 21/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment Table 1. Labels (Continued) 6. Seat belt 7. In case of rollover This sticker shows what the operator must do in case of rollover. Do not jump out of the cabin in case of rollover. Brace feet against the floor and hold on tightly to the steering wheel. Climb out of the machine when it has stopped moving. 8. Working zone 9. Crush injury risk 22/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions Table 1. Labels (Continued) 10. Injection hazard 11. Do not stand under or on lifted load. 12. Tire pressure 10 bar (1.0 MPa) 13. Tie down point for loading the machine for transport Secure the machine here when loading it for transport. 14. Accumulator pressure Warning, read instructions in the manual. 23/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment Table 1. Labels (Continued) 15. Hydraulic oil 16. Diesel fuel 17. Brake cooling oil 18. Do not step here 19. Remove pressure before demounting tire 20. Warning - Read operating instructions first 21. Battery main switch 24/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions Table 1. Labels (Continued) 1 2 22. Cab tilting 23. Fuses and relays, battery compartment 24. Warning - Acid and explosion risk 25. Crushing risk by tire 26. Machine working zone 25/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment 2.2 Responsibilities of the operational manager 2.2.1 Preventing work-related hazards The operational manager must ensure that operators, and maintenance personnel have sufficient knowledge of the work-related hazards, and the ways to avoid the hazards. The operational manager must ensure to inform the operator that a local risk assessment always must be performed before every work phase or shift. The assessment ensures that the operator stops and thinks about what to do before starting to work. • Identify potential hazards that could affect the operator, other personnel, the environment, the product, or work methods while performing the task • Assess the risks and implement the actions that are required to eliminate or reduce the risks Only personnel with sufficient competence are allowed to operate the machine, and carry out other tasks on the machine. The responsibilities of the operational manager are, for example, to: • Provide training and orientation. • Validate training methods. • Verify competence and skills. • Monitor and evaluate user performance regularly. • Provide fire-fighting equipment. • Make sure that the working site has guidelines on how to prevent fires. • Make sure that the working site has guidelines to follow concerning fire-fighting. • Make sure that the working site has guidelines on how to operate the machine during strong wind. • Make sure that the instructions from Konecranes Lift Trucks are accessible and up to date. • Make a risk assessment of the work site, for example, regarding height limitations, door openings, overhead powerlines, and ground conditions. • Make sure that the work site follows all local rules and regulations. 2.2.2 Personal protective equipment For safety, all personnel working in or near the machine are required to wear personal NOTE protective equipment (PPE). This section proposes personal protective equipment to ensure the safety of all personnel working in or near the machine. Follow the local regulations and requirements NOTE of the working environment. Use only approved and accepted personal protective equipment. Operators and anyone near and around the product must wear the following items: • Safety shoes • High-visibility clothing Various types of PPE are available as listed, depending on the situation, other types of PPE than listed can be required. It is the responsibility of the operational manager to make sure that all local PPE requirements are followed. • Hard hat • Eye protection • Ear protection • Respirator • Safety gloves • Protective clothing • Safety harness when working at heights 26/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions Do not wear loose clothing or jewelry that can get caught on controls or pulled into moving parts of the product. Do not wear jewelry or metal accessories such as watches when working with or near the electrical system or the batteries. Tie back long hair. Long hair can get entangled. Select the appropriate clothing for each task, for example: • Wear fire-resistant clothing when welding, flame cutting, or using an angle grinder. • Tear-resistant clothing must resist damage from sharp edges in the steel structure. • Wear anti-static clothing when working on electrical circuits so that components do not get damaged by a discharge of static electricity. • Always use safety goggles when working with high voltage or pressurized fluids. • When working with lubricants, clothing must prevent direct skin contact with the lubricant. • Choose clothing with consideration to the temperature at the working site, and stay hydrated. 2.2.3 Incident reporting Product safety issues that you must report are events in which the manufacturer's product has been involved in an accident or near-miss incident. Contact your local manufacturer's representative immediately to report any safety-related feedback, such as unauthorized modifications, missing instructions and safety labels, neglected maintenance, or misuse. Reporting is mandatory to ensure safe working conditions for employees, to provide information for the risk assessment process, and to initiate product and work procedure improvements. 2.3 Limitations of the product 2.3.1 Operating conditions Thunderstorm When in danger of being struck by lightning, operating or being close to the machine is strongly discouraged. Protection from lightning during work must be managed by the workplace risk assessment that is made by the operational manager. Following a lightning strike (or if you suspect the machine has been struck) the machine must be checked by authorized personnel. The check must follow the instructions of the daily maintenance. Surfaces Do not operate the machine on uneven surfaces or in unstable conditions. NOTE Do not drive on slopes that are greater than 15%. 2.3.2 Inclination angles WARNING TIPPING AND COLLISION HAZARD If you drive on slopes greater than 15%, the parking brake may fail and risk of tipping increases considerably. Risk of serious personal injury and damage to the machine. Do not drive on slopes greater than 15%. 27/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment WARNING RISK OF LOAD DROP Driving downhill on slopes carrying a load, can lead to a load drop. This can damage the machine and can lead to serious personal injury. If carrying a load, always drive downhill in reverse. If you must drive the machine along greater slopes, contact your Konecranes Lift Trucks NOTE authorized dealer. NOTE Do not drive on slopes that are greater than 15%. Figure 5. Do not drive on slopes greater than 15% 28/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions 2.3.3 Lift truck danger zones, general DANGER MOVING MACHINERY HAZARD The moving machine and its moving parts can cause death or serious injury. While the machine operates, unauthorized personnel should never enter or be within the danger zone. During operation, the authorized personnel working within the danger zone and the operator must constantly communicate verbally or visually to stay aware of each other. The following images show the danger zones surrounding the machine and its parts. 15 m/16 yd Figure 6. General danger zone 2.3.4 Tire explosion danger zone DANGER HIGH-PRESSURE HAZARD The tires may explode when you inflate or deflate them, or in case of fire. Standing inside the tire explosion danger zone during a tire explosion can cause death or serious injury. Always stand to the side of the wheel when deflating or inflating tires, see "tire explosion danger zone" illustration. Use safety glasses. The tire explosion danger zone follows the positioning of the wheels. The illustration NOTE applies when the wheels are in line with the machine. 29/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment 120° 120° 50 yd m/ 55 55 m/ yd 50 50 d 5y m/5 m/5 5y 50 d 120° 120° Figure 7. Tire explosion danger zones 30/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions 2.3.5 Prohibited use WARNING MACHINE MALFUNCTION HAZARD Using the machine outside the limits of its capacity or operating conditions could cause malfunction of the equipment. Unauthorized usage could lead to death, severe injury, or property damage. Do not use the machine outside the limits of its capacity or operating conditions. The misuse of the equipment includes, but is not limited to: • Lifting or transporting people. • Driving with the load above transport position. • Driving with heavy loads in slings. • Driving with swinging load. • Having passengers in the cabin 1) • Driving on uneven terrain • Exceeding the load limit, which is shown on the lifting capacity plate • Adding extra counterweights • Driving uphill and downhill on slopes with an inclination over 15%. • Using tools that are not approved by the manufacturer. • Using the low-voltage battery switch when the machine is in motion. • Overriding any safety systems. • Using the emergency stop in a none emergency situation. NOTE Only use the emergency stop in an emergency situation. 1) If a truck is equipped with an optional trainer's seat, another person is allowed to sit there, as long as the person uses the seat belt. For more information, see the lifting capacity plate of the machine, and, if applicable, lifting capacity plates on attachments. Contact the manufacturer or the representative for the manufacturer if there are any doubts. 2.3.6 Changes to the product DANGER MACHINE MALFUNCTION HAZARD Unauthorized changes, or modifications to the product can lead to death, severe injury, or property damage. Always contact Konecranes Lift Trucks, or an authorized representative to get a written approval in advance for any product change or modification. 31/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment DANGER MACHINE MALFUNCTION HAZARD Changes, and modifications without proper risk assessment, can lead to death, or serious personal injuries. It can also damage property, or the environment. Unauthorized modifications void the warranty and responsibility of the manufacturer. Perform a risk assessment, which eliminates, or reduces risks, and considers appropriate safety measures. WARNING MACHINE MISUSE HAZARD Adding and using equipment that is not supplied with the machine, can cause the products to malfunction. Risk of serious personal injury and damage to the machine. If using equipment that was not supplied with the machine, an authorized dealer must approve the combination and use of the equipment. The authorized dealer must ensure that safe operations can be guaranteed concerning lifting capacity, stability, and visibility. WARNING MACHINE NON-COMPLIANCE Replacing components with non-genuine components, or components not authorized by Konecranes Lift Trucks, can affect the safety of the machine. This is considered as a modification of the machine and therefore voids the liability of Konecranes as a manufacturer. The party that performed the modification will thereafter legally be liable for the safety of the modified machine, and the related CE marking. For any clarification always contact your authorised Konecranes Lift Trucks representative. All modifications and corrections that are not authorized in the product documents or which may affect the maintenance, operation, safety, and availability of the product must be approved in writing by Konecranes Lift Trucks before implementation. Approval requires a risk assessment which consider any new risks that the changes and modifications may bring. All safety and information labels on the machine, must be updated to match the machine after any modifications. To avoid using obsolete spare parts, always check the specific spare parts catalogue for the machine. For the latest version, contact Konecranes Lift Trucks spare parts department. If a modification or correction has been implemented without the permission from Konecranes Lift Trucks, its effect on warranty liability is considered case-by-case. Thus, the warranty application may be rejected altogether. If a modification, or alteration is considered necessary, contact an authorized dealer, or the organization that manufactured, and designed the product. No modification is permitted, unless the written approval from the manufacturer is obtained. 2.4 Emissions The noise and vibration levels are checked according to industry standards. This is to make sure that the operator's have a healthy environment while operating the machine. 32/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions 2.4.1 Noise Measured sound levels WARNING NOISE HAZARD Continuous exposure to noise above 80 dB(A) can cause hearing impairment, and make the operator tired and unfocused. Wear approved hearing protectors. The noise values were measured according to the harmonized standard EN12053 – A1:2008, following the conditions described therein, by a notified body. The noise values are reported according to ISO4871:2009. The specified equipment has been assessed in accordance with Directive 2000/14/EC (amended by Directive 2005/88/EC), annex VI by notified body 0404, RISE SMP Svensk Maskinprovning AB (The Swedish Machinery Testing Institute). Declared dual-number noise emission values In accordance with ISO4871:2009 Lift mode Idle mode Drive mode Total Time proportion factors of the operating cycle (%) - 0.18 0.58 0.24 1 ref. EN12053+A1:2008 A-weighted emission sound pressure level 75 74 76 76 at the operator position LpAZ (dB) Uncertainty (dB) 1 1 1 1 C-weighted peak emission sound < 130 < 130 < 130 < 130 pressure level Measured sound power level in an 102 operational cycle (A- weighted) Guaranteed sound power level in an 104 operational cycle (A- weighted) Measured on 16-33 ton forklifts, for other sizes, the values may vary slightly. Where the time proportion factors are used in defining the operational cycle, they are as defined in EN12053+A1:2008. 2.4.2 Vibration The whole-body vibration has been measured according to the harmonized standard EN13059:2008, following the conditions described therein, by a notified body. • Measured whole body vibration: below 0.9 m/s₂ • Overall uncertainty of the measurement: 1 m/s₂ 33/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment The reported expanded uncertainty is based on a standard uncertainty that is multiplied by a coverage factor K = 2. For a normal distribution, this value provides a level of confidence of approx. 95%. The standard uncertainty has been determined in accordance with EA publication EA-4/16/2003. 2.5 Protective measures 2.5.1 Emergency stopping DANGER UNCONTROLLED MOVEMENT HAZARD If the machine moves unexpectedly, it could result in personal injury, death, or damage to the equipment. To stop any unexpected movement, press the emergency stop button. WARNING FORWARD TIPPING HAZARD If the emergency stop is used when the machine moves, the machine may tip over. Risk of serious personal injury and damage to the machine. Only use the emergency stop in an emergency. Do not operate the equipment without knowing the location of the emergency stop NOTE buttons. After the emergency stop button (1) is pressed, all functions are cut out, the parking brake is activated and the engine stops. In normal operation, do not use the emergency stop button to stop the machine. Instead, use the brake pedal. Only use the emergency stop button in an emergency situation. Routinely using the NOTE emergency stop button increases wear on the product and can cause a breakdown. After each time the emergency stop is used, a daily maintenance must be performed to check the overall function of the machine. If the machine moves when pressing the emergency button, the condition of the parking brake disc and pads must also be checked. Contact authorized service personnel for the check-up. Figure 8. Emergency stop inside the cabin 34/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions Emergency stop on the outside of the machine 1 2.5.2 Battery main switch DANGER EXPLOSION HAZARD Short-circuiting the battery may cause a fire or explosion, which can cause a risk of serious injury or death. To reduce the risks of fire, explosion, electric shock and personal injury, always remove jewelry and conductive material before working on the electrical system. DANGER EXPLOSION HAZARD Batteries generate explosive hydrogen when charged, which can cause a risk of serious injury or death. Always use the necessary protective equipment. Ensure that there is good ventilation and avoid sparking. 35/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment DANGER ELECTRIC SHOCK HAZARD If the engine is on, there may still be voltage present in some parts, even when the battery main switch is turned off. The main switch does not cut the power from the alternator. This causes a risk of electric shocks, which can lead to death or serious personal injury. To reduce the risks of electric shock and personal injury always remove jewelry and conductive material before working on the electrical system. Always disconnect the ground (minus) cable at the battery when working near or on the alternator. Be aware of the battery main switch functionality. WARNING TIPPING OVER HAZARD If the battery main switch is turned off when the machine moves, the parking brake is activated. The machine may tip over, causing a risk of serious personal injury and damage to the machine. Unless there is an emergency situation, do not turn off the battery main switch when the engine runs. NOTE Do not operate the machine without knowing the location of the battery main switch (1). If the machine has an engine that uses diesel exhaust fluid (DEF) solution (for example AdBlue), turn off the engine, but do not turn off the battery main switch. Wait for the DEF NOTE pump to finish pumping back all the fluid from the hoses to the DEF tank before turning off the battery main switch (1). The required time varies slightly between different engine models. NOTE Remove the main switch handle when parking the machine. The battery main switch is found on the right-hand side of the machine, near the battery compartment. The machine can only be operated when the power is turned on. 1 Figure 9. Battery main switch 36/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions 2.5.3 Releasing the hydraulic pressure WARNING HIGH-PRESSURE HAZARD The hydraulic system contains hydraulic accumulators to maintain the brake function during a possible engine failure. Risk of serious personal injury. Do not stand close to the engine or transmission when the engine runs. Never loosen any hydraulic hoses. Only authorized maintenance personnel are permitted to loosen any hydraulic hoses. For more information about how to release the hydraulic pressure, see the Maintenance NOTE instructions. 2.5.4 Fire safety DANGER FIRE AND EXPLOSION HAZARD Ignition sources together with combustible materials can cause fire. If these risks are not avoided, they could lead to death or severe injury. Smoking, open flames, and sparks are examples of ignition sources. Fuel is an example of combustible material. Ignition sources are prohibited near the machine. During maintenance, follow appropriate fire prevention and protection measures. Measures include but are not limited to trained personnel and proper fire extinguishing equipment. Before starting any maintenance or repairs that require ignition sources, carry out a proper risk assessment to control the risk. 120° 120° 50 yd m/ 55 55 m/ yd 50 50 d 5y m/5 m/5 5y 50 d 120° 120° In case of fire, approach the machine from the front or the back. If possible, always avoid NOTE the tire explosion danger zones. 37/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment • Smoking and open fire are prohibited near the product. • Access to all fire-fighting equipment must be granted always, especially during maintenance and repair works. Fire-fighting equipment is not a standard part of the machine. It is the responsibility of NOTE the operational manager to make sure that fire-fighting equipment is available. • All fire-fighting equipment must be inspected and serviced regularly, according to local regulations. • Damaged fire-fighting equipment and used fire extinguishers must be replaced immediately. • Know the various types of fires and the appropriate fire-fighting methods. Various fires must not be extinguished with water. Special extinguishing agents, dry powders, or deoxygenating agents are required. • It is the responsibility of the operational manager to make sure that the working site has guidelines to follow concerning fire-fighting. • All personnel must be aware of the guidelines and trained regularly in fire-fighting methods. It is strongly suggested that guidelines, and training is performed in cooperation with NOTE local authorities, and rescue organizations. 2.5.5 Emergency exits The cabin door on the left-hand side is the main emergency exit. If the left-hand side door is blocked, use the right-hand side door. If both the left and right doors are blocked, use the emergency hammer (option) to smash the rear window to exit the cabin. Using the emergency hammer (Option) 1. Pull the emergency hammer from its mounting above the rear window. WARNING FLYING OBJECTS TO FACE HAZARD Breaking glass may fly into your face and eyes. Shield your eyes and face with your other arm while breaking the window with the hammer. 2. Smash the rear window with the hammer. 3. Use the hammer to scrape the remaining glass. 4. Exit the cabin through the rear window. 38/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions 2.5.6 Mounting, and dismounting the machine WARNING SLIPPING HAZARD Failing to maintain three points of contact can cause serious injury or death. Maintain three points of contact when mounting, or dismounting the machine. Three points of contact are either two hands, and one foot, or two feet, and one hand. NOTE Climb on and off only when the machine is stationary. NOTE Do not jump from the steps to the ground. Following this procedure reduces the risk of falling, and decreases wear on back, and NOTE knees. 1. Face the steps, when mounting, or dismounting the machine. The cabin entrance is on the left side of the machine. 2. Maintain three points of contact until reaching the cabin, or ground. 2.5.7 Locking the cabin door in open position 1. To fasten the cabin door in open position, open the cabin door and push it into the lock. 39/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment 2. To unlock the door from open position, press the handle on the inside of the cabin door. 2.5.8 Personnel requirements DANGER SPECIALIST SKILLS REQUIRED Incompetent operation and maintenance could cause death or severe injuries. Operation and maintenance procedures require professional skills and special training regarding the tasks and working methods. Do not operate the equipment or do any maintenance tasks without proper training. Always follow the instructions. Use appropriate personal protective equipment, depending on the task. 40/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions To avoid hazardous situations and dangerous consequences, leave all operation and maintenance work to authorized personnel. Tasks that are mentioned are examples of tasks which are allowed only for authorized personnel. Instructions for safe handling and other risks that are related to the tasks, can be found in the following chapters. Tasks that require special technical skills and training include, but are not limited to: 1. Hydraulic system maintenance 2. Electric system maintenance 3. Battery maintenance 4. Tire maintenance 5. Changing parameters in the control system 2.6 Environmental information Environmental impacts have been taken into account when designing and manufacturing this product. To prevent environmental risks during use, follow the instructions and local regulations for disposal of waste material. Proper use and maintenance improve the environmental performance of this product. 2.6.1 Energy consumption Energy consumption during the use phase has the biggest environmental impact. Diesel fuel is needed for lifting, transporting, lighting, heating, cooling, and other optional components that are part of the machine. Konecranes machines minimize the use of fuel in the following ways: • Engineering diesel engines with the best possible fuel efficiency and lowest emission levels. • Engine downsizing. • Fuel saving transmission features, like lock-up and continuously variable transmission. • Using load-sensing hydraulic systems, so no hydraulic flow (with resulting energy losses) is created unless it is needed by an actual load command. • ECO-driving supports the operators so they can minimize fuel consumption by reducing the harshness of operations. • Connectivity for the operational managers to optimize the use and operational efficiency of their machine fleet by: ◦ maximizing time driving with payload ◦ minimizing travelling distances over the yard ◦ select the most suitable machine capacity for specific lifting needs ◦ monitoring the right tire pressure for the lowest rolling resistance in connected machines • Eliminating idling time with: ◦ automatic start and stop • Means to optimize the preventive maintenance of the machines, to ensure long-term fuel efficiency. 2.6.2 Product lifecycle stages The environmental impact of a Konecranes machine is taken into account for the whole lifecycle of the vehicle. “Lifecycle” refers to the extraction and processing of raw materials, the production of components, manufacturing, use, and maintenance. "Lifecycle" also refers to disposal of the product and the transportation that is involved from one stage to the next. Each stage of the lifecycle has a different impact on the environment. The two most significant environmental impacts of the machines are the energy consumption during the use phase (in particular, the effects of diesel emissions) and the raw materials and component production (in particular, the effects of steel production). The significance of energy consumption depends on actual usage, including operating time, efficiency of operations, and load collective. Product lifecycle stages include: 41/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment • Production of materials and components • Equipment manufacturing and assembly • Use phase, including maintenance, repairs, and modernization • Dismantling and recycling of waste materials • Transports between each stage Figure 10. Product lifecycle stages 2.6.2.1 Production of materials and components 84%–92% of machine materials are metals, and rubber tires form 3%–9%. The rest of the materials include electrical and electromechanical components, fluids (hydraulic oil, diesel fuel, and grease), plastic, and glass. The main raw material is steel. The most significant environmental impacts of steel production are the use of raw materials and energy, as well as carbon dioxide and particle emissions. More than 75% of the steel content can be manufactured from recycled steel scrap. Lubricants, which are used from factory on the products, are industrial hydrocarbons. Table 2. Materials used in Konecranes machines Konecranes Lift Trucks Konecranes Liftace Forklift Forklift, Empty Laden Reach Forklift Empty Reach electric container container stacker container stacker handler handler handler Steel 88% 84% 91% 90% 92% 88% 92% 92% Rubber 6% 6% 4% 5% 3% 6% 3% 3% Copper <1% <2% <1% <1% <1% <1% <1% <1% Electronics <1% <4% <1% <1% <1% <1% <1% <1% Fluids <2% <2% <2% <2% <2% <2% <2% <2% Polymers <1% <1% <1% <1% <1% <1% <1% <1% Others <1% <1% <1% <1% <1% <1% <1% <1% 2.6.2.2 Equipment manufacturing and assembly Production mainly involves assembling of machines and some installations. Welding is only carried out for complementing or repair work. Surface treatment for reconditioning is conducted to a lesser extent. Testing of machines is carried out outdoors after assembly, before delivery. 42/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions The most significant environmental impact is the energy consumption, and diesel emissions during test-driving. To decrease the impact, Konecranes Lift Trucks is using HVO100 bio diesel. It is recommended that HVO100 bio diesel is used generally to decrease the environmental footprint. There are also some lower impacts from the chemicals that are used, like paints, oils and fuels. The waste from the production is disposed of, according to local regulations. Examples of waste are wood, plastic, and paper as well as hazardous waste such as residue of paint, and waste oil. 2.6.2.3 Use phase, including maintenance and modernization Most significant environmental impacts of machines are the energy consumption during the use phase (in particular, the effects of diesel emissions). Konecranes machines minimize the use of fuel, as described in "Energy consumption". Timely repairs and proper maintenance support each machine’s efficiency, safety and, performance which contributes to less environmental impact. The optional hydraulic long-life (HLL) filter removes small particles, reduces the water in the oil, and extends the life of the hydraulic oil. This filter increases the amount of time between hydraulic oil replacements. With the option TRUCONNECT® Smart Connected Lift Trucks the customer can plan service on real machine use, which in most situations extend service intervals. A sensor for monitoring the status of the hydraulic oil, and estimate the remaining life of the oil, can also be provided. The monitoring of the hydraulic oil status prevents unnecessary hydraulic oil replacement. Certain major components like diesel engine, transmission, and some electronics can be restored to like-new condition. Konecranes Service offers restored spare parts, where the old part is requested back (as core unit for later renovation). This restoration process extends the useable machine life and reduced the environmental impact. 2.6.2.4 Dismantling and handling waste material Konecranes Lifttrucks strive to optimize all packaging to minimize waste and to follow the EU waste hierarchy. The most preferable actions are: prevention, reuse, recycle, burning of material to recover the energy in the material, and as a final resort, safe disposal as landfills. Waste material from dismantling shall be handled and disposed according to local regulations. As waste regulations and types of available recovery and disposal methods vary regionally, no general detailed guidance can be given. Dismantling should always be planned and executed by authorized personnel. A local risk assessment must be performed in advance. Depending on available recovery and disposal methods, wood can be recycled and reused but is the responsibility of the customer. Plastic waste is collected and, depending on the infrastructure, recycled, burned to recover the energy in the material, or as a final resort, safely disposed as landfills. NOTE Always use licensed recycling companies. The following list provides proposals for adequate waste handling methods. 43/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment Table 3. Proposed waste handling methods (example for EU states) Proposed waste handling methods (example of EU states) Material Handling method Metals Material recycling, multi-metal scrap recycling. Rubber tires Recycle rubber according to local regulations. Whenever possible, return the used rubber tires to the tire supplier for recycling. Electronics and Some electrical parts may be treated as hazardous waste. electromechanical components Collect and recycle the electronics and electromechanical components separately. Use e-waste management. Batteries Batteries and other energy storage components may contain hazardous substances. Collect these items separately and recycle according to local regulations. Fluids, Recycling, hazardous waste management accumulators, oil filters Plastics and Recycle plastic as material, burn to recover the energy in the material, or polymers deliver it to a landfill site. Chemicals Never spill chemicals, such as oil, grease, and other liquids, onto the ground, soil, or sewage. Store waste oil and grease in containers that are indicated for the purpose. More detailed information on chemical handling as waste can be found in the chemical safety data sheet. The data sheet is available from the manufacturer of the chemical. Packing materials Reuse or recycle packing materials, such as plastics, wood, and cardboard. Glass Recycle glass according to local regulations. 2.6.2.5 Deliveries between each stage Materials and components are provided by various suppliers worldwide, however steel structure is primarily sourced from local vendors to reduce the transportation need. It is an ethical, environmental, and employee-related principle that is applied. Shipment of materials to the respective factories is primarily by road transport, and containerized whenever feasible. Before shipment, each machine is partly dismantled, depending on dimensional and/or weight constraints for road transportation. The shipment of a machine to local and regional customers is usually by road from the factory. When shipment is to more remote customers or the shipping route involves waterways, sea transport is often involved. By sea, Ro-Ro type ships are used (where the machine drives onto the ship). 44/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions 2.6.3 Notice on the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH) Konecranes is fully aware of its obligations under Regulation (EC) No 1907/2006 of the European Parliament and of the Council of 18 December 2006 concerning the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH), and under the UK REACH in the United Kingdom. Twice a year the EU publishes a Candidate list of Substances of Very High Concern (“SVHC”) for Authorization. Producers and EU importers/UK importers have the duty to inform their EU/UK customers when a product contains SVHCs in a concentration above 0.1 % weight by weight. Some Konecranes products do include small quantities of SVHCs, such as lead which is typically used in brass and in certain electric components. These cases are exemptions, as there are currently no satisfactory alternatives available for such substances. We are actively searching for alternatives to substitute articles including SVHCs. For a list of SVHCs, please see https://www.konecranes.com/about/corporate-responsibility/konecranes-reach-notice. 2.7 Storage information 2.7.1 Storage The following chapter describes the recommended procedure for storage of machines. To preserve the condition of the stored machine, it must be driven regularly during storage. Preparation before storage Before storing the machine, make sure that all required services according to the NOTE maintenance schedule are performed. Be aware that some points in the storage handling process, must be performed by NOTE trained and authorized maintenance personnel. If using a pressure washer, never aim the water directly at radiators, air intakes, seals, NOTE rubber hoses, or electrical components. • Clean the machine • Perform daily maintenance check, see section "Daily maintenance" • Run all hydraulic functions and steer cylinders to end position and back again • Fill the fuel tank before storing the machine • Charge the battery • Lubricate the machine, see section "Regular service" • To prevent corrosion, apply a rust inhibitor to all the metallic surfaces • To protect the coating from corrosion, touch up painted surfaces • If possible, store the machine indoors or under a roof • If stored outside, it is recommended to cover the whole machine Maintenance during storage When driving the machine, the engine temperature must reach at least 80 degrees and NOTE the transmission must reach at least 65 degrees. To preserve the condition of the machine during storage, the following steps must be performed at least once a month. • Check the battery, charge if needed • Check for visible leakage under the machine. If needed, tighten all connections before filling any fluid • Bleed the fuel system, if needed, see section "Bleeding the fuel system" • Start the machine, and idle to warm up the engine 45/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment • Drive the machine for a while, both forwards and in reverse • Run all hydraulic functions and steer cylinders to end position and back again • Before parking the machine again, check the guidelines for "Preparation before storage". Perform the steps, if needed. Bringing out of storage • Check for visible leakage under the machine and on the ground. • Tighten all connections before filling any fluid, if needed • Perform daily maintenance check, see section "Daily maintenance" • Lubricate the machine, see section "Regular service" • Check the battery, charge if needed • Bleed the fuel system, if needed, see section "Bleeding the fuel system" • Start the machine, and idle to warm up the engine • When the engine has reached the required temperature, and while idling, check for visible oil, fuel, or coolant leakage • Test drive the machine, to make sure all systems function properly 2.7.2 Alternative storage, up to two months The following chapter describes the procedure for storage of machines that cannot be accessed or driven during storage. This way of storing the machine should only be used if necessary. See section "Storage" NOTE for the recommended procedure. Preparation before storage Before storing the machine, make sure that all required services according to the NOTE maintenance schedule are performed. Be aware that some points in the storage handling process, must be performed by NOTE trained and authorized maintenance personnel. If using a pressure washer, never aim the water directly at radiators, air intakes, seals, NOTE rubber hoses, or electrical components. • Clean the machine • Perform daily maintenance check, see section "Daily maintenance" • Run all hydraulic functions and steer cylinders to end position and back again • Fill the fuel tank • Fill up the windshield washer fluid • Fill the AdBlue/DEF tank, if applicable • Charge the battery • Lubricate the machine, see section "Regular service" • To prevent corrosion, apply a rust inhibitor to all the metallic surfaces • To protect the coating from corrosion, touch up painted surfaces • If possible, store the machine indoors or under a roof • If stored outside, it is recommended to cover the whole machine Bringing out of storage • If applicable, remove the cover from the machine • Check for visible leakage under the machine and on the ground. • Tighten all connections before filling any fluid, if needed • Perform daily maintenance check, see section "Daily maintenance" • Lubricate the machine, see section "Regular service" • Check the battery, charge if needed • Bleed the fuel system, if needed, see section "Bleeding the fuel system" • Check the condition of all rubber hoses, and retighten the hose clamps if necessary • Check that no oil, fuel, or coolant leakage occurs • Start the machine, and idle to warm up the engine 46/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions • When the engine has reached the required temperature, and while idling, check for visible oil, fuel, or coolant leakage • Run all hydraulic functions and steer cylinders to end position and back again • Check for visible leakage also when using the hydraulic functions after storage • Test drive the machine, to make sure all systems function properly 2.7.3 Alternative storage, longer than two months The following chapter describes the procedure for storage of machines that cannot be accessed or driven during storage. This way of storing the machine should only be used if necessary. See section "Storage" NOTE for the recommended procedure. Preparation before storage Before storing the machine, make sure that all required services according to the NOTE maintenance schedule are performed. Be aware that some points in the storage handling process, must be performed by NOTE trained and authorized maintenance personnel. If using a pressure washer, never aim the water directly at radiators, air intakes, seals, NOTE rubber hoses, or electrical components. When performing the regular service, also consider the procedure for conserving the NOTE machine. • Clean the machine • Perform maintenance service according to the 500 hours schedule, see section "Regular service" • Run all hydraulic functions and steer cylinders to end position and back again • Apply a long-term rust inhibitor to the cylinder pistons • Drain any water and contamination from the fuel filters and fuel tank • Fill the fuel tank • Fill up the windshield washer fluid • Fill the hydraulic tank completely, to avoid corrosion above the maximum level • Empty the AdBlue/DEF tank, if applicable, and rinse it with distilled water • Disconnect, and charge the battery • Store the battery in a safe way • Loosen the fan belt • To prevent corrosion, apply a long-term rust inhibitor to all the metallic surfaces • To protect the coating from corrosion, touch up painted surfaces • Conserve the machine, see section "Conservation of the lubrication and fuel system" • Cover the air filter, exhaust pipe, and engine if necessary • If possible, store the machine indoors or under a roof • If stored outside, it is recommended to cover the whole machine 47/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment Conservation of the engine and fuel system WARNING RISK OF FIRE AND PERSONAL INJURY Conservation oils are flammable and are dangerous to inhale. Ensure good ventilation. Use a face mask when applying the conservation oil. • Drain the engine oil and fill with conservation oil just over the MIN marking on the dipstick • Connect the fuel suction and return hoses to a fuel can (app. 20 l) containing 1/3 conservation oil and 2/3 diesel fuel • Bleed the fuel system, see section "Bleeding the fuel system" • Start the engine and idle until about 2 l of the fluid in the fuel can have been used • Stop the engine and reconnect the fuel suction and return lines to the machine • Drain the excess fluid from the engine, see section "Cleaning and draining the fuel tank, all engines" • Put a note on the machine with the date, type of conservation and the conservation oil used Bringing out of storage • If applicable, remove the cover from the machine • Remove covers from air intake systems and exhaust systems • Remove the rust inhibitor • Check for visible leakage under the machine and on the ground. • Tighten all connections before filling any fluid, if needed • Check and adjust the hydraulic oil level, remove excess oil • Charge and reconnect the battery • Tighten the fan belt • Fill the AdBlue/DEF tank, if applicable • Perform maintenance service according to the 500 hours schedule, see section "Regular service" • Lubricate the machine, see section "Regular service" • Bleed the fuel system, if applicable, see section "Bleeding the fuel system" • Check the condition of all rubber hoses, and retighten the hose clamps if necessary • Check that no oil, fuel, or coolant leakage occurs • Start the machine, and idle to warm up the engine • When the engine has reached the required temperature, and while idling, check for visible oil, fuel, or coolant leakage • Run all hydraulic functions and steer cylinders to end position and back again • Check for visible leakage also when using the hydraulic functions after storage • Test drive the machine, to make sure all systems function properly 48/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 3 PRODUCT DESCRIPTION 3.1 Technical description Specification SMV 33-1200C means: • SMV = Product name • 33-1200 = 33-ton lifting capacity on 1200-mm load center • C = Model C Engine The engine is a water-cooled, turbo-charged diesel engine. The engine drives a transmission using a torque converter. Transmission The transmission is of power declutch type. The transmission is equipped with an oil cooler. On the brake pedal in the cabin, there is a declutch switch. The declutch switch disengages the transmission so that the operator can control the hydraulics while maintaining a high engine RPM during stacking maneuvers. Axles Drive axle The transmission uses a universally jointed propshaft to drive the drive axle. The drive axle is of the heavy-duty double reduction type. The primary reduction is through the hypoid crown wheel and a pinion. The secondary reduction is achieved by a planetary gear that is set within the wheel hubs. The wheel hubs are carried on tapered roller bearings. Steer axle The steer axle is mounted in sphere-elastic bushes which allow sufficient wheel movements for stability on uneven ground. The parallel steering links are between the steer cylinder and the spindles. Brakes Service brake The service brakes are controlled by the foot brake pedal, which activates the brakes in the drive axle. An oil-cooled wet disc brake system are used for the brakes. Parking brake The parking brake is controlled electrically and activates a hydraulic cylinder. The hydraulic cylinder acts on a brake disc that is mounted between the drive axle and the propshaft. The parking brake is spring applied and uses the hydraulic pressure to release. Hydraulic system The hydraulic system is equipped with load-sensing variable piston pumps. The brake system is equipped with one or two gear pumps. Steering The steering is fully servo-assisted. 49/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description Control valve Machine sizes 10-16 are equipped with the L90 control valve, and machine sizes 18-60 with the K220/L90 control valve. The control valve is mounted on the chassis. The operator controls the valve by either levers or a joystick. The valve regulates the functions for mast lifts, tilts, and attachment, and any optional functions. Mast The duplex standard mast consists of: • One outer mast • One inner mast • One fork carriage • Two lift cylinders • Two tilt cylinders The inner mast section moves along the outer section using mast wheels and support rollers. The mast is mounted on two axles in the chassis using bearings. The fork carriage is of a rolling type with sideshift movement and fork positioning. Operator's cabin The operator’s cabin fulfills international safety standards, and is rubber-mounted to protect the operator from vibrations. Entrance to the cabin is on the left side using the steps on the machine. The cabin air is efficiently filtered to ensure a healthy work environment. Instruments and controls The hydraulic control levers, or the joystick, and the display are on the right-hand side of the operator’s seat. The gear switch is on the left side of the control levers, or at the back of the joystick. The control for windshield wipers, ceiling light, and any optional functions are on the keypad. The indicator lamps for the hazard lights, parking lights, and the rotating beacon are on the armrest, on the right-hand side of the keypad. For more information, see "Keypad", "Controls and indicators in cabin", and "Lifting loads". Electrical system The electrical system is 24 V. 50/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 3.2 Machine outline, forklift 7 6 4 5 2 3 1 8 10 9 1. Steer axle 6. Lift cylinder 2. Counterweight 7. Mast 3. Engine hood 8. Forks 4. Operator's cabin 9. Fork carriage 5. Tilt cylinder 10. Drive axle 51/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 3.3 Controls and indicators in cabin with lever control Figure 11. Controls and indicators in cabin with lever control 1. Adjustment pedal for the steering wheel 9. Rotating beacon (option) column 10. Keypad 2. Steering wheel 11. Emergency stop 3. Adjustment lever for tilting the steering 12. Gear switch for forward, neutral, and wheel reverse 4. Control levers for the hydraulics 13. Horn 5. Display 14. Accelerator pedal 6. Ignition key switch 15. Brake pedal 7. Hazard light 16. Declutch 8. Position lights The position of controls may vary from machine to machine depending on the customer order. 52/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 3.4 Controls and indicators in cabin with joystick (option) Figure 12. Controls and indicators in cabin with joystick (option) 1. Steering wheel 9. Position lights 2. Adjustment lever for tilting the steering 10. Rotating beacon (option) wheel 11. Keypad 3. Horn activation 12. Emergency stop 4. Gear switch for forward, neutral, and 13. Accelerator pedal reverse 14. Adjustment pedal for the steering wheel 5. Buttons for optional functions column 6. Display 15. Brake pedal 7. Ignition key switch 16. Declutch 8. Hazard lights Position of controls may vary from machine to machine depending on the ordered options. 53/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 3.5 Keypad 1 19 2 18 3 17 16 15 4 14 5 6 13 7 12 8 11 9 10 Figure 13. Keypad 1. Start and stop engine 12. Extra work light 2. Wiper one-stroke 13. Work light for mast 3. Rear window defroster 14. Turn signal indicator, left 4. Turn signal indicator, right 15. Main beam headlights 5. Cabin interior light 16. Parking brake 6. Work light for attachment 17. Rear window wiper, push, and hold down 7. Extra work light for washer 1) 8. Option 2 (not in use) 18. Roof window wiper, push, and hold down 9. Option 4 (not in use) for washer 1) 10. Option 3 (not in use) 19. Windshield wiper, push, and hold down for 11. Option 1 (not in use) washer 2) 1) intermittent/second speed/off 2) intermittent/first speed/second speed/off 54/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 3.6 MD4 display Figure 14. MD4 touch display The display has a user-friendly touch interface: to navigate between views, you simply tap on the screen. With the display, you can monitor the hydraulics system and drive line with the help of analog and digital signals from various sensors. It gives you a complete overview of the activities of the machine during operation. The active keypad function is shown at the bottom-left corner. Figure 15. Example of active keypad function: roof window wipers, intermittent 55/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 3.6.1 User interface 3.6.1.1 Introduction to MD4 pages The MD4 pages can be accessed by clicking on the touch screen display icons. They show various data needed during operation and allow the operator to change required settings. The operator's menu is only available from the main pages. There are five main pages: • Home page (weight page) • Date and time page • Attachment settingspage • ECO-driving page • Operator page 3.6.2 MD4 display frame The MD4 display frame is always visible, except in the settings pages. This makes it easy to navigate in the system. 1 2 9 3 4 5 6 7 8 Figure 16. MD4 frame icons 1. Home page (Main page number 1 – Weight 6. Previous Main page page) 7. Adjust display brightness 2. Machine overview page 8. Next Main page 3. Information page 9. Operator's menu (only available on the 4. Settings page Main pages) 5. Main page number (only visible on the Main pages) 56/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions Left side of the MD4 display frame Using the left-side frame icons, you can return to the Home page and access Machine overview page, Information page, and Settings page. Icon Meaning Home page (Main page number 1 – Weight page) Machine overview page shows engine fluid data and gives access to transmission page, engine page, and tire pressure monitoring page. Information page shows various counters, such as container counter and time to next service. Settings page allows you to view and edit settings and to calibrate all functions. Only service personnel are allowed to modify the settings, a service code is required. Bottom of the MD4 display frame The bottom of the MD4 display shows operator control and engine status symbols. The symbols are gray when the function is not on or the status is normal. From the bottom frame, you can also cycle between the five Main pages by tapping the left and right arrows. The Main page currently in view is shown in the bottom-left corner. Symbol Meaning Neutral gear is selected Forward gear is selected Reverse gear is selected The turn signal blinks green when you press the turn signal button Red when the battery voltage level is low Red when the engine oil pressure is low Fasten seat belt indicator 57/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description Symbol Meaning Red when the parking brake is on Red when the accumulator pressure is low Green when the low beam is on Blue when the high beam is on Tap to go to the previous Main page Tap to change the display brightness Tap to go to the next Main page Windshield wipers Windshield wipers, slow Windshield wipers, fast Windshield wipers, intermittent Rear window wipers Rear window wipers, intermittent Rear defroster Roof and rear washer Roof window wipers 58/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions Symbol Meaning Roof window wipers, intermittent Cabin interior light Working light Electrical lever / mini-wheel steering (option) active Right side of the MD4 display frame When viewing any of the five Main pages (either Home/Weight, Date and time, Attachment, ECO-driving, or Operator page), the MD4 display shows a button on the right side of the frame. By tapping this button, you can access the Operator’s menu. Symbol Meaning Operator's menu The MD4 display frame is always visible, except in the settings pages. This makes it easy to navigate in the system. 1 2 3 4 5 6 7 8 Figure 17. Operator's menu 1. Select top gear 6. Operator login (option) 2. Safety override for the twistlock on the 7. Autostop function (option): the symbol is attachment visible if the machine has the autostop 3. Starting gear function. Press the symbol to disable the 4. Automatic or manual gear selection autostop function for 2 min. 5. Eco mode or productivity mode 8. Intermittent wiper 59/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 3.6.3 MD4 pages 3.6.3.1 Start-up page 1 2 3 4 5 Figure 18. Start-up page 1. Engine check 4. AdBlue check 2. Battery check 5. Engine oil check 3. Engine coolant check The Start-up page is displayed when you start the machine. After 10-15 seconds, it changes automatically to the Main page viewed the last time the machine was on. Green light indicates normal status, red light indicates error. 60/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 3.6.3.2 Home page (weight page) Main page 1 1. Add weight (option) 8. Fuel level 2. Tare (option) 9. Engine RPM 3. Last load (option) 10. Engine coolant water temperature 4. Total load (option) 11. AdBlue level 5. Current load (option) 12. Transmission oil temperature 6. Twistlock indication (if applicable) 13. Driving speed 7. Date and time 14. Percentage of maximum load NOTE Calibrating the weight scale can only be done by authorized service personnel. 61/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 3.6.3.3 Date and time page Main page 2 1 2 3 4 10 9 8 7 6 5 1. Date and time 6. Cooling water temperature 2. Twistlock indication (if applicable) 7. Fuel level 3. Current load 8. AdBlue level 4. Percentage of maximum load 9. Transmission oil temperature 5. Engine RPM 10. Driving speed 62/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 3.6.3.4 ECO-driving page Main page 4 1 2 3 4 5 6 7 8 1. Fuel level 3. Fuel economy bar: red in the bar indicates 2. Resets the following values: less economic driving style, gray indicates • Fuel rate: current hourly fuel more economic driving style consumption 4. AdBlue level • Average: average hourly fuel 5. Twistlock indicators (if applicable) consumption 6. Date and time • Time elapsed: time since last reset 7. Current load (option) • Consumption: fuel consumption since last reset 8. Percentage of maximum load 63/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 3.6.3.5 Operator page Main page 5 1 2 3 4 5 6 11 10 9 8 7 1. Transmission oil temperature 7. Engine coolant temperature 2. Driving speed 8. Next in-focus value 3. Fuel level 9. Current load in percentage 4. In-focus value (adjustable) 10. AdBlue level 5. Speed limiter (option) 11. Previous in-focus value 6. Twistlock indication (if applicable) The in-focus value can show the following values: • Driving speed • Weight in percentage • Weight in tons (option) • Transmission oil temperature • Fuel level • Engine coolant temperature • Engine RPM Use the left (11) and right (8) arrow to cycle between the options. 64/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 3.6.3.6 Machine overview page The visible content of the Machine overview page may vary depending on ordered NOTE options. 1 2 3 4 5 6 7 8 9 13 12 11 10 The Machine overview page gives access to engine data, transmission data, tire pressure monitoring, and several other diagnostics pages. 1. Raw value from accelerator pedal 8. Engine coolant level 2. Accelerator pedal angle 0%–100% 9. Fuel level 0%–100% 3. Engine RPM 10. Tire pressure monitoring page (option) (1) 4. Transmission oil temperature 11. Access to TRUCONNECT® statistics page 5. Engine coolant temperature (option) 6. Brake oil temperature 12. Transmission diagnostics page 7. AdBlue level, if applicable 13. Emission page (1) Only visible if you have entered the service code. Engine diagnostics 65/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description The menu button in the top-right corner allows you switch between Scaled and Raw values for the measurements. Table 4. Measurements for engine diagnostics Measurement Meaning Engine RPM Actual engine RPM. Engine RPM TSC1 [rpm] Requested engine RPM. Coolant temperature [°C] The temperature of the engine coolant. Oil pressure [kPa] Engine oil pressure. DNL1 Pedal (Byte 2) [bits] Request to Scania engine for auto engine acceleration. Engine hours Not used for reading machine hours. SW Engine level engine Special option for Scania engine. Request cooling fan speed function Requested cooling fan RPM from machine. Urea level Urea/AdBlue level in %. SW Engine start/stop Start request signal (engines with CAN bus start). 66/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions Table 5. Measurements for engine diagnostics Measurement Meaning MC42 V Battery 24 V. Power voltage supply to MC42 unit. Engine command This value is the requested engine RPM. Depending on the action being performed, for instance, when accelerating or using a lifting function, the percentage can vary: 0% is approximately 700 rpm and 100% 2200 rpm. Engine RPM [rpm] The actual engine RPM in rpm. FGO Engine Fan Speed The actual speed of the engine fan in rpm. This speed depends on the engine temperature, as the fan speed varies according to the engine temperature. FGO Engine Coolant temp. The temperature of the engine coolant, more than 102 C is too high. (Warning at 105 C on Volvo engines) FGO Engine Oil Temp. The temperature of the engine oil. If the temperature is too high, the system sends an error message. (Warning at 125 C on Volvo engines) FGO Fuel Delivery Pressure Gage pressure of fuel in system as delivered from supply pump to the injection pump. FGO Oil Pressure Gage pressure of oil in engine lubrication system as provided by oil pump. When the pressure is less than 100 Kpa, it is too low, and causes the system to send an error message. FGO Engine Coolant level Should be above minimum level. The sensor indicates if the level is too low. Measurement Meaning FGO Engine Coolant pressure Gage pressure of coolant in engine cooling system. FGO Engine Oil Level Ratio of volume of oil found in engine lubrication system to total lubrication system volume. Never fill the engine oil to 100%. FGO Act. Engine Torque The calculated output torque of the engine. 67/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description Measurement Meaning FGO Engine Intake Manifold #1 Pressure The gage pressure measurement of the air intake manifold #1. FGO Engine Air Intake Pressure Absolute air pressure at inlet to intake manifold or air box. If the filter is clogged, the system sends the operator an error message. FGO Engine Intake Manifold 1 Temperature Temperature of pre-combustion air found in intake manifold number 1 of engine air supply system. FGO Engine Exhaust Gas Temperature Temperature of combustion by-products leaving the engine. FGO Engine System Powerdown Ack Whether engine can be powered down. 0 Power off not allowed (cannot power off), 1 is Power off allowed, 2 is error state, 3 is not available. Measurement Meaning FGO Running Indication Indicates whether engine running or stopped. 0 is stopped, 1 is running, 2 is reserved, 3 is not available. Requested Percent Fan Speed Fan speed as a ratio of the actual fan drive (current speed) to the fully engaged fan drive (maximum fan speed). Stop request Engine stop request: 0 is inactive, 1 is active, 2 is error indication, 3 is not available. Start request Engine start request: 0 is inactive, 1 is active, 2 is error indication, 3 is not available. TSC1 The TSC1 message can be used to request speed/ torque instead of the VP70 message. FGO SCR Catalyst Tank Level AdBlue tank level. Measured in %, FGO Tank Low Level Indicator Indication that the AdBlue tank level is low. 68/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions Measurement Meaning FGO SCR Catalyst Temperature Temperature of the AdBlue solution in the storage tank. FGO SCR Catalyst Tank level [mm] Measured in mm3, AdBlue tank level. ZF transmission Machine overview > ZF transmission 1 2 3 4 5 6 7 9 8 1. Temperature of the converter out oil 5. AEB button to start calibration temperature 6. Status of transmission calibration 2. Temperature of the sump oil temperature 7. Digital input 1-8 on-off 3. Engine RPM from transmission 8. Digital input 9-16 on-off 4. Output shaft RPM 9. Transmission status and fault information NOTE Transmission calibration can only be done by service personnel. 69/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description DANA transmission Machine overview > DANA transmission 1 2 3 4 5 6 7 8 1. Digital inputs and outputs of the 6. Transmission drop-down menu (selection transmission, 0-9 and 0-10 of various measurements and other 2. State selected in (6) actions) 3. Value in RPM from the speed sensors 7. Shows traveled distance in [km] 4. Value in Hz from the speed sensors 8. Converter torque and ratio difference 5. Information about analog inputs and between impeller and turbine outputs NOTE To access menu (6), a service code is required. 70/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions Truconnect page Options, and values shown in the display illustration, are examples, and varies NOTE depending on the model. Machine overview > TRUCONNECT page 1 2 3 4 5 SMV 4636 T.X5 (T.X6) IP address (WAN): ID: 540500000/10-10000180647 IP address/TCP (Server): 10.255.249.231:10001 S/N: 540500000 Software: Time: Longitude: Error 1 Latitude: 8 Error 2 Satellites: Fault 1 GSM signal: Fault 2 Voltage: Board temperature: Performance Speed limit: 10 km/h 7 IP address 1: IP address 3: IP address 4: 6 1. Machine specific information 5. Available functions (see separate table) 2. Modem specific information 6. Battery connectivity information (if 3. Data log test button applicable) 4. Modem operation mode 7. Geofencing related information • Green = Status OK 8. Active faults or errors on modem • Yellow, flashing = Booting • Red = Fault Available functions Button Function Button for opening the measure group for alarms related to the modem. Button for accessing the log for alarms related to the modem. Button for opening the Hydraulic oil quality page. 71/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description Available functions Button Function Button for initiating the data log test. The data log test verifies that: • all required data from the MD4, the engine, and the transmission is available. • the data logging reports can be generated successfully. • reports can be sent to the Truconnect database successfully. • the Truconnect database was able to successfully process the generated report. Button for initiating the communication test. The communication test verifies that: • the GPRS/3G connection can be opened. • route to the Truconnect database is available. • a connection to the Truconnect database can be established. • the modem can register to the Truconnect database. • the RMP (Regatta Messaging Protocol) connection to the database works. • the time synchronization with NTP sever works. • that the GPS location is available. Button for rebooting the modem. Button for updating the modem software. 72/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions Tire pressure monitoring system page (option) Machine overview > TPMS 1 2 1. Tire pressure unit 2. Pressure unit (bar, psi, kPa) Adding, removing, and replacing sensors, as well as changing the pressure between bar, NOTE kPa, and psi, can only be done by service personnel. 3.6.3.7 Information page 1 2 3 4 5 6 7 8 9 10 11 12 1. Container counter *) 4. Container counter, can be reset *) 2. Machine hours 5. Resets service hour (3) (can only be done 3. Time to the next service by service personnel) 6. Resets container counter (4) 73/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 7. Machine information 11. Total hour counter 8. Total engine hours 12. Lamp test button (button must be activated 9. Driving hour counter for daily maintenance) 10. Neutral hour counter *) Standard feature for attachments with twistlock, optional feature for attachments with clamps. 3.6.4 Preferences Settings > Preferences Select the item to be changed from the Preferences menu: • Display (backlight strength and screen saver on/off) • Date and time • Language 3.6.4.1 Setting the display backlight and screen saver 1. To set the backlight, set the value with - and + . 2. To choose between screen saver Off, Dimmed and Black, press - and + . 3. To set the timeout (when Dimmed or Black), set the value with - and + . 4. To set the dimmed light (when Dimmed), set the value with - and + . 74/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 3.6.4.2 Setting the date 1. To set the year: 1.1 Set the year with - and + . 1.2 Press . 2. To set the month: 2.1 Set the month with - and + . 2.2 Press . 3. To set the day: 3.1 Set the day with - and + . 3.2 Press . 3.6.4.3 Setting the time 1. To set the time: 1.1 Set the hours with - and + . 1.2 Press . 1.3 Set the minutes with - and + . 1.4 Press . 75/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 3.7 Lifting loads 3.7.1 Lifting capacity plate WARNING MACHINE MISUSE HAZARD Incorrect lifting of a load may lead to serious personal injury and damage to the machine. Check that the load is centered between the forks. Check that the forks are in good condition. WARNING MACHINE MISUSE HAZARD Exceeding the maximum load affects the stability and safety margins of the machine. Do not use the machine to handle a greater load than what is stated on the lifting capacity plate. WARNING MACHINE MISUSE HAZARD Konecranes is responsible for the safety of the machine. The warranty only applies as long as the machine is used within the areas of limitation. The areas of limitation are found on the the lifting capacity plate, EC assurance, and in the operating and maintenance instructions. Lifting capacity plate KONECRANES LIFTTRUCKS AB P.O.BOX 103 SE-285 23 MARKARYD SWEDEN RATED CAPACITY AT LIFT HEIGHT LOAD CENTRE DIST. TYPE kg mm mm SERIAL NUMBER SALES ORDER NUMBER ACTUAL CAPACITY TOW-COUPLING TONGUE LOAD UP/DOWN YEAR OF MANUFACTURE kg mm mm XX / YY kN mm kg mm mm MAXIMUM LIFT HEIGHT TOW-COUPLING PULLING CAPACITY mm kg mm mm MACHINE HEIGHT XX kN SERVICE MASS kg kg mm mm NOMINAL POWER kW kg mm mm The lifting capacity plate is on the left side of the cabin. If an extra unit has been fitted, read the lifting capacity plate for the additional unit. The values that are indicated on the lifting capacity plate are valid for compact and regular loads. If the values are exceeded, there is a risk to the stability of the machine and the tensile strength of the machine, forks, and mast. The maximum capacity depends on the lifting height and the distance to the load center (LC). LC is the distance between the front face of the forks (with the mast vertical) and the center of gravity of the load. The following is an example of values for the main lifting capacity and the alternative lifting capacities, which are indicated on the lifting capacity plate. 76/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions Example of lifting capacity, model SMV 33-1200C Lifting capacity is 33 tons (72,753 lbs) at lifting height 4,000 mm (157.5 in) and center of load 1,200 mm (47.2 in) (depending on the model). Alternative lifting capacities, model SMV 33-1200C The lifting capacity decreases as the center of load and the lifting height increase, according to the following examples: Lifting capacity is 22 tons (48,502 lbs) at lifting height 4,500 mm (177.2 in) and center of load 1,500 mm (59 in) (depending on the truck model). Lifting capacity is 19.5 tons (42,990 lbs) at lifting height 4,500 mm (177.2 in) and center of load 1,800 mm (70.9 in) (depending on the truck model). LC 77/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 3.7.2 Maneuvering the mast with levers DANGER UNCONTROLLED MOVEMENT HAZARD If the machine, or the equipment moves unexpectedly, it could result in personal injury, death, or damage to the equipment. To stop any unexpected movement, press the emergency stop button. WARNING MACHINE MALFUNCTION HAZARD Incorrect lifting of a load can lead to serious personal injury and damage to the machine. Handling of the machine outside of its area of use can lead to overloading and instability. Use the mast and its additional equipment only for approved work. The operator must be trained in the handling of the machine and its equipment. • Always maneuver the levers gently and slowly. • The speed of the hydraulic functions depends on the lever position. • The lever automatically returns to its neutral position when released. • The levers for the hydraulic functions are on the console to the right of the operator's seat. WARNING MACHINE MISUSE HAZARD Adding an attachment that is not suitable for the machine can cause the attachment to fall off. Risk of serious personal injury and damage to the machine. Optional equipment that was not supplied with the machine may only be used if an authorized dealer has ensured that safe operations can be guaranteed in terms of lifting capacity and stability. NOTE For more information, see Changes to the product (page 31). NOTE Pay attention to the operational symbols and the directional arrows. 3 4 2 1 Figure 19. Lever functions 1. Fork carriage maneuvering • Pull lever backwards = raise the fork carriage. • Push lever forwards = lower the fork carriage. 2. Tilting of mast 78/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions • Pull lever backwards = tilt the mast backwards. • Push lever forwards = tilt the mast forwards. 3. Fork maneuvering (side shift) 1) • Pull lever backwards = move the forks to the right • Push lever forwards = move the forks to the left 4. Fork distance maneuvering (spread) 1) • Pull lever backwards = decrease the distance between the forks • Push lever forwards = increase the distance between the forks 1) Function can vary depending on options. NOTE A fifth lever can be added for additional functions (optional). 3.7.3 Maneuvering the mast with joystick (option) DANGER UNCONTROLLED MOVEMENT HAZARD If the machine, or the equipment moves unexpectedly, it could result in personal injury, death, or damage to the equipment. To stop any unexpected movement, press the emergency stop button. WARNING MACHINE MALFUNCTION HAZARD Incorrect lifting of a load may lead to serious personal injury and damage to the machine. Handling of the machine outside of its area of use may lead to overloading and instability. Use the mast and its additional equipment only for approved work. The operator must be trained in the handling of the machine and its equipment. • Always maneuver the joystick gently and slowly. • Hydraulic function speed depends on joystick movement. • When released, the joystick automatically returns to its neutral position, and the movement stops. 79/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 1 5 2 10 6 7 4 3 8 9 10 Figure 20. Maneuvering the mast and forks with joystick 1. Load down 6. Spreading forks 2. Tilt mast forward 7. Side shifting forks 3. Load up 8. Capacitive/hand presence sensor 4. Tilt mast back 9. Gear switch 5. Horn, * one-stroke windshield wipers, roof, 10. Alternative function trigger and front * with (10) pressed 1 2 3 4 5 Figure 21. Joystick options 1. Optional function button 4. Activation button mini-wheel steering 2. Optional function button function (option) 3. Optional function button 5. Radio control key (option) 3.7.4 Mast and attachment symbols The following table shows the meaning of symbols for the joystick and control stickers. 80/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 0 Tilt mast backward Tilt mast forward Mast autotilt (option) Mast tilt One-stroke Horn windshield wipers, roof, and front Sideshift forks left Sideshift forks right Spread forks Bring forks together Forks down Forks up 30' stop off 30' stop on 20' 40' Mast with integrated attachment, top lift 81/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description Skewing fork down Skewing fork up Top lift, slewing left Top lift, slewing left Top lift, slewing right Top lift, slewing right rear front front rear Forklift side lift 1 Load stabilizer tilts Twistlock locked Twistlock open Load stabilizer tilts up down Lifting magnet Lifting magnet Paper clamp disengaged engaged 82/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions Rotate Rotate clockwise Tighten clamp Release clamp counterclockwise Upender-rotate Upender-rotate Fork leveling forward backward Forks rotate Forks rotate Top lift, lower Top lift, raise counterclockwise clockwise 83/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4 OPERATING INSTRUCTIONS WARNING RISK OF DAMAGE AND PERSONAL INJURY Loose objects or liquids in the cabin can cause unintended incidents. There is a risk of tripping, visibility reduction, fire, and other hazards due to unpredictable interference with the machine commands. In case of a machine tip-over, loose objects can also cause damage and personal injury. Always keep the cabin tidy and clear of debris and loose objects or liquids. Never add any fixtures other than the ones provided from the manufacturer. 4.1 Daily maintenance before operation DANGER UNCONTROLLED MOVEMENT HAZARD If the machine moves unexpectedly, it could result in personal injury, death, or damage to the equipment. To stop any unexpected movement, press the emergency stop button. WARNING MOVING PARTS HAZARD There is a risk of getting trapped by moving parts of the engine. There is also a cutting risk from moving parts of the engine. Do not open the hood or perform maintenance work while the engine runs. WARNING TOXIC SUBSTANCE HAZARD Breathing diesel engine exhaust exposes you to chemicals that may cause cancer, birth defects, or other reproductive harm. Never run the engine in unventilated places. Use fume extraction. Do not keep the engine idling, except when necessary. Do not modify or tamper with the exhaust system. WARNING IGNITION HAZARD During operation, parts of the machine can become very hot. If there are flammable or combustible materials, on or near any hot surfaces on the machine, there is a risk of fire. Examples of such materials are paper, or saw dust. Before taking the machine into operation, make sure that there are no flammable or combustible materials on or around any hot surfaces. Examples of hot surfaces can be the turbo, exhaust pipe, DPF, and so on. Visually inspect the machine for damage while going through the checklist during daily NOTE maintenance. NOTE Check the condition of the safety and information labels, replace if needed. 84/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions After performing the daily maintenance tasks, start the machine and listen for any NOTE abnormal noise from the engine and transmission. If any abnormal noise is heard, contact maintenance personnel. 1. Check the battery main switch 2. Check the wheel nuts and clamps. 3. Check the tire pressure and the condition of tires and rims (visible cracks and damages). 4. Check the engine oil level. 5. Check the transmission oil level. 6. Check the coolant level in all tanks. 7. Check the hydraulic oil level. 8. Check the brake cooling oil level (option, not available for all models). 9. Check the grease level in the two reservoirs for the automatic lubrication system (option). NOTE If automatic lubrication is installed (optional), there can be one or two tanks. 10. Check the MD4 warnings for clogging of engine air filter. 11. Check the windshield washer fluid level. 12. Check the fuel level. 13. Check the AdBlue level (when applicable). 14. Check the soot level (when applicable). 15. Check that the mirrors are clean and adjust them to make sure of good visibility. 16. Check that the windows are clean. 17. Clean the rearview camera (option). 18. Check for visual signs of leakage, around and under the machine 19. Check the seat adjustments and adjust if needed. 20. Check the steering wheel adjustments. 21. Check the service brake functionality. 22. Check the parking brake functionality. 23. Check the functionality of the steering system. 24. Check the hydraulic functions. 25. Check the electrical functions. 26. Check the climate unit (option) settings. 85/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2 Daily maintenance checks 4.2.1 Turning on and turning off the battery main switch DANGER EXPLOSION HAZARD Short-circuiting the battery may cause a fire or explosion, which can cause a risk of serious injury or death. To reduce the risks of electric shock and personal injury always remove jewelry and conductive material before working on the electrical system. DANGER EXPLOSION HAZARD Batteries generate explosive hydrogen when charged, which can cause a risk of serious injury or death. Always use the necessary protective equipment. Ensure that there is good ventilation and avoid sparking. DANGER ELECTRIC SHOCK HAZARD Even when the battery main switch is turned off, there may still be voltage present in some parts of the machine. The main disconnect does not cut the power to the alternator. This causes a risk of electric shocks, which can lead to death or serious personal injury. To reduce the risks of electric shock and personal injury always remove jewelry and conductive material before working on the electrical system. Always disconnect the ground (minus) cable at the battery when working near or on the alternator. Be aware of the battery main switch functionality. WARNING TIPPING OVER HAZARD If the battery main switch is turned off when the machine moves, the parking brake is activated. The machine may tip over, causing a risk of serious personal injury and damage to the machine. Unless there is an emergency situation, do not turn off the battery main switch when the engine runs. NOTE Do not operate the machine unless you know the location of the battery main switch (1). If the machine has an engine that uses AdBlue solution, wait after turning off the combustion engine. After the AdBlue pump has finished pumping all the fluid from the NOTE hoses to the AdBlue tank, turn off the battery main switch (1). The required time varies slightly between different engine models. NOTE Remove the main switch handle when parking the machine. 86/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 1 Figure 22. Battery main switch 1. Before operating, turn on the battery main switch (1). Turn the battery main switch (1) clockwise. 2. After operating, turn off the battery main switch (1). Turn the battery main switch (1) counterclockwise. 87/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2.2 Checking the condition and pressure of the tires DANGER HIGH-PRESSURE HAZARD Release of high-pressured air could cause death or serious personal injury. Proceed with caution when working with pressured air systems. Use approved personal protective equipment. Follow all safety requirements. Only trained personnel are allowed to check tire pressure and inflate tires. DANGER HIGH-PRESSURE HAZARD The tires may explode when inflated or deflated. Standing inside the tire explosion danger zone during a tire explosion causes death. Always stand beside the wheel when deflating or inflating tires, see tire explosion danger zone illustration. Use safety glasses. If the machine is equipped with tire pressure monitoring system (TPMS), the tire pressure NOTE can be checked on the display. Driving with incorrect tire pressure makes the machine unstable, and increases the fuel NOTE consumption. It can also cause unnecessary wear and tear of the tire, which can result in a flat tire or a tire explosion. 120° 120° yd 50 55 m/ m/ 55 50 d yd 5y 50 m/5 m/5 5y 50 d 120° 120° Figure 23. Forklift tire - explosion danger zones 88/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions Figure 24. Drive axle tires Figure 25. Steer axle tires 1. Check that the tires have not become too worn and are undamaged. 2. Remove any deposits (debris and dirt) from the tread. 3. Remove any deposits (debris or objects) stuck between the tires. DANGER HIGH-PRESSURE HAZARD The tires may explode if you try to remove objects that are stuck in them, which could cause death or serious personal injury. To remove any objects that are stuck in the tire, contact authorized personnel. 4. Check that no wheel nuts are missing or loose. 5. Check that the tires have the correct pressure according to the recommendations of the manufacturer. 6. Inflate or deflate the tires according to the relevant recommendations. Always take the ambient temperature into account. 89/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2.3 Checking the engine oil level WARNING IRRITATING SUBSTANCE HAZARD The machine contains several chemical substances which may cause skin irritations and allergies. Personal injury hazard if long-term skin contact. Avoid direct contact with skin when handling chemical substances. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. Use safety goggles. NOTE Make sure that the engine is switched off before checking the engine oil level. 2 1 Figure 26. Checking the engine oil level, Volvo engines 90/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 1 2 Figure 27. Checking the engine oil level, Cummins engines 1. To access the dipsticks and oil filling, open the engine hood. 2. Remove the dipstick (2) and dry it off with a clean cloth. 3. Put back the dipstick fully and remove again. The oil level must be between the minimum and maximum level indicators (in the operating temperature, at least 65°C or 149°F). 4. If necessary, remove the filler cap (1) and top up the oil. NOTE Only trained service personnel are allowed to fill oil. 5. Fill with the recommended oil. See Recommended fluids and lubricants (page 172). Make sure that the oil level is between the minimum and maximum marks on the dipstick. Do not fill above the maximum oil level. See maintenance data for the volume. 91/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2.4 Checking the DANA transmission oil level WARNING HOT FLUID HAZARD Risk of serious personal injury. Avoid spilling hot oil and do not touch hot surfaces. 1 2 Figure 28. Checking transmission oil level NOTE Park the machine on level ground in a safe working area. 1. Start the engine. 2. Run the engine until it has reached operating temperature 82–93° C (180–200° F). NOTE Oil temperature must be at least 65° C (149° F). 3. Open the hatch for the dipstick (1) and the oil filling (2). 4. Remove the dipstick (1) and dry it off with a clean and lint free cloth. 5. With the engine idling, insert the dipstick (1) fully. 6. Remove the dipstick (1) again. 7. Check that the oil level is between the minimum and maximum level indicators. 8. If the level is incorrect, contact your local service team. NOTE Only trained service personnel are allowed to top up transmission oil. 92/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.2.5 Checking the ZF transmission oil level WARNING HOT FLUID HAZARD Risk of serious personal injury. Avoid spilling hot oil and do not touch hot surfaces. 1 2 Figure 29. Checking the ZF transmission oil level NOTE Park the machine on level ground in a safe working area. 1. Start the engine and run until the oil has reached operating temperature (at least 65°C or 149°F). 2. Remove the dipstick (1) and dry it off with a clean and lint free cloth. 3. With the engine idling, put back the dipstick fully into the tube (2) and remove it again. The oil level must be between the minimum and maximum level indicators. 4. If level is low, contact your local service team. NOTE Only trained service personnel are allowed to top up transmission oil. 93/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2.6 Checking the coolant level, Volvo engines WARNING TOXIC SUBSTANCE HAZARD It is highly dangerous to drink ethylene glycol. Contact with skin or spray from the refill can cause skin irritation and eye damage. Do not drink ethylene glycol, and avoid contact with skin. WARNING HOT COOLANT HAZARD Opening the pressure chamber cap can cause serious personal injury. Never open the pressure chamber cap (1) when checking, or refilling coolant. NOTE Only authorized maintenance personnel are allowed to fill the coolant. 1 2 1. Check the level of the coolant on the level indicator (2). The level should always be above the minimum level. NOTE If the coolant level decreases much every day, notify the maintenance personnel. 94/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.2.7 Checking the coolant level, Cummins WARNING TOXIC SUBSTANCE HAZARD It is highly dangerous to drink ethylene glycol. Contact with skin or spray from the refill can cause skin irritation and eye damage. Do not drink ethylene glycol, and avoid contact with skin. NOTE Only authorized maintenance personnel are allowed to fill the coolant. 2 1 1. Check the level of the coolant. The level should be at maximum on the level indicator (1) of the coolant tank (2). NOTE If the coolant level decreases much every day, notify the maintenance personnel. 95/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2.8 Checking the hydraulic oil level WARNING HOT FLUID HAZARD Hot hydraulic oil may spray from the oil refill, which may cause a risk of serious personal injury. Do not fill hydraulic oil while the machine runs. 1 Before checking the hydraulic oil level, make sure that the mast and forks are lowered. The mast should also be tilted to the maximum rear position. 1. Check that the oil level is between the minimum and maximum level marks on the indicator (1) at the side of the hydraulic oil tank. NOTE When the oil is warm, the oil level raises. NOTE Only trained service personnel are allowed to fill the oil. 96/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.2.9 Checking the brake cooling oil level (option) WARNING HOT FLUID HAZARD Hot oil may spray from the oil refill, which may cause a risk of serious personal injury. Do not fill oil while the engine is running. NOTE Park machine on level ground in a safe working area. 1 High Low High Low 1. Check that the brake cooling oil level is between the minimum and maximum level marks of the indicator at the side of the brake cooling oil tank (1). 2. If level is low, contact your local service team. NOTE Only trained service personnel is allowed to top up the brake-cooling oil. 4.2.10 Checking the engine air filter, Volvo engines In sandy or dusty environments with a large number of particles, clean the engine air NOTE filter more frequently. Only authorized maintenance personnel are allowed to clean the air filter. 1 Figure 30. Checking the engine air filter 1. When the engine air filter (1) needs to be checked, a warning about air inlet pressure appears on the MD4 display. 97/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 2. If warning appears in the MD4 display, contact your local service team. 4.2.11 Checking the windshield washer level NOTE Park machine on level ground in a safe working area. 1 Figure 31. Windshield washer fluid tank 1. Check the windshield washer fluid level in the washer fluid tank (1). NOTE To see the level, open the lid. 2. If level is low, contact your local service team. NOTE Only trained service personnel are allowed to top up the windshield washer fluid. 98/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.2.12 Checking the fuel level DANGER IGNITION HAZARD Spilling fuel may start a fire, which can cause serious injury or death and can damage the machine. Spilling fuel can also damage the environment. Do not spill fuel. If air enters the fuel system, the engine stops. To avoid air being sucked into the fuel NOTE system, never run the machine until the fuel tank is empty. If air enters the fuel system, a service technician must bleed the fuel system. NOTE Turn off the engine before filling fuel. 1 Figure 32. Checking the fuel level 1. Check the fuel level (1) in the MD4 display. 2. If the level is too low, fill up the fuel. 99/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 2 Figure 33. Adding fuel 1. Clean the area around the filler cap (2). 2. Open the filler cap (2) on the fuel tank. 3. Fill with the recommended fuel. See Recommended fluids and lubricants (page 172). See maintenance data for volume. 4. Refit the filler cap (2), and tighten it. 4.2.13 Checking the AdBlue level WARNING HARMFUL SUBSTANCE HAZARD Causes irritation on skin or eye contact. Handle carefully, avoiding contact with skin and eyes. If you get AdBlue solution on your skin or eyes, quickly wash it off with soap and water. WARNING CORROSIVE SUBSTANCE HAZARD The AdBlue solution is corrosive towards certain metals such as copper and aluminum, which is used in harnesses, cables and connectors. Do not allow the AdBlue solution to come into contact with any parts that are made of copper or aluminum. Corrosion starts and progresses rapidly. AdBlue information for Volvo stage V engines is found here, Selective catalyst reduction NOTE (SCR) - Volvo stage V (page 111), and for Cummins stage IV engines here, Selective catalyst reduction (SCR) - Cummins engines (page 116). AdBlue level must be more than 10%. If the AdBlue level becomes less than 8%, the NOTE engine generates an error code which must be restored by Volvo. If the AdBlue level is less than 23%, the torque of the engine starts to derate, which NOTE reduces the capacity of the machine. In temperatures below -11°C (12°F), the AdBlue solution freezes. Do not store below -11°C NOTE (12°F), recommended storing temperature is approximately 20°C (room temperature). 1. Start the engine. 100/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 2. All Main pages show the AdBlue level (1) as percentage of the total tank volume. 1 3. If the level is too low, open the hatch to access the AdBlue tank. NOTE When the level is too low, the symbol for AdBlue level (1) becomes red. 2 4. Clean the area around the AdBlue tank cap (2). 5. Open the AdBlue tank cap (2) and fill with the recommended AdBlue solution. See maintenance data for maximum volume. 6. Refit the AdBlue tank cap. 7. Close the hatch for AdBlue. 101/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2.14 Check the soot level 1 2 Figure 34. Emission page 1. Check the soot level (1) in the MD4 display. 2. Check the reason and severity of the soot level (2). 3. Perform a parked regeneration when needed. NOTE For Volvo engines, see Parked regeneration - Volvo stage V (page 113). 4.2.15 Adjusting the operator's seat DANGER UNCONTROLLED MOVEMENT HAZARD During an accident, not wearing the seat belt could result in serious personal injury or death. Always fasten the seat belt before driving. For optimum safety, and ergonomics, always adjust the seat to the individual preferences before starting the machine. Check and replace or repair if you notice any of the following: • cut or frayed straps • worn or damaged hardware, including anchor points • buckle or retractor malfunction • loose stitching 102/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.2.15.1 Adjusting the BE-GE operator's seat Be-Ge 91-series 1 3 8 2 3 4 5 7 6 Figure 35. Controls for the BE-GE operator's seat 1. Headrest (option) 5. Height and weight adjustment 2. Backrest adjustment 6. Quick-release 3. Integrated 3-point seat belt (option) 7. Length adjustment 160 mm (6.30 in) 4. Seat cushion angle adjustment 8. Lumbar adjustment 103/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions Be-Ge 92-series 1 3 7 2 3 4 6 5 Figure 36. Controls for the BE-GE operator's seat 1. Headrest (option) 5. Height and weight adjustment 2. Backrest adjustment 6. Length adjustment 160 mm (6.30 in) 3. Integrated 3-point seat belt (option) 7. Lumbar adjustment 4. Seat cushion angle adjustment 104/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions Be-Ge 31-series 1 3 9 2 3 4 5 6 7 8 Figure 37. Controls for the BE-GE operator's seat 1. Headrest (option) 6. Height adjustment 2. Quick-release backrest adjustment 7. Seat cushion angle adjustment 3. Integrated 3-point seat belt (option) 8. Length adjustment 210 mm (8.27 in) 4. Air controlled backrest functions 1) 9. Seat cushion length adjustment 5. Shock absorber 1)Heating and airvent (option) 105/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2.15.2 Adjusting the Isringhausen operator's seat 1 1 8 2 7 3 6 5 4 Figure 38. Controls for the Isringhausen operator's seat 1. Integrated 3-point seat belt 5. Horizontal adjustment 2. Backrest adjustment 6. Weight and height adjustment 3. Integrated pneumatic system (IPS) 7. Seat cushion adjustment 4. Adjustable vertical shock absorber 8. Tilt adjustment 106/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.2.15.3 Adjusting the Grammer operator's seat 1 2 3 9 4 8 7 6 5 Figure 39. Controls for the Grammer operator's seat 1. Headrest (option) 6. Height adjustment 2. Seat heating 7. Shock absorber (adjustable) 3. Adjustable backrest angle 8. Forward and backward adjuster (170 mm) 4. Integrated 3-point seat belt 9. Adjustable seat cushion depth and angle 5. Forward and backward isolator (lockable) 1) 1)Reduces horizontal vibration in the direction of travel, for a more comfortable ride on tough terrain. 107/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2.16 Adjusting the steering wheel Figure 40. Controls for the steering wheel 1. Pull lever (1) upwards to adjust the height of the steering wheel. 2. Push lever (1) downwards to adjust the tilt of the steering wheel. 3. Step on the pedal (2) to adjust the angle of the steering column. 4.3 Hydraulic long life (HLL) filter (option) 4.3.1 Placement of the hydraulic long life (HLL) filter 1 Figure 41. Placement of filter, SMV 10-16 108/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 1 Figure 42. Placement of filter, SMV 18-60 1. Placement of the HLL filter 4.3.2 Checking the HLL filter 1 Figure 43. Pressure indicator The pressure indicator (1) shows the status of the HLL filter, when the machine is on. If the indicator points towards the red area between service intervals, contact authorized maintenance personnel. 4.4 Engine After-treatment System (EATS) - Volvo stage V The Engine After-treatment System (EATS) display page shows information concerning the "Selective Catalytic Reduction" system (SCR). The SCR system includes information about "Nox Control Diagnostics" (NCD) and "Diesel Particle Filter" system (DPF) including "Particle Control Diagnostics" (PCD). 109/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 1 2 3 Figure 44. Machine overview page - Volvo stage V 1. Navigate to the Machine overview page (1). 2. Navigate to the Emission page (2). The EATS display page can also be accessed by clicking the warning symbols (3) in the NOTE bottom frame. 1 2 3 4 5 6 7 11 10 8 9 Figure 45. Emission page - Volvo stage V 1. AdBlue level indication 2. Soot level indication 3. Ash level indication 4. Parked regeneration "start" button 5. Parked regeneration "cancel" button 6. Reason and severity indication AdBlue level 7. Reason and severity indication soot level DPF 8. Engine diagnostics button 110/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 9. Warning symbols "Parked regeneration", "Parked regeneration cancel", and "AdBlue level" warning. 10. Engine warning 11. Engine stop NOTE When the ash level indication (3) reaches 80%, the filter needs to be changed. 4.4.1 Selective catalyst reduction (SCR) - Volvo stage V Nox is one of the residual products during the combustion of diesel fuel. To reduce the Nox levels that the engine is fitted with an SCR system. The SCR system converts Nox into nitrogen and water using AdBlue. NOTE If the AdBlue level is 0, the SCR system is not able to reduce the Nox levels. 1 2 1. AdBlue level indication 2. Reason and severity indication AdBlue level Nox control diagnostics (NCD) - Reason and severity AdBlue is essential for the aftertreatment system (EATS) and is a part of the NCD. On the emission page, the reason and severity level codes are displayed with the letters R and S. An NCD reason (R) value of 1 indicates a low AdBlue level. The NCD severity value (S) increases as the AdBlue level decreases. NOTE If the reason (R) has a value other than 0 or 1, contact an authorized dealer. Figure 46. AdBlue level and severity values There are four levels of severity depending on the AdBlue level and time: 111/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions Table 6. Nox control diagnostics (NCD) Nox control diagnostics (NCD) – Low AdBlue level AdBlue Level < 15% < 6% < 6% < 6%> 7 min Severity 1 3 4 5 Active warning symbols Solid amber Flashing amber Flashing amber Flashing amber Solid amber Solid red Solid red Solid red 50% torque and 25% torque 25% torque Derate None 40% RPM reduction reduction reduction Recommended Refill AdBlue Refill AdBlue Refill AdBlue Refill AdBlue action 4.4.2 Diesel Particulate Filter (DPF) - Volvo stage V 1 2 3 Figure 47. EATS emission page Volvo stage V 1. Soot level indication (1). 2. Ash level indication (2) 3. Reason and severity soot level DPF (3) Passive regeneration Soot is one of the residual products during the combustion of diesel fuel. The engine continuously strives to maintain the passive regeneration, which maintains a slow accumulation of soot in the DPF. 112/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions The passive regeneration is sufficient to maintain an acceptable level of soot in the DPF under normal circumstances. If the engine operates or idle at low RPM or is unable to reach a normal working NOTE temperature during operation, soot in the engine accumulates faster. NOTE When the ash level indication (2) reaches 80%, the filter needs to be changed. Particle Control Diagnostics (PCD) The engine sends information about the status of the particulate filter. On the emission page, the error code is displayed with the letters R and S. R shows the reason of the error and S shows the severity level. If an error occurs, different notifications are triggered depending on the severity level. Soot accumulation is normal and gradual over time, it is therefore not part of the PCD. The R (reason) and S (severity) next to the DPF symbol should always show the value 0. Figure 48. PCD reason and severity values NOTE If R (reason) has a value other than 0, contact an authorized workshop. 4.4.3 Parked regeneration - Volvo stage V WARNING IGNITION HAZARD When a parked regeneration is performed, the exhaust gas temperature may exceed 500°C. If there are flammable or combustible materials, on or near the machine, the exhaust gas can cause a fire. Examples of such materials are paper, saw dust or fuel. When performing a parked regeneration, the machine must be positioned in a well- ventilated area away from flammable material. If possible, the machine should be parked on gravel. Over time the DPF (Diesel Particulate Filter) will accumulate soot. The time that it takes depends on the machine operation. Performing a parked regeneration burns the soot and cleans the filter. During the regeneration, the engine RPM gradually increases to 1400 RPM. During the NOTE regeneration, the parking brake cannot be released and the hydraulic functions are disabled. The procedure takes about 45 min, but can vary from 20–60 min depending on the current engine temperature and soot level. The engine RPM decreases to idle RPM and normal operation can be resumed when the regeneration is completed. Operating or idling at low RPM and below normal operating engine temperatures causes NOTE the soot in the DPF to accumulate faster. The increasing level of soot makes the engine struggle to maintain the passive regeneration. When the soot level is 80%, the parked regeneration can only be initiated by "Volvo NOTE Penta" service dealers using VODIA (Volvo diagnostics). 113/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 1 2 3 4 1. Soot level indication bar 2. Parked regeneration "start" button 3. Parked regeneration "cancel" button 4. Reason and severity indication soot level DPF (Diesel Particulate Filter) To initiate a parked regeneration: 1. Position the machine in a safe location. 2. Check the fuel and AdBlue levels, top up if needed. 3. Select neutral gear. 4. Activate the parking brake. 5. Press the regeneration "start" button (2) for 2 s. If an emergency occurs, press and hold the "cancel" button (3) for 0.1 s to stop the NOTE parked regeneration. The machine resumes normal operation. Always wait for the parked regeneration to complete. The procedure can be stopped four times in a row without completion. After five consecutive stops, the next parked NOTE regeneration can only be activated by a Volvo Penta dealer using VODIA (Volvo diagnostics). There are four different intervals of severity depending on the soot level: 114/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions Table 7. Soot level severity Soot level 0%–60% 61%–69% 70%–79% 80%–100% Torque limit No No No Yes Parked No Yes Yes No regeneration enabled Active warning None symbols Solid amber Flashing amber Flashing amber Solid amber Solid red Contact Start Recommended Time to start authorized No action. regeneration action regeneration. workshop immediately. immediately. 4.5 Engine aftertreatment System - Cummins engines The Engine After-treatment System (EATS) display pages show information concerning the "Selective Catalytic Reduction" system (SCR). The SCR system includes information about "Nox Control Diagnostics" (NCD) and "Diesel Particle Filter" system (DPF) including "Particle Control Diagnostics" (PCD). 1 2 3 Figure 49. Machine overview page 1. Navigate to the Machine overview page (1). 2. Navigate to the Emission page (2). The display page for the engine aftertreatment system can also be accessed by clicking NOTE the warning symbols in the bottom frame (3). 115/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 1 2 3 4 8 7 5 6 Figure 50. Emission page 1. AdBlue/DEF (Diesel Exhaust Fluid) level indication 2. Soot level indication 3. Parked regeneration "start" button 4. Parked regeneration "cancel" button 5. Engine diagnostics button 6. Warning symbols "Parked regeneration", "Parked regeneration cancel", and "AdBlue/DEF level" warning. 7. Engine warning 8. Engine stop 4.5.1 Selective catalyst reduction (SCR) - Cummins engines Applicable for B 6.7 and X12 EU stage V / tier 4f, QSB 6.7 tier 4f If the AdBlue/DEF level is 0, the SCR system is not able to reduce the NOx levels. High NOTE NOx levels reduce and limits the performance. Nitrogen Oxide (NOx) is one of the residual products during the combustion of diesel fuel. To reduce the NOx levels that the engine is fitted with an SCR system. The SCR system converts NOx into nitrogen gas (N2) and water using AdBlue/DEF (Diesel Exhaust Fluid). NOx control diagnostics (NCD) 116/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions NOx control diagnostics (NCD) – Low AdBlue/DEF level AdBlue/DEF < 10% < 5% < 2.5% < 0% Level Severity 1-2 3 4 5 Active warning symbols Solid amber Flashing amber Flashing amber Flashing amber Solid amber Solid amber Solid red Solid red Solid red No torque (1) 50% torque (3) 75% torque and no engine and 40% engine Derate None reduction and RPM (2) RPM (4) Engine idle RPM reduction reduction Recommended Refill Refill Refill Refill action AdBlue/DEF AdBlue/DEF AdBlue/DEF AdBlue/DEF (1) Starts to derate 5 min before reaching next severity level, down to 50% reduction. (2) Starts to derate 5 min before reaching next severity level, down to 40% reduction. (3) Starts to derate 5 min before reaching next severity level, down to 75% reduction. (4) Starts to derate 5 min before reaching next severity level, down to "Engine idle RPM". 117/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.5.2 Diesel Particulate Filter (DPF) - Cummins engines Applicable for B 6.7 and X12 EU stage V / tier 4f 1 2 3 Figure 51. Emission page 1. Soot level indication. 2. Parked regeneration "start" button. 3. Parked regeneration "cancel" button. Soot is one of the residual products during the combustion of diesel fuel. The engine control module (ECM) continuously controls the soot load in the DPF. The soot levels are shown on the display page and are presented on the soot level indicator. Above the indicator, the DPF symbol is displayed. When the different levels in the DPF are reached, they are transmitted to the VCU (Vehicle Control Unit). If the engine operates or idle at low RPM or is unable to reach a normal working NOTE temperature during operation, soot in the engine accumulates faster. The following image shows the approximate soot level indications. Full High Medium Low Empty Passive regeneration A passive regeneration can be initiated by the ECM (Engine Control Module). Usually, the passive exhaust system cleaning can be performed while the machine performs its normal functions and remains unnoticeable to the operator. The passive regeneration provides the least disruption to the productivity of the machine. 118/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.5.3 Parked regeneration - Cummins engines Applicable for B 6.7 and X12 EU stage V / tier 4f WARNING IGNITION HAZARD When a parked regeneration is performed, the exhaust gas temperature may exceed 500°C. If there are flammable or combustible materials, on or near the machine, the exhaust gas can cause a fire. Examples of such materials are paper, saw dust or fuel. When performing a parked regeneration, the machine must be positioned in a well- ventilated area away from flammable material. If possible, the machine should be parked on gravel. Operating or idling at low RPM and below normal operating engine temperatures causes NOTE the soot in the DPF (Diesel Particulate Filter) to accumulate faster. The increasing level of soot makes the engine struggle to maintain the passive regeneration. Always wait for the parked regeneration to complete. If the regeneration is interrupted two times within 30 min, a warning is shown in the display unit. If the regeneration is NOTE canceled three times within 30 min, or is interrupted five times, it is no longer possible to start regeneration using the display unit. Contact with an authorized service technician is required. If the button for cancel regeneration is pressed, both the automatic and the parked regeneration is disallowed. If the button is pressed when regeneration is active, NOTE regeneration is stopped. It is recommended by the engine supplier that the "cancel" button is only used when high exhaust temperatures may cause a hazardous condition. During the regeneration, the engine RPM gradually increases to 1400 RPM. During the NOTE regeneration, the parking brake cannot be released and the hydraulic functions are disabled. It is not possible to activate forward or reverse gear. Over time the DPF (Diesel Particulate Filter) will accumulate soot. The time that it takes depends on the machine operation. Performing a parked regeneration burns the soot and cleans the particulate filter. The procedure takes about 45 min, but can vary from 20–60 min depending on the current engine temperature and soot level. The engine RPM decreases to idle RPM and normal operation can be resumed when the regeneration is completed. 119/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 1 2 3 1. "Soot level indication" bar 2. Parked regeneration "start" button 3. Parked regeneration "cancel" button If high levels of soot are indicated, initiate a parked regeneration: 1. Position the machine in a safe location. 2. Check the fuel and AdBlue/DEF levels, top up if needed. 3. Select neutral gear. 4. Activate the parking brake. 5. Press the regeneration "start" button (2) for 2 s. If an emergency occurs, press and hold the "cancel" button (3) for 0.1 s to stop the NOTE parked regeneration. The machine resumes normal operation. If regeneration is active, the indication light below the start regeneration button is lit. If regeneration is not possible, due to low soot levels or if the "cancel" button has been pressed, the regeneration button is grayed out. 120/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions If regeneration has been canceled, the indication light below the cancel button is lit. There are four different intervals of severity depending on the soot level: Table 8. Soot level severity Soot level 0%–60% 61%–69% 70%–79% 80%–100% Reduction and No No No Yes Torque limit Parked No Yes Yes No regeneration enabled Active warning None symbols Solid amber Flashing amber Flashing amber Solid amber Solid amber Solid red Contact Start Recommended Time to start authorized No action. regeneration action regeneration. workshop immediately. immediately. 4.5.4 Diesel Oxidation Catalyst (DOC) - Cummins engines Applicable for QSB 6.7 tier 4f Diesel Oxidation Catalyst (DOC) is an aftertreatment component that converts carbon monoxide (CO) and hydrocarbons into carbon dioxide (CO2) and water vapor. DOC works in a passive mode and require no active regeneration or other special requirements. The DOC component breaks down pollutants in the exhaust stream from the engine. DOC also reduces particulate matter (PM) through a chemical reaction that requires no cleaning or maintenance. Exhaust flows through the Engine Aftertreatment System (EATS), and passes from the turbo through the DOC. Even after the DOC collects particles from the harmful substances in the exhaust, it still contains Nitrogen oxide (NOx). NOx levels are reduced by using AdBlue/DEF (Diesel Exhaust Fluid). See Selective catalyst reduction (SCR) - Cummins engines (page 116). 121/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.6 Using the cabin heating and ventilation 1 2 1. Fan speed 2. Heat control 1. To select the desired fan speed, turn the left handle (1). 2. To control the temperature, turn the right handle (2). 122/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.7 Using the cabin ventilation (option) 1 2 3 4 5 6 7 8 Figure 52. Cabin ventilation A lamp lights up when a function (2, 3, 5, 6) is active. Press again to deactivate. 1. Fan speed 5. Display outside temperature 2. Air recirculation 6. Defrost 3. Air conditioning 7. Temperature control - 4. Temperature display 8. Temperature control + The cabin temperature is controlled by a heating/air conditioning unit with a motorized water valve and an external air flap. The temperature display (4) shows the inside temperature you have set for the cabin. You can set the value 18°C…28°C (corresponding to 64°…82°F). Set the temperature by pressing the - and + buttons (7, 8). Press (5) to display the outside temperature on the 4-digit display (4). To switch the unit of temperature between Celsius and Fahrenheit, press (5) for more than 20 s. Controls may vary according to customer options. Tips for working with the air conditioning: • To reduce humidity in the cabin, operate the machine with the air conditioning system on. • Recirculated air helps to cool down the cabin faster. • When driving and with normal humidity, use external air intake. • To reduce fog build-up during humid weather, and ice during cold weather, use the defroster. 4.8 Driver login (option) If the machine is shut down and restarted, the login code of the operator must be NOTE reentered. 1. When opening one of the Main pages, a pop-up screen (1) appears. 123/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 2 1 2. Press Enter PIN (2). 3 3. Enter the personal login code and press (3). 4.9 Changing the operator If the operator changes, the login code of the new operator must be entered. Figure 53. Operator's button on the right side 1. On any of the Main pages, tap the button on the right side to open the Operator’s menu. 124/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions Driver 11 1 2. Press the driver selection button (1) , a drop-down menu opens. Driver 13 2 3 3. Select your driver's number from the drop-down menu, for instance, Driver 13 (2). 4. A pop-up window opens. Press Enter PIN (3). 125/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions Driver 13 4 5. Enter your personal login code and press (4) Now you can start the machine. 4.10 Break-in period The machine can be driven at full speed right from the start. However, prolonged maximum loading of the hydraulic system and transmission must be avoided during the first 50 hours of operation. After the first 150 hours, perform the first service. For more information, see the maintenance instruction. 4.11 Steering and braking 4.11.1 Steering To minimize unnecessary wear and tear to the tires, turn the steering wheel only when the machine is moving. 126/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.11.2 Using the electrical mini-wheel steering (option) DANGER MOVING MACHINE HAZARD Losing control of the steering system of the machine can cause material damage, personal injury, or death. If the system detects a fault in the electrical mini-wheel steering system, a warning buzzer sounds in the cabin. The operator must then use the ordinary steering wheel. DANGER MOVING MACHINE HAZARD Losing control of the steering system of the machine can cause material damage, personal injury, or death. If any faults or malfunctions with the mini-wheel steering system is detected, the machine must immediately be taken out of use. Maintenance staff must be contacted. The mini-wheel is an ergonomic feature that helps to reduce stress on the shoulders and back of the operator. 1 2 Figure 54. Mini-wheel steering 1. Mini-wheel steering 2. F-N-R switch 127/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 2 1 Figure 55. F-N-R mini-wheel steering 1. Mini-wheel steering 2. F-N-R switch 1 2 Figure 56. Dome lever steering 1. Lever steering 2. F-N-R switch 128/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 1 2 Figure 57. Lever steering 1. Lever steering 2. F-N-R switch It is always possible to steer the machine with the ordinary steering wheel. When the NOTE ordinary steering wheel is in use, the mini-wheel steering is deactivated. The main steering wheel retains priority over mini-wheel steering in case you must grab NOTE it suddenly. 3 3 1. To activate mini-wheel steering, press the button (3). 2. To deactivate mini-wheel steering, press the button (3) again. NOTE The F-N-R switch is disabled when the mini-wheel steering function is deactivated. 129/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.11.3 Force neutral when braking The function "force neutral when braking" helps avoid abnormal wear on the brakes. When the driving speed is higher than 4 km/h, and the operator presses the brake pedal the gear is forced into neutral. When the operator releases the brake, the gear is reactivated. NOTE When using the inching brake function, "force neutral when braking" is not activated. 130/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.11.4 Activating the declutch 3 1 2 Figure 58. Activating the declutch, cabin with levers 3 1 2 Figure 59. Activating the declutch, cabin with joystick The declutch switch (1) disengages the transmission, and enables the operator to control the hydraulics while maintaining a high engine RPM. During stacking maneuvers, this function prevents overheating of the engine, transmission, or brakes. The additional benefits are that the reverse or forward gear can remain activated. 1. To activate the declutch, press the declutch switch (1). 2. If you press the declutch switch (1) at the same time as the brake pedal (2), the brakes are applied. When you brake using only the brake pedal (2), the declutch is not activated. If the gear switch (3) is in forward or reverse position, the transmission is activated again NOTE when releasing the pressure on the declutch switch (1). 131/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.11.5 Activating the declutch, with pressure switch (option) 3 Figure 60. Activating the declutch with pressure switch The declutch with pressure switch disengages the transmission depending on the brake pressure. When the brake pressure exceeds approximately 30 bar, the transmission disengages (Neutral). This function enables the operator to control the hydraulics while maintaining a high engine RPM without overheating the engine, transmission, or brakes during stacking maneuvers. 1. To activate the pressure switch, press either the left or the right brake pedal (2). 2. Control the lifting speed by pressing the accelerator pedal (1). If the gear switch (3) is in forward or reverse position, the transmission is reactivated NOTE when the brakes are released. 4.11.6 Activating the inching function (option) 2 1 Figure 61. Activating the inching function The inching function disengages the transmission depending on, and parallel to the brake pressure. The inching function enables a smooth propulsion in parallel with an effective lifting speed. 1. To activate the inching function, press either the left or the right brake pedal (2). 132/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 2. Control the lifting speed by pressing the accelerator pedal (1). NOTE The higher brake pressure, the lower propulsion. When using the inching function, "force neutral when braking" is not activated. Force NOTE neutral when braking (page 130) 4.11.7 Parking WARNING RISK OF UNINTENDED MOVEMENT The parking brake can fail and cause unintended movement. Park the machine on level ground. Before parking the machine: • Make sure that the forks are fully lowered. • Tilt the mast forward, the fork tips must touch the ground. • Park the machine on level ground. To hold the machine still while working on slopes with up to 15% inclination, the parking NOTE brake can be used. 1. Use the service brake to bring the machine to a standstill. 2. Select neutral gear. 3. Activate the parking brake. 4. Turn off the ignition. 5. Wait until the AdBlue pump has stopped. NOTE After parking the machine, make sure to switch off the battery main switch. 133/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.11.8 Activating the parking brake Figure 62. Parking brake, cabin with levers 1 If the operator leaves the seat without activating the parking brake, an audio signal is activated. Check the function of the parking brake daily. Contact your authorized dealer, or NOTE maintenance personnel if the parking brake does not function properly. If there is doubt, they can ensure that the parking brake is in a safe condition to use. 1. Bring the machine to a standstill, using the service brake. 2. Select the neutral gear. 3. Press (1) to activate the parking brake. 4.11.9 Automatically applied parking brake (option) The parking brake is activated automatically, when there is no signal from the seat switch sensor. The machine must be stationary, for the parking brake to be activated. 134/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 1 To release the parking brake again, the parking brake button (1) on the keypad must be pressed. 4.11.10 Differential lock function (option) WARNING RISK OF DAMAGE TO THE MACHINE Wrong usage can damage the axle drive line parts Only use the function when operating with low and bad traction (when driving in snow, ice, or mud). Do not use for long-distance driving. Only apply the differential lock when the machine stands still. Do not drive with full engine power. No steering is allowed when the differential lock is applied. Only use the differential lock when driving forwards. The differential lock function enables the possibility to have the same propulsion power and speed on all drive wheels. The differential lock function can be used to stabilize the forward propulsion when operating with bad and low traction (such as snow, ice, or mud). The following symbol (2) is shown in the display when the differential lock function is activated: 2 135/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 1. Slow down the machine to a standstill. 2. Press the activation button for the differential lock (1). 3. Drive slowly forwards max speed 5 km / hour. 4. Slow down the machine to a standstill. 5. Press the activation button (1) again to deactivate the differential lock. 4.12 Sideways sliding cabin DANGER PERSONAL INJURY HAZARD When the cabin is sideways positioned, the distance to the ground is high. A fall from this height, can cause serious personal injury or death. If the cabin is sideways positioned, do not exit the cabin on the right side. In an emergency situation, when the left door is blocked, use the emergency hammer and exit through the rear window. WARNING PERSONAL INJURY HAZARD If walking in the area to the right of the cabin, when the cabin is sideways positioned, there is a risk of tripping. Tripping causes a risk of serious personal injury. Be careful when moving in this area, preferably return the cabin to normal position before exiting the cabin. WARNING RISK OF DAMAGE When moving the cabin sideways, there is a risk of colliding with objects or persons in the surrounding area. There is a risk of personal injury and damage to the machine. Make sure that there is enough space to slide the cabin sideways. Make sure that there are no personnel near the area when moving the cabin. WARNING LIMITED VISIBILITY HAZARD The working range of the machine is large and visibility from the operator’s cabin is limited. Risk of serious personal injury and damage to the machine Before you start to move the machine, check that the road ahead is free and that you have an unobstructed view. If the view forwards is obstructed, use the sideways sliding feature to change the position of the cabin. If the view is still obstructed, drive in reverse. 136/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions The cabin must be in end position, either in normal position, or in sideways position to NOTE be able to operate the machine. The sideways sliding cabin function is an option which enables the operator to change the position of the cabin. The feature can be used when the view is obstructed when operating the machine. The function is hydraulic, and the following criteria must be fulfilled move the cabin: • Engine runs • Parking brake is engaged 1 1. Use the switch (1) to move the cabin sideways. The cabin moves proportionally depending on the angle of the switch. When the switch NOTE is released, the cabin movement stops. 2 137/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 2. Cabin in normal position (2). 3 3. Cabin positioned sideways (3). 138/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.13 Using the 180° rotating seat (option) WARNING PERSONAL INJURY HAZARD If the operator is not correctly positioned in the seat, the rotating movement could cause personal injury. When rotating the seat, wear a seat belt, and make sure that legs and arms are safely positioned. Make sure that seat, and backrest settings does not interfere, when rotating the operator seat. WARNING CRUSH INJURY HAZARD If there are several persons in the cabin when rotating the seat, there is a risk of personal injury due to the rotating movement. There is a risk of getting pinned between the seat and the cabin. When rotating the seat, the operator must make sure that there are no other persons in the cabin. When rotating the seat, the operator must make sure that there are no other items, such as bags, or jackets, in the cabin. Make sure to not release the hand and foot switches before the seat is fully rotated to 180°. If any of the switches are released too early, the seat returns to either a forward or NOTE reverse position. Depending on the position of the seat when releasing the switches, the seat can also stop between end positions. If so, the parking brake cannot be released and a warning is shown in the display. When the seat rotates, the hydraulic functions are disabled. When the seat is fully rotated NOTE to end direction, facing forwards, the hydraulic functions are enabled. When the seat is fully rotated to end direction, facing backwards, the hydraulic functions are disabled. 1) When equipped with "Armrest inclination sensor" (option), it is not possible to rotate the NOTE seat when the armrest inclination is more than 45°. 1) All hydraulic functions, can be activated in the settings. For more information, contact Konecranes Lift Trucks, or an authorized dealer. Figure 63. Rotating seat in forward driving position (left) and reverse driving position (right) 139/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions The rotating seat option allows the operator to rotate the seat 180° for reverse driving. As this feature eliminates the need for reversing, it decreases strain and stress on the operator. Rotating seat also gives a better view of the rear and increases safety when driving. The steering wheel rotates together with the seat, but there are pedals on both sides of the cabin. When the seat is rotated, the following changes take place: • The turning directions of the steering wheel adapt to the new driving direction. • The lights adapt to the new driving direction. • The gear switch adapts to the new driving direction. 2 1 1. Bring the machine to a standstill. 2. Make sure that the machine is in neutral. 3. Apply the parking brake. 4. Press both feet against the two switches (1) under the seat. 5. Activate the switch (2) for seat rotation on the armrest. 6. Keep pressing the switches (1) and (2) until the seat has rotated fully to 180°. 7. Release the switches (1) and (2). The machine can now be driven in the opposite direction. If the accelerator pedal is not pressed within 10 s, the parking brake must be disengaged manually, by pressing the parking brake button. When finished, rotate the seat back to the original position by following the same procedure. 140/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.14 Operating 4.14.1 Daily inspection before operation (option) Daily inspection 2 • Check the battery main switch • Check lifting equipment, forks and lifting chains • Check the tire pressure, condition, rims and wheel nuts • Check the engine oil level 1 • • Check the transmission oil level Check the coolant level • Check the hydraulic oil level • Check the grease level in the container for the automatic lubrication system (option) • Check the MD4 warnings for clogging of engine air filter (option) • Check the windshield washer fluid level • Check the fuel level • Check the AdBlue level (when applicable) • Check that the mirrors are clean and adjust them. Clean the rearview camera (option) • Check the seat adjustments • Check the functionality of the brake system • Check the functionality of the steering system • Check the functionality of the hydraulic system • Check the lights and horn • Check the climate unit (option) settings When starting the machine for the first time each day, a checklist is displayed. The operator must go through the list and confirm that the machine functions as expected before the engine can be started. Press the check mark button (1) to confirm the functions. If a fault is detected during the inspection, press the cross button (2). If a fault is detected, evaluate the problem, contact maintenance personnel if needed. NOTE When the problem is solved, start the machine again. If the machine passes all the tests, and the inspection is confirmed, it is possible to start the engine. The status of the inspection is transmitted to TRUCONNECT®. When no status is uploaded, the machine sends “No status” to TRUCONNECT®. 4.14.2 Operating - general information To be able to start the machine, the operator needs to be identified. The machine can be started in the following ways: • Ignition key - for more information see: Starting the engine (page 142) • Ignition key and driver login with code - for more information see: Driver login (option) (page 123) • RFID - for more information see: Starting the engine, with RFID tag (option) (page 144) 141/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.14.3 Starting the engine WARNING TOXIC SUBSTANCE HAZARD Breathing diesel engine exhaust exposes you to chemicals that may cause cancer, birth defects or other reproductive harm. Never run the engine in unventilated places. Use fume extraction. Do not keep the engine idling, except when necessary. Do not modify or tamper with the exhaust system. Figure 64. Starting the engine, cabin with levers 142/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions Figure 65. Starting the engine , cabin with a joystick 1. Position yourself in the operator’s seat. 2. Ensure that the gear switch (1) is in neutral. 3. Insert the ignition key (2). 4. Turn the key clockwise. 5. Wait until the display shows the home page. 6. Press the start button (3). The engine starts. 143/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.14.4 Starting the engine, with RFID tag (option) WARNING TOXIC SUBSTANCE HAZARD Breathing diesel engine exhaust exposes you to chemicals that may cause cancer, birth defects, or other reproductive harm. Never run the engine in unventilated places. Use fume extraction. Do not keep the engine idling, except when necessary. Do not modify or tamper with the exhaust system. The RFID (Radio-frequency identification) tag identifies the operator and is used to start and stop the machine. If the RFID tag is used, it replaces the ignition key, there can be up to 200 individual tags/machine. 1. Position yourself in the operator’s seat. 2. Ensure that the gear switch is in the neutral gear. 3 2 2 START 1 1 3. Lift the cover of the armrest (1). 4 4. Swipe the RFID tag (4) over the RFID reader (2). 5. Wait until the display shows the home page. 6. Press the start button (3). The engine starts. 144/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.14.5 Stopping the engine WARNING RISK OF DAMAGE TO THE MACHINE If you do not let the turbo slow down before turning off the engine, there is a risk of turbo damage. Allow the engine to idle for a few minutes before turning of the engine. Use the emergency stop only in an emergency situation. For more information, see NOTE Emergency stopping (page 34). 4 2 1 1. Release the accelerator pedal (1). 2. Apply the service brakes (2) and bring the machine to a standstill. 3. Select the neutral gear (4). 4. Activate the parking brake (3). See Activating the parking brake (page 134). 5. Let the engine idle for a few minutes. 6. To stop the engine, press the start/stop button (5). 5 145/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 7. Turn the ignition key anti-clockwise. The engine and the ignition are now both NOTE turned off. 8. If you leave the machine unsupervised, turn off the battery main switch. For more information, see Battery main switch (page 35) NOTE Do not turn off the battery main switch before the engine has stopped. If the machine has en engine that uses diesel exhaust fluid (DEF) solution (AdBlue), turn off the engine, but do not turn off the battery main switch. Wait for the DEF pump to NOTE finish pumping back all the fluid from the hoses to the DEF tank before turning off the battery main switch (1). 4.14.6 Stopping the engine, with RFID tag (option) WARNING RISK OF DAMAGE TO THE MACHINE If you do not let the turbo slow down before turning off the engine, there is a risk of damaging the turbo. Allow the engine to idle for a few minutes before turning off the engine. Use the emergency stop only in an emergency situation. For more information, see NOTE Emergency stopping (page 34). Figure 67. Stopping the engine 1. Release the accelerator pedal (1). 2. Apply the brakes (2) and stop the machine. 146/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 3 4 5 2 START 1 6 3. Activate the parking brake (3). 4. Ensure that the gear switch is in the neutral gear. 5. To stop the engine, press the start/stop button (4). 6. Lift the cover of the armrest (6). 7 7. Swipe the RFID tag (7) over the RFID reader (5) to switch off the ignition. NOTE The machine must be in a standstill to use the RFID tag (7) to switch off the ignition. If you leave the machine unsupervised, switch off the battery main switch. Battery main NOTE switch (page 35) NOTE Do not turn off the battery main switch before the engine has stopped. 147/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.14.7 Operating the machine DANGER RISK OF TIPPING If driving with the load placed higher than the recommended transport position, the machine can roll or tip. Risk of death, serious injury and damage to the machine. If needed, reverse from stack, and lower the load to transport position before driving away. WARNING RISK OF DAMAGE TO MACHINE HAZARD Keeping the machine idling or operating at low load for long periods of time may cause oil leak, increased levels of soot, and damage the engine. Do not keep the machine idling or operating at low load for long periods of time. WARNING SIDEWAYS TILTING HAZARD Driving on uneven terrain may damage the machine. Driving on surfaces with insufficient support may cause the machine to roll or sink. Risk of serious personal injury and damage to the machine. Drive the machine only on level ground that is intended for the total weight and ground pressure of the machine. Figure 68. Do not drive on uneven terrain WARNING HIGH-VOLTAGE HAZARD Electric arcing can cause burns or electrocution even without direct contact with the power line. Be careful when operating the machine near electricity power lines. WARNING LIMITED VISIBILITY HAZARD The working range of the machine is large and visibility from the operator’s cabin is limited. Risk of serious personal injury and/or damage to the machine. Before you start to move the machine, check that the road ahead is free and that you have an unobstructed view. 148/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions WARNING RISK OF LOAD DROP Driving downhill on slopes carrying a load, can lead to a load drop. This can damage the machine and can lead to serious personal injury. If carrying a load, always drive downhill in reverse. WARNING TIPPING AND COLLISION HAZARD If you drive on slopes greater than 15%, the brakes may fail to stop the machine and machine may roll. Risk of serious personal injury and damage to the machine. Do not drive on slopes greater than 15%. If you must drive the machine along greater slopes, contact your Konecranes Lift Trucks NOTE authorized dealer. Figure 69. Do not drive on slopes steeper than 15% • The machine is not intended for off-road driving. • The machine is not equipped with wheel suspension. • Always adjust your method of driving to the condition of the road (bumps, and so on), to hazards within the working area and the load. • The indicated hill-climbing capacity of the machine in the data sheet is based on the pulling power of the machine. It applies only to driving over obstacles and minor irregularities in ground level. If leaving the seat when operating the machine, the transmission is forced into neutral. The gear must be reactivated when returning. Due to the "Operator presence" function, NOTE the operator must sit in the seat to activate the seat switch for the propulsion and the hydraulics. 1. Start the engine. 2. Lift just enough to still maintain a clear view above the load. If the load is so large it obstructs your view, drive the machine in reverse for better visibility. 3. Hold the steering wheel steady. Always use the whole of your hand to hold the wheel knob. 149/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.14.8 Driving forwards For more information regarding transport position of the forks, see Lifting and driving NOTE with a load (page 161). Figure 70. Driving controls, cabin with levers 150/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions Figure 71. Driving controls, cabin with joystick(option) 1. Press the brake pedal (1). To avoid damage and prevent the transmission from overheating, always start in the first NOTE or second gear. 2. Release the parking brake (2). 3. Select forward (3). 4. Release the brake pedal (1). 5. Press the accelerator pedal (4) slowly. When starting uphill, hold the machine still using the brake pedal (4), until you have NOTE sufficient pulling power. 151/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.14.9 Stopping the machine For more information regarding position of the forks when parking, see NOTE Parking (page 133). 4 3 2 1 Figure 72. Driving controls, cabin with levers 152/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4 3 2 1 Figure 73. Driving controls, cabin with joystick(option) 1. Take your foot off the accelerator pedal (1). 2. Press the brake pedal (2) and stop the machine in a gentle, controlled manner. WARNING FORWARD TIPPING HAZARD Sudden braking and acceleration may cause the machine to roll or tip. Risk of serious personal injury and damage to the machine. Avoid violent acceleration and braking. RISK OF PROPERTY DAMAGE NOTICE Do not use the transmission as a brake. 3. Select the neutral gear (4). 4. When the machine has stopped, activate the parking brake (3) before releasing the brake pedal. 153/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.14.10 Driving in reverse DANGER MOVING VEHICLE HAZARD Reversing without a direct view in the reverse direction may cause death, serious personal injury, or damage to property. Only drive in reverse when you have a direct and unobstructed view in the reverse direction. Figure 74. Driving controls, cabin with levers 154/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions Figure 75. Driving controls, cabin with joystick 1. Press the brake pedal (1). To avoid damage and prevent the transmission from overheating, always start in the first NOTE or second gear. 2. Release the parking brake (2). 3. Select reverse (3). 4. Release the brake pedal (1). 5. Press the accelerator pedal (4) slowly. NOTE Make sure that there is a direct view in the reverse direction. When starting uphill, hold the machine still using the brake pedal (4) until you have NOTE sufficient pulling power. 155/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.15 Mounting the attachment - ELME 815 4.15.1 Parts of the attachment 4 5 10 1 9 2 3 6 8 7 1. Fork in standard position 7. Fork in inverted position 2. Fixation for the safety and mounting 8. Safety and mounting bracket (inverted bracket (std position) position) 3. Safety and mounting bracket (std position) 9. Safety edge on bracket (inverted position) 4. Safety edge on bracket (std position) 10. Lower fixation point (inverted position) 5. Upper fixation point (std position) 6. Fixation for the safety and mounting bracket (inverted position) 4.15.2 Mounting the attachment - forks in standard position WARNING RISK OF DAMAGE TO THE MACHINE If the attachment is not fixated correctly on the forks, there is risk of dropping the attachment. Dropping the attachment can damage the machine and the surrounding area. Make sure to use the upper fixation points and position the mounting brackets with the safety edge upwards. 156/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 1 1. Insert the forks (1) in the pockets on the attachment. 4 5 1 2 3 2. Secure the forks (1) with the mounting brackets (3). NOTE The safety edge (4) on the mounting brackets (3) must be positioned upwards. Use the upper fixation points (5) for the mounting brackets (3) when using forks in NOTE standard position (1). 3. Secure the mounting brackets (3) with the fixations (2). 157/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.15.3 Mounting the attachment - forks in inverted position WARNING RISK OF DAMAGE TO THE MACHINE If the attachment is not fixated correctly on the forks, there is risk of dropping the attachment. Dropping the attachment can damage the machine and the surrounding area. Make sure to use the lower fixation points and position the mounting brackets with the safety edge downwards. 7 158/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 1. Insert the forks (7) in the pockets on the attachment. 10 9 6 7 8 2. Secure the forks (7) with the mounting brackets (8). NOTE The safety edge (9) on the mounting brackets (8) must be positioned downwards. Use the lower fixation points (10) for the mounting brackets (8) when using forks in NOTE inverted position (7). 3. Secure the mounting brackets (8) with the fixations (6). 4.15.4 Connecting the hydraulic quick couplings WARNING RISK OF MALFUNCTION The hydraulics may not work properly if the hydraulic hoses are not connected correctly. Make sure to attach the quick couplings for the hydraulics to the corresponding connections on the carriage. 159/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 2 1 3 Figure 76. Hydraulic quick couplings - ELME 815 1. Select the hydraulic quick couplings from the hose package (1) on the attachment. 2. Remove the four yellow protection plugs (3) from the quick couplings. 3. Connect the quick couplings (2) for the hydraulics to the corresponding connection on the carriage. NOTE Always reattach the protection plugs (3) when disconnecting the quick couplings. 4.15.5 Connecting the electric contact 3 2 1 4 Figure 77. Electric contact - ELME 815 160/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 1. Select the electric contact (3) from the hose package (1). 2. Remove the protection lids (4) from the electric box (2) on the carriage, and from the electric contact (3) on the hose package (1). 3. Connect the electric contact (3) to the electric box (2) on the carriage. Always reattach the protection lids (4) when disconnecting the electric contact (3) from NOTE the electric box (2). 4.16 Lifting and driving with a load DANGER UNCONTROLLED MOVEMENT HAZARD If the machine moves unexpectedly, it could result in personal injury, death, or damage to the equipment. To stop any unexpected movement, push the emergency stop button. WARNING RISK OF TIPPING If activating the emergency stop when driving, the parking brake is activated. This safety maneuver can cause the load to rapidly slide forwards, and cause imbalance or cause a load drop. Drive slowly and follow the recommendations for Transporting a load (page 163). 4.16.1 Lifting a load DANGER MOVING VEHICLE HAZARD Reversing without a direct view in the reverse direction may cause death, serious personal injury, or damage to property. Only drive in reverse when you have a direct and unobstructed view in the reverse direction. 1. Drive forward towards the load. If the load is not centered, the operator must take extra precautions to center the load on the forks. If the operator does not take the precautions that are recommended above, the load can NOTE move unexpectedly. Avoiding to take precautions could cause the load to fall or move towards the mast and carriage. To center the load also reduces the stress on the lifting equipment. 161/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 2. Raise or lower the forks to the correct height. 3. Place the mast in its vertical position. 4. Carefully push the forks under the load until the fork shafts touch the load. 5. Raise the forks until the load rests on the forks. A = 20–40 cm (8–16 in). Raise only so much that the load is free from the surface. Check that the weight of the NOTE load is centered in regards to the mast and the machine. Sideshift the forks to adjust the weight balance if necessary. 6. Tilt the mast backwards. 7. Reverse the machine until the load is free from the front of the stack. B = 20–40 cm (8–16 in). NOTE Make sure that there is a direct view in the reverse direction. 162/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 8. Lower the load to the transport position. Distance between the forks and the ground should be 30 cm (11.8 in) or 50 cm (19.6 in) NOTE depending on the size of the machine. See Transporting a load (page 163) for more information. 4.16.2 Transporting a load DANGER MOVING VEHICLE HAZARD Reversing without a direct view in the reverse direction may cause death, serious personal injury, or damage to property. Only drive in reverse when you have a direct and unobstructed view in the reverse direction. WARNING FALLING LOAD HAZARD Load and attachment may drop and lead to serious personal injury or death. Do not allow anyone to stand or walk under the elevated part of the machine whether it is empty or loaded. Never park or leave a machine with raised load unsupervised. WARNING COLLISION HAZARD Driving with the forks or load in the raised position could result in serious personal injury or death. Never drive with the forks or load in the raised position. WARNING RISK OF LOAD DROP Driving downhill on slopes carrying a load, can lead to a load drop. This can damage the machine and can lead to serious personal injury. If carrying a load, always drive downhill in reverse. 163/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions • Do not drive with the load displaced sideways (for example, by side maneuvering). • Tilt the mast backwards. • Transport the load close to the ground. In transport position, the distance between the forks and the ground should be: ◦ 30 cm (11.8 in) for machines up to 10 T. NOTE ◦ 50 cm (19.6 in) for machines larger than 10 T. ◦ 30 cm (11.8 in) when lifting containers with fork pockets (machines up to 10 T). ◦ 50 cm (19.6 in) when lifting containers with fork pockets (machines larger than 10 T). When handling containers, using an attachment, the bottom of the lifted container should NOTE be at eye height. • Avoid driving on slopes or uneven surfaces when transporting a load. • Always drive with the load turned upwards on a slope. Never drive across, or turn on a slope. • Never drive with raised forks, or a raised load above the recommendations for transport position. • If the view is reduced, ask someone to guide you. • If the load has been stacked so high that it prevents a forward view, drive the machine in reverse. NOTE Make sure that there is a direct view in the reverse direction. If the load is transported a longer distance, check the height of the load every now and NOTE then. 164/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.16.3 Unloading a load DANGER COLLISION HAZARD Driving with the forks or load in the raised position could result in serious personal injury or death. Never drive with the forks or load in the raised position, or with a raised load above 30 cm (11.8 in), or 50 cm (19.6 in) depending on the size of the machine. See Transporting a load (page 163) for more information. DANGER MOVING VEHICLE HAZARD Reversing without a direct view in the reverse direction may cause death, serious personal injury, or damage to property. Only drive in reverse when you have a direct and unobstructed view in the reverse direction. DANGER UNCONTROLLED MOVEMENT HAZARD If the machine moves unexpectedly, it could result in personal injury, death, or damage to the equipment. To stop any unexpected movement, push the emergency stop button. WARNING RISK OF TIPPING If activating the emergency stop when driving, the parking brake is activated. This can cause the load to rapidly slide forwards, and cause imbalance or cause a load drop. Drive slowly and follow the recommendations for Transporting a load (page 163). 1. Drive up to the stack or unit on which you want to unload as precisely as possible. 2. Raise the fork carriage to the correct height. 165/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 3. Place the load vertically. 4. Carefully drive up to the stack. 5. Lower the load. To avoid scratching the load (depending on the weight of the load), tilt slightly forward. The mast and forks should be vertical and horizontal before reversing from the stack. 6. Carefully reverse from the stack. Ensure that the forks are free. NOTE Make sure that there is a direct view in the reverse direction. 7. Lower the forks to the transport position. Tilt the mast backwards. Distance between the forks and the ground should be 30 cm (11.8 in) or 50 cm (19.6 in) NOTE depending on the size of the machine. See Transporting a load (page 163) for more information. 166/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.17 Emergency lowering, general DANGER FALLING LOAD HAZARD Danger of serious personal injury, death, or damage to the vehicle. The mast and carriage descend fast, about 1 m/s. Ensure that the carriage and the mast can be lowered without hindrance. Ensure that there are no people or items underneath or near the forks. Emergency lowering must be performed by trained service personnel. DANGER FALLING LOAD HAZARD Danger of serious personal injury, death, or damage to the vehicle. If the locking screw and the locking nuts are repositioned wrongly, the mast and carriage can descend unexpectedly during operation. Ensure that the locking screw is returned to the exact same position when restored. This task must be performed by trained service personnel. The machine is equipped with hydraulic assistance. If the engine stops or if a fault occurs in the hydraulics preventing the assistance from working, you cannot lower using the maneuvering levers. The directional control valve is therefore equipped with a mechanical control that allows manual lowering. 4.17.1 Emergency lowering for SMV 10-16 - L90 main valve NOTE The emergency lowering locknut is located behind the hoses. Figure 78. L90 view from above (look for the 90-degree hydraulic coupling placed horizontally) 167/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 1 2 Figure 79. L90 view from side, left side, behind NOTE The locking screw (2) is the one nearest to the 90-degree hydraulic coupling. 1. Tilt the cabin upwards. 2. Loosen the locknut (1). 3. Open the locking screw (2) with an Allen wrench. NOTE The mast and carriage descends rapidly. When the mast has been lowered, it is not possible to raise it again until the engine runs and the hydraulics works correctly. Always count the turns when loosening the locknut (1) and locking screw (2). Always NOTE reset the locknut (1) and locking screw (2) to their original position, after emergency lowering is performed. 4.17.2 Emergency lowering for SMV 18-60 - K220/L90 main valve 2 1 Figure 80. K220/L90 main valve 1. Tilt the cabin upwards. 168/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 2. Loosen the locknut (1). 3. Open the locking screw (2) with an Allen wrench. NOTE The mast and carriage descends rapidly. When the mast has been lowered, it is not possible to raise it again until the engine runs and the hydraulics works correctly. Always reset the locknut (1) and locking screw (2) to their original position, after NOTE emergency lowering is performed. 4.18 Towing WARNING RUN OVER HAZARD If the engine, the electrical system or the hydraulic system is broken, the parking brake may need to be released manually to tow the machine. In this situation, the machine has no brakes or steering capability, which may lead to serious personal injury and damage to the machine. When towing the machine, the engine must idle, or a vehicle with sufficient braking capacity to stop both vehicles must be used. WARNING MOVING VEHICLE HAZARD When towing the machine, there is a risk that the machine becomes unattached from the towing vehicle. It can lead to serious personal injury and damage to the machine. Do not exceed the towing capacity of the transporting vehicle. NOTE Only trained and authorized personnel are allowed to tow the machine. If possible, the engine should idle when being towed. If not, the hydraulic brake system, and servo-assisted steering system cannot be used. If idling is not possible, release the hydraulic parking brake manually. After the hydraulic parking brake is released, the machine has no brakes. To stop both vehicles when towing the machine, use a vehicle with sufficient brake capacity. Use a towing bar if possible. 1. Attach the towing bar to the machine. Use the rear towing peg, if applicable, when fitting a sturdy towing bar on the machine. NOTE Otherwise use slings and secure them around the back counterweight when towing. 169/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 2. Remove the propshaft (1). 3. Release the parking brake manually. 170/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX I: Fuel and oil recommendations Operating Instructions APPENDIX I: FUEL AND OIL RECOMMENDATIONS Quality of the engine oil Depending on engine type, the engine oil must comply with one of the following oil classifications: • Volvo VDS-4.5 • Volvo VDS-4 • Volvo VDS-3 • CES20081 / ACEA E9 / API CJ-4 • CES20071 / ACEA E5 / API CH-4 • ACEA E5 / API CI-4 Table 9. Oil classifications according to engine type Oils Engine CES20081 / CES20071 / ACEA E5 / VDS-4.5 VDS-4 VDS-3 ACEA E9 / ACEA E5 / API CI-4 API CJ-4 API CH-4 Volvo TAD 581, 881, 883, 1181 X VE Volvo TAD 571, 871, 873, 1171, X 1371 VE Volvo TAD 541, 551, 841, 851, X 853, 1141, 1151 VE Cummins QSB 6.7 T4, B 6.7, X X12 1) Cummins QSB 6.7, QSM 11 X 1) For Cummins B 6.7 and X12 engines, SAE 15W-40 must be used. Check with your oil supplier that your oil meets these demands. For engines that do not use fuel with low sulphur content, the TBN (Total Base Number) value should be at least 12 according to ASTM 2896. Check with your oil supplier that your oil meets these demands. Depending on operating conditions, and the quality of the oil and fuel, the intervals between changing the oil may vary in length. The engine oil must be replaced within a maximum operation time of one year. If the machine is parked in cold weather, the viscosity of the oil can vary according to the temperature. Therefore the ambient temperature is vital to the choice of the engine oil viscosity range (see following figure). NOTE If the machine is warm, the oil is also warm. Changing the oil due to a change in season may be avoided by using multi-grade oils. Specified intervals for changing the oil also apply to multi-grade oils. No oil additives should be added to the recommended oils. Using such additives may NOTE invalidate the engine warranty. Avoid mixing different brands of oil. The temperature ranges for adjacent SAE classes overlap, so you do not need to replace the oil when short-term temperature changes occur. To ensure trouble-free cold starts, select the SAE class according to the ambient NOTE temperature. 171/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions APPENDIX I: Fuel and oil recommendations Figure 81. Oil temperature ranges Extended oil change interval Extended oil change interval may differ when using synthetic fluids. To determine a baseline, appropriate change intervals should be determined for each engine by measuring oil oxidation and wear metals over time. Wear metals analysis can provide useful information, but an engine should not be removed from service based solely on this analysis. For more information contact Konecranes Lift Trucks, an authorized dealer, or the engine supplier. Recommended fluids and lubricants Diesel fuel It is recommended to use diesel fuel HVO 100, which complies with the following classification: • EN 15940 Class A If using other diesel fuels than HVO 100, they must comply with one of the following classifications: • EN 590 • ASTM D 975 No 1-D or 2-D For Tier 4F, stage 4 and stage 5 engines ULSD (Ultra-Low Sulfur Diesel) fuel must be used (sulphur content below 15 mg/kg). For more information, contact the engine manufacturer, or an authorized representative. As the ambient temperature falls, the flow characteristics of the diesel fuel are reduced NOTE and paraffin begins to precipitate, i.e the diesel is gelling in cold temperatures. Use the correct diesel quality according to the ambient temperature. Using additives to improve the flow is not recommended. Additives may reduce the NOTE capacity to start from cold. Biodiesel (FAME) Vegetable oil esters (Fatty Acid Methyl Esters, FAME), also called "biodiesel", are increasingly available as a blending component in diesel fuels. The engine manufacturer accepts the same FAME content as in major on-road fuels EN590 and ASTM D975. The maximum FAME content is 7%, without any specific extra service requirements. For more information, contact the engine manufacturer, or an authorized representative. Higher FAME blends negatively impact performance, emissions, and fuel consumption. It NOTE also affects negatively the function of the SCR engines exhaust after treatment system. 172/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX I: Fuel and oil recommendations Operating Instructions AdBlue solution Only use an AdBlue solution that fulfills the ISO 22241 standard. The AdBlue solution consists of deionized water that is mixed with 32.5% urea. Table 10. Engines using AdBlue solution Engine family Engine VOLVO TAD 571 VE TAD 871 / 873 VE TAD 1171 VE TAD 1371 VE TAD 581 VE TAD 881 / 883 VE TAD 1181 VE CUMMINS QSB 6.7 1) / B 6.7 / X12 1) EU stage 4 / US tier 4f Transmission oil DANA transmission: ATF Dexron III ZF transmission: Mineral oil -based engine oil (API CD/CE/CF-4/CF/CG-4/CH-4/ CI-4/SF/SG/SH/SJ/SL or ACEA, categories A, B, E). Viscosity degrees: SAE 20W-20 / 30 / 10W-30 / 10W-40 / 15W-30 / 15W-40 / 20W-40. For more information, see the ZF recommended oil list TE-ML 03. Table 11. ZF Transmission: Approved and recommended oil types Lubricant class Oil type / viscosity Temperature 03C, 03M ATF (Automatic transmission fluids) -40°C 03F UTTO in accordance with JDM 20D / John Deere Low -40°C Viscosity Hy-Gard 03E, 03G, 03H UTTO -30°C 03K SAE 0W-30, 0W-40 -40°C 03B, 03C, 03K SAE 5W-30, 5W-40 -35°C 03A, 03B, 03C, 03K SAE 10 W, 10W-30, 10W-40 -30°C 03A, 03C, 03K SAE 15W-30, 15W-40 -25°C 03A, 03C, 03K SAE 20W-20, 20W-40 -20°C 03A, 03C, 03K SAE 30 -10°C Oil change interval Drain and refill the system every 1000 h for average environmental and duty cycle conditions. Severe or sustained high operating temperature or dusty environments cause accelerated deterioration or contamination. Judgment must be used to determine the required change intervals for extreme conditions. For more information, contact your local authorized dealer. Drive axle oil Axle housing / Hub assembly / Drive Assembly API GL.5 SAE 90 173/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions APPENDIX I: Fuel and oil recommendations Table 12. Oil filling quantities Drive Width Planetary Model Brake Differential Hub axle (mm) gear FLT 10-16 D81 2274 PL478 NLB5340 19 l (5.02 US gal) 2.3 l (0.6 US gal) FLT 18-25 D91 2717 PL488 NLB4460 31 l (8.2 US gal) 3.2 l (0.8 US gal) FLT 28-33 D91 3015 PL408 NLB6460 36.5 l (9.6 US gal) 3.7 l (0.97 US gal) FLT / LCH 37-50 D102 3807 PL341 NLB8460 72 l (19 US gal) 11 l (2.9 US gal) FLT / LCH 37-50 D102 3431 PL341 NLB8460 58 l (15.3 US gal) 11 l (2.9 US gal) LCH 52 D102 4549 PL341 NLB8460 121 l (31.9 US gal) 12.5 l (3.3 US gal) FLT / LCH 52-55 D106 3807 PL341 NLB8460 85 l (22.4 US gal) 11 l (2.9 US gal) FLT 60-55 D111 4188 PL545 NLB6650-1 108 l (28.5 US gal) 12.5 l (3.3 US gal) ECH 80 D81 3218 PL478 NLB5340 39 l 10.3 US gal) 2.3 l (0.6 US gal) ECH 90/100 D81 3713 PL488 NLB6340 45 l (11.9 US gal) 3.5 l (0.9 US gal) ECH 90/100 D91 4218 PL488 NLB6340 45 l (11.9 US gal) 3.5 l (0.9 US gal) ECH 90/100 *) D91 4203 PL489 NLB4460 66 l (17.4 US gal) 3.2 l (0.8 US gal) RST 108 D81 3713 PL488 NLB6340 45 l (11.9 US gal) 3.5 l (0.9 US gal) RST 2518 D91 3015 PL408 NLB6460 36.5 l (9.6 US gal) 3.7 l (0.97 US gal) RST 4127-4638 D102 3807 PL341 NLB8460 72 l (19 US gal) 11 l (2.9 US gal) RST 4537-4644 D106 3807 PL341 NLB8460 85 l (22.4 US gal) 11 l (2.9 US gal) RST 4646 D111 4188 PL545 NLB6650-1 108 l (28.5 US gal) 12.5 l (3.3 US gal) *) = with clamped wheel rims The volumes are strictly recommendations. If you have any doubts, contact your NOTE Konecranes Lift Trucks authorized dealer for advice. Hydraulic oil For machines without separate brake cooling tank Universal Tractor transmission oil (UTTO) The oil must comply with one of the following classifications: • John Deere: JD20C • Massey Ferguson: MF1141/MF1135/ MF1143 • ZF: TE-ML 03E/TE-ML 05F/TE-ML 06K For machines with separate brake cooling tank (option) DIN 51524 Part 2 HLP and Part 3 HVLP Use hydraulic oil from a well-known oil company for mobile applications. Viscosity Temperature range SHS 32 -30°C...+10°C (-22°F...+50°F) SHS 46 -20°C...+50°C (-4°F...+122°F) SHS 68 ±0°C...+50°C (+32°F...+122°F) Brake cooling oil (option) Universal Tractor transmission oil (UTTO) The oil must comply with one of the following classifications: 174/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX I: Fuel and oil recommendations Operating Instructions • John Deere: JD20C • Massey Ferguson: MF1141/MF1135/ MF1143 • ZF: TE-ML 03E/TE-ML 05F/TE-ML 06K Grease Multipurpose type E.P. according to NLGI Grade 2. Coolant WARNING HARMFUL SUBSTANCE HAZARD Using wrong coolant may damage the machine. Use the recommended coolant and never mix different coolants. WARNING TOXIC SUBSTANCE HAZARD It is highly dangerous to drink ethylene glycol. Contact with skin or spray from the refill can cause skin irritation and eye damage. Do not drink ethylene glycol and avoid contact with skin. Use only ethylene glycol-based coolants with an additive that prevents corrosion. Do not mix different coolant types with each other. Do not mix the coolant with antifreeze that contains ethanolamine. Table 13. Coolants for Volvo engines Engine Coolant VOLVO TAD 541, 551 VE VOLVO TAD 571 VE VOLVO TAD 581 VE VOLVO TAD 841 VE VOLVO TAD 851 VE VOLVO TAD 871, 873 VE Volvo Penta Coolant VCS-2 and VCS-2 Ready Mixed VOLVO TAD 881, 883 VE VOLVO TAD 1141, 1151 VE VOLVO TAD 1171 VE VOLVO TAD 1181 VE VOLVO TAD 1371 VE Table 14. Coolants for Cummins engines Engine Coolant CUMMINS QSB 6.7-C240 CUMMINS B 6.7 To comply with Cummins CES 14603 CUMMINS QSM 11-C335 Recommended: Cummins ES Compleat EG CUMMINS X12 175/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions APPENDIX I: Fuel and oil recommendations Liquid antifreeze at the lowest Percentage of volume mixture liquid Mixture of antifreeze and water temperature antifreeze -12°C (10.4°F) 25 1:3 -18°C (-0.4°F) 30 1:2 -25°C (-13°F) 40 1:1.5 -37°C (-34.6°F) 50 1:1 -60°C (-76°F) 66 2:1 176/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX II: Fuses and relays Operating Instructions APPENDIX II: FUSES AND RELAYS Fuses Fuses are located behind the operator's seat in the cabin and in the battery compartment on the right side of the machine. Figure 82. Location of fuses 101 121 141 163 185 190 120 140 162 184 Figure 83. Numbering order of the fuses 177/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions APPENDIX II: Fuses and relays Table 15. Fuses and their function (Functions may vary depending on machine model and chosen options) Number Size Function F101 7.5 A Cabin heating F102 7.5 A Option F103 7.5 A Option F104 7.5 A Central lubr. pump chassis F105 10 A Converter 12-V option F106 7.5 A Reverse light F107 7.5 A Working light extra 2 F108 7.5 A PCB 48-PIN STD D F109 7.5 A PCB 48-PIN STD D F110 7.5 A PCB 48-PIN STD D F111 7.5 A PCB 48-PIN STD D F112 7.5 A Clutch for HVAC compressor F113 5A Position light right F114 5A Position light left F115 7.5 A High beam F116 7.5 A Low beam F117 15 A Seat suspension air compressor F118 7.5 A Reverse alarm in the front F119 7.5 A Working lights extra 1 F120 10 A Option F121 7.5 A Working light mast, right F122 7.5 A Working light mast, left F123 10 A Main fuse for the lights, F115 and F116 F124 5A ACR RFID keyless ignition F125 5A Battery clock (RTC) F126 7.5 A Ignition F127 7.5 A Beacon F128 7.5 A Power supply controller F129 7.5 A Hazard F130 10 A HV/AC condensor blower 1 F131 10 A HV/AC condensor blower 2 F132 10 A HV/AC condensor blower 3 F133 7.5 A K128 Door open switch F134 5A Reading light F135 15 A Rear window heating F136 7.5 A RCU F137 7.5 A Diagnostic, PCB connector F138 7.5 A CAN extra, PCB connector F139 5A Turn signal F140 7.5 A PCB 48-PIN STD D F141 7.5 A PCB 48-PIN STD D F142 7.5 A Rearview mirror heater F143 5A I/O units in the armrest, XC21, XC21 OPT C1, XC21 OPT C2 F144 7.5 A Seat heater F145 7.5 A MD4 178/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX II: Fuses and relays Operating Instructions Table 15. Fuses and their function (Functions may vary depending on machine model and chosen options) (Continued) Number Size Function F146 5A TRUCONNECT® modem F147 5A RFID nearguard 2 F148 5A Tire pressure gateway F149 10 A Connection for computer F150 5A RFID nearguard 1 F151 7.5 A Main fuse for position light (F113, F114) and brake lights F152 5A Alcohol ignition interlock F153 10 A 24 V dashboard F154 5A GSM G2 modem F155 10 A 12 V reverse camera F156 10 A 12 V dashboard F157 10 A 24 V roof F158 7.5 A Converter roof F159 10 A 12 V roof F160 7.5 A 12 V radio F161 15 A Working light roof (option) F162 15 A Working light roof (option) F163 10 A Wiper rear/roof/front washer F164 7.5 A PCB 48-PIN STD E F165 7.5 A PCB 48-PIN STD E F166 7.5 A Converter F167 7.5 A Converter 2 rear wall F168 15 A Horn F169 7.5 A PCB 48-PIN STD E F170 7.5 A PCB 48-PIN STD E F171 7.5 A PCB 48-PIN STD E F172 7.5 A PCB 48-PIN STD E F173 7.5 A Fuel heater F174 7.5 A Option F175 7.5 A Option F176 15 A Electrical seat column F177 7.5 A Option F178 7.5 A Particle detecting monitor (PDM) F179 10 A XA2 OPT, external expansion unit in the chassis F180 10 A XA2-STD, external expansion unit in the chassis F181 10 A Connection for computer F182 7.5 A Reverse camera F183 5A HVAC controller F184 15 A HVAC blower F185 3A Spare fuse F186 5A Spare fuse F187 7.5 A Spare fuse F188 10 A Spare fuse F189 15 A Spare fuse F190 - Fuse test 179/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions APPENDIX II: Fuses and relays Fuses and relays in the battery compartment DANGER EXPLOSION HAZARD Short-circuiting the battery may cause a fire or explosion, which can cause a risk for serious injury or death. DANGER CORROSIVE SUBSTANCE HAZARD The battery contains corrosive acid that may cause a risk for serious injury or death. Always use the necessary protective equipment. DANGER EXPLOSION HAZARD Batteries generate explosive hydrogen when charged, or when being jump-started, which may cause a risk for serious injury or death. Always use the necessary protective equipment. Ensure that there is good ventilation and avoid sparking. WARNING ELECTRICAL HAZARD The battery main switch disconnect does not cut the power to the alternator. To reduce the risks of electric shock and personal injury always remove jewelry and conductive material before working on the electrical system. Always disconnect the ground (minus) cable at the battery when working near or on the alternator. WARNING TIPPING OVER HAZARD Turning off the battery main switch while the machine is moving applies the parking brake and the machine may tip over. The software in the control unit can get damaged. Do not turn it off while the engine is running. 180/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX II: Fuses and relays Operating Instructions 1 3 2 1 Figure 84. Fuses and relays in the battery compartment 1. Fuses F51–F58, F71-78, F92-F98 (1) 2. Relay K32 (2), behind the three fuse lines 3. Fuses F61-F62, F80 Figure 86. Numbering order of the fuses Table 16. Fuses and their functions (Functions may vary depending on machine model and chosen options) Number Size Function F51 10 A MD4 internal clock (IQAN-MD4 RTC) F52 20 A Starter for Scania DC13 EU4/Cummins QSB (15A) F53 20 A Scania DC13 EU4 AdBlue control unit/Cummins QSB (15 A) F54 7.5 A Cummins QSB (15 A) F55 7.5 A Fuel heater (Cummins 20A) F56 7.5 A TCU battery power supply (DANA) F57 20 A Scania DC13 EU4, VOLVO 660/760 (10A) /Cummins QSB (15A) F58 20 A Scania DC13 EU4/Cummins QSB (15A) 181/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions APPENDIX II: Fuses and relays Table 16. Fuses and their functions (Functions may vary depending on machine model and chosen options) (Continued) Number Size Function F61 100 A Main fuse 15 ignition F62 60 A Main fuse 30 battery F71 7.5 A Option F72 7.5 A Option (fuel shut-off) (seat suspension air compressor 15 A) F73 7.5 A Option F74 10 A Engine ignition F75 7.5 A DANA/ZF transmission control unit (TCU) ignition power supply F76 25 A Hydraulic oil cooler F77 20 A Scania DC13 EU4 exhaust gas recirculation valve (EGR) F78 - Option F80 70 A Cummins engine starter F81 100 A Cummins intake air heater F91 10 A Attachment lights F92 10 A Chassis 48-pin STD F F93 10 A Chassis 48-pin STD F F94 10 A Chassis 48-pin STD F F95 10 A Chassis 48-pin STD F F96 10A Chassis 48-pin STD F F97 10A Chassis 48-pin STD F F98 10 A Power supply, attachment Relays Relays K32, K35, and K36 are mounted next to the main fuses in the battery compartment. K101-K135 are mounted behind the operator seat in the cabin. Figure 87. Relay location K101-K135 182/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX II: Fuses and relays Operating Instructions 135 117 118 119 120 121 122 123 124 116 115 125 126 114 127 128 113 129 130 112 131 132 111 133 134 110 109 108 107 104 103 102 101 106 105 Figure 88. Relays K101-135 Table 17. Relay functions (Functions may vary depending on machine model and chosen options) Number Function K31 Volvo 620, 722, Engine starter K32 Q1 ignition K33 Ground support for K31 K35 Engine shut-off for Volvo engines (Engine starter Cummins QSB and QSM) K36 Fuel heater K63 Starter lockout Cummins K64 Intake air heater Cummins K65 DEF hose heating 1 Cummins K66 DEF hose heating 2 Cummins K67 DEF hose heating 3 Cummins K68 DEF heater relay K101 Pre-heating power supply for HVAC (heating, ventilation, air-conditioning) K102 Signal for HVAC (heating, ventilation, air-conditioning), engine running with cabin doors closed K103 Brake lights K104 Inverted road light (turnable seat) K105 ACR RFID keyless ignition 183/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions APPENDIX II: Fuses and relays Table 17. Relay functions (Functions may vary depending on machine model and chosen options) (Continued) Number Function K106 Working light mast F121 and F122 K107 Working light extra 1 K108 Front alarm K109 Door switch K110 Low beam K111 High beam K112 Clutch for HVAC compressor K113 Blinker right K114 Blinker left K115 Working light extra 2 K116 Backup Light/Right K117 Central lubrication pump chassis K118 Option K119 Option K120 RCU 3 K121 Working light roof F161, F162 K122 Windshield wiper motor roof K123 Windshield wiper motor rear K124 Rear/front window washer motor K125 Rear window heating K126 Windshield wiper motor front, 1st speed K127 Rear/front window washer motor K128 Windshield wiper motor front, 2nd speed K129 Horn K130 Fuel heater K131 RCU 1 K132 RCU 2 K133 Option K134 Communication radio K135 Hazard K201 Attachment lights (opt) 184/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved.  Maintenance Instructions Forklift SMV 10-65, Gen C MIFLTC_RevE Original Instructions 24 May 2024 Document ID: DOC2726785A / en-US This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Internal reference: X166890 en-US / E Contact information Contact the manufacturer’s local representative or Konecranes Lifttrucks AB Anders Anderssons väg 13 285 35 Markaryd SWEDEN Tel. +46 433 733 00 For UK, contact: Konecranes Demag UK Ltd Coalfield Way LE65 1NF Asby De La Zouch UNITED KINGDOM www.kclifttrucks.com Table of contents Maintenance Instructions TABLE OF CONTENTS 1 INTRODUCTION.............................................................................................................9 1.1 About this document.................................................................................................... 9 1.1.1 Use of the document......................................................................................... 9 1.1.2 Terminology.......................................................................................................9 1.1.3 Abbreviations.................................................................................................. 10 1.1.4 Copyright notice.............................................................................................. 11 1.1.5 Available technical documents........................................................................ 11 1.1.6 Feedback on documents................................................................................. 11 1.2 About this product...................................................................................................... 12 1.2.1 Use of the product ..........................................................................................12 1.2.2 Conditions of warranty.................................................................................... 12 1.2.3 Identification of the product............................................................................. 13 1.2.4 Standards and directives.................................................................................14 1.2.5 Declaration of conformity.................................................................................15 2 SAFETY AND ENVIRONMENT.................................................................................... 17 2.1 Safety messages and symbols.................................................................................. 17 2.1.1 Signal words................................................................................................... 17 2.1.2 Hazard symbols.............................................................................................. 17 2.1.3 Mandatory action symbols...............................................................................20 2.1.4 Prohibited action symbols............................................................................... 21 2.1.5 Safety and information labels on the product...................................................21 2.1.6 Location of the safety and information labels...................................................22 2.2 Responsibilities of the operational manager............................................................ 28 2.2.1 Preventing work-related hazards.....................................................................28 2.2.2 Preventive maintenance..................................................................................28 2.2.3 Personal protective equipment........................................................................ 29 2.2.3.1 Fall protection............................................................................................. 30 2.2.4 Incident reporting............................................................................................ 30 2.3 Limitations of the product.......................................................................................... 31 2.3.1 Operating conditions....................................................................................... 31 2.3.2 Inclination angles............................................................................................ 31 2.3.3 Lift truck danger zones, general...................................................................... 32 2.3.4 Tire explosion danger zone............................................................................. 32 2.3.5 Prohibited use................................................................................................. 34 2.3.6 Changes to the product................................................................................... 34 2.4 Emissions.................................................................................................................... 36 2.4.1 Noise...............................................................................................................37 2.4.2 Vibration .........................................................................................................37 2.5 Protective measures................................................................................................... 38 2.5.1 Emergency stopping....................................................................................... 38 2.5.2 Battery main switch......................................................................................... 39 2.5.3 Releasing the hydraulic pressure ................................................................... 41 2.5.4 Fire safety....................................................................................................... 41 2.5.5 Emergency exits..............................................................................................42 2.5.6 Mounting, and dismounting the machine......................................................... 43 2.5.7 Locking the cabin door in open position.......................................................... 43 2.5.8 Personnel requirements.................................................................................. 44 2.6 Environmental information.........................................................................................45 2.6.1 Energy consumption....................................................................................... 45 2.6.2 Product lifecycle stages...................................................................................45 2.6.2.1 Production of materials and components.................................................... 46 2.6.2.2 Equipment manufacturing and assembly.....................................................46 3/262 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Maintenance Instructions Table of contents 2.6.2.3 Use phase, including maintenance and modernization................................47 2.6.2.4 Dismantling and handling waste material.................................................... 47 2.6.2.5 Deliveries between each stage....................................................................48 2.6.3 Notice on the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH)....................................................................................... 49 2.7 Storage information.................................................................................................... 49 2.7.1 Storage........................................................................................................... 49 2.7.2 Alternative storage, up to two months............................................................. 50 2.7.3 Alternative storage, longer than two months....................................................51 3 TRANSPORT AND TOWING........................................................................................53 3.1 Lifting the machine - General safety..........................................................................53 3.2 Lifting points SMV 10-25.............................................................................................54 3.3 Lifting points SMV 28-65.............................................................................................55 3.4 Rear top lifting ears SMV 10-25 (option)....................................................................56 3.5 Lifting the machine without the mast........................................................................ 58 3.6 Lifting the mast........................................................................................................... 59 3.7 Towing..........................................................................................................................60 3.8 Transportation.............................................................................................................60 3.8.1 Securing the rear end......................................................................................61 3.8.2 Securing the front end - machines without mast..............................................61 3.8.3 Securing the front end - machines with mast...................................................62 4 SERVICE AND MAINTENANCE INSTRUCTIONS....................................................... 63 4.1 Maintenance safety information.................................................................................63 4.2 Reset service hour counter........................................................................................ 64 4.3 RFID - Adding an operator (option)............................................................................65 4.4 Electric welding...........................................................................................................68 4.5 Jump-starting.............................................................................................................. 69 4.6 Tilting the cabin...........................................................................................................70 4.6.1 Manual cabin tilting......................................................................................... 71 4.6.2 Electrical cabin tilting (option)..........................................................................72 4.7 Releasing the hydraulic accumulator pressure........................................................ 73 4.8 Changing the wheels.................................................................................................. 74 4.8.1 Before changing the wheels............................................................................ 74 4.8.2 Positioning the jack......................................................................................... 75 4.8.3 Deflating the tire..............................................................................................76 4.8.4 Inflating the tire............................................................................................... 78 4.8.5 Dismantling the outer drive wheel, general......................................................80 4.8.5.1 Dismantling the outer drive wheel, wheels without clamp units....................80 4.8.5.2 Dismantling the outer drive wheel, wheels with clamp units........................ 81 4.8.6 Dismantling the inner drive wheel....................................................................82 4.8.7 Mounting the inner drive wheels......................................................................83 4.8.8 Mounting the outer drive wheel....................................................................... 83 4.8.8.1 Mounting the outer drive wheel, wheels without clamp units....................... 83 4.8.8.2 Mounting the outer drive wheel, wheels with clamp units............................ 84 4.8.9 Dismantling the steer wheel, general...............................................................86 4.8.9.1 Dismantling the steer wheels, wheels without clamp units...........................86 4.8.9.2 Dismantling the steer wheels, wheels with clamp units............................... 87 4.8.10 Mounting the steer wheels.............................................................................. 88 4.8.10.1 Mounting the steer wheels, wheels without clamp units.............................. 88 4.8.10.2 Mounting the steer wheels, wheels with clamp units................................... 89 4.9 Tightening the bolted joints....................................................................................... 90 4.9.1 Tightening torque............................................................................................ 90 4/262 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Table of contents Maintenance Instructions 4.9.2 Tightening the wheel nuts................................................................................91 4.9.3 Tightening the bolts in the propshaft................................................................92 4.9.4 Tightening the bolts in the engine and transmission mounting.........................93 4.9.5 Tightening the bolts in the drive axle suspension............................................ 94 4.9.6 Tightening the bolts in the hydraulic pumps.....................................................95 4.9.7 Tightening the bolts in the cabin suspension................................................... 95 4.9.8 Tightening the bolts in the counterweights.......................................................97 4.9.9 Tightening the bolts in the steer axle............................................................... 98 4.10 Lubricating the machine.............................................................................................98 4.10.1 General lubrication rules................................................................................. 98 4.10.2 Lubricating the steer axle................................................................................ 99 4.10.3 Lubricating the hinges................................................................................... 100 4.11 Lubricating the mast................................................................................................. 101 4.12 Lubricating the fork rollers.......................................................................................102 4.13 Lubricating the attachment...................................................................................... 103 4.13.1 Attachment lubrication points - ELME 815 Toplift...........................................103 4.13.2 Lubricating the wear pads for main beams and extending beams................. 104 4.13.3 Lubricating extension beams and twistlocks..................................................104 4.13.4 Lubricating extension cylinder support wear pads and tracks........................ 104 4.13.5 Lubricating the fork frame - ELME 815.......................................................... 105 4.13.6 Lubricating stop cylinders - ELME 815 (option)............................................. 106 4.14 Maintenance common to all engines....................................................................... 106 4.14.1 Cleaning and draining the fuel tank, all engines............................................ 106 4.14.2 Cleaning the engine air filter's coarse separator............................................107 4.14.3 Cleaning and changing the engine air filter, all engines................................. 109 4.14.4 Changing the safety cartridge, all engines..................................................... 111 4.14.5 Checking the air intake system, all engines................................................... 112 4.14.6 Checking the coolant system, Volvo engines.................................................113 4.14.7 Checking the coolant system, Cummins engines...........................................114 4.14.8 Changing the coolant, Volvo engines.............................................................115 4.14.9 Changing the coolant, Cummins engines...................................................... 117 4.14.10 Cleaning the radiator, intercooler, and oil coolers, all engines........................119 4.14.11 Checking the valve clearance, all engines.....................................................120 4.14.12 Checking the fuel system and fuel injectors, all engines................................120 4.14.13 Checking the exhaust system, all engines.....................................................121 4.15 Maintaining the Volvo engines................................................................................. 122 4.15.1 Bleeding the fuel system: Volvo 5- and 8-liter engines.................................. 122 4.15.2 Bleeding the fuel system: Volvo 11 and 13-liter engines................................ 123 4.15.3 Draining the fuel prefilter: Volvo 5- and 8-liter engines.................................. 127 4.15.4 Draining the fuel prefilter: Volvo 11- and 13-liter engines...............................128 4.15.5 Changing the fuel prefilter: Volvo 5- and 8-liter engines.................................129 4.15.6 Changing the fuel prefilter: Volvo 11- and 13-liter engines ............................ 130 4.15.7 Changing the fuel filter: Volvo 5- and 8-liter engines......................................132 4.15.8 Changing the fuel filter: Volvo 11- and 13-liter engines ................................. 134 4.15.9 Changing the AdBlue filters, Volvo................................................................ 135 4.15.9.1 Changing the AdBlue pump filter...............................................................135 4.15.9.2 Changing the AdBlue breather filter...........................................................138 4.15.9.3 Changing the AdBlue armature (level) filter............................................... 139 4.15.10 Changing the Volvo engine oil....................................................................... 141 4.15.11 Changing the engine oil filter: Volvo 5- and 8-liter engines............................ 142 4.15.12 Changing the engine oil filter: Volvo 11- and 13-liter engines.........................143 4.15.13 Changing the crankcase breather filter..........................................................144 4.15.14 Checking the Volvo drive belt........................................................................ 146 4.15.15 Checking the Volvo vibration damper............................................................ 148 4.15.16 Checking the Volvo water pump.................................................................... 148 4.16 Maintaining the Cummins engines.......................................................................... 149 5/262 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Maintenance Instructions Table of contents 4.16.1 Bleeding the fuel system - QSB 6.7...............................................................150 4.16.1.1 Bleeding the fuel prefilter - QSB 6.7 and B 6.7.......................................... 150 4.16.1.2 Bleeding the distributor pump - QSB 6.7................................................... 152 4.16.1.3 Bleeding the fuel filter - QSB 6.7 and B 6.7............................................... 153 4.16.2 Bleeding the fuel system - QSM 11............................................................... 155 4.16.3 Bleeding the fuel system - X12......................................................................156 4.16.3.1 Bleeding the fuel prefilter - X12................................................................. 156 4.16.3.2 Bleeding the fuel filter - X12...................................................................... 157 4.16.4 Draining the fuel prefilter - X12......................................................................158 4.16.5 Changing the fuel prefilter - QSB 6.7 and B 6.7.............................................160 4.16.6 Changing the fuel prefilter - X12....................................................................162 4.16.7 Changing the AdBlue filters, Cummins.......................................................... 163 4.16.7.1 Changing the AdBlue pump filter...............................................................135 4.16.7.2 Changing the AdBlue pump filter, B 6.7 and X12.......................................167 4.16.7.3 Changing the AdBlue tank filter................................................................. 168 4.16.8 Changing the Cummins engine oil.................................................................171 4.16.9 Changing the Cummins engine oil filter......................................................... 173 4.16.10 Changing the Cummins fuel filter.................................................................. 175 4.16.11 Checking the Cummins drive belt..................................................................177 4.16.12 Checking the Cummins cooling fan............................................................... 180 4.16.13 Checking the Cummins vibration damper...................................................... 182 4.16.14 Checking the Cummins water pump..............................................................182 4.17 Maintaining the DANA transmissions......................................................................183 4.17.1 Changing the DANA transmission oil.............................................................183 4.17.2 Changing the DANA transmission oil filter..................................................... 186 4.17.2.1 DANA TE17 transmission oil filter............................................................. 186 4.17.2.2 DANA TE14 and TE30 transmission oil filter............................................. 187 4.17.3 Checking the DANA transmission breather................................................... 188 4.17.4 Calibrating the DANA transmission............................................................... 189 4.17.4.1 Heating up the DANA transmission........................................................... 189 4.17.4.2 Activating the DANA transmission calibration............................................191 4.18 Maintaining the ZF transmissions............................................................................192 4.18.1 Changing the ZF transmission oil.................................................................. 193 4.18.2 Changing the ZF transmission oil filter.......................................................... 194 4.18.2.1 Changing the ZF 191 transmission oil filter................................................194 4.18.2.2 Changing the ZF 261/311 transmission oil filter......................................... 194 4.18.3 Checking the ZF transmission breather.........................................................196 4.18.4 Calibrating the ZF transmission.....................................................................196 4.18.4.1 Heating up the ZF transmission.................................................................196 4.18.4.2 Activating the ZF transmission calibration................................................. 197 4.19 Maintaining the drive axle.........................................................................................198 4.19.1 Checking the drive axle oil level.................................................................... 198 4.19.2 Changing the drive axle oil............................................................................ 199 4.19.2.1 Changing the drive axle oil - hub............................................................... 199 4.19.2.2 Changing the drive axle oil - differential.....................................................200 4.19.3 Checking the drive axle breather...................................................................200 4.19.4 Measuring the parking brake pressure.......................................................... 201 4.19.5 Adjusting the parking brake...........................................................................202 4.19.6 Manually releasing the parking brake............................................................ 203 4.19.7 Bleeding the parking brake............................................................................204 4.20 Maintaining the steer axle.........................................................................................205 4.20.1 Checking the steer axle bearings.................................................................. 205 4.20.2 Adjusting the wheel bearings.........................................................................206 4.20.3 Adjusting the spindle bearings.......................................................................207 4.21 Maintaining the hydraulic system............................................................................ 208 4.21.1 Changing the hydraulic oil ............................................................................ 208 4.21.2 Starting the hydraulic pumps......................................................................... 209 6/262 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Table of contents Maintenance Instructions 4.21.3 Changing the hydraulic oil filter..................................................................... 210 4.21.4 Hydraulic long life (HLL) filter (option)........................................................... 213 4.21.4.1 Placement of the hydraulic long life (HLL) filter......................................... 213 4.21.4.2 Checking the HLL filter.............................................................................. 214 4.21.4.3 Changing the hydraulic long life (HLL) filter (option).................................. 214 4.21.5 Changing the hydraulic tank breather filter.................................................... 217 4.21.5.1 Replace filter element in the breather filter housing...................................218 4.21.6 Changing the brake cooling oil ..................................................................... 218 4.21.7 Changing the brake cooling oil filter ..............................................................219 4.21.8 Changing the breather filter for the brake cooling oil tank .............................219 4.22 Maintaining the mast and fork carriage................................................................... 220 4.22.1 Checking the mast and fork carriage............................................................. 220 4.22.2 Checking the fork arms................................................................................. 221 4.22.3 Checking the clearance between the mast and fork carriage........................ 222 4.22.4 Checking the fork shaft system (option)........................................................ 222 4.22.5 Checking the lift chains................................................................................. 223 4.22.6 Adjusting the lift chains..................................................................................224 4.23 Maintaining the machine.......................................................................................... 225 4.23.1 Cleaning the machine....................................................................................225 4.23.2 Changing the internal cabin air filter.............................................................. 226 4.23.3 Changing the external cabin air filter............................................................. 227 4.23.4 Checking the battery..................................................................................... 228 4.23.5 Changing the batteries.................................................................................. 229 4.23.6 Checking the weld constructions................................................................... 232 4.23.7 Changing the windshield wipers.................................................................... 232 5 MAINTENANCE SCHEDULE..................................................................................... 233 5.1 Commissioning inspection.......................................................................................233 5.2 Commissioning service............................................................................................ 233 5.3 Daily maintenance ....................................................................................................233 5.4 Maintenance points after the first 150 operating hours......................................... 235 5.5 Regular service......................................................................................................... 236 5.6 Maintenance data...................................................................................................... 248 APPENDIX I: FUEL AND OIL RECOMMENDATIONS........................................................... 249 Quality of the engine oil...............................................................................................249 Extended oil change interval....................................................................................... 250 Recommended fluids and lubricants............................................................................250 APPENDIX II: FUSES AND RELAYS..................................................................................... 255 Fuses.......................................................................................................................... 255 Relays.........................................................................................................................260 7/262 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Maintenance Instructions Table of contents 8/262 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. 1 Introduction Maintenance Instructions 1 INTRODUCTION 1.1 About this document This maintenance instruction offers guidance to enable safe and efficient maintenance of the equipment. Taking the time to read this document helps to prevent damage to the equipment, and, most importantly, keep the personnel safe. The equipment is safe when used correctly. However, there are many potential hazards that are associated with incorrect operation and maintenance. These hazards can be avoided with knowledge about how to recognize and anticipate them. This document increases the awareness of the responsibilities regarding the equipment. Following the content of this document will ensure that the equipment is kept in a safe operating condition throughout its lifetime. This document is not intended as a substitute for proper training but provides recommendations and methods for safe and efficient operation and maintenance. The operational manager must ensure that operators are properly trained before operation. They must always comply with all the applicable and prevailing safety, as well as other standards, rules, and regulations. 1.1.1 Use of the document Every person that is exposed to the equipment must, before operating, servicing and maintaining such products, read, and understand the contents of this document. Also to strictly adhere and conform their conduct with and to the information, recommendations, and warnings that are provided in this document. NOTE Keep the maintenance instructions in a safe and accessible location for future reference. WARNING IGNORING INSTRUCTIONS HAZARD Failure to follow the given instructions could cause death or serious injury. Read and understand the contents of this document before operating, servicing, and maintaining the equipment. The manufacturer makes absolutely no warranty whatsoever regarding the contents of this document, express or implied, whether arising by operation of law or otherwise. This includes, but are not limited to, any implied warranties of merchantability or fitness for a particular purpose. 1.1.2 Terminology All brand names, product names, and trademarks that are used in this document are registered trademarks of their respective owners. The following terms and definitions may have been used in this document: 9/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 1 Introduction Authorized dealer Company, or person authorized by Konecranes Lifttrucks AB to carry out service actions, and represent the manufacturer. Authorized Persons who have the necessary training and who are authorized by personnel Konecranes Lifttrucks AB or their representative to carry out operation, or service actions. Manufacturer Refers to Konecranes Lifttrucks AB, or supplier of part when otherwise specificed. Operational Person, or persons, with different areas of responsibility at the working manager site where the machine is used. The areas of responsibility include, but are not limited to risk assessments, daily operations and maintenance tasks. Battery A compartment containing the 24V batteries and fuses, which are compartment found on the right side of the machine. CE marking The CE marking of the machine is displayed on the lifting capacity plate. The symbol indicates that the machine complies with the appropriate CE regulations. Check A visual and functional assessment (not a test) of the machine without dismantling it. Touch screen A touch screen where the user receives information, and enter display commands by touching designated areas on the screen. TRUCONNECT® TRUCONNECT® is a suite of remote service products and applications to support maintenance operations and drive improvements in safety and productivity. The collected data from the machines can be viewed at yourKONECRANES customer portal. 1.1.3 Abbreviations The following abbreviations and shortenings can occur in this document: Abbreviation Description Abbreviation Description Automated determination of the filling paramaters AEB LV Low Voltage (Automatisiertes Ermitteln der Befüllparameter) COG Center Of Gravity NCD Nox Control Diagnostics DEF Diesel Exhaust Fluid PCB Printed Circuit Board DOC Diesel Oxidation Catalyst PCD Particle Control Diagnostics Personal Protective DPF Diesel Particulate Filter PPE Equipment Engine After-treatment EATS PPS Power Pile Slope System Radio Frequency ECM Engine Control Module RFID Identification Electric Magnetic EMC SCR Selective Catalyst Reduction Compatibility FGO Function Group Output SWL Safe Working Load 10/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 1 Introduction Maintenance Instructions Abbreviation Description Abbreviation Description Tire Pressure Monitoring HLL Hydraulic Long-Life TPMS System Heating, ventilation, and air HVAC ULSD Ultra-Low Sulphur Diesel conditioning International Organization for ISO VCU Vehicle Control Unit Standardization LC Load Center 1.1.4 Copyright notice This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Konecranes © 2024. All rights reserved. 1.1.5 Available technical documents For this equipment, there are technical documents that serve different purposes and audiences. Contact your supplier if you require any of the documents that are listed here. Operating instructions Describes the responsibilities of the operator and the operating instructions, along with some mandatory daily maintenance tasks and safety information. The operating instruction must be stored in the cabin of the truck. Maintenance instructions Describes maintenance tasks such as lubrication and oil change and the recommended safety instructions. Technical instructions Describes in greater detail the hydraulic and electrical systems, vehicle control unit, and other components of the machine and its software. Spare part catalogue Includes part numbers of all components for the supplied parts, drawings, and exploded views. Supplier documentation Describes components that are assembled on the machine, and provided by approved suppliers to the manufacturer. This includes component-specific documents, for example, for installation, operation, and maintenance. NOTE Store documents in a safe, dry place where they can be easily located when required. 1.1.6 Feedback on documents As the goal is constant improvement, this document may be updated or revised to provide operational managers and maintenance personnel with the most accurate information currently available. Current versions of instructions can be found at document portal www.kclifttrucks.com. To communicate any inaccuracies or omissions, or to provide general feedback or suggestions regarding the quality of this document, send an email to [email protected]. 11/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 1 Introduction 1.2 About this product 1.2.1 Use of the product The machine is designed to perform lifting and transporting of loads within the limits that are specified in the machine's lifting capacity plate. For more information, see the machine's lifting capacity plate in front of the left side cabin door. Contact the manufacturer or manufacturer's representative in case of doubt. 1.2.2 Conditions of warranty The terms under which seller's equipment and/or services are warranted are defined pursuant to the warranty set forth in the contract between seller and customer for seller's products and/or services and, if not so set forth, the warranty for seller's products and/or services is seller's standard warranty in effect at the time of sale, a copy of which is available from seller upon request. THE FOREGOING REPRESENTS THE SOLE AND EXCLUSIVE WARRANTY GIVEN BY SELLER AND IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, ARISING BY OPERATION OF LAW OR OTHERWISE, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Seller provides no warranties for products manufactured or services provided by parties other than seller ("Third Party Products"). Third Party Products may be warranted separately by their respective manufacturers or such other parties from whom seller purchases such Third Party Products and seller shall, to the extent possible, assign to you whatever rights seller may obtain under any such warranties. Modifying any seller product or incorporating any Third Party Product into any seller product or service without the seller's approval invalidates the warranty. Seller does not accept, shall not have any responsibility and disclaims any liability for accidents, injury or physical or property damage arising as a consequence of such unauthorized modifications and/or incorporation of Third Party Products. Further, each of the following invalidates any warranty of seller and relieves seller from any responsibility to repair or replace any seller product due to a failure to operate and/or maintain seller products in accordance with the applicable manuals, instructions, guides, recommendations, and any other manuals, guidelines or recommendations of seller concerning the maintenance and operation of seller products that may be communicated to you from time to time; damage or defects caused by side-pulling of load, shock loading, excessive jogging, eccentric loading or overloading, accidental occurrence, improper repair, improper handling or storage of products, chemical exposure, abnormal operating conditions, or any other cause that in seller's sole discretion is not attributable to defects in the material and workmanship of seller’s product. The applicable seller manuals, instructions, guidelines, and recommendations must be strictly complied with by customer which may include, by way of example and not by limitation, installation and commissioning instructions, owner's manuals, operator's/user’s manuals, operating and maintenance instructions and user's guides. SELLER SHALL HAVE NO LIABILITY TO YOU OR ANY END USER OF PRODUCTS FOR LOST PROFITS OR FOR INDIRECT, SPECIAL, CONSEQUENTIAL, EXEMPLARY OR INCIDENTAL DAMAGES OF ANY KIND WHETHER ARISING IN, CONTRACT, TORT, PRODUCT LIABILITY, STRICT LIABILITY OR OTHERWISE, EVEN IF SELLER WAS ADVISED OF THE POSSIBILITY OF SUCH LOST PROFITS OR DAMAGES. SELLER’S LIABILITY IS LIMITED TO THE AMOUNT OF YOUR DIRECT DAMAGES UP TO THE AMOUNT OF THE CONTRACT PRICE AND IN NO EVENT SHALL SELLER BE LIABLE TO YOU FOR ANY DAMAGES WHATSOEVER IN EXCESS OF THE TOTAL PRICE PAID BY YOU FOR THE APPLICABLE SELLER PRODUCTS. YOU HEREBY WAIVE ANY CLAIM THAT THE EXCLUSIONS OR LIMITATIONS IDENTIFIED HEREIN DEPRIVE YOU OF AN ADEQUATE REMEDY OR CAUSES YOUR AGREEMENT WITH SELLER TO FAIL OF ITS ESSENTIAL PURPOSE. YOU SHALL BE ENTITLED TO NO OTHER REMEDY OTHER THAN THOSE IDENTIFIED IN THE CONTRACT BETWEEN YOU AND SELLER OR SELLER’S STANDARD 12/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 1 Introduction Maintenance Instructions WARRANTY, WHICHEVER IS APPLICABLE, WITH RESPECT TO THE PROVISION OF PRODUCTS BY SELLER REGARDLESS OF THE FORM OF CLAIM OR CAUSE OF ACTION, WHETHER BASED IN AGREEMENT, NEGLIGENCE, STRICT LIABILITY OR OTHERWISE. UNLESS OTHERWISE REQUIRED BY MANDATORY LAW, SELLER DISCLAIMS ALL WARRANTIES RELATING TO THE CONTENTS OF THIS DOCUMENT, EXPRESS OR IMPLIED, ARISING BY OPERATION OF LAW OR OTHERWISE. 1.2.3 Identification of the product 1 2 3 4 5 6 7 8 Figure 1. Plates and serial numbers 1. Mast serial number 6. Transmission serial number 2. Lifting capacity plate 7. Engine serial number 3. Fork carriage number 8. Steer axle serial number 4. Drive axle serial number 5. Chassis serial number (punched into the frame) NOTE The appearance may deviate from the delivered product depending on model size. 13/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 1 Introduction 1.2.4 Standards and directives This product has been designed and manufactured to conform to the following standards and directives: • Health and safety: EU: Machinery directive 2006/42/EC UK: Supply of Machinery (Safety) Regulations 2008 S.I. 2008:1597 ◦ EN ISO 3691-1:2015/A1:2020. "Industrial trucks – Safety requirements and verification - Part 1: Self-propelled industrial trucks, other than driverless trucks, variable-reach trucks, and burden-carrier trucks". ◦ ISO/TS 3691-8:2012,IDT. Industrial trucks – Safety requirements and verification. Regional requirements for countries outside the EC. ◦ EN 16307-1:2013+A1:2015. "Safety requirements and verification. Supplementary requirements for self-propelled industrial trucks, other than driverless trucks, variable-reach trucks, and burden-carrier trucks" (EU/EFTA market). ◦ EN 13059+A1:2008. "Safety of industrial trucks. Test methods for measuring vibration" (EU/EFTA market). ◦ EN 12053+A1: 2008. "Safety of industrial trucks. Test methods for noise emission" (EU/ EFTA market). ◦ EN 1175-2+A1:2010 “Safety of industrial trucks – Electrical Requirements - Part 2: General requirements of internal combustion engine powered trucks“. • EMC: EU: 2014/30/EU UK: Electromagnetic Compatibility Regulations 2016 S.I. 2016:1091 ◦ EN 12895:2015+A1:2019. Industrial trucks - Electromagnetic compatibility. • Emissions: EU: 2016/1628/EC (EU/EFTA market, stage 4, and 5 engines). UK: The Non-Road Mobile Machinery (Type-Approval and Emission of Gaseous and Particulate Pollutants) Regulations 2018 2018 No. 764 • 2016/1628/EU “REGULATION (EU) 2016/1628 OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 14 September 2016 on requirements relating to gaseous and particulate pollutant emission limits and type-approval for internal combustion engines for non-road mobile machinery, amending Regulations (EU) No 1024/2012 and (EU) No 167/2013, and amending and repealing Directive 97/68/EC" Declaration of conformity and other certificates are included in the delivery package. Manufacturer reserves the right to modify the design and material specifications without NOTE prior notice. Applicable sections of EN13155 are used for all lifting ears on the machine. 14/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 1 Introduction Maintenance Instructions 1.2.5 Declaration of conformity EC DECLARATION OF CONFORMITY OF THE MACHINERY (Machinery Directive 2006/42/EC, Annex II, sub. A) Manufacturer: Konecranes Lifttrucks AB Anders Anderssons väg 13, P.O. Box 103 SE-28523 MARKARYD SE Name and address of the person authorised to compile the technical file: XXXXX XXXXX Anders Anderssons väg 13, P.O. Box 103 SE-28523 MARKARYD SE The manufacturer declares that Description: Forklift Model: XXXXX Serial number: XXXXX • Is in conformity with the relevant provisions of the DIRECTIVES OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL: - of May 17, 2006, "relating to machinery" 2006/42/EC - of February 26, 2014, "relating to electromagnetic compatibility" 2014/30/EU - Directive 2000/14/EC as amended by Directive 2005/88/EC on the noise emission in the environment by equipment for use outdoors and fulfils the requirements of the following harmonised standards: • regarding Machinery Directive: EN ISO 3691-1 • regarding EMC Directive: EN 12895 Place and date of issue MARKARYD DD.MM.YYYY Signature: Anders Nilsson Technical Director Konecranes Lift trucks Figure 2. EC Declaration of conformity of the machinery (template) 15/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 1 Introduction UK DECLARATION OF CONFORMITY OF THE MACHINERY (Supply of Machinery (Safety) Regulations 2008, Annex II, sub. A) Manufacturer: Konecranes Lifttrucks AB Anders Anderssons väg 13, P.O. Box 103 SE-28523 MARKARYD SE Name and address of the person authorised to compile the technical file: XXXXX XXXXX Coalfield Way LE65 1NF Ashby De La Zouch UK The manufacturer declares that Description: Forklift Model: XXXXX Serial number: XXXXX • is in conformity with the relevant provisions of statutory instruments - Supply of Machinery (Safety) Regulations 2008 No.1597 - Electromagnetic Compatibility Regulations 2016 No.1091 - Noise emission in the environment by Equipment for use Outdoors Regulations 2001 No.1071 and fulfils the requirements of the following designated standards: • regarding 2008 No. 1597: EN ISO 3691-1 • regarding 2016 No. 1091: EN 12895 Place and date of issue MARKARYD DD.MM.YYYY Signature: Anders Nilsson Technical Director Konecranes Lift trucks Figure 3. UK Declaration of conformity of the machinery (template) 16/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions 2 SAFETY AND ENVIRONMENT 2.1 Safety messages and symbols 2.1.1 Signal words The following signal words and symbols are used to identify safety messages in these instructions. Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation that, if not avoided, could result in damage to property or environment. 2.1.2 Hazard symbols Hazard symbols are used to indicate the type of the hazard and the potential consequences. Hazard symbols are indicated by a yellow triangle with black symbols and a black triangle band. All personnel working on or in proximity of the machine must understand and follow the information that is given in all hazard symbols. General hazard symbol General hazard The general hazard symbol identifies important safety messages in this document. When you see this symbol, carefully read and understand the message that follows, and inform other users when necessary. 17/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment Mechanical hazard symbols Moving vehicle Sideways tipping Forward or backward Run over hazard hazard hazard tipping hazard Moving parts hazard Falling load hazard Slipping hazard Hanging load hazard Crushing hazard Crushing hand Flying objects to face Flying objects hazard hazard hazard Skin injection hazard Electrical hazard symbols Electrical hazard Material hazard symbols Hot liquid hazard Explosion hazard Harmful substance High-pressure hazard hazard Ignition hazard Corrosive chemical Pressurized gas Hazardous or substance hazard hazard poisonous material hazard 18/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions Thermal hazard symbols Hot surface hazard Slippery when frozen hazard Noise hazard symbols Noise hazard Laser hazard symbols Laser hazard Ergonomic hazard symbols Lifting hazard 19/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment 2.1.3 Mandatory action symbols Mandatory action symbols specify actions to be taken to avoid a hazard. Mandatory actions are indicated by blue circle with white symbols. All personnel working on or in proximity of the machine must understand and follow the information that is given in all mandatory action symbols. Wear approved safety Wear approved Wear approved Wear approved safety gloves hearing protectors protective clothing shoes Wear approved safety Wear approved hard Wear approved high Wear approved eye harness hat visibility clothing protector Disconnect Apply indicator for Use jack Alarm horn equipment from pin-hole leak test power source Read instructions Two persons for Wear approved Use seat belt handling respirator 20/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions 2.1.4 Prohibited action symbols Prohibited action symbols indicate actions that are prohibited in order to avoid a hazard. Prohibited actions are indicated by a red circle with a red diagonal line across the circle. The action that is prohibited is always in black. All personnel working on or in proximity of the machine must understand and follow the information that is given in all prohibited action symbols. General prohibition Do not walk or stand Do not weld No open fire here Do not smoke Do not modify Do not test for leak Do not touch with hands Restrict access 2.1.5 Safety and information labels on the product The safety and information labels communicate the following: • Level of risk that is based on the signal word Danger, Warning, or Notice • Type of hazard, such as cutting parts, hanging load, hot surface, live parts • Consequence of hazard, such as cutting, injection, crushing, burn, electric shock • How to avoid the hazard Always keep safety and information labels visible, and check the condition of the labels daily. Before operating the machine, replace labels that are damaged, have come loose, NOTE or do not meet the readability requirements for safe viewing distance. New safety and information labels can be ordered from the manufacturer of the machine. 21/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment 2.1.6 Location of the safety and information labels 1 5 6 7 4 8 10 3 1 9 1 12 2 26 25 11 12 1 13 13 21 20 19 18 15 14 22 16 23 17 24 Figure 4. Location of the safety and information labels 1. Lifting point 14. Accumulator pressure 2. Engine oil 15. Hydraulic oil 3. Transmission oil 16. Diesel fuel 4. Fuses and relays, PCB 17. Brake cooling oil 5. Emergency exit only 18. Do not step here 6. Seat belt 19. Remove pressure before demounting tire 7. In case of rollover 20. Read operating instructions first 8. Working zone 21. Battery main switch 9. Crush injury risk 22. Cab tilting 10. Injection hazard 23. Fuses and relays, battery compartment 11. Do not stand under or on lifted load 24. Warning-Acid and explosion risk 12. Tire pressure 10 bar (1.0 MPa)*) 25. Crushing risk by tire 13. Tie down point when transporting the 26. Machine working zone machine *) Sign present above all tires. 22/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions Table 1. Labels 1. Lifting point 2. Engine oil 3. Transmission oil 4. Fuses and relays, PCB 5. Emergency exit only 23/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment Table 1. Labels (Continued) 6. Seat belt 7. In case of rollover This sticker shows what the operator must do in case of rollover. Do not jump out of the cabin in case of rollover. Brace feet against the floor and hold on tightly to the steering wheel. Climb out of the machine when it has stopped moving. 8. Working zone 9. Crush injury risk 24/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions Table 1. Labels (Continued) 10. Injection hazard 11. Do not stand under or on lifted load. 12. Tire pressure 10 bar (1.0 MPa) 13. Tie down point for loading the machine for transport Secure the machine here when loading it for transport. 14. Accumulator pressure Warning, read instructions in the manual. 25/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment Table 1. Labels (Continued) 15. Hydraulic oil 16. Diesel fuel 17. Brake cooling oil 18. Do not step here 19. Remove pressure before demounting tire 20. Warning - Read operating instructions first 21. Battery main switch 26/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions Table 1. Labels (Continued) 1 2 22. Cab tilting 23. Fuses and relays, battery compartment 24. Warning - Acid and explosion risk 25. Crushing risk by tire 26. Machine working zone 27/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment 2.2 Responsibilities of the operational manager 2.2.1 Preventing work-related hazards The operational manager must ensure that operators, and maintenance personnel have sufficient knowledge of the work-related hazards, and the ways to avoid the hazards. The operational manager must ensure to inform the operator that a local risk assessment always must be performed before every work phase or shift. The assessment ensures that the operator stops and thinks about what to do before starting to work. • Identify potential hazards that could affect the operator, other personnel, the environment, the product, or work methods while performing the task • Assess the risks and implement the actions that are required to eliminate or reduce the risks Only personnel with sufficient competence are allowed to operate the machine, and carry out other tasks on the machine. The responsibilities of the operational manager are, for example, to: • Provide training and orientation. • Validate training methods. • Verify competence and skills. • Monitor and evaluate user performance regularly. • Provide fire-fighting equipment. • Make sure that the working site has guidelines on how to prevent fires. • Make sure that the working site has guidelines to follow concerning fire-fighting. • Make sure that the working site has guidelines on how to operate the machine during strong wind. • Make sure that the instructions from Konecranes Lift Trucks are accessible and up to date. • Make a risk assessment of the work site, for example, regarding height limitations, door openings, overhead powerlines, and ground conditions. • Make sure that the work site follows all local rules and regulations. 2.2.2 Preventive maintenance WARNING MACHINE MALFUNCTION HAZARD Failure to regularly and properly maintain the product can result in death, injury, or damage. Do not allow the product to be used if it is not in proper condition or if it has not been maintained correctly. Contact an authorized service agent or manufacturer's representative immediately if there are doubts. WARNING MACHINE NON-COMPLIANCE Replacing components with non-genuine components, or components not authorized by Konecranes Lift Trucks, can affect the safety of the machine. This is considered as a modification of the machine and therefore voids Konecranes' liability as manufacturer. The party that performed the modification will thereafter legally be liable for the safety of the modified machine, and the related CE marking. For any clarification always contact your authorized Konecranes Lift Trucks representative. 28/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions RISK OF PROPERTY DAMAGE Only use genuine spare parts or materials and lubricants that are approved by the NOTICE product manufacturer or manufacturer's representative. For more information, see the spare part catalogue and section Fuel and oil recommendations (page 249). Scheduled inspections and preventive maintenance are essential for keeping the product in safe working condition. Here are some general guidelines for preventive maintenance. • It is the responsibility of the operational manager to organize maintenance inspections regularly. These inspections are to ensure long-term safety, reliability, durability, operability, and warranty for the product. • The operational manager must keep a record (log book) of all maintenance activities and usage relating to the product. • Maintenance must be carried out at different intervals and by authorized personnel who are qualified for the individual task. • Daily checks and minor lubrication must be carried out by operators or maintenance personnel. These checks are important for catching small faults before they become major faults and causes breakdowns. • Other maintenance actions must be done by service personnel that are authorized by the operational manager. • Replacement parts and materials must comply with the specifications that are defined by the product manufacturer. It is the responsibility of the operational manager to ensure that only genuine replacement parts, and components that are approved by the manufacturer are used. • Keep this document in a safe, accessible location during the whole lifetime of the product. 2.2.3 Personal protective equipment For safety, all personnel working in or near the machine are required to wear personal NOTE protective equipment (PPE). This section proposes personal protective equipment to ensure the safety of all personnel working in or near the machine. Follow the local regulations and requirements NOTE of the working environment. Use only approved and accepted personal protective equipment. Operators and anyone near and around the product must wear the following items: • Safety shoes • High-visibility clothing Various types of PPE are available as listed, depending on the situation, other types of PPE than listed can be required. It is the responsibility of the operational manager to make sure that all local PPE requirements are followed. • Hard hat • Eye protection • Ear protection • Respirator • Safety gloves • Protective clothing • Safety harness when working at heights Do not wear loose clothing or jewelry that can get caught on controls or pulled into moving parts of the product. Do not wear jewelry or metal accessories such as watches when working with or near the electrical system or the batteries. Tie back long hair. Long hair can get entangled. Select the appropriate clothing for each task, for example: 29/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment • Wear fire-resistant clothing when welding, flame cutting, or using an angle grinder. • Tear-resistant clothing must resist damage from sharp edges in the steel structure. • Wear anti-static clothing when working on electrical circuits so that components do not get damaged by a discharge of static electricity. • Always use safety goggles when working with high voltage or pressurized fluids. • When working with lubricants, clothing must prevent direct skin contact with the lubricant. • Choose clothing with consideration to the temperature at the working site, and stay hydrated. 2.2.3.1 Fall protection While personnel installs, inspects, or do maintenance work at heights, they must follow fall protection procedures as required by local regulations. Fall prevention practices and equipment aim at protecting personnel working on or around the equipment. If the equipment does not have a service platform or guardrail, personnel must use a properly fitted safety harness. The safety harness is attached to the dedicated fixing points on a building or equipment to prevent falls. If dedicated fall protection fixing points are missing, it is the operational manager's responsibility to make sure that suitable and secure fixing points are available. If not possible it is necessary for the operational manager to provide an appropriate manlift. If ladders must be used, personnel must practice setting and securing the ladders before using them for actual work. Fall protection system has four components: • Safety harness: Safety harness helps to prevent employees to get hurt in a fall. • Lanyard belt: Lanyard belt is connected to the anchor point and is attached to the safety harness. Lanyard belts are shock absorbing, which means that they slow down and eventually stop a fall. • Snap hook: Snap hooks connect the D-ring to the safety harness. Snap hooks must be double locking. To connect only one snap hook to one D-ring, is the basic rule. • Anchorage point: Anchorage point is the point to which personal fall protection equipment is attached. The point must be capable of supporting at least 2,268 kg (5,000 lb) for each employee. If there is any doubt about the strength of the attachment point, find an alternative point that can support the worker. A typical fall protection program may include: • Documented and established site policies and procedures • Conducting site assessments for fall hazards • Selection of the proper fall protection system and equipment • Training on fall protection procedures and the proper use of fall protection systems • Inspection and proper maintenance of fall protection equipment • Measures to prevent falling objects • Rescue plans If necessary, contact your supplier or service organization for assistance with designing your fall protection program. For more information about lifting operations and equipment, see "Lifting Operations and Lifting Equipment Regulations" (LOLER). 2.2.4 Incident reporting Product safety issues that you must report are events in which the manufacturer's product has been involved in an accident or near-miss incident. Contact your local manufacturer's representative immediately to report any safety-related feedback, such as unauthorized modifications, missing instructions and safety labels, neglected maintenance, or misuse. Reporting is mandatory to ensure safe working conditions for employees, to provide information for the risk assessment process, and to initiate product and work procedure improvements. 30/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions 2.3 Limitations of the product 2.3.1 Operating conditions Thunderstorm When in danger of being struck by lightning, operating or being close to the machine is strongly discouraged. Protection from lightning during work must be managed by the workplace risk assessment that is made by the operational manager. Following a lightning strike (or if you suspect the machine has been struck) the machine must be checked by authorized personnel. The check must follow the instructions of the daily maintenance. Surfaces Do not operate the machine on uneven surfaces or in unstable conditions. NOTE Do not drive on slopes that are greater than 15%. 2.3.2 Inclination angles WARNING TIPPING AND COLLISION HAZARD If you drive on slopes greater than 15%, the parking brake may fail and risk of tipping increases considerably. Risk of serious personal injury and damage to the machine. Do not drive on slopes greater than 15%. WARNING RISK OF LOAD DROP Driving downhill on slopes carrying a load, can lead to a load drop. This can damage the machine and can lead to serious personal injury. If carrying a load, always drive downhill in reverse. If you must drive the machine along greater slopes, contact your Konecranes Lift Trucks NOTE authorized dealer. NOTE Do not drive on slopes that are greater than 15%. Figure 5. Do not drive on slopes greater than 15% 31/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment 2.3.3 Lift truck danger zones, general DANGER MOVING MACHINERY HAZARD The moving machine and its moving parts can cause death or serious injury. While the machine operates, unauthorized personnel should never enter or be within the danger zone. During operation, the authorized personnel working within the danger zone and the operator must constantly communicate verbally or visually to stay aware of each other. The following images show the danger zones surrounding the machine and its parts. 15 m/16 yd Figure 6. General danger zone 2.3.4 Tire explosion danger zone DANGER HIGH-PRESSURE HAZARD The tires may explode when you inflate or deflate them, or in case of fire. Standing inside the tire explosion danger zone during a tire explosion can cause death or serious injury. Always stand to the side of the wheel when deflating or inflating tires, see "tire explosion danger zone" illustration. Use safety glasses. The tire explosion danger zone follows the positioning of the wheels. The illustration NOTE applies when the wheels are in line with the machine. 32/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions 120° 120° 50 yd m/ 55 55 m/ yd 50 50 d 5y m/5 m/5 5y 50 d 120° 120° Figure 7. Tire explosion danger zones 33/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment 2.3.5 Prohibited use WARNING MACHINE MALFUNCTION HAZARD Using the machine outside the limits of its capacity or operating conditions could cause malfunction of the equipment. Unauthorized usage could lead to death, severe injury, or property damage. Do not use the machine outside the limits of its capacity or operating conditions. The misuse of the equipment includes, but is not limited to: • Lifting or transporting people. • Driving with the load above transport position. • Driving with heavy loads in slings. • Driving with swinging load. • Having passengers in the cabin 1) • Driving on uneven terrain • Exceeding the load limit, which is shown on the lifting capacity plate • Adding extra counterweights • Driving uphill and downhill on slopes with an inclination over 15%. • Using tools that are not approved by the manufacturer. • Using the low-voltage battery switch when the machine is in motion. • Overriding any safety systems. • Using the emergency stop in a none emergency situation. NOTE Only use the emergency stop in an emergency situation. 1) If a truck is equipped with an optional trainer's seat, another person is allowed to sit there, as long as the person uses the seat belt. For more information, see the lifting capacity plate of the machine, and, if applicable, lifting capacity plates on attachments. Contact the manufacturer or the representative for the manufacturer if there are any doubts. 2.3.6 Changes to the product DANGER MACHINE MALFUNCTION HAZARD Unauthorized changes, or modifications to the product can lead to death, severe injury, or property damage. Always contact Konecranes Lift Trucks, or an authorized representative to get a written approval in advance for any product change or modification. 34/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions DANGER MACHINE MALFUNCTION HAZARD Changes, and modifications without proper risk assessment, can lead to death, or serious personal injuries. It can also damage property, or the environment. Unauthorized modifications void the warranty and responsibility of the manufacturer. Perform a risk assessment, which eliminates, or reduces risks, and considers appropriate safety measures. WARNING MACHINE MISUSE HAZARD Adding and using equipment that is not supplied with the machine, can cause the products to malfunction. Risk of serious personal injury and damage to the machine. If using equipment that was not supplied with the machine, an authorized dealer must approve the combination and use of the equipment. The authorized dealer must ensure that safe operations can be guaranteed concerning lifting capacity, stability, and visibility. WARNING MACHINE NON-COMPLIANCE Replacing components with non-genuine components, or components not authorized by Konecranes Lift Trucks, can affect the safety of the machine. This is considered as a modification of the machine and therefore voids the liability of Konecranes as a manufacturer. The party that performed the modification will thereafter legally be liable for the safety of the modified machine, and the related CE marking. For any clarification always contact your authorised Konecranes Lift Trucks representative. All modifications and corrections that are not authorized in the product documents or which may affect the maintenance, operation, safety, and availability of the product must be approved in writing by Konecranes Lift Trucks before implementation. Approval requires a risk assessment which consider any new risks that the changes and modifications may bring. All safety and information labels on the machine, must be updated to match the machine after any modifications. To avoid using obsolete spare parts, always check the specific spare parts catalogue for the machine. For the latest version, contact Konecranes Lift Trucks spare parts department. If a modification or correction has been implemented without the permission from Konecranes Lift Trucks, its effect on warranty liability is considered case-by-case. Thus, the warranty application may be rejected altogether. If a modification, or alteration is considered necessary, contact an authorized dealer, or the organization that manufactured, and designed the product. No modification is permitted, unless the written approval from the manufacturer is obtained. Before doing any modifications, the following information must be sent to Konecranes Lift Trucks. • Product model and type • Serial number of product • Description of the modification or correction 35/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment • Related blueprints • Related photos • And other material, if necessary The manufacturer then approves, or rejects the modifications in writing. 2.4 Emissions The noise and vibration levels are checked according to industry standards. This is to make sure that the operator's have a healthy environment while operating the machine. 36/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions 2.4.1 Noise Measured sound levels WARNING NOISE HAZARD Continuous exposure to noise above 80 dB(A) can cause hearing impairment, and make the operator tired and unfocused. Wear approved hearing protectors. The noise values were measured according to the harmonized standard EN12053 – A1:2008, following the conditions described therein, by a notified body. The noise values are reported according to ISO4871:2009. The specified equipment has been assessed in accordance with Directive 2000/14/EC (amended by Directive 2005/88/EC), annex VI by notified body 0404, RISE SMP Svensk Maskinprovning AB (The Swedish Machinery Testing Institute). Declared dual-number noise emission values In accordance with ISO4871:2009 Lift mode Idle mode Drive mode Total Time proportion factors of the operating cycle (%) - 0.18 0.58 0.24 1 ref. EN12053+A1:2008 A-weighted emission sound pressure level 75 74 76 76 at the operator position LpAZ (dB) Uncertainty (dB) 1 1 1 1 C-weighted peak emission sound < 130 < 130 < 130 < 130 pressure level Measured sound power level in an 102 operational cycle (A- weighted) Guaranteed sound power level in an 104 operational cycle (A- weighted) Measured on 16-33 ton forklifts, for other sizes, the values may vary slightly. Where the time proportion factors are used in defining the operational cycle, they are as defined in EN12053+A1:2008. 2.4.2 Vibration The whole-body vibration has been measured according to the harmonized standard EN13059:2008, following the conditions described therein, by a notified body. • Measured whole body vibration: below 0.9 m/s₂ • Overall uncertainty of the measurement: 1 m/s₂ 37/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment The reported expanded uncertainty is based on a standard uncertainty that is multiplied by a coverage factor K = 2. For a normal distribution, this value provides a level of confidence of approx. 95%. The standard uncertainty has been determined in accordance with EA publication EA-4/16/2003. 2.5 Protective measures 2.5.1 Emergency stopping DANGER UNCONTROLLED MOVEMENT HAZARD If the machine moves unexpectedly, it could result in personal injury, death, or damage to the equipment. To stop any unexpected movement, press the emergency stop button. WARNING FORWARD TIPPING HAZARD If the emergency stop is used when the machine moves, the machine may tip over. Risk of serious personal injury and damage to the machine. Only use the emergency stop in an emergency. Do not operate the equipment without knowing the location of the emergency stop NOTE buttons. After the emergency stop button (1) is pressed, all functions are cut out, the parking brake is activated and the engine stops. In normal operation, do not use the emergency stop button to stop the machine. Instead, use the brake pedal. Only use the emergency stop button in an emergency situation. Routinely using the NOTE emergency stop button increases wear on the product and can cause a breakdown. After each time the emergency stop is used, a daily maintenance must be performed to check the overall function of the machine. If the machine moves when pressing the emergency button, the condition of the parking brake disc and pads must also be checked. Contact authorized service personnel for the check-up. Figure 8. Emergency stop inside the cabin 38/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions Emergency stop on the outside of the machine 1 2.5.2 Battery main switch DANGER EXPLOSION HAZARD Short-circuiting the battery may cause a fire or explosion, which can cause a risk of serious injury or death. To reduce the risks of fire, explosion, electric shock and personal injury, always remove jewelry and conductive material before working on the electrical system. DANGER EXPLOSION HAZARD Batteries generate explosive hydrogen when charged, which can cause a risk of serious injury or death. Always use the necessary protective equipment. Ensure that there is good ventilation and avoid sparking. 39/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment DANGER ELECTRIC SHOCK HAZARD If the engine is on, there may still be voltage present in some parts, even when the battery main switch is turned off. The main switch does not cut the power from the alternator. This causes a risk of electric shocks, which can lead to death or serious personal injury. To reduce the risks of electric shock and personal injury always remove jewelry and conductive material before working on the electrical system. Always disconnect the ground (minus) cable at the battery when working near or on the alternator. Be aware of the battery main switch functionality. WARNING TIPPING OVER HAZARD If the battery main switch is turned off when the machine moves, the parking brake is activated. The machine may tip over, causing a risk of serious personal injury and damage to the machine. Unless there is an emergency situation, do not turn off the battery main switch when the engine runs. NOTE Do not operate the machine without knowing the location of the battery main switch (1). If the machine has an engine that uses diesel exhaust fluid (DEF) solution (for example AdBlue), turn off the engine, but do not turn off the battery main switch. Wait for the DEF NOTE pump to finish pumping back all the fluid from the hoses to the DEF tank before turning off the battery main switch (1). The required time varies slightly between different engine models. NOTE Remove the main switch handle when parking the machine. The battery main switch is found on the right-hand side of the machine, near the battery compartment. The machine can only be operated when the power is turned on. 1 Figure 9. Battery main switch 40/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions 2.5.3 Releasing the hydraulic pressure WARNING HIGH-PRESSURE HAZARD The hydraulic system contains hydraulic accumulators to maintain the brake function during a possible engine failure. Risk of serious personal injury. Only authorized maintenance personnel are permitted to loosen any hydraulic hoses. Before maintaining or servicing the hydraulics of the machine: - Always lower the mast and fork carriage to the bottom position. - If maintaining the brake system, always ensure that the accumulator pressure for the hydraulics is released before loosening any hydraulic hoses in the brake circuit. - Make sure that no other hydraulic hoses or components are pressurized before loosening any hoses. For more information about releasing the hydraulic pressure, see Releasing the hydraulic accumulator pressure (page 73). 2.5.4 Fire safety DANGER FIRE AND EXPLOSION HAZARD Ignition sources together with combustible materials can cause fire. If these risks are not avoided, they could lead to death or severe injury. Smoking, open flames, and sparks are examples of ignition sources. Fuel is an example of combustible material. Ignition sources are prohibited near the machine. During maintenance, follow appropriate fire prevention and protection measures. Measures include but are not limited to trained personnel and proper fire extinguishing equipment. Before starting any maintenance or repairs that require ignition sources, carry out a proper risk assessment to control the risk. 120° 120° 50 yd m/ 55 55 m/ yd 50 50 d 5y m/5 m/5 5y 50 d 120° 120° 41/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment In case of fire, approach the machine from the front or the back. If possible, always avoid NOTE the tire explosion danger zones. • Smoking and open fire are prohibited near the product. • Access to all fire-fighting equipment must be granted always, especially during maintenance and repair works. Fire-fighting equipment is not a standard part of the machine. It is the responsibility of NOTE the operational manager to make sure that fire-fighting equipment is available. • All fire-fighting equipment must be inspected and serviced regularly, according to local regulations. • Damaged fire-fighting equipment and used fire extinguishers must be replaced immediately. • Know the various types of fires and the appropriate fire-fighting methods. Various fires must not be extinguished with water. Special extinguishing agents, dry powders, or deoxygenating agents are required. • It is the responsibility of the operational manager to make sure that the working site has guidelines to follow concerning fire-fighting. • All personnel must be aware of the guidelines and trained regularly in fire-fighting methods. It is strongly suggested that guidelines, and training is performed in cooperation with NOTE local authorities, and rescue organizations. 2.5.5 Emergency exits The cabin door on the left-hand side is the main emergency exit. If the left-hand side door is blocked, use the right-hand side door. If both the left and right doors are blocked, use the emergency hammer (option) to smash the rear window to exit the cabin. Using the emergency hammer (Option) 1. Pull the emergency hammer from its mounting above the rear window. WARNING FLYING OBJECTS TO FACE HAZARD Breaking glass may fly into your face and eyes. Shield your eyes and face with your other arm while breaking the window with the hammer. 2. Smash the rear window with the hammer. 3. Use the hammer to scrape the remaining glass. 4. Exit the cabin through the rear window. 42/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions 2.5.6 Mounting, and dismounting the machine WARNING SLIPPING HAZARD Failing to maintain three points of contact can cause serious injury or death. Maintain three points of contact when mounting, or dismounting the machine. Three points of contact are either two hands, and one foot, or two feet, and one hand. NOTE Climb on and off only when the machine is stationary. NOTE Do not jump from the steps to the ground. Following this procedure reduces the risk of falling, and decreases wear on back, and NOTE knees. 1. Face the steps, when mounting, or dismounting the machine. The cabin entrance is on the left side of the machine. 2. Maintain three points of contact until reaching the cabin, or ground. 2.5.7 Locking the cabin door in open position 1. To fasten the cabin door in open position, open the cabin door and push it into the lock. 43/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment 2. To unlock the door from open position, press the handle on the inside of the cabin door. 2.5.8 Personnel requirements DANGER SPECIALIST SKILLS REQUIRED Incompetent operation and maintenance could cause death or severe injuries. Operation and maintenance procedures require professional skills and special training regarding the tasks and working methods. Do not operate the equipment or do any maintenance tasks without proper training. Always follow the instructions. Use appropriate personal protective equipment, depending on the task. 44/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions To avoid hazardous situations and dangerous consequences, leave all operation and maintenance work to authorized personnel. Tasks that are mentioned are examples of tasks which are allowed only for authorized personnel. Instructions for safe handling and other risks that are related to the tasks, can be found in the following chapters. Tasks that require special technical skills and training include, but are not limited to: 1. Hydraulic system maintenance 2. Electric system maintenance 3. Battery maintenance 4. Tire maintenance 5. Changing parameters in the control system 2.6 Environmental information Environmental impacts have been taken into account when designing and manufacturing this product. To prevent environmental risks during use, follow the instructions and local regulations for disposal of waste material. Proper use and maintenance improve the environmental performance of this product. 2.6.1 Energy consumption Energy consumption during the use phase has the biggest environmental impact. Diesel fuel is needed for lifting, transporting, lighting, heating, cooling, and other optional components that are part of the machine. Konecranes machines minimize the use of fuel in the following ways: • Engineering diesel engines with the best possible fuel efficiency and lowest emission levels. • Engine downsizing. • Fuel saving transmission features, like lock-up and continuously variable transmission. • Using load-sensing hydraulic systems, so no hydraulic flow (with resulting energy losses) is created unless it is needed by an actual load command. • ECO-driving supports the operators so they can minimize fuel consumption by reducing the harshness of operations. • Connectivity for the operational managers to optimize the use and operational efficiency of their machine fleet by: ◦ maximizing time driving with payload ◦ minimizing travelling distances over the yard ◦ select the most suitable machine capacity for specific lifting needs ◦ monitoring the right tire pressure for the lowest rolling resistance in connected machines • Eliminating idling time with: ◦ automatic start and stop • Means to optimize the preventive maintenance of the machines, to ensure long-term fuel efficiency. 2.6.2 Product lifecycle stages The environmental impact of a Konecranes machine is taken into account for the whole lifecycle of the vehicle. “Lifecycle” refers to the extraction and processing of raw materials, the production of components, manufacturing, use, and maintenance. "Lifecycle" also refers to disposal of the product and the transportation that is involved from one stage to the next. Each stage of the lifecycle has a different impact on the environment. The two most significant environmental impacts of the machines are the energy consumption during the use phase (in particular, the effects of diesel emissions) and the raw materials and component production (in particular, the effects of steel production). The significance of energy consumption depends on actual usage, including operating time, efficiency of operations, and load collective. Product lifecycle stages include: 45/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment • Production of materials and components • Equipment manufacturing and assembly • Use phase, including maintenance, repairs, and modernization • Dismantling and recycling of waste materials • Transports between each stage Figure 10. Product lifecycle stages 2.6.2.1 Production of materials and components 84%–92% of machine materials are metals, and rubber tires form 3%–9%. The rest of the materials include electrical and electromechanical components, fluids (hydraulic oil, diesel fuel, and grease), plastic, and glass. The main raw material is steel. The most significant environmental impacts of steel production are the use of raw materials and energy, as well as carbon dioxide and particle emissions. More than 75% of the steel content can be manufactured from recycled steel scrap. Lubricants, which are used from factory on the products, are industrial hydrocarbons. Table 2. Materials used in Konecranes machines Konecranes Lift Trucks Konecranes Liftace Forklift Forklift, Empty Laden Reach Forklift Empty Reach electric container container stacker container stacker handler handler handler Steel 88% 84% 91% 90% 92% 88% 92% 92% Rubber 6% 6% 4% 5% 3% 6% 3% 3% Copper <1% <2% <1% <1% <1% <1% <1% <1% Electronics <1% <4% <1% <1% <1% <1% <1% <1% Fluids <2% <2% <2% <2% <2% <2% <2% <2% Polymers <1% <1% <1% <1% <1% <1% <1% <1% Others <1% <1% <1% <1% <1% <1% <1% <1% 2.6.2.2 Equipment manufacturing and assembly Production mainly involves assembling of machines and some installations. Welding is only carried out for complementing or repair work. Surface treatment for reconditioning is conducted to a lesser extent. Testing of machines is carried out outdoors after assembly, before delivery. 46/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions The most significant environmental impact is the energy consumption, and diesel emissions during test-driving. To decrease the impact, Konecranes Lift Trucks is using HVO100 bio diesel. It is recommended that HVO100 bio diesel is used generally to decrease the environmental footprint. There are also some lower impacts from the chemicals that are used, like paints, oils and fuels. The waste from the production is disposed of, according to local regulations. Examples of waste are wood, plastic, and paper as well as hazardous waste such as residue of paint, and waste oil. 2.6.2.3 Use phase, including maintenance and modernization Most significant environmental impacts of machines are the energy consumption during the use phase (in particular, the effects of diesel emissions). Konecranes machines minimize the use of fuel, as described in "Energy consumption". Timely repairs and proper maintenance support each machine’s efficiency, safety and, performance which contributes to less environmental impact. The optional hydraulic long-life (HLL) filter removes small particles, reduces the water in the oil, and extends the life of the hydraulic oil. This filter increases the amount of time between hydraulic oil replacements. With the option TRUCONNECT® Smart Connected Lift Trucks the customer can plan service on real machine use, which in most situations extend service intervals. A sensor for monitoring the status of the hydraulic oil, and estimate the remaining life of the oil, can also be provided. The monitoring of the hydraulic oil status prevents unnecessary hydraulic oil replacement. Certain major components like diesel engine, transmission, and some electronics can be restored to like-new condition. Konecranes Service offers restored spare parts, where the old part is requested back (as core unit for later renovation). This restoration process extends the useable machine life and reduced the environmental impact. 2.6.2.4 Dismantling and handling waste material Konecranes Lifttrucks strive to optimize all packaging to minimize waste and to follow the EU waste hierarchy. The most preferable actions are: prevention, reuse, recycle, burning of material to recover the energy in the material, and as a final resort, safe disposal as landfills. Waste material from dismantling shall be handled and disposed according to local regulations. As waste regulations and types of available recovery and disposal methods vary regionally, no general detailed guidance can be given. Dismantling should always be planned and executed by authorized personnel. A local risk assessment must be performed in advance. Depending on available recovery and disposal methods, wood can be recycled and reused but is the responsibility of the customer. Plastic waste is collected and, depending on the infrastructure, recycled, burned to recover the energy in the material, or as a final resort, safely disposed as landfills. NOTE Always use licensed recycling companies. The following list provides proposals for adequate waste handling methods. 47/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment Table 3. Proposed waste handling methods (example for EU states) Proposed waste handling methods (example of EU states) Material Handling method Metals Material recycling, multi-metal scrap recycling. Rubber tires Recycle rubber according to local regulations. Whenever possible, return the used rubber tires to the tire supplier for recycling. Electronics and Some electrical parts may be treated as hazardous waste. electromechanical components Collect and recycle the electronics and electromechanical components separately. Use e-waste management. Batteries Batteries and other energy storage components may contain hazardous substances. Collect these items separately and recycle according to local regulations. Fluids, Recycling, hazardous waste management accumulators, oil filters Plastics and Recycle plastic as material, burn to recover the energy in the material, or polymers deliver it to a landfill site. Chemicals Never spill chemicals, such as oil, grease, and other liquids, onto the ground, soil, or sewage. Store waste oil and grease in containers that are indicated for the purpose. More detailed information on chemical handling as waste can be found in the chemical safety data sheet. The data sheet is available from the manufacturer of the chemical. Packing materials Reuse or recycle packing materials, such as plastics, wood, and cardboard. Glass Recycle glass according to local regulations. 2.6.2.5 Deliveries between each stage Materials and components are provided by various suppliers worldwide, however steel structure is primarily sourced from local vendors to reduce the transportation need. It is an ethical, environmental, and employee-related principle that is applied. Shipment of materials to the respective factories is primarily by road transport, and containerized whenever feasible. Before shipment, each machine is partly dismantled, depending on dimensional and/or weight constraints for road transportation. The shipment of a machine to local and regional customers is usually by road from the factory. When shipment is to more remote customers or the shipping route involves waterways, sea transport is often involved. By sea, Ro-Ro type ships are used (where the machine drives onto the ship). 48/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions 2.6.3 Notice on the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH) Konecranes is fully aware of its obligations under Regulation (EC) No 1907/2006 of the European Parliament and of the Council of 18 December 2006 concerning the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH), and under the UK REACH in the United Kingdom. Twice a year the EU publishes a Candidate list of Substances of Very High Concern (“SVHC”) for Authorization. Producers and EU importers/UK importers have the duty to inform their EU/UK customers when a product contains SVHCs in a concentration above 0.1 % weight by weight. Some Konecranes products do include small quantities of SVHCs, such as lead which is typically used in brass and in certain electric components. These cases are exemptions, as there are currently no satisfactory alternatives available for such substances. We are actively searching for alternatives to substitute articles including SVHCs. For a list of SVHCs, please see https://www.konecranes.com/about/corporate-responsibility/konecranes-reach-notice. 2.7 Storage information 2.7.1 Storage The following chapter describes the recommended procedure for storage of machines. To preserve the condition of the stored machine, it must be driven regularly during storage. Preparation before storage Before storing the machine, make sure that all required services according to the NOTE maintenance schedule are performed. Be aware that some points in the storage handling process, must be performed by NOTE trained and authorized maintenance personnel. If using a pressure washer, never aim the water directly at radiators, air intakes, seals, NOTE rubber hoses, or electrical components. • Clean the machine • Perform daily maintenance check, see section "Daily maintenance" • Run all hydraulic functions and steer cylinders to end position and back again • Fill the fuel tank before storing the machine • Charge the battery • Lubricate the machine, see section "Regular service" • To prevent corrosion, apply a rust inhibitor to all the metallic surfaces • To protect the coating from corrosion, touch up painted surfaces • If possible, store the machine indoors or under a roof • If stored outside, it is recommended to cover the whole machine Maintenance during storage When driving the machine, the engine temperature must reach at least 80 degrees and NOTE the transmission must reach at least 65 degrees. To preserve the condition of the machine during storage, the following steps must be performed at least once a month. • Check the battery, charge if needed • Check for visible leakage under the machine. If needed, tighten all connections before filling any fluid • Bleed the fuel system, if needed, see section "Bleeding the fuel system" • Start the machine, and idle to warm up the engine 49/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment • Drive the machine for a while, both forwards and in reverse • Run all hydraulic functions and steer cylinders to end position and back again • Before parking the machine again, check the guidelines for "Preparation before storage". Perform the steps, if needed. Bringing out of storage • Check for visible leakage under the machine and on the ground. • Tighten all connections before filling any fluid, if needed • Perform daily maintenance check, see section "Daily maintenance" • Lubricate the machine, see section "Regular service" • Check the battery, charge if needed • Bleed the fuel system, if needed, see section "Bleeding the fuel system" • Start the machine, and idle to warm up the engine • When the engine has reached the required temperature, and while idling, check for visible oil, fuel, or coolant leakage • Test drive the machine, to make sure all systems function properly 2.7.2 Alternative storage, up to two months The following chapter describes the procedure for storage of machines that cannot be accessed or driven during storage. This way of storing the machine should only be used if necessary. See section "Storage" NOTE for the recommended procedure. Preparation before storage Before storing the machine, make sure that all required services according to the NOTE maintenance schedule are performed. Be aware that some points in the storage handling process, must be performed by NOTE trained and authorized maintenance personnel. If using a pressure washer, never aim the water directly at radiators, air intakes, seals, NOTE rubber hoses, or electrical components. • Clean the machine • Perform daily maintenance check, see section "Daily maintenance" • Run all hydraulic functions and steer cylinders to end position and back again • Fill the fuel tank • Fill up the windshield washer fluid • Fill the AdBlue/DEF tank, if applicable • Charge the battery • Lubricate the machine, see section "Regular service" • To prevent corrosion, apply a rust inhibitor to all the metallic surfaces • To protect the coating from corrosion, touch up painted surfaces • If possible, store the machine indoors or under a roof • If stored outside, it is recommended to cover the whole machine Bringing out of storage • If applicable, remove the cover from the machine • Check for visible leakage under the machine and on the ground. • Tighten all connections before filling any fluid, if needed • Perform daily maintenance check, see section "Daily maintenance" • Lubricate the machine, see section "Regular service" • Check the battery, charge if needed • Bleed the fuel system, if needed, see section "Bleeding the fuel system" • Check the condition of all rubber hoses, and retighten the hose clamps if necessary • Check that no oil, fuel, or coolant leakage occurs • Start the machine, and idle to warm up the engine 50/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions • When the engine has reached the required temperature, and while idling, check for visible oil, fuel, or coolant leakage • Run all hydraulic functions and steer cylinders to end position and back again • Check for visible leakage also when using the hydraulic functions after storage • Test drive the machine, to make sure all systems function properly 2.7.3 Alternative storage, longer than two months The following chapter describes the procedure for storage of machines that cannot be accessed or driven during storage. This way of storing the machine should only be used if necessary. See section "Storage" NOTE for the recommended procedure. Preparation before storage Before storing the machine, make sure that all required services according to the NOTE maintenance schedule are performed. Be aware that some points in the storage handling process, must be performed by NOTE trained and authorized maintenance personnel. If using a pressure washer, never aim the water directly at radiators, air intakes, seals, NOTE rubber hoses, or electrical components. When performing the regular service, also consider the procedure for conserving the NOTE machine. • Clean the machine • Perform maintenance service according to the 500 hours schedule, see section "Regular service" • Run all hydraulic functions and steer cylinders to end position and back again • Apply a long-term rust inhibitor to the cylinder pistons • Drain any water and contamination from the fuel filters and fuel tank • Fill the fuel tank • Fill up the windshield washer fluid • Fill the hydraulic tank completely, to avoid corrosion above the maximum level • Empty the AdBlue/DEF tank, if applicable, and rinse it with distilled water • Disconnect, and charge the battery • Store the battery in a safe way • Loosen the fan belt • To prevent corrosion, apply a long-term rust inhibitor to all the metallic surfaces • To protect the coating from corrosion, touch up painted surfaces • Conserve the machine, see section "Conservation of the lubrication and fuel system" • Cover the air filter, exhaust pipe, and engine if necessary • If possible, store the machine indoors or under a roof • If stored outside, it is recommended to cover the whole machine 51/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment Conservation of the engine and fuel system WARNING RISK OF FIRE AND PERSONAL INJURY Conservation oils are flammable and are dangerous to inhale. Ensure good ventilation. Use a face mask when applying the conservation oil. • Drain the engine oil and fill with conservation oil just over the MIN marking on the dipstick • Connect the fuel suction and return hoses to a fuel can (app. 20 l) containing 1/3 conservation oil and 2/3 diesel fuel • Bleed the fuel system, see section "Bleeding the fuel system" • Start the engine and idle until about 2 l of the fluid in the fuel can have been used • Stop the engine and reconnect the fuel suction and return lines to the machine • Drain the excess fluid from the engine, see section "Cleaning and draining the fuel tank, all engines" • Put a note on the machine with the date, type of conservation and the conservation oil used Bringing out of storage • If applicable, remove the cover from the machine • Remove covers from air intake systems and exhaust systems • Remove the rust inhibitor • Check for visible leakage under the machine and on the ground. • Tighten all connections before filling any fluid, if needed • Check and adjust the hydraulic oil level, remove excess oil • Charge and reconnect the battery • Tighten the fan belt • Fill the AdBlue/DEF tank, if applicable • Perform maintenance service according to the 500 hours schedule, see section "Regular service" • Lubricate the machine, see section "Regular service" • Bleed the fuel system, if applicable, see section "Bleeding the fuel system" • Check the condition of all rubber hoses, and retighten the hose clamps if necessary • Check that no oil, fuel, or coolant leakage occurs • Start the machine, and idle to warm up the engine • When the engine has reached the required temperature, and while idling, check for visible oil, fuel, or coolant leakage • Run all hydraulic functions and steer cylinders to end position and back again • Check for visible leakage also when using the hydraulic functions after storage • Test drive the machine, to make sure all systems function properly 52/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Transport and towing Maintenance Instructions 3 TRANSPORT AND TOWING 3.1 Lifting the machine - General safety DANGER FALLING LOAD HAZARD When the machine is lifted, the machine or parts from the machine could fall. There is a risk of serious personal injury or death to people who stands or walks near or under the machine. Do not stand or walk near or under the machine when it is lifted. WARNING RISK OF DAMAGE TO THE MACHINE When the machine is lifted, it could fall. Visually check the lifting equipment and the lifting points for damages before lifting the machine. Use only lifting equipment and cranes which have sufficient lifting capacity. See the information on the lifting capacity plate from the manufacturer, for the weight of the lifted machine. Follow local regulations for lifting procedures and equipment. WARNING RISK OF DAMAGE TO THE LIFT SLINGS If the lift slings grind against the chassis, the lift slings can get damaged. Lift the machine with the lift slings positioned as straight as possible. The maximum allowed angle of the front lift slings for SMV 10-25 is 15 degrees. The maximum allowed angle of the front lift slings for SMV 28-65 is 10 degrees. The maximum allowed angles of the rear lift slings are: - 15 degrees forwards and backwards for SMV 10-25 - 10 degrees to the left and to the right for SMV 10-25 - 10 degrees forwards and backwards for SMV 28-65 - 5 degrees to the left and to the right for SMV 28-65 When the machine is lifted, the lift slings must not grind against any part of the machine. Protect the lift slings with some appropriate protection if contact with the chassis cannot be avoided. 53/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 3 Transport and towing 5° X. 1 MAX. 10° MAX. 10° MAX. 10° MAX. 10° MA 5° 5° MA X. 1 X. 1 X. 1 MA MA 5° Figure 11. Maximum allowed angles of the slings SMV 10-25 (Rear lifting ears optional for SMV 10-25) 0° X. 1 MA X. 5° MA X. 5 X. 5 ° MA X. 5 MA ° MA ° 0° MA X. 1 X. 1 0° MA 0° X. 1 MA Figure 12. Maximum allowed angles of the slings SMV 28-65 3.2 Lifting points SMV 10-25 NOTE Always inspect the lifting ears before lifting the machine. When lifting the machine, the lift slings must always be as vertical as possible, never NOTE exceed the recommended angles. See Lifting the machine - General safety (page 53). NOTE If the machine is equipped with a high mast, always use the lower front lifting points. 54/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Transport and towing Maintenance Instructions 5 3 4 2 2 1 Figure 13. Lifting points SMV 10-25 1. Attach two shackles on the rear lifting ears (1) at the counterweight. 2. Attach two shackles to either the upper or the lower front lifting points (2). 3. Attach lift slings to the shackles in the front and the rear. 4. Attach the lift slings to the lifting hook (3) and secure the safety lock (4). Figure 14. Rear lifting ears 5. To protect the slings when lifting the machine, place appropriate protection (5) between the lift slings and the chassis. When lifting the machine, always use the rear lifting ears (1). The lifting ears on the NOTE removable counterweight (if applicable) must not be used for lifting the complete machine. 3.3 Lifting points SMV 28-65 NOTE Always inspect the lifting ears before lifting the machine. 55/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 3 Transport and towing 3 4 2 1 2 Figure 15. Lifting points SMV 28-65 1. Attach two shackles on the top rear lifting ears (1) at the counterweight. 2. Attach two shackles to either the upper or the lower front lifting points (2). 3. Attach lift slings to the shackles in the front and the rear. 4. Attach the lift slings to the lifting hook (3) and secure the safety lock (4). When lifting the machine, always use the welded lifting ears (1), or the rear lifting ears. NOTE The lifting ears on the removable counterweight (if applicable) must not be used for lifting the complete machine. 3.4 Rear top lifting ears SMV 10-25 (option) WARNING RISK OF DAMAGE TO THE MACHINE The machine can be dropped when lifted. Visually check the lifting ears and the bolts for the lifting ears for damages before lifting the machine. There should not be any visible damage on either the lifting ears or the bolts for the lifting ears. NOTE If the machine is equipped with a high mast, always use the lower front lifting points. 56/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Transport and towing Maintenance Instructions 3 4 2 5 1 2 Figure 16. Lifting points when using optional lifting ears The bolts for the lifting ears (5) are tightened with an appropriate locking glue when NOTE delivered. If the bolts are not loose, they do not need to be retightened. 1. Attach two shackles on the top rear lifting ears (1) at the counterweight. 2. Attach two shackles to either the upper or the lower front lifting points (2). 3. Attach lift slings to the shackles in the front and the rear. 4. Attach the lift slings to the lifting hook (3) and secure the safety lock (4). When lifting the machine, always use the rear lifting ears (1). The lifting ears on the NOTE removable counterweight (if applicable) must not be used for lifting the complete machine. 57/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 3 Transport and towing 3.5 Lifting the machine without the mast WARNING RISK OF DAMAGE TO THE MACHINE Using shackles damages the bushings of the machine. Do not use shackles to lift the machine when the mast is dismounted. Instead, use appropriate lifting equipment which does not damage the bushings. NOTICE Be careful not to damage the suspension ears when lifting the machine. When the mast is dismantled, it is possible to use the mast suspension ears (5) as lifting points. 1. To lift the machine without the mast, attach appropriate lifting equipment to the mast suspension ears (5). 58/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Transport and towing Maintenance Instructions 3.6 Lifting the mast When lifting only the mast, the lower lifting point must be used. This lifting point can also be used when lifting the complete machine, if needed. 3 4 5 2 2 1 Figure 17. Lower lifting point - Mast 1. Attach two shackles on the lower front lifting points (1). 2. Attach lift slings to the shackles (2). 3. Thread the lift slings behind the top front beam (3). When lifting the complete machine, the lift slings must be threaded between the top front NOTE beam (3), and the mast. 4. Attach the lift slings to the lifting hook (4) and secure the safety lock (5). 59/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 3 Transport and towing 3.7 Towing WARNING RUN OVER HAZARD If the engine, the electrical system or the hydraulic system is broken, the parking brake may need to be released manually to tow the machine. In this situation, the machine has no brakes or steering capability, which may lead to serious personal injury and damage to the machine. When towing the machine, the engine must idle, or a vehicle with sufficient braking capacity to stop both vehicles must be used. WARNING MOVING VEHICLE HAZARD When towing the machine, there is a risk that the machine becomes unattached from the towing vehicle. It can lead to serious personal injury and damage to the machine. Do not exceed the towing capacity of the transporting vehicle. NOTE Only trained and authorized personnel are allowed to tow the machine. If possible, the engine should idle when being towed. If not, the hydraulic brake system, and servo-assisted steering system cannot be used. If idling is not possible, release the hydraulic parking brake manually. After the hydraulic parking brake is released, the machine has no brakes. To stop both vehicles when towing the machine, use a vehicle with sufficient brake capacity. Use a towing bar if possible. For more information, see Manually releasing the parking brake (page 203). 1. Attach the towing bar to the machine. Use the rear towing peg, if applicable, when fitting a sturdy towing bar on the machine. NOTE Otherwise use slings and secure them around the back counterweight when towing. 2. Remove the propshaft (1). 3. Release the parking brake manually. 3.8 Transportation RISK OF DAMAGE TO THE MACHINE NOTICE Do not exceed the load limits of the transporting vehicle. See the lifting capacity plate for the weight of the transported machine. 60/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Transport and towing Maintenance Instructions RISK OF DAMAGE TO THE MACHINE NOTICE Check the total clearance height of the transporting vehicle and the transported machine. There can be low overpasses along the transportation route. 3.8.1 Securing the rear end 2 3 1 1. Engage the parking brake. 2. Place blocks (1) in front of and behind the wheels to prevent the truck from moving. 3. Hold the truck in place with two chains that are attached with shackles (2) to the eyes (3) beneath the counterweight. 3.8.2 Securing the front end - machines without mast 4 5 5 1. Attach two shackles to the front lifting eyes (4) positioned on the chassis. 2. Place blocks (5) in front of and behind the wheels to prevent the truck from moving. 61/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 3 Transport and towing 3.8.3 Securing the front end - machines with mast 3 1. Lower the mast and fork carriage. 2. Attach two lifting hooks (3) to the fork carriage to hold the truck in place. 3. Secure the cylinders with straps and cable ties. 62/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4 SERVICE AND MAINTENANCE INSTRUCTIONS 4.1 Maintenance safety information WARNING IRRITATING SUBSTANCE HAZARD The machine contains several chemical substances, which can cause skin irritation and allergies. Personal injury hazard when in prolonged contact with skin. When handling chemical substances, such as oils, hydraulic oils, fuel, grease, paint, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. WARNING BODY INJURY HAZARD Lifting or moving heavy components could cause musculoskeletal disorders and back strains. Use appropriate lifting equipment. Use power tools when possible instead of manual tools. WARNING TIPPING AND COLLISION HAZARD If a collision occurs, the machine can tip over. Risk of personal injury, and or damage to the machine. Evaluate the height of overhead structures concerning the mast position when driving and before entering maintenance buildings with the machine. Preventive maintenance and service must be carried out regularly and in accordance with the regulations that are supplied in the maintenance schedule. Maintenance must only be carried out by trained staff, dealers, or service technicians authorized by the operational manager, or Konecranes Lift Trucks. During the warranty period, maintenance must always be carried out by personnel authorized by Konecranes Lift Trucks. Maintenance must be carried out in accordance with the maintenance schedule. Before any service work, check that: • The machine is parked on firm, level ground. • The mast, and carriage are fully lowered, and the mast is tilted to vertical position. • The machine is blocked, so that it cannot move. • The engine is turned off and the ignition key removed. • The battery main switch is turned off, and the handle is removed. • The mast, and fork carriage have been secured, if they are in a raised position. • The machine is firmly secured if work must be carried out underneath when the machine is lifted. NOTE Make sure to use appropriate lifting equipment when handling heavy components. After every service, check the machine for leakage and carry out a test drive and an operational test on the machine. If applicable, check that TRUCONNECT® functions properly. Perform a daily maintenance check. 63/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions RISK OF DAMAGE TO THE MACHINE When the machine is used in extremely warm, cold, or dusty environments or in other NOTICE unfavorable conditions, it is more exposed. If so, the service must be carried out more frequently than the service and maintenance schedule recommends. Clean the area around each component before lubricating, changing filters, or repairing the hydraulic system. Use only clean receptacles when topping up lubricants, and other fluids. 4.2 Reset service hour counter WARNING RISK OF DAMAGE TO THE MACHINE If service is not performed according to the maintenance schedule, there is a risk of degradation and damage to the machine. Reset of the service hours must only be performed by trained maintenance personnel. Reset of the service hours must only be performed after each completed service of the machine. 1 2 Figure 18. Reset service hours After service is performed, the service hours (1) can be reset. The reset restarts the counter to the next service interval and removes all service reminders until the next interval is reached. 1. Perform service of the machine. 2. Press the reset button (2). 3. Enter the requested service code. 4. Press the reset button (2) for 5 s. 64/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.3 RFID - Adding an operator (option) 1. Start the ignition. 1 2. Go to the Machine overview page (1). 2 3 3. Press the RFID selection button (2). 65/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4. Enter the service code (3). 4 5. The Access card page (4) appears. 5 START 6 1 2 6. Lift the cover of the armrest (5). 66/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 7. Swipe the RFID tag over the RFID reader (6). 7 8 9 10 NOTE The ID-number of the operator appears in the top right corner (8). 8. Choose a number in the list (7), the colour changes to green. 9. Press the "plus" button (9) to add the ID-number (8) to the operator number (7) NOTE Press the "minus" button to remove an operator. 10. Press "confirm" (10). 11 11. If the warning message (11) appears, turn off the ignition to store the new settings. 67/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.4 Electric welding WARNING RISK OF FIRE While welding, molten particles can be projected and set fire to surrounding materials. Keep the working area clean and use appropriate protective gear. WARNING TOXIC FUMES HAZARD Breathing in the toxic fumes from welding can cause breathing difficulties and suffocation. Do not inhale the welding fumes. Use appropriate protection gear such as breathing mask. Only qualified and trained personnel may perform this action. RISK OF DAMAGE TO THE MACHINE NOTICE Follow these instructions when doing electric welding on the machine. Disconnect all battery connections, alternator connections, and all control units. NOTE All welding work must be performed by authorized welders. 1. Remove the battery connections. 2. Remove the connections to the alternator. 3. Disconnect all control units in, and on the machine. 4. Connect the welding clamp, close to the welding point. Never attach the welding clamp to the engine, or anywhere that enables the current to NOTE pass over a bearing, or a vibration damper. 5. When the welding is done, connect the alternator, and control units before connecting the batteries. 6. Perform a daily maintenance check. To ensure that everything works properly, test all functions before returning the machine NOTE to operation. 68/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.5 Jump-starting DANGER RISK OF ARCING AND EXPLOSION Touching the connections during a jump-start attempt can cause arcing and lead to serious personal injury or death. Do not touch the connections during a jump-start attempt. WARNING RISK OF EXPLOSIVE GAS When jump-starting the machine with a new battery, the empty battery is charged with a high effect. The high-effect charging causes the empty battery to release explosive gas. Always connect the black cable from the negative pole on the new battery to the chassis, as far away as possible from the empty battery. RISK OF DAMAGE TO THE MACHINE Jump-starting the machine with a quick charger, booster, power pack, or similar, can NOTICE cause a current surge and serious damage to the control units. Do not jump-start the machine with a quick charger, booster, power pack, or similar. NOTE To avoid risk of fire, keep the working area clean when performing a jump-start attempt. 1. Connect the red cable on the positive pole of the two auxiliary batteries to the positive pole of the discharged battery. 2. Connect the black cable that is on the negative pole of the two auxiliary batteries to a chassis point, away from the discharged battery. 3. When the engine starts, remove the cables in the reverse order. 69/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.6 Tilting the cabin WARNING FLYING OBJECTS HAZARD Loose objects can fall out of the cabin. If left open when tilting the cabin, the cabin doors may come off their hinges. Risk of serious injury and damage to the machine. Before the cabin is tilted, both cabin doors must be shut. Loose objects should be removed from the cabin. The mast should be vertical and the fork carriage in its lowest position. WARNING FALLING LOAD HAZARD If the cabin is not fully tilted, the cabin may fall and cause serious injury. If the cabin is not fully tilted, secure the cabin to prevent it from falling down. Take care if you must work underneath the cabin. WARNING MACHINE MISUSE HAZARD Risk of serious injury and damage to the machine. Do not drive the machine with the cabin partially or fully tilted. WARNING RISK OF DAMAGE TO THE MACHINE When tilting the cabin, it collides with the mast if the mast is tilted backwards. This can cause damage to the cabin. Do not tilt the cabin if the mast is tilted backwards. 1 2 All standard machines are equipped with manual cabin tilting (electrical cabin tilting is available as an option). 70/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.6.1 Manual cabin tilting 2 3 1 Figure 19. Manual cabin tilting 1. Warning sticker 2. Pump handle 3. Direction valve A warning sticker (1) is attached to the pump. Figure 20. Pump warning sticker 1. Open the hatch by using a special key. Hatch is found on the left side of the machine. 2. Fit the pump handle (2) in the direction valve (3). 3. To tilt the cabin upwards, turn the direction valve (3) clockwise. To turn the valve (3), use the bottom end of the pump handle (2). 4. Pump to tilt the cabin. 5. To tilt the cabin downwards, turn the direction valve (3) counter-clockwise. 6. Pump to tilt the cabin. 71/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.6.2 Electrical cabin tilting (option) 1 2 4 3 1. Warning sticker 2. Pump handle 3. Direction valve 4. Electrical tilt button A warning sticker (1) is attached to the pump. Figure 21. Pump warning sticker 1. Open the hatch by using a special key. Hatch is found on the left side of the machine. 2. Fit the pump handle (2) in the direction valve (3). 3. To tilt the cabin upwards, turn the direction valve (3) clockwise. To turn the valve (3), use the bottom end of the pump handle (2). 4. Press the electrical tilt button (4). 5. To tilt the cabin downwards, turn the direction valve (3) counter-clockwise. 6. Press the electrical tilt button (4). 72/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.7 Releasing the hydraulic accumulator pressure WARNING HIGH-PRESSURE HAZARD The hydraulic system contains a hydraulic accumulator to maintain the brake function during a possible machine failure. Risk of serious personal injury. Before performing maintenance or service on the hydraulics of the machine: - Always lower the mast to the bottom position. - Always ensure that the accumulator pressure for the hydraulic brake system is released before loosening any hydraulic hoses in the brake circuit. Be careful as high nitrogen pressure remain in the accumulator even after the oil pressure is released. 1. Locate the accumulator charging block. 2. Loosen the locknut using a wrench (1). 2 1 3. Loosen the drainage screw using an Allen key (2). After performing maintenance on the machine, make sure to tighten the drainage screw NOTE and locknut. 73/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.8 Changing the wheels DANGER HIGH-PRESSURE HAZARD The tires may explode when you deflate or inflate them, or in case of fire. Standing inside the tire explosion danger zone during a tire explosion can cause death or serious injury. Always stand to the side of the wheel when deflating or inflating tires, see "tire explosion danger zone" illustration. Use safety glasses. WARNING HIGH-PRESSURE HAZARD If the valve is broken, air cannot come out of the tire while deflating. If there is visual damage to the tire or rim, it may cause the tire to explode. To deflate the tire, drill a hole into the thread, as shown in the illustration. Only authorized and properly trained personnel are allowed to maintain and change the NOTICE wheels. NOTE When changing tires, always perform a dye penetration test on the rims. 4.8.1 Before changing the wheels Changing a wheel is a two-man operation. A support truck that is fitted with an attachment for the wheel (1) facilitates the work. 1 Figure 22. Support truck 1. Position the machine on even ground. 2. Lift the side of the machine and support the underside of the chassis according to recommendations. 74/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.8.2 Positioning the jack WARNING MOVING VEHICLE HAZARD. The machine can move if not parked on level ground and with the wheels firmly secured. If the machine moves, there is a risk of serious injury or death. Park the machine on level ground and firmly secure the wheels before jacking up the machine. Observe the following regulations before lifting the machine. • Specifications for tires: See machine card. • Specifications for rims: Use only rims that are approved by the manufacturer of the machine. • Other type of tires: The machine is designed to use pneumatic tires. Solid tires are used only in consultation with the manufacturer of the machine. NOTE Changing wheels is a two-man operation. 1 2 1. Block the drive wheels and position the jack underneath the steer axle (1) to lift the steer axle of the machine. 2. Block the steer wheels and position the jack underneath the drive axle (2) to lift the drive axle of the machine. 75/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.8.3 Deflating the tire DANGER HIGH-PRESSURE HAZARD The tires may explode when you deflate them. Standing inside the danger zone during a tire explosion causes death. Always stand beside the wheel when deflating or inflating tires, see "tire explosion danger zone" illustration. Wear appropriate safety glasses. DANGER HIGH-PRESSURE HAZARD If the valve mechanism shoots out at high pressure, it may cause serious personal injury or death. Make sure that no part of the body is in the trajectory of the valve mechanism. Wear appropriate safety glasses. WARNING HIGH-PRESSURE HAZARD If the valve is broken, air cannot come out of the tire while deflating. If there are visual damages on the tire or the rim, it may cause the tire to explode. To deflate the tire, drill a hole into the tread, as shown in the illustration. RISK OF PROPERTY DAMAGE When you deflate the tire, the high pressure and moisture of the air may cause the valve NOTICE to get covered with ice. Heat the valve with a heat gun. 76/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 120° 120° 50 yd m/ 55 55 m/ y 50 d 50 d 5y m/5 m/5 5y 50 d 120° 120° Figure 23. Tire explosion danger zone Only drill if the valve is broken and does not release air. It is only allowed to drill in the surface of the tread that has contact with the ground (shown in the picture). If only NOTE drilling in the contact surface of the tread, it is possible to reuse the tire when it has been repaired. Figure 24. Drilling a hole into the tread NOTE Recommended size of the drill bit, approximately 7-8 mm. Deflate as follows: 1. Unscrew the valve cap. 2. Unscrew the valve plug. Ensure that no part of the body is in the possible trajectory of the valve mechanism. 77/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.8.4 Inflating the tire DANGER HIGH-PRESSURE HAZARD The tires may explode while being inflated or if the maximum tire pressure is exceeded. Standing inside the danger zone during a tire explosion can cause death or serious injury. Never exceed the maximum tire pressure. Always stand aside the wheel when deflating or inflating tires, outside the tire explosion danger zone. Use safety glasses. Only authorized and properly trained personnel are allowed to maintain and change the NOTICE wheels. The recommended tire pressure is 10 bar at 20° Celsius. When checking the tire pressure, consider the temperature. The recommended tire pressure can vary depending on the temperature. If the machine is equipped with tire pressure monitoring system (TPMS), the 10-bar recommendation is monitored. Should the pressure drop too far or get too high, the operator gets a notification in the display unit. Always contact the manufacturer of the machine in advance for a written approval to use NOTE other tires. The maximum pressures that are specified by the tire manufacturer must never be exceeded. If using another rim or tire than the ones delivered with the machine, other NOTE pressure values could be valid. It is the responsibility of the operational manager to make sure that the machine has the correct safety labels if using other tires. 120° 120° 50 yd m/ 55 55 m/ yd 50 50 d 5y m/5 m/5 5y 50 d 120° 120° Figure 25. Tire explosion danger zone 78/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions Figure 26. Example of staying out of the tire explosion danger zone when inflating or deflating a tire • If using rims with clamps, never fit a tire or rim which is fully or partly inflated. All parts must be assembled before inflating the tire. • Rim components must never be assembled with hammer blows. • When the tire is deflated, disassemble the tire and check the rim for wear, cracks, and damage. Perform a dye penetration test on the rim. • It is important that all rim components comply with each other and are certified and approved for use on heavy-duty machines. • 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 machine. • If a safety cage is used, the tire can be inflated to maximum pressure. Otherwise the tire must be inflated until the bead is seated to the rim. • Never exceed the maximum pressures that are specified by the tire manufacturer. If using another rim or tire than the ones delivered with the machine, other pressure values could be valid. Contact Konecranes Lift Trucks for advice. Inflate the tire as follows: NOTE If using rims with clamps, always mount the tire to the machine before inflating the tires. 1. Check that locking rings and locking lugs (if applicable) are in place, and tightened with correct torque, before inflating the tire. 2. Connect the compressor line to the tire air valve. To prevent the entry of humidity which leads to corrosion, use a dryer filter on the NOTE compressor air line. 3. Check that all components are in place when bead seating pressure is achieved. NOTE Always stand beside the wheel when inflating the tire. 4. If using rims without clamps, mount the tire to the machine according to instructions. 5. Stand beside the wheel, inflate the tire to the maximum pressures specified by the tire manufacturer. NOTE The recommended tire pressure varies depending on the temperature. 79/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.8.5 Dismantling the outer drive wheel, general DANGER HIGH-PRESSURE HAZARD Fitting tires that are not approved by the manufacturer may cause a tire explosion, which can cause serious personal injury or death. When changing tires, only use tires which are approved by the manufacturer. DANGER HIGH-PRESSURE HAZARD The bead seat bands (2) and locking rings (3) may release and shoot off when the pressure changes. Risk of serious personal injury and death. Always release the air from both tires, before loosening or removing any wheel nuts or clamp units (if applicable). 1 2 3 Figure 27. Parts of the rim 1. Rim base 2. Bead seat band 3. Locking ring 4.8.5.1 Dismantling the outer drive wheel, wheels without clamp units 1. Jack up the drive axle. See: Positioning the jack (page 75) 2. Deflate both outer and inner wheel (if applicable). 3. Remove all but two of the nuts (1). 80/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 1 4. Use the support truck to support the weight of the outer wheel (3) on its forks. 5. Remove the two remaining nuts (1). 6. Lean the outer wheel (3) against the wheel support of the support truck (4). 7. Secure the wheel with a chain (5). 3 5 4 8. Reverse the support truck carefully and unload the outer wheel (3). 4.8.5.2 Dismantling the outer drive wheel, wheels with clamp units 1. Jack up the drive axle. See: Positioning the jack (page 75) 2. Deflate both outer and inner wheel (if applicable). 3. Remove all but two of the nuts (1) and clamp units (2). 81/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 2 1 1 2 4. Use the support truck to support the weight of the outer wheel (3) on its forks. 5. Remove the two remaining nuts (1) and clamp units (2). 6. Remove the outer clamp unit ring. 7. Lean the outer wheel (3) against the wheel support of the support truck (4). 8. Secure the wheel with a chain (5) to the support truck. 3 5 4 9. Reverse the support truck carefully and unload the outer wheel (3). 4.8.6 Dismantling the inner drive wheel 7 8 9 6 1. Remove the outer drive wheel. 2. Remove the spacer (6). 82/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 3. Make sure that the inner drive wheel (7) is deflated. 4. Use the forks of the support truck to support the weight of the inner drive wheel (7). 5. Lean the inner drive wheel (7) against the wheel support (8) and secure it with a chain (9). 6. Carefully reverse the support truck and unload the inner drive wheel (7). 4.8.7 Mounting the inner drive wheels 1. Load the inner drive wheel (7) onto the support truck and fasten it to the support. 6 7 2. Clean the contact surfaces. 3. Carefully drive the support truck to the required position and place the inner drive wheel (7) over the drive axle and the hub. 4. Straighten the wheel (7). 5. Lower the forks of the support truck until the inner drive wheel (7) is resting on the hub. 6. Carefully reverse the support truck. 7. Mount the spacer (6). 4.8.8 Mounting the outer drive wheel 4.8.8.1 Mounting the outer drive wheel, wheels without clamp units 1. Secure the wheel support (4) to the support truck. 2. Load the outer wheel (3) onto the wheel support (4). 3. Secure the wheel to the wheel support (4). 4. Carefully drive the support truck into position. 5. Place the outer wheel (3) over the hub. 83/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 3 4 6. Straighten the wheel (3). 7. To avoid putting too much weight on the drive axle, continue supporting the outer wheel (3). 8. To keep the rim in place, fasten two wheel nuts placed diagonally to each other. 9. Carefully reverse the support truck. 10. Tighten the wheel nuts crosswise, in the order 1-10 as shown in the figure. 1 8 6 9 3 10 4 5 7 2 For the required torque, see Tightening the wheel nuts (page 91). 11. Pump the tires according to the recommendations from the tire manufacturer. 4.8.8.2 Mounting the outer drive wheel, wheels with clamp units 1. Secure the wheel support (1) to the support truck. 2. Load the outer wheel (3) onto the wheel support (1). 3. Secure the wheel (3) to the wheel support (1). 4. Carefully drive the support truck into position. 5. Place the outer wheel (3) over the hub. 84/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 3 1 2 6. Straighten the wheel (3). 7. To avoid putting too much weight on the drive axle, continue supporting the outer wheel (3). 8. Fit the outer clamp unit ring (2). 9. To keep the rim in place, fasten two clamp units (5) and two wheel nuts (4). NOTE Place the clamp units (5) and the wheel nuts (4) diagonally to each other. 5 4 4 5 10. Carefully reverse the support truck. 11. Fasten the remaining clamp units (5). 12. Tighten the wheel nuts crosswise, in the order 1-24 as shown in the figure. 85/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 1 9 23 17 15 6 7 14 19 21 11 4 3 12 22 20 13 8 5 16 18 24 10 2 For required torque, see Tightening the wheel nuts (page 91). 13. Pump the tires according to the recommendations from the tire manufacturer. 4.8.9 Dismantling the steer wheel, general DANGER HIGH AIR PRESSURE If the air is not released from the tire, it can explode. Risk of serious injury or death. Release the air from the tire before dismantling. 4.8.9.1 Dismantling the steer wheels, wheels without clamp units 1. Jack up the steer axle. See Positioning the jack (page 75) 2. Deflate the tires. 3. Remove all but two of the nuts (1). 1 86/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4. To support the weight of the steer wheel (5), use the forks of the support truck. 5. Remove the remaining nuts. 6. Lean the steer wheel (5) against the wheel support (3). 7. Fasten the steer wheel with a chain (4). 3 4 5 8. Carefully reverse the support truck and unload the steer wheel (5). 4.8.9.2 Dismantling the steer wheels, wheels with clamp units 1. Jack up the steer axle. See: Positioning the jack (page 75) 2. Deflate the tire. 1 3. Remove all but two of the nuts (1) and clamp units. 3 4 2 4. To support the weight of the steer wheel (2), use the forks of the support truck. 87/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 5. Remove the remaining nuts and clamp units. 6. Lean the steer wheel (2) against the wheel support (3). 7. Fasten the steer wheel with a chain (4). 8. Carefully reverse the support truck and unload the steer wheel (2). 4.8.10 Mounting the steer wheels 4.8.10.1 Mounting the steer wheels, wheels without clamp units 3 4 5 1. Load the steer wheel (5) onto the support truck. 2. Secure the steer wheel (5) to the wheel support (3) with a chain (4). 3. Clean the contact surfaces. 4. Carefully drive the support truck into position. 5. Place the steer wheel (5) against the hub. 6. To support the weight of the steer wheel (5), use the forks of the support truck. 7. Fix and tighten two of the nuts (1) diagonal to each other. 1 8. Carefully reverse the support truck. 9. Fasten and tighten the remaining nuts (1) crosswise. For the required torque, see Tightening torque (page 90). 10. Pump the tires according to the recommendations of the tire manufacturer. 88/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.8.10.2 Mounting the steer wheels, wheels with clamp units 3 4 5 1. Load the steer wheel (5) onto the support truck. 2. Secure the steer wheel (5) to the wheel support (3) with a chain (4). 3. Clean the contact surfaces. 4. Carefully drive the support truck into position. 5. Place the steer wheel (5) against the hub. 6. To support the weight of the steer wheel (5), use the forks of the support truck. 7. Fix and tighten two of the clamp units (2) and nuts (1) diagonal to each other. 2 1 1 2 8. Carefully reverse the support truck. 9. Fasten and tighten the remaining clamp units (2) and nuts (1) in the correct sequence. For the required torque, see Tightening torque (page 90). 89/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 1 9 7 6 11 4 3 12 5 8 10 2 10. Pump the tires according to the recommendations of the tire manufacturer. 4.9 Tightening the bolted joints This chapter gives general informaton about the tightening torques for nuts and bolts, as well as more precise information about tightening torques for the nuts and bolts that are used in specific parts of the truck. 4.9.1 Tightening torque DANGER MACHINE MALFUNCTION HAZARD Failure to check the torque, can result in death, injury, or damage. Check the torque of the bolted joints during first service and on regular intervals. DANGER MACHINE MALFUNCTION HAZARD If lubricating the bolts before tightening them, the bolts are not properly fixated. Bolts which are not properly fixated, can cause accidents which can result in death, injury, or damage. The torques which are presented in the table apply only for dry bolts. Do not lubricate the bolts before tightening. The following table contains general tightening torque information for nuts and bolts in the truck. Check the following chapters for more precise information about tightening torques for NOTE the nuts and bolts of specific parts. Table 4. Tightening torques for untreated, unoiled, steel screw joints Millimeter bolts Inch bolts Thread M Tensile strength class Thread Tensile strength class UNC 8.8 10.9 12.9 8.8 10.9 12.9 6 9.8 Nm 14 Nm 17 Nm 1/4” 11 Nm 15 Nm 19 Nm 8 24 Nm 33 Nm 40 Nm 5/16” 22 Nm 31 Nm 38 Nm 90/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions Table 4. Tightening torques for untreated, unoiled, steel screw joints (Continued) Millimeter bolts Inch bolts 10 47 Nm 65 Nm 79 Nm 3/8” 38 Nm 54 Nm 68 Nm 12 81 Nm 114 Nm 136 Nm 7/16” 61 Nm 87 Nm 108 Nm 14 128 Nm 181 Nm 217 Nm 1/2” 93 Nm 131 Nm 163 Nm 16 197 Nm 277 Nm 333 Nm 9/16” 133 Nm 187 Nm 234 Nm 18 275 Nm 386 Nm 463 Nm 5/8” 183 Nm 259 Nm 323 Nm 20 385 Nm 541 Nm 649 Nm 3/4” 322 Nm 455 Nm 568 Nm 22 518 Nm 728 Nm 874 Nm 7/8” 516 Nm 729 Nm 909 Nm 24 665 Nm 935 Nm 1120 Nm 1” 772 Nm 1090 Nm 1360 Nm 27 961 Nm 1350 Nm 1620 Nm 1 1/8” 1090 Nm 1550 Nm 1930 Nm 30 1310 Nm 1840 Nm 2210 Nm 1 1/4” 1530 Nm 2160 Nm 2690 Nm 33 1770 Nm 2480 Nm 2980 Nm 1 3/8” 2020 Nm 2850 Nm 3550 Nm 36 2280 Nm 3210 Nm 3850 Nm 1 1/2” 2650 Nm 3750 Nm 4680 Nm 4.9.2 Tightening the wheel nuts DANGER MACHINE MALFUNCTION HAZARD Failure to check the torque, can cause the wheel nuts, and the rim to loosen, and destroy the hub. This can result in death, injury or damage. Check the torque of the wheels nuts as described. Check the torque of the wheel nuts daily for 14 days, or until the rim, clamp units, and nuts have settled in, and no more tightening is obtained. Perform these checks: • After a new delivery of machine • After the machine has been taken into use • After a wheel has been removed or replaced Figure 28. Drive wheel nuts 91/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions Figure 29. Steer wheel nuts Tighten the nuts crosswise according to the following table. Table 5. Drive wheel and steer wheel nuts torque Position Size Strength class Torque Clamps Drive axle M18x2 10.9 400 Nm Yes (295 lbf ft) Drive axle M22x1.5 10.9 768 Nm No (disc rim) (566.4 lbf ft) Steer axle M22x1.5 10.9 400 Nm Yes (295 lbf ft) Steer axle M22x1.5 10.9 700 Nm No (disc rim) (516.3 lbf ft) 4.9.3 Tightening the bolts in the propshaft 2 1 Figure 30. Propshaft SMV 10-18 92/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 2 1 Figure 31. Propshaft SMV 32-60 Select the correct torque according to the bolt size on the drive axle side (1) and the transmission side (2). Table 6. Propshaft torque Size Strength class Torque M14 8.8 128 Nm (94.4 lbf ft) M12 8.8 81 Nm (59.7 lbf ft) 4.9.4 Tightening the bolts in the engine and transmission mounting Check the condition of the rubber suspensions. If any wear and tear is discovered, replace the damaged parts. The engine mountings are accessible from the engine compartment, one on each side of the rear part of the engine. The transmission mountings are accessible from the engine compartment, one on each side of the transmission. 1 2 1 2 1 Figure 32. Engine mounting (left) and transmission mounting (right) 93/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions Table 7. Engine and transmission mounting torque Size Strength class Torque M20 8.8 385 Nm (284 lbf ft) M16 8.8 197 Nm (145.3 lbf ft) M16 10.9 277 Nm (204.3 lbf ft) 4.9.5 Tightening the bolts in the drive axle suspension WARNING RISK OF PROPERTY DAMAGE The bolts must be tightened in the order that is shown in the figure. There are four bolts on each side of the drive axle suspension. Select the correct torque from the table according to the bolt size. The screws, nuts, and washers must be installed dry. Do not use lubricants on the NOTE threads, or contact surfaces of the screws, nuts, or washers. 5 7 6 8 4 2 3 1 ° 60° 0 / 360° 60 60° 60° 60 ° ° 60 150° 120° Figure 33. Order to tighten bolts, including bolt angle torque The torque values in this table do not correspond to the standard torque values NOTE presented in the table in Tightening the bolted joints (page 90). Table 8. Drive axle suspension torque Size Method Strength class Torque M24 1 10.9 900 Nm (663.8 lbf ft) M30 1 10.9 1,550 Nm (1,143.2 lbf ft) M30 2 10.9 750 Nm (553.2 lbf ft) + 120° 94/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions Table 8. Drive axle suspension torque (Continued) Size Method Strength class Torque M36 1 10.9 3,000 Nm (2,212.7 lbf ft) M36 2 10.9 1,500 Nm (1,106.3) + 150° 4.9.6 Tightening the bolts in the hydraulic pumps 1 Figure 34. Hydraulic pumps Table 9. Hydraulic pumps torque Size Strength class Torque M12x40 8.8 81 Nm (59.7 lbf ft) 4.9.7 Tightening the bolts in the cabin suspension WARNING RISK OF DAMAGE TO THE MACHINE The suspension ears can get scrunched and damage the mounting brackets. When tightening the bolts, do not exceed the recommended torque values. WARNING RISK OF DAMAGE TO THE MACHINE When using the machine, the nuts and bolts of the front cabin suspension can come loose due to vibrations. The threads on the bolt must pass through the entire locking part of the nut. The torque value does not correspond to the standard torque value presented in the NOTE table at the beginning of the chapter. 95/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions Figure 35. Cabin suspension Cabin suspension - front 1. Place the bolt (1) with washers (2) in the suspension ears (3) and the mounting brackets. 2. Secure the bolt (1) with the locknut (4). NOTE The threads on the bolt (1) must pass through the entire locking part of the nut (4). 3. Tighten according to the recommended torque. Cabin suspension - rear 1. Apply Loctite to the bolt (1). 2. Thread the bolt (1) with washer (2) through the suspension ears (3) and the mounting brackets. 3. Secure the bolt (1) with the locking screw (5). 4. Tighten according to the recommended torque. Table 10. Cabin suspension torque Size Strength class Torque M24 12.9 100 Nm (73.8 lbf ft) 96/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.9.8 Tightening the bolts in the counterweights 1 2 3 4 Figure 36. Counterweights Select the right torque from the table according to the bolt size for the bolts of the counterweights (1), and (2). If equipped with counterweights on the steer axle, also check (3), and (4). Table 11. Counterweights torque Size Strength class Torque M24 8.8 665 Nm (490.5 lbf ft) M30 8.8 1,310 Nm (966.21 lbf ft) M36 8.8 2,280 Nm (1,682 lbf ft) 97/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.9.9 Tightening the bolts in the steer axle 1 2 Figure 37. Steer axle Tightening the bolts in the steer axle (1), and (2). Table 12. Steer axle torque Size Strength class Torque M36 8.8 2,280 Nm (1,682 lbf ft) M20 8.8 385 Nm (284 lbf ft) M30 8.8 1,310 Nm (966.2 lbf ft) 4.10 Lubricating the machine 4.10.1 General lubrication rules Follow these rules during lubrication: • Clean off old grease and clean grease nipples. • Lubricate until fresh grease protrudes. • Use only recommended grease. • All wear pads must be free of pressure for the grease to be able to penetrate. • Wear pads require frequent lubrication with a small amount of grease. Roller bearings require more grease less often. • Check the function and bearing slackness when lubricating. • Specified lubrication intervals apply in favorable conditions. More frequent lubrication is recommended in more demanding conditions, particularly of the wear pads. Examples of more demanding conditions can be dusty environments and heavy handling. For more information, see Recommended fluids and lubricants (page 250). 98/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.10.2 Lubricating the steer axle 1 3 3 Figure 38. Lubrication points 1. Remove any old grease and clean the grease nipples. 2. Lubricate the steering links (1), four points - two points on each steer link. 3. Lubricate the spindle bolts (2), one upper and one lower on each side. 4. Lubricate the wheel bearings (3), one on each side. Grease penetrates onto the inside. 99/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.10.3 Lubricating the hinges Figure 39. Lubrication points 1. Check and clean the hinges of the cabin door, battery hatch, and the hatch for the cabin tilting equipment. 2. Lubricate the hinges. To check that all parts of the hinges have been lubricated, open and close the hatches. 100/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.11 Lubricating the mast DANGER FALLING LOAD HAZARD Certain tasks require that the inner mast and carriage are raised. If you do not secure them, they may fall and cause serious injury or death. Secure the inner mast and carriage with a wooden block before starting work. 3 6 3 2 2 5 5 4 4 1 1 4 4 5 5 Figure 40. SMV 10-16 (left) and SMV 18-60 (right) mast lubrication points 1. Suspension shaft grease nipples 4. Side support reels 2. Tilt cylinder shafts 5. Mast wheels 3. Top support rollers 6. Chain wheels Do not use to much grease. Grease in the mast beams cause the rollers and wheels to NOTE slide instead of roll. Apply grease only to the bearings, not to the support rollers and mast wheels. Remember NOTE to lubricate on both sides of the mast. 1. Apply grease to the suspension shaft grease nipples (1). 101/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions The suspension shaft grease nipples (1) are accessible through the mast. Offload the shaft pins by lifting the mast either using a jack or a bench trestle and tilting it forwards. 2. Apply grease to the center of the tilt cylinder shafts (2). To offload the tilt cylinders, tilt the mast backwards. 3. Apply grease to the grease nipples of the top support rollers (3) on the outer mast. To reach the top support rollers (3), raise the mast. 4. Apply grease to the bearings of the side support reels (4) on the inner mast and the fork carriage. To reach the rollers, raise the carriage. The side support reels (4) of the fork carriage can be reached from the backside of the carriage. The side support reels (4) of the inner mast can be reached from the backside of the inner mast. 5. Apply grease to the bearings of the mast wheels (5) on the inner mast and the carriage. To reach the wheels, raise the carriage. The mast wheels (5) can be reached from the backside of the inner mast and carriage. 6. For SMV18-60: Apply grease to the chain wheels (6) through the grease nipples. 4.12 Lubricating the fork rollers 1 2 1 2 2 3 3 Figure 41. Fork rollers - lubrication points 1. Upper support rollers 2. Grease nipples 3. Lower support rollers Do not use too much grease. Grease in the carriage beams cause the rollers and wheels NOTE to slide instead of roll. Only apply grease through the grease nipples (2) to the bearings, not directly on the NOTE support rollers (1, and 3). 1. Apply grease through the grease nipples (2) for the upper support rollers (1). There are four upper support rollers (1) on each fork. 2. Apply grease through the grease nipples (2) for the lower support rollers (3). There are two lower support rollers (3) on each fork. 102/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.13 Lubricating the attachment 4.13.1 Attachment lubrication points - ELME 815 Toplift 3 3 1 2 2 1 4 5 5 4 1. Wear pads for main beams and extension 3. Stop cylinders beams 4. End beams and twistlocks 2. Extension cylinders 5. Fork frame and slew cylinders 103/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.13.2 Lubricating the wear pads for main beams and extending beams There are 20 or 24 lubrication points depending on model: 2 1 3 Figure 42. Lubrication points • Four tracks (1) on the inside of each main beam • Six tracks (2) on each extending beam • Two tracks (3) on the inside of each main beam 4.13.3 Lubricating extension beams and twistlocks NOTE Twistlocks on ELME New Generation (NG) are lubrication free. There are eight lubrication points: • One grease nipple in each end box (1) • One grease nipple in each sleeve (2) 1 2 Figure 43. Lubrication points 4.13.4 Lubricating extension cylinder support wear pads and tracks There are four lubrication points, two tracks in each extension beam. 104/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 1 Figure 44. Lubrication points 4.13.5 Lubricating the fork frame - ELME 815 There are 6 lubrication points: • Two greasing points on each slew cylinder, and one greasing point in the surface of the fork frame (4). 4 Figure 45. Lubrication points 105/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.13.6 Lubricating stop cylinders - ELME 815 (option) One grease nipple (1) on each stop cylinder. 1 100 m m 100 m m Figure 46. Lubrication points * * Locking plate shown in illustration. 4.14 Maintenance common to all engines 4.14.1 Cleaning and draining the fuel tank, all engines To collect the fuel, put a receptacle underneath the drain plug, and dispose of it in an NOTE environmentally responsible way. 2 1 Figure 47. Fuel tank 1. Check the tank for any leaks. 2. Place a receptacle underneath the tank. 3. Loosen the drain plug (1). 4. Drain the tank of any dirt and water through the drain plug (1). 5. When clear fuel comes through, refit the drain plug (1). Before refitting the drain plug, check the seal and change if needed. 106/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 6. Check the seal around the fuel cap (2), and change if needed. 4.14.2 Cleaning the engine air filter's coarse separator WARNING TOXIC SUBSTANCE HAZARD The engine air filter contains a significant number of dust particles, which may lead to breathing problems. If the filter element is damaged, the dust particles are also a major risk factor for engine damage. Always wear a face mask when servicing the air intake system. Do not inhale the dust particles. Consider the environment when carrying out this work. In sandy or dusty environments with many particles, clean the coarse separator more NOTE frequently. 2 1 Figure 48. Coarse separator, standard 2 Turbo II 1 Figure 49. Coarse separator, Turbo II (option) 1. Clean around the coarse separator (2). 2. Clean the clamp (1). 107/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 3. Remove the clamp (1) from the coarse separator (2). 4. Remove the coarse separator (2). 5. Clean the coarse separator (2) with air and remove the particles. 6. Dry the coarse separator (2) with a cloth. 7. Refit the coarse separator (2) and screw the clamp (1) in place. 108/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.14.3 Cleaning and changing the engine air filter, all engines WARNING TOXIC SUBSTANCE HAZARD The engine air filter contains a significant number of dust particles. If the filter element is damaged, it may lead to breathing problems. Always wear a protective mask when servicing the air intake system. Do not inhale the dust particles. Consider the environment when carrying out this work. WARNING RISK OF PROPERTY DAMAGE The engine air filter contains a significant number of dust particles. If the filter element is damaged, it causes a risk of damage to the engine. Always make sure that the engine air filter is cleaned and undamaged. Follow the "daily maintenance" instructions, and the maintenance schedule. RISK OF PROPERTY DAMAGE Do not clean the inside of the filter housing with compressed air. All maintenance on the NOTICE air intake system must be carried out while the engine is turned off. Do not use any liquids to clean the engine air filter, as it is a dry filter element. Cleaning the engine air filter always induce a risk of damaging it. After cleaning, the NOTE engine air filter has lower dust capacity than a new element. Clean or change the filter element when a warning about air inlet pressure appears on the MD4 display. Clean the area around the filter before opening the clamp units. 109/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4 3 2 1 Figure 50. Main filter element 1. Open all the clamp units (2) and remove the air filter cover (1). 2. Empty out the dust which has collected in the air filter cover (1). 3. Dry the air filter cover (1) using a damp cloth. 4. Remove the element (3) carefully. NOTE The safety cartridge inside the filter element (3), must stay in place. 5. Clean inside the filter housing (4) using a damp cloth. 6. Use a flashlight to check from the outside that there are no holes or cracks in the filter paper. 7. To clean the filter element (3), carefully blow compressed air of maximum 5 bar (72.5 psi) from the inside. Continue to blow until no more dust comes out. NOTE Do not use any liquids to clean the engine air filter, as it is a dry filter element (5). 8. After cleaning, write the date of cleaning on the filter element (3). 9. Discard the filter element (3) if it is damaged, or when it has been cleaned four times. 10. Put back the filter element (3) and close the air filter cover (1). 11. On the MD4 display, push (X) on the error message to close it. 110/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.14.4 Changing the safety cartridge, all engines NOTE Never clean the safety cartridge. Do not remove the safety cartridge unnecessarily. Replace the safety cartridge (1) if there has been any damage to the main filter. 1 2 3 Figure 51. Safety cartridge 1. Disassemble the filter element (2) as in Cleaning and changing the engine air filter, all engines (page 109). 2. Fit in a new safety cartridge (1). 3. Put back the filter element (2) and close the air filter cover (3). 111/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.14.5 Checking the air intake system, all engines The air intake system must be intact. Broken and leaking pipes shorten the life of the engine. Check the system regularly. 1 1 2 2 Figure 52. Air intake system 1. Check the hoses (1) for fissures and damage. If necessary, replace them. 2. Make sure that all hose clamps (2) are fit well. 3. Check that the filter housing is intact. 112/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.14.6 Checking the coolant system, Volvo engines For Volvo engines, there is a cover on the coolant tank. Turn the hand wheel (1) of the NOTE coolant tank cover anti-clockwise. Slide the cover back to gain access to the Volvo coolant tank. 1 Figure 53. Cover on Volvo cooling tank Figure 54. Cooling system, Volvo 1. To discover leaks and cracks, check all the hoses by pressing them. When in doubt, replace the hoses. 2. Check the radiator for damage and leaks, and that there are no deposits. 3. Check the functioning of the cabin heater. 4. Check the coolant in terms of: • Level • Freezing points • Any contaminations 5. Replace the coolant if it is not clean and clear. 6. If the coolant level is below minimum mark, top it up. 7. Check the rubber suspensions in the radiator mounting brackets at the bottom of the radiator. Replace the rubber mounts as necessary. 8. Make sure to tighten the fixing bolts. 113/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.14.7 Checking the coolant system, Cummins engines 1. To discover leaks and cracks, check all the hoses by pressing them. When in doubt, replace the hoses. 2. Check the radiator for damages and leaks, and that there are no deposits. 3. Check the functioning of the cabin heater. 4. Check the coolant in terms of: • Level • Freezing points • Any contaminations 5. Replace the coolant if it is not clean and clear. 6. If the coolant level is below minimum mark, top it up. 7. Check the rubber suspensions in the radiator mounting brackets at the bottom of the radiator. Replace the rubber mounts as necessary. 8. Ensure that the fixing bolts are tightened. 114/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.14.8 Changing the coolant, Volvo engines WARNING HOT FLUID HAZARD Hot coolant may spray from the refill, which may cause a risk of serious injury. Allow engine to cool and release pressure before opening the filler cap. Only authorized and trained service personnel is allowed to fill the coolant. WARNING HIGH-PRESSURE HAZARD The system may be under pressure even if it is not of the high-pressure type. The coolant may be under pressure and hot, which may cause serious injury. Open the filler cap slowly. WARNING HARMFUL SUBSTANCE HAZARD Using wrong coolant may damage the machine. Use the recommended coolant and never mix different coolants. For recommended coolants, see Fuel and oil recommendations (page 249). WARNING TOXIC SUBSTANCE HAZARD It is highly dangerous to drink ethylene glycol. Contact with skin or spray from the refill can cause skin irritation and eye damage. Do not drink ethylene glycol, and avoid contact with skin. WARNING HOT COOLANT HAZARD Opening the pressure chamber cap (1) can cause serious personal injury. Never open the pressure chamber cap (1) when checking, or refilling coolant. 115/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 2 1 3 4 1. Remove the filler cap (2) on the expansion tank (3). To ensure that the system is not pressurized when removing the filler cap (2) , only open NOTE 1/4 of a turn first. 2. Switch on the ignition to adjust the temperature for the cabin heater to maximum. 3. After adjusting the temperature, switch off the ignition again. 5 4. Place a receptacle under the drain valve (5). 5. To lead the coolant to the receptacle, connect a hose to the drain valve (5). 6. Open the drain valve (5). NOTE Be careful, risk of burning when opening the valve (5). 7. Drain the whole system, using the drain valve (5) on the side of the radiator. NOTE Drain the whole system, when replacing hoses and components in the system. 8. Close the drain valve (5). 9. Remove the hose from the drain valve (5). 10. Fill to the maximum level through the filler cap (2) on the expansion tank (3). 116/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 11. Start the engine, let it idle, and check for leaks. 12. Observe the level and fill as necessary. • When the operating temperature has been reached, the level stabilizes. • The tank (3) should be filled to the maximum. 13. Refit the filler cap (2). 4.14.9 Changing the coolant, Cummins engines WARNING HOT FLUID HAZARD Hot coolant may spray from the refill, which may cause a risk of serious injury. Allow engine to cool and release pressure before opening the filler cap. WARNING HIGH-PRESSURE HAZARD The system may be under pressure even if it is not of the high-pressure type. The coolant may be under pressure and hot, which may cause serious injury. Open the filler cap slowly. WARNING HARMFUL SUBSTANCE HAZARD Using wrong coolant may damage the machine. Use the recommended coolant and never mix different coolants. WARNING TOXIC SUBSTANCE HAZARD It is highly dangerous to drink ethylene glycol. Contact with skin or spray from the refill can cause skin irritation and eye damage. Do not drink ethylene glycol and avoid contact with skin. 1. Remove the filler cap (1) on the expansion tank (2). To ensure that the system is not pressurized when removing the filler cap (1), only open 1/4 of a turn first. 2. Switch on the ignition to adjust the temperature for the cabin heater to maximum. After adjusting the temperature, switch off the ignition. 117/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 3 3. Place a receptacle under the drain valve (3). 4. To lead the coolant to the receptacle, connect a hose to the drain valve (3). 5. Open the drain valve (3). NOTE Be careful, risk of burning when opening the valve. 6. Drain the whole system. Drain the whole system using the drain valve on the side of the radiator when replacing NOTE hoses and components in the system. 7. Close drain valve (3). 8. Remove the hose from the drain valve (3). 9. Fill through the filler cap (1) on the expansion tank (2) to the maximum level. 10. Start the engine, run on idle, and check for leaks. 11. Observe the level and fill as necessary. • When the operating temperature has been reached, the level stabilizes. • Level should be at the maximum level indicator (4) on the side of the expansion tank. 4 12. Refit the filler cap (1). 118/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.14.10 Cleaning the radiator, intercooler, and oil coolers, all engines WARNING HOT SURFACE HAZARD If you touch the radiator and coolers when they are hot, the heat may cause serious injury. Only clean the radiator and coolers when the engine has been turned off and cooled down. Do not apply cold water on hot surface. RISK OF PROPERTY DAMAGE If you use a high-pressure steam cleaner, it may damage the fins of the radiator, NOTICE intercooler, and oil coolers. Use compressed air. 1 2 3 4 Figure 55. Radiator 1. Intercooler (contains air from the turbo to 3. Oil cooler for brakes(not applicable for all the engine) models and sizes) 2. Engine radiator (contains engine coolant) 4. Transmission oil cooler To clean the radiator (2), intercooler (1), and oil coolers (3 and 4), use compressed air. 1. Blow against the direction of the fan. The radiator (2), intercooler (1), and oil coolers (3 and 4) must not be cleaned with high- pressure water. In extreme cases, solvents or a jet of steam can be used with great care. 2. Allow the solvent time to penetrate. Rinse off with water. 3. Run the engine warm so that surplus water evaporates and does not cause corrosion. 119/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.14.11 Checking the valve clearance, all engines The valve clearance must be checked and adjusted by a service technician who has the NOTICE necessary special equipment. The technician must be authorized by Konecranes Lift Trucks or by the engine manufacturer. Check the valve clearance when the engine is cold. Follow the instructions in the engine NOTE manufacturer’s instruction book. Figure 56. Valve clearance 4.14.12 Checking the fuel system and fuel injectors, all engines WARNING SKIN INJECTION HAZARD If the high-pressure fluid from the fuel injectors penetrates the skin, it may cause serious bodily injury or death. Never check leakage of the fuel system when the engine runs. Use protective gear such as safety gloves and protective wear. RISK OF DAMAGE TO THE MACHINE The fuel injectors must be checked and adjusted by a service technician who has the NOTICE necessary special equipment. The technician must be authorized by Konecranes Lifttrucks or by the engine manufacturer. 120/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions Figure 57. Fuel system and fuel injectors 1. Check the fuel system for leakage. 4.14.13 Checking the exhaust system, all engines WARNING HOT SURFACE HAZARD Touching the exhaust system while it is hot may cause serious injury. Wait until the exhaust system has cooled down before starting any maintenance work. NOTE Always check the exhaust system, if the engine or machine sounds changes. Figure 58. Exhaust system 1. Check the overall condition of the exhaust system. If leaking, replace the pipes or the muffler. 2. Check all joints. 3. Check the exhaust manifold. 4. Check the suspension of the muffler. Replace if necessary. 121/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 5. Start the engine. 6. Check for any leaks in the exhaust system. 4.15 Maintaining the Volvo engines This chapter includes the instructions specific to Volvo engines. 4.15.1 Bleeding the fuel system: Volvo 5- and 8-liter engines WARNING HIGH-PRESSURE HAZARD High-pressure fuel may cause serious personal injury. Never disconnect a fuel line or a component from a fuel pump that is to be bled. The fuel is highly pressurized and can penetrate the skin. NOTE Working with the fuel system requires special cleanliness. Check that there is sufficient fuel in the tank, and that the fuel taps are open (if NOTE applicable). NOTE To collect fuel, put a receptacle under the fuel filter. Take care of the excess fuel and store the used filter in a suitable container. Dispose of NOTE both in an environmentally responsible way. Bleed the system if it has run dry or after filter change. Bleed the fuel system with the NOTE hand pump on the fuel filter bracket. 1. Clean thoroughly around the bleeder nipple (2) and cap (1). 2. Remove the protective cap (1) on the bleeder nipple (2). 1 2 3. Connect a transparent hose (3) to the nipple (2). To collect the excess fuel, place the loose end of the hose (3) in a receptacle. 4. Loosen the nipple (2), at least two turns. 122/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 3 2 5. Bleed the fuel system by pumping up fuel with the hand pump (4) until air-free fuel flows out. Pump rapidly, to maintain pressure in the pump. 4 6. Tighten the bleeder nipple with torque 3.5 Nm, while air-free fuel flows out. 7. Wait for 15 s. and then repeat step 4 to 6. 8. Remove the hose (3). 9. Fit the protective cap (1) on the bleeder nipple (2). 10. Start the engine. NOTE If the engine does not run smoothly, repeat the procedure. 4.15.2 Bleeding the fuel system: Volvo 11 and 13-liter engines WARNING HIGH-PRESSURE HAZARD High-pressure fuel may cause serious personal injury. Never disconnect a fuel line or a component from a fuel pump that is to be bled. The fuel is highly pressurized and can penetrate the skin. NOTE Working with the fuel system requires special cleanliness. Check that there is sufficient fuel in the tank, and that the fuel taps are open (if NOTE applicable). NOTE To collect fuel, put a receptacle under the fuel filter. 123/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions Take care of the excess fuel and store the used filter in a suitable container. Dispose of NOTE both in an environmentally responsible way. Bleed the system if it has run dry, if the filter is changed, or after a longer downtime. In NOTE such a case, bleed the system with the hand pump on the fuel filter bracket. 1. Clean thoroughly around the filter before starting to bleed the filter. 2. Free the hand pump (1) from the fuel filter bracket. 2.1 Turn the fuel pump handle (1) counter-clockwise. 2.2 Pull upwards. 2.3 The hand pump (1) is now open. A 1 B C 3. Open the bleeder nipple (2). 4. To collect fuel, connect a hose and a receptacle to the other end of the hose. 2 124/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 5. Bleed the fuel system by pumping with the hand pump (1) until the fuel flows without air bubbles. 1 6. Close the nipple (2). Tightening torque: 3.5 Nm (2.6-lbf ft). 2 7. Remove the hose. 8. Replace the rubber cap. 9. Tighten the fuel pump handle (1). 9.1 Press the pump handle (1) downwards. 9.2 Turn the pump handle (1) clockwise. 9.3 The hand pump (1) is now closed. 125/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions A 1 B C 10. Wipe dry any spilled fuel. 11. Check that there is no leakage. 12. Start the engine. NOTE If the engine does not run smoothly, repeat the procedure. 126/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.15.3 Draining the fuel prefilter: Volvo 5- and 8-liter engines WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid fuel spillage, place a receptacle underneath the filter. NOTE Take care of the excess fuel and dispose of it in an environmentally responsible way. Figure 59. Fuel prefilter 1. Stop the engine. 2. Close the fuel tap if applicable. 3. To collect the water and fuel, put a receptacle under the fuel prefilter. 4. Open the drain valve (1) at the bottom of the water separator (2). 5. Drain the water contained in the water separator (2) into the receptacle. NOTE Do not drain the water separator (2) completely. 6. Tighten the drain valve (1) and open the fuel tap if applicable. 7. Start the engine. 8. Check that there is no leakage from fuel prefilter. 127/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions If the engine is not working properly, bleed the system. For more information, see NOTE "Bleeding the fuel system" for Volvo engines. 4.15.4 Draining the fuel prefilter: Volvo 11- and 13-liter engines WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. NOTE Working with the fuel system requires special cleanliness. Take care of the water and fuel and dispose of it in a safe, controlled, and NOTE environmentally responsible way. 1 1. To collect the water and fuel, put a receptacle under the fuel prefilter. 2. Open the drain valve (1) in the base of the fuel prefilter. 3. Tighten the drain valve (1) when fuel without water starts to run out. 128/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.15.5 Changing the fuel prefilter: Volvo 5- and 8-liter engines WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. If the machine is equipped with a fuel tap (option), close tap before proceeding with the NOTE change of the fuel filter. To collect the water and fuel, put a receptacle under the fuel filter. Store the used filter in NOTE a suitable container and dispose of it in an environmentally responsible way. 8 1 7 2 6 3 5 4 1. Clean thoroughly around the fuel prefilter (1) and water separator (2). 2. Disconnect the cable (4) from the water trap sensor (3). 3. To drain the filter, open the drain valve (5) at the bottom of the water separator (2). 4. Tighten the drain valve (5) again. 5. Remove the fuel prefilter (1) and the water separator (2). Put the used filter in a suitable container and dispose of it in an environmentally responsible way. 6. Lubricate the new O-ring (7) with diesel. 7. Screw the new filter (1) onto the mounting bracket (8) by hand, until it bottoms. 129/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions Tighten a further 1/2–2/3 turns. 8. Remove the water separator (2) from the old fuel prefilter (1). 9. Clean the upper section of the water separator (2) and the contact surfaces. 10. Lubricate the new rubber seal (6) with diesel. 11. Reattach the water separator (2) to the new filter (1). 12. Reconnect the cable (4) to the water trap sensor (3). 13. Open fuel taps, if applicable, and bleed the fuel system. For more information, see Bleeding the Volvo fuel system. 14. Start the engine and make sure that there is no leakage. If the engine is not working properly, bleed the system. For more information, see NOTE "Bleeding the fuel system" for Volvo engines. 4.15.6 Changing the fuel prefilter: Volvo 11- and 13-liter engines WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. NOTE Working with the fuel system requires special cleanliness. NOTE To collect the water and fuel, put a receptacle under the fuel filter. Take care of the water and fuel and dispose of it in a safe controlled manner. Store the NOTE used filter in a suitable container, and dispose of it in an environmentally responsible way. 1 2 1. Clean thoroughly around the fuel prefilter (1) and water separator (2). 2. Disconnect the cable from the water separator sensor. 3. Remove the fuel prefilter (1) from the mounting bracket. Collect any spilled fuel in a receptacle. 130/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4. Remove the water separator (2) from the fuel prefilter (1). 5. Clean the upper part of the water separator (2) with a soft rag. 6. Check that the drain hole in the water separator (2) is not clogged. 7. Install a new seal on the water separator (2). 8. Lubricate the seal with diesel fuel. 9. Reinstall the water separator (2) to the new filter. 10. Screw the new filter onto the mounting bracket by hand. The rubber seal should touch the mating surface. 11. Tighten another half turn, no more. 12. Reconnect the cable to the water separator sensor. 13. If necessary, bleed the fuel system. For more information, see Bleeding the Volvo fuel system. 14. Start the engine, check that there is no leakage. 131/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.15.7 Changing the fuel filter: Volvo 5- and 8-liter engines WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. WARNING IGNITION HAZARD Fuel spill onto a hot surface or an electrical component can cause a fire. Causing a risk of personal injury or death. When carrying out work on the fuel system, make sure that the engine is cold. Store the fuel soaked rags in a suitable container, so that they cannot cause fire. Dispose of them in an environmentally responsible way. RISK OF MATERIAL DAMAGE A leaking seal allows air to enter the system and thus prevent the flow of fuel from the NOTICE tank to the fuel pump. The wrong type of fuel filter may damage the fuel injection circuit. Always use original parts when replacing the filters. NOTE Replace the fuel filter when the engine is cold. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid spillage, place a receptacle underneath the filter. Take care of the excess fuel and dispose of it in a safe controlled manner. Store the used NOTE filter in a suitable container, dispose of it in an environmentally responsible way. 132/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 1 2 3 4 1. Clean around the filter cover (1) and filter housing (4). 2. Carefully remove the fuel filter cover (1). Be prepared to gather up fluid. The filter is still full of fuel and there is a risk of spillage NOTE when the cover is removed. 3. Remove the O-ring (2) and filter (3). Let the fuel drip off into a receptacle. 4. If the filter housing is empty, lubricate with diesel around the inner section of the filter sealing surface. 5. Lubricate the O-ring (2) with diesel before installing the filter cover. 6. Install the filter (3) in the filter cover. Make sure that the filter fits properly in the cover. 7. Install the filter cover (1) and filter (3) in the bracket. 8. Carefully screw in the cover (1) and check that the O-ring (2) does not get twisted. Relubricate the seal as necessary. Tighten the cover to: 25 Nm (18.4 lbf. ft.) 9. Bleed the fuel system. See Bleeding the fuel system for Volvo engines. 10. Start the engine, check that there is no leakage. NOTE If the engine is not working properly, bleed the system again. 133/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.15.8 Changing the fuel filter: Volvo 11- and 13-liter engines WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. WARNING IGNITION HAZARD Fuel spill onto a hot surface or an electrical component can cause a fire. Causing a risk of personal injury or death. When carrying out work on the fuel system, make sure that the engine is cold. Store fuel soaked rags so that they cannot cause fire. RISK OF MATERIAL DAMAGE A leaking seal allows air to enter the system and thus prevent the flow of fuel from the NOTICE tank to the fuel pump. The wrong type of fuel filter may damage the fuel injection circuit. Always use original parts when replacing the filters. Do not fill the new fuel filter with fuel before assembly. There is a risk that NOTICE contamination could get into the system and cause malfunctions or damage. NOTE Replace the fuel filter when the engine is cold. NOTE To avoid fuel spillage, place a receptacle underneath the filter. Take care of the excess fuel and dispose of it in a safe controlled manner. Store the used NOTE filter in a suitable container, dispose of it in an environmentally responsible way. 1 1. Clean around the fuel filter (1). 2. Remove the filter (1) with a suitable filter remover. Collect any spilled fuel in a receptacle. 3. Clean the filter mating surface on the mounting bracket. 4. Lubricate the seal with diesel fuel. 134/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 5. Install the new fuel filter. 6. Tighten the fuel filter in accordance with the instructions on the fuel filter. 7. If necessary, bleed the fuel system. For more information, see Bleeding the Volvo fuel system. 8. If a water separator is installed, change the water separator filter at the same time as the fuel filter. Clean inside the water separator with a soft rag. 4.15.9 Changing the AdBlue filters, Volvo 4.15.9.1 Changing the AdBlue pump filter This section is applicable for machines that are equipped with Volvo or Cummins QSB 6.7 engines. WARNING CORROSIVE SUBSTANCE HAZARD The AdBlue solution may cause skin and eye damage. It is corrosive towards certain metals such as copper and aluminum. Do not allow AdBlue solution to come in contact with other chemicals. Use safety gloves. If the AdBlue solution comes in contact with the skin or eyes, quickly wash it off with soap and water. Wait at least 2-5 min after the engine has been turned off to disconnect the battery NOTE negative terminal. By doing so, the automatic drainage and depressurization of the selective catalytic reduction system can take place. NOTE To avoid spillage, place a receptacle underneath the filter. Take care of the excess fluid and dispose of it in a safe controlled manner. Store the NOTE used filter in a suitable container, dispose of it in an environmentally responsible way. 1. Switch off the engine. 1 2. After 2-5 min, disconnect the battery negative terminal (1). 135/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 2 3. Place a receptacle under the filter cover (2). 4. Remove the filter cover (2), let AdBlue run into the receptacle. 3 4 5. Press the puller, which is supplied with the filter kit (3), into the filter hole until a click is heard. 6. Pull out the old filter (4). 7. Put the used filter (4) in a suitable container, and dispose of it in an environmentally responsible way. 136/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 2 6 5 8. Install the new filter (5). 9. Install the rubber gasket (6). 2 10. Reattach the filter cover (2). 11. Tighten the filter cover (2) using a torque wrench. NOTE Tightening torque is 20 + 5 Nm (14.8 + 3.68-lbf ft). 12. Reconnect the battery negative terminal (1). 13. Start the engine. 14. Check that there are no leaks. 15. Delete any error codes. 137/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.15.9.2 Changing the AdBlue breather filter WARNING CORROSIVE SUBSTANCE HAZARD The AdBlue solution may cause skin and eye damage. It is corrosive towards certain metals such as copper and aluminum. Do not allow AdBlue solution to come in contact with other chemicals. Use safety gloves. If the AdBlue solution comes in contact with the skin or eyes, quickly wash it off with soap and water. Wait at least 2-5 min after the engine has been turned off to disconnect the battery NOTE negative terminal. By doing so, the automatic drainage and depressurization of the selective catalytic reduction system can take place. NOTE To avoid spillage, place a receptacle underneath the filter. Take care of the excess fluid and dispose of it in a safe controlled manner. Store the NOTE used filter in a suitable container, dispose of it in an environmentally responsible way. NOTE The size and appearance of the tank can vary depending on machine model and size. 1 2 4 3 1. Breather filter 3. From tank 2. From sensor 4. Hose clamp How to replace the breather filter 1. Switch off the engine. 2. Disconnect the battery negative terminal (after 2-5 min). 3. Clean around the filter area. 4. Loosen the hose clamp (4). 5. Remove the breather filter (1) from the AdBlue tank. 6. Put the used filter in a suitable container and dispose of it in an environmentally responsible way. 7. Reverse the procedure to install the new breather filter. It is important that the new filter is installed in the exact same position as the removed NOTE filter. 138/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.15.9.3 Changing the AdBlue armature (level) filter WARNING CORROSIVE SUBSTANCE HAZARD The AdBlue solution may cause skin and eye damage. It is corrosive towards certain metals such as copper and aluminum. Do not allow AdBlue solution to come in contact with other chemicals. Use safety gloves. If the AdBlue solution comes in contact with the skin or eyes, quickly wash it off with soap and water. Wait at least 2-5 min after the engine has been turned off to disconnect the battery NOTE negative terminal. By doing so, the automatic drainage and depressurization of the selective catalytic reduction system can take place. NOTE To avoid spillage, place a receptacle underneath the filter. Take care of the excess fluid and dispose of it in a safe controlled manner. Store the NOTE used filter in a suitable container, dispose of it in an environmentally responsible way. The size and appearance of the armature filter can vary depending on machine model NOTE and size. 1. Switch off the engine. 2. Disconnect the battery negative terminal (after 2-5 min). 3. Clean around the hose connection area. 1 3 2 4. Remove the connector hoses (1). 5. Wrap a plastic bag around the connectors to protect them. 6. Remove the coolant hoses (2). 139/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 7. Remove the hose clamp (3). 4 8. Lift out the armature (4). 5 9. Remove the armature (level) filter (5). 10. Flush warm water through the armature to clean it. 11. Reverse the procedure to reinstall the new armature (level) filter. NOTE After reinstalling the new armature (level) filter (5), check the coolant level. 140/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.15.10 Changing the Volvo engine oil WARNING HOT FLUID HAZARD Hot engine oil may cause serious personal injury. To avoid burns, use care when opening the drain plug. NOTE Drain the oil when the engine is at the operating temperature, at least 65°C (149°F). NOTE To avoid spillage, place a receptacle under the filter. NOTE Take care of the excess oil and dispose of it in an environmentally responsible way. 1. Place a receptacle underneath the drain plug (1). 1 1 EU stage 3a/4 / US tier 3/4i/4f EU stage 5 2. Unscrew the drain plug (1). 3. Allow the oil to run out. 4. Check the seal for damage or deformation. If necessary, renew the seal. 5. Refit the drain plug (1). 6. Tighten up the drain plug (1). 7. Remove the filler cap (2). 2 3 8. Fill oil through the opening, use the recommended oil. 9. Check the oil level using the dipstick (3). Make sure that the oil level is between the minimum and maximum marks on the dipstick (3). Do not fill above the maximum oil level. 141/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 10. Refit the filler cap (2). 11. Check that there are no leaks from the drain plug (1) or the oil filter. 12. Start the engine. Check that there is no warning symbol for low oil pressure on the display. 13. Turn off the engine. Check the oil level after 5 min. 4.15.11 Changing the engine oil filter: Volvo 5- and 8-liter engines WARNING HOT OIL AND HOT SURFACES HAZARD Risk of personal injury. Use protective gloves. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid spillage, place a receptacle under the filter. Take care of the excess oil and dispose of it in a safe controlled manner. Put the filter in a NOTE suitable container, dispose of it in an environmentally responsible way. Drain the oil according to the instructions in Changing the engine oil. 1 2 3 4 1. Before opening the oil filter, clean around the filter cover (1) and the filter housing (4). 2. Clean around the oil filter (3). 3. Carefully remove the filter cover (1) together with the filter (3). 4. Remove the O-ring (2) and filter (3) from the cover (1). 5. Let the oil drip off into a receptacle. 6. Lubricate the new O-ring (2) and the gasket of the new filter (3) with new oil before installation. 142/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 7. Install the new filter (3) and new O-ring (2) in the filter cover (1). Make sure to install the filter correctly in the cover. 8. Install the filter cover (1) and filter (3) in the filter housing (4). 9. Tighten the cover to 40 Nm (29.5-lbf. ft.). 10. Fill with required volume of oil. See Fuel and oil recommendations (page 249). 11. Start the engine. Check that there is no oil leakage from the oil filter or drain plug. 12. Switch off the engine and check the oil level after a few minutes. 13. If necessary, top up with oil. 4.15.12 Changing the engine oil filter: Volvo 11- and 13-liter engines WARNING HOT OIL AND HOT SURFACES HAZARD Risk of personal injury. Use protective gloves. NOTE Working with the oil system requires special cleanliness. NOTE To avoid spillage, place a receptacle underneath the filter. Take care of the excess oil and dispose of it in a safe controlled manner. Put the used NOTE filter in a suitable container, and dispose of it in an environmentally responsible way. 2 4 3 1 1. Clean the oil filter bracket (2). 2. Remove all oil filters with a suitable oil filter extractor (1). 3. Clean the mating surface of the oil filter bracket. 3.1 Make sure to not leave any old oil seal remnants behind. 3.2 Carefully clean inside the protective rim on the oil filter bracket (2). 4. Put a thin layer of new engine oil on the seals of the new oil filters. 5. Install the new oil filters. 5.1 Tighten the two full-flow filters (3) 1/2–3/4 of a turn after they bottom. 5.2 Tighten the bypass filter (4) 3/4–1 turn after it bottoms. 143/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 6. Top up with engine oil, start the engine, and let it run for 20–30 s. See Fuel and oil recommendations (page 249). 7. Turn off the engine. 8. Check the oil level, and top up as required. 9. Check the seals around the oil filters. 4.15.13 Changing the crankcase breather filter The crankcase breather filter (1) is used on 5- and 8-liter Volvo engines (EU stage 4 and NOTE below). NOTE Always change the crankcase breather filter (1), it must not be cleaned and reused. Store the used filter in a suitable receptacle, and dispose of it in an environmentally NOTE responsible way. 1 Figure 60. Placement of crankcase breather filter (1) - Volvo TAD 571 VE 144/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions Changing the crankcase breather filter 2 3 4 5 1. Clean around the filter cover (2) and the filter housing (5). 2. Remove the filter cover (2), using a suitable tool. 3. Remove the filter element (3) from the filter housing (5). 4. Remove the O-ring (4). 5. Clean inside the filter cover (2) and filter housing (5) with a lint free cloth. 6. Lubricate the new O-ring, using clean engine oil. 7. Fit the new O-ring to the filter cover (2). 8. Insert the new filter element in the filter housing (5). 9. Reattach the filter cover (2) on to the filter housing (5). 145/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.15.14 Checking the Volvo drive belt NOTE If the drive belt is oily, worn, or damaged, it must be replaced. 1 2 3 Figure 61. EU stage 3a/4 / US tier 3/4i/4f 2 1 3 Figure 62. EU stage 5 - TAD 581, 583 VE 146/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 2 1 3 Figure 63. EU stage 5 - TAD 881, 883 VE 1 2 3 Figure 64. EU stage 5 - TAD 1181, 1183 VE 1. Check the belt (1) for cracks and wear. The belt (1) should be checked after operation, when it is hot. It should be possible to depress the belt (1) 3–4 mm (0.12–0.16 in) between the pulleys (2). 2. Check that the automatic belt tensioners (3) function and maintains the tension in the belt (1). 3. Check the idler pulleys (2) for damage. 147/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.15.15 Checking the Volvo vibration damper WARNING RISK OF DAMAGE TO THE MACHINE If the vibration damper does not function properly, it can lead to serious engine or drive line failure. Check the condition of the vibration damper regularly, follow the regular service schedule. Service must be performed by an authorized service technician. If service or replacement of parts is needed, contact your local dealer for more information. 1 Figure 65. Vibration damper 1. Check the vibration damper (1) for wear and damage. 4.15.16 Checking the Volvo water pump WARNING RISK OF DAMAGE TO THE MACHINE A leaking or damaged water pump can lead to serious engine or drive line failure. Check the condition of the water pump regularly, follow the regular service schedule. Service must be performed by an authorized service technician. If service or replacement of the water pump is needed, contact your local dealer for more information. 148/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 1 Figure 66. Water pump NOTE Location, and appearance can vary depending on size and model of the motor. 1. Check the water pump (1) for leaks, and wear. If dripping, or a steady flow of coolant or oil is found, the water pump (1) must be NOTE replaced. Contact your local authorized dealer for more information. 4.16 Maintaining the Cummins engines This chapter includes the maintenance instructions for the Cummins engines. 149/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.16.1 Bleeding the fuel system - QSB 6.7 4.16.1.1 Bleeding the fuel prefilter - QSB 6.7 and B 6.7 WARNING HIGH-PRESSURE HAZARD High-pressure fuel may cause serious personal injury. Never disconnect a fuel line or a component from a fuel pump that is to be bled. The fuel is highly pressurized and can penetrate the skin. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid fuel spillage, place a receptacle underneath the filter. NOTE Take care of the excess fuel, and dispose of it in an environmentally responsible way. Bleed the fuel system if it has run dry or after filter change. Bleed the fuel system with NOTE the hand pump on the fuel filter bracket. 2 1 Figure 67. Bleeding the fuel prefilter - QSB 6.7 150/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 1 2 Figure 68. Bleeding the fuel prefilter - B 6.7 1. Clean thoroughly around the bleeder nipples (2) and the fuel prefilter. 2. Open the bleeder nipples (2). 3. Place a receptacle underneath the fuel prefilter. 4. Bleed the fuel system by pumping up fuel with the hand pump (1) until air-free fuel flows out. NOTE Pump rapidly, to maintain pressure in the pump. 5. Close the nipples (2). NOTE Tightening torque 3.5 Nm (2.6-lbf ft). 6. Wipe dry any spilled fuel. 7. Start the engine and make sure that there is no leakage. NOTE If the engine does not run smoothly, repeat the procedure. 151/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.16.1.2 Bleeding the distributor pump - QSB 6.7 WARNING HIGH-PRESSURE HAZARD High-pressure fuel may cause serious personal injury. Never disconnect a fuel line or a component from a fuel pump that is to be bled. The fuel is highly pressurized and can penetrate the skin. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid fuel spillage, place a receptacle underneath the filter. NOTE Take care of the excess fuel, and dispose of it in an environmentally responsible way. Bleed the system if it has run dry or after filter change. Bleed the fuel system with the NOTE hand pump on the fuel filter bracket. 2 1 Figure 69. Bleeding the distributor pump - QSB 6.7 1. Clean thoroughly around the bleeder nipple (2) and the distributor pump. 2. Open the bleeder nipple (2). 3. Place a receptacle underneath the distributor pump. 4. Bleed the fuel system by pumping up fuel with the hand pump (1) until air-free fuel flows out. NOTE Pump rapidly, to maintain pressure in the pump. 5. Close the nipple (2). NOTE Tightening torque: 3.5 Nm (2.6-lbf ft). 6. Wipe dry any spilled fuel. 7. Start the engine and make sure that there is no leakage. NOTE If the engine does not run smoothly, repeat the procedure. 152/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.16.1.3 Bleeding the fuel filter - QSB 6.7 and B 6.7 WARNING HIGH-PRESSURE HAZARD High-pressure fuel may cause serious personal injury. Never disconnect a fuel line or a component from a fuel pump that is to be bled. The fuel is highly pressurized and can penetrate the skin. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid fuel spillage, place a receptacle underneath the filter. NOTE Take care of the excess fuel, and dispose of it in an environmentally responsible way. Bleed the system if it has run dry or after filter change. Bleed the fuel system with the NOTE hand pump on the fuel filter bracket. 2 1 Figure 70. Bleeding the fuel filter - QSB 6.7 153/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 2 1 Figure 71. Bleeding the fuel filter - B 6.7 1. Clean thoroughly around the bleeder nipples (2) and the fuel filter. 2. Open the bleeder nipples (2). 3. Place a receptacle underneath the fuel filter. 4. Bleed the fuel system by pumping up fuel with the hand pump (1) until air-free fuel flows out. NOTE Pump rapidly, to maintain pressure in the pump. 5. Close the nipples (2). NOTE Tightening torque 3.5 Nm (2.6-lbf ft). 6. Wipe dry any spilled fuel. 7. Start the engine and make sure that there is no leakage. NOTE If the engine does not run smoothly, repeat the procedure. 154/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.16.2 Bleeding the fuel system - QSM 11 WARNING HIGH-PRESSURE HAZARD High-pressure fuel may cause serious personal injury. Never disconnect a fuel line or a component from a fuel pump that is to be bled. The fuel is highly pressurized and can penetrate the skin. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid fuel spillage, place a receptacle underneath the filter. NOTE Take care of the excess fuel, and dispose of it in an environmentally responsible way. NOTE Bleed the system if it has run dry, if the filter is changed, or after a longer downtime. 1 Figure 72. Bleeding fuel filter - QSM 11 1. Clean thoroughly around the bleeder nipples (1). 2. Connect draining hoses to the bleeder nipples (1). NOTE To open the bleeder nipples (1), select a hose with a suitable connection. 3. To collect any excess fluid, place the opposite ends of the hoses in a receptacle. 4. Start the engine. 5. Bleed the fuel system until air-free fuel flows out. 6. Close the nipples (1). NOTE Tightening torque: 3.5 Nm (2.6-lbf ft). 7. Stop the engine. 155/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 8. Check that there is no leakage from the fuel filter. NOTE If the engine does not run smoothly, repeat the procedure. 4.16.3 Bleeding the fuel system - X12 4.16.3.1 Bleeding the fuel prefilter - X12 WARNING HIGH-PRESSURE HAZARD High-pressure fuel may cause serious personal injury. Never disconnect a fuel line or a component from a fuel pump that is to be bled. The fuel is highly pressurized and can penetrate the skin. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid fuel spillage, place a receptacle underneath the filter. NOTE Take care of the excess fuel, and dispose of it in an environmentally responsible way. Bleed the system if it has run dry or after filter change. Bleed the fuel system with the NOTE hand pump on the fuel filter bracket. 1 2 Figure 73. Bleeding the fuel prefilter - X12 1. Clean thoroughly around the bleeder nipple (2) and hand pump (1). 2. Open the bleeder nipple (2). 3. Place a receptacle underneath the fuel prefilter. 4. Bleed the fuel system by pumping up fuel with the hand pump (1) until air-free fuel flows out. NOTE Pump rapidly, to maintain pressure in the pump. 5. Close the nipple (2). NOTE Tightening torque: 3.5 Nm (2.6-lbf ft). 156/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 6. Remove the hose. 7. Wipe dry any spilled fuel. 8. Start the engine and make sure that there is no leakage. NOTE If the engine does not run smoothly, repeat the procedure. 4.16.3.2 Bleeding the fuel filter - X12 WARNING HIGH-PRESSURE HAZARD High-pressure fuel may cause serious personal injury. Never disconnect a fuel line or a component from a fuel pump that is to be bled. The fuel is highly pressurized and can penetrate the skin. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid fuel spillage, place a receptacle underneath the filter. NOTE Take care of the excess fuel, and dispose of it in an environmentally responsible way. Bleed the system if it has run dry or after filter change. Bleed the fuel system with the NOTE hand pump on the fuel filter bracket. 2 1 Figure 74. Bleeding the fuel filter - X12 1. Clean thoroughly around the bleeder nipple (2) and hand pump (1). 2. Open the bleeder nipple (2). 3. Place a receptacle underneath the fuel filter. 4. Bleed the fuel system by pumping up fuel with the hand pump (1) until air-free fuel flows out. NOTE Pump rapidly, to maintain pressure in the pump. 5. Close the nipple (2). 157/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions NOTE Tightening torque: 3.5 Nm (2.6-lbf ft). 6. Remove the hose. 7. Wipe dry any spilled fuel. 8. Start the engine and make sure that there is no leakage. NOTE If the engine does not run smoothly, repeat the procedure. 4.16.4 Draining the fuel prefilter - X12 WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid fuel spillage, place a receptacle underneath the filter. NOTE Take care of the excess fuel, and dispose of it in an environmentally responsible way. 1 2 Figure 75. Fuel prefilter - X12 1. Stop the engine. 2. Close the fuel tap, if applicable. 158/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 3. To collect the water and fuel, put a receptacle under the fuel prefilter. 4. Open the drain valve (2) at the bottom of the water separator (1). 5. Drain the water contained in the water separator (1) into the receptacle. NOTE Do not drain the water separator (1) completely. 6. Tighten the drain valve (2) and open the fuel tap, if applicable. 7. If needed, bleed the system. For more information, see sections about "Bleeding the fuel system". 8. Start the engine. 9. Check that there is no leakage from the fuel prefilter. 159/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.16.5 Changing the fuel prefilter - QSB 6.7 and B 6.7 WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. To collect the water and fuel, put a receptacle under the fuel prefilter. Store the used filter NOTE in a suitable container and dispose of it in an environmentally responsible way. NOTE Working with the fuel system requires special cleanliness. 1 2 3 4 5 Figure 76. Fuel prefilter - QSB 6.7 and B 6.7 1. Close fuel taps, if applicable. 2. Clean thoroughly around the fuel prefilter (4) and the mounting bracket (1). 3. Disconnect the cable (5) from the fuel prefilter (4). 4. Remove the filter (4) from the mounting bracket (1). Put the used filter (4) in a suitable container and dispose of it in an environmentally responsible way. 5. Install a new seal (2) to the new filter. 6. Lubricate the new seal (2) with diesel fuel. 160/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 7. Lubricate the seal (3) on the new filter with diesel fuel. 8. Screw the new filter onto the mounting bracket (1) by hand, until it bottoms. Tighten a further 1/2–2/3 turns. 9. Reconnect the cable (5) to the fuel prefilter (4). 10. Open fuel taps, if applicable, and bleed the fuel system. For more information, see sections about "Bleeding the fuel system". 11. Start the engine and make sure that there is no leakage. 161/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.16.6 Changing the fuel prefilter - X12 WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. To collect the water and fuel, put a receptacle under the fuel prefilter. Store the used filter NOTE in a suitable container and dispose of it in an environmentally responsible way. NOTE Working with the fuel system requires special cleanliness. 1 2 3 4 6 7 8 5 Figure 77. Fuel prefilter - X12 1. Close fuel taps, if applicable. 2. Clean thoroughly around the fuel prefilter (3) and the water separator (6). 3. Disconnect the cables (8) from the water trap sensors (7). 162/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4. Remove the fuel prefilter (3) from the mounting bracket (1). 5. Remove the the water trap (6) from the filter (3). Put the used filter in a suitable container and dispose of it in an environmentally responsible way. 6. Clean the water trap (6) with a soft rag. Check that the drain hole (5) in the water trap (6) is not blocked. 7. Install a new O-ring (4) on the water separator (6). 8. Lubricate the O-ring (4) with diesel fuel. 9. Reinstall the water trap (6) to the new filter (3). 10. Lubricate the O-ring (2) with diesel fuel. 11. Screw the new filter (3) onto the mounting bracket (1) by hand, until it bottoms. Tighten a further 1/2–2/3 turns. 12. Reconnect the cables (8) to the water trap sensors (7). 13. Open fuel taps, if applicable, and bleed the fuel system. For more information, see sections about "Bleeding the fuel system". 14. Start the engine and make sure that there is no leakage. 4.16.7 Changing the AdBlue filters, Cummins 4.16.7.1 Changing the AdBlue pump filter This section is applicable for machines that are equipped with Volvo or Cummins QSB 6.7 engines. WARNING CORROSIVE SUBSTANCE HAZARD The AdBlue solution may cause skin and eye damage. It is corrosive towards certain metals such as copper and aluminum. Do not allow AdBlue solution to come in contact with other chemicals. Use safety gloves. If the AdBlue solution comes in contact with the skin or eyes, quickly wash it off with soap and water. Wait at least 2-5 min after the engine has been turned off to disconnect the battery NOTE negative terminal. By doing so, the automatic drainage and depressurization of the selective catalytic reduction system can take place. NOTE To avoid spillage, place a receptacle underneath the filter. Take care of the excess fluid and dispose of it in a safe controlled manner. Store the NOTE used filter in a suitable container, dispose of it in an environmentally responsible way. 1. Switch off the engine. 163/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 1 2. After 2-5 min, disconnect the battery negative terminal (1). 2 3. Place a receptacle under the filter cover (2). 164/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4. Remove the filter cover (2), let AdBlue run into the receptacle. 3 4 5. Press the puller, which is supplied with the filter kit (3), into the filter hole until a click is heard. 6. Pull out the old filter (4). 7. Put the used filter (4) in a suitable container, and dispose of it in an environmentally responsible way. 2 6 5 8. Install the new filter (5). 9. Install the rubber gasket (6). 165/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 2 10. Reattach the filter cover (2). 11. Tighten the filter cover (2) using a torque wrench. NOTE Tightening torque is 20 + 5 Nm (14.8 + 3.68-lbf ft). 12. Reconnect the battery negative terminal (1). 13. Start the engine. 14. Check that there are no leaks. 15. Delete any error codes. 166/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.16.7.2 Changing the AdBlue pump filter, B 6.7 and X12 WARNING CORROSIVE SUBSTANCE HAZARD The AdBlue solution may cause skin and eye damage. It is corrosive towards certain metals such as copper and aluminum. Do not allow AdBlue solution to come in contact with other chemicals. Use safety gloves. If the AdBlue solution comes in contact with the skin or eyes, quickly wash it off with soap and water. Wait at least 2-5 min after the engine has been turned off to disconnect the battery NOTE negative terminal. By doing so, the automatic drainage and depressurization of the selective catalytic reduction system can take place. NOTE To avoid spillage, place a receptacle underneath the filter. Take care of the excess fluid and dispose of it in a safe controlled manner. Store the NOTE used filter in a suitable container, dispose of it in an environmentally responsible way. 1. Switch off the engine. 1 2. After 2-5 min, disconnect the battery negative terminal (1). 3 2 3. Place a suitable receptacle under the pump (3). 167/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4. Clean around the filter cover (2) and the pump (3). 5. Unscrew the filter cover (2). Use a 46-mm socket. 3 6 4 7 5 2 6. Remove the O-ring (7). 7. Remove the frost protection device (6) and the filter (5). 8. Put the used filter (5) in a suitable container and dispose of it in an environmentally responsible way. 9. Wipe the pump (3) and threads (4) clean. 10. Fit the new filter. 11. Fit the new frost protection device. 12. Lubricate the threads (4). 13. Lubricate the new O-ring with AdBlue. 14. Fit the new O-ring in the filter cover (2). 15. Check that the frost protection device and O-ring are correctly fitted. 16. Reattach the filter cover (2) on the pump (3) and tighten to 80 Nm (59 lbf ft). 17. Reconnect the battery negative terminal (1). 4.16.7.3 Changing the AdBlue tank filter WARNING CORROSIVE SUBSTANCE HAZARD The AdBlue solution may cause skin and eye damage. It is corrosive towards certain metals such as copper and aluminum. Do not allow AdBlue solution to come in contact with other chemicals. Use safety gloves. If the AdBlue solution comes in contact with the skin or eyes, quickly wash it off with soap and water. Wait at least 2-5 min after the engine has been turned off to disconnect the battery NOTE negative terminal. By doing so, the automatic drainage and depressurization of the selective catalytic reduction system can take place. 168/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions NOTE To avoid spillage, place a receptacle underneath the filter. Take care of the excess fluid and dispose of it in a safe controlled manner. Store the NOTE used filter in a suitable container, dispose of it in an environmentally responsible way. 1. Switch off the engine. 1 2. Disconnect the battery negative terminal (1) after 2-5 min. 5 6 3 2 4 2 7 3. Disconnect the coolant supply and return (2). 4. Disconnect the AdBlue supply and return (3). 5. Disconnect the electrical connector (4). NOTE To prevent contamination, disconnect the connector (4) last. 6. To avoid contamination, cover the connector (4) and the exposed inlets and outlets (2 and 3) on the AdBlue tank assembly. 7. Loosen and remove the screws (5). 8. Remove the attachment plate (6). 169/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 9. Lift out the AdBlue tank assembly (7) from the tank. AdBlue tank assembly and filter - X12 11 10 9 8 AdBlue tank assembly and filter - QSB 6.7 and B 6.7 11 10 9 8 10. Remove the clip (8) from the inlet port. 11. Remove the AdBlue tank filter (9) from the inlet pipe (10). 12. Remove the O-ring (11). 13. Reverse the procedure to install the new AdBlue tank filter and O-ring. 170/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.16.8 Changing the Cummins engine oil WARNING HOT FLUID HAZARD Hot engine oil may cause serious personal injury. To avoid burns, be careful when opening the drain plug. NOTE Drain the oil when the engine is at the operating temperature, at least 65°C (149°F). NOTE Working with the oil system requires special cleanliness. Put the used filter in a suitable container, and dispose of it in an environmentally NOTE responsible way. 1 1 QSB 6.7 - EU stage 3a / US tier 3 QSB 6.7 - EU stage 4 / US tier 4f 1 1 B 6.7 - EU stage 5 / US tier 4f QSM 11 171/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 1 X12 1. To avoid spillage, place a receptacle underneath the drain hole. 2. Unscrew the drain plug (1). 3. Allow the oil to run out. 4. Check that the seal is undamaged. If necessary, renew the seal. 5. Fit the drain plug. 6. Tighten up the drain plug (1). 7. Remove the filler cap (2). 2 3 8. Pour oil through the opening. 9. Check the oil level using the dipstick (3). 10. Fill up to the maximum indicator level. 11. Refit the filler cap (2). 12. Start the engine. 13. Check that there is no warning symbol for low oil pressure on the display. 14. Check that there are no leaks from the drain plug or the oil filter. 15. Turn off the engine and check the oil level again after 5 min. 172/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.16.9 Changing the Cummins engine oil filter WARNING HOT OIL AND HOT SURFACES HAZARD Risk of personal injury. Use protective gloves. NOTE Working with the oil system requires special cleanliness. Put the used filter in a suitable container, dispose of it in an environmentally responsible NOTE way. 1 1 QSB 6.7 - EU stage 3a / US tier 3 QSB 6.7 - EU stage 4 / US tier 4f 1 1 B 6.7 - EU stage 5 / US tier 4f QSM 11 173/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 1 X 12 1. To avoid spillage, place a receptacle underneath the filter (1). 2. Clean around filter on the outside of the filter. 3. Remove and dispose of the old filter (1). 4. Clean the mating surface of the filter housing. 5. Lubricate the rubber seal with new oil and fit a new filter. 6. Secure the filter by hand. NOTE Never use tools. The filter could get damaged and the circulation obstructed. 7. Top up with engine oil, start the engine, and let it run for 20–30 s. 8. Turn off the engine, check the oil level, and top up as required. See Fuel and oil recommendations (page 249). 9. Check the seal around the oil filters. 174/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.16.10 Changing the Cummins fuel filter NOTE Working with the fuel system requires special cleanliness. Put the used filter in a suitable container, dispose of it in an environmentally responsible NOTE way. 1 1 QSB 6.7 - EU stage 3a / US tier 3 QSB 6.7 - EU stage 4 / US tier 4f 1 1 B 6.7 - EU stage 5 / US tier 4f QSM 11 1 X12 1. To collect any spilled fuel, place a receptacle under the fuel filter (1). 2. Clean around the fuel filter (1). 3. Remove the fuel filter (1) with a suitable filter remover. 4. Remove the thread adapter seal. Clean the gasket surface on the fuel filter head. 175/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 5. Lubricate the fuel filter gasket with clean engine oil. 6. Fill the new fuel filter (1) with clean diesel fuel. 7. Install the new thread adapter seal (included in the filter kit). 8. Install the filter (1) on the filter head. 9. Turn the filter (1) until the gasket contacts the filter head surface. 10. Tighten the fuel filter (1) in accordance with the instructions of the filter manufacturer. 11. Bleed the fuel system. See "Bleeding the Cummins fuel system". 12. Start the engine, check that there is no leakage. NOTE If the engine is not working properly, bleed the system again. 176/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.16.11 Checking the Cummins drive belt NOTE If the drive belt is oily, worn, or damaged, it must be replaced. 2 2 1 3 Figure 78. QSB 6.7 - EU stage 3a / US tier 3 2 2 1 3 Figure 79. QSB 6.7 - EU stage 4 / US tier 4f 177/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 2 1 2 3 Figure 80. B 6.7 - EU stage 5 / US tier 4f 2 1 2 3 Figure 81. QSM 11 178/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 2 1 3 Figure 82. X12 1. Check the belt (1) for cracks and wear. 2. Check that the automatic belt tensioners (3) function and maintain the tension in the belt. 3. Check the idler pulleys (2) for damage. 179/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.16.12 Checking the Cummins cooling fan WARNING EQUIPMENT: FAN DAMAGE HAZARD Risk of personal injury or equipment damage If a fan blade is damaged, it can cause the fan to fail, which can cause personal injury or property damage. Do not rotate the engine by pulling or prying on the fan. Use the accessory drive shaft or the crankshaft barring tool to rotate the crankshaft. WARNING EQUIPMENT: BENT FAN BLADE HAZARD Risk of personal injury or equipment damage A bent fan blade can cause the fan to fail, which can cause personal injury or property damage. Do not straighten a bent fan blade or continue to use a damaged fan. NOTE The fan must be visually inspected daily. Replace a damaged fan with a fan that has an identical part number. Any other fan must NOTE be approved by Cummins to be covered under warranty. 180/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions P.N. XXXXXX Figure 83. Original fan part number, Cummins 1. Check for cracks, loose rivets. 2. Check for bent or loose blades (1). 1 3. Check that the fan is securely mounted. 4. Tighten the capscrews if necessary. NOTE Refer to the engine manufacturer's specifications for capscrew torque. 181/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.16.13 Checking the Cummins vibration damper WARNING RISK OF DAMAGE TO THE MACHINE The silicone fluid in the vibration damper will harden after an extended operating time, and will cause the damper to not function properly. This can lead to serious engine or drive line failure. Check the condition of the vibration damper regularly, follow the regular service schedule. Service must be performed by an authorized service technician. If service or replacement of parts is needed, contact your local dealer for more information. 1 2 Figure 84. Vibration damper 1. Check the inner part (1) of the vibration damper for cracks, dents, or silicone fluid loss. 2. Check the outer part (2) of the vibration damper for cracks, deformations, or raising of the damper cover plate. 4.16.14 Checking the Cummins water pump WARNING RISK OF DAMAGE TO THE MACHINE A leaking or damaged water pump can lead to serious engine or drive line failure. Check the condition of the water pump regularly, follow the regular service schedule. Service must be performed by an authorized service technician. If service or replacement of the water pump is needed, contact your local dealer. 182/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 2 1 Figure 85. Water pump Check the drainage hole (2) on the water pump (1) for leakage of coolant or oil. If dripping or a steady flow of coolant or oil is found, the water pump (1) must be NOTE replaced. Contact your local authorized dealer for more information. If the drainage hole (2) is clogged, a small screwdriver or similar tool can be used to remove any debris. NOTE Always make sure that the drainage hole (2) on the water pump (1) is clear. 4.17 Maintaining the DANA transmissions 4.17.1 Changing the DANA transmission oil WARNING HOT OIL HAZARD Risk of serious personal injury. To avoid burns, use care in opening the drain plug. NOTE Replace the oil when it is at the operating temperature, 82–93° C (180–200° F). NOTE Working with the oil system requires special cleanliness. NOTE Take care of the excessive oil and dispose of it in an environmentally responsible way. 183/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 1 1 DANA TE14 DANA TE17 1 DANA TE30 (not available for all models) 184/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 2 3 Figure 86. DANA TE17 1. Place a receptacle underneath the drain plug (1). 2. Clean around the drain plug (1). 3. Remove the drain plug (1) and allow the oil to run out. 4. Check the seal on the drain plug (1). 5. Refit the drain plug (1). 6. Remove the filler cap (2). 7. Fill with the recommended oil to the maximum level indicator on the dipstick (3). For more information, see Recommended fluids and lubricants (page 250). 8. To fill the torque converter and pipes, turn on the engine. Let it idle for 1 min. 9. Check the level of the oil while the engine runs. 10. Fill up with oil to the minimum indicator. 11. Check the oil level again when the engines operating temperature has reached 82-93° C (180-200° F). Fill to the maximum level indicator. 185/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.17.2 Changing the DANA transmission oil filter RISK OF PROPERTY DAMAGE NOTICE Handle the filter with care. Do not fit a damaged filter. Make sure that no dirt or sludge penetrates into the transmission. NOTE Working with the oil system requires special cleanliness. NOTE To avoid spillage, place a receptacle under the filter. Take care of the excessive oil and dispose of it in a safe controlled manner. Put the used NOTE filter in a suitable container, and dispose of it in an environmentally responsible way. 4.17.2.1 DANA TE17 transmission oil filter 1 Figure 87. DANA TE17 1. Clean the outside of the filter unit. 2. Loosen the filters by hand or with a filter wrench. 3. Remove the filters. 4. Check the new filters and the seals. 5. Lightly lubricate the seals with oil. 6. Clean the mating surface of the filter housing (1). 7. Screw on the filters until the seal is in contact with the filter housing (1). Tighten another half turn, no more. 8. Start the engine, check that there are no leaks. 9. Check the oil level with the dipstick. 10. Switch off the engine. 186/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.17.2.2 DANA TE14 and TE30 transmission oil filter 1 2 3 4 Figure 88. DANA TE14 and TE30 1. Clean around the filter cover (1) and filter housing (3). 2. Remove the drain plug (4). 3. Remove the filter cover (1) with a suitable filter remover. 4. To collect any excess oil, place the filter (2) and the cover (1) in a suitable container. 5. Clean inside the filter (2) with a lint free cloth. 6. Inspect and lubricate the O-ring on the drain plug (4). 7. Insert the drain plug (4) again. 8. Insert the new filter into the filter cover (1). 9. Lubricate the O-ring on the filter cover (1) with clean transmission oil. 10. Screw the filter cover (1) back onto the filter housing (3). 11. Tighten the cover (1) with 35 Nm. 12. Start the engine. 13. Check that there are no leaks. 14. Check the oil level with the dipstick. 15. Switch off the engine. 187/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.17.3 Checking the DANA transmission breather 1 1 DANA TE14 (not available for all models) DANA TE17 1 DANA TE30 (not available for all models) 1. Clean the transmission breather (1) with a cloth. 2. Check that the transmission breather (1) is not clogged. 3. Replace if necessary. Unscrew the transmission breather (1) and replace with a new transmission breather. 188/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.17.4 Calibrating the DANA transmission 4.17.4.1 Heating up the DANA transmission WARNING RUN OVER HAZARD If the parking brake fails, the machine can start moving. If so, it can cause death, severe injury, and property damage. Check the parking brake and replace worn disk pads before heating and calibration. Heat up the transmission before the calibration procedure. When the heating mode is selected, the following functions are possible: • Forward or reverse can be selected when the parking brake is activated • Highest gear is selected automatically 1. Go to Machine overview > DANA transmission. 2. From the top-right panel, select Heating mode. 189/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 3. Make sure that you activate the parking brake and that it works properly. 4. If the parking brake fails, use the foot brake. 5. Select driving direction forward. 6. Run the engine at maximum RPM. 7. After about 15 s at maximum RPM, select neutral. 8. Continue at maximum RPM. 9. Keep the transmission in neutral at maximum RPM for another 15 s. The figure shows the heating cycle for the transmission. 10. Release the speed pedal and allow the engine to slow down to idle. 11. Repeat the procedure from step 3 until the transmission has reached a temperature of 80°C...90°C (176°F...190°F). 12. You can now calibrate the transmission. 190/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions When the converter output temperature exceeds 120°C (248°F), the engine is reduced to NOTE half RPM. 4.17.4.2 Activating the DANA transmission calibration WARNING RUN OVER HAZARD If the parking brake fails, the machine can start moving. Never leave your seat during calibration. If the parking brake fails, you can use the foot brake. The transmission calibration determines the amount of oil that is required to fill the clutch until the clutch starts to transfer torque. To activate the transmission calibration, the following conditions must be met: • Parking brake must be activated and work properly • Transmission oil temperature must exceed 70°C (150°F) • Engine RPM must be 800 RPM ± 200 RPM 1. Go to Machine overview > DANA transmission. 2. To enter the PIN code (2), press the panel (1). 1 2 3. Enter the service PIN code. 4. From the drop-down list, select Transmission calibration. 191/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 5. To start calibration, tap on Select. The calibration automatically calibrates all the clutches in the transmission. The calibration takes about 20 min to perform. If any problems occur during calibration, an error code appears on the display. 6. After finishing the calibration, turn off the ignition. 7. Wait for 5–10 s. 8. Turn on the ignition. After the restart, the new settings for gear shifting are in use. Remember to select "OFF" in the request code menu when you are finished with the NOTE calibration. 4.18 Maintaining the ZF transmissions This chapter includes the maintenance instructions for the ZF transmissions. 192/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.18.1 Changing the ZF transmission oil WARNING HOT FLUID HAZARD Risk of serious personal injury. Avoid spilling hot oil and do not touch hot surfaces. NOTE Replace the oil when it is at the operating temperature. NOTE Working with the oil system requires special cleanliness. 2 1 Figure 89. Changing the transmission oil 1. Place a suitable container under the drain plug. 2. Clean around the drain plug (1). 3. Remove the drain plug. 4. Allow the oil to drain. 5. Clean the drain plug. 6. Replace the O-ring on the drain plug. 7. Remove the filler cap (2). 8. Fill with the recommended oil to the maximum level indicator on the dipstick (2). 9. Run the engine on idle for 1 min to fill the torque converter and pipes. 10. Check the oil level when the engine has run for 1 min and then refill to the minimum indicator level. 11. Check the oil level again when the transmission has reached operating temperature. Fill to the maximum indicator level. See maintenance data for volume. 12. Put the dipstick and the filler cap (2) back again. 193/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.18.2 Changing the ZF transmission oil filter RISK OF PROPERTY DAMAGE NOTICE Handle the filter with care. Do not fit a damaged filter. Make sure that no dirt or sludge penetrates into the transmission. NOTE Working with the oil system requires special cleanliness. 4.18.2.1 Changing the ZF 191 transmission oil filter 1. Clean the outside of the filter unit. 2. To collect any excess oil, place a receptacle underneath the filters (1). 1 3. Loosen the filters (1) by hand or with a filter wrench. 4. Remove the filters (1). 5. Check the new filters (1) and the seals. 6. Lightly lubricate the seals with oil. 7. Screw on the filters (1) until the seal is in contact with the filter housing. Tighten another half turn, no more. 8. Start the engine, check that there are no leaks. 9. Check the oil level with the dipstick. 10. Switch off the engine. 4.18.2.2 Changing the ZF 261/311 transmission oil filter 1. Clean the outside of the filter unit. 2. Place a receptacle underneath the filters (1) to collect any oil. 194/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 1 3. Loosen the filters (1) by hand or with a filter wrench. 4. Remove the filters (1). 5. Check the new filters (1) and the seals. 6. Lightly lubricate the seals with oil. 7. Screw on the filters (1) until the seal is in contact with the filter housing, tighten the filter (1) one half turn by hand at the most. Cleaning the ZF 261/311 transmission oil strainer 8. Clean the transmission oil strainer (2), if available. 9. Carefully clean the outside of the oil strainer unit. 10. Place a receptacle under the oil strainer (2) to collect any oil. 2 11. Loosen the oil strainer (2). NOTE Make sure that no larger particles (metal pieces or similar) are stuck to the oil strainer (2). 12. Clean the oil strainer (2). 13. Slightly lubricate the oil strainer (2). 14. Fit the oil strainer (2). 15. Start the engine and check that there are no leaks. 16. Check the oil level with the dipstick. 17. Switch off the engine. 195/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.18.3 Checking the ZF transmission breather 1 Figure 90. ZF transmission breather 1. Clean the transmission breather (1) with a cloth. 2. Check that the transmission breather (1) is not clogged. 3. Replace if necessary. 4.18.4 Calibrating the ZF transmission 4.18.4.1 Heating up the ZF transmission WARNING UNCONTROLLED MOVEMENT HAZARD Risk of personal injury or damage to the machine. Only the service brake is in use. Use chocks to block the wheels. Heat up the transmission before the calibration procedure. 1. To monitor the transmission temperature, go to the Machine overview> 1 Transmission page. The transmission temperature displays on the right on the MD4 display (1). 2. Select manual gear shifting. 3. Select the highest gear. 4. Apply the service brake by using the brake pedal in the cabin. 5. Release the parking brake. 6. Select driving direction forward. 7. Run the engine at maximum RPM. 8. After about 15 s at maximum RPM, select neutral. 196/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 9. Continue at maximum RPM. 10. Keep the transmission in neutral at maximum RPM for another 15 s. The figure shows the heating cycle for the transmission. 11. Release the speed pedal and allow the engine to slow down to idle. 12. Repeat the procedure from step 6 until the transmission has reached a temperature of 80°C...90°C (176°F...190°F). 13. You can now calibrate the transmission. When the converter output temperature exceeds 125°C (257°F), the engine is reduced to NOTE half RPM. 4.18.4.2 Activating the ZF transmission calibration The transmission calibration determines the amount of oil that is required to fill the clutch until the clutch starts to transfer torque. To activate the transmission calibration, the following conditions are required: • Parking brake must be activated and work properly • Transmission oil temperature must exceed 70°C (158°F) 1. Start the calibration by pressing AEB on the Transmission page. AEB = Automatisiertes Ermitteln der Befüllparameter (Automated determination of the filling parameters). 197/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 2. The calibration takes 15–20 min. The grey progress bar shows when the calibration is complete. Click OK. 3. Switch off ignition. 4. Wait 5–10 s. before turning on the machine again. 5. Switch the machine back on. The new values are in use now. 4.19 Maintaining the drive axle 4.19.1 Checking the drive axle oil level NOTE Check the oil level in both hubs and the differential. 1. Park the machine on level ground. 2. Make sure the hub level mark (1) is horizontal and you can read the text "oil" on the hub. 2 1 3. Open the filling and level plugs (2) and check the oil level. 198/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions • If oil seeps out of the filling and level plug, there is enough oil. NOTE If a large amount of oil comes out, check for internal leakage. • If no oil seeps out, the oil level must be checked. NOTE Minimum oil level is at least 1 cm from the edge of the filling and level hole. 4. If there is not enough oil, refill oil to at least the minimum level. 5. Tighten the filling and level plug (2). 4.19.2 Changing the drive axle oil NOTE Change the oil in both hubs and the differential. NOTE Take care of the excess oil and dispose of it in an environmentally responsible way. Park the machine on level ground. 4.19.2.1 Changing the drive axle oil - hub 3 2 1 1. Make sure that the drain hole (3) is located in the highest position on the wheel. 2. Clean around the drain hole (3) and plug. 3. Remove the plug from the drain hole (3). 4. Fix a suitable hose in the drain hole (3). Use a hose that fits the threads in the the drain hole (3). 5. To reposition the drain hole (3), carefully drive the machine in any direction. Make sure that the drain hole (3) is located in the lowest position on the wheel. 6. Drain the oil through the hose into a receptacle. 7. Refit the plug into the drain hole (3). 8. Place the machine with the level mark (1) and the text "oil" in horizontal position on the hub. 9. Open the filling and level plug (2). 10. Fill the drive axle through the filling and level plug (2). 199/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions NOTE Minimum oil level is at least 1 cm from the edge of the filling and level hole. 11. Close the filling and level plug (2). 12. Repeat the procedure on the opposite side. 4.19.2.2 Changing the drive axle oil - differential 1 2 1. Clean around the drain plug (2). 2. Remove the drain plug (2). 3. Drain the differential through the drain plug (2). Drain the oil at operating temperature or overnight, as the oil is of high viscosity. 4. Refit the drain plug (2). 5. Open the filling and level plug (1). 6. Fill the drive axle through the filling and level plug (1). NOTE Minimum oil level is at least 1 cm from the edge of the filling and level hole. 7. Close the filling and level plug (1). 4.19.3 Checking the drive axle breather 1 1. Check that the drive axle breather is not clogged. 2. Replace if necessary. 200/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions Unscrew the drive axle breather (1) and replace with a new drive axle breather. 4.19.4 Measuring the parking brake pressure 1. Connect a pressure gauge (0–300 bar or 0–5000 psi) to the measuring point (1) marked PRM on the accumulator charging valve. 1 2. Start the engine and let it idle. 3. Release the parking brake. 4. Read the pressure. Check according to the machine card. 201/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.19.5 Adjusting the parking brake WARNING MOVING VEHICLE HAZARD. The machine can move if not parked on level ground and with the wheels firmly secured. If the machine moves, there is a risk of serious injury or death. Park the machine on level ground and firmly secure the wheels. Adjusting the parking brake is required after installing new brake pads or brake disc, after all repairs, and to improve braking performance. Adjust the parking brake when it is cold. The parking brake must be in the released condition while adjusting. 9 1 2 7 8 3 6 5 4 Figure 91. Parking brake 1. Spring 6. Dust cap 2. Lock ring 7. Screw cap 3. Locknut 8. Adjusting screw 4. Seal 9. Bleeder screw 5. Piston sealing 1. Park the machine on a level surface. NOTE To prevent the vehicle from moving, block the wheels. 2. To release the parking brake, press the parking brake switch. NOTE The parking brake pressure must be correct and the ignition must be on. 3. Remove the screw cap (7). 4. Loosen the locknut (3). Turn the adjusting screw (8) clockwise until both brake pads contact the brake disc. 5. Turn the adjusting screw counterclockwise to set the total clearance to 1–0.5 mm (0.04– 0.02 in). 6. Tighten the locknut (3). 7. Recheck the clearance. 202/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.19.6 Manually releasing the parking brake DANGER RUN OVER HAZARD If the engine is running, the service brake is working. If the engine is not running, only the parking brake is working. If it is released, the machine has no brakes. Risk of serious personal injury or death. To prevent the machine from moving, block the wheels. 3 8 7 Figure 92. Manually releasing the parking brake If hydraulic pressure is not available, the parking brake can be manually released as follows: 1. To prevent the machine from moving, block the wheels. 2. Remove the screw cap (7). 3. Loosen the locknut (3). 4. Turn the adjusting bolt (8) counterclockwise until the brake is released. 5. Tighten the locknut (3). Install and hand-tighten the screw cap. Before you return the machine to operation, adjust the parking brake, see Adjusting the NOTE parking brake (page 202). 203/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.19.7 Bleeding the parking brake When you loosen the hydraulic hose of the parking brake, bleed the parking brake to remove the air from the system. To obtain the correct functionality, all air in the brake cylinder must be vented out. 9 Figure 93. Bleeding the parking brake 1. Attach a clear tube to the bleeder screw (9). Insert the other end of the tube in a receptacle. 2. Apply hydraulic pressure to the parking brake. 3. Loosen the bleeder screw (9). 4. Continue to apply pressure until no air bubbles appear in the hydraulic oil in the receptacle. 5. Tighten the bleeder screw and release the pressure. 204/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.20 Maintaining the steer axle 4.20.1 Checking the steer axle bearings Check the wheel and spindle bearings regularly and always when the tires are replaced. It is important to check the steer axle bearing during running in. It is important that there is no play in the steer axle bearings, as they are exposed to heavy loads and shocks. Any play results sooner or later in bearing breakdown. Bearings are adjustable. For more information, see Adjusting the wheel bearings (page 206). Play in link bearings are acceptable to 1–2 mm (0.04–0.08 in) for each bearing. Link NOTE bearings are not adjustable. 2 3 1 Figure 94. Checking the steer axle bearings 1. To lift each side, use a jack. See Positioning the jack (page 75). 2. Check the plays when the wheel rises from the ground. 3. Check the spindle bearings by lifting the wheel with a crowbar (1). See Adjusting the spindle bearings (page 207). 4. Check the wheel bearings by prying the wheel vertically (2). See Adjusting the wheel bearings (page 206). 5. Check the link bearings by turning the wheels in the steering direction (3). 205/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.20.2 Adjusting the wheel bearings 5 4 3 2 1 NOTE For instructions on how to jack up the machine, see Positioning the jack (page 75). 1. Remove bearing cover (1) and gasket (2). 2. Check that the grease is clean and free from particles. If the the grease is not clean or free from particles, the reason for the play may be a damaged bearing. 3. Loosen the outer nut (3) and remove the lock washer (4). 4. Tighten the inner nut (5). First tighten the nut to 500 Nm (368. 78-lbf ft). 5. Rotate the hub ten revs anti-clockwise. The hub should only offer light resistance when rotating. A noise or irregular rotation NOTE means that the bearings are damaged. If so, the bearings must be replaced. 6. Repeat steps 4 and 5 once. 7. Tighten the inner nut (5) again to achieve the correct torque of 500 Nm (368. 78-lbf ft). 8. Mount the lock washer (4). 9. Tighten the outer nut (3) to achieve the correct torque of 300 Nm (162.3-lbf ft). 10. Lock the outer nut (3) using the lock washer (4). 11. Refit the gasket (2) and bearing cover (1). 206/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.20.3 Adjusting the spindle bearings 2 3 4 5 1 6 NOTE For instructions on how to jack up the machine, see Positioning the jack (page 75). The steer wheel may have to be removed to access the spindle and bearing. For NOTE instructions on how to remove the steer wheel, see Dismantling the steer wheels, wheels with clamp units (page 87). 1. Remove the steering link (1). 2. Remove the bearing cover (2) and gasket (3). 3. Check that the grease is clean and free from particles. If the the grease is not clean or free from particles, the reason for the play may be a damaged bearing. 4. Unscrew the upper nut (4) completely. Otherwise, you cannot reach 1000 Nm (737.6-lbf ft) with the lower nut. 5. Loosen the lock washer (5). 6. Check that the lower nut (6) is tightened. Tighten the stop screw with 35 Nm and Loctite. The correct torque is 1000 Nm (737.6-lbf ft). 207/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions The lower nut (6) is not used to preload the bearing. All bearing preload is adjusted with NOTE the upper nut (3). 7. Tighten the upper nut (4). The correct torque for KM12 and KM17 is 300 Nm (221.3-lbf ft), and for KM22 is 350 Nm (258.1-lbf ft). 8. Rotate or swing the spindle ten times to the end positions (left-right-left-right, and so on). 9. Tighten the upper nut (4) again. The spindle should only offer light resistance when turning. NOTE A noise or irregular rotation means that the bearing is broken. Replace the bearing. 10. Lock the upper nut (4) with the lock washer (5). 11. Refit a new gasket (3). 12. Refit the bearing cover (2). 13. Fill the bearing house with grease. 4.21 Maintaining the hydraulic system 4.21.1 Changing the hydraulic oil The filter should be changed when the hydraulic oil is changed. 2 1 Figure 95. Changing the hydraulic oil 1. Drain out the oil through the drain plug (1), using a receptacle. NOTE If the filters have been removed, soak up the oil through the filter housings. 2. Check the tank for cracks and signs of leakage. 3. Inspect the bottom of the tank through the inspection hatches for any deposits. 4. Clean the tank if needed. 5. Assemble the filters and covers if removed. 6. Fill up the hydraulic oil through the filling cap (2) in the filter cover, the oil flows through the filters. To make sure that the oil goes through the filters quickly, connect the oil pump to the NOTE filling cap (2). 208/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.21.2 Starting the hydraulic pumps RISK OF DAMAGE TO THE MACHINE NOTICE Air in the system may damage the hydraulic system. Never start the machine if the pumps are not air-bled. The machine is equipped with variable pumps. After servicing pumps or other parts of the hydraulic system, the pumps are started as follows. 1 2 3 Figure 96. Hydraulic pump 1. Disconnect hoses (1) and (2). 2. Unscrew pump plug (3). 3. Fill the three pump housings with the recommended hydraulic oil. 4. Refit the hoses (1), (2) and the pump plug (3). 5. Start the machine and raise the forks slowly. Any noise should disappear after a few seconds. If there is a consistent noise, which NOTE does not disappear after a few seconds, turn of the machine and check the hydraulic system. 209/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.21.3 Changing the hydraulic oil filter RISK OF DAMAGE TO THE MACHINE Changing the hydraulic oil filter without following these instructions may damage the NOTICE hydraulic system. Always follow these instructions when changing the hydraulic oil filter. NOTE To be able to check the oil, the forks must be lowered to ground level. The hydraulic oil filters are in the hydraulic tank. In smaller forklifts, the tank is located under the steps, in bigger ones, the tank is next to the steps. Table 13. Location of hydraulic tank and filter - smaller forklifts (SMV 10-16) Location of hydraulic tank Hydraulic oil filter components Figure 97. Hydraulic oil filter components 1. Filter cover 2. Filter housing 3. Hydraulic oil filter 4. Overflow valve 1. With smaller forklifts, remove the top step to access the hydraulic tank. 2. Clean around the filter cover (1). 210/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 3. Remove the filter cover (1). 4. Check the condition of the seal (5). 5. Remove the four screws (6) of the filter housing in the return chamber. 5 6 6. Remove the rim (7) of the filter housing. 7 7. Lift the complete filter housing from the hydraulic tank. Let it drain before disassembling it. NOTE With smaller forklifts, open the cabin door before you remove the filter housing. 8. After you have removed the filter housing, check the filter area for any deposits. 9. Remove the overflow valve (4) by pressing and turning it. 211/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 10. Take the filter from the filter housing. 11. Remove the hydraulic filter spring (8). 8 12. Remove the filters. 13. Check the filters for any deposits. Remove the deposits. 14. Clean the filter housing, using a lint free cloth. 212/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 15. Fit new filters, close with the overflow valve (4). Press and turn to the correct position. 16. Fit the filter housing in the tank. 17. Fit rim (7) and then put back the screws in the filter housing. 18. Fit the filter covers using new O-rings. 19. Fill with oil if the oil has been drained. 20. Start the machine and check for leakage. 21. Turn off the machine and check the oil level. For more information, see Starting the hydraulic pumps (page 209). 4.21.4 Hydraulic long life (HLL) filter (option) NOTE Working with the oil system requires special cleanliness. NOTE To avoid spillage, place a receptacle under the filter. Take care of the excessive oil and dispose of it in a safe controlled manner. Put the used NOTE filter in a suitable receptacle, and dispose of it in an environmentally responsible way. 4.21.4.1 Placement of the hydraulic long life (HLL) filter 1 Figure 98. Placement of filter, SMV 10-16 213/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 1 Figure 99. Placement of filter, SMV 18-60 1. Placement of the HLL filter 4.21.4.2 Checking the HLL filter 1 Figure 100. Pressure indicator The pressure indicator (1) shows the status of the HLL filter, when the machine is on. If the indicator points towards the red area between service intervals, the HLL filter must be changed. For more information, see Changing the hydraulic long life (HLL) filter (option) (page 214). 4.21.4.3 Changing the hydraulic long life (HLL) filter (option) If the pressure indicator (5) points towards the red area between service intervals, the NOTE filter must be changed. Otherwise, follow the regular service recommendations. See Regular service (page 236) 214/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 1 2 3 4 5 Figure 101. Parts of the HLL filter 1. Filter cover 4. Filter housing 2. Seal (O-ring) 5. Pressure indicator 3. Filter 1. Clean the surface around and on the filter housing (4) and cover (1). 2. To open the cover (1), turn it counterclockwise. 215/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 3. Lift the cover (1) and filter (3) slowly. NOTE Let the excess oil drip into the filter housing (4). 7 6 4. To collect any remaining oil, place the filter (3) and the cover (1) in a suitable container. 5. To remove the cover (1) from the filter (3), slide the cover outwards (6) and pull upwards (7). 6. Dispose of the filter (3) in a responsible way. 7. Remove and change the seal (2). 8 9 8. To attach the cover (1) to the new filter, move the filter downwards (8), and fit the pin in the filter. 216/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 9. Slide the cover (1) towards the middle (9). 10. Insert the new filter with the attached cover (1) into the filter housing (4). 11. To fixate the cover (1), turn it clockwise in the filter housing (4). 4.21.5 Changing the hydraulic tank breather filter 1 1 Remove breather filter, single Remove breather filter, double 2 2 Replace breather filter, single Replace breather filter, double 1. Clean around the breather filter housing. 2. Unscrew the breather filter (1). 3. Replace with a new breather filter (2). 217/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.21.5.1 Replace filter element in the breather filter housing 1 2 1 1. Clean around the filter cap (1). 2. Unscrew the filter cap (1). 3. Remove the filter cap (1). 4. Remove the filter element (2). 1 3 1 5. Add the new filter element (3). 6. Screw the filter cap (1) back on. 4.21.6 Changing the brake cooling oil NOTE Working on the oil system requires special cleanliness. 1 1. Clean around the breather filter (1). 2. Drain out the oil through the drain plug, using a receptacle placed underneath. Drain plug is found in the bottom of the tank. 3. To speed up the draining of the oil, remove the filler cap. 4. Fill up the brake cooling oil through the breather filter (1). 218/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.21.7 Changing the brake cooling oil filter NOTE Working on the oil system requires special cleanliness. To avoid spillage, place a receptacle underneath the filter. Store the used filter in a NOTE suitable container and dispose of it in an environmentally responsible way. 1 1. Clean around the filter (1). 2. Remove the old filter (1). 3. Clean the mating surface of the filter housing. 4. Lubricate the rubber seal and fit a new filter. 5. Secure the filter by hand. 4.21.8 Changing the breather filter for the brake cooling oil tank 1 1. Clean around the breather filter (1). 2. Unscrew the breather filter (1). 3. Replace with a new breather filter (1). 219/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.22 Maintaining the mast and fork carriage 4.22.1 Checking the mast and fork carriage Figure 102. Checking the mast and fork carriage Using a crowbar or a lever: 1. Check the play between the carriage and the inner mast. 2. Check the play between the inner and the outer mast. If there is a play exceeding 5 mm (0.2 in), seek the advice of the nearest authorized dealer. 220/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.22.2 Checking the fork arms WARNING RISK OF PROPERTY DAMAGE The forks can crack, become deformed, or break. Only specially trained personnel can inspect the forks for cracks. The inspection interval is one year. Only a company that is certified can do fork inspections. Do not rectify surface cracks and wear by welding, only an authorized dealer can evaluate if the forks can be repaired. 150 m m 1 1. Check the fork arms for the thickness of the fork blade, crack formation, and deformation. The wear on the fork blade must not exceed 10%, based on the stamped dimension on the fork (1). The wear on the fork blade is measured 150 mm (6 in) from the heal of the fork (1). NOTE Do not use the fork if it has any visible cracks. 2. Check for crack formations in the fork heal. Surface cracks are usually not longer than 5 mm (0.2 in). 3. If surface cracks are found, grind off about 0.5 mm (0.02 in). Use magnetic powder to check if the crack is still visible. NOTE Only a company that is certified to do fork inspections are allowed to perform this step. 4. Check the fork suspension for play. If the forks are in need of repair, contact an authorized dealer, that can evaluate if it is possible to repair the forks. 221/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.22.3 Checking the clearance between the mast and fork carriage 2 Between base plate on the outer mast and the fork carriage. 1. Lower the mast and carriage to their lowest position. Keep the mast in vertical position. 2. Check the space between the base plate on the outer mast and the fork carriage (2). NOTE The space must be 10 mm (0.4 in). 3. If the space is not 10 mm (0.4 in), readjust the lift chains equally. 4.22.4 Checking the fork shaft system (option) 3 2 1 3 Figure 103. Fork shaft system Check the fork shaft system as follows: 1. Check that the welding on the locking mechanism (1) is undamaged. 2. Check that the locking pin (2) is undamaged. 3. Check that the ball bearings, and rollers (3) are undamaged. 222/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.22.5 Checking the lift chains DANGER FALLING LOAD HAZARD If a chain breaks, the load can fall, and cause death, personal injury or damage to the machine. If in doubt, replace the chain. Always replace the full chain, do not join, or restore broken lift chains. Before inspection, clean the chains in their entire length. Always check the chains when without a load. 1 2 p + + + + p Figure 104. Lift chains For inspection intervals, see Regular service (page 236). 1. Check that the length of the chain has not increased by more than 3% compared to its original length. Measure the 25 links that are lifted first, counting from the chain wheel down towards the carriage. These 25 links are the part of the chain where the extension is the greatest and most often brake. 2. Compare with the value for the given chain sizes in the following table. 3. If the 3% limit is exceeded, replace the chain. Local regulations may require that the chain must be replaced when the length increases NOTE by 2%. Table 14. Length of 25 links of chain Parting (p) Length of 25 links for Length of 25 links at 2% Length of 25 links at 3% new chain extension extension 38.1 mm (1.5 in) 952.5 mm (37.5 in) 971 mm (38.2 in) 981 mm (38.6 in) 50.8 mm (2 in) 1270 mm (50 in) 1295 mm (51 in) 1308 mm (51.5 in) 63.5 mm (2.5 in) 1587.5 mm (62.5 in) 1619 mm (63.7 in) 1635 mm (64.37 in) 76.2 mm (3 in) 1905 mm (75 in) 1943 mm (76.5 in) 1962 mm (77.2 in) 4. Check the state of the lift chains, make sure that there are: 223/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions • No twisted pins. Normal pin position (1), and twisted pin postion (2). • No loose pins in the outside washers • No visible cracks in any washer (link section) • No visible mechanical damage • No visible cracks or damages on the chain attachments on mast and carriage • No jarring noise when the chain moves • No corrosion in the chain • No resistance when the chain bends over the chain wheel NOTE If any of these deviations are found, always replace the chains. 5. Lubricate the chains after inspection using a thin oil or lubrication spray. 4.22.6 Adjusting the lift chains NOTE Follow the same procedure, and adjust both lift chains simultaneously. 1 2 3 4 1. Adjust the lift chains with the adjusting nuts (1-4). When the mast is in the lowest position, the distance between the base plate of the outer NOTE mast, and the bottom of the carriage should be 10 mm. 2. Raise the carriage to 50 mm. 3. Place a 10 mm spacer on both sides, under the carriage. 4. Lower the carriage until it rests on the spacer. 5. Loosen the upper adjusting nut (2), and the upper locking nut (1). 6. Adjust both the lift chains with the lower adjusting nut (3), until both have the same tension. 7. Lock the lower locking nut (4), on both lift chains. 8. Raise the carriage with load. 9. Tighten the upper adjusting nut (2). 10. Lock the upper locking nut (1). 224/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.23 Maintaining the machine 4.23.1 Cleaning the machine WARNING HARMFUL SUBSTANCE HAZARD Risk of serious injury. Hot steam or aggressive degreasing agents must be used with great care. Protective clothing and eye protection must be worn. Figure 105. Cleaning the machine The length of time between cleaning sessions depends on the type of work that the machine carries out. If the machine is used in aggressive environments, it must be cleaned after it has been NOTE used. Examples of aggressive environments are: • salt water • fertilizers • chemicals • cement 1. Protect all electrical components and the air intake filter from steam, water, and so on, during cleaning. 2. Clean the areas around the oil filling and lubrication areas before servicing. 3. If using a degreasing agent when cleaning, allow sufficient time for it to penetrate. Rinse with a powerful jet of water afterwards. 4. After cleaning the engine, run the engine warm so that it dries. Check that no water that has penetrated has caused any faults. 5. Dispose of all used cleaning materials in an environmentally responsible way. 6. Always lubricate the machine after cleaning. For more information, see Lubricating the machine (page 98). 225/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.23.2 Changing the internal cabin air filter Take care when changing the air filter, the filter may contain unhealthy particles. Dispose NOTE of the old filter in an environmentally responsible way. The internal and external cabin air filters are under the dashboard on the right side of the cabin. 1. Loosen the screws to open the cabin ventilation system cover (1). The filter frame with the blue cabin air filter is revealed. 1 2. Loosen the screws on the filter frame and open it. 3. Pull out the filter gently to avoid dust in the climate unit and cabin. 4. Replace the filter in the frame. 5. Put back the filter frame and tighten the screws. 6. Close the cover on the cabin ventilation system and tighten the cover screws. 226/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.23.3 Changing the external cabin air filter Take care when changing the air filter, the filter may contain unhealthy particles. Dispose NOTE of the old filter in an environmentally responsible way. The internal and external cabin air filters are under the right-hand dashboard. 1 Figure 106. Replacing the external cabin air filter 1. To open the "cabin ventilation" system cover (1), loosen the screws. The filter frame with the blue cabin air filter is revealed. 2 2. Loosen the screws on the filter frame (2). 3. To reveal the beige external air filter, remove the frame and the internal filter. 3 4. Loosen the screws on the external air filter frame (3). 227/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 5. Replace the filter element. 6. Replace the covers and fasten the frame screws again. 7. Remount the internal filter. 8. Close the cover of the cabin ventilation system and fasten the screws. 4.23.4 Checking the battery WARNING CORROSIVE SUBSTANCE HAZARD The battery contains corrosive acid that may cause a risk for serious injury or death. Always use the necessary protective equipment. WARNING ELECTRICAL HAZARD The main disconnect does not cut the power to the alternator. To reduce the risks of electric shock and personal injury always remove jewelry and conductive material before working on the electrical system. Always disconnect the ground (minus) cable at the battery when working near or on the alternator. WARNING TIPPING OVER HAZARD Turning off the battery main switch while the machine is moving applies the parking brake and the machine may tip over. The software in the control unit can get damaged. Do not turn off the battery main switch while the engine is running. The batteries are in the battery compartment. Figure 107. Battery compartment 1. Keep the batteries clean. 2. Remove corrosion from the battery connections and check that the cable connections are tightened. 3. Lubricate the battery terminals using acid-free grease. 228/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4. Check the battery acid level. If necessary, fill with distilled battery water. 4.23.5 Changing the batteries DANGER RISK OF EXPLOSIVE GAS There can be explosive gas around the batteries, which can cause serious personal injury or death. Always disconnect the ground (minus) cable, when working with, or around the batteries. Never smoke, or have flammable, or combustible material near, when working with or around the batteries. DANGER CORROSIVE SUBSTANCE HAZARD The battery contains corrosive acid that can cause a risk for serious injury or death. Always use necessary protective equipment, such as eye-protector, and safety gloves. WARNING RISK OF ARCING AND ELECTRIC SHOCK Touching the connections during a battery change can cause arcing, and lead to serious personal injury or death. Do not touch the connections during the battery change. Always remove jewlery, and conductive material before working on the electrical system. Take care of the old batteries, and dispose of them in an environmentally responsible NOTE way. Before installing new batteries, check for damages, or leakage. Make sure that the NOTE batteries are charged. Check the cables for damages, replace if needed. Clean, and lubricate the battery poles. 229/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 1. Turn off the machine, and the ignition. 1 2. Turn off the battery main switch (1) 3. Clean the surface around the battery connections. 3 2 4. Disconnect the ground connection (2), the cable is marked with blue color. 5. Disconnect the "plus" connector (3), the cable is marked with red color. 4 230/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 6. Remove the connecting cable between the batteries (4). 7 6 5 7. Remove the locking pin for the battery attachment (5). 8. Remove the wing nut and the washer (6). 9. Remove the mounting bracket for the batteries (7). 8 10. Use the handles (8) to lift out the batteries from the battery compartment. NOTE When installing the new batteries, reverse the procedure. 231/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.23.6 Checking the weld constructions To see if there are any visible signs of damage, deformation, metal fatigue, and so on, check the mast, chassis, and all welded parts. Check them at least once a year, more often if the machine is used in shift work or in tough environments with a frequent heavy load. If you have any doubts, contact your Konecranes Lift Trucks authorized dealer. Figure 108. Weld constructions 4.23.7 Changing the windshield wipers 1 2 3 Figure 109. Windshield wipers 1. Raise the wiper from the windshield. 2. Remove the nut (1). 3. Remove the blade (2) from the arm (3). 4. Insert the new blade (2) into the arm (3). 5. Refit the nut. 6. Lower the wiper back onto the windshield. 232/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 5 Maintenance schedule Maintenance Instructions 5 MAINTENANCE SCHEDULE 5.1 Commissioning inspection Always perform maintenance, lubrication, inspection, and daily maintenance according to the instructions in this document. Before starting up the machine for the first time, check the inspection points according to the warranty commissioning report. The warranty commissioning report must be filled in and returned to Konecranes Lifttrucks within one week from starting up the machine to make the warranty valid from the commissioning date. If the warranty commissioning report is not returned within one week, the warranty is valid from the day the machine was delivered by Konecranes Lifttrucks. 5.2 Commissioning service 1. Clean the machine. 2. Tighten the wheel nuts according to correct torque. 3. Check the pressure and condition of the tires. 4. Check the windshield washer level. 5. Check the fuel level. 6. Check the coolant level. 7. Check the transmission oil level. 8. Check the engine oil level. 9. Check the hydraulic oil level. 10. Check the functioning of the service and parking brake. 11. Check the functioning of the steering system. 12. Lubricate according to the lubrication chart 13. Check the functioning and the condition of the electrical system, lighting, instruments, switches, and safety system. 14. Check the functioning of the hydraulic system. 15. Check the drive axle oil level. 16. Check the condition of batteries. 17. Check the safety and condition of the operator's cabin, fuel and oil tanks, chassis, counterweights, lifting equipment, and attachment. 18. Check the condition of the paintwork and windows. 19. Compare the specifications with the customer's acceptance of order. 20. Check the ID and warning signs, compare against available documentation. 21. Check that the operating instruction is delivered with the machine. 22. If applicable, activate TRUCONNECT® with customer information in the portal. 5.3 Daily maintenance DANGER UNCONTROLLED MOVEMENT HAZARD If the machine moves unexpectedly, it could result in personal injury, death, or damage to the equipment. To stop any unexpected movement, press the emergency stop button. 233/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 5 Maintenance schedule WARNING MOVING PARTS HAZARD There is a risk of getting trapped by moving parts of the engine. There is also a cutting risk from moving parts of the engine. Do not open the hood or perform maintenance work while the engine runs. WARNING TOXIC SUBSTANCE HAZARD Breathing diesel engine exhaust exposes you to chemicals that may cause cancer, birth defects, or other reproductive harm. Never run the engine in unventilated places. Use fume extraction. Do not keep the engine idling, except when necessary. Do not modify or tamper with the exhaust system. WARNING IGNITION HAZARD During operation, parts of the machine can become very hot. If there are flammable or combustible materials, on or near any hot surfaces on the machine, there is a risk of fire. Examples of such materials are paper, or saw dust. Before taking the machine into operation, make sure that there are no flammable or combustible materials on or around any hot surfaces. Examples of hot surfaces can be the turbo, exhaust pipe, DPF, and so on. Visually inspect the machine for damage while going through the checklist during daily NOTE maintenance. NOTE Check the condition of the safety and information labels, replace if needed. After performing the daily maintenance tasks, start the machine and listen for any NOTE abnormal noise from the engine and transmission. If any abnormal noise is heard, contact maintenance personnel. Separate instructions on how to perform each task, can be found in the Operating NOTE Instructions. 1. Check the battery main switch 2. Check the wheel nuts and clamps. 3. Check the tire pressure and the condition of tires and rims (visible cracks and damages). 4. Check the engine oil level. 5. Check the transmission oil level. 6. Check the coolant level in all tanks. 7. Check the hydraulic oil level. 8. Check the brake cooling oil level (option, not available for all models). 9. Check the grease level in the two reservoirs for the automatic lubrication system (option). NOTE If automatic lubrication is installed (optional), there can be one or two tanks. 10. Check the MD4 warnings for clogging of engine air filter. 11. Check the windshield washer fluid level. 12. Check the fuel level. 13. Check the AdBlue level (when applicable). 14. Check the soot level (when applicable). 234/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 5 Maintenance schedule Maintenance Instructions 15. Check that the mirrors are clean and adjust them to make sure of good visibility. 16. Check that the windows are clean. 17. Clean the rearview camera (option). 18. Check for visual signs of leakage, around and under the machine 19. Check the seat adjustments and adjust if needed. 20. Check the steering wheel adjustments. 21. Check the service brake functionality. 22. Check the parking brake functionality. 23. Check the functionality of the steering system. 24. Check the hydraulic functions. 25. Check the electrical functions. 26. Check the climate unit (option) settings. 5.4 Maintenance points after the first 150 operating hours 1. Change the engine oil. 2. Change the engine oil filter. 3. Change the transmission oil. 4. Change the transmission oil filter. 5. Lubricate the machine. 6. Check the drive axle oil level. 7. Check the coolant level. 8. Check the coolant freezing point. 9. Check the engine drive belt. 10. Check the hydraulic oil level. 11. Check the battery condition. 12. Check the exhaust system. 13. Check (clean if necessary) the engine air filter and air intake. 14. Check the mast and carriage. 15. Check pressure and condition of the tires. 16. Tighten the wheel nuts to the correct torque. 17. Check the steer axle bearings. 18. Check and tighten the bolted joints. 19. Check the condition and functioning of the electrical system, lighting, instrumentation, switches, and safety system. 20. Check the safety and condition of the cabin, tanks, chassis, counterweights, lifting equipment, and attachments. 21. Check the condition of the paintwork and windows. 22. Check the functioning of the service and parking brake. 23. Check the functioning of the steering system. 24. Check the functioning of the hydraulic system. 25. If applicable, check that TRUCONNECT® functions properly. 235/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 5 Maintenance schedule 5.5 Regular service Table 15. Machine maintenance Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Contact your local authorized dealer for updates about the X X X X latest changes and service information Cleaning the machine X Lubricating hinges X X X X Changing the cabin air filters X X X X Tightening the bolted joints X X X X X Checking the battery X X X X Checking the condition of paintwork and windows X X X X Checking the safety and condition of the cabin, tanks, X X X X body, counterweights, lifting equipment, and attachment Checking the machine plate and the warning stickers X X X X Checking the weld constructions X X Checking for leaks X X X X Table 16. Engine maintenance Volvo TAD 581, 881, 883 VE Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1) X X X Changing the engine oil filter 1) X X X Draining the fuel prefilter X X X X X Draining the extra fuel prefilter (if applicable X X X X X Changing the fuel filter X X X Changing the fuel prefilter X X X Changing the extra fuel prefilter (if applicable X X X Changing the AdBlue-pump filter X X Changing the AdBlue breather filter X X Changing the AdBlue armature (level) filter X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X Checking the freezing point of the coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the coolant hoses X X X Replacing the drive belts X X 236/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 5 Maintenance schedule Maintenance Instructions Table 16. Engine maintenance Volvo TAD 581, 881, 883 VE (Continued) Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Checking for leaks X X X X Checking and adjusting the valve clearance X X Checking the cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of VDS4.5 1) More often if necessary. Table 17. Engine maintenance Volvo TAD 1181 VE Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1) X X X Changing the engine oil filter 1) X X X Draining the fuel prefilter X X X X X Draining the extra fuel prefilter (if applicable X X X X X Changing the fuel filter X X X Changing the fuel prefilter X X X Changing the extra fuel prefilter (if applicable X X X Changing the AdBlue-pump filter X X Changing the AdBlue breather filter X X Changing the AdBlue armature (level) filter X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X Checking the freezing point of the coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the coolant hoses X X X Replacing the drive belts X X Checking for leaks X X X X Checking and adjusting the valve clearance X X Checking the cable clamping X X Checking the exhaust system X X X X 237/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 5 Maintenance schedule Table 17. Engine maintenance Volvo TAD 1181 VE (Continued) Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of VDS4.5 1) More often if necessary. Table 18. Engine maintenance Volvo TAD 571, 871, 873 VE Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1), 2) X X X X Changing the engine oil filter 1), 2) X X X X Draining the fuel prefilter X X X X X Changing the fuel filter X X X Changing the fuel prefilter X X X Changing the crankcase filter X X X Changing the AdBlue-pump filter (AdBlue engines) X X Changing the AdBlue breather filter (AdBlue engines) X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter 1) X X X X X Changing the engine air filter 1) X X X Changing the safety filter X X X Checking the coolant level X X X X Checking the freezing point of the coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and hub X X X Checking the water pump for wear and leaks X X X Check the vibration damper on the front pulley X X X Check the cooling hoses X X X Replacing the drive belts X X Checking for leaks X X X X Checking and adjusting the valve clearance X X Checking cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of VDS4 1) More often if necessary. 2) 1000-hour service intervals require an approved oil analysis 238/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 5 Maintenance schedule Maintenance Instructions Table 19. Engine maintenance Volvo TAD 1171, 1371 VE Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1), 2) X X X Changing the engine oil filter 1), 2) X X X Changing the engine by-pass filter X X X X Draining the fuel prefilter X X X X X Changing the fuel filter X X X Changing the fuel prefilter X X X Changing the AdBlue-pump filter (AdBlue engines) X X Changing the AdBlue breather filter (AdBlue engines) X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter 1) X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X Change the coolant 3) X X X Checking the freezing point of the coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and hub X X X Checking the water pump for wear and leaks X X X Check the vibration damper on the front pulley X X X Check the cooling hoses X X X Replacing the drive belts X X Checking for leaks X X X X Checking and adjusting the valve clearance X X Checking cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of VDS4 1) More often if necessary. 2) 1000-hour service intervals require an approved oil analysis 3) Only valid for Volvo TAD 1371 VE Table 20. Engine maintenance Volvo TAD 541, 551 VE Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1), 2) X X X X Changing the engine oil filter 1), 2) X X X X Draining the fuel prefilter X X X X X 239/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 5 Maintenance schedule Table 20. Engine maintenance Volvo TAD 541, 551 VE (Continued) Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Draining the extra fuel prefilter X X X X X Changing the fuel filter X X X Changing the fuel prefilter X X X Changing the extra fuel prefilter X X X Changing the crankcase filter X X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X Checking the coolant level X X X X Checking the freezing point of the coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the cooling hoses X X X Replacing the drive belts X X Checking for leaks X X X X Checking and adjusting the valve clearance X X Checking the cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of VDS3. 1) More often if necessary. 2) 1000-hour service intervals require an approved oil analysis. Table 21. Engine maintenance Volvo TAD 841, 851, 853 VE Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1), 2) X X X X Changing the engine oil filter 1), 2) X X X X Draining the fuel prefilter X X X X X Draining the extra fuel prefilter X X X X X Changing the fuel filter X X X Changing the fuel prefilter X X X Changing the extra fuel prefilter X X X Cleaning and draining the fuel tank 1) X X 240/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 5 Maintenance schedule Maintenance Instructions Table 21. Engine maintenance Volvo TAD 841, 851, 853 VE (Continued) Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X Checking the freezing point of the coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the cooling hoses X X X Replacing the drive belts X X Checking for leaks X X X X Checking and adjusting the valve clearance X X Checking the cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of VDS3. 1) More often if necessary.. 2) 1000-hour service intervals require an approved oil analysis. Table 22. Engine maintenance Volvo TAD 1141, 1151 VE Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1), 2) X X X X Changing the engine oil filter 1), 2) X X X X Changing the engine by-pass filter X X X X Draining the fuel prefilter X X X X X Draining the extra fuel prefilter X X X X X Changing the fuel filter X X X Changing the fuel prefilter X X X Changing the extra fuel prefilter X X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X Checking the freezing point of the coolant 1) X X X X 241/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 5 Maintenance schedule Table 22. Engine maintenance Volvo TAD 1141, 1151 VE (Continued) Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the cooling hoses X X X Replacing the drive belts X X Checking for leaks X X X X Checking and adjusting the valve clearance X X Checking the cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of VDS3. 1) More often if necessary.. 2) 1000-hour service intervals require an approved oil analysis. Table 23. Engine maintenance Cummins X12 Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1) X X X X Changing the engine oil filter 1) X X X X Changing the fuel filter X X X X Changing the water separator X X X X Changing the Ad-Blue pump filter X Changing the Ad-Blue tank filter X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X Checking the freezing point of coolant 1) X X X X Checking the supplemental coolant additive (SCA) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X 242/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 5 Maintenance schedule Maintenance Instructions Table 23. Engine maintenance Cummins X12 (Continued) Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Checking the vibration damper on the front pulley X X X Checking the cooling hoses X X X Checking for leaks X X X X Checking and adjusting the valve clearance 2) X X Checking the cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of CES20081 / ACEA E9 / API CJ-4 1) More often if necessary.. 2) If using HVO 100 diesel fuel, valve clearance should be checked every 1000 hours. Table 24. Engine maintenance Cummins B 6.7 - EU stage 5 / US tier 4f Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1) X X X X Changing the engine oil filter 1) X X X X Changing the fuel filter X X X X Changing the water separator X X X X Changing the Ad-Blue pump filter X Changing the Ad-Blue tank filter X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Changing the coolant filter X X X X Checking the coolant level X X X X Checking the freezing point of coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Changing the coolant X X Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the cooling hoses X X X Checking for leaks X X X X Checking and adjusting the valve clearance X Checking the cable clamping X X Checking the exhaust system X X X X 243/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 5 Maintenance schedule Table 24. Engine maintenance Cummins B 6.7 - EU stage 5 / US tier 4f (Continued) Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of CES20081 / ACEA E9 / API CJ-4 1) More often if necessary. Table 25. Engine maintenance Cummins QSB 6.7 T4 Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1) X X X X Changing the engine oil filter 1) X X X X Changing the fuel filter X X X X Changing the water separator X X X X Changing the Ad-Blue pump filter X Changing the Ad-Blue tank filter X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X Checking the freezing point of coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the cooling hoses X X X Checking for leaks X X X X Checking and adjusting the valve clearance X Checking the cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of CES20081 / ACEA E9 / API CJ-4 1) More often if necessary. 244/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 5 Maintenance schedule Maintenance Instructions Table 26. Engine maintenance Cummins QSM 11-C335 Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1) X X X X Changing the engine oil filter 1) X X X X Changing the fuel filter X X X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X Checking the freezing point of coolant 1) X X X X Checking the supplemental coolant additive (SCA) X X X X Replacing the coolant filter 2) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the cooling hoses X X X Checking for leaks X X X X Checking and adjusting the valve clearance X X Checking the cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of CES20071 / ACEA E5 / API CH-4 1) More often if necessary. 2) Do not replace the coolant filter if the SCA concentration level is over three units. Table 27. Engine maintenance Cummins QSB 6.7-C260 Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1) X X X X Changing the engine oil filter 1) X X X X Changing the fuel filter X X X X Changing the water separator X X X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X 245/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 5 Maintenance schedule Table 27. Engine maintenance Cummins QSB 6.7-C260 (Continued) Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Checking the freezing point of coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the cooling hoses X X X Checking for leaks X X X X Checking and adjusting the valve clearance X Checking the cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of CES20071 / ACEA E5 / API CH-4 1) More often if necessary. Table 28. Transmission maintenance Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the transmission oil 1) X X X Changing the transmission oil filter X X X Cleaning the transmission oil cooler: Cleaning the radiator, X X X X intercooler, and oil coolers Checking the transmission breather X X X X X Calibrating the transmission X X X X 1) Check oil level daily with engine idling, maintain oil level at full mark (temperature depending). Table 29. Drive axle maintenance Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the drive axle oil X Checking the drive axle oil level X X X X Checking the drive axle breather X X X X X Checking the condition and pressure of the tires X X X X X Tightening the wheel nuts X X X X X Adjusting the parking brake X X X X 246/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 5 Maintenance schedule Maintenance Instructions Table 30. Steer axle maintenance Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Lubricating the steer axle X X X X Checking the steer axle bearings X X X Checking the condition and pressure of the tires X X X X X Tightening the wheel nuts X X X X X Table 31. Hydraulic system maintenance Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the hydraulic oil 1) X X Changing the hydraulic oil filter X X X Changing the HLL (hydraulic long life) filter (machines with X X HLL filter) 2) Changing the hydraulic tank breathing filter X X Changing the brake cooling oil (machines with brake X X cooling oil) Changing the brake cooling oil filter (machines with brake X X cooling oil) Changing the hydraulic high pressure oil filter 3) X X Changing the breathing filter for the brake cooling oil tank X X (machines with brake cooling oil) Checking the hydraulic hoses X 1) If fitted with an HLL filter, the oil change interval can reach up to 12,000 hours. Oil analysis must be carried out every 1000 hours after the initial oil change at 4000 hours. 2) The filter element should be replaced as necessary when implied on the pressure indicator on the filter housing. 3) The high pressure filter is used on the Reachstacker, but is an option for all other models. Table 32. Mast and forks maintenance Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Lubricating the mast X X X X Lubricating the fork shaft system X X X X Checking the mast and fork carriage X X X X Checking the fork arms X X X X Checking the fork shaft system X X X X Table 33. Functional test Testing points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Checking the function of the electrical system X X X X Checking the function of the steering system X X X X Checking the function of the hydraulic system X X X X Checking the function of the service and parking brake X X X X 247/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 5 Maintenance schedule 5.6 Maintenance data Unit Material/oil/lubricant Volume VOLVO 541 / 551: 16 l (4.23 US gal) VOLVO 571: 16 l (4.23 US gal) VOLVO 581 / 583: 16 l (4.23 US gal) VOLVO 841 / 851: 27 l (7.13 US gal) VOLVO 871 / 873: 27 l (7.13 US gal) VOLVO 881 / 883: 27 l (7.13 US gal) Engine Engine oil VOLVO 1141 / 1151: 37 l (9.77 US gal)) VOLVO 1171: 37 l (9.77 US gal) VOLVO 1181: 37 l (9.77 US gal) VOLVO 1371: 36 l (9.51 US gal) CUMMINS QSM 11-C335 / X12: 37 l (9.77 US gal) CUMMINS QSB 6.7 / B 6.7: 16,7 l (4.41 US gal) CUMMINS QSB 4.5 T3: 13 l (3.43 US gal) Fuel tank Diesel 130–700 l (114–184.9 US gal) AdBlue tank AdBlue 30–60 l (7.9–15.8 US gal) Cooling system Glycol and water mixture 50–60 l (13.2–15.9 US gal) Hydraulic oil system (total volume) Hydraulic oil 150–900 l (39–237.8 US gal) Brake cooling oil tank (option) Brake cooling oil 110 l (29 US gal) See table "Oil filling quantities" in section "Recommended Drive axle Drive axle oil fluids and lubricants". DANA TE10: 25.6 l (6.8 US gal) DANA TE14: 27 l (7 US gal) DANA TE17: 25–30 l (6.6–7.9 US gal) DANA TE27 / TE32: 60–70 l (15.9–18.5 US gal) Transmission See fluid recommendations DANA TE30: 55 l (14.5 US gal) ZF 191: 25–30 l (6.6–7.9 US gal) ZF 261 / 311: 40–50 l (10.6–13.2 US gal) Always check with dipstick Tires Air See manufacturer's recommendations. 248/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX I: Fuel and oil recommendations Maintenance Instructions APPENDIX I: FUEL AND OIL RECOMMENDATIONS Quality of the engine oil Depending on engine type, the engine oil must comply with one of the following oil classifications: • Volvo VDS-4.5 • Volvo VDS-4 • Volvo VDS-3 • CES20081 / ACEA E9 / API CJ-4 • CES20071 / ACEA E5 / API CH-4 • ACEA E5 / API CI-4 Table 34. Oil classifications according to engine type Oils Engine CES20081 / CES20071 / ACEA E5 / VDS-4.5 VDS-4 VDS-3 ACEA E9 / ACEA E5 / API CI-4 API CJ-4 API CH-4 Volvo TAD 581, 881, 883, 1181 X VE Volvo TAD 571, 871, 873, 1171, X 1371 VE Volvo TAD 541, 551, 841, 851, X 853, 1141, 1151 VE Cummins QSB 6.7 T4, B 6.7, X X12 1) Cummins QSB 6.7, QSM 11 X 1) For Cummins B 6.7 and X12 engines, SAE 15W-40 must be used. Check with your oil supplier that your oil meets these demands. For engines that do not use fuel with low sulphur content, the TBN (Total Base Number) value should be at least 12 according to ASTM 2896. Check with your oil supplier that your oil meets these demands. Depending on operating conditions, and the quality of the oil and fuel, the intervals between changing the oil may vary in length. The engine oil must be replaced within a maximum operation time of one year. If the machine is parked in cold weather, the viscosity of the oil can vary according to the temperature. Therefore the ambient temperature is vital to the choice of the engine oil viscosity range (see following figure). NOTE If the machine is warm, the oil is also warm. Changing the oil due to a change in season may be avoided by using multi-grade oils. Specified intervals for changing the oil also apply to multi-grade oils. No oil additives should be added to the recommended oils. Using such additives may NOTE invalidate the engine warranty. Avoid mixing different brands of oil. The temperature ranges for adjacent SAE classes overlap, so you do not need to replace the oil when short-term temperature changes occur. To ensure trouble-free cold starts, select the SAE class according to the ambient NOTE temperature. 249/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions APPENDIX I: Fuel and oil recommendations Figure 110. Oil temperature ranges Extended oil change interval Extended oil change interval may differ when using synthetic fluids. To determine a baseline, appropriate change intervals should be determined for each engine by measuring oil oxidation and wear metals over time. Wear metals analysis can provide useful information, but an engine should not be removed from service based solely on this analysis. For more information contact Konecranes Lift Trucks, an authorized dealer, or the engine supplier. Recommended fluids and lubricants Diesel fuel It is recommended to use diesel fuel HVO 100, which complies with the following classification: • EN 15940 Class A If using other diesel fuels than HVO 100, they must comply with one of the following classifications: • EN 590 • ASTM D 975 No 1-D or 2-D For Tier 4F, stage 4 and stage 5 engines ULSD (Ultra-Low Sulfur Diesel) fuel must be used (sulphur content below 15 mg/kg). For more information, contact the engine manufacturer, or an authorized representative. As the ambient temperature falls, the flow characteristics of the diesel fuel are reduced NOTE and paraffin begins to precipitate, i.e the diesel is gelling in cold temperatures. Use the correct diesel quality according to the ambient temperature. Using additives to improve the flow is not recommended. Additives may reduce the NOTE capacity to start from cold. Biodiesel (FAME) Vegetable oil esters (Fatty Acid Methyl Esters, FAME), also called "biodiesel", are increasingly available as a blending component in diesel fuels. The engine manufacturer accepts the same FAME content as in major on-road fuels EN590 and ASTM D975. The maximum FAME content is 7%, without any specific extra service requirements. For more information, contact the engine manufacturer, or an authorized representative. Higher FAME blends negatively impact performance, emissions, and fuel consumption. It NOTE also affects negatively the function of the SCR engines exhaust after treatment system. 250/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX I: Fuel and oil recommendations Maintenance Instructions AdBlue solution Only use an AdBlue solution that fulfills the ISO 22241 standard. The AdBlue solution consists of deionized water that is mixed with 32.5% urea. Table 35. Engines using AdBlue solution Engine family Engine VOLVO TAD 571 VE TAD 871 / 873 VE TAD 1171 VE TAD 1371 VE TAD 581 VE TAD 881 / 883 VE TAD 1181 VE CUMMINS QSB 6.7 1) / B 6.7 / X12 1) EU stage 4 / US tier 4f Transmission oil DANA transmission: ATF Dexron III ZF transmission: Mineral oil -based engine oil (API CD/CE/CF-4/CF/CG-4/CH-4/ CI-4/SF/SG/SH/SJ/SL or ACEA, categories A, B, E). Viscosity degrees: SAE 20W-20 / 30 / 10W-30 / 10W-40 / 15W-30 / 15W-40 / 20W-40. For more information, see the ZF recommended oil list TE-ML 03. Table 36. ZF Transmission: Approved and recommended oil types Lubricant class Oil type / viscosity Temperature 03C, 03M ATF (Automatic transmission fluids) -40°C 03F UTTO in accordance with JDM 20D / John Deere Low -40°C Viscosity Hy-Gard 03E, 03G, 03H UTTO -30°C 03K SAE 0W-30, 0W-40 -40°C 03B, 03C, 03K SAE 5W-30, 5W-40 -35°C 03A, 03B, 03C, 03K SAE 10 W, 10W-30, 10W-40 -30°C 03A, 03C, 03K SAE 15W-30, 15W-40 -25°C 03A, 03C, 03K SAE 20W-20, 20W-40 -20°C 03A, 03C, 03K SAE 30 -10°C Oil change interval Drain and refill the system every 1000 h for average environmental and duty cycle conditions. Severe or sustained high operating temperature or dusty environments cause accelerated deterioration or contamination. Judgment must be used to determine the required change intervals for extreme conditions. For more information, contact your local authorized dealer. Drive axle oil Axle housing / Hub assembly / Drive Assembly API GL.5 SAE 90 251/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions APPENDIX I: Fuel and oil recommendations Table 37. Oil filling quantities Drive Width Planetary Model Brake Differential Hub axle (mm) gear FLT 10-16 D81 2274 PL478 NLB5340 19 l (5.02 US gal) 2.3 l (0.6 US gal) FLT 18-25 D91 2717 PL488 NLB4460 31 l (8.2 US gal) 3.2 l (0.8 US gal) FLT 28-33 D91 3015 PL408 NLB6460 36.5 l (9.6 US gal) 3.7 l (0.97 US gal) FLT / LCH 37-50 D102 3807 PL341 NLB8460 72 l (19 US gal) 11 l (2.9 US gal) FLT / LCH 37-50 D102 3431 PL341 NLB8460 58 l (15.3 US gal) 11 l (2.9 US gal) LCH 52 D102 4549 PL341 NLB8460 121 l (31.9 US gal) 12.5 l (3.3 US gal) FLT / LCH 52-55 D106 3807 PL341 NLB8460 85 l (22.4 US gal) 11 l (2.9 US gal) FLT 60-55 D111 4188 PL545 NLB6650-1 108 l (28.5 US gal) 12.5 l (3.3 US gal) ECH 80 D81 3218 PL478 NLB5340 39 l 10.3 US gal) 2.3 l (0.6 US gal) ECH 90/100 D81 3713 PL488 NLB6340 45 l (11.9 US gal) 3.5 l (0.9 US gal) ECH 90/100 D91 4218 PL488 NLB6340 45 l (11.9 US gal) 3.5 l (0.9 US gal) ECH 90/100 *) D91 4203 PL489 NLB4460 66 l (17.4 US gal) 3.2 l (0.8 US gal) RST 108 D81 3713 PL488 NLB6340 45 l (11.9 US gal) 3.5 l (0.9 US gal) RST 2518 D91 3015 PL408 NLB6460 36.5 l (9.6 US gal) 3.7 l (0.97 US gal) RST 4127-4638 D102 3807 PL341 NLB8460 72 l (19 US gal) 11 l (2.9 US gal) RST 4537-4644 D106 3807 PL341 NLB8460 85 l (22.4 US gal) 11 l (2.9 US gal) RST 4646 D111 4188 PL545 NLB6650-1 108 l (28.5 US gal) 12.5 l (3.3 US gal) *) = with clamped wheel rims The volumes are strictly recommendations. If you have any doubts, contact your NOTE Konecranes Lift Trucks authorized dealer for advice. Hydraulic oil For machines without separate brake cooling tank Universal Tractor transmission oil (UTTO) The oil must comply with one of the following classifications: • John Deere: JD20C • Massey Ferguson: MF1141/MF1135/ MF1143 • ZF: TE-ML 03E/TE-ML 05F/TE-ML 06K For machines with separate brake cooling tank (option) DIN 51524 Part 2 HLP and Part 3 HVLP Use hydraulic oil from a well-known oil company for mobile applications. Viscosity Temperature range SHS 32 -30°C...+10°C (-22°F...+50°F) SHS 46 -20°C...+50°C (-4°F...+122°F) SHS 68 ±0°C...+50°C (+32°F...+122°F) Brake cooling oil (option) Universal Tractor transmission oil (UTTO) The oil must comply with one of the following classifications: 252/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX I: Fuel and oil recommendations Maintenance Instructions • John Deere: JD20C • Massey Ferguson: MF1141/MF1135/ MF1143 • ZF: TE-ML 03E/TE-ML 05F/TE-ML 06K Grease Multipurpose type E.P. according to NLGI Grade 2. Coolant WARNING HARMFUL SUBSTANCE HAZARD Using wrong coolant may damage the machine. Use the recommended coolant and never mix different coolants. WARNING TOXIC SUBSTANCE HAZARD It is highly dangerous to drink ethylene glycol. Contact with skin or spray from the refill can cause skin irritation and eye damage. Do not drink ethylene glycol and avoid contact with skin. Use only ethylene glycol-based coolants with an additive that prevents corrosion. Do not mix different coolant types with each other. Do not mix the coolant with antifreeze that contains ethanolamine. Table 38. Coolants for Volvo engines Engine Coolant VOLVO TAD 541, 551 VE VOLVO TAD 571 VE VOLVO TAD 581 VE VOLVO TAD 841 VE VOLVO TAD 851 VE VOLVO TAD 871, 873 VE Volvo Penta Coolant VCS-2 and VCS-2 Ready Mixed VOLVO TAD 881, 883 VE VOLVO TAD 1141, 1151 VE VOLVO TAD 1171 VE VOLVO TAD 1181 VE VOLVO TAD 1371 VE Table 39. Coolants for Cummins engines Engine Coolant CUMMINS QSB 6.7-C240 CUMMINS B 6.7 To comply with Cummins CES 14603 CUMMINS QSM 11-C335 Recommended: Cummins ES Compleat EG CUMMINS X12 253/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions APPENDIX I: Fuel and oil recommendations Liquid antifreeze at the lowest Percentage of volume mixture liquid Mixture of antifreeze and water temperature antifreeze -12°C (10.4°F) 25 1:3 -18°C (-0.4°F) 30 1:2 -25°C (-13°F) 40 1:1.5 -37°C (-34.6°F) 50 1:1 -60°C (-76°F) 66 2:1 254/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX II: Fuses and relays Maintenance Instructions APPENDIX II: FUSES AND RELAYS Fuses Fuses are located behind the operator's seat in the cabin and in the battery compartment on the right side of the machine. Figure 111. Location of fuses 101 121 141 163 185 190 120 140 162 184 Figure 112. Numbering order of the fuses 255/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions APPENDIX II: Fuses and relays Table 40. Fuses and their function (Functions may vary depending on machine model and chosen options) Number Size Function F101 7.5 A Cabin heating F102 7.5 A Option F103 7.5 A Option F104 7.5 A Central lubr. pump chassis F105 10 A Converter 12-V option F106 7.5 A Reverse light F107 7.5 A Working light extra 2 F108 7.5 A PCB 48-PIN STD D F109 7.5 A PCB 48-PIN STD D F110 7.5 A PCB 48-PIN STD D F111 7.5 A PCB 48-PIN STD D F112 7.5 A Clutch for HVAC compressor F113 5A Position light right F114 5A Position light left F115 7.5 A High beam F116 7.5 A Low beam F117 15 A Seat suspension air compressor F118 7.5 A Reverse alarm in the front F119 7.5 A Working lights extra 1 F120 10 A Option F121 7.5 A Working light mast, right F122 7.5 A Working light mast, left F123 10 A Main fuse for the lights, F115 and F116 F124 5A ACR RFID keyless ignition F125 5A Battery clock (RTC) F126 7.5 A Ignition F127 7.5 A Beacon F128 7.5 A Power supply controller F129 7.5 A Hazard F130 10 A HV/AC condensor blower 1 F131 10 A HV/AC condensor blower 2 F132 10 A HV/AC condensor blower 3 F133 7.5 A K128 Door open switch F134 5A Reading light F135 15 A Rear window heating F136 7.5 A RCU F137 7.5 A Diagnostic, PCB connector F138 7.5 A CAN extra, PCB connector F139 5A Turn signal F140 7.5 A PCB 48-PIN STD D F141 7.5 A PCB 48-PIN STD D F142 7.5 A Rearview mirror heater F143 5A I/O units in the armrest, XC21, XC21 OPT C1, XC21 OPT C2 F144 7.5 A Seat heater F145 7.5 A MD4 256/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX II: Fuses and relays Maintenance Instructions Table 40. Fuses and their function (Functions may vary depending on machine model and chosen options) (Continued) Number Size Function F146 5A TRUCONNECT® modem F147 5A RFID nearguard 2 F148 5A Tire pressure gateway F149 10 A Connection for computer F150 5A RFID nearguard 1 F151 7.5 A Main fuse for position light (F113, F114) and brake lights F152 5A Alcohol ignition interlock F153 10 A 24 V dashboard F154 5A GSM G2 modem F155 10 A 12 V reverse camera F156 10 A 12 V dashboard F157 10 A 24 V roof F158 7.5 A Converter roof F159 10 A 12 V roof F160 7.5 A 12 V radio F161 15 A Working light roof (option) F162 15 A Working light roof (option) F163 10 A Wiper rear/roof/front washer F164 7.5 A PCB 48-PIN STD E F165 7.5 A PCB 48-PIN STD E F166 7.5 A Converter F167 7.5 A Converter 2 rear wall F168 15 A Horn F169 7.5 A PCB 48-PIN STD E F170 7.5 A PCB 48-PIN STD E F171 7.5 A PCB 48-PIN STD E F172 7.5 A PCB 48-PIN STD E F173 7.5 A Fuel heater F174 7.5 A Option F175 7.5 A Option F176 15 A Electrical seat column F177 7.5 A Option F178 7.5 A Particle detecting monitor (PDM) F179 10 A XA2 OPT, external expansion unit in the chassis F180 10 A XA2-STD, external expansion unit in the chassis F181 10 A Connection for computer F182 7.5 A Reverse camera F183 5A HVAC controller F184 15 A HVAC blower F185 3A Spare fuse F186 5A Spare fuse F187 7.5 A Spare fuse F188 10 A Spare fuse F189 15 A Spare fuse F190 - Fuse test 257/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions APPENDIX II: Fuses and relays Fuses and relays in the battery compartment DANGER EXPLOSION HAZARD Short-circuiting the battery may cause a fire or explosion, which can cause a risk for serious injury or death. DANGER CORROSIVE SUBSTANCE HAZARD The battery contains corrosive acid that may cause a risk for serious injury or death. Always use the necessary protective equipment. DANGER EXPLOSION HAZARD Batteries generate explosive hydrogen when charged, or when being jump-started, which may cause a risk for serious injury or death. Always use the necessary protective equipment. Ensure that there is good ventilation and avoid sparking. WARNING ELECTRICAL HAZARD The battery main switch disconnect does not cut the power to the alternator. To reduce the risks of electric shock and personal injury always remove jewelry and conductive material before working on the electrical system. Always disconnect the ground (minus) cable at the battery when working near or on the alternator. WARNING TIPPING OVER HAZARD Turning off the battery main switch while the machine is moving applies the parking brake and the machine may tip over. The software in the control unit can get damaged. Do not turn it off while the engine is running. 258/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX II: Fuses and relays Maintenance Instructions 1 3 2 1 Figure 113. Fuses and relays in the battery compartment 1. Fuses F51–F58, F71-78, F92-F98 (1) 2. Relay K32 (2), behind the three fuse lines 3. Fuses F61-F62, F80 Figure 115. Numbering order of the fuses Table 41. Fuses and their functions (Functions may vary depending on machine model and chosen options) Number Size Function F51 10 A MD4 internal clock (IQAN-MD4 RTC) F52 20 A Starter for Scania DC13 EU4/Cummins QSB (15A) F53 20 A Scania DC13 EU4 AdBlue control unit/Cummins QSB (15 A) F54 7.5 A Cummins QSB (15 A) F55 7.5 A Fuel heater (Cummins 20A) F56 7.5 A TCU battery power supply (DANA) F57 20 A Scania DC13 EU4, VOLVO 660/760 (10A) /Cummins QSB (15A) F58 20 A Scania DC13 EU4/Cummins QSB (15A) 259/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions APPENDIX II: Fuses and relays Table 41. Fuses and their functions (Functions may vary depending on machine model and chosen options) (Continued) Number Size Function F61 100 A Main fuse 15 ignition F62 60 A Main fuse 30 battery F71 7.5 A Option F72 7.5 A Option (fuel shut-off) (seat suspension air compressor 15 A) F73 7.5 A Option F74 10 A Engine ignition F75 7.5 A DANA/ZF transmission control unit (TCU) ignition power supply F76 25 A Hydraulic oil cooler F77 20 A Scania DC13 EU4 exhaust gas recirculation valve (EGR) F78 - Option F80 70 A Cummins engine starter F81 100 A Cummins intake air heater F91 10 A Attachment lights F92 10 A Chassis 48-pin STD F F93 10 A Chassis 48-pin STD F F94 10 A Chassis 48-pin STD F F95 10 A Chassis 48-pin STD F F96 10A Chassis 48-pin STD F F97 10A Chassis 48-pin STD F F98 10 A Power supply, attachment Relays Relays K32, K35, and K36 are mounted next to the main fuses in the battery compartment. K101-K135 are mounted behind the operator seat in the cabin. Figure 116. Relay location K101-K135 260/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX II: Fuses and relays Maintenance Instructions 135 117 118 119 120 121 122 123 124 116 115 125 126 114 127 128 113 129 130 112 131 132 111 133 134 110 109 108 107 104 103 102 101 106 105 Figure 117. Relays K101-135 Table 42. Relay functions (Functions may vary depending on machine model and chosen options) Number Function K31 Volvo 620, 722, Engine starter K32 Q1 ignition K33 Ground support for K31 K35 Engine shut-off for Volvo engines (Engine starter Cummins QSB and QSM) K36 Fuel heater K63 Starter lockout Cummins K64 Intake air heater Cummins K65 DEF hose heating 1 Cummins K66 DEF hose heating 2 Cummins K67 DEF hose heating 3 Cummins K68 DEF heater relay K101 Pre-heating power supply for HVAC (heating, ventilation, air-conditioning) K102 Signal for HVAC (heating, ventilation, air-conditioning), engine running with cabin doors closed K103 Brake lights K104 Inverted road light (turnable seat) K105 ACR RFID keyless ignition 261/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions APPENDIX II: Fuses and relays Table 42. Relay functions (Functions may vary depending on machine model and chosen options) (Continued) Number Function K106 Working light mast F121 and F122 K107 Working light extra 1 K108 Front alarm K109 Door switch K110 Low beam K111 High beam K112 Clutch for HVAC compressor K113 Blinker right K114 Blinker left K115 Working light extra 2 K116 Backup Light/Right K117 Central lubrication pump chassis K118 Option K119 Option K120 RCU 3 K121 Working light roof F161, F162 K122 Windshield wiper motor roof K123 Windshield wiper motor rear K124 Rear/front window washer motor K125 Rear window heating K126 Windshield wiper motor front, 1st speed K127 Rear/front window washer motor K128 Windshield wiper motor front, 2nd speed K129 Horn K130 Fuel heater K131 RCU 1 K132 RCU 2 K133 Option K134 Communication radio K135 Hazard K201 Attachment lights (opt) 262/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved.  Käsikahvelkäru info https://www.vmh.sk/hpts-with-weight-system.html Lisa 2 19.05.2026 lepingu nr 2-2/26/607-2 juurde Julgeolekutingimused Riigihanke objekti asumisega Kaitseväe julgeolekualal teavitatakse lepingupartnerit alljärgnevatest tingimustest, õigustest ja kohustustest eesmärgiga selgitada lepingupartnerile poolte õigusi ja kohustusi julgeolekualaste nõuete täitmisel Kaitseväe julgeolekualal. 1. MÕISTED 1.1 Julgeoleku eest vastutav isik (edaspidi JEVI) - konkreetsel KV JOA-l asuva riigihanke objekti julgeolekualaste nõuete täitmise eest vastutav Kaitseväe allüksus või teenistuja. 1.2 Julgeolekualased nõuded - Kaitseväe julgeolekualale sisenemisel ja viibimisel kehtestatud üldised julgeolekunõuded (lisa 5) ning muudest õigusaktidest tulenevad Kaitseväe julgeoleku tagamiseks kehtestatud nõuded. 1.3 Kaitseväe julgeolekuala (edaspidi KV JOA) - Kaitseväe valduses olev territoorium, Kaitseväe laevad, lennuvahendid ja sõidukid. 1.4 Lepingupartneri kontaktisik - lepingu täitmise nõuete ja julgeolekualaste nõuete täitmise eest vastutav lepingupartneri ja/või tema alltöövõtja määratud isik. 1.5 Nõusolek – taustakontrolli tegemiseks vajalik eelnev kirjalik nõusolek, millega isik lubab Kaitseväel koguda enda kohta andmeid ja teha päringuid nõusoleku andmisest viie aasta jooksul (KKS § 416) (lisa 2 eesti keeles ja lisa 3 inglise keeles). 1.6 Riigi Kaitseinvesteeringute Keskuse (edaspidi RKIK) kontaktisik - lepingujärgne isik, kelle kaudu toimub lepingujärgsete kohustuste täitmise korraldamine ja lepingus ettenähtud teadete, nõuete ja teiste dokumentide edastamine. 1.7 Riigihanke objekt - lepingu täitmiseks ettenähtud Kaitseväe julgeolekualal paiknev tööpiirkond. 1.8 Taustakontroll - Kaitseväele teenuse osutamisega seotud isiku (edaspidi teenuseosutaja) KV JOA-le lubamise otsustamiseks läbiviidav kontroll Kaitseväe korralduse seaduse (edaspidi KKS) § 413 alusel ja KKS §-s 41⁵ viisil. 1.9 Taustakontrolli taotlus (e-kiri) - lepingupartneri kontaktisiku poolt esitatav taotlus teenuseosutajale taustakontrolli tegemise algatamiseks (lisa 1). 1.10 Teenuseosutaja - lepingupartneri ja/või tema alltöövõtja töötaja, kelle suhtes teostatakse taustakontrolli tema eelneval kirjalikul nõusolekul, seoses sissepääsuõiguse taotlemisega KV JOA-le. 1.11 Turvaala - konfidentsiaalse, salajase või täiesti salajase taseme riigisaladuse või salastatud välisteabe ja seda sisaldava salastatud teabekandja töötlemiseks lubatav ala. 1.12 Sissepääsutaotlus (e-kiri) - lepingupartneri kontaktisiku poolt esitatav taotlus teenuseosutaja KV JOA-le lubamiseks (lisa 4). 1.13 Sissepääsuõigus - õigus viibida KV JOA-l asuval riigihanke objektil seoses lepingu täitmisega. 1.14 Sissepääsuõigust omav isik - taustakontrolli läbinud isik, kelle sissepääs KV JOA-l asuvale riigihanke objektile on otsustatud ning kellel on õigus saatjata siseneda ja viibida KV JOA-l asuval riigihanke objektil seoses lepingu täitmisega. 1/3 2. LEPINGUPARTNERI ÕIGUSED JA KOHUSTUSED 2.1 Lepingupartneril, sh teenuseosutajal ja lepingupartneri kontaktisikul, on õigus riigihanke objekti JEVI-lt saada julgeolekualaste nõuete täitmiseks vajalikku informatsiooni ja teavet KV JOA-le sissepääsuõiguse saamise kohta. Konkreetse riigihanke objekti JEVI kontaktid edastab lepingupartnerile esimesel võimalusel RKIK-i kontaktisik. 2.2 Lepingupartner kohustub: 2.2.1 mitte planeerima KV JOA-le teenust osutama teatamiskohustusega välisriikide kodanikke. Teatamiskohustusega riikideks on lepingu sõlmimise hetkel siseministri 29.09.2023 käskkirja nr 1-3/112 alusel1: Armeenia Vabariik; Aserbaidžaani Vabariik; Hiina Rahvavabariik (sh Hongkongi ja Macau erihalduspiirkonnad); Iraani Islamivabariik; Kasahstani Vabariik; Kirgiisi Vabariik; Korea Rahvademokraatlik Vabariik; Tadžikistani Vabariik; Türkmenistan; Usbekistani Vabariik; Valgevene Vabariik; Venemaa Föderatsioon. Juhul kui nimetatud siseministri käskkirjas tehakse muudatusi, siis teavitatakse sellest lepingupartnerit ning vajadusel muudetakse käesolevaid julgeolekutingimusi; 2.2.2 tagama, et lepingupartneri kontaktisik esitab taustakontrolli taotluse (lisa 1 koos lisadega 2 ja/või 3) esimesel võimalusel, arvestades lepingus kokkulepitud töö teostamise alguskuupäeva ning taustakontrollile kuluvat aega (14 kalendripäeva), e- posti aadressile [email protected]; 2.2.3 tagama, et lepingupartneri kontaktisik lisab välismaalasele taustakontrolli algatamise taotlusele juurde: 2.2.3.1 koopia isikut tõendava dokumendi pildiga leheküljest, sh viisast vm Eestis viibimise seaduslikku alust kinnitavast dokumendist; 2.2.3.2 isiku kodukohariigi karistusregistri väljavõtte; 2.2.4 tagama, et lepingupartneri kontaktisik esitab sissepääsutaotluse (lisa 4) esimesel võimalusel, arvestades lepingus kokkulepitud töö teostamise alguskuupäeva ning sissepääsutaotluse menetlemiseks kuluda võivat mõistlikku aega, RKIK kontaktisiku või tema määratud isiku e-posti aadressile; 2.2.5 teavitama viivitamatult teenuseosutaja ennetähtaegse sissepääsuvajaduse lõppemisest KV JOA-le e-kirja teel Kaitseväe taustakontrolli [email protected] ja RKIK kontaktisikut; 2.2.6 täitma ja tagama teenuseosutaja julgeolekualaste nõuete järgimise KV JOA-l kehtestatud tingimustel ning tagama nende täitmise alltöövõtja poolt. 1 https://kapo.ee/sites/default/files/content_page_attachments/Teatamiskohustusega%20v%C3%A4lisriikideni mekirja%20kehtestamine_0.pdf 2/3 3. KAITSEVÄE ÕIGUSED JA KOHUSTUSED 3.1 Kaitseväel on õigus: 3.1.1 teha taustakontrolli Kaitseväele teenuse osutamisega seotud isikule KV JOA-le lubamise otsustamiseks; 3.1.2 anda või piirata taustakontrolli käigus ilmnenud asjaoludele tuginedes teenuseosutaja sissepääsuõigus KV JOA-le; 3.1.3 jätta taustakontrolli taotlus läbi vaatamata haldusmenetluse seaduses sätestatud korras2; 3.1.4 keelduda julgeolekukaalutlustel sissepääsuõiguse andmisest isikule, kellele ei ole taustakontrolli tehtud, kes ei läbinud taustakontrolli või kellele ei ole võimalik seda teha; 3.1.5 piirata või keelduda sissepääsuõiguse andmisest julgeoleku- ja turvaaladele kodakondsuseta või välisriigi kodakondsusega isikutele, lähtudes julgeolekukaalutlusest. 3.1.6 kontrollida riigihanke objektil kehtestatud julgeolekualastest nõuetest kinni pidamist sissepääsuõigust omava teenuseosutaja suhtes ning julgeolekualaste nõuete mittejärgimisel või nende rikkumisel keelata teenuseosutajal viibimine KV JOA-l. 3.2 Kaitsevägi kohustub: 3.2.1 teavitama taustakontrolli taotluse esitanud isikut kirjalikus taasesitamist võimaldavas vormis teenuseosutaja taustakontrolli tulemusest; 3.2.2 teavitama KV JOA-le sissepääsutaotluse esitanud isikut kirjalikus taasesitamist võimaldavas vormis teenuseosutajale sissepääsuõiguse saamisest, sh sellekohastest piirangutest; 3.2.3 tutvustama teenuseosutajale KV JOA-l paikneva riigihanke objektil kehtivaid julgeolekualaseid nõudeid; 3.2.4 teavitama RKIKi, kui teenuseosutaja ja/või lepingupartner rikub julgeolekutingimusi ega järgi riigihanke objektil kehtestatud julgeolekualaseid nõudeid (lisa 5); 3.2.5 teavitama vastavalt punktile 3.1.3 taotluse läbi vaatamata jätmisel kirjalikult. 4. LÕPPSÄTTED 4.1 Julgeolekutingimustes nimetatud kontaktisikud määratakse kindlaks hankelepingu sõlmimisel ja nende muutumisest teavitatakse pooli e-kirja teel. 4.2 Isikuandmete töötlemisel lähtutakse kehtivate õigusaktide nõuetest. 2 https://www.riigiteataja.ee/akt/106072023031#para14 3/3 LISA 1: Näidis Taustakontrolli taotlus (e-kiri) Taotlus saata e-posti aadressile [email protected] PEALKIRI: Taustakontrolli taotlus (linnaku ja objekti nimetus) ASUTUSESISESEKS KASUTAMISEKS TEKST: KAITSEVÄGI Juurdepääsupiirang kehtib alates dokumendi koostamise kuupäevast kuni vajaduse möödumiseni, kuid mitte kauem kui 75 aastat Alus: avaliku teabe seadus § 35 lg 1 p 12 Tere Seoses RKIK (lepingu nimi) lepinguga nr xxxxxxxxx, sõlmitud pp.kk.aaaa, edastan Kaitseväele taustakontrolli tegemiseks allolevate isikute andmed. Taustakontrolli dokumendid on lisatud e-kirja manusesse. Lisainfo on tabelis: Teenuse Teenuse Teenuse Teenuse osutamise Osutatav osutamise osutamine Eesnimi Perenimi Isikukood Ettevõte osutamise perioodi algus teenus perioodi lõpp turvaalal JAH/EI objekt pp.kk.aaaa pp.kk.aaaa Olen teadlik, et taustakontroll võib võtta nõuetekohase taotluse esitamisest aega kuni 14 kalendripäeva. Lugupidamisega Taotluse esitaja ees- ja perenimi Ametikoht Ettevõtte nimi Kontakttelefon, e-posti aadress 1/1 LISA 2: NÕUSOLEKUVORM (eesti keeles) ASUTUSESISESEKS KASUTAMISEKS Teabevaldaja: Kaitsevägi Juurdepääsupiirang kehtib alates dokumendi koostamise kuupäevast kuni vajaduse möödumiseni, kuid mitte kauem kui 75 aastat Alus: AvTS § 35 lg 1 p 12 KINNITATUD Kaitseväe juhataja 23.03.2026 käskkirjaga nr 0.1-3.1/26/63 Lisa 2 ISIKU NÕUSOLEK TAUSTAKONTROLLI TEOSTAMISEKS (ees- ja perekonnanimi) Isikukood: Luban Kaitseväel teostada minu suhtes taustakontrolli Kaitseväe korralduse seaduse (edaspidi KKS) § 413 alusel ning KKS § 41⁵ sätestatud viisil käesoleva nõusoleku andmisest viie aasta jooksul. Olen teadlik, et: 1. mul on õigus keelduda nõusoleku andmisest (KKS 416 lg 2 p 1); 2. mul on õigus keelduda selliste andmete esitamisest, mis võivad põhjustada minu teenistusest või ametikohalt vabastamise või töölepingu ülesütlemise või minu või minu lähedase või elukaaslase suhtes süüteo- või distsiplinaarmenetluse (KKS 416 lg 2 p 2); 3. mul on õigus taotleda minu kohta andmete kogumise või päringute tegemise lõpetamist (KKS 416 lg 2 p 3); 4. mul on õigus esitada minu kohta kogutud andmete kohta selgitusi (KKS 416 lg 2 p 4); 5. mul on õigus pöörduda oma õiguste kaitseks ja § 415 alusel kogutud andmete põhjal tehtud otsuse vaidlustamiseks kohtu, õiguskantsleri, Andmekaitse Inspektsiooni või töövaidluskomisjoni poole, et kontrollida, kas minu põhiõiguste ja -vabaduste tagamise põhimõtet ning hea halduse tava on järgitud (KKS 416 lg 2 p 5). 6. kui ma keeldun nõusoleku andmisest või taotlen andmete kogumise või päringute tegemise lõpetamist (KKS § 417), siis on see minu taustakontrolli lõpetamise aluseks (KKS § 413); 7. Kaitsevägi võib piirata minu õigusi töödeldavate isikuandmete suhtes (KKS § 41¹⁰ lg 3 ja lg 4). Olen teadlik, et Kaitseväe julgeolekualal(e) (s.o. Kaitseväe laevad, lennuvahendid, sõidukid ja Kaitseväe territoorium): 1. ei tohi viibida ilma Kaitseväe loata (KKS § 52 lg 1); 2. peab täitma Kaitseväes kehtivat korda ja Kaitseväe esindaja korraldusi (KKS § 52 lg 2); 3. ei tohi pilti või kujutist salvestada ja edastada (KKS § 563); 4. ei tohi kasutada osaliselt või täielikult automaatset või kaugjuhitavat sõidukit (KKS § 52 lg2, KKS § 562); 5. ei tohi kasutada agressioonisümboleid (KarS § 1511); 6. on Kaitseväel õigus teostada minu, minuga kaasas oleva eseme ja sõiduki turvakontrolli (KKS § 56); 7. peab sõiduki pardakaamera olema kaetud ja video-ja helisalvestus välja lülitatud (KKS § 52 lg 2); 8. ei tohi tuua kolmandaid isikuid ega lemmikloomi (KKS § 52 lg 2); 9. ei tohi tuua ega tarvitada alkoholi, narkootilist või psühhotroopset ainet ega viibida julgeolekualal selle tarvitamise kahtlusega või joobes (KKS § 52 lg 2); 1/2 10. ei tohi tuua relva, drooni, lõhke- ja süüteainet või -seadeldist või seda sisaldavat eset ja muud vahendit, mis võib ohustada alal viibivaid isikuid, tehnikat ja seadmeid. Loetelu ei ole lõplik, Kaitseväel on õigus hinnata kaasatoodu ohtlikkust ja seda julgeolekualale mitte lubada (KKS § 52 lg 2); Olen teadlik, et ma ei tohi avaldada mulle teatavaks saanud riigi- ja ärisaladust, salastatud välisteavet, Kaitseväe teenistujate perekonna- ja eraelulisi andmeid ning muud Kaitseväega seotud teavet ilma Kaitseväe kirjaliku loata (KKS § 52 lg 2). (päev, kuu, aasta) [ allkirjastatud digitaalselt ]3 3 lubatud allkirjastada ka paberkandjal 2/2 LISA 3: NÕUSOLEKUVORM (inglise keeles) FOR OFFICIAL USE ONLY Information owner: ESTONIAN DEFENCE FORCES Restrictions on access to information were enforced when this document was created and are valid as long as necessary but no longer than 75 years Legal grounds: Public Information Act clause 35 (1) 12) Annex 3 APPROVED With the 23.03.2026 Directive of the Commander of the Estonian Defence Forces No 0.1-3.1/26/63 AUTHORISATION FOR BACKGROUND CHECK (first and last name) Personal identification code: I hereby authorise the Estonian Defence Forces to perform a background check on me in accordance with section 413 of the Estonian Defence Forces Organisation Act and in the manner specified in section 415 of the Estonian Defence Forces Organisation Act during five years as of my authorisation. I am aware of the following conditions. 1. I have the right to refuse authorisation (clause 416 (2) 1) of the Estonian Defence Forces Organisation Act). 2. I have the right to refuse to disclose information that might cause me being released from service or my position, or my employment contract being terminated, or that might lead to an offence or disciplinary proceeding for my loved ones or partner (clause 416 (2) 2) of the Estonian Defence Forces Organisation Act). 3. I have the right to request the termination of data collection and inquiries about me (clause 416 (2) 3) of the Estonian Defence Forces Organisation Act). 4. I have the right to provide explanations about the information collected about me (clause 416 (2) 4) of the Estonian Defence Forces Organisation Act). 5. I have the right to turn to the court, the Chancellor of Justice, the Data Protection Inspectorate, and the labour dispute committee to protect my rights and dispute the decision made about me based on the information collected on the grounds of section 415 to confirm whether the principles of protecting my basic rights and freedoms, and the code of good administration behaviour were followed (clause 416 (2) 5) of the Estonian Defence Forces Organisation Act). 6. If I refuse authorisation or request that data collection and inquiries were terminated (section 417 of the Estonian Defence Forces Organisation Act), it serves as the basis to end my background check (section 413 of the Estonian Defence Forces Organisation Act). 7. The Estonian Defence Forces may restrict my rights to the personal data being processed (subsections 4110 (3) and (4) of the Estonian Defence Forces Organisation Act). 1/2 I am aware of the following rules that apply on the restricted area of the Estonian Defence Forces (including vessels, aircraft, vehicles, and the territory of the Estonian Defence Forces). 1. Staying on the restricted area is not allowed without the permission of the Estonian Defence Forces (EDF) (subsection 52 (1) of the Estonian Defence Forces Organisation Act). 2. Each person on the restricted area must follow the procedures in force in the Estonian Defence Forces and the orders given by a representative of the EDF (subsection 52 (2) of the Estonian Defence Forces Organisation Act). 3. It is not allowed to take pictures or other images on the restricted area, or forward such pictures or images (section 563 of the Estonian Defence Forces Organisation Act). 4. It is not allowed to use partially or entirely automatic or remote-controlled devices on the restricted area (section 562 of the Estonian Defence Forces Organisation Act). 5. It is not allowed to display symbols of aggression on the restricted area (section 1511 of the Penal Code). 6. The Estonian Defence Forces has a right to perform a security check on any person, personal item or vehicle on the restricted area (section 56 of the Estonian Defence Forces Organisation Act). 7. The board camera of a vehicle must be covered and any video and sound recording devices shut off on the restricted area (subsection 52 (2) of the Estonian Defence Forces Organisation Act). 8. It is not allowed to bring third persons or pets to the restricted area (subsection 52 (2) of the Estonian Defence Forces Organisation Act). 9. It is not allowed to bring or use alcohol, narcotic or psychotropic substances, nor be under the influence of such substances on the restricted area (subsection 52 (2) of the Estonian Defence Forces Organisation Act). 10. It is not allowed to bring a weapon, a drone, explosives, fuels or ignitions or anything that contains such substances, or any equipment that might endanger the people, technology and devices on the restricted area. This list is not conclusive, and the Estonian Defence Forces has the right to evaluate the hazards of any personal items and prevent any person from entering with a potentially dangerous item (subsection 52 (2) of the Estonian Defence Forces Organisation Act). 11. It is not allowed to disclose to any third persons the information made available to a person on the restricted area (subsection 52 (2) of the Estonian Defence Forces Organisation Act). (day, month, year) [ signed digitally ]4 4 Could also be signed on paper. 2/2 LISA 4: Näidis Sissepääsutaotlus (e-kiri) Taotlus saata lepingus määratud RKIK kontaktisiku või tema poolt määratud isiku e-posti aadressile. PEALKIRI: Sissepääsutaotlus (linnaku ja objekti nimetus) TEKST: ASUTUSESISESEKS KASUTAMISEKS KAITSEVÄGI Tere Juurdepääsupiirang kehtib alates dokumendi koostamise kuupäevast kuni vajaduse möödumiseni, kuid mitte kauem kui 75 aastat Alus: avaliku teabe seadus § 35 lg 1 p 12 Seoses RKIK (lepingu nimi) lepinguga nr xxxxxxxxx, sõlmitud pp.kk.aaaa, edastan sissepääsutaotluse. Lisainfo on manuses (NB! kasutada MS Exceli formaati): Teenuse Teenuse Sõiduki mark ja reg Teenuse Osutatav osutamise osutamise number Eesnimi Perenimi Isikukood Ettevõte osutamise teenus perioodi algus perioodi lõpp objekt pp.kk.aaaa pp.kk.aaaa Taotluse esitaja on teadlik, et: 1. taustakontrolli läbimine ei taga automaatset sissepääsu Kaitseväe julgeolekualale; 2. Kaitseväel on õigus piirata isikute sissepääsu Kaitseväe julgeolekualale. Lugupidamisega Taotluse esitaja ees- ja perenimi Ametikoht Ettevõtte nimi Kontakttelefon, e-posti aadress 1/1 LISA 5: Kaitseväe julgeolekualale sisenemisel ja viibimisel kehtestatud üldised julgeolekunõuded. Kaitseväe julgeolekualal viibimisel (KKS § 52 lg 3) peab täitma Kaitseväes kehtivat korda (sh tuleohutuse-, liiklemise- ja parkimise korda) ja Kaitseväe esindaja korraldusi (KKS § 52 lg 2), sealhulgas 1. Kaitseväe julgeolekualale on keelatud siseneda alkoholi, narkootiliste-või psühhotroopsete ainetega, tulirelvaga, lõhkematerjaliga, osaliselt või täielikult automaatse või kaugjuhitava lendava seadmega (droon, jmt), radioaktiivsete- ja kergesti süttivate ainetega või neid sisaldavate esemetega ja muude vahenditega, mis võivad ohustada isikut ennast või objektil viibivaid isikuid, tehnikat ja seadmeid; 2. Kaitseväe loata ei tohi Kaitseväe julgeolekualale tuua ega lubada kolmandaid isikuid; 3. Sõidukiga Kaitseväe julgeolekualale sisenedes on kohustuslik video- ja/või helisalvestavad sõidukaamerad katta, välja lülitada või eemaldada; 4. Kaitseväel on õigus turvakontrolli läbiviimiseks pidada kinni isikut (sealhulgas sõidukit) sisenemisel Kaitseväe julgeolekualale, viibimisel Kaitseväe julgeolekualal või väljumisel Kaitseväe julgeolekualalt ning kontrollida isikut (sealhulgas tema riietust või temaga kaasas olevat asja (sealhulgas sõidukit) vaatlemise ja kompimise teel või tehnilise vahendi või väljaõppe saanud teenistuskoera abil; 5. Kaitsevägi võib julgeoleku- või ohutuskaalutlustel ajutiselt keelata isikutele sissepääsu Kaitseväe julgeolekualale ja anda korralduse Kaitseväe julgeolekualal viibivatele isikutele Kaitseväe julgeolekualalt lahkuda või keelata sealt lahkumist; 6. Kaitseväe eelneva nõusolekuta on keelatud pildistamine, video- ja helisalvestamine Kaitseväe julgeolekualal ja -hoonetes ning nimetatud materjali jagamine/üleslaadimine mis tahes kujul ja keskkonnas; 7. Kaitseväe julgeolekualal on keelatud viibida alkoholi, narkootiliste- või psühhotroopsete ainete tarvitamise kahtlusega, -tunnustega või -joobes; 8. Kaitseväe julgeolekualal on keelatud kasutada (sealhulgas sõidukites) agressioonisümboleid. 1/1 HANKELEPING 19.05.2026 nr 2-2/26/607-2 Riigi Kaitseinvesteeringute Keskus (registrikood 70009764, aadress Järve 34a, 11314 Tallinn), keda esindab direktori 07.12.2020 käskkirja nr 77 punkti 6.3² alusel kategooriajuht Maia Prunt hankebüroo juhi ülesannetes (edaspidi ostja), ning Alwark OÜ (endise ärinimega Willenbrock Baltic OÜ) (registrikood 11341282, aadress Uus-Ringi tee 11, Jüri alevik, Rae vald 75301, Harju maakond), keda esindavad põhikirja alusel juhatuse liikmed Siimo Tänavots ja Marek Ploom (edaspidi müüja), eraldi pool ja ühiselt pooled, on sõlminud järgmise lepingu: 1. Lepingu sõlmimise alus ja ese 1.1. Leping on sõlmitud lähtudes riigihanke „Tõstukite ostmine, rentimine, hooldus ja remont“ (viitenumber 274884) tulemusel sõlmitud raamlepingu nr 2-2/24/607-1 alt riigihanke osas 1 läbi viidud minikonkursi „Tõstukid ja käsikahvelkärud“ (viitenumber 305669) osa 1 alusdokumentidest ja selles riigihankes müüja esitatud pakkumusest. 1.2. Lepingu ese on 2 tk rasketõstukite SMV 25-1200 C ostmine (kaup kirjeldatud minikonkursi raames esitatud tehnilises kirjelduses). 1.3. Kauba tarneaeg on 12 kuud alates lepingu jõustumisest. 1.4. Lepingus kohalduvad kõik raamlepingu nr 2-2/24/607-1 tingimused. 2. Lepingu täitmine 2.1. Ostja sõlmib hankelepingu pakkujaga, kes on esitanud minikonkursi raames riigihanke alusdokumentidele vastava ja pakkumuste hindamiskriteeriumite alusel parima pakkumuse (kes sai pakkumuste hindamisel enim väärtuspunkte) ning kellel puuduvad eduka pakkuja kontrollimise hetkel kõrvaldamise alused. 2.2. Hankeleping sõlmitakse kauba ostmiseks või teenuste tellimiseks minikonkursi tehnilises kirjelduses kirjeldatud kauba nimekirja ja kirjelduste alusel. 3. Kauba üleandmine-vastuvõtmine 3.1. Kauba transportimine ostja määratud sihtkohta toimub müüja poolt korraldatud transpordiga ja müüja kulul. 3.2. Müüja on kohustatud kooskõlastama täpse kauba üleandmise aja ostja kontaktisikuga hiljemalt 5 tööpäeva enne planeeritud kaupade üleandmist. 3.3. Kauba vastuvõtuaeg on üldjuhul esmaspäevast neljapäevani ajavahemikus 8.30–15.00, v.a rahvus- ja riigipühad ning nendele eelnevad tööpäevad ja iga kuu kolm viimast tööpäeva. 3.4. Kui kauba tarnimine viibib, kui kaupa ei ole võimalik kokkulepitud kuupäevaks kohale toimetada, on müüja kohustatud sellest koheselt teavitama ostja kontaktisikut e-kirja teel. 3.5. Kauba üleandmine müüjalt ostjale toimub saatelehega. Saatelehel peab olema kirjas vähemalt ostja nimi (Riigi Kaitseinvesteeringute Keskus), ostja kontaktisiku nimi, raamlepingu ja hankelepingu (ostutellimuse jms) number, kauba nimi, kogus, ühik, tarne aeg ja koht. 3.6. Vastavalt tarnekohtade arvule koostatakse ka nii mitu saatelehte. 3.7. Saatelehe puudumise korral on ostjal õigus vastav kaup enda valdusesse võtta, kuid üleandmine-vastuvõtmine loetakse toimunuks korrektse saatelehe kättesaamisel. 3.8. Müüja kohustub andma ostjale üle kõik dokumendid, mis on vajalikud kauba vastuvõtmiseks, valdamiseks, kasutamiseks ja käsutamiseks.  3.9. Kaup ei tohi saada transportimise ja käsitlemise käigus kahjustada. 3.10. Müüja peab arvestama, et kui kaupade tarnimine toimub julgeolekualal/objektil/erivalverežiimiga alal, eeldab see müüjalt kui ka tema alltöövõtjatelt Kaitseväe dokumendis „Julgeolekutingimused“ sätestatud nõuete ja tingimuste täitmist (Lisa 2). Müüja peab taotlema Kaitseväe korralduse seaduse § 41³ sätestatud nõuete alusel vähemalt 14 kalendripäeva enne tarne algust või teenuse osutamist sissepääsuluba Kaitseväe julgeolekualale ning esitama sissepääsutaotluse oma töötajate (sh ka alltöövõtjate) andmetega ja nende taustakontrolli teostamist lubava kirjaliku nõusoleku. Müüja peab arvestama asjaoluga, et julgeolekualaste nõuete mittejärgimise korral on ostjal õigus keelduda müüja ja tema alltöövõtjate territooriumile lubamisest. 4. Lepingu maksumus ja maksetingimused 4.1. Leping on sõlmitud ostja vajaduse põhiselt ühekordse tellimuse tegemiseks. Kauba ühiku hind on määratud müüja pakkumuses ja see on lepinguperioodil siduv. Lepingu kogumaksumus on 839 162 eurot, millele lisandub käibemaks seaduses sätestatud juhul. 4.2. Müüja kanda jäävad kauba üleandmisest ja veost tulenevad kulud kuni kauba üleandmiseni. Müüja kanda jäävad ka kaubaga seotud kulud ja koormatised kauba üleandmiseni, v.a kulud, mis on põhjustatud ostjast tulenevast asjaolust. 4.3. Ostja kanda jäävad kauba vastuvõtmiseks, lepingu ettevalmistamiseks ja ostuhinna tasumiseks tehtavad kulud. 4.4. Müüja esitab arve pärast kauba nõuetekohast üle andmist või teenuse nõuetekohast osutamist. 4.5. Müüja esitab arve e-arvena (masintöödeldavas XML-formaadis). Juhul, kui väljaspool Eesti Vabariiki registreeritud müüjal ei ole tehnilistel põhjustel võimalik esitada e-arvet, siis ta esitab lepingus nimetatud e-posti aadressile PDF-formaadis arve juhul, kui ei ole teisiti kokku lepitud. Müüja esitab arve järgmiste andmetega: Riigi Kaitseinvesteeringute Keskus, registrikood 70009764, Järve 34a, 11314 Tallinn. Muud arvele märgitavad andmed: kontaktisiku nimi; raamlepingu number: 2-2/24/607-1; hankelepingu number: riigihanke viitenumber: 305669; riigihanke viitenumber osa 1: 274884005001001; kauba kogus ja nimetus, tootekood (selle olemasolul); ühiku hind ja muu vajalik teave. Müüja pangarekvisiidid: Saaja pank: OP Corporate Bank plc Eesti filiaal Saaja pangakonto number (IBAN): EE935100005100121473 SWIFT OKOYEE2X 4.6. Ostja tasub vastuvõetud ja lepingu tingimustele vastava kauba eest lepingus nimetatud arveldusarvele 28 päeva jooksul pärast lepingutingimustele vastava arve kättesaamist. Arve esitamise aluseks on poolte poolt allkirjastatud saateleht ja vajadusel kvaliteedikontrolli akt. 4.7. Ostja ei aktsepteeri arvet, mis ei vasta lepingutingimustele. Sellisel juhul müüja esitab uue arve 7 päeva jooksul. 4.8. Müüja kohustub esitama vajadusel eraldi arve NATO relvajõudude tarbeks tehtud kulude kohta. 4.8.1. NATO relvajõudude tarbeks tellitud kaubale rakendub 0%-line käibemaksumäär vastavalt käibemaksuseaduse §-le 15. 4.8.2. Maksusoodustuse rakendamise aluseks on müüjale ostja poolt esitatud käibemaksuvabastuse tõend. 2/3 5. Garantiikohustus Lepinguga annab müüja kõikidele rasketõstukitele garantii vähemalt 2 aastat või 5000 h. 6. Kontaktisikud 6.1. Ostja kontaktisik on Katrin Maidlas (e-post [email protected], tel +372 5785 4991). 6.2. Müüja kontaktisik on Marek Ploom (e-post [email protected], tel +372 5349 1868). 7. Lõppsätted Leping jõustub mõlemapoolsest allkirjastamisest ja kehtib kuni lepinguliste kohustuste täitmiseni. 8. Lisad 8.1. Lisa 1. Müüja pakkumus; 8.2. Lisa 2. Julgeolekutingimused koos lisadega. Ostja: Müüja: (allkirjastatud digitaalselt) (allkirjastatud digitaalselt) Maia Prunt Marek Ploom kategooriajuht juhatuse liige hankebüroo juhi ülesannetes (allkirjastatud digitaalselt) Siimo Tänavots juhatuse liige 3/3  PAKKUMUS HINDAMISKRITEERIUMID JA HINNATAVAD NÄITAJAD Viitenumber: 305669 Hankija: Riigi Kaitseinvesteeringute Keskus (70009764) Hange: Tõstukid ja käsikahvelkärud Pakkumus: 616886 Ettevõtja: Willenbrock Baltic OÜ (11341282), roll: peapakkuja OSA 1 – RASKETÕSTUK 25T Pakkumuse maksumust hinnatakse - Ilma maksudeta 1. Pakkumuse kogumaksumus Pakkumuse kogumaksumus ilma käibemaksuta. Pakkumuse kogumaksumus peab sisaldama kõiki tarnega seotud kulusid. Tüüp ja hindamismeetod: Maksumus, vähim on parim Osakaal: 100% Hindamismetoodika kirjeldus: Madalaima väärtusega pakkumus saab maksimaalse arvu punkte. Teised pakkumused saavad punkte arvutades valemiga: "osakaal" - ("pakkumuse väärtus" - madalaim väärtus") / "suurim väärtus" * "osakaal". a. Rasketõstuk 25T Tehniline kirjeldus alusdokumentide juures. Tõstuki(te) tarne Eesti Vabariigi piires vastavalt etteantud tellimusaadressile. Kogus Ühik Ühiku hind Maksumus KM% Maksumus KM-ga Märkused 2 tk 419581,000 839162,000 24 1040560,880 Osa maksumus kokku KM-ta: 839162,000 Osa maksumus kokku KM-ga: 1040560,880 OSA 2 – KÄSIKAHVELKÄRU 1200MM KAHVLITEGA, KAALUGA Pakkumuse maksumust hinnatakse - Ilma maksudeta 1. Pakkumuse kogumaksumus Koostatud 13.03.2026 11:52:04 1/2 https://riigihanked.riik.ee/rhr-web/#/procurement/ 9878684/general-info  Pakkumuse kogumaksumus ilma käibemaksuta. Pakkumuse kogumaksumus peab sisaldama kõiki tarnega seotud kulusid. Tüüp ja hindamismeetod: Maksumus, vähim on parim Osakaal: 100% Hindamismetoodika kirjeldus: Madalaima väärtusega pakkumus saab maksimaalse arvu punkte. Teised pakkumused saavad punkte arvutades valemiga: "osakaal" - ("pakkumuse väärtus" - madalaim väärtus") / "suurim väärtus" * "osakaal". a. Käsikahvelkäru 1200mm kahvlitega, kaaluga Tehniline kirjeldus alusdokumentide juures. Tarneaeg max 90 päeva. Kogus Ühik Ühiku hind Maksumus KM% Maksumus KM-ga Märkused 25 tk 1595,000 39875,000 24 49445,000 Osa maksumus kokku KM-ta: 39875,000 Osa maksumus kokku KM-ga: 49445,000 Pakkumuse maksumus kokku Maksumus kokku KM-ta: 879037,000 Maksumus kokku KM-ga: 1090005,880 Koostatud 13.03.2026 11:52:04 2/2 https://riigihanked.riik.ee/rhr-web/#/procurement/ 9878684/general-info  1/4 PAKKUMUS VASTAVUSTINGIMUSED Viitenumber: 305669 Hankija: Riigi Kaitseinvesteeringute Keskus (70009764) Hange: Tõstukid ja käsikahvelkärud Pakkumus: 616886 Ettevõtja: Willenbrock Baltic OÜ (11341282), roll: peapakkuja OSA 1: RASKETÕSTUK 25T PAKKUMUSE ESITAMINE Pakkumuse esitamisega kinnitab pakkuja kõigi riigihanke alusdokumentides esitatud tingimuste ülevõtmist. Pakkumus peab vastama riigihanke „Tõstukite ostmine, rentimine, hooldus ja remont" (viitenumber 274884), selle tulemusena sõlmitud raamlepingu ja minikonkursi (305669) tingimustele. Tingimusliku pakkumuse esitamine ei ole lubatud. Kõik täiendavad dokumendid pakkumuses, mida hankija riigihanke alusdokumentides ei ole nõudnud, on informatiivsed lisamaterjalid, mida hankija ei ole kohustatud arvestama pakkumuste menetlemisel. Ettevõtjalt oodatavad vastused: 1. Kas pakkuja kinnitab, et pakkumus vastab riigihanke „Tõstukite ostmine, rentimine, hooldus ja remont" (viitenumber 274884) raamlepingu ja antud minikonkursi tingimustele? (Raadionupp valikutega "Jah/Ei") Vastus: Jah TEHNILINE KIRJELDUS Ettevõtjalt oodatavad vastused: 1. Kinnitan, et pakkuja poolt täidetud tehniline kirjeldus ja selles nõutavad dokumendid on lisatud pakkumusele. (Raadionupp valikutega "Jah/Ei") Vastus: Jah PAKUTAV TOODE Lisada pakkumise juurde foto või link pakutavast tootest Ettevõtjalt oodatavad vastused: 1. Pakkuja kinnitab, et on lisanud pakkumise juurde foto või lingi tootest (Raadionupp valikutega "Jah/Ei") Vastus: Jah PAKKUMUSE MAKSUMUS Pakkumuse maksumus tuleb esitada töölehel "Hindamiskriteeriumid ja hinnatavad näitajad" toodud struktuuri kohaselt. Koostatud 13.03.2026 11:52:04 https://riigihanked.riik.ee/rhr-web/#/procurement/9878684/general-info  2/4 Ettevõtjalt oodatavad vastused: 1. Kas pakkuja kinnitab, et täidab pakkumuse lehe "Hindamiskriteeriumid ja hinnatavad näitajad" lehel ette antud struktuuri kohaselt? (Raadionupp valikutega "Jah/Ei") Vastus: Jah ÄRISALADUS Pakkuja märgib pakkumuses, milline teave on pakkuja ärisaladus ning põhjendab teabe määramist ärisaladuseks. Teabe ärisaladuseks määramisel lähtutakse ebaausa konkurentsi takistamise ja ärisaladuse kaitse seaduse § 5 lõikes 2 sätestatust. Pakkuja ei või ärisaladusena märkida: 1) pakkumuse maksumust ega osamaksumusi; 2) teenuste hankelepingute puhul lisaks punktis 1 nimetatule muid pakkumuste hindamise kriteeriumidele vastavaid pakkumust iseloomustavaid numbrilisi näitajaid; 3) asjade ja ehitustööde hankelepingute puhul lisaks punktis 1 nimetatule muid pakkumuste hindamise kriteeriumidele vastavaid pakkumust iseloomustavaid näitajaid (RHS § 46 (1)). Ettevõtjalt oodatavad vastused: 1. Kirjeldage lühidalt pakkumuses sisalduvat ärisaladust ja lisage selle määramise põhjendus või märkige, et pakkumus ei sisalda ärisaladust. (Suur sisestusala (max pikkus 4000 tähemärki)) Vastus: ei sisalda ärisaladust EL NÕUKOGU SANKTSIOON. ALLTÖÖVÕTJAD JA TARNIJAD. Pakkuja kinnitab, et ta ei kaasa üle 10% hankelepingu maksumusest hankelepingu täitmisele alltöövõtjaid ega tarnijaid, kes on: 1. Vene Föderatsiooni kodanik, resident või Vene Föderatsioonis asutatud ettevõtja, sh füüsilisest isikust ettevõtja, juriidiline isik, asutus või muu üksus; 2. rohkem kui 50% ulatuses otseselt või kaudselt punktis 1 nimetatud isiku, asutuse või muu üksuse omandis; 3. punktis 1 või 2 nimetatud isiku, asutuse või muu üksuse esindaja või tegutseb sellise isiku juhiste alusel. Hankija lükkab tagasi pakkumuse, mille alusel sõlmitav hankeleping oleks RSanS § 7 lg 1 alusel tühine. Määrust kohaldatakse riigihangetele alates rahvusvahelisest piirmäärast. NÕUKOGU MÄÄRUS (EL) 2022/576, 8. aprill 2022, millega muudetakse määrust (EL) nr 833/2014, mis käsitleb piiravaid meetmeid seoses Venemaa tegevusega, mis destabiliseerib olukorda Ukrainas. Ettevõtjalt oodatavad vastused: 1. Pakkuja kinnitab, et ta ei kaasa üle 10% hankelepingu maksumusest hankelepingu täitmisele alltöövõtjaid ega tarnijaid, kes on: 1. Vene Föderatsiooni kodanik, resident või Vene Föderatsioonis asutatud ettevõtja, sh füüsilisest isikust ettevõtja, juriidiline isik, asutus või muu üksus; 2. rohkem kui 50% ulatuses otseselt või kaudselt punktis 1 nimetatud isiku, asutuse või muu üksuse omandis; 3. punktis 1 või 2 nimetatud isiku, asutuse või muu üksuse esindaja või tegutseb sellise isiku juhiste alusel. (Raadionupp valikutega "Jah/Ei") Vastus: Jah RAHVUSVAHELISE SANKTSIOONI OBJEKT Pakkuja kinnitab, et pakutav kaup ei ole rahvusvahelise sanktsiooni objektiks või pärit sanktsiooni all olevatest piirkondadest. Hankija lükkab tagasi pakkumuse, mille alusel sõlmitav hankeleping oleks RSanS § 7 lg 1 alusel tühine. Ettevõtjalt oodatavad vastused: 1. Pakkuja kinnitab, et pakutav kaup ei ole rahvusvahelise sanktsiooni objektiks ega pärit sanktsiooni all olevatest piirkondadest. (Raadionupp valikutega "Jah/Ei") Vastus: Jah Koostatud 13.03.2026 11:52:04 https://riigihanked.riik.ee/rhr-web/#/procurement/9878684/general-info  3/4 OSA 2: KÄSIKAHVELKÄRU 1200MM KAHVLITEGA, KAALUGA PAKKUMUSE ESITAMINE Pakkumuse esitamisega kinnitab pakkuja kõigi riigihanke alusdokumentides esitatud tingimuste ülevõtmist. Pakkumus peab vastama riigihanke „Tõstukite ostmine, rentimine, hooldus ja remont" (viitenumber 274884), selle tulemusena sõlmitud raamlepingu ja minikonkursi (305669) tingimustele. Tingimusliku pakkumuse esitamine ei ole lubatud. Kõik täiendavad dokumendid pakkumuses, mida hankija riigihanke alusdokumentides ei ole nõudnud, on informatiivsed lisamaterjalid, mida hankija ei ole kohustatud arvestama pakkumuste menetlemisel. Ettevõtjalt oodatavad vastused: 1. Kas pakkuja kinnitab, et pakkumus vastab riigihanke „Tõstukite ostmine, rentimine, hooldus ja remont" (viitenumber 274884) raamlepingu ja antud minikonkursi tingimustele? (Raadionupp valikutega "Jah/Ei") Vastus: Jah TEHNILINE KIRJELDUS Ettevõtjalt oodatavad vastused: 1. Kinnitan, et pakkuja pakutav toode vastab tehnilisele kirjeldusele. (Raadionupp valikutega "Jah/ Ei") Vastus: Jah PAKUTAV TOODE Lisada pakkumise juurde foto või link pakutavast tootest Ettevõtjalt oodatavad vastused: 1. Pakkuja kinnitab, et on lisanud pakkumise juurde foto või lingi tootest (Raadionupp valikutega "Jah/Ei") Vastus: Jah PAKKUMUSE MAKSUMUS Pakkumuse maksumus tuleb esitada töölehel "Hindamiskriteeriumid ja hinnatavad näitajad" toodud struktuuri kohaselt. Ettevõtjalt oodatavad vastused: 1. Kas pakkuja kinnitab, et täidab pakkumuse lehe "Hindamiskriteeriumid ja hinnatavad näitajad" lehel ette antud struktuuri kohaselt? (Raadionupp valikutega "Jah/Ei") Vastus: Jah ÄRISALADUS Pakkuja märgib pakkumuses, milline teave on pakkuja ärisaladus ning põhjendab teabe määramist ärisaladuseks. Teabe ärisaladuseks määramisel lähtutakse ebaausa konkurentsi takistamise ja ärisaladuse kaitse seaduse § 5 lõikes 2 sätestatust. Pakkuja ei või ärisaladusena märkida: 1) pakkumuse maksumust ega osamaksumusi; 2) teenuste hankelepingute puhul lisaks punktis 1 nimetatule muid pakkumuste hindamise Koostatud 13.03.2026 11:52:04 https://riigihanked.riik.ee/rhr-web/#/procurement/9878684/general-info  4/4 kriteeriumidele vastavaid pakkumust iseloomustavaid numbrilisi näitajaid; 3) asjade ja ehitustööde hankelepingute puhul lisaks punktis 1 nimetatule muid pakkumuste hindamise kriteeriumidele vastavaid pakkumust iseloomustavaid näitajaid (RHS § 46 (1)). Ettevõtjalt oodatavad vastused: 1. Kirjeldage lühidalt pakkumuses sisalduvat ärisaladust ja lisage selle määramise põhjendus või märkige, et pakkumus ei sisalda ärisaladust. (Suur sisestusala (max pikkus 4000 tähemärki)) Vastus: ei sisalda ärisaladust EL NÕUKOGU SANKTSIOON. ALLTÖÖVÕTJAD JA TARNIJAD. Pakkuja kinnitab, et ta ei kaasa üle 10% hankelepingu maksumusest hankelepingu täitmisele alltöövõtjaid ega tarnijaid, kes on: 1. Vene Föderatsiooni kodanik, resident või Vene Föderatsioonis asutatud ettevõtja, sh füüsilisest isikust ettevõtja, juriidiline isik, asutus või muu üksus; 2. rohkem kui 50% ulatuses otseselt või kaudselt punktis 1 nimetatud isiku, asutuse või muu üksuse omandis; 3. punktis 1 või 2 nimetatud isiku, asutuse või muu üksuse esindaja või tegutseb sellise isiku juhiste alusel. Hankija lükkab tagasi pakkumuse, mille alusel sõlmitav hankeleping oleks RSanS § 7 lg 1 alusel tühine. Määrust kohaldatakse riigihangetele alates rahvusvahelisest piirmäärast. NÕUKOGU MÄÄRUS (EL) 2022/576, 8. aprill 2022, millega muudetakse määrust (EL) nr 833/2014, mis käsitleb piiravaid meetmeid seoses Venemaa tegevusega, mis destabiliseerib olukorda Ukrainas. Ettevõtjalt oodatavad vastused: 1. Pakkuja kinnitab, et ta ei kaasa üle 10% hankelepingu maksumusest hankelepingu täitmisele alltöövõtjaid ega tarnijaid, kes on: 1. Vene Föderatsiooni kodanik, resident või Vene Föderatsioonis asutatud ettevõtja, sh füüsilisest isikust ettevõtja, juriidiline isik, asutus või muu üksus; 2. rohkem kui 50% ulatuses otseselt või kaudselt punktis 1 nimetatud isiku, asutuse või muu üksuse omandis; 3. punktis 1 või 2 nimetatud isiku, asutuse või muu üksuse esindaja või tegutseb sellise isiku juhiste alusel. (Raadionupp valikutega "Jah/Ei") Vastus: Jah RAHVUSVAHELISE SANKTSIOONI OBJEKT Pakkuja kinnitab, et pakutav kaup ei ole rahvusvahelise sanktsiooni objektiks või pärit sanktsiooni all olevatest piirkondadest. Hankija lükkab tagasi pakkumuse, mille alusel sõlmitav hankeleping oleks RSanS § 7 lg 1 alusel tühine. Ettevõtjalt oodatavad vastused: 1. Pakkuja kinnitab, et pakutav kaup ei ole rahvusvahelise sanktsiooni objektiks ega pärit sanktsiooni all olevatest piirkondadest. (Raadionupp valikutega "Jah/Ei") Vastus: Jah Koostatud 13.03.2026 11:52:04 https://riigihanked.riik.ee/rhr-web/#/procurement/9878684/general-info  1/1 PAKKUMUS KÕRVALDAMISE ALUSED JA KVALIFITSEERIMISTINGIMUSED Viitenumber: 305669 Hankija: Riigi Kaitseinvesteeringute Keskus (70009764) Hange: Tõstukid ja käsikahvelkärud Pakkumus: 616886 Ettevõtja: Willenbrock Baltic OÜ (11341282), roll: peapakkuja KÕRVALDAMISE ALUSED KÕRVALDAMISE ALUSED Hankija ei sõlmi hankelepingut pakkujaga ja kõrvaldab pakkuja, kellel esinevad riigihangete seaduse (RHS) § 95 lg 1 ja lg 4 välja toodud kõrvaldamise alused. Hankija kontrollib edukal pakkujal kõrvaldamise aluste puudumist avalikest registritest Kehtib: Kogu hanke kohta Ettevõtjalt oodatavad vastused: 1. Kas pakkuja kinnitab, et tal puuduvad kõrvaldamise alused? Vastus: Jah Kokkuvõtlikud kinnitused Ettevõtja kinnitab, et esitatud teave on täpne ja õige ning et ta on teadlik valeandmete esitamise tagajärgedest. Ettevõtja kinnitab, et tal on võimalik vajaduse korral viivitamata tema kinnitustele vastavad dokumendid hankijale esitada. Ettevõtja kinnitab, et ta on nõus oma kinnitustele vastavate andmete väljastamisega hankijale, kui need andmed on avalike andmete põhjal hankijale oluliste kulutusteta elektroonilisest andmekogust kättesaadavad. Kinnituse andja nimi: Marek Ploom Koostatud 13.03.2026 09:00:50 https://riigihanked.riik.ee/rhr-web/#/procurement/9878684/general-info  Calculationnumber:..........SMV4535TB5Volvo1171 Creator/Version:................KLSDSJ/2.54.11 7(&+1,&$/'$7$609͈& Machinetype SMV25Ͳ1200C LOADHANDLINGDATA Liftingcapacity/Loadcenter kg/mm 25000/1200 Maximumliftingspeed,unloaded/at70%ofratedload m/s 0,32/0,30 Maximumloweringspeed,unloaded/atratedload m/s 0,38/0,40 DRIVINGDATA Drivespeedforward,unloaded/atratedload km/h 26/25 Drivespeedreverse,unloaded/atratedload km/h 26/25 Incline(drivingability)atratedloadat0km/h/at2km/h % 38/27 Towing(powerability)atratedloadat0km/h/at2km/h kN 218/164 SERVICEWEIGHT/AXLELOADS Serviceweight kg 34100 Axleloadfront,unloaded/atratedload kg 16700/55100 Axleloadrear,unloaded/atratedload kg 17400/4000 ENGINE Enginemake,modelname VolvoTAD851ͲVE EmissionapprovalEU/US StageIIIA/Tier3 Monitoring/emissioncontrolled/CanBus  Yes/yes/yes Fuel/typeofengine Diesel/4ͲstrokeCI RatedpowerISO3046/maxspeed kW/rpm 185/2200 RatedtorqueISO3046/atspeed Nm/rpm 1160/1350 Displacement/No.ofcylinders/configuration L// 7,7/6/Inline Fuelconsumption,normaloperations L/h 8Ͳ12 Alternator,type/power/amperage W/Amp AC/3080/110 Startingbattery,voltage/capacity V/Ah 2x12/140 TRANSMISSION Transmissionmake,modelname DANATEͲ17 Monitoring/reverseprotection/CanBus Yes/yes/yes Clutch,type Torqueconverter Transmissiontype/typeofshiftgear Softshift–Powershift/Automatic No.ofgears,forward/reverse 3/3 DRIVEAXLE&STEERSYSTEM Driveaxlemake,modelname KesslerD91 Driveaxletype Differential+hubreduction Servicebrake,type/affectedwheels OilcooledWetDiscBrakes/drivewheels Parkingbrake,type/affectedwheels Drydiscbrake/springapplied/drivewheels STEERAXLE&STEERSYSTEM Steeraxlemake/type Konecranes/doubleactingsinglecylinder Steeringsystem Hydraulicservoassisted/powersteering WHEELS Numberofwheels,front+rear/Type(*driven)  4*+2/pneumatic Tirepressurefront/rear MPa 1,0/1,0 Tiredimensions(Plyrating)front/rear Inch(No) 14.00x24"(PR24)/14.00x24"(PR24) Rimdimensionfront/rear Inch 10.00x24"/10.00x24" HYDRAULICSYSTEM Hydraulicpumpmake,modelname ParkerP2Ͳseries Hydraulicsystem/pumptype Loadsensingsystem/variableaxialpistonpump PowerͲonͲdemand/Lowenergy  Yes/yes Hydraulicoilpressuremast MPa 24,0 TANKVOLUMES Fueltankvolume L 336 Hydraulictankvolume L 312 LIFTINGEQUIPMENT Liftmastmodel/masttype/design Konecranesduplexstandard/2Ͳstage/freevisibility Carriagemake/model Konecranes/Hydraulicintegralrollertype Forkmake/Model Konecranes/Rollertype OTHERS Noiselevel(insideCab/Lm)DIN45635 dB(A) 67 Noiselevel(insideCab/LpAZ)EN12053(EU+EFTAonly) dB(A) 73 Maximumnoiselevel(outsideLwa)2000/14/EC(EU+EFTAonly) LWA 107 NORMS&STANDARDS StabilityofIndustrialTrucksISO22915Ͳ2 Yes SafetyofIndustrialTrucksENISO3691Ͳ1 Yes .21(&5$1(6/,)7758&.6$% ZZZNFOLIWWUXFNVFRP %R[6(0DUNDU\G6:('(1 3KRQH 'DWDLQWKLVGRFXPHQWLVEDVHGRQDVWDQGDUGPDFKLQHLPSDFWIURPPRGLILFDWLRQVRUFXVWRPL]DWLRQVDUHQRWFRYHUHG .RQHFUDQHV/LIWWUXFNVUHVHUYHWKHULJKWWRDOWHUGHVLJQDQGVSHFLILFDWLRQZLWKRXWSULRUQRWLFH 7(&+1,&$/'$7$609͈&         .21(&5$1(6/,)7758&.6$% ZZZNFOLIWWUXFNVFRP %R[6(0DUNDU\G6:('(1 3KRQH 'DWDLQWKLVGRFXPHQWLVEDVHGRQDVWDQGDUGPDFKLQHLPSDFWIURPPRGLILFDWLRQVRUFXVWRPL]DWLRQVDUHQRWFRYHUHG .RQHFUDQHV/LIWWUXFNVUHVHUYHWKHULJKWWRDOWHUGHVLJQDQGVSHFLILFDWLRQZLWKRXWSULRUQRWLFH  Tõstuki operaatorite koolituse kava Eesmärk: Koolituse eesmärk on pakkuda tõstukite operaatoritele vajalikke teadmisi ja oskusi, mis tagavad masina ohutu ja tõhusa kasutamise, vähendades vigade ja ohtude riski. Kava teemad ja järjestus: Ohutuse põhimõtted Tõstukite kasutamise üldine ohutus. Tööohutuse reeglid töökeskkonnas. A kude laadimis ega seotud ohutusnõuded Kaitsevarustuse kasutamine ja ohutustsoonide määratlemine. Masina kasutamise üldised põhimõtted Tõstukite töökeskkonna ja tööülesannete mõistmine. Nõuded masina eelkontrolliks enne töö alustamist. Mida järgida tõstuki kasutamise ajal. Masina kasutamise spetsiifilised teadmised Konkreetse tõstuki mudeli tehnilised omadused. Spetsiaalsed funktsioonid ja lisaseadmete kasutamine. Connecti kasutamine Digitaalse süsteemi Connect kasutamise tutvustus. Andmete sisestamine, ülevaatamine ja aruannete koostamine. Kaugjuhtimise ja diagnostika võimalused. Lihtsamate vigade tuvastamine ja kõrvaldamine Tõstuki rutiinne hooldus ja lihtsate probleemide lahendamine. Tüüpilised vead ja nende ennetamine. Veakoodide ja märgutulede selgitus Veakoodide tähenduse mõistmine ja kasutusjuhendi järgimine. Märgutulede roll ja tähtsus masina töös. Lisamärkused: Koolitus peaks sisaldama nii teoreetilist osa kui ka praktilist harjutamist. Oluline on kohandada kava vastavalt kasutatavate tõstukite tüübile ja ettevõtte vajadustele. Koolituse lõpuks peaksid osalejad suutma iseseisvalt tõstukit opereerida ja järgida ohutusnõudeid. C&D RANGER 6TAGM BATTERY With over 5.5 million batteries sold yearly in over 120 countries, C&D Technologies is a world leader in energy storage solutions. The Ranger 6TAGM battery delivers high performance and reliability for military-style and power sports vehicles. BENEFITS HIGH-STARTING POWER: Powerful cold UNMATCHED RELIABILITY: Our batteries are cranking amps significantly reduce engine designed for durability in extreme temperatures start-up wear and tear and improve engine and demanding environments. efficiency and lifespan. MAINTENANCE-FREE​: AGM/VRLA technology LONG SHELF LIFE: Even when not in use, requires no service and comes with safety expect the longest battery life and, therefore, features like a flame arrestor and leak-proof reduced lifetime replacement costs thanks all-welded construction for longer life. to AGM/VRLA technology. FEATURES • 6T NATO-Size Battery • 120 Ah C20 Battery • 24-Month Shelf Life @ 77˚F (25˚C) • 1100 Cold Cranking Amps • 230 Min Reserve Capacity • 90 lb (40kg) Weight • Non-Spillable Transport-Class C&D RANGER 6TAGM BATTERY SPECIFICATIONS RANGER 6TAGM BATTERY SIZE 6T CHEMISTRY / BATTERY TYPE AGM / VRLA NOMINAL VOLTAGE 12-volt NOMINAL CAPACITY 120Ah (C/20: 6A to 1.75VPC, 27°C) COLD CRANKING AMPS 1100 amps RESERVE CAPACITY 230 minutes (25A to 1.75VPC, 27°C) DIMENSIONS IN [MM] See figure WEIGHT (LB / KG) 90 lb (40.75 kg) TERMINAL TYPE AP TERMINAL TORQUE 50-70 in.lb ©2025 C&D Technologies Inc. Any data, descriptions or specifications presented herein are subject to revision by C&D RANGER 6TAGM DATASHEET REV 02/21/2025 C&D Technologies, Inc. without notice. While such information is believed to be accurate as indicated herein, C&D Technologies, Inc. makes no warranty and hereby disclaims all warranties, express or implied, with regard to the accuracy or completeness of such information. Further, because the product(s) featured herein may be used under conditions beyond its control, C&D Technologies, Inc. hereby disclaims all warranties, either express or implied, concerning the fitness or suitability of such product(s) for any particular use or in any specific application or arising from any course of dealing or usage of trade. The user is solely responsible for determining the suitability of the product(s) featured herein for user’s intended purpose and in user’s specific application. 200 Precision Road, Horsham, Pennsylvania 19044 USA | www.cdtechno.com   Your trusted business partner for independent testing and certification of agricultural machinery Prüfbericht Test report Industrial trucks - Overhead guards - Specification and testing Berichts-Nr. 2411-0007 Report no. Prüfgrundlage ISO 6055:2023 Test standard Prüfobjekt Optima cab Test item Auftraggeber FRITZMEIER Systems GmbH Applicant FO-DLGTS_PrüfberichtVL_DE-EN_DAkkS_2024_V00 DLG TestService GmbH Geschäftsführer: Rudolf Hepp, Christian Grachtrup Max-Eyth-Weg 1 Sitz der Organisation: Gau-Bickelheim D-64823 Groß-Umstadt Amtsgericht Mainz HRB 40800 USt-IdNr.: DE114139855 Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 2 von / of 14 Prüfobjekt / Test item Optima cab I Allgemein General Auftraggeber (Name und Adresse) FRITZMEIER Systems GmbH Applicant (Name and address) Großhelfendorf, Forststraße 2 D-85653 Aying Hersteller (Name und Adresse) FRITZMEIER Systems GmbH Manufacturer (Name and address) Großhelfendorf, Forststraße 2 D-85653 Aying II Anhänge Annexes Anhang A Prüfprotokoll - ISO 6055:2023 Test record - ISO 6055:2023 III Anlagen Enclosures Anlage A Darstellung der Kabine Description of cab Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 3 von / of 14 Prüfobjekt / Test item Optima cab IV Zusammenfassung Summary Das Prüfobjekt erfüllt vollumfänglich die Anforderungen der Prüfgrundlage ISO 6055:2023. Alle Ergebnisse beziehen sich nur auf die geprüften Muster. Bei Konformitätsentscheidungen wurde die Messunsicherheit gemäß der Norm angewendet. Es wurden keine anderen Messungen als die beschriebenen durchgeführt. Dieser Bericht darf nur vom Auftraggeber und nur in vollem Wortlaut vervielfältigt und weitergegeben werden. Eine auszugsweise Vervielfältigung und Veröffentlichung des Berichtes ist nur nach schriftlicher Genehmigung zulässig. The test object is in full compliance with the test standard ISO 6055:2023. All results refer only to the tested object. In conformity decisions, the measurement uncertainty was applied according to the standard. No other measurements than those described were carried out. This report may only be reproduced and passed on by the client and only in full. Reproduction and publication of extracts of the report is only permitted with written consent. Unterschriftsberechtigter Interne Qualitätskontrolle Authorised signatory Internal Quality Check M.Sc. Dubielski Dipl.-Ing. (FH) Keunecke Groß-Umstadt, 15.11.2024 Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 4 von / of 14 Prüfobjekt / Test item Optima cab Anhang A Annex A Prüfprotokoll ISO 6055:2023 Test record 0 Vorbemerkungen Die Festigkeitsüberprüfungen wurden für 2 Remarks Kabinenvarianten, Standard- und Hochkabine, durchgeführt. The strength tests were performed on 2 cab options, standard and high cab. 1 Prüfgrundlagen ISO 6055:2023 Test standard 2 Prüfbedingungen Test conditions 2.1 Prüfobjekt Kabine Test object cab 2.2 Mess- und Prüfeinrichtungen Prüfstand Nr. 2.58 Equipment for measuring and testing test rig no. 2.3 Prüfortparameter 20°C Parameter of the test area 3 Prüfergebnisse Gliederung in Klammern gemäß Test results Prüfgrundlage Structure in brackets according to test standard (A.1) Kennzeichnung Identification (A.1.1) Fahrzeug Machine Bauart: Gabelstapler, Leercontainerstapler, Type Teleskopstapler Forklift truck, Empty container handler, Reach stacker Hersteller: Konecranes Lifttrucks AB Manufacturer Anders Anderssons väg 13 285 23 Markaryd / Sweden Typ Bezeichnung: SMV 10-100, SMV 28-52G, SMV EC, Model number SMV RS Serien Nummer: -n/a- Serial number Maschinen-Rahmen-Nummer: -n/a- Machine frame part number Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 5 von / of 14 Prüfobjekt / Test item Optima cab (A.1.2) Schutzdach Overhead guard Hersteller: FRITZMEIER Systems GmbH Manufacturer Großhelfendorf, Forststraße 2 D-85653 Aying Typ: Optima cab Model Serien Nummer: -n/a- Serial number Bauteil-Nr.: Standardkabine / standard cab Part number Konecranes: 6211.001, 6211.040 Fritzmeier: 826380, 833620 Hochkabine / high cab Konecranes: 6211.151, 6238.180 Fritzmeier: 859355, 859377 (A.2) Informationen der Prüfeinrichtung Information supplied by test facility (A.2.1) Beschreibung der Fallprüfkörper Test object description (A.2.1.1) Dynamische Prüfung & Schutz der Beine und Füße des Bedieners Dynamic test & Operators' legs and feet protection test Genormter Fallprüfkörper mit einer quadratischen Eichenholzgrundplatte und einer Kantenlänge von 300 mm. Standard laboratory drop test object with a square striking face made of oak wood and side dimension of 300 mm. Masse: 45,00 kg Mass Fallhöhe bei der Prüfung: 1,50 m Drop height in the test Anzahl der dyn. Belastungen: 10 Number of drops (A.2.1.2) Aufprallprüfung Impact drop test Die Prüflast besteht aus einem Stapel normalem Bauholzes mit dem Querschnitt 50 mm x 100 mm. Der Holzstapel ist 3600 mm lang, 1000 mm breit und hat eine Höhe von 700 mm. Die einzelnen Hölzer sind mit der 100 mm Abmessung in horizontaler Richtung angeordnet. Zusammengehalten werden die einzelnen Hölzer über einen Spanngurt in der Mitte und zweien jeweils 900 mm von jedem Ende entfernt. The test load is composed of 50 mm x 100 mm nominal construction timber boards. The stack of wood has a length of 3600 mm, a width of 1000 mm and has a height of 700 mm. The timber is placed with the 100 mm nominal dimension of the cross section Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 6 von / of 14 Prüfobjekt / Test item Optima cab horizontal. The timbers are bound together with one tension belt in the centre and two tension belts 900 mm from each end. Masse: 1340 kg Mass Fallhöhe bei der Prüfung: 3,72 m Drop height in the test (A.3) Informationen vom Hersteller Information supplied by manufacturer Tragfähigkeit der Maschine: * > 10000 kg Truck rated capacity Lagebestimmung des SIP: Auf der Längsmittelebene der Kabine und Location of SIP 477 mm vor der Rückwand. On longitudinal median plane of the cab and 477 mm in front of rear wall. (A.4) Fotos Photographs (A.4.1) Dynamische Prüfung Dynamic test Bild / Picture 1: Oberseite vor dem Test / Top surface before the test Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 7 von / of 14 Prüfobjekt / Test item Optima cab Bild / Picture 2: Zweiter Fall bei -20°C / Second drop at -20°C Bild / Picture 3: Zehnter Fall bei -20°C / Tenth drop at -20°C Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 8 von / of 14 Prüfobjekt / Test item Optima cab Bild / Picture 4: Oberseite nach der Prüfung bei -20°C / Top surface after the test at -20°C Bild / Picture 5: Zweiter Fall bei 40°C / Second drop at 40°C Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 9 von / of 14 Prüfobjekt / Test item Optima cab Bild / Picture 6: Zehnter Fall bei 40°C / Tenth drop at 40°C Bild / Picture 7: Oberseite nach der Prüfung bei 40°C / Top surface after the test at 40°C (A.4.2) Schutz der Beine und Füße des Bedieners Operators' legs and feet protection test -n/a- (A.4.3) Aufprallprüfung Impact drop test Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 10 von / of 14 Prüfobjekt / Test item Optima cab Bild / Picture 8: Vor der Prüfung, Hochkabine / Before the test, high cab Bild / Picture 9: Aufschlag der Prüflast, Hochkabine / Impact of test load, high cab Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 11 von / of 14 Prüfobjekt / Test item Optima cab Bild / Picture 10: Nach dem Aufschlag der Prüflast, Hochkabine / After impact of test load, high cab Bild / Picture 11: Vor der Prüfung, Standardkabine / Before the test, standard cab Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 12 von / of 14 Prüfobjekt / Test item Optima cab Bild / Picture 12: Nach dem Aufschlag der Prüflast, Standardkabine / After impact of test load, standard cab (A.5) Prüfergebnisse Test results (A.5.1) Dynamische Prüfung Dynamic test Standardkabine bei -20°C / standard cab at -20°C: Die gesamte vertikale Verformung des Schutzdachs nach der dynamischen 5 mm Prüfung beträgt: The total vertical deformation of the overhead guard after the dynamic test was Standardkabine bei 40°C / standard cab at 40°C: Die gesamte vertikale Verformung des Schutzdachs nach der dynamischen 7 mm Prüfung beträgt: The total vertical deformation of the overhead guard after the dynamic test was (A.5.2) Schutz der Beine und Füße des Bedieners Operators' legs and feet protection test Die gesamte vertikale Verformung der Schutzstruktur für Beine und Füße -n/a- des Bedieners beträgt: The total vertical deformation of the operators' legs and feet protection structure after the test was (A.5.3) Aufprallprüfung Impact drop test Standardkabine / standard cab: Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 13 von / of 14 Prüfobjekt / Test item Optima cab Die vom Fallprüfkörper (Prüflast) aufgebrachte Energie, ohne dass 48,96 kJ irgendein Aufbauteil in den Verformungsgrenzbereich noch der Fallprüfkörper in den Schutzaufbau eingedrungen ist, beträgt: The energy applied to the protective structure by the drop test object (test load) without intrusion of any structural members into the deflection-limiting volume was Die gesamte vertikale Verformung des Schutzaufbaus nach der 110 mm Aufprallprüfung beträgt: The total vertical deformation of the protective structure after the impact drop test was Hochkabine / high cab: Die vom Fallprüfkörper (Prüflast) aufgebrachte Energie, ohne dass 48,96 kJ irgendein Aufbauteil in den Verformungsgrenzbereich noch der Fallprüfkörper in den Schutzaufbau eingedrungen ist, beträgt: The energy applied to the protective structure by the drop test object (test load) without intrusion of any structural members into the deflection-limiting volume was Die gesamte vertikale Verformung des Schutzaufbaus nach der 270 mm Aufprallprüfung beträgt: The total vertical deformation of the protective structure after the impact drop test was (A.5.4) Transparente Materialien Transparent material Transparente Materialien, die zur Überbrückung von Öffnungen in der Oberseite der Schutzstruktur verwendet werden, die nicht ISO 6055:2023; 4.3.1 entsprechen, gelten als Bauteile der Schutzstruktur, und die transparenten Materialien müssen mindestens die Anforderungen der ISO 16936-1:2020, P4A erfüllen. Die Prüfung ist gemäß ISO 16936-1:2020 bei Temperaturen von -20°C und +60°C durchzuführen. Transparent material(s) used to bridge openings in the top of the overhead guard structure not conforming to ISO 6055:2023; 4.3.1 shall be considered as structural parts and the transparent material(s) shall fulfil at least the requirements of ISO 16936-1:2020, P4A. The test shall be performed according to ISO 16936-1:2020 at temperatures of -20°C and +60°C. erfüllt / fulfilled Siehe Prüfbericht 2405-0023 nicht erfüllt / not fulfilled See test report 2405-0023 -n/a- (A.6) Werkstoff, Temperatur Material, temperature Die Prüfungen wurde bei Umgebungstemperatur, -20°C und 40°C durchgeführt. The strength tests were performed at ambient temperature, -20°C and 40°C. Berichts-Nr. / Report no. 2411-0007 Seite / Page Auftraggeber / Applicant FRITZMEIER Systems GmbH 14 von / of 14 Prüfobjekt / Test item Optima cab (A.7) Prüfbescheinigung Attestation statement Mindestleistungsanforderungen nach ISO 6055:2023 wurden bei dieser Prüfung erfüllt. The minimum performance requirements of ISO 6055:2023 were met in this test. Anmerkungen: - Keine - Remarks - None - 4 Datum der Prüfung 11./12.02.2014, Date of test 28.04.2022, 26./28.09.2022 Name und Anschrift der DLG TestService GmbH Prüfstelle Max-Eyth-Weg 1 Name and address of test D-64823 Groß-Umstadt facility Prüfer M.Sc. Dubielski Tester *Angaben gemäß Hersteller Information according to manufacturer Ende des Berichts End of Report  Anlage A zu 2411-0007 Seite 1 von 4 Standardkabine / standard cab: 6211.001, 826380 6211.040, 833620  Anlage A zu 2411-0007 Seite 2 von 4 Teil Material B-Säule Blech EN10130-DC01-A-m-2,99 C-Säule Karosserieprof. 89x68x4, EN1049-S355MC Profilrohr Rahmenprofil 43x25x1,6, EN10025-S235JRG2C Rechteckrohr 50x50x4 CFRHS EN10219-S355J2H- 50x50x4 Rechteckrohr 50x50x3 Ro EN10305-5-E275+CR1 Rechteckrohr 50x40x3 Ro EN10305-5-E275+CR1 Rechteckrohr 30x30x3 Ro EN10305-5-E275+CR1 Rundrohr 30x1,5 Ro EN10305-1-E235+N Blech 10mm Blech EN10149-S355MC-10A Blech 8mm Blech EN10149-S355MC- 8A Blech 6mm Blech EN10149-S355MC- 6A Blech 5mm Blech EN10149-S355MC- 5A Blech 4mm Blech EN10149-S355MC- 4A Blech 3mm Blech EN10149-S355MC- 3A Blech 2.99mm Blech EN10130-DC01-A-m-2,99 Blech 2mm Blech EN10130-DC05-A-m-2,00 Blech 2mm Blech EN10130-DC01-A-m-2,00 Blech 1mm Blech EN10130-DC01-A-m-1,00  Anlage A zu 2411-0007 Seite 3 von 4 Hochkabine / high cab: 6211.151, 859355 6238.180, 859377  Anlage A zu 2411-0007 Seite 4 von 4 Teil Material B-Säule Karprof-S355MC- 70.8x49.1x3 C-Säule Karosserieprof. 89x68x4, EN1049-S355MC Profilrohr Rahmenprofil 43x25x1,6, EN10025-S235JRG2C Rechteckrohr 50x50x4 CFRHS EN10219-S355J2H- 50x50x4 Rechteckrohr 50x50x3 Ro EN10305-5-E275+CR1 Rechteckrohr 50x40x3 Ro EN10305-5-E275+CR1 Rechteckrohr 30x30x3 Ro EN10305-5-E275+CR1 Rundrohr 30x1,5 Ro EN10305-1-E235+N Blech 10mm Blech EN10149-S355MC-10A Blech 8mm Blech EN10149-S355MC- 8A Blech 6mm Blech EN10149-S355MC- 6A Blech 5mm Blech EN10149-S355MC- 5A Blech 4mm Blech EN10149-S355MC- 4A Blech 3mm Blech EN10149-S355MC- 3A Blech 2.99mm Blech EN10130-DC01-A-m-2,99 Blech 2.49mm Blech EN10130-DC01-A-m-2,49 Blech 2mm Blech EN10130-DC05-A-m-2,00 Blech 2mm Blech EN10130-DC01-A-m-2,00 Blech 1mm Blech EN10130-DC01-A-m-1,00  NATO riigid kus kaitsevägi kasutab Konecranes -i tõstetehnikat Leedu Saksamaa Iirimaa Kütusekulu arvutus SMV25-1200 kütusepaagi maht on 336 liitrit Masina kütusekulu Volvo TAD851-VE tase3 mootoriga on normaaltingimustes 8-12 liitrit tunnis. Seega tuleb tööaeg ühe paagitäiega 42-28h 4575 Built in battery charger Stationary battery charger in the machine for charging the batteries at parking . C an also be in combination with additional heaters. Offer QUO0000040508 2026-03-13 Offer revision 0 Offer 26001672 Forklift truck SMV 25-1200 C for Riigi Kaitseivesteeringute Keskus  Offer QUO0000040508 2026-03-13 Offer revision 0 WILLENBROCK BALTIC OÜ 2026-03-13 Dear, Thank you for the opportunity to offer the SMV 25-1200 to your company site in Estonia. Konecranes is the world’s leading manufacturer in the material lifting business. We have delivered more than 10,000 Lift Trucks all over the world. The Medium Forklift Truck we are offering you today is designed to meet the toughest demands and is built according to your specific requirements. That is what we call ‘Built for your World’. It has been purchased by some of the world’s leading industrial companies due to its high productivity, high reliability, and low total cost of ownership. I look forward to discussing this offer with you in detail. Please find our offer on the subsequent pages. Marek Ploom Willenbrock Baltic OÜ Mobile Email [email protected] 5 reasons to choose Konecranes +600 Global footprint Optima – The best Smart Lower total cost Lifetime Advantage Operations at over 600 cabin on the Connected Lift of ownership Experience locations. in more than Years of experience Far more than just after 120 countries worldwide market Trucks Every detail has been Remote monitoring is has proven that the sales-service. Our and served by a broad combination of high extensive resources are distributor network. carefully designed for a key toward a more comfort and safety. productive, efficient quality components available to you for the Controls, displays, and safe workplace. and cutting edge entire life cycle of your ventilation and seating With TRUCONNECT technology together Konecranes lift trucks. We work to boost driver you get more out of with low running costs will always be at your productivity. Excellent your lift trucks. results in a lower total side. visibility in all directions. cost of ownership (TCO). Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 SMV 25-1200 C - Medium Forklift Truck DESCRIPTION OF STANDARD FEATURES AND OPTIONS INCLUDED IN THIS OFFER 00. GENERAL INFORMATION, STANDARDS & NORMS The fork lift truck is designed and built in accordance with the current legislations and norms, which are described below: 2006 / 42 / EC ................................................................... Machinery Directive ISO 22915 series ............................................................... Stability for Industrial Trucks EN ISO 3691-1 .................................................................. Safety for Industrial Trucks ISO 3046 ........................................................................... Engine power, torque, fuel & emission norm EN 12895 .......................................................................... Electro Magnetic Compatibility approvals (EMC) EN 16842 series ............................................................... Visibility norm for driver EN 13059 .......................................................................... Vibration norm for driver EN 12053 .......................................................................... Noise level norm (DIN 45635 inside cab) 01. TRUCK MISCELLANEOUS INFO Standard • Included options • Compliance EN 1175:2020 10. CHASSIS “BOX-TYPE” The chassis is made with long life time, low concentration of stress, and a high torsion strength in mind. This is possible through the high-strength rectangular design that is built from 2 longitudinal welded box sections with powerful cross members. The front end of the chassis is made even stronger by reinforcements with thick steel plates, support plates and brackets, and the fork lift trucks gets additional safety and strength from reinforced tilt cylinder fixations. All fixation points for vital main components, including drive axle, steer axle and lift mast, have very powerful fixation points which together with the design gives a durable and rigid chassis. Chassis components in this offer Standard • Box type chassis, bolted tanks, mudguards front & rear • 2+2 lifting ears (front in mast & rear in steer axle stops) • Access steps, hand rails upto cabin on chassis sides (left & right) Included options • License plate holder with light on top counter weight • Electric heated external mirror (mudguard) • Strainer on Fuel Filler • Galvanized storage box on left bottom step + lock (Appr. 40 Lit) Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 20-30. DRIVE LINE (ENGINE, TRANSMISSION, DRIVE / STEER AXLES) The engine is certified low-emission CanBus diesel, with turbo charger, air-to-air intercooler, fuel injection, common rails technology with high capacity cooling system. The automatic transmission is bolted directly to the engines and connected via flexible steel plates. Automatic gear shifting with hydraulic operation and electronic controls, the softshift type gives safe and smooth driving performance. The Kessler axle has a two-stage reductions and integral “Wet Disc Brakes”. The two-stage reduction reduces stresses in the axle transmission system. The “Wet Disc Brakes” system for service brakes are mounted in each hub with multiple brake discs. Strong welded steer axle of sandwich design in wide version, mounted in two (2) long life bushings between chassis and axle. Mechanical side stops between axle and chassis for best side stability. Hydrostatic powersteering with double acting single cylinder. Drive Line components in this offer Standard • Engine air filter standard, 2-stage filtration • Kessler D91 Wet Disc Brakes • Volvo TAD-851-VE + TE-17312 (185 kW, 1060 Nm, 2200 rpm, 7.7 L, 6-cyl / EU Stage 3a) • DANA TE-17312, Automatic Transmission (3+3 gear, CanBus) • External fuel water separator Included options • Mechanical wheelnut indicators front- indicators on the bolts • Mechanical wheelnut indicators rear - indicators on the bolts • Engine heater 220V (electric) 40. LOAD SENSING HYDRAULIC SYSTEM (LOW-ENERGY) Low energy consumption is reached with the “power-on-demand” function that builds up Konecranes load sensing hydraulic system. The system is designed to work together as one unit and we use the same components in all our trucks and stackers. This means that all of them includes powerful and silent running variable piston pumps, accurate proportional valves, efficient valve regulators and electronic controls. These very efficient and proven hydraulic systems are the most powerful on the market, with the key features being lowest power and fuel consumption, extended service intervals, reduced wear on components and oil, lower heat generation, fingertip precision and safety for the driver. Hydraulic components in this offer Standard • Load-sensing hydraulic system (variable piston pumps), return filter (10 µm) • Four hydraulic functions (lift-tilt-sideshift-fork positioning), 4 electronic servo levers, power steering Included options • Extra hydraulic function Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 45. ELECTRICAL SYSTEM The 24V electrical system is designed and EMC-approved according to EN 12895. Electrical components in this offer Standard • Electrical system 24V with monitoring system, CanBus, MD4 controls, 7" colour touch display (Compliance: Machinery Directive 2006/14/EC) • Road light Kit, LED lights (position-brake-tail-blinkers), LED working lights (mast-reverse-front) • Transmission in neutral when seat switch is not activated Included options • 6 extra working lights LED (3000 Lum) on light console, 4 pointing forward, 2 reverse • Light console on cab roof (for extra lights & warning beacon) • Reverse alarm (acoustic signal when reversing) • Warning beacon LED (on counter weight) • NATO electric starting aid connection (power supply) • Built in battery charger 20A • One (1) power connection 230V/16A/1-phase for electric engine & cab heater, right side (incl starting locking device) 49. ELECTRONIC MACHINE CONTROL (EMC) Electronic Overload, Control & Monitoring System The truck is equipped with electronic control & monitoring system to optimize performance and efficiency of the truck. This gives the operator a unique possibility to control and monitor the performance of the truck or truck fleet. EMC components in this offer Standard • EMC Master incl. MD4-controller with 7" colour touch display • EMC Chassis G • EMC 106 Monitoring (engine, transmission, hydraulics, levers & service) • EMC 107 Electronic weight scale (resolution 0,1 tons) • EMC 114 Electronic servo levers (incl. auto accelerator/power control) • EMC 123 ECO Drive module (fuel measure functions & settings) • EMC 124 Driver login module (max 40 logins) • EMC 125 Data logger module (alarms + errors) • EMC 129 Productivity Hour Counter (idle-neutral-driving) • EMC 134 TRUCONNECT - Basic HW (Incl. TRUCONNECT Essentials feature pack & CheckApp) Included options • Reverse alarm on/off switch Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 50. OPTIMA – DRIVERS CABIN Remarkable visibility Visibility is very difficult to measure objectively: you just know it when you see it. When you sit down in OPTIMA, you will see what visibility from a lift truck really means. The remarkable visibility is made possible by very large, lowered windows with no corner posts, thin but very strong roof cross member, and curved panes. New EMC Master with MD4 7” touch screen enables a more spacious cabin with its integrated solutions. There is also more space for operating the foot pedals. The positioning of the instrumentation improves operating ergonomics and is located to the right-hand side of the operator´s seat, easily accessible from the right hand side arm rest. OPTIMA is customizable for your exact operational needs. You can select levers or joystick, mini-wheel steering, the driver’s seat and precisely the instrumentation you need. Optima Cabin features in this offer Standard • Cabin Optima (L x W x H = 1605 x 1480 x 1620 mm) • Seat BEGE 9230 Mechanical spring (4 settings, high back, 2-p belt black) • El. connection 24V / 7.5A / 12.5mm plug front of dashboard right side Included options • Electrical pump for powered cabin tilting • DAB / Analog Radio incl. Bluetooth, MP3, AUX, USB-A, 2 speakers • Interval wiper speed switch front / roof / rear window • ACC Switch off when doors are open • Climate control unit (ACC) • El. connection 12V / 10A / 21.4mm plug cabin roof right side • Diesel powered cabin & engine water heater • Laminated glass front & side windows • Assembly of customers com.radio/door opener/computer etc. (data sheet/drawing needed at order date) 60-75. LIFT MAST, CARRIAGE AND FORKS The Konecranes lift mast is designed for maximum strength and stability. The heavy-duty lift mast is of 2-stage design and the structures welded in high quality steel, with large cross section areas and strong profiles. Cross members of thick profiles and support plates sits between the mast channels, and strong roller bearings and side roller bearings are located between the outer and inner mast, and between the inner mast and the carriage. The fork carriage is designed for high strength, durability and good visibility, and is made of high quality steel with large cross section areas. The carriage has hydraulic powered sideshift and fork positioning of the two (2) integral forks, by means of 2 hydraulic cylinders. Lift mast, carriage and forks in this offer Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 Standard • Tilt angle 10° rear / 5° front (15º) • Full cylinder stroke in carriage (longer SS/FP) • Fork dimension 2400 x 250 x 110 • Tapering STD (full thickness 0-600 mm, tapering 600-2400 mm, tip 25 mm) Included options • Triplex Freelift, Lift Height max=4500, Mast Height min-max=3310-6310, Freelift Height =1500 mm • Reinforced top beam, outer mast • Wider carriage 3500 mm • Center levelling carriage ±3,5 deg (excl. hyd func) • Assembly kit for spreaders (Control unit, cables, hoses, couplings) Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 80. EXTRA EQUIPMENT Extra equipment consists of factory mounted accessories that help improve productivity and safety in the daily operation of Konecranes lift trucks. Extra Equipment in this offer Included options • Protection greasing container • Central greasing "Lincoln Auto-Lube" basic truck (steer axle, mast fix, tilt, carriage mast wheels & rollers) • Reverse camera (1) colour monitor integrated in MD4 85. WHEELS, TIRES & RIMS Standard Included options • Solid Conti SC15/SC20 14.00x24"/PR24 (6x) Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 90. COLOUR & PAINTING Standard • Black (Cabin) RAL 7021 • Seagreen (Engine hood) TVT 553S • Seagreen (Chassis, Tanks, mudguards, counter weights) TVT 553S • Black (Mast, carriage, forks) RAL 7021 • Black (Axles) RAL 7021 • Lift lever / Joystick function sticker (A5-size, transparent, on right window) 95. DOCUMENTATION The standard package includes the following: Operator’s Manual, Maintenance Manual, Spare Parts Catalogue, Machine Card, Warranty/Start-up Protocol, Engine Operator’s Manual. Documents in this offer Standard • Operators Manual • Doc set on OneDrive - Maintenance Instructions & Operating Instructions • Doc set on OneDrive - Spare Part Catalogue Included options • Doc set on OneDrive - Technical Instructions • Doc set on OneDrive - Transmission & drive axle manual • Doc set hardcopy - Maintenance Instructions & Operating Instructions • Doc set hardcopy - Spare Part Catalogue • Doc set hardcopy - Technical Instructions • Doc set hardcopy - Transmission & drive axle manuals 98. SPARE PART KIT Spare part kit in this offer Included options • Tool kit according to separate list 100. WARRANTY Warranty according to Konecranes standard or extended warranty conditions. For further information see warranty documentation. Included in this offer Standard Included options • Warranty 30 months / 5000 hours (whichever comes first) Month 13 up to month 30 or 2001 – 5000 hours according to extended warranty terms Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 LOCAL OPTIONS Included in this offer • Fuel separatorfilter with heating • Coolant heater in engine block at 230V • Fire extinguisher with pressure gauge 12 kg 2 pcs • Safety vest XXL • Medical first aid kit • Universal mount for weapons: AK4, Galil, R20 • Starting cable NATO Stanang 4074 type 1 • Fork extensions 3200 mm • Lifting chains 4m with capacity 8t/pc Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 COMMERCIAL TERMS 1. DELIVERY SCHEDULE Approx. 40 weeks Ex. works after fully clarified order. 2. DELIVERY TERMS Seller shall deliver the Equipment on the delivery terms: DDP Delivered Duty Paid (INCOTERMS 2020) 3. PAYMENT TERMS 4. GENERAL TERMS AND CONDITIONS This offer shall be subject to Seller’s General Terms and Conditions attached hereto and available upon request and incorporated as if fully rewritten herein: General Terms and Conditions of Sale (KC LT December 2017). 5. VALIDITY OF OFFER This offer is valid until 2026-04-03. 6. WARRANTY Warranty 30 months / 5000 hours (whichever comes first) Month 13 up to month 30 or 2001 – 5000 hours according to extended warranty terms 7. CURRENCY CLAUSE Prices are based on a fixed currency (USD/EUR). If the currency exchange rate is changed more than 2%, we reserve the right to adjust the prices. 8. FREIGHT COST CLAUSE The freight pricing is based on a rate of 10 000 eur. If, at the date of actual shipment, the shipping rate quoted by us differs from the contractual rate of by more than 5 percent, we reserve the right to adjust the freight pricing accordingly. PRICE 419 581 EUR OFFER is valid only after final confirmation from Swedesh Goverment export authorities The Parties understand and acknowledge the current global component shortages may and will cause direct and/or indirect adverse effect or effects and/or hardship to the Seller. To the extent such effect or effects and/or hardship is/are caused, in Seller’s reasonable opinion, by component shortage, the Seller is entitled at its sole discretion and without any liability or liquidated damages/penalties to withhold or postpone the performance of any and/or all of its obligations under this Agreement. Any relevant deadline, delivery milestone or other agreed timeline shall be adjusted accordingly. The Seller shall inform the Buyer of any such withholding or postponement and its practical consequences as soon as practically possible. Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 RECOMMENDED OPTIONS (NOT INCLUDED IN THIS OFFER) Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 GENERAL TERMS AND CONDITIONS OF SALE -LIFT TRUCKS 1. APPLICATION OF THESE TERMS reimburse the Seller for the payment. If the Seller so demands, the Buyer shall furnish the Seller with documentation on its domicile, These Terms and Conditions of Sale ("Terms") shall apply to any residence and other necessary certificates, documentation and/or tender and any contract of sale ("Agreement"), unless the parties information required by taxing authority for tax purposes. agree otherwise in writing. The parties object to any other or different terms and conditions than these even if they or one of them have not made an express objection. In the event of any inconsistency between the Agreement and these Terms, the Agreement shall 6. TERMS OF PAYMENT govern. 6.1. The payments shall be made in accordance with the 2. SCOPE OF DELIVERY payment schedule specified in the Agreement. 2.1. The delivery of the equipment ("Equipment") includes all 6.2. Whenever any part of the payment is to be made by means components, materials and services expressly specified in the of a Documentary Credit, Section 23. shall apply. Agreement. 6.3. If the Buyer delays making any payment or in the 2.2. The delivery includes Seller's standard technical establishment of the Documentary Credit or if it becomes evident that documents, such as spare part lists, operating manuals, erection the Buyer will not fulfil his contractual obligations, the Seller may instructions (if the erection is not included in the scope of delivery) and postpone the fulfilment of its obligations until such a payment is made main dimension drawings in English. The Seller shall not be obliged to or the Documentary Credit is established. provide manufacturing drawings for the Equipment or spare parts. 6.4. The Seller shall be entitled to charge interest from the 2.3. Design, work at site, erection, supervision of erection, Buyer, if payment to the Seller is past due. The rate of the interest is training services, start-up assistance and materials other than the highest rate permissible under the applicable law. The interest components are included to the extent they are expressly specified in shall be counted from the due date until the actual date of the the Agreement. payment. The Buyer shall pay such interest within thirty (30) days from the date of the respective invoice. 3. INTELLECTUAL PROPERTY RIGHTS AND CONFIDENTIALITY If the Buyer has not paid the amount due within three months, the Seller shall be entitled to terminate the Agreement by notice in writing 3.1. The Seller shall have all rights, title and interest including to the Buyer and to claim compensation for the loss it has incurred. ownership right, copyright and other intellectual and industrial property rights to documents, drawings, software, reports, technical 7. STANDARDS OF MANUFACTURING AND DESIGN information, definitions, descriptions, manuals and any other The Equipment supplied and the work carried out shall be in intellectual property that the Seller has or creates and to Equipment accordance with the technical standards commonly used in Seller’s Usage Data as well as to the data and reports made available in the country. If the Equipment shall be operated outside of Seller`s country, Portal or data or reports created by the Seller. the scope of the work agreed in the Agreement shall prevail. The 3.2. Documents, drawings, software, reports, technical Seller shall not take into consideration laws and regulations prevailing information, definitions, descriptions, manuals and any other at the place of operation, if they are not agreed in the Agreement. The intellectual property received by the Buyer shall not, without the Buyer shall inform the Seller of the applicable safety regulations. Any consent of the Seller, be used for any other purpose than for the costs in excess of the costs of compliance with European standards erection, commissioning, operation or maintenance of the Equipment. resulting from mandatory local laws and regulations shall be added to They may not otherwise be used or copied, reproduced, transmitted or the price and paid by the Buyer. communicated to a third party. The Buyer may, however, transmit the 8. INSPECTIONS DURING MANUFACTURING documents or software to a third party that the Buyer sells the Equipment to. The Buyer has the right at its own expense, subject to the Agreement with the Seller as to the time and place, to inspect the progress of 3.3. The Buyer shall keep confidential and shall not disclose to manufacture and the quality of the Equipment. The inspections of the any third parties, or use for any other purposes than those of the Equipment shall be carried out at Seller's works or at the place of Agreement, any information regarding Agreement, Seller’s business, manufacturing. Inspection carried out by the Buyer is not a Equipment Usage Data, reports and/or data in Apps and/or Portal precondition to the delivery of the Equipment. provided or made available to the Buyer. This obligation of confidentiality shall survive the termination of the Agreement. 9. DELIVERY TERM AND PASSING OF THE RISK 4. PACKING AND MARKING 9.1. Any agreed delivery term shall be construed in accordance with INCOTERMS 2020. If no delivery term is specifically agreed, the The Equipment shall be packed in accordance with Seller's standard delivery term shall be Ex Works Seller's manufacturing plant (EXW). packing procedures as required for transportation under normal transportation conditions. The Equipment shall be clearly marked and 9.2. The risk of loss of or damage to the Equipment shall pass carry the necessary information concerning Buyer's identification and from the Seller to the Buyer in accordance with the agreed delivery place of destination. term. If no delivery term is set forth in the Agreement, the risk of loss shall pass to the Buyer Ex Works Seller's manufacturing plant. 5. PRICE 10. DELIVERY TIME 5.1. In addition to the price set forth in the Agreement, the Buyer shall be responsible for additional charges as set forth in these Terms. 10.1. The delivery time shall start to run on the latest of 5.2. If any part of the delivery of the Equipment is delayed due (a) the date of execution of the Agreement by the Seller; to reasons caused by the Buyer or any third party under the control of the Buyer, the Buyer shall compensate any additional expenses (b) the date of receipt by the Seller of the agreed down incurred by the Seller due to the late delivery. payment as set forth in the Agreement; or; 5.3. Prices do not include any stamp duty, turnover or value- (c) the date of receipt by the Seller of all agreed information added tax, bank charges or any other similar taxes, duties, tariffs or and approval by the Buyer of the general arrangement drawings. charges payable in the country into which the Equipment is to be 10.2. The Seller shall be entitled to a reasonable extension of the imported and where the installation is to be carried out. In the event delivery time (which shall not be less than the length of the delay), if the Seller is required to pay any such tax or charge, the tax or charge the delivery is delayed due to the Buyer's actions or actions by a third will be added to the invoice as a separate charge and the Buyer shall party under the control of the Buyer such as modifications requested Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 by the Buyer, delay in the approval of the relevant drawings, delay in 14.2. These warranty conditions apply to the Equipment named the preparing work at the erection site and delay in payments or it in this Agreement. The warranty applies for the original Buyer and for becomes evident that the Buyer will not fulfil his contractual later owners who have acquired the Equipment within 6 months from obligations. the delivery date to the Buyer. 11. TRANSFER OF PROPERTY 14.3. The period of the warranty for any part of the Equipment is the earliest of 11.1. Notwithstanding Section 9.1, the Equipment shall remain Seller's property until the total purchase price has been paid. In the (i) twelve (12) months from the date of the delivery event the applicable laws do not permit the Seller to retain title, the of the Equipment in accordance with applicable delivery Seller shall be entitled to a security interest or charge in the property. term or The Buyer shall give the Seller every assistance in securing an interest in the property or taking any measure required to protect (ii) 2000 operating hours whichever occurs earlier. Seller's title or such other rights. The retention of title, security interest 14.4. The warranty period for replaced or repaired parts is twelve or charge shall not affect the passing of risk of loss under Section 9. (12) months from the date of repair or replacement. However, no 11.2. The Seller shall retain title to any software and warranty for any parts shall apply after twenty-four (24) months from documentation. To the extent that such software and documentation the delivery of the Equipment. are included in the scope of delivery, the Buyer shall receive a royalty- 14.5. The Seller provides a warranty on genuine spare parts for free, non-exclusive and non-transferable license to use such software 12 months or 2000 hours, whichever occurs earlier, counted from the and documentation only in connection with the Equipment and for no date of delivery. The Seller does not reimburse labor costs or other other purpose whatsoever. costs referable to the replacement or repair of a defected spare part. 12. ACCEPTANCE TESTS Otherwise, the same warranty conditions apply in applicable parts as for new Equipment. 12.1. Should the Agreement require separate acceptance tests, the tests shall be carried out in accordance with the Agreement. If the 14.6. Should defects occur during the period of this warranty, the Agreement does not specify the requirements, the tests shall be Seller or its authorized dealer will, at its option, either repair the carried out in accordance with general practice in the industry in the defects or supply the correct parts free of charge. The defected parts country of manufacture. of the Equipment shall on request of the Seller be sent to the Seller together with a claim report according to Section 14.7 below. In case 12.2. The Seller shall notify the Buyer of the tests on sufficient the parts have not been defected, the Buyer will cover all the costs time to permit the Buyer to be represented. If the Buyer is not including, but not limited to repair, replacement and/or sending costs. represented, the test report shall be sent to the Buyer and shall be deemed accepted as accurate. 14.7. Claims must be reported in writing to the Seller within 45 days after the alleged fault has been discovered. Claims must always 12.3. If the tests show the Equipment not to be in accordance include information concerning Equipment’s serial number, type with the Agreement, the Seller shall without delay remedy any designation, and date of delivery and total hours of operation. In deficiencies in order to ensure that the Equipment complies with the addition, a complete description of the nature of the fault must be Agreement. New tests shall then be carried out at Buyer's request, given. unless the deficiency was insignificant. 14.8. This warranty is given on the condition that the Equipment 12.4. The Seller shall bear its own costs for tests carried out at is in all respects operated, handled, serviced and maintained properly, the place of manufacture. the Buyer shall bear all its own costs, in accordance with Seller's instructions and under specified operating including but not limited to travelling and living expenses for Buyer's conditions. Excluded from the warranty are those parts including spare representatives in connection with such tests. parts 13. FINAL ACCEPTANCE (a) To which repair or replacement becomes necessary due to normal wear, tear and corrosion; 13.1. Should the Agreement require separate acceptance, the Equipment is deemed to be finally accepted when acceptance tests (b) To which repair or replacement becomes necessary due to the have been carried out and the Equipment is found to be in accordance overloading of the Equipment with the Agreement. Minor defects do not prevent the acceptance of the Equipment. Such defects shall be listed and the Seller shall (c) Which are used for purposes other than for those intended by remedy any listed deficiencies without delay. If acceptance tests are the Seller and have not otherwise been used in an appropriate not to be carried out, the Equipment is deemed to be delivered and manner, taken over when delivered in accordance with the delivery term (d) Which are exhaustible items, including but not limited to such specified in Section 9. items as bulbs and fuses; 13.2. If the acceptance has been agreed, the acceptance is to be (e) Which are not approved by the Seller made without delay after the notification of readiness for acceptance. If the acceptance is not carried out in due time or completely, the (f) On which repairs, alterations or adjustments have been Equipment is deemed to be finally accepted seven (7) days after the performed or begun by the Buyer or any third party without the notification of readiness for acceptance. Seller's previous consent; 13.3. The Buyer is not entitled to take the Equipment into use (g) Which failures are not promptly reported to the Seller within the before final acceptance. If the Buyer takes the Equipment into use warranty period above; before final acceptance without Seller's consent, the Equipment is deemed to be finally accepted. (h) Which failures or damage are due to negligence other than that of the Seller, included but not limited to accident, abuse, 13.4. In the cases specified in Section 13.2 and 13.3, the Seller is improper installation (other than installations made by the entitled to invoice the Equipment from the Buyer and the period of Seller), improper operation, or abnormal conditions of warranty shall start to run. temperature, moisture, dirt, corrosive matter, dust or other similar type of reason; 14. WARRANTY (i) Which have been damaged otherwise without the fault of the 14.1. The Seller warrants that to the best of its knowledge the Seller. Equipment is free from defects caused by faulty design, materials or workmanship, which would prevent the electrical or mechanical functioning of the Equipment. The cost of disassembling and installing a repaired or replaced part furnished under this warranty is excluded. The delivery inspection and warranty service specified in the service manual are to be carried out by the Seller or by a dealer or service Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 workshop authorized by the Seller. If the Buyer and Seller have The clauses 18.3 – 18.9 only apply to an Agreement in case the EU agreed on a longer warranty period (called also extended warranty) Data Act (2023/2854) is applicable. such an extended warranty is subject to these Terms and additionally: 18.3. “Raw Product Data” shall mean raw and pre-processed (a) The extended warranty covers only the main components data collected from the Equipment, if any, limited to product data and including engine, transmission, drive axle, hydraulic pumps, related service data, including the relevant metadata necessary to valves and cylinders, electric control units and structural parts interpret and use those data, that the Seller as data holder has obligation to share or provide access to under EU Data Act (b) It is to be noted that the extended warranty does not cover on (2023/2854). bolded items, for example, turbo alternator, starter, water pump, sensors, hydraulic hoses, connections, seals, solenoids, 18.4. The Seller shall, when acting as data holder, be entitled to electrical cabling, plugs, switches, fan and wiper motors. use, share and transfer to third parties Raw Product Data, product data and related service data for the purposes of (i) performance of 14.9. THIS IS THE SOLE AND EXCLUSIVE WARRANTY GIVEN the Agreement and related arrangements, including but not limited to BY THE SELLER TO THE BUYER WITH RESPECT TO THE delivering and monitoring the Equipment, and services, service level EQUIPMENT AND IS IN LIEU OF AND EXCLUDES ALL OTHER agreements, remote connections and troubleshooting, (ii) improving WARRANTIES, EXPRESS OR IMPLIED ARISING BY OPERATION the functioning of connected products and/or related services, OF LAW OR OTHERWISE, INCLUDING, BUT NOT LIMITED TO ANY research and development, development of new products or services IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR and (iii) development and use, as applicable, of algorithms, A PARTICULAR PURPOSE. simulations, machine learning, artificial intelligence, statistics and 15. FORCE MAJEURE indexes, and more generally aggregating data with the aim of making available the resulting derived data to the Seller and third parties for Either party shall be entitled to suspend performance of its obligations commercial and non-commercial use, provided that such derived data under the Agreement to the extent that such performance is impeded do not allow the identification of specific data transmitted to the data by circumstances beyond the control of the party, including but not holder from the connected product, or allow a third party to derive limited to war (whether declared or not), revolution, strikes, failure of those data from the dataset. supplies of power, fuel, transport, equipment or other goods or services, natural disasters, unacceptable weather conditions, acts of 18.5. The Seller shall, when acting as data holder, provide the government, traffic accidents, export or import prohibitions, fire, Buyer and third-party recipients access to Raw Product Data, in case explosions, floods, accidents, sabotage, civil commotions, riots, and the Buyer makes a request, in accordance with EU Data Act. Such breakage or loss during transportation or storage as well as delays of request shall include purpose for which the data is being used by the deliveries by the subcontractors (when caused by Force Majeure as third-party. The Seller shall provide access to the data on as is and as herein defined). available basis without undue delay. The Buyer warrants that it is entitled to make such request as user and that the scope of request 16. LIQUIDATED DAMAGES OF DELAY OF THE SELLER does not exceed the mandatory requirements set forth in the EU Data Act. In case the Buyer has authorized a representative to make such The Buyer is entitled to liquidated damages for delay from the date on request, the Buyer shall provide the Seller with necessary information which the delivery should have taken place in case the delivery is for the purpose of verifying such authorization. The third-party shall delayed due to Seller's fault. The liquidated damages shall be 0,5 per pay compensation to the Seller. Seller is entitled to define such cent of the price of the delayed portion of the Equipment for each compensation provided that it meets the statutory requirements of the complete week of delay. In no event shall the liquidated damages for EU Data Act. The Seller shall provide access to third parties as may delay exceed 5 % of the price of the delayed portion of the Equipment. be designated by the Buyer only provided that (i) such request does The Buyer shall forfeit his right to liquidated damages if the Buyer fails not exceed the scope of the statutory requirement, (ii) third-party pays to claim liquidated damages by written notice within one (1) month compensation to the Seller and (iii) the Buyer and third party comply after the date when the delivery took place. The liquidated damages with the EU Data Act. referenced in this Section shall be the sole and exclusive remedy for such delay. The parties agree that such liquidated damages are a 18.6. In case the Raw Product Data includes personal data, the reasonable estimate of the damages the Buyer is likely to incur as a Buyer shall instruct the Seller of the transfer of such personal data result of such delay. expressly in writing. In case the transfer is to a third party, the instructions shall include necessary details in order to conduct the 17. LIQUIDATED DAMAGES OF DELAY OF THE BUYER transfer including but not limited to details of the third party recipient. The Buyer shall be responsible that it has the right to instruct the Seller If any part of the delivery or the acceptance of the Equipment is in such a manner and that the instruction and transfer complies with delayed due to reasons not caused by the Seller, the risk of loss the applicable personal data legislation. In no event shall the Seller be passes to the Buyer and the Buyer pays the liquidated damages in the liable for any costs or damages related to the transfer conducted by amount of 0.5% of price of the delayed portion of the Equipment for the Seller in accordance with the instructions from the Buyer and the each complete week of delay, starting 14 days after notification of the Buyer indemnifies and holds the Seller harmless for any claims, costs readiness for shipment or acceptance, where the liquidated damages and damages thereto. are limited to 5% of the price of the delayed portion of the Equipment, unless higher costs or damages can be proven by the Seller. The 18.7. In case the Raw Product Data includes Seller’s trade Buyer shall compensate any additional expenses incurred by the secrets, the Seller shall identify such trade secrets appropriately and Seller due to delay. agree the terms of disclosure in accordance with the EU Data Act. The Seller is entitled to, prior to any disclosure, to require users and third 18. REPORTING parties to preserve the confidentiality and secrecy of such trade 18.1. If separately agreed, the Seller may deliver reporting secrets encumbered data by agreeing to and implementing services to the Buyer including also remote Data Connection reporting safeguards necessary to that end. The Seller is further entitled to services using distribution channel of its choice without being withhold or suspend the sharing of trade secrets if no agreement is responsible or liable for the selected channel. The Buyer may prohibit reached, if the user or third party does not implement the agreed the collection of data at any time. Despite of such prohibition the Buyer measures, or if the confidentiality of the trade secrets is undermined. is obliged to pay the agreed charges till the end of contract period. 18.8. The Buyer shall indemnify and hold the Seller harmless 18.2. The Seller is entitled, at its sole discretion and without any against any costs, losses or claims incurred by the Seller (including liability, to suspend and/or to cancel the remote Data Connection directors and employees), or its affiliates (including directors and service at any time. The Seller reserves the right to use and develop employees) in connection with any breach by the Buyer of its the Equipment Usage Data for its general research and development obligations under this Section 17. of equipment, for delivering services, for other services and products, 18.9. If and to the extent applicable (i) the Seller shall comply for marketing them and for other purposes. with laws regarding cyber and IT security, including but not limited to the EU Cyber Resilience Act (2024/2847), to the extent they are applicable to the products and/or services the Seller shall deliver to Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 the Buyer and provided that the Buyer's use of the Equipment and/or act in violation of his/her or its lawful duties or proper services complies with this Agreement; and (ii) the Seller shall inform performance of functions); or the Buyer of actively exploited vulnerabilities or severe incidents having an impact on the security of the product and, where (ii,) obtain or retain business or an improper advantage for the necessary, of risk mitigation and corrective measures to deploy to Buyer or any of its business partner or a third-party mitigate the impact of that vulnerability or incident, where appropriate intermediary. in a machine-readable, easily processable format. (b) Neither the Buyer nor any of its Representative is a public 18.10. The Seller shall keep confidential and not disclose official who may have responsibility for or oversight of any Equipment Usage Data to any third parties in such manner that the business activities of the Buyer, other than any relationships or identity of the Buyer or its customers would remain recognizable but associations that have been disclosed in writing to the Seller. may otherwise use the said Equipment Usage Data without restriction. 20.5. To ensure full compliance with Trade Laws, prior to any use 18.11. The Buyer accepts and agrees that the Seller is not or transfer of the Sold Items to a third party the Buyer shall in responsible to monitor, inspect or otherwise follow any Equipment, particular ensure that: Equipment Usage Data, report including Equipment Usage Data or (a) The use and/or transfer of the Sold Items does not infringe other information that is generated by using CMS Unit, Data the Trade Laws, also considering the prohibitions of by-passing those Connection and/or otherwise. Any such Equipment Usage Data, report embargos; and and/or other data shall be created and provided to the Buyer on “as is” and as available basis and without warranties of any kind either (b) If the Sold Items are intended for use in connection with express or implied made in relation to the correctness, accuracy or armaments, nuclear technology or weapons, all required reliability of such Equipment Usage Data, report and/or other data. authorizations have been obtained. The Buyer is obliged to inform the Seller about such use or possible use immediately after such use or 18.12. The Words have the following definitions: possible use has been identified. "Data Connection" means any data connection (including but not limited to machine to machine connection) to be used for transferring information between the Seller and the Buyer from and to the 20.6. In case of conflicting Trade Laws or differences in Trade Equipment. Laws resulting in ambiguity over applicability of different Trade Laws, “Equipment Usage Data” means any data relating to the Equipment the Buyer shall contact the Seller for Seller’s final decision. The Buyer and/or its usage collected and/or processed by the Seller in will accept Seller’s decision without any further claims or demands. connection with remote services, remote reporting or by other means. 20.7. The Buyer shall maintain all documentation required by the 19. LIMITATION OF LIABILITY Trade Laws and shall provide the same to the Seller without delay at Seller’s reasonable request. This recordkeeping obligation of the SELLER'S LIABILITY UNDER THE AGREEMENT SHALL BE Buyer shall continue for five (5) years from the final acceptance of the LIMITED TO THE AMOUNT OF THE ACTUAL DIRECT DAMAGES Sold Items. INCURRED BY THE BUYER OR TO 40 % OF THE PRICE PAID BY THE BUYER TO THE SELLER FOR THE EQUIPMENT OR TO THE 20.8. The Buyer shall at its own expense apply for, obtain and REPLACEMENT OF THE EQUIPMENT, WHICHEVER IS THE have renewed all permits, authorizations and licences, including LOWEST. THE BUYER SHALL BE ENTITLED TO NO OTHER export control authorizations, required for its activity or needed to REMEDY REGARDLESS OF THE FORM OF CLAIM OR CAUSE OF perform its obligations pursuant this Agreement. ACTION, WHETHER BASED IN AGREEMENT, NEGLIGENCE, TORT, LAW, STRICT LIABILITY OF OTHERWISE. 20.9. If the Buyer learns or has a reason to believe that there has been any violation of Laws or Regulations, especially relating to Trade Laws or Anti-Corruption Laws, or violations of the Seller’s Code of Conduct by the Buyer or any of its Representatives, it shall IN NO EVENT SHALL THE SELLER BE LIABLE FOR ANY SPECIAL, immediately notify the Compliance and Ethics Officer of the Seller. In PUNITIVE, INCIDENTAL, INDIRECT OR CONSEQUENTIAL such case the Buyer agrees to undertake all actions reasonably DAMAGES LOSS OF PRODUCTION, LOSS OF PROFIT, LOSS OF requested by the Seller, including investigative and remedial actions. USE, LOSS OF REPUTATION OR LOSS OF AGREEMENTS. 20.10. The Buyer shall assist and cooperate fully with the Seller’s 20. COMPLIANCE AND EXPORT LAWS AND efforts to comply with Laws and Regulations. Upon request the Buyer REGULATIONS shall provide the Seller with all information and documents necessary 20.1. The Buyer undertakes to comply with these terms, the to verify the Buyer’s compliance with its obligations under the Agreement; all Laws and Regulations, including but not limited to Agreement. The Seller may also audit the premises, books and Trade Laws in relation to the Sold Items, Anti-Corruption Laws, records and other documents of the Buyer which reasonably relate to competition laws and ethical business practices. the performance of its obligations under this Section 20, not only Any breach of this Section 20 is deemed to be a material breach of during the continuance of this Agreement, but for seven (7) years after this Agreement. its expiry or termination. The Seller shall provide at least 15 days prior written notice of the audit. The Seller has the right to make copies of 20.2. The Buyer understands that the Laws and Regulations documents audited. change over time and may vary depending on, for example, the product, software, documentation, and technical data. The Buyer 20.11. If required by applicable competition laws, the above audit undertakes to know about and comply with such changes. right and collection and review of information provided by the Buyer shall be exercised through a third party auditor selected by the Seller 20.3. The Buyer confirms that it has sufficient and effective to ensure that no commercially sensitive information is disclosed or internal controls, ethics and compliance programs or measures for exchanged between the Seller and the Buyer. preventing and detecting any violations of Section 20.1 above. The Buyer’s Representatives are to Buyer’s best knowledge in compliance 20.12. The Seller hereby informs the Buyer that certain personal with all Laws and Regulations and ethical business practices. data relating to the Buyer and its customers may and will be collected by the Seller as data controller for the purpose of executing the 20.4. The Buyer represents and warrants that: Agreement, of complying with the applicable laws and regulations, including tax and accounting laws as well as for other purposes in (a) The Buyer or any of its Representatives will neither solicit or accordance with Konecranes personal data processing information at accept nor give, offer or promise to give anything of value, http://www.konecranes.com/data-protection. For special purposes the directly or indirectly, to any private individual or organization, or Seller may also act as a data processor. public official in an effort to: 20.13. The Buyer accepts and agrees with the foregoing and (i,) improperly influence any act or decision by the above confirms that providing the data is necessary for executing the mentioned parties (including a decision to do or omit to do any Agreement and managing the contractual relationship and accepts an Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 obligation to inform its customers (if applicable), employees and other 24. PORTAL representatives about the handing of personal data by the Seller as part of the Agreement. 24.1. The Seller may provide the Buyer with an access to a portal and/or app. The Buyer undertakes to act in strict compliance with the 20.14. The words have the following definitions: applicable portal and/or app terms of use that are applicable from time to time. Such terms shall be available in the portal and/or in the app (a) “Anti-Corruption Laws” means Laws and Regulations and shall also be provided to the Buyer upon written request. relating to anti-bribery and anti-corruption, always including the US Foreign Corrupt Practices Act and the UK Bribery Act 2010, money 24.2. The Buyer expressly accepts and agrees that if not laundering and extortion. otherwise agreed the use of the portal and/or app, its content and any services or items obtained through the portal and/or app are at Buyer’s (b) “Laws and Regulations” means all international, country own risk, on “as is” and “as available basis, without any warranties of specific, federal, state and local laws, rules and regulations applicable any kind, either express or implied. The Buyer further accepts that the to either party, as amended from time to time. Seller does not make any warranty or representation with respect to (c) "Representatives" means a party’s partners, officers, the completeness, security, reliability, quality, accuracy or availability directors, employees, agents and anyone acting on its behalf or for its of the portal and/or app without limiting the foregoing and if not benefit. otherwise agreed, the Seller does not represent or warrant that the portal and/or app, its content or any services or items obtained (d) “Sold Items” means the Equipment, spare parts and through the portal and/or app will be accurate, error-free or services and all related software. uninterrupted, that defects will be corrected, that the portal and/or app are free of viruses or other harmful components or that the portal (e) “Trade Laws” means Laws and Regulations relating to and/or app meet Buyer’s expectations. The Seller reserves the right to export control, trade sanctions, re-export and trade, normally including revise portal and/or app or withdraw access to them at any time. the Trade Laws of the United Nations, European Union and the United States of America. 25. NO WAIVER 21. APPLICABLE LAW AND SETTLEMENT OF DISPUTES No course of dealing between either party, no failure or delay on the part of either party in exercising any right or remedy under the 21.1. The Agreement shall be governed by and construed in Agreement or no single or partial exercise of any other right or remedy accordance with the laws of Seller's place of incorporation. of either party shall operate as a waiver of any such right or remedy. 21.2. All disputes arising out of or in connection with the present 26. SEPARABILITY; REFORMATION AND AMENDMENTS Agreement shall be finally settled under the Rules of the Arbitration Institute of the Stockholm Chamber of Commerce by one or more 26.1. The invalidity or enforceability of any provisions of the arbitrators appointed in accordance with the said Rules. The Agreement shall not impair the validity or enforceability of any other arbitration shall take place in Stockholm, Sweden. The language of the provisions; provided, however, that the Agreement shall be reformed arbitration proceedings shall be English. to the maximum extent permitted by law to carry out the parties’ original intention. 21.3. Notwithstanding the above, The Seller shall be entitled to take action for collecting its receivables from The Buyer at the courts 26.2. The Agreement may be amended only in writing signed by of the Buyer's place of domicile. both parties. 22. LANGUAGE KC 1 July 2025 All documents and correspondence between The Seller and The Buyer shall be in English. 23. LETTER OF CREDIT (DOCUMENTARY CREDIT) 23.1. The Documentary Credit shall be irrevocable and transferable, it shall allow partial shipments, loading on deck, charter party Bill of Lading, shipment on barge and transhipments. 23.2. The Documentary Credit shall be established in a form acceptable to the Seller not later than 30 days from the date on which the Agreement is executed by the Seller and it shall remain valid for a period of at least 30 days after the date of last shipment. 23.3. The Documentary Credit shall be confirmed by a first class international bank acceptable to the Seller and it shall be payable at sight at the counters of a bank nominated by the Seller against presentation of a commercial invoice and/or other documents specified in the Agreement. 23.4. Regardless of any other section or term of these Terms, if any, if the Seller is unable to ship the goods due to any reason outside of its control, the Documentary Credit shall be payable against the forwarding agent's receipt, or, should The Buyer fail to name the forwarding agent, against the warehouse receipt. 23.5. The Documentary Credit shall provide that the rules in the "Uniform Customs and Practice for Documentary Credits (2007 Revision) ICC Publication No. 600" are applicable to the Documentary Credit. 23.6. All charges and expenses, related to the fulfilment of this Contract of Buyer’s Bank including opening and extension of Documentary Credit and confirmation commission of the same in the Seller’s Bank shall be borne by the Buyer. The charges and expenses of Seller’s bank, except the confirmation commissioning of Documentary Credit, shall be borne by the Seller. Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 EXTENDED WARRANTY REGULATIONS FOR NEW KONECRANES LIFT TRUCKS (KCLT) 1. SCOPE b. To which repair or replacement becomes necessary due to the overloading of the Machine These warranty conditions apply to the machine (Machine) named in this warranty certificate and/or specified as agreed in the purchasing c. Which are used for purposes other than for those intended by agreement. The original warranty period applies for the original Buyer KCLT and has not otherwise been used in an appropriate and for later owners. manner, d. Which are exhaustible items, including but not limited to such items as bulbs and fuses; 2. WARRANTY PERIOD e. Which are not approved by KCLT Warranty time is 12 months or 2.000 running hours from date of signing the “Warranty start up report”, or as latest 15 months from f. On which repairs, alterations or adjustments have been KLFT invoice date, whichever comes first performed or begun by the Buyer or any third party without KCLT previous consent The Extended Warranty time is limited to following components: g. Which failures are not promptly reported to KCLT within the Including major components such as; warranty period above - Engine. h. Which failures or damage are due to negligence other than that of KCLT, including but not limited to accident, abuse, improper - Transmission. installation (other than installation by KCLT), improper - Drive axle. operation, or abnormal conditions of temperature, moisture, dirt, corrosive matter, dust or other similar type of reason. - Hydraulic pumps, valves and cylinders. i. Which have been damaged otherwise without the fault of KCLT. - Electric control units. - Structural parts. Further, this warranty is given on the condition that, Excluding on-bolted items such as; The delivery inspection, warranty service and other in Service manual - Turbo, alternator, starter, water pump, sensors, specified services have been carried out by KCLT or by a KCLT authorised dealer or service workshop - Engine after treatment systems, - Hydraulic hoses, connections, seals, solenoids, 6. LIMITATION OF LIABILITY - Electrical cabling, plugs, connections, switches, fan and wiper motors. This is the sole and exclusive warranty given by KCLT to the Buyer with respect to the equipment and is in lieu of and excludes all other The warranty period for replaced or repaired parts during the warranty warranties, express or implied, arising by operation of law or period is limited to the machine warranty. otherwise, including but not limited to, any implied warranties of merchantability or fitness for particular purpose. 3. WARRANTY OBLIGATIONS Should defects occur during the period of this warranty, KCLT or its 7. E-VER BATTERY & SPARE PARTS WARRANTY authorized dealer will, at its option, either repair the defects or supply See separate terms and conditions. the correct parts free of charge. The defective parts of the Machine shall on request of KCLT be sent to KCLT together with a claim report according to clause 4 below. In case the parts are not defective, the Buyer will cover all the costs including, but not limited to, repair, replacement and/or shipping costs. 4. CLAIMS Claims must be reported in writing or via Konecranes Warranty On- Line (WOL) system to KCLT within 45 days of discovery of the alleged fault. Claims must always include information concerning the machine’s serial number, type designation, and date of delivery and total hours of operation. In addition, a complete description of the nature of the fault must be given. 5. FAULTS This warranty is given on the condition that the Machine is in all respects operated, handled, serviced and maintained properly, in accordance with KCLT instructions and under specified operating conditions. Excluded from the warranty are those parts including spare parts, to which repair or replacement becomes necessary due to: a. Normal wear, tear and corrosion, tyre equipment, batteries, fuses, light bulbs or LED’s or other wear parts of the machine. It does neither cover fluids, filters and unspecified material such as grease, oil, cleaning material. Konecranes Lifttrucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN. Tel +46 433 733 00, Fax +46 433 733 10, VAT: SE556142496001, E-mail: [email protected], www.kclifttrucks.com  Offer QUO0000040508 2026-03-13 Offer revision 0 We thank you for your interest Konecranes in a snapshot History and experience Global market leader Growing Maintenance Going back to the 1930s in lifting equipment and steadily contracts service and financially solid covering over 400,000 items of lifting equipment of different makes © 2025 Konecranes. All rights reserved. “Konecranes”, “Moves what matters” and are either registered trademarks or trademarks of Konecranes Global Corporation. Konecranes Li,trucks AB, Box: 103, SE-28523 MARKARYD, SWEDEN, Finland. Tel +46 433 733 00, Fax +46 433 733 10 VAT: SE556142496001, E-mail: info.li,[email protected], www.kcli,trucks.com  Tehniline kirjeldus Tehnikavahendi nimetus: rasketõstuk (Edaspidi „Masin“) Pakutava tehnika mark ja mudel: Konecranes SMV 25-1200 Pakkumus peab vastama tehnilises kirjelduses esitatud miinimumnõuetele. Alternatiivsete pakkumuste esitamine ei ole lubatud. Hangitav masin on mõeldud mitmesugusteks tõstetöödeks. Masin on mõeldud töötama kõikides ilmastiku- ja valgustustingimustes keskmise ning kõva pinnasega tööplatsidel, kus tööplatside vahemaad on kuni üks kilomeeter. Suuremate vahemaade korral kasutatakse transportimiseks treilereid. Hankija soovib osta Eesti Kaitseväele kaks tõstukit, mis vastavad käesolevas dokumendis toodud nõuetele. V ajadusel võib hankija tellitavat kogust suurendada kuni kahe ühiku võrra . Lühendid RKIK Riigi K aitseinvesteeringute K eskus STANAG NATO standardiseerimise kokkulepe (Standardization Agreement) Ed. Edition (Dokumendi versioon) Normatiivid Pakkuja peab tundma ja täitma alljärgnevaid normatiive. EN 590 Mootorikütused. Diislikütus. Nõuded ja katsemeetodid. STANAG 7090 Ed. 7 NATO maismaasõidukitel kasutavate kütuste miinimumnõuded. STANAG 4015 Ed. 3 Käivitusakude akukastid kasutamiseks taktikalistel maismaasõidukitel. STANAG 4074 Ed.3 Käivitusabi pistikud kasutamiseks taktikalistel maismaasõidukitel. ISO 12117-2-2008 Ümbermineku kaitsekonstruktsioonide karakteristika RT I, 10.02.2023, 32 Seadme ohutuse seadus 2006/42/EÜ EUROOPA PARLAMENDI JA NÕUKOGU DIREKTIIV Kui nõutud standardil on järelliide „või samaväärne”, võib selle nõude täita, täites mõne muu samaväärse standardi nõudeid. Lisaks kohustuslikule vastusele peab pakkuja nimetama samaväärse standardi ja selgitama, kuidas alternatiivne standard täidab mainitud/nõutud standardis esitatud nõudeid, ning vajadusel esitama vastava dokumendi. Seotud dokumendid Nõuetes viidatud dokumendid on antud tehnilise kirjelduse osa. Nõuded, mis esinevad viidatud dokumentides, on antud tehnilise kirjelduse osad ja kuuluvad täitmisele, välja arvatud juhul, kui tehnilises kirjelduses on eraldi välja toodud eri- või lisatingimused. Juhul, kui viidatud dokument viitab edasi teistele dokumentidele, kuuluvad ka need täitmisele, välja arvatud juhul, kui need ei rakendu hankeobjekti kohta või hankedokumentides ei ole sätestatud teisiti. Juhul, kui ei ole sätestatud teisiti, kuuluvad täitmisele dokumentide kõige uuemad versioonid, sh standardi muudatused, tehnilised parandused ja muud seotud muudatused ja teatised. Dokumente, millele on viidatud tehnilises kirjelduses, kuid mis ei ole RKIK-i poolt loodud, RKIK ei edastada. Nimetud dokumendid (STANAG, ISO jne) on leitavad näiteks www.nato.int või www.iso.org . Tingimused pakkumusele Nõuded antud tehnilises kirjelduses on miinimumnõuded, mis on kohustuslikuks täitmiseks Pakkujale. Pakkuja peab täitama kollase taustaga väljad tulbas „TÄIDAB PAKKUJA“ järgmises peatükis olevas tabelis. Hankija loeb pakkumuse mittevastavaks, kui Pakkuja on jätnud väljad täitmata või on esitanud muu sinna mittekuuluva info. Pakkuja ei pea täitma väljasid, mis on Hankija poolt täidetud musta taustaga. Tulpa „JAH“ tuleb sisestada sõna „JAH“. Sisestades sõna „JAH“ Pakkuja kinnitab, et on üheselt aru saanud nõudest ja suudab ning kohustub seda nõuet täitma. Tulpa „Esitada dokumendi ja peatüki nimi/number“ tuleb sisestada dokumendi nimi ja peatüki nimi/number selles dokumendis , kus nõude täitmine on tõendatud/kirjeldatud. Juhul, kui on lisatud täpsustav nõue „#“, tuleb esitada dokument vähemalt nõutud sisuga. Tulpa ei tohi kirjutada mitte midagi muud, isegi mitte ühesõnalist ja/või numbrilist vastust! Tulpa „Esitada viide“ sisestatud dokumendi nimi ja peatüki nimi/number peavad ühtima pakkumuses esitatud dokumendi nimega ja peatüki nime/numbriga selles dokumendis. Pakkuja peab hoiduma mittevajalike turunduslike materjalide kasutamisest. Esitatud dokumendid peavad andma selge vastuse/kirjelduse sellest, kuidas Pakkuja nõuet täitma hakkab. Pakkuja ei tohi muuta dokumendi struktuuri ja sõnastust. Tolerantsid käesolevas tehnilises kirjelduses on ± 1% Rasketõstuk, diiselmootoriga, tõstejõuga vähemalt 25 tonni 1200 mm raskuskeskme korral. Nr Tehniline nõue TÄIDAB PAKKUJA 1 JAH Si sestada dokumendi number ja pea tüki nimi /number 1.1 Tõstuk on uus (kasutamata), tootmisaasta vähemalt 202 5 Jah Offer 26001672 1.2 Tõstuki nõutav töökeskkonna temperatuurivahemik - 3 2 °C kuni +4 9 °C . Masin, kõik selle komponendid ning tehnilised vedelikud peavad vastama nõudele. Jah User manual 1.3 Pakutava tõstuki mark ja mudel SMV 25-1200 Offer 26001672 1.4 Tõstevõime vähemalt 25 000 kg / 1200 mm Jah Offer 26001672 1.5 Tõstekõrgus vähemalt 4 000 mm Kolme osaline mast Masina maksimaalne ehituslik kõrgus kuni 3300mm Jah Offer 26001672 1.6 Masti kallutus ette ja taha vähemalt 5 °/ 5 ° Jah Offer 26001672 1.7 Vabatõste kõrgus vähemalt 15 00 mm Jah Offer 26001672 2 Mootor 2.1 Diiselmootor (Vähemalt EURO 3 heitmenormile vastav) 2.1.1 Mootori võimsus peab tagama koos maksimum koormaga startida 20% kallakust üles. Jah 2.1.2 Masin peab olema võimeline töötama, kasutades kütusena EN 590 vastavat diislikütust ja NATO STANAG 7090 vastavat F-63 kütust ilma ümberehituseta; AdBlue süsteemi peab saama välja lülitada ilma erivahenditeta ja/või AdBlue vedeliku otsasaamine ei tohi mõjutada masina opereerimisvõimet , kui AdBlue süsteem on paigaldatud . # Esitada mootori või masinatootja kinnitus ja ekspluatatsiooni tingimused F-63 kütuse kasutamise korral. Jah Confi r mation AN 06-03-2026 2.1.3 Heitgaasi järeltöötlussüsteemi olemasolul ( nt DPF, SCR) korral peab olema tagatud masina täielik töövõime juhtudel , kui nimetatud seadmed ei tööta või esinevad rikked / tõrked . Masina töövõimet ei tohi seeläbi piirata ka elektroonselt . Jah 2.1.4 Kütuse veeseparaator filter koos kütuse elektrilise eelsoojendiga. Jah 2.1.5 Jahutusvedeliku soojendiga integreeritud 230V töötav akulaadija , mis on varustatud automaatse ülelaadimise kaitsefunktsiooniga . #Esitada tõendus , et laadija on sobilik masinale paigaldatud akude laadimiseks välitingimustel . Jahutusvedeliku soojendi mootoriplokis, mis töötab 230V pingel; seadet peab olema võimalik kasutada ilma ajalise piiranguta 24/7. Jah 2.1.6 Kütusepaagi maht peab tagama vähemalt 8 h katkematut tööaega. Jah Technical data 2.1.7 Masinale peab olema paigaldatud autonoomne diislikütusel töötav soojendussüsteem vähemalt kabiini ja mootori veesärgi soojendamiseks. Jah Offer 26001672 2.2 Masin peab olema varustatud automaatse kesk määrdesüsteemiga , määrdeaine mahuti peab olema kaitstud metallist või tugevast plastikust kaanega, et vältida mehaanilisi kahjustusi. Määrdeaine mahuti peab olema kaitstud niiskuse eest, nt survepesu ajal ei tohi niiskus määrdeaine mahutisse sattuda. Masti määrimiseks on lubatud keskmäärde süsteem käsitsi määrimiseks (st määrdeliinide väljavõte) Jah 3 Ülekanne 3.1 Piduri- ja hüdraulikasüsteem peavad võimaldama avariiteisaldamist juhul kui mootor ei tööta või akud on tühjad Jah 3.2 Veoskeem 4x2 või 4x4 Jah Tech nical data 3.3 Esi- ja tagateljel peavad olema elastikrehvid. Jah 3.4 Minimaalne liikumiskiirus vähemalt 15 km/h koormatult ja koormamata Jah Technical data 3.5 Mehaaniline seisupidur , sõidupidur mehaaniline või hü d r auliline Jah 4 Juhtimine 4.1 Tööorgani juhtimine kabiinist Jah 4.2 K ahvlite külgnihe Jah 4.3 K ahvli käppade pikkus vähemalt 2000 mm Jah 4.4 Sõidusuuna, masti tööoperatsioone ja lisaseadmete juhtimine elektriliselt juhtkangilt (elektriliselt juhitav hüdrojagaja ). Jah Offer 26001672 4.5 Roolivõimendi Jah 4.6 Tõstukiga peab olema võimalik töötada 5 tundi järjest ilma pausideta Jah 4.7 Reguleeritav roolisammas. Jah 4.8 Vajalik operaatori tuvastamise süsteem tööoperatsioonide teostamiseks. Jah 4.9 Reverseerimise alarm väljalülitamise võimalusega Jah 5 Kabiin Cabin 5.1 ISO 3471 ROPS – Roll Over Protective Structure 5.2 ISO 3449 FOPS – Falling Object Protective Structure Jah PM-FM Konecranes 5.3 Kabiini õhuvõtusüsteem peab olema varustatud tolmufiltriga (salongifilter). Jah 5.4 Mehaaniliselt kiige süsteemiga või õhkvedrustusega reguleeritav juhiiste koos turvavööga . Jah 5.5 Elektrilise soojendusega välised tahavaatepeeglid ja vähemalt üks sisepeegel . Jah 5.6 Esi- ja tagaklaasi pesur ja kojamees. Jah 5.7 Mehaaniline või elektriliselt lülitatav massilüliti, mis võimaldab kogu elektrisüsteemi väljalülitamist. Jah 5.8 Kabiini soojendus- ja jahutussüsteem koos konditsioneeriga Jah 5.9 Kabiin peab hoolduste teostamiseks olema elektriliselt või elektrohüdrauliliselt kallutatav. Jah 6 Elektrisüsteem 6.1 Põhi- ja töötuled, täielikult väljalülitatavad 6.1.1 kaks vähemalt 24W LED töötuld katuse esi - ja kaks vähemalt 24 W LED töötuld katuse tagaservas , mõlemal masina küljel vähemalt üks vähemalt 24W LED töötuli, vähemalt kaks töötuld masina taga, vähemalt kaks töötuld mastil Jah 6.1.2 töötulede valgustussuund peab olema reguleeritav; Jah 6.1.3 Sõidu- ja pidurituled Jah 7 Muu varustus 7.1 Ettenähtud tehasepoolne tööriistakomplekt kasutajatasandi hooldus- ja remonttööde teostamiseks ning hüdraulikasüsteemi mutrite pingutamiseks. Mehaaniliste määrdepunktide olemasolul peab olema tööriistakomplektis määrdetuubiga täidetav määrdeprits. Komplekt peab asuma selleks ettenähtud veekindlast kastis või sahtlis. Jah Offer 26001672 7.2 Masinas kasutuses olevad õlid peavad tagama aastaringse kasutamise, arvestades nõutavat töökeskkonna temperatuurivahemikku Jah 7.3 Manomeetriga tulekustuti d, 2 tk, kokku vähemalt 12 kg kustutusainega, kinnitatuna, kaitstud mehaaniliste vigastuste eest Jah 7.4 Ohutusvest XXL suuruses. Jah 7.5 Meditsiinilise esmaabi komplekt, kinnitatult ning komplekteeritud vastavalt kehtivale seadusandlusele. Jah 7.6 Akende, peeglite, tulede katted, mis peavad olema pakendatud veekindlalt . 8 Üldine 8.1 Tarneaeg mitte üle 12 kuu pärast hankelepingu sõlmimist . Jah 8.2 Tõstuki(te) tarne Eesti Vabariigi piires vastavalt etteantud tellimusaadressile. Jah 8.3 Garantii vähemalt 2 aastat või 5 000 h Jah 8.4 Vähemalt inglis keelne varuosade kataloog ning hüdraulika- ja elektrisüsteemide diagrammid paberkandjal ja digitaalselt. Jah 8.5 Ho olduse ja remondi teostaja(d), h oolduskeskus( ed ) Eesti Vabariigis Jah 8.6 Hooldusvälp mitte vähem kui 500 töötundi. Jah 8.7 CE sertifikaat Jah Offer 26001672 8.8 Pakkuja peab tagama mehaaniku ja operaatori kasutajataseme väljaõppe oma kuludega 4-6 Eesti Kaitseväe isikule. Koolitus peab toimuma 14 päeva jooksul pärast esimeste masinate tarnimist. Jah 9 Lisanõuded 9.1 Masin ja lisaseadmed peavad vastama direktiivi „EUROOPA PARLAMENDI JA NÕUKOGU DIREKTIIV 2006/42/EÜ“ nõuetele. Jah 9.2 Masin ja lisaseadmed peavad vastama Eesti ja Euroopa kehtivatele nõuetele. Jah Offer 26001672 9.3 Pakutava masinaga sama marki üle 10t tõstejõuga masinad peavad olema kasutusel vähemalt kolme NATO riigi relvajõudude poolt. (esitada nimekiri) 9.4 Masin peab olema varustatud vähemalt masina laiuse kahvliraamiga . 20’ konteinerit peab olema võimalik liigutada külgnihkega külgsuunas standardsetest tõstekohtadest tõstes , vähemalt 800mm . Jah 9.4.1 Masinal peab olema nn viies sektsioon kahvliraami kallutamiseks pikitelje suhtes ( kallutav kahvliraam ). Kahvliraam peab kallutama vähemalt 3 ° mõlemale poole Jah 9.4.2 Masinale peab olema võimalik kinnitada ja kasutada konteinerite tõstmiseks üla ja külg spreederit . Jah 9.5 Masina ja lisaseadmete värvus tehase standard, masin peab olema värvitud valmistajatehase poolt Jah 9.6 Masinal ei tohi olla kroomitud või nikeldatud vms läikivaid kere detaile ( v.a peeglid , klaasid ning hüdraulika silindrite tööpinnad ). Jah 9.7 Masinal ei tohi olla andmeside monitooringut masina töö - ja veainfo kuvamiseks , millel on GPS positsioneerimise või muud sarnane sidesüsteemi ( Julgeolek ). Jah 9.8 Kütusepaak ( või - paagid ) korrosioonikindlast materjalist ja lukustatav (ad). Jah 9.9 Kütusepaagi maht peab tagama vähemalt 8 h katkematut tööd keskmise kütusekulu järgi . #Esitada arvutus , mille alusel on saadud kriteeriumile vastavuse andmed . Jah 9.10 Süsteem peab olema 24V, et saaks käivitusabiks ühendada Eesti Kaitseväe teiste sõidukitega . Jah 9.11 Akuruum , akude kinnitus , klemmide mõõtmed ja asukohad peavad vastama STANAG 4015 Ed.3 nõuetele . # Esitada nõutele vastav akukastide joonis koos klemmide asetusega . Jah 9.12 Akud peavad olema hooldusvabad ja vastama STANAG 4015 Ed.3 nõuetele mõõtmete ja ühendusklemmide asetuse suhtes . #Esitada paigaldatavate akude andmeleht . Jah 9.13 Masin on varustatud NATO STANAG 4074 tüüp 1 -le vastava stardiabi pistikuga , paigaldatuna kergesti ligipääsetavasse kohta . Jah 9.14 Töötuled peavad olema LED- tüüpi . Jah 9.15 Masina tööala peab olema valgustatud ümber masina 360 kraadi . Iga töötuli peab olema vähemalt 24W. Jah Töö- ja parkimistuled peavad olema kaitstud mehaaniliste kahjustuste eest. Jah 9.16 Masinal peab olema registreerimismärgi alus koos valgustusega . Jah 9.17 Sõidualarm ( liikumise helisignaal ); peab olema väljalülitatav . Jah 9.18 Masin peab olema varustatud kollase LED vilkuriga . Vilkur peab olema kabiinist lülitatav ja lihtsasti eemaldatav . Jah 9.19 Peab olema varustatud FM- raadio , kõlarite ja antenniga . Jah 9.20 Iste peab olema reguleeritav vähemalt edasi-tagasi suunal , istmepadi pikikalde osas ning seljatoe nurk istmepadja suhtes . Jah 9.21 Istme amortisatsioon peab olema reguleeritav vastavalt operaatori kehakaalule . Jah 9.22 Istmekate peab olema valmistatud kulumis - ja määrdumiskindlast materjalist . Ei tohi olla nahast . Jah 9.23 Töötuledel peab olema soojendus lume sulatamiseks tule klaasidelt Jah 9.24 Kabiini ventilatsioonisüsteem peab olema varustatud välisõhu filtri ( te )ga. Jah 9.25 Klaasid peavad olema kaetud päikesekaitsekilega (UV kaitse , läbipaistvus vähemalt 75%) . Jah 9.26 Masinas peab olema DIN1 pesa raadiojaama paigaldamiseks , raadiojaama tarnib hankija , raadiojaama ühendused , antenni - ja toitekaablid peavad olema paigaldatud ja ühendatud Jah 9.27 Kabiinis peab olema koht, kuhu kinnitada relv masinaga opereerimise ajaks; kinnitus peab olema universaalne ja sobima relvadele: AK4, GALIL, R20. Jah 9.28 Küljepeegli kinnitused peavad olema valmistatud löögijõudu neelavast materjalist või varustatud vedrusüsteemiga , et vältida nende küljest murdumist või deformeerumist valise jõu rakendumisel . Jah 9.29 Küljepeeglid peavad purunemise vältimiseks olema kokku lükatavad või - klapitavad . Jah 9.30 Masina rehvid peavad võimaldama liikumist nii kõvakattega teedel kui ka pinnasel . Rehvi muster peab olema sobilik pinnasel töötamiseks . Jah 9.31 Kabiinis peab asetsema mõõteseadmete paneel , millel asuvad vähemalt : 9.31.1 töötunnilugeja Jah Offer 26001672 9.31.2 mootori jahutusvedeliku temperatuurinäidik ; Jah Offer 26001672 9.31.3 kütusepaagi taseme näidik; Jah Offer 26001672 9.31.4 audio-visuaalne hoiatussüsteem elektrisüsteemi rikete, jahutusvedeliku, mootori ja tööhüdraulika õlisurve, õhufiltri ummistumise, ülekuumenemise jne vigadest alarmeerimiseks; Jah Offer 26001672 9.31.5 Sees oleva käigu indikaator Jah Offer 26001672 9.31.6 Lasti kaal koos hoiatussüsteemiga ülekoormuse osas Jah Offer 26001672 9.32 Kabiini uks peab olema fikseeritav avatud ja suletud asendis Jah 9.33 Juhul, kui masinal on T ahavaate / külgvaate kaamerad , siis peavad need olema kaitstud mehaaniliste vigastuste eest . Jah 9.33.1 Masinal peab olema vähemalt tahavaate kaamera Jah 9.34 Hüdraulikasüsteem peab võimaldama proportsionaalset ehk tööorgani liigutuste sujuvat juhtimist. Jah 9.35 Peab võimaldama avariiteisaldamist juhul, kui mootor ei tööta (st peab olema võimalik tööorganeid alla lasta või tõsta abivahendite abil). Jah 9.36 Tööriistakomplekt, mis on vajalik kasutajatasandi hooldus- ja remonttööde läbiviimiseks ja hüdroliinide kinni-lahti keeramiseks. Tööriistkomplekt peab asuma selleks ette nähtud ilmastikukindlas kastis või sahtlis. Jah 9.37 V ähemalt 6 m pikkune käivitusvoolu ülekandekaabel , varustatud mõlemas otsas NATO STANAG 4074 tüüp 1 -le vastava stardiabi pistikuga koos üleminekuga Type 2 ühendusele . Jah 9.38 Masinaga koos tarnitakse kahvlipikendused pikkusega vähemalt 1,5 masina kahvlite pikkust Jah 9.39 Masina tõstekahvlid peavad võimaldama kauba tõstmist tõstekettidega . Ketid peavad olema masinaga kaasas . Kettide pikkus minimaalselt 4m. Tõstekettide nominaalne tõstejõud peab olema vähemalt 8 t/ tk Jah 10. Dokumentatsioon ja muud tingimused 10.1 Varuosade kataloog , hüdro - ja elektriskeemid vähemalt inglise keeles . Jah 10.2 Kasutamisjuhend (paberkandjal ning elektrooniliselt eesti keeles ja elektrooniliselt inglise keeles). #Esitada kasutusjuhend inglise või eesti keeles. Jah 10.3 Mehaaniku ja operaatori koolitus (kasutajatasemel) 4-6 kaitseväelasele. Väljaõpe peab olema läbi viidud mitte hiljem kui kaks nädalat pärast esimese masina üleandmist. Mehaanikutele on nõutud lihtsamate hooldustööde ja ekspluatatsioonimaterjalide (töövedelikud, filtrid, tihendid, rihmad jne) vahetamise koolitus. #Esitada koolituskava, ajakava (üldine) ja koolituse sisu ülevaatus. Sammuti eeldused personali varasema pädevuse osas. Esitada muud koolitusega seotud olulised kommentaarid. Jah 10.4 Pakkujapoolne vea määratlemine tõstuki juures tööpäevadel hiljemalt 24 h jooksul ja nädalavahetustel ning riiklikel pühadel hiljemalt 72 h jooksul Eesti Vabariigi piires alates rikke teatamisest. Jah 10.5 Kuluvaruosade tarneaeg maksimaalselt 7 päeva . Jah Operating Instructions Forklift SMV 10-65, Gen C OIFLTC_RevE Original Instructions 24 May 2024 Document ID: DOC2730881A / en-US This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Internal reference: X101986 en-US / E Contact information Contact the manufacturer’s local representative or Konecranes Lifttrucks AB Anders Anderssons väg 13 285 35 Markaryd SWEDEN Tel. +46 433 733 00 For UK, contact: Konecranes Demag UK Ltd Coalfield Way LE65 1NF Asby De La Zouch UNITED KINGDOM www.kclifttrucks.com Table of contents Operating Instructions TABLE OF CONTENTS 1 INTRODUCTION.............................................................................................................7 1.1 About this document.................................................................................................... 7 1.1.1 Use of the document......................................................................................... 7 1.1.2 Terminology.......................................................................................................7 1.1.3 Abbreviations.................................................................................................... 8 1.1.4 Copyright notice................................................................................................ 9 1.1.5 Available technical documents.......................................................................... 9 1.1.6 Feedback on documents................................................................................... 9 1.2 About this product........................................................................................................ 9 1.2.1 Use of the product ............................................................................................9 1.2.2 Conditions of warranty.................................................................................... 10 1.2.3 Identification of the product............................................................................. 11 1.2.4 Standards and directives.................................................................................12 1.2.5 Declaration of conformity.................................................................................13 2 SAFETY AND ENVIRONMENT.................................................................................... 15 2.1 Safety messages and symbols.................................................................................. 15 2.1.1 Signal words................................................................................................... 15 2.1.2 Hazard symbols.............................................................................................. 15 2.1.3 Mandatory action symbols...............................................................................18 2.1.4 Prohibited action symbols............................................................................... 19 2.1.5 Safety and information labels on the product...................................................19 2.1.6 Location of the safety and information labels...................................................20 2.2 Responsibilities of the operational manager............................................................ 26 2.2.1 Preventing work-related hazards.....................................................................26 2.2.2 Personal protective equipment........................................................................ 26 2.2.3 Incident reporting............................................................................................ 27 2.3 Limitations of the product.......................................................................................... 27 2.3.1 Operating conditions....................................................................................... 27 2.3.2 Inclination angles............................................................................................ 27 2.3.3 Lift truck danger zones, general...................................................................... 29 2.3.4 Tire explosion danger zone............................................................................. 29 2.3.5 Prohibited use................................................................................................. 31 2.3.6 Changes to the product................................................................................... 31 2.4 Emissions.................................................................................................................... 32 2.4.1 Noise...............................................................................................................33 2.4.2 Vibration .........................................................................................................33 2.5 Protective measures................................................................................................... 34 2.5.1 Emergency stopping....................................................................................... 34 2.5.2 Battery main switch......................................................................................... 35 2.5.3 Releasing the hydraulic pressure ................................................................... 37 2.5.4 Fire safety....................................................................................................... 37 2.5.5 Emergency exits..............................................................................................38 2.5.6 Mounting, and dismounting the machine......................................................... 39 2.5.7 Locking the cabin door in open position.......................................................... 39 2.5.8 Personnel requirements.................................................................................. 40 2.6 Environmental information.........................................................................................41 2.6.1 Energy consumption....................................................................................... 41 2.6.2 Product lifecycle stages...................................................................................41 2.6.2.1 Production of materials and components.................................................... 42 2.6.2.2 Equipment manufacturing and assembly.....................................................42 2.6.2.3 Use phase, including maintenance and modernization................................43 2.6.2.4 Dismantling and handling waste material.................................................... 43 3/184 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Operating Instructions Table of contents 2.6.2.5 Deliveries between each stage....................................................................44 2.6.3 Notice on the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH)....................................................................................... 45 2.7 Storage information.................................................................................................... 45 2.7.1 Storage........................................................................................................... 45 2.7.2 Alternative storage, up to two months............................................................. 46 2.7.3 Alternative storage, longer than two months....................................................47 3 PRODUCT DESCRIPTION........................................................................................... 49 3.1 Technical description .................................................................................................49 3.2 Machine outline, forklift.............................................................................................. 51 3.3 Controls and indicators in cabin with lever control .................................................52 3.4 Controls and indicators in cabin with joystick (option)........................................... 53 3.5 Keypad.........................................................................................................................54 3.6 MD4 display................................................................................................................. 55 3.6.1 User interface..................................................................................................56 3.6.1.1 Introduction to MD4 pages.......................................................................... 56 3.6.2 MD4 display frame ......................................................................................... 56 3.6.3 MD4 pages......................................................................................................60 3.6.3.1 Start-up page.............................................................................................. 60 3.6.3.2 Home page (weight page)........................................................................... 61 3.6.3.3 Date and time page.....................................................................................62 3.6.3.4 ECO-driving page........................................................................................63 3.6.3.5 Operator page ............................................................................................64 3.6.3.6 Machine overview page...............................................................................65 3.6.3.7 Information page......................................................................................... 73 3.6.4 Preferences.....................................................................................................74 3.6.4.1 Setting the display backlight and screen saver............................................74 3.6.4.2 Setting the date...........................................................................................75 3.6.4.3 Setting the time........................................................................................... 75 3.7 Lifting loads.................................................................................................................76 3.7.1 Lifting capacity plate........................................................................................76 3.7.2 Maneuvering the mast with levers................................................................... 78 3.7.3 Maneuvering the mast with joystick (option).................................................... 79 3.7.4 Mast and attachment symbols.........................................................................80 4 OPERATING INSTRUCTIONS..................................................................................... 84 4.1 Daily maintenance before operation..........................................................................84 4.2 Daily maintenance checks .........................................................................................86 4.2.1 Turning on and turning off the battery main switch.......................................... 86 4.2.2 Checking the condition and pressure of the tires............................................. 88 4.2.3 Checking the engine oil level...........................................................................90 4.2.4 Checking the DANA transmission oil level ......................................................92 4.2.5 Checking the ZF transmission oil level............................................................ 93 4.2.6 Checking the coolant level, Volvo engines...................................................... 94 4.2.7 Checking the coolant level, Cummins..............................................................95 4.2.8 Checking the hydraulic oil level....................................................................... 96 4.2.9 Checking the brake cooling oil level (option)................................................... 97 4.2.10 Checking the engine air filter, Volvo engines .................................................. 97 4.2.11 Checking the windshield washer level............................................................. 98 4.2.12 Checking the fuel level.................................................................................... 99 4.2.13 Checking the AdBlue level............................................................................ 100 4.2.14 Check the soot level......................................................................................102 4.2.15 Adjusting the operator's seat......................................................................... 102 4.2.15.1 Adjusting the BE-GE operator's seat......................................................... 103 4.2.15.2 Adjusting the Isringhausen operator's seat................................................106 4/184 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Table of contents Operating Instructions 4.2.15.3 Adjusting the Grammer operator's seat..................................................... 107 4.2.16 Adjusting the steering wheel..........................................................................108 4.3 Hydraulic long life (HLL) filter (option).................................................................... 108 4.3.1 Placement of the hydraulic long life (HLL) filter............................................. 108 4.3.2 Checking the HLL filter.................................................................................. 109 4.4 Engine After-treatment System (EATS) - Volvo stage V......................................... 109 4.4.1 Selective catalyst reduction (SCR) - Volvo stage V........................................ 111 4.4.2 Diesel Particulate Filter (DPF) - Volvo stage V...............................................112 4.4.3 Parked regeneration - Volvo stage V............................................................. 113 4.5 Engine aftertreatment System - Cummins engines................................................ 115 4.5.1 Selective catalyst reduction (SCR) - Cummins engines................................. 116 4.5.2 Diesel Particulate Filter (DPF) - Cummins engines........................................118 4.5.3 Parked regeneration - Cummins engines.......................................................119 4.5.4 Diesel Oxidation Catalyst (DOC) - Cummins engines....................................121 4.6 Using the cabin heating and ventilation.................................................................. 122 4.7 Using the cabin ventilation (option).........................................................................123 4.8 Driver login (option).................................................................................................. 123 4.9 Changing the operator..............................................................................................124 4.10 Break-in period..........................................................................................................126 4.11 Steering and braking.................................................................................................126 4.11.1 Steering........................................................................................................ 126 4.11.2 Using the electrical mini-wheel steering (option)............................................127 4.11.3 Force neutral when braking...........................................................................130 4.11.4 Activating the declutch.................................................................................. 131 4.11.5 Activating the declutch, with pressure switch (option)....................................132 4.11.6 Activating the inching function (option).......................................................... 132 4.11.7 Parking..........................................................................................................133 4.11.8 Activating the parking brake.......................................................................... 134 4.11.9 Automatically applied parking brake (option)................................................. 134 4.11.10 Differential lock function (option)................................................................... 135 4.12 Sideways sliding cabin............................................................................................. 136 4.13 Using the 180° rotating seat (option)....................................................................... 139 4.14 Operating................................................................................................................... 141 4.14.1 Daily inspection before operation (option)..................................................... 141 4.14.2 Operating - general information.....................................................................141 4.14.3 Starting the engine ....................................................................................... 142 4.14.4 Starting the engine, with RFID tag (option)....................................................144 4.14.5 Stopping the engine...................................................................................... 145 4.14.6 Stopping the engine, with RFID tag (option).................................................. 146 4.14.7 Operating the machine ................................................................................. 148 4.14.8 Driving forwards............................................................................................ 150 4.14.9 Stopping the machine....................................................................................152 4.14.10 Driving in reverse ......................................................................................... 154 4.15 Mounting the attachment - ELME 815......................................................................156 4.15.1 Parts of the attachment................................................................................. 156 4.15.2 Mounting the attachment - forks in standard position.................................... 156 4.15.3 Mounting the attachment - forks in inverted position......................................158 4.15.4 Connecting the hydraulic quick couplings......................................................159 4.15.5 Connecting the electric contact..................................................................... 160 4.16 Lifting and driving with a load..................................................................................161 4.16.1 Lifting a load..................................................................................................161 4.16.2 Transporting a load....................................................................................... 163 4.16.3 Unloading a load........................................................................................... 165 4.17 Emergency lowering, general...................................................................................167 5/184 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Operating Instructions Table of contents 4.17.1 Emergency lowering for SMV 10-16 - L90 main valve................................... 167 4.17.2 Emergency lowering for SMV 18-60 - K220/L90 main valve..........................168 4.18 Towing........................................................................................................................169 APPENDIX I: FUEL AND OIL RECOMMENDATIONS........................................................... 171 Quality of the engine oil...............................................................................................171 Extended oil change interval....................................................................................... 172 Recommended fluids and lubricants............................................................................172 APPENDIX II: FUSES AND RELAYS..................................................................................... 177 Fuses.......................................................................................................................... 177 Relays.........................................................................................................................182 6/184 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. 1 Introduction Operating Instructions 1 INTRODUCTION 1.1 About this document This operating instruction offers guidance to enable safe and efficient operation of the equipment. Taking the time to read this document helps to prevent damage to the equipment, and, most importantly, keep the personnel safe. The equipment is safe when used correctly. However, there are many potential hazards that are associated with incorrect operation. These hazards can be avoided with knowledge about how to recognize and anticipate them. This document increases the awareness of the responsibilities regarding the equipment. Following the content of this document will ensure that the equipment is kept in a safe operating condition throughout its lifetime. This document is not intended as a substitute for proper training but provides recommendations and methods for safe and efficient operation and maintenance. The operational manager must ensure that operators are properly trained before operation. They must always comply with all the applicable and prevailing safety, as well as other standards, rules, and regulations. 1.1.1 Use of the document Every person that is exposed to the equipment must, before operating, servicing and maintaining such products, read, and understand the contents of this document. Also to strictly adhere and conform their conduct with and to the information, recommendations, and warnings that are provided in this document. NOTE Keep the operating instructions in the cabin of the machine for future reference. WARNING IGNORING INSTRUCTIONS HAZARD Failure to follow the given instructions could cause death or serious injury. Read and understand the contents of this document before operating, servicing, and maintaining the equipment. The manufacturer makes absolutely no warranty whatsoever regarding the contents of this document, express or implied, whether arising by operation of law or otherwise. This includes, but are not limited to, any implied warranties of merchantability or fitness for a particular purpose. 1.1.2 Terminology All brand names, product names, and trademarks that are used in this document are registered trademarks of their respective owners. The following terms and definitions may have been used in this document: 7/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 1 Introduction Authorized dealer Company, or person authorized by Konecranes Lifttrucks AB to carry out service actions, and represent the manufacturer. Authorized Persons who have the necessary training and who are authorized by personnel Konecranes Lifttrucks AB or their representative to carry out operation, or service actions. Manufacturer Refers to Konecranes Lifttrucks AB, or supplier of part when otherwise specificed. Operational Person, or persons, with different areas of responsibility at the working manager site where the machine is used. The areas of responsibility include, but are not limited to risk assessments, daily operations and maintenance tasks. Battery A compartment containing the 24V batteries and fuses, which are compartment found on the right side of the machine. CE marking The CE marking of the machine is displayed on the lifting capacity plate. The symbol indicates that the machine complies with the appropriate CE regulations. Check A visual and functional assessment (not a test) of the machine without dismantling it. Touch screen A touch screen where the user receives information, and enter display commands by touching designated areas on the screen. TRUCONNECT® TRUCONNECT® is a suite of remote service products and applications to support maintenance operations and drive improvements in safety and productivity. The collected data from the machines can be viewed at yourKONECRANES customer portal. 1.1.3 Abbreviations The following abbreviations and shortenings can occur in this document: Abbreviation Description Abbreviation Description Automated determination of the filling paramaters AEB LV Low Voltage (Automatisiertes Ermitteln der Befüllparameter) COG Center Of Gravity NCD Nox Control Diagnostics DEF Diesel Exhaust Fluid PCB Printed Circuit Board DOC Diesel Oxidation Catalyst PCD Particle Control Diagnostics Personal Protective DPF Diesel Particulate Filter PPE Equipment Engine After-treatment EATS PPS Power Pile Slope System Radio Frequency ECM Engine Control Module RFID Identification Electric Magnetic EMC SCR Selective Catalyst Reduction Compatibility FGO Function Group Output SWL Safe Working Load 8/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 1 Introduction Operating Instructions Abbreviation Description Abbreviation Description Tire Pressure Monitoring HLL Hydraulic Long-Life TPMS System Heating, ventilation, and air HVAC ULSD Ultra-Low Sulphur Diesel conditioning International Organization for ISO VCU Vehicle Control Unit Standardization LC Load Center 1.1.4 Copyright notice This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Konecranes © 2024. All rights reserved. 1.1.5 Available technical documents For this equipment, there are technical documents that serve different purposes and audiences. Contact your supplier if you require any of the documents that are listed here. Operating instructions Describes the responsibilities of the operator and the operating instructions, along with some mandatory daily maintenance tasks and safety information. The operating instruction must be stored in the cabin of the truck. Maintenance instructions Describes maintenance tasks such as lubrication and oil change and the recommended safety instructions. Technical instructions Describes in greater detail the hydraulic and electrical systems, vehicle control unit, and other components of the machine and its software. Spare part catalogue Includes part numbers of all components for the supplied parts, drawings, and exploded views. Supplier documentation Describes components that are assembled on the machine, and provided by approved suppliers to the manufacturer. This includes component-specific documents, for example, for installation, operation, and maintenance. NOTE Store documents in a safe, dry place where they can be easily located when required. 1.1.6 Feedback on documents As the goal is constant improvement, this document may be updated or revised to provide operational managers and operators with the most accurate information currently available. Current versions of instructions can be found at document portal www.kclifttrucks.com. To communicate any inaccuracies or omissions, or to provide general feedback or suggestions regarding the quality of this document, send an email to [email protected]. 1.2 About this product 1.2.1 Use of the product The machine is designed to perform lifting and transporting of loads within the limits that are specified in the machine's lifting capacity plate. For more information, see Lifting capacity plate (page 76) in front of the left side cabin door. 9/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 1 Introduction Contact the manufacturer or manufacturer's representative in case of doubt. 1.2.2 Conditions of warranty The terms under which seller's equipment and/or services are warranted are defined pursuant to the warranty set forth in the contract between seller and customer for seller's products and/or services and, if not so set forth, the warranty for seller's products and/or services is seller's standard warranty in effect at the time of sale, a copy of which is available from seller upon request. THE FOREGOING REPRESENTS THE SOLE AND EXCLUSIVE WARRANTY GIVEN BY SELLER AND IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, ARISING BY OPERATION OF LAW OR OTHERWISE, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Seller provides no warranties for products manufactured or services provided by parties other than seller ("Third Party Products"). Third Party Products may be warranted separately by their respective manufacturers or such other parties from whom seller purchases such Third Party Products and seller shall, to the extent possible, assign to you whatever rights seller may obtain under any such warranties. Modifying any seller product or incorporating any Third Party Product into any seller product or service without the seller's approval invalidates the warranty. Seller does not accept, shall not have any responsibility and disclaims any liability for accidents, injury or physical or property damage arising as a consequence of such unauthorized modifications and/or incorporation of Third Party Products. Further, each of the following invalidates any warranty of seller and relieves seller from any responsibility to repair or replace any seller product due to a failure to operate and/or maintain seller products in accordance with the applicable manuals, instructions, guides, recommendations, and any other manuals, guidelines or recommendations of seller concerning the maintenance and operation of seller products that may be communicated to you from time to time; damage or defects caused by side-pulling of load, shock loading, excessive jogging, eccentric loading or overloading, accidental occurrence, improper repair, improper handling or storage of products, chemical exposure, abnormal operating conditions, or any other cause that in seller's sole discretion is not attributable to defects in the material and workmanship of seller’s product. The applicable seller manuals, instructions, guidelines, and recommendations must be strictly complied with by customer which may include, by way of example and not by limitation, installation and commissioning instructions, owner's manuals, operator's/user’s manuals, operating and maintenance instructions and user's guides. SELLER SHALL HAVE NO LIABILITY TO YOU OR ANY END USER OF PRODUCTS FOR LOST PROFITS OR FOR INDIRECT, SPECIAL, CONSEQUENTIAL, EXEMPLARY OR INCIDENTAL DAMAGES OF ANY KIND WHETHER ARISING IN, CONTRACT, TORT, PRODUCT LIABILITY, STRICT LIABILITY OR OTHERWISE, EVEN IF SELLER WAS ADVISED OF THE POSSIBILITY OF SUCH LOST PROFITS OR DAMAGES. SELLER’S LIABILITY IS LIMITED TO THE AMOUNT OF YOUR DIRECT DAMAGES UP TO THE AMOUNT OF THE CONTRACT PRICE AND IN NO EVENT SHALL SELLER BE LIABLE TO YOU FOR ANY DAMAGES WHATSOEVER IN EXCESS OF THE TOTAL PRICE PAID BY YOU FOR THE APPLICABLE SELLER PRODUCTS. YOU HEREBY WAIVE ANY CLAIM THAT THE EXCLUSIONS OR LIMITATIONS IDENTIFIED HEREIN DEPRIVE YOU OF AN ADEQUATE REMEDY OR CAUSES YOUR AGREEMENT WITH SELLER TO FAIL OF ITS ESSENTIAL PURPOSE. YOU SHALL BE ENTITLED TO NO OTHER REMEDY OTHER THAN THOSE IDENTIFIED IN THE CONTRACT BETWEEN YOU AND SELLER OR SELLER’S STANDARD WARRANTY, WHICHEVER IS APPLICABLE, WITH RESPECT TO THE PROVISION OF PRODUCTS BY SELLER REGARDLESS OF THE FORM OF CLAIM OR CAUSE OF ACTION, WHETHER BASED IN AGREEMENT, NEGLIGENCE, STRICT LIABILITY OR OTHERWISE. UNLESS OTHERWISE REQUIRED BY MANDATORY LAW, SELLER DISCLAIMS ALL WARRANTIES RELATING TO THE CONTENTS OF THIS DOCUMENT, EXPRESS OR IMPLIED, ARISING BY OPERATION OF LAW OR OTHERWISE. 10/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 1 Introduction Operating Instructions 1.2.3 Identification of the product 1 2 3 4 5 6 7 8 Figure 1. Plates and serial numbers 1. Mast serial number 6. Transmission serial number 2. Lifting capacity plate 7. Engine serial number 3. Fork carriage number 8. Steer axle serial number 4. Drive axle serial number 5. Chassis serial number (punched into the frame) NOTE The appearance may deviate from the delivered product depending on model size. 11/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 1 Introduction 1.2.4 Standards and directives This product has been designed and manufactured to conform to the following standards and directives: • Health and safety: EU: Machinery directive 2006/42/EC UK: Supply of Machinery (Safety) Regulations 2008 S.I. 2008:1597 ◦ EN ISO 3691-1:2015/A1:2020. "Industrial trucks – Safety requirements and verification - Part 1: Self-propelled industrial trucks, other than driverless trucks, variable-reach trucks, and burden-carrier trucks". ◦ ISO/TS 3691-8:2012,IDT. Industrial trucks – Safety requirements and verification. Regional requirements for countries outside the EC. ◦ EN 16307-1:2013+A1:2015. "Safety requirements and verification. Supplementary requirements for self-propelled industrial trucks, other than driverless trucks, variable-reach trucks, and burden-carrier trucks" (EU/EFTA market). ◦ EN 13059+A1:2008. "Safety of industrial trucks. Test methods for measuring vibration" (EU/EFTA market). ◦ EN 12053+A1: 2008. "Safety of industrial trucks. Test methods for noise emission" (EU/ EFTA market). ◦ EN 1175-2+A1:2010 “Safety of industrial trucks – Electrical Requirements - Part 2: General requirements of internal combustion engine powered trucks“. • EMC: EU: 2014/30/EU UK: Electromagnetic Compatibility Regulations 2016 S.I. 2016:1091 ◦ EN 12895:2015+A1:2019. Industrial trucks - Electromagnetic compatibility. • Emissions: EU: 2016/1628/EC (EU/EFTA market, stage 4, and 5 engines). UK: The Non-Road Mobile Machinery (Type-Approval and Emission of Gaseous and Particulate Pollutants) Regulations 2018 2018 No. 764 • 2016/1628/EU “REGULATION (EU) 2016/1628 OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 14 September 2016 on requirements relating to gaseous and particulate pollutant emission limits and type-approval for internal combustion engines for non-road mobile machinery, amending Regulations (EU) No 1024/2012 and (EU) No 167/2013, and amending and repealing Directive 97/68/EC" Declaration of conformity and other certificates are included in the delivery package. Manufacturer reserves the right to modify the design and material specifications without NOTE prior notice. Applicable sections of EN13155 are used for all lifting ears on the machine. 12/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 1 Introduction Operating Instructions 1.2.5 Declaration of conformity EC DECLARATION OF CONFORMITY OF THE MACHINERY (Machinery Directive 2006/42/EC, Annex II, sub. A) Manufacturer: Konecranes Lifttrucks AB Anders Anderssons väg 13, P.O. Box 103 SE-28523 MARKARYD SE Name and address of the person authorised to compile the technical file: XXXXX XXXXX Anders Anderssons väg 13, P.O. Box 103 SE-28523 MARKARYD SE The manufacturer declares that Description: Forklift Model: XXXXX Serial number: XXXXX • Is in conformity with the relevant provisions of the DIRECTIVES OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL: - of May 17, 2006, "relating to machinery" 2006/42/EC - of February 26, 2014, "relating to electromagnetic compatibility" 2014/30/EU - Directive 2000/14/EC as amended by Directive 2005/88/EC on the noise emission in the environment by equipment for use outdoors and fulfils the requirements of the following harmonised standards: • regarding Machinery Directive: EN ISO 3691-1 • regarding EMC Directive: EN 12895 Place and date of issue MARKARYD DD.MM.YYYY Signature: Anders Nilsson Technical Director Konecranes Lift trucks Figure 2. EC Declaration of conformity of the machinery (template) 13/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 1 Introduction UK DECLARATION OF CONFORMITY OF THE MACHINERY (Supply of Machinery (Safety) Regulations 2008, Annex II, sub. A) Manufacturer: Konecranes Lifttrucks AB Anders Anderssons väg 13, P.O. Box 103 SE-28523 MARKARYD SE Name and address of the person authorised to compile the technical file: XXXXX XXXXX Coalfield Way LE65 1NF Ashby De La Zouch UK The manufacturer declares that Description: Forklift Model: XXXXX Serial number: XXXXX • is in conformity with the relevant provisions of statutory instruments - Supply of Machinery (Safety) Regulations 2008 No.1597 - Electromagnetic Compatibility Regulations 2016 No.1091 - Noise emission in the environment by Equipment for use Outdoors Regulations 2001 No.1071 and fulfils the requirements of the following designated standards: • regarding 2008 No. 1597: EN ISO 3691-1 • regarding 2016 No. 1091: EN 12895 Place and date of issue MARKARYD DD.MM.YYYY Signature: Anders Nilsson Technical Director Konecranes Lift trucks Figure 3. UK Declaration of conformity of the machinery (template) 14/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions 2 SAFETY AND ENVIRONMENT 2.1 Safety messages and symbols 2.1.1 Signal words The following signal words and symbols are used to identify safety messages in these instructions. Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation that, if not avoided, could result in damage to property or environment. 2.1.2 Hazard symbols Hazard symbols are used to indicate the type of the hazard and the potential consequences. Hazard symbols are indicated by a yellow triangle with black symbols and a black triangle band. All personnel working on or in proximity of the machine must understand and follow the information that is given in all hazard symbols. General hazard symbol General hazard The general hazard symbol identifies important safety messages in this document. When you see this symbol, carefully read and understand the message that follows, and inform other users when necessary. 15/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment Mechanical hazard symbols Moving vehicle Sideways tipping Forward or backward Run over hazard hazard hazard tipping hazard Moving parts hazard Falling load hazard Slipping hazard Hanging load hazard Crushing hazard Crushing hand Flying objects to face Flying objects hazard hazard hazard Skin injection hazard Electrical hazard symbols Electrical hazard Material hazard symbols Hot liquid hazard Explosion hazard Harmful substance High-pressure hazard hazard Ignition hazard Corrosive chemical Pressurized gas Hazardous or substance hazard hazard poisonous material hazard 16/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions Thermal hazard symbols Hot surface hazard Slippery when frozen hazard Noise hazard symbols Noise hazard Laser hazard symbols Laser hazard Ergonomic hazard symbols Lifting hazard 17/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment 2.1.3 Mandatory action symbols Mandatory action symbols specify actions to be taken to avoid a hazard. Mandatory actions are indicated by blue circle with white symbols. All personnel working on or in proximity of the machine must understand and follow the information that is given in all mandatory action symbols. Wear approved safety Wear approved Wear approved Wear approved safety gloves hearing protectors protective clothing shoes Wear approved safety Wear approved hard Wear approved high Wear approved eye harness hat visibility clothing protector Disconnect Apply indicator for Use jack Alarm horn equipment from pin-hole leak test power source Read instructions Two persons for Wear approved Use seat belt handling respirator 18/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions 2.1.4 Prohibited action symbols Prohibited action symbols indicate actions that are prohibited in order to avoid a hazard. Prohibited actions are indicated by a red circle with a red diagonal line across the circle. The action that is prohibited is always in black. All personnel working on or in proximity of the machine must understand and follow the information that is given in all prohibited action symbols. General prohibition Do not walk or stand Do not weld No open fire here Do not smoke Do not modify Do not test for leak Do not touch with hands Restrict access 2.1.5 Safety and information labels on the product The safety and information labels communicate the following: • Level of risk that is based on the signal word Danger, Warning, or Notice • Type of hazard, such as cutting parts, hanging load, hot surface, live parts • Consequence of hazard, such as cutting, injection, crushing, burn, electric shock • How to avoid the hazard Always keep safety and information labels visible, and check the condition of the labels daily. Before operating the machine, replace labels that are damaged, have come loose, NOTE or do not meet the readability requirements for safe viewing distance. New safety and information labels can be ordered from the manufacturer of the machine. 19/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment 2.1.6 Location of the safety and information labels 1 5 6 7 4 8 10 3 1 9 1 12 2 26 25 11 12 1 13 13 21 20 19 18 15 14 22 16 23 17 24 Figure 4. Location of the safety and information labels 1. Lifting point 14. Accumulator pressure 2. Engine oil 15. Hydraulic oil 3. Transmission oil 16. Diesel fuel 4. Fuses and relays, PCB 17. Brake cooling oil 5. Emergency exit only 18. Do not step here 6. Seat belt 19. Remove pressure before demounting tire 7. In case of rollover 20. Read operating instructions first 8. Working zone 21. Battery main switch 9. Crush injury risk 22. Cab tilting 10. Injection hazard 23. Fuses and relays, battery compartment 11. Do not stand under or on lifted load 24. Warning-Acid and explosion risk 12. Tire pressure 10 bar (1.0 MPa)*) 25. Crushing risk by tire 13. Tie down point when transporting the 26. Machine working zone machine *) Sign present above all tires. 20/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions Table 1. Labels 1. Lifting point 2. Engine oil 3. Transmission oil 4. Fuses and relays, PCB 5. Emergency exit only 21/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment Table 1. Labels (Continued) 6. Seat belt 7. In case of rollover This sticker shows what the operator must do in case of rollover. Do not jump out of the cabin in case of rollover. Brace feet against the floor and hold on tightly to the steering wheel. Climb out of the machine when it has stopped moving. 8. Working zone 9. Crush injury risk 22/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions Table 1. Labels (Continued) 10. Injection hazard 11. Do not stand under or on lifted load. 12. Tire pressure 10 bar (1.0 MPa) 13. Tie down point for loading the machine for transport Secure the machine here when loading it for transport. 14. Accumulator pressure Warning, read instructions in the manual. 23/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment Table 1. Labels (Continued) 15. Hydraulic oil 16. Diesel fuel 17. Brake cooling oil 18. Do not step here 19. Remove pressure before demounting tire 20. Warning - Read operating instructions first 21. Battery main switch 24/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions Table 1. Labels (Continued) 1 2 22. Cab tilting 23. Fuses and relays, battery compartment 24. Warning - Acid and explosion risk 25. Crushing risk by tire 26. Machine working zone 25/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment 2.2 Responsibilities of the operational manager 2.2.1 Preventing work-related hazards The operational manager must ensure that operators, and maintenance personnel have sufficient knowledge of the work-related hazards, and the ways to avoid the hazards. The operational manager must ensure to inform the operator that a local risk assessment always must be performed before every work phase or shift. The assessment ensures that the operator stops and thinks about what to do before starting to work. • Identify potential hazards that could affect the operator, other personnel, the environment, the product, or work methods while performing the task • Assess the risks and implement the actions that are required to eliminate or reduce the risks Only personnel with sufficient competence are allowed to operate the machine, and carry out other tasks on the machine. The responsibilities of the operational manager are, for example, to: • Provide training and orientation. • Validate training methods. • Verify competence and skills. • Monitor and evaluate user performance regularly. • Provide fire-fighting equipment. • Make sure that the working site has guidelines on how to prevent fires. • Make sure that the working site has guidelines to follow concerning fire-fighting. • Make sure that the working site has guidelines on how to operate the machine during strong wind. • Make sure that the instructions from Konecranes Lift Trucks are accessible and up to date. • Make a risk assessment of the work site, for example, regarding height limitations, door openings, overhead powerlines, and ground conditions. • Make sure that the work site follows all local rules and regulations. 2.2.2 Personal protective equipment For safety, all personnel working in or near the machine are required to wear personal NOTE protective equipment (PPE). This section proposes personal protective equipment to ensure the safety of all personnel working in or near the machine. Follow the local regulations and requirements NOTE of the working environment. Use only approved and accepted personal protective equipment. Operators and anyone near and around the product must wear the following items: • Safety shoes • High-visibility clothing Various types of PPE are available as listed, depending on the situation, other types of PPE than listed can be required. It is the responsibility of the operational manager to make sure that all local PPE requirements are followed. • Hard hat • Eye protection • Ear protection • Respirator • Safety gloves • Protective clothing • Safety harness when working at heights 26/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions Do not wear loose clothing or jewelry that can get caught on controls or pulled into moving parts of the product. Do not wear jewelry or metal accessories such as watches when working with or near the electrical system or the batteries. Tie back long hair. Long hair can get entangled. Select the appropriate clothing for each task, for example: • Wear fire-resistant clothing when welding, flame cutting, or using an angle grinder. • Tear-resistant clothing must resist damage from sharp edges in the steel structure. • Wear anti-static clothing when working on electrical circuits so that components do not get damaged by a discharge of static electricity. • Always use safety goggles when working with high voltage or pressurized fluids. • When working with lubricants, clothing must prevent direct skin contact with the lubricant. • Choose clothing with consideration to the temperature at the working site, and stay hydrated. 2.2.3 Incident reporting Product safety issues that you must report are events in which the manufacturer's product has been involved in an accident or near-miss incident. Contact your local manufacturer's representative immediately to report any safety-related feedback, such as unauthorized modifications, missing instructions and safety labels, neglected maintenance, or misuse. Reporting is mandatory to ensure safe working conditions for employees, to provide information for the risk assessment process, and to initiate product and work procedure improvements. 2.3 Limitations of the product 2.3.1 Operating conditions Thunderstorm When in danger of being struck by lightning, operating or being close to the machine is strongly discouraged. Protection from lightning during work must be managed by the workplace risk assessment that is made by the operational manager. Following a lightning strike (or if you suspect the machine has been struck) the machine must be checked by authorized personnel. The check must follow the instructions of the daily maintenance. Surfaces Do not operate the machine on uneven surfaces or in unstable conditions. NOTE Do not drive on slopes that are greater than 15%. 2.3.2 Inclination angles WARNING TIPPING AND COLLISION HAZARD If you drive on slopes greater than 15%, the parking brake may fail and risk of tipping increases considerably. Risk of serious personal injury and damage to the machine. Do not drive on slopes greater than 15%. 27/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment WARNING RISK OF LOAD DROP Driving downhill on slopes carrying a load, can lead to a load drop. This can damage the machine and can lead to serious personal injury. If carrying a load, always drive downhill in reverse. If you must drive the machine along greater slopes, contact your Konecranes Lift Trucks NOTE authorized dealer. NOTE Do not drive on slopes that are greater than 15%. Figure 5. Do not drive on slopes greater than 15% 28/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions 2.3.3 Lift truck danger zones, general DANGER MOVING MACHINERY HAZARD The moving machine and its moving parts can cause death or serious injury. While the machine operates, unauthorized personnel should never enter or be within the danger zone. During operation, the authorized personnel working within the danger zone and the operator must constantly communicate verbally or visually to stay aware of each other. The following images show the danger zones surrounding the machine and its parts. 15 m/16 yd Figure 6. General danger zone 2.3.4 Tire explosion danger zone DANGER HIGH-PRESSURE HAZARD The tires may explode when you inflate or deflate them, or in case of fire. Standing inside the tire explosion danger zone during a tire explosion can cause death or serious injury. Always stand to the side of the wheel when deflating or inflating tires, see "tire explosion danger zone" illustration. Use safety glasses. The tire explosion danger zone follows the positioning of the wheels. The illustration NOTE applies when the wheels are in line with the machine. 29/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment 120° 120° 50 yd m/ 55 55 m/ yd 50 50 d 5y m/5 m/5 5y 50 d 120° 120° Figure 7. Tire explosion danger zones 30/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions 2.3.5 Prohibited use WARNING MACHINE MALFUNCTION HAZARD Using the machine outside the limits of its capacity or operating conditions could cause malfunction of the equipment. Unauthorized usage could lead to death, severe injury, or property damage. Do not use the machine outside the limits of its capacity or operating conditions. The misuse of the equipment includes, but is not limited to: • Lifting or transporting people. • Driving with the load above transport position. • Driving with heavy loads in slings. • Driving with swinging load. • Having passengers in the cabin 1) • Driving on uneven terrain • Exceeding the load limit, which is shown on the lifting capacity plate • Adding extra counterweights • Driving uphill and downhill on slopes with an inclination over 15%. • Using tools that are not approved by the manufacturer. • Using the low-voltage battery switch when the machine is in motion. • Overriding any safety systems. • Using the emergency stop in a none emergency situation. NOTE Only use the emergency stop in an emergency situation. 1) If a truck is equipped with an optional trainer's seat, another person is allowed to sit there, as long as the person uses the seat belt. For more information, see the lifting capacity plate of the machine, and, if applicable, lifting capacity plates on attachments. Contact the manufacturer or the representative for the manufacturer if there are any doubts. 2.3.6 Changes to the product DANGER MACHINE MALFUNCTION HAZARD Unauthorized changes, or modifications to the product can lead to death, severe injury, or property damage. Always contact Konecranes Lift Trucks, or an authorized representative to get a written approval in advance for any product change or modification. 31/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment DANGER MACHINE MALFUNCTION HAZARD Changes, and modifications without proper risk assessment, can lead to death, or serious personal injuries. It can also damage property, or the environment. Unauthorized modifications void the warranty and responsibility of the manufacturer. Perform a risk assessment, which eliminates, or reduces risks, and considers appropriate safety measures. WARNING MACHINE MISUSE HAZARD Adding and using equipment that is not supplied with the machine, can cause the products to malfunction. Risk of serious personal injury and damage to the machine. If using equipment that was not supplied with the machine, an authorized dealer must approve the combination and use of the equipment. The authorized dealer must ensure that safe operations can be guaranteed concerning lifting capacity, stability, and visibility. WARNING MACHINE NON-COMPLIANCE Replacing components with non-genuine components, or components not authorized by Konecranes Lift Trucks, can affect the safety of the machine. This is considered as a modification of the machine and therefore voids the liability of Konecranes as a manufacturer. The party that performed the modification will thereafter legally be liable for the safety of the modified machine, and the related CE marking. For any clarification always contact your authorised Konecranes Lift Trucks representative. All modifications and corrections that are not authorized in the product documents or which may affect the maintenance, operation, safety, and availability of the product must be approved in writing by Konecranes Lift Trucks before implementation. Approval requires a risk assessment which consider any new risks that the changes and modifications may bring. All safety and information labels on the machine, must be updated to match the machine after any modifications. To avoid using obsolete spare parts, always check the specific spare parts catalogue for the machine. For the latest version, contact Konecranes Lift Trucks spare parts department. If a modification or correction has been implemented without the permission from Konecranes Lift Trucks, its effect on warranty liability is considered case-by-case. Thus, the warranty application may be rejected altogether. If a modification, or alteration is considered necessary, contact an authorized dealer, or the organization that manufactured, and designed the product. No modification is permitted, unless the written approval from the manufacturer is obtained. 2.4 Emissions The noise and vibration levels are checked according to industry standards. This is to make sure that the operator's have a healthy environment while operating the machine. 32/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions 2.4.1 Noise Measured sound levels WARNING NOISE HAZARD Continuous exposure to noise above 80 dB(A) can cause hearing impairment, and make the operator tired and unfocused. Wear approved hearing protectors. The noise values were measured according to the harmonized standard EN12053 – A1:2008, following the conditions described therein, by a notified body. The noise values are reported according to ISO4871:2009. The specified equipment has been assessed in accordance with Directive 2000/14/EC (amended by Directive 2005/88/EC), annex VI by notified body 0404, RISE SMP Svensk Maskinprovning AB (The Swedish Machinery Testing Institute). Declared dual-number noise emission values In accordance with ISO4871:2009 Lift mode Idle mode Drive mode Total Time proportion factors of the operating cycle (%) - 0.18 0.58 0.24 1 ref. EN12053+A1:2008 A-weighted emission sound pressure level 75 74 76 76 at the operator position LpAZ (dB) Uncertainty (dB) 1 1 1 1 C-weighted peak emission sound < 130 < 130 < 130 < 130 pressure level Measured sound power level in an 102 operational cycle (A- weighted) Guaranteed sound power level in an 104 operational cycle (A- weighted) Measured on 16-33 ton forklifts, for other sizes, the values may vary slightly. Where the time proportion factors are used in defining the operational cycle, they are as defined in EN12053+A1:2008. 2.4.2 Vibration The whole-body vibration has been measured according to the harmonized standard EN13059:2008, following the conditions described therein, by a notified body. • Measured whole body vibration: below 0.9 m/s₂ • Overall uncertainty of the measurement: 1 m/s₂ 33/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment The reported expanded uncertainty is based on a standard uncertainty that is multiplied by a coverage factor K = 2. For a normal distribution, this value provides a level of confidence of approx. 95%. The standard uncertainty has been determined in accordance with EA publication EA-4/16/2003. 2.5 Protective measures 2.5.1 Emergency stopping DANGER UNCONTROLLED MOVEMENT HAZARD If the machine moves unexpectedly, it could result in personal injury, death, or damage to the equipment. To stop any unexpected movement, press the emergency stop button. WARNING FORWARD TIPPING HAZARD If the emergency stop is used when the machine moves, the machine may tip over. Risk of serious personal injury and damage to the machine. Only use the emergency stop in an emergency. Do not operate the equipment without knowing the location of the emergency stop NOTE buttons. After the emergency stop button (1) is pressed, all functions are cut out, the parking brake is activated and the engine stops. In normal operation, do not use the emergency stop button to stop the machine. Instead, use the brake pedal. Only use the emergency stop button in an emergency situation. Routinely using the NOTE emergency stop button increases wear on the product and can cause a breakdown. After each time the emergency stop is used, a daily maintenance must be performed to check the overall function of the machine. If the machine moves when pressing the emergency button, the condition of the parking brake disc and pads must also be checked. Contact authorized service personnel for the check-up. Figure 8. Emergency stop inside the cabin 34/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions Emergency stop on the outside of the machine 1 2.5.2 Battery main switch DANGER EXPLOSION HAZARD Short-circuiting the battery may cause a fire or explosion, which can cause a risk of serious injury or death. To reduce the risks of fire, explosion, electric shock and personal injury, always remove jewelry and conductive material before working on the electrical system. DANGER EXPLOSION HAZARD Batteries generate explosive hydrogen when charged, which can cause a risk of serious injury or death. Always use the necessary protective equipment. Ensure that there is good ventilation and avoid sparking. 35/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment DANGER ELECTRIC SHOCK HAZARD If the engine is on, there may still be voltage present in some parts, even when the battery main switch is turned off. The main switch does not cut the power from the alternator. This causes a risk of electric shocks, which can lead to death or serious personal injury. To reduce the risks of electric shock and personal injury always remove jewelry and conductive material before working on the electrical system. Always disconnect the ground (minus) cable at the battery when working near or on the alternator. Be aware of the battery main switch functionality. WARNING TIPPING OVER HAZARD If the battery main switch is turned off when the machine moves, the parking brake is activated. The machine may tip over, causing a risk of serious personal injury and damage to the machine. Unless there is an emergency situation, do not turn off the battery main switch when the engine runs. NOTE Do not operate the machine without knowing the location of the battery main switch (1). If the machine has an engine that uses diesel exhaust fluid (DEF) solution (for example AdBlue), turn off the engine, but do not turn off the battery main switch. Wait for the DEF NOTE pump to finish pumping back all the fluid from the hoses to the DEF tank before turning off the battery main switch (1). The required time varies slightly between different engine models. NOTE Remove the main switch handle when parking the machine. The battery main switch is found on the right-hand side of the machine, near the battery compartment. The machine can only be operated when the power is turned on. 1 Figure 9. Battery main switch 36/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions 2.5.3 Releasing the hydraulic pressure WARNING HIGH-PRESSURE HAZARD The hydraulic system contains hydraulic accumulators to maintain the brake function during a possible engine failure. Risk of serious personal injury. Do not stand close to the engine or transmission when the engine runs. Never loosen any hydraulic hoses. Only authorized maintenance personnel are permitted to loosen any hydraulic hoses. For more information about how to release the hydraulic pressure, see the Maintenance NOTE instructions. 2.5.4 Fire safety DANGER FIRE AND EXPLOSION HAZARD Ignition sources together with combustible materials can cause fire. If these risks are not avoided, they could lead to death or severe injury. Smoking, open flames, and sparks are examples of ignition sources. Fuel is an example of combustible material. Ignition sources are prohibited near the machine. During maintenance, follow appropriate fire prevention and protection measures. Measures include but are not limited to trained personnel and proper fire extinguishing equipment. Before starting any maintenance or repairs that require ignition sources, carry out a proper risk assessment to control the risk. 120° 120° 50 yd m/ 55 55 m/ yd 50 50 d 5y m/5 m/5 5y 50 d 120° 120° In case of fire, approach the machine from the front or the back. If possible, always avoid NOTE the tire explosion danger zones. 37/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment • Smoking and open fire are prohibited near the product. • Access to all fire-fighting equipment must be granted always, especially during maintenance and repair works. Fire-fighting equipment is not a standard part of the machine. It is the responsibility of NOTE the operational manager to make sure that fire-fighting equipment is available. • All fire-fighting equipment must be inspected and serviced regularly, according to local regulations. • Damaged fire-fighting equipment and used fire extinguishers must be replaced immediately. • Know the various types of fires and the appropriate fire-fighting methods. Various fires must not be extinguished with water. Special extinguishing agents, dry powders, or deoxygenating agents are required. • It is the responsibility of the operational manager to make sure that the working site has guidelines to follow concerning fire-fighting. • All personnel must be aware of the guidelines and trained regularly in fire-fighting methods. It is strongly suggested that guidelines, and training is performed in cooperation with NOTE local authorities, and rescue organizations. 2.5.5 Emergency exits The cabin door on the left-hand side is the main emergency exit. If the left-hand side door is blocked, use the right-hand side door. If both the left and right doors are blocked, use the emergency hammer (option) to smash the rear window to exit the cabin. Using the emergency hammer (Option) 1. Pull the emergency hammer from its mounting above the rear window. WARNING FLYING OBJECTS TO FACE HAZARD Breaking glass may fly into your face and eyes. Shield your eyes and face with your other arm while breaking the window with the hammer. 2. Smash the rear window with the hammer. 3. Use the hammer to scrape the remaining glass. 4. Exit the cabin through the rear window. 38/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions 2.5.6 Mounting, and dismounting the machine WARNING SLIPPING HAZARD Failing to maintain three points of contact can cause serious injury or death. Maintain three points of contact when mounting, or dismounting the machine. Three points of contact are either two hands, and one foot, or two feet, and one hand. NOTE Climb on and off only when the machine is stationary. NOTE Do not jump from the steps to the ground. Following this procedure reduces the risk of falling, and decreases wear on back, and NOTE knees. 1. Face the steps, when mounting, or dismounting the machine. The cabin entrance is on the left side of the machine. 2. Maintain three points of contact until reaching the cabin, or ground. 2.5.7 Locking the cabin door in open position 1. To fasten the cabin door in open position, open the cabin door and push it into the lock. 39/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment 2. To unlock the door from open position, press the handle on the inside of the cabin door. 2.5.8 Personnel requirements DANGER SPECIALIST SKILLS REQUIRED Incompetent operation and maintenance could cause death or severe injuries. Operation and maintenance procedures require professional skills and special training regarding the tasks and working methods. Do not operate the equipment or do any maintenance tasks without proper training. Always follow the instructions. Use appropriate personal protective equipment, depending on the task. 40/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions To avoid hazardous situations and dangerous consequences, leave all operation and maintenance work to authorized personnel. Tasks that are mentioned are examples of tasks which are allowed only for authorized personnel. Instructions for safe handling and other risks that are related to the tasks, can be found in the following chapters. Tasks that require special technical skills and training include, but are not limited to: 1. Hydraulic system maintenance 2. Electric system maintenance 3. Battery maintenance 4. Tire maintenance 5. Changing parameters in the control system 2.6 Environmental information Environmental impacts have been taken into account when designing and manufacturing this product. To prevent environmental risks during use, follow the instructions and local regulations for disposal of waste material. Proper use and maintenance improve the environmental performance of this product. 2.6.1 Energy consumption Energy consumption during the use phase has the biggest environmental impact. Diesel fuel is needed for lifting, transporting, lighting, heating, cooling, and other optional components that are part of the machine. Konecranes machines minimize the use of fuel in the following ways: • Engineering diesel engines with the best possible fuel efficiency and lowest emission levels. • Engine downsizing. • Fuel saving transmission features, like lock-up and continuously variable transmission. • Using load-sensing hydraulic systems, so no hydraulic flow (with resulting energy losses) is created unless it is needed by an actual load command. • ECO-driving supports the operators so they can minimize fuel consumption by reducing the harshness of operations. • Connectivity for the operational managers to optimize the use and operational efficiency of their machine fleet by: ◦ maximizing time driving with payload ◦ minimizing travelling distances over the yard ◦ select the most suitable machine capacity for specific lifting needs ◦ monitoring the right tire pressure for the lowest rolling resistance in connected machines • Eliminating idling time with: ◦ automatic start and stop • Means to optimize the preventive maintenance of the machines, to ensure long-term fuel efficiency. 2.6.2 Product lifecycle stages The environmental impact of a Konecranes machine is taken into account for the whole lifecycle of the vehicle. “Lifecycle” refers to the extraction and processing of raw materials, the production of components, manufacturing, use, and maintenance. "Lifecycle" also refers to disposal of the product and the transportation that is involved from one stage to the next. Each stage of the lifecycle has a different impact on the environment. The two most significant environmental impacts of the machines are the energy consumption during the use phase (in particular, the effects of diesel emissions) and the raw materials and component production (in particular, the effects of steel production). The significance of energy consumption depends on actual usage, including operating time, efficiency of operations, and load collective. Product lifecycle stages include: 41/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment • Production of materials and components • Equipment manufacturing and assembly • Use phase, including maintenance, repairs, and modernization • Dismantling and recycling of waste materials • Transports between each stage Figure 10. Product lifecycle stages 2.6.2.1 Production of materials and components 84%–92% of machine materials are metals, and rubber tires form 3%–9%. The rest of the materials include electrical and electromechanical components, fluids (hydraulic oil, diesel fuel, and grease), plastic, and glass. The main raw material is steel. The most significant environmental impacts of steel production are the use of raw materials and energy, as well as carbon dioxide and particle emissions. More than 75% of the steel content can be manufactured from recycled steel scrap. Lubricants, which are used from factory on the products, are industrial hydrocarbons. Table 2. Materials used in Konecranes machines Konecranes Lift Trucks Konecranes Liftace Forklift Forklift, Empty Laden Reach Forklift Empty Reach electric container container stacker container stacker handler handler handler Steel 88% 84% 91% 90% 92% 88% 92% 92% Rubber 6% 6% 4% 5% 3% 6% 3% 3% Copper <1% <2% <1% <1% <1% <1% <1% <1% Electronics <1% <4% <1% <1% <1% <1% <1% <1% Fluids <2% <2% <2% <2% <2% <2% <2% <2% Polymers <1% <1% <1% <1% <1% <1% <1% <1% Others <1% <1% <1% <1% <1% <1% <1% <1% 2.6.2.2 Equipment manufacturing and assembly Production mainly involves assembling of machines and some installations. Welding is only carried out for complementing or repair work. Surface treatment for reconditioning is conducted to a lesser extent. Testing of machines is carried out outdoors after assembly, before delivery. 42/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions The most significant environmental impact is the energy consumption, and diesel emissions during test-driving. To decrease the impact, Konecranes Lift Trucks is using HVO100 bio diesel. It is recommended that HVO100 bio diesel is used generally to decrease the environmental footprint. There are also some lower impacts from the chemicals that are used, like paints, oils and fuels. The waste from the production is disposed of, according to local regulations. Examples of waste are wood, plastic, and paper as well as hazardous waste such as residue of paint, and waste oil. 2.6.2.3 Use phase, including maintenance and modernization Most significant environmental impacts of machines are the energy consumption during the use phase (in particular, the effects of diesel emissions). Konecranes machines minimize the use of fuel, as described in "Energy consumption". Timely repairs and proper maintenance support each machine’s efficiency, safety and, performance which contributes to less environmental impact. The optional hydraulic long-life (HLL) filter removes small particles, reduces the water in the oil, and extends the life of the hydraulic oil. This filter increases the amount of time between hydraulic oil replacements. With the option TRUCONNECT® Smart Connected Lift Trucks the customer can plan service on real machine use, which in most situations extend service intervals. A sensor for monitoring the status of the hydraulic oil, and estimate the remaining life of the oil, can also be provided. The monitoring of the hydraulic oil status prevents unnecessary hydraulic oil replacement. Certain major components like diesel engine, transmission, and some electronics can be restored to like-new condition. Konecranes Service offers restored spare parts, where the old part is requested back (as core unit for later renovation). This restoration process extends the useable machine life and reduced the environmental impact. 2.6.2.4 Dismantling and handling waste material Konecranes Lifttrucks strive to optimize all packaging to minimize waste and to follow the EU waste hierarchy. The most preferable actions are: prevention, reuse, recycle, burning of material to recover the energy in the material, and as a final resort, safe disposal as landfills. Waste material from dismantling shall be handled and disposed according to local regulations. As waste regulations and types of available recovery and disposal methods vary regionally, no general detailed guidance can be given. Dismantling should always be planned and executed by authorized personnel. A local risk assessment must be performed in advance. Depending on available recovery and disposal methods, wood can be recycled and reused but is the responsibility of the customer. Plastic waste is collected and, depending on the infrastructure, recycled, burned to recover the energy in the material, or as a final resort, safely disposed as landfills. NOTE Always use licensed recycling companies. The following list provides proposals for adequate waste handling methods. 43/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment Table 3. Proposed waste handling methods (example for EU states) Proposed waste handling methods (example of EU states) Material Handling method Metals Material recycling, multi-metal scrap recycling. Rubber tires Recycle rubber according to local regulations. Whenever possible, return the used rubber tires to the tire supplier for recycling. Electronics and Some electrical parts may be treated as hazardous waste. electromechanical components Collect and recycle the electronics and electromechanical components separately. Use e-waste management. Batteries Batteries and other energy storage components may contain hazardous substances. Collect these items separately and recycle according to local regulations. Fluids, Recycling, hazardous waste management accumulators, oil filters Plastics and Recycle plastic as material, burn to recover the energy in the material, or polymers deliver it to a landfill site. Chemicals Never spill chemicals, such as oil, grease, and other liquids, onto the ground, soil, or sewage. Store waste oil and grease in containers that are indicated for the purpose. More detailed information on chemical handling as waste can be found in the chemical safety data sheet. The data sheet is available from the manufacturer of the chemical. Packing materials Reuse or recycle packing materials, such as plastics, wood, and cardboard. Glass Recycle glass according to local regulations. 2.6.2.5 Deliveries between each stage Materials and components are provided by various suppliers worldwide, however steel structure is primarily sourced from local vendors to reduce the transportation need. It is an ethical, environmental, and employee-related principle that is applied. Shipment of materials to the respective factories is primarily by road transport, and containerized whenever feasible. Before shipment, each machine is partly dismantled, depending on dimensional and/or weight constraints for road transportation. The shipment of a machine to local and regional customers is usually by road from the factory. When shipment is to more remote customers or the shipping route involves waterways, sea transport is often involved. By sea, Ro-Ro type ships are used (where the machine drives onto the ship). 44/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions 2.6.3 Notice on the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH) Konecranes is fully aware of its obligations under Regulation (EC) No 1907/2006 of the European Parliament and of the Council of 18 December 2006 concerning the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH), and under the UK REACH in the United Kingdom. Twice a year the EU publishes a Candidate list of Substances of Very High Concern (“SVHC”) for Authorization. Producers and EU importers/UK importers have the duty to inform their EU/UK customers when a product contains SVHCs in a concentration above 0.1 % weight by weight. Some Konecranes products do include small quantities of SVHCs, such as lead which is typically used in brass and in certain electric components. These cases are exemptions, as there are currently no satisfactory alternatives available for such substances. We are actively searching for alternatives to substitute articles including SVHCs. For a list of SVHCs, please see https://www.konecranes.com/about/corporate-responsibility/konecranes-reach-notice. 2.7 Storage information 2.7.1 Storage The following chapter describes the recommended procedure for storage of machines. To preserve the condition of the stored machine, it must be driven regularly during storage. Preparation before storage Before storing the machine, make sure that all required services according to the NOTE maintenance schedule are performed. Be aware that some points in the storage handling process, must be performed by NOTE trained and authorized maintenance personnel. If using a pressure washer, never aim the water directly at radiators, air intakes, seals, NOTE rubber hoses, or electrical components. • Clean the machine • Perform daily maintenance check, see section "Daily maintenance" • Run all hydraulic functions and steer cylinders to end position and back again • Fill the fuel tank before storing the machine • Charge the battery • Lubricate the machine, see section "Regular service" • To prevent corrosion, apply a rust inhibitor to all the metallic surfaces • To protect the coating from corrosion, touch up painted surfaces • If possible, store the machine indoors or under a roof • If stored outside, it is recommended to cover the whole machine Maintenance during storage When driving the machine, the engine temperature must reach at least 80 degrees and NOTE the transmission must reach at least 65 degrees. To preserve the condition of the machine during storage, the following steps must be performed at least once a month. • Check the battery, charge if needed • Check for visible leakage under the machine. If needed, tighten all connections before filling any fluid • Bleed the fuel system, if needed, see section "Bleeding the fuel system" • Start the machine, and idle to warm up the engine 45/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment • Drive the machine for a while, both forwards and in reverse • Run all hydraulic functions and steer cylinders to end position and back again • Before parking the machine again, check the guidelines for "Preparation before storage". Perform the steps, if needed. Bringing out of storage • Check for visible leakage under the machine and on the ground. • Tighten all connections before filling any fluid, if needed • Perform daily maintenance check, see section "Daily maintenance" • Lubricate the machine, see section "Regular service" • Check the battery, charge if needed • Bleed the fuel system, if needed, see section "Bleeding the fuel system" • Start the machine, and idle to warm up the engine • When the engine has reached the required temperature, and while idling, check for visible oil, fuel, or coolant leakage • Test drive the machine, to make sure all systems function properly 2.7.2 Alternative storage, up to two months The following chapter describes the procedure for storage of machines that cannot be accessed or driven during storage. This way of storing the machine should only be used if necessary. See section "Storage" NOTE for the recommended procedure. Preparation before storage Before storing the machine, make sure that all required services according to the NOTE maintenance schedule are performed. Be aware that some points in the storage handling process, must be performed by NOTE trained and authorized maintenance personnel. If using a pressure washer, never aim the water directly at radiators, air intakes, seals, NOTE rubber hoses, or electrical components. • Clean the machine • Perform daily maintenance check, see section "Daily maintenance" • Run all hydraulic functions and steer cylinders to end position and back again • Fill the fuel tank • Fill up the windshield washer fluid • Fill the AdBlue/DEF tank, if applicable • Charge the battery • Lubricate the machine, see section "Regular service" • To prevent corrosion, apply a rust inhibitor to all the metallic surfaces • To protect the coating from corrosion, touch up painted surfaces • If possible, store the machine indoors or under a roof • If stored outside, it is recommended to cover the whole machine Bringing out of storage • If applicable, remove the cover from the machine • Check for visible leakage under the machine and on the ground. • Tighten all connections before filling any fluid, if needed • Perform daily maintenance check, see section "Daily maintenance" • Lubricate the machine, see section "Regular service" • Check the battery, charge if needed • Bleed the fuel system, if needed, see section "Bleeding the fuel system" • Check the condition of all rubber hoses, and retighten the hose clamps if necessary • Check that no oil, fuel, or coolant leakage occurs • Start the machine, and idle to warm up the engine 46/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Operating Instructions • When the engine has reached the required temperature, and while idling, check for visible oil, fuel, or coolant leakage • Run all hydraulic functions and steer cylinders to end position and back again • Check for visible leakage also when using the hydraulic functions after storage • Test drive the machine, to make sure all systems function properly 2.7.3 Alternative storage, longer than two months The following chapter describes the procedure for storage of machines that cannot be accessed or driven during storage. This way of storing the machine should only be used if necessary. See section "Storage" NOTE for the recommended procedure. Preparation before storage Before storing the machine, make sure that all required services according to the NOTE maintenance schedule are performed. Be aware that some points in the storage handling process, must be performed by NOTE trained and authorized maintenance personnel. If using a pressure washer, never aim the water directly at radiators, air intakes, seals, NOTE rubber hoses, or electrical components. When performing the regular service, also consider the procedure for conserving the NOTE machine. • Clean the machine • Perform maintenance service according to the 500 hours schedule, see section "Regular service" • Run all hydraulic functions and steer cylinders to end position and back again • Apply a long-term rust inhibitor to the cylinder pistons • Drain any water and contamination from the fuel filters and fuel tank • Fill the fuel tank • Fill up the windshield washer fluid • Fill the hydraulic tank completely, to avoid corrosion above the maximum level • Empty the AdBlue/DEF tank, if applicable, and rinse it with distilled water • Disconnect, and charge the battery • Store the battery in a safe way • Loosen the fan belt • To prevent corrosion, apply a long-term rust inhibitor to all the metallic surfaces • To protect the coating from corrosion, touch up painted surfaces • Conserve the machine, see section "Conservation of the lubrication and fuel system" • Cover the air filter, exhaust pipe, and engine if necessary • If possible, store the machine indoors or under a roof • If stored outside, it is recommended to cover the whole machine 47/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 2 Safety and environment Conservation of the engine and fuel system WARNING RISK OF FIRE AND PERSONAL INJURY Conservation oils are flammable and are dangerous to inhale. Ensure good ventilation. Use a face mask when applying the conservation oil. • Drain the engine oil and fill with conservation oil just over the MIN marking on the dipstick • Connect the fuel suction and return hoses to a fuel can (app. 20 l) containing 1/3 conservation oil and 2/3 diesel fuel • Bleed the fuel system, see section "Bleeding the fuel system" • Start the engine and idle until about 2 l of the fluid in the fuel can have been used • Stop the engine and reconnect the fuel suction and return lines to the machine • Drain the excess fluid from the engine, see section "Cleaning and draining the fuel tank, all engines" • Put a note on the machine with the date, type of conservation and the conservation oil used Bringing out of storage • If applicable, remove the cover from the machine • Remove covers from air intake systems and exhaust systems • Remove the rust inhibitor • Check for visible leakage under the machine and on the ground. • Tighten all connections before filling any fluid, if needed • Check and adjust the hydraulic oil level, remove excess oil • Charge and reconnect the battery • Tighten the fan belt • Fill the AdBlue/DEF tank, if applicable • Perform maintenance service according to the 500 hours schedule, see section "Regular service" • Lubricate the machine, see section "Regular service" • Bleed the fuel system, if applicable, see section "Bleeding the fuel system" • Check the condition of all rubber hoses, and retighten the hose clamps if necessary • Check that no oil, fuel, or coolant leakage occurs • Start the machine, and idle to warm up the engine • When the engine has reached the required temperature, and while idling, check for visible oil, fuel, or coolant leakage • Run all hydraulic functions and steer cylinders to end position and back again • Check for visible leakage also when using the hydraulic functions after storage • Test drive the machine, to make sure all systems function properly 48/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 3 PRODUCT DESCRIPTION 3.1 Technical description Specification SMV 33-1200C means: • SMV = Product name • 33-1200 = 33-ton lifting capacity on 1200-mm load center • C = Model C Engine The engine is a water-cooled, turbo-charged diesel engine. The engine drives a transmission using a torque converter. Transmission The transmission is of power declutch type. The transmission is equipped with an oil cooler. On the brake pedal in the cabin, there is a declutch switch. The declutch switch disengages the transmission so that the operator can control the hydraulics while maintaining a high engine RPM during stacking maneuvers. Axles Drive axle The transmission uses a universally jointed propshaft to drive the drive axle. The drive axle is of the heavy-duty double reduction type. The primary reduction is through the hypoid crown wheel and a pinion. The secondary reduction is achieved by a planetary gear that is set within the wheel hubs. The wheel hubs are carried on tapered roller bearings. Steer axle The steer axle is mounted in sphere-elastic bushes which allow sufficient wheel movements for stability on uneven ground. The parallel steering links are between the steer cylinder and the spindles. Brakes Service brake The service brakes are controlled by the foot brake pedal, which activates the brakes in the drive axle. An oil-cooled wet disc brake system are used for the brakes. Parking brake The parking brake is controlled electrically and activates a hydraulic cylinder. The hydraulic cylinder acts on a brake disc that is mounted between the drive axle and the propshaft. The parking brake is spring applied and uses the hydraulic pressure to release. Hydraulic system The hydraulic system is equipped with load-sensing variable piston pumps. The brake system is equipped with one or two gear pumps. Steering The steering is fully servo-assisted. 49/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description Control valve Machine sizes 10-16 are equipped with the L90 control valve, and machine sizes 18-60 with the K220/L90 control valve. The control valve is mounted on the chassis. The operator controls the valve by either levers or a joystick. The valve regulates the functions for mast lifts, tilts, and attachment, and any optional functions. Mast The duplex standard mast consists of: • One outer mast • One inner mast • One fork carriage • Two lift cylinders • Two tilt cylinders The inner mast section moves along the outer section using mast wheels and support rollers. The mast is mounted on two axles in the chassis using bearings. The fork carriage is of a rolling type with sideshift movement and fork positioning. Operator's cabin The operator’s cabin fulfills international safety standards, and is rubber-mounted to protect the operator from vibrations. Entrance to the cabin is on the left side using the steps on the machine. The cabin air is efficiently filtered to ensure a healthy work environment. Instruments and controls The hydraulic control levers, or the joystick, and the display are on the right-hand side of the operator’s seat. The gear switch is on the left side of the control levers, or at the back of the joystick. The control for windshield wipers, ceiling light, and any optional functions are on the keypad. The indicator lamps for the hazard lights, parking lights, and the rotating beacon are on the armrest, on the right-hand side of the keypad. For more information, see "Keypad", "Controls and indicators in cabin", and "Lifting loads". Electrical system The electrical system is 24 V. 50/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 3.2 Machine outline, forklift 7 6 4 5 2 3 1 8 10 9 1. Steer axle 6. Lift cylinder 2. Counterweight 7. Mast 3. Engine hood 8. Forks 4. Operator's cabin 9. Fork carriage 5. Tilt cylinder 10. Drive axle 51/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 3.3 Controls and indicators in cabin with lever control Figure 11. Controls and indicators in cabin with lever control 1. Adjustment pedal for the steering wheel 9. Rotating beacon (option) column 10. Keypad 2. Steering wheel 11. Emergency stop 3. Adjustment lever for tilting the steering 12. Gear switch for forward, neutral, and wheel reverse 4. Control levers for the hydraulics 13. Horn 5. Display 14. Accelerator pedal 6. Ignition key switch 15. Brake pedal 7. Hazard light 16. Declutch 8. Position lights The position of controls may vary from machine to machine depending on the customer order. 52/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 3.4 Controls and indicators in cabin with joystick (option) Figure 12. Controls and indicators in cabin with joystick (option) 1. Steering wheel 9. Position lights 2. Adjustment lever for tilting the steering 10. Rotating beacon (option) wheel 11. Keypad 3. Horn activation 12. Emergency stop 4. Gear switch for forward, neutral, and 13. Accelerator pedal reverse 14. Adjustment pedal for the steering wheel 5. Buttons for optional functions column 6. Display 15. Brake pedal 7. Ignition key switch 16. Declutch 8. Hazard lights Position of controls may vary from machine to machine depending on the ordered options. 53/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 3.5 Keypad 1 19 2 18 3 17 16 15 4 14 5 6 13 7 12 8 11 9 10 Figure 13. Keypad 1. Start and stop engine 12. Extra work light 2. Wiper one-stroke 13. Work light for mast 3. Rear window defroster 14. Turn signal indicator, left 4. Turn signal indicator, right 15. Main beam headlights 5. Cabin interior light 16. Parking brake 6. Work light for attachment 17. Rear window wiper, push, and hold down 7. Extra work light for washer 1) 8. Option 2 (not in use) 18. Roof window wiper, push, and hold down 9. Option 4 (not in use) for washer 1) 10. Option 3 (not in use) 19. Windshield wiper, push, and hold down for 11. Option 1 (not in use) washer 2) 1) intermittent/second speed/off 2) intermittent/first speed/second speed/off 54/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 3.6 MD4 display Figure 14. MD4 touch display The display has a user-friendly touch interface: to navigate between views, you simply tap on the screen. With the display, you can monitor the hydraulics system and drive line with the help of analog and digital signals from various sensors. It gives you a complete overview of the activities of the machine during operation. The active keypad function is shown at the bottom-left corner. Figure 15. Example of active keypad function: roof window wipers, intermittent 55/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 3.6.1 User interface 3.6.1.1 Introduction to MD4 pages The MD4 pages can be accessed by clicking on the touch screen display icons. They show various data needed during operation and allow the operator to change required settings. The operator's menu is only available from the main pages. There are five main pages: • Home page (weight page) • Date and time page • Attachment settingspage • ECO-driving page • Operator page 3.6.2 MD4 display frame The MD4 display frame is always visible, except in the settings pages. This makes it easy to navigate in the system. 1 2 9 3 4 5 6 7 8 Figure 16. MD4 frame icons 1. Home page (Main page number 1 – Weight 6. Previous Main page page) 7. Adjust display brightness 2. Machine overview page 8. Next Main page 3. Information page 9. Operator's menu (only available on the 4. Settings page Main pages) 5. Main page number (only visible on the Main pages) 56/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions Left side of the MD4 display frame Using the left-side frame icons, you can return to the Home page and access Machine overview page, Information page, and Settings page. Icon Meaning Home page (Main page number 1 – Weight page) Machine overview page shows engine fluid data and gives access to transmission page, engine page, and tire pressure monitoring page. Information page shows various counters, such as container counter and time to next service. Settings page allows you to view and edit settings and to calibrate all functions. Only service personnel are allowed to modify the settings, a service code is required. Bottom of the MD4 display frame The bottom of the MD4 display shows operator control and engine status symbols. The symbols are gray when the function is not on or the status is normal. From the bottom frame, you can also cycle between the five Main pages by tapping the left and right arrows. The Main page currently in view is shown in the bottom-left corner. Symbol Meaning Neutral gear is selected Forward gear is selected Reverse gear is selected The turn signal blinks green when you press the turn signal button Red when the battery voltage level is low Red when the engine oil pressure is low Fasten seat belt indicator 57/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description Symbol Meaning Red when the parking brake is on Red when the accumulator pressure is low Green when the low beam is on Blue when the high beam is on Tap to go to the previous Main page Tap to change the display brightness Tap to go to the next Main page Windshield wipers Windshield wipers, slow Windshield wipers, fast Windshield wipers, intermittent Rear window wipers Rear window wipers, intermittent Rear defroster Roof and rear washer Roof window wipers 58/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions Symbol Meaning Roof window wipers, intermittent Cabin interior light Working light Electrical lever / mini-wheel steering (option) active Right side of the MD4 display frame When viewing any of the five Main pages (either Home/Weight, Date and time, Attachment, ECO-driving, or Operator page), the MD4 display shows a button on the right side of the frame. By tapping this button, you can access the Operator’s menu. Symbol Meaning Operator's menu The MD4 display frame is always visible, except in the settings pages. This makes it easy to navigate in the system. 1 2 3 4 5 6 7 8 Figure 17. Operator's menu 1. Select top gear 6. Operator login (option) 2. Safety override for the twistlock on the 7. Autostop function (option): the symbol is attachment visible if the machine has the autostop 3. Starting gear function. Press the symbol to disable the 4. Automatic or manual gear selection autostop function for 2 min. 5. Eco mode or productivity mode 8. Intermittent wiper 59/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 3.6.3 MD4 pages 3.6.3.1 Start-up page 1 2 3 4 5 Figure 18. Start-up page 1. Engine check 4. AdBlue check 2. Battery check 5. Engine oil check 3. Engine coolant check The Start-up page is displayed when you start the machine. After 10-15 seconds, it changes automatically to the Main page viewed the last time the machine was on. Green light indicates normal status, red light indicates error. 60/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 3.6.3.2 Home page (weight page) Main page 1 1. Add weight (option) 8. Fuel level 2. Tare (option) 9. Engine RPM 3. Last load (option) 10. Engine coolant water temperature 4. Total load (option) 11. AdBlue level 5. Current load (option) 12. Transmission oil temperature 6. Twistlock indication (if applicable) 13. Driving speed 7. Date and time 14. Percentage of maximum load NOTE Calibrating the weight scale can only be done by authorized service personnel. 61/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 3.6.3.3 Date and time page Main page 2 1 2 3 4 10 9 8 7 6 5 1. Date and time 6. Cooling water temperature 2. Twistlock indication (if applicable) 7. Fuel level 3. Current load 8. AdBlue level 4. Percentage of maximum load 9. Transmission oil temperature 5. Engine RPM 10. Driving speed 62/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 3.6.3.4 ECO-driving page Main page 4 1 2 3 4 5 6 7 8 1. Fuel level 3. Fuel economy bar: red in the bar indicates 2. Resets the following values: less economic driving style, gray indicates • Fuel rate: current hourly fuel more economic driving style consumption 4. AdBlue level • Average: average hourly fuel 5. Twistlock indicators (if applicable) consumption 6. Date and time • Time elapsed: time since last reset 7. Current load (option) • Consumption: fuel consumption since last reset 8. Percentage of maximum load 63/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 3.6.3.5 Operator page Main page 5 1 2 3 4 5 6 11 10 9 8 7 1. Transmission oil temperature 7. Engine coolant temperature 2. Driving speed 8. Next in-focus value 3. Fuel level 9. Current load in percentage 4. In-focus value (adjustable) 10. AdBlue level 5. Speed limiter (option) 11. Previous in-focus value 6. Twistlock indication (if applicable) The in-focus value can show the following values: • Driving speed • Weight in percentage • Weight in tons (option) • Transmission oil temperature • Fuel level • Engine coolant temperature • Engine RPM Use the left (11) and right (8) arrow to cycle between the options. 64/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 3.6.3.6 Machine overview page The visible content of the Machine overview page may vary depending on ordered NOTE options. 1 2 3 4 5 6 7 8 9 13 12 11 10 The Machine overview page gives access to engine data, transmission data, tire pressure monitoring, and several other diagnostics pages. 1. Raw value from accelerator pedal 8. Engine coolant level 2. Accelerator pedal angle 0%–100% 9. Fuel level 0%–100% 3. Engine RPM 10. Tire pressure monitoring page (option) (1) 4. Transmission oil temperature 11. Access to TRUCONNECT® statistics page 5. Engine coolant temperature (option) 6. Brake oil temperature 12. Transmission diagnostics page 7. AdBlue level, if applicable 13. Emission page (1) Only visible if you have entered the service code. Engine diagnostics 65/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description The menu button in the top-right corner allows you switch between Scaled and Raw values for the measurements. Table 4. Measurements for engine diagnostics Measurement Meaning Engine RPM Actual engine RPM. Engine RPM TSC1 [rpm] Requested engine RPM. Coolant temperature [°C] The temperature of the engine coolant. Oil pressure [kPa] Engine oil pressure. DNL1 Pedal (Byte 2) [bits] Request to Scania engine for auto engine acceleration. Engine hours Not used for reading machine hours. SW Engine level engine Special option for Scania engine. Request cooling fan speed function Requested cooling fan RPM from machine. Urea level Urea/AdBlue level in %. SW Engine start/stop Start request signal (engines with CAN bus start). 66/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions Table 5. Measurements for engine diagnostics Measurement Meaning MC42 V Battery 24 V. Power voltage supply to MC42 unit. Engine command This value is the requested engine RPM. Depending on the action being performed, for instance, when accelerating or using a lifting function, the percentage can vary: 0% is approximately 700 rpm and 100% 2200 rpm. Engine RPM [rpm] The actual engine RPM in rpm. FGO Engine Fan Speed The actual speed of the engine fan in rpm. This speed depends on the engine temperature, as the fan speed varies according to the engine temperature. FGO Engine Coolant temp. The temperature of the engine coolant, more than 102 C is too high. (Warning at 105 C on Volvo engines) FGO Engine Oil Temp. The temperature of the engine oil. If the temperature is too high, the system sends an error message. (Warning at 125 C on Volvo engines) FGO Fuel Delivery Pressure Gage pressure of fuel in system as delivered from supply pump to the injection pump. FGO Oil Pressure Gage pressure of oil in engine lubrication system as provided by oil pump. When the pressure is less than 100 Kpa, it is too low, and causes the system to send an error message. FGO Engine Coolant level Should be above minimum level. The sensor indicates if the level is too low. Measurement Meaning FGO Engine Coolant pressure Gage pressure of coolant in engine cooling system. FGO Engine Oil Level Ratio of volume of oil found in engine lubrication system to total lubrication system volume. Never fill the engine oil to 100%. FGO Act. Engine Torque The calculated output torque of the engine. 67/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description Measurement Meaning FGO Engine Intake Manifold #1 Pressure The gage pressure measurement of the air intake manifold #1. FGO Engine Air Intake Pressure Absolute air pressure at inlet to intake manifold or air box. If the filter is clogged, the system sends the operator an error message. FGO Engine Intake Manifold 1 Temperature Temperature of pre-combustion air found in intake manifold number 1 of engine air supply system. FGO Engine Exhaust Gas Temperature Temperature of combustion by-products leaving the engine. FGO Engine System Powerdown Ack Whether engine can be powered down. 0 Power off not allowed (cannot power off), 1 is Power off allowed, 2 is error state, 3 is not available. Measurement Meaning FGO Running Indication Indicates whether engine running or stopped. 0 is stopped, 1 is running, 2 is reserved, 3 is not available. Requested Percent Fan Speed Fan speed as a ratio of the actual fan drive (current speed) to the fully engaged fan drive (maximum fan speed). Stop request Engine stop request: 0 is inactive, 1 is active, 2 is error indication, 3 is not available. Start request Engine start request: 0 is inactive, 1 is active, 2 is error indication, 3 is not available. TSC1 The TSC1 message can be used to request speed/ torque instead of the VP70 message. FGO SCR Catalyst Tank Level AdBlue tank level. Measured in %, FGO Tank Low Level Indicator Indication that the AdBlue tank level is low. 68/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions Measurement Meaning FGO SCR Catalyst Temperature Temperature of the AdBlue solution in the storage tank. FGO SCR Catalyst Tank level [mm] Measured in mm3, AdBlue tank level. ZF transmission Machine overview > ZF transmission 1 2 3 4 5 6 7 9 8 1. Temperature of the converter out oil 5. AEB button to start calibration temperature 6. Status of transmission calibration 2. Temperature of the sump oil temperature 7. Digital input 1-8 on-off 3. Engine RPM from transmission 8. Digital input 9-16 on-off 4. Output shaft RPM 9. Transmission status and fault information NOTE Transmission calibration can only be done by service personnel. 69/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description DANA transmission Machine overview > DANA transmission 1 2 3 4 5 6 7 8 1. Digital inputs and outputs of the 6. Transmission drop-down menu (selection transmission, 0-9 and 0-10 of various measurements and other 2. State selected in (6) actions) 3. Value in RPM from the speed sensors 7. Shows traveled distance in [km] 4. Value in Hz from the speed sensors 8. Converter torque and ratio difference 5. Information about analog inputs and between impeller and turbine outputs NOTE To access menu (6), a service code is required. 70/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions Truconnect page Options, and values shown in the display illustration, are examples, and varies NOTE depending on the model. Machine overview > TRUCONNECT page 1 2 3 4 5 SMV 4636 T.X5 (T.X6) IP address (WAN): ID: 540500000/10-10000180647 IP address/TCP (Server): 10.255.249.231:10001 S/N: 540500000 Software: Time: Longitude: Error 1 Latitude: 8 Error 2 Satellites: Fault 1 GSM signal: Fault 2 Voltage: Board temperature: Performance Speed limit: 10 km/h 7 IP address 1: IP address 3: IP address 4: 6 1. Machine specific information 5. Available functions (see separate table) 2. Modem specific information 6. Battery connectivity information (if 3. Data log test button applicable) 4. Modem operation mode 7. Geofencing related information • Green = Status OK 8. Active faults or errors on modem • Yellow, flashing = Booting • Red = Fault Available functions Button Function Button for opening the measure group for alarms related to the modem. Button for accessing the log for alarms related to the modem. Button for opening the Hydraulic oil quality page. 71/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description Available functions Button Function Button for initiating the data log test. The data log test verifies that: • all required data from the MD4, the engine, and the transmission is available. • the data logging reports can be generated successfully. • reports can be sent to the Truconnect database successfully. • the Truconnect database was able to successfully process the generated report. Button for initiating the communication test. The communication test verifies that: • the GPRS/3G connection can be opened. • route to the Truconnect database is available. • a connection to the Truconnect database can be established. • the modem can register to the Truconnect database. • the RMP (Regatta Messaging Protocol) connection to the database works. • the time synchronization with NTP sever works. • that the GPS location is available. Button for rebooting the modem. Button for updating the modem software. 72/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions Tire pressure monitoring system page (option) Machine overview > TPMS 1 2 1. Tire pressure unit 2. Pressure unit (bar, psi, kPa) Adding, removing, and replacing sensors, as well as changing the pressure between bar, NOTE kPa, and psi, can only be done by service personnel. 3.6.3.7 Information page 1 2 3 4 5 6 7 8 9 10 11 12 1. Container counter *) 4. Container counter, can be reset *) 2. Machine hours 5. Resets service hour (3) (can only be done 3. Time to the next service by service personnel) 6. Resets container counter (4) 73/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 7. Machine information 11. Total hour counter 8. Total engine hours 12. Lamp test button (button must be activated 9. Driving hour counter for daily maintenance) 10. Neutral hour counter *) Standard feature for attachments with twistlock, optional feature for attachments with clamps. 3.6.4 Preferences Settings > Preferences Select the item to be changed from the Preferences menu: • Display (backlight strength and screen saver on/off) • Date and time • Language 3.6.4.1 Setting the display backlight and screen saver 1. To set the backlight, set the value with - and + . 2. To choose between screen saver Off, Dimmed and Black, press - and + . 3. To set the timeout (when Dimmed or Black), set the value with - and + . 4. To set the dimmed light (when Dimmed), set the value with - and + . 74/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 3.6.4.2 Setting the date 1. To set the year: 1.1 Set the year with - and + . 1.2 Press . 2. To set the month: 2.1 Set the month with - and + . 2.2 Press . 3. To set the day: 3.1 Set the day with - and + . 3.2 Press . 3.6.4.3 Setting the time 1. To set the time: 1.1 Set the hours with - and + . 1.2 Press . 1.3 Set the minutes with - and + . 1.4 Press . 75/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 3.7 Lifting loads 3.7.1 Lifting capacity plate WARNING MACHINE MISUSE HAZARD Incorrect lifting of a load may lead to serious personal injury and damage to the machine. Check that the load is centered between the forks. Check that the forks are in good condition. WARNING MACHINE MISUSE HAZARD Exceeding the maximum load affects the stability and safety margins of the machine. Do not use the machine to handle a greater load than what is stated on the lifting capacity plate. WARNING MACHINE MISUSE HAZARD Konecranes is responsible for the safety of the machine. The warranty only applies as long as the machine is used within the areas of limitation. The areas of limitation are found on the the lifting capacity plate, EC assurance, and in the operating and maintenance instructions. Lifting capacity plate KONECRANES LIFTTRUCKS AB P.O.BOX 103 SE-285 23 MARKARYD SWEDEN RATED CAPACITY AT LIFT HEIGHT LOAD CENTRE DIST. TYPE kg mm mm SERIAL NUMBER SALES ORDER NUMBER ACTUAL CAPACITY TOW-COUPLING TONGUE LOAD UP/DOWN YEAR OF MANUFACTURE kg mm mm XX / YY kN mm kg mm mm MAXIMUM LIFT HEIGHT TOW-COUPLING PULLING CAPACITY mm kg mm mm MACHINE HEIGHT XX kN SERVICE MASS kg kg mm mm NOMINAL POWER kW kg mm mm The lifting capacity plate is on the left side of the cabin. If an extra unit has been fitted, read the lifting capacity plate for the additional unit. The values that are indicated on the lifting capacity plate are valid for compact and regular loads. If the values are exceeded, there is a risk to the stability of the machine and the tensile strength of the machine, forks, and mast. The maximum capacity depends on the lifting height and the distance to the load center (LC). LC is the distance between the front face of the forks (with the mast vertical) and the center of gravity of the load. The following is an example of values for the main lifting capacity and the alternative lifting capacities, which are indicated on the lifting capacity plate. 76/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions Example of lifting capacity, model SMV 33-1200C Lifting capacity is 33 tons (72,753 lbs) at lifting height 4,000 mm (157.5 in) and center of load 1,200 mm (47.2 in) (depending on the model). Alternative lifting capacities, model SMV 33-1200C The lifting capacity decreases as the center of load and the lifting height increase, according to the following examples: Lifting capacity is 22 tons (48,502 lbs) at lifting height 4,500 mm (177.2 in) and center of load 1,500 mm (59 in) (depending on the truck model). Lifting capacity is 19.5 tons (42,990 lbs) at lifting height 4,500 mm (177.2 in) and center of load 1,800 mm (70.9 in) (depending on the truck model). LC 77/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 3.7.2 Maneuvering the mast with levers DANGER UNCONTROLLED MOVEMENT HAZARD If the machine, or the equipment moves unexpectedly, it could result in personal injury, death, or damage to the equipment. To stop any unexpected movement, press the emergency stop button. WARNING MACHINE MALFUNCTION HAZARD Incorrect lifting of a load can lead to serious personal injury and damage to the machine. Handling of the machine outside of its area of use can lead to overloading and instability. Use the mast and its additional equipment only for approved work. The operator must be trained in the handling of the machine and its equipment. • Always maneuver the levers gently and slowly. • The speed of the hydraulic functions depends on the lever position. • The lever automatically returns to its neutral position when released. • The levers for the hydraulic functions are on the console to the right of the operator's seat. WARNING MACHINE MISUSE HAZARD Adding an attachment that is not suitable for the machine can cause the attachment to fall off. Risk of serious personal injury and damage to the machine. Optional equipment that was not supplied with the machine may only be used if an authorized dealer has ensured that safe operations can be guaranteed in terms of lifting capacity and stability. NOTE For more information, see Changes to the product (page 31). NOTE Pay attention to the operational symbols and the directional arrows. 3 4 2 1 Figure 19. Lever functions 1. Fork carriage maneuvering • Pull lever backwards = raise the fork carriage. • Push lever forwards = lower the fork carriage. 2. Tilting of mast 78/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions • Pull lever backwards = tilt the mast backwards. • Push lever forwards = tilt the mast forwards. 3. Fork maneuvering (side shift) 1) • Pull lever backwards = move the forks to the right • Push lever forwards = move the forks to the left 4. Fork distance maneuvering (spread) 1) • Pull lever backwards = decrease the distance between the forks • Push lever forwards = increase the distance between the forks 1) Function can vary depending on options. NOTE A fifth lever can be added for additional functions (optional). 3.7.3 Maneuvering the mast with joystick (option) DANGER UNCONTROLLED MOVEMENT HAZARD If the machine, or the equipment moves unexpectedly, it could result in personal injury, death, or damage to the equipment. To stop any unexpected movement, press the emergency stop button. WARNING MACHINE MALFUNCTION HAZARD Incorrect lifting of a load may lead to serious personal injury and damage to the machine. Handling of the machine outside of its area of use may lead to overloading and instability. Use the mast and its additional equipment only for approved work. The operator must be trained in the handling of the machine and its equipment. • Always maneuver the joystick gently and slowly. • Hydraulic function speed depends on joystick movement. • When released, the joystick automatically returns to its neutral position, and the movement stops. 79/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description 1 5 2 10 6 7 4 3 8 9 10 Figure 20. Maneuvering the mast and forks with joystick 1. Load down 6. Spreading forks 2. Tilt mast forward 7. Side shifting forks 3. Load up 8. Capacitive/hand presence sensor 4. Tilt mast back 9. Gear switch 5. Horn, * one-stroke windshield wipers, roof, 10. Alternative function trigger and front * with (10) pressed 1 2 3 4 5 Figure 21. Joystick options 1. Optional function button 4. Activation button mini-wheel steering 2. Optional function button function (option) 3. Optional function button 5. Radio control key (option) 3.7.4 Mast and attachment symbols The following table shows the meaning of symbols for the joystick and control stickers. 80/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions 0 Tilt mast backward Tilt mast forward Mast autotilt (option) Mast tilt One-stroke Horn windshield wipers, roof, and front Sideshift forks left Sideshift forks right Spread forks Bring forks together Forks down Forks up 30' stop off 30' stop on 20' 40' Mast with integrated attachment, top lift 81/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 3 Product description Skewing fork down Skewing fork up Top lift, slewing left Top lift, slewing left Top lift, slewing right Top lift, slewing right rear front front rear Forklift side lift 1 Load stabilizer tilts Twistlock locked Twistlock open Load stabilizer tilts up down Lifting magnet Lifting magnet Paper clamp disengaged engaged 82/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Product description Operating Instructions Rotate Rotate clockwise Tighten clamp Release clamp counterclockwise Upender-rotate Upender-rotate Fork leveling forward backward Forks rotate Forks rotate Top lift, lower Top lift, raise counterclockwise clockwise 83/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4 OPERATING INSTRUCTIONS WARNING RISK OF DAMAGE AND PERSONAL INJURY Loose objects or liquids in the cabin can cause unintended incidents. There is a risk of tripping, visibility reduction, fire, and other hazards due to unpredictable interference with the machine commands. In case of a machine tip-over, loose objects can also cause damage and personal injury. Always keep the cabin tidy and clear of debris and loose objects or liquids. Never add any fixtures other than the ones provided from the manufacturer. 4.1 Daily maintenance before operation DANGER UNCONTROLLED MOVEMENT HAZARD If the machine moves unexpectedly, it could result in personal injury, death, or damage to the equipment. To stop any unexpected movement, press the emergency stop button. WARNING MOVING PARTS HAZARD There is a risk of getting trapped by moving parts of the engine. There is also a cutting risk from moving parts of the engine. Do not open the hood or perform maintenance work while the engine runs. WARNING TOXIC SUBSTANCE HAZARD Breathing diesel engine exhaust exposes you to chemicals that may cause cancer, birth defects, or other reproductive harm. Never run the engine in unventilated places. Use fume extraction. Do not keep the engine idling, except when necessary. Do not modify or tamper with the exhaust system. WARNING IGNITION HAZARD During operation, parts of the machine can become very hot. If there are flammable or combustible materials, on or near any hot surfaces on the machine, there is a risk of fire. Examples of such materials are paper, or saw dust. Before taking the machine into operation, make sure that there are no flammable or combustible materials on or around any hot surfaces. Examples of hot surfaces can be the turbo, exhaust pipe, DPF, and so on. Visually inspect the machine for damage while going through the checklist during daily NOTE maintenance. NOTE Check the condition of the safety and information labels, replace if needed. 84/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions After performing the daily maintenance tasks, start the machine and listen for any NOTE abnormal noise from the engine and transmission. If any abnormal noise is heard, contact maintenance personnel. 1. Check the battery main switch 2. Check the wheel nuts and clamps. 3. Check the tire pressure and the condition of tires and rims (visible cracks and damages). 4. Check the engine oil level. 5. Check the transmission oil level. 6. Check the coolant level in all tanks. 7. Check the hydraulic oil level. 8. Check the brake cooling oil level (option, not available for all models). 9. Check the grease level in the two reservoirs for the automatic lubrication system (option). NOTE If automatic lubrication is installed (optional), there can be one or two tanks. 10. Check the MD4 warnings for clogging of engine air filter. 11. Check the windshield washer fluid level. 12. Check the fuel level. 13. Check the AdBlue level (when applicable). 14. Check the soot level (when applicable). 15. Check that the mirrors are clean and adjust them to make sure of good visibility. 16. Check that the windows are clean. 17. Clean the rearview camera (option). 18. Check for visual signs of leakage, around and under the machine 19. Check the seat adjustments and adjust if needed. 20. Check the steering wheel adjustments. 21. Check the service brake functionality. 22. Check the parking brake functionality. 23. Check the functionality of the steering system. 24. Check the hydraulic functions. 25. Check the electrical functions. 26. Check the climate unit (option) settings. 85/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2 Daily maintenance checks 4.2.1 Turning on and turning off the battery main switch DANGER EXPLOSION HAZARD Short-circuiting the battery may cause a fire or explosion, which can cause a risk of serious injury or death. To reduce the risks of electric shock and personal injury always remove jewelry and conductive material before working on the electrical system. DANGER EXPLOSION HAZARD Batteries generate explosive hydrogen when charged, which can cause a risk of serious injury or death. Always use the necessary protective equipment. Ensure that there is good ventilation and avoid sparking. DANGER ELECTRIC SHOCK HAZARD Even when the battery main switch is turned off, there may still be voltage present in some parts of the machine. The main disconnect does not cut the power to the alternator. This causes a risk of electric shocks, which can lead to death or serious personal injury. To reduce the risks of electric shock and personal injury always remove jewelry and conductive material before working on the electrical system. Always disconnect the ground (minus) cable at the battery when working near or on the alternator. Be aware of the battery main switch functionality. WARNING TIPPING OVER HAZARD If the battery main switch is turned off when the machine moves, the parking brake is activated. The machine may tip over, causing a risk of serious personal injury and damage to the machine. Unless there is an emergency situation, do not turn off the battery main switch when the engine runs. NOTE Do not operate the machine unless you know the location of the battery main switch (1). If the machine has an engine that uses AdBlue solution, wait after turning off the combustion engine. After the AdBlue pump has finished pumping all the fluid from the NOTE hoses to the AdBlue tank, turn off the battery main switch (1). The required time varies slightly between different engine models. NOTE Remove the main switch handle when parking the machine. 86/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 1 Figure 22. Battery main switch 1. Before operating, turn on the battery main switch (1). Turn the battery main switch (1) clockwise. 2. After operating, turn off the battery main switch (1). Turn the battery main switch (1) counterclockwise. 87/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2.2 Checking the condition and pressure of the tires DANGER HIGH-PRESSURE HAZARD Release of high-pressured air could cause death or serious personal injury. Proceed with caution when working with pressured air systems. Use approved personal protective equipment. Follow all safety requirements. Only trained personnel are allowed to check tire pressure and inflate tires. DANGER HIGH-PRESSURE HAZARD The tires may explode when inflated or deflated. Standing inside the tire explosion danger zone during a tire explosion causes death. Always stand beside the wheel when deflating or inflating tires, see tire explosion danger zone illustration. Use safety glasses. If the machine is equipped with tire pressure monitoring system (TPMS), the tire pressure NOTE can be checked on the display. Driving with incorrect tire pressure makes the machine unstable, and increases the fuel NOTE consumption. It can also cause unnecessary wear and tear of the tire, which can result in a flat tire or a tire explosion. 120° 120° yd 50 55 m/ m/ 55 50 d yd 5y 50 m/5 m/5 5y 50 d 120° 120° Figure 23. Forklift tire - explosion danger zones 88/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions Figure 24. Drive axle tires Figure 25. Steer axle tires 1. Check that the tires have not become too worn and are undamaged. 2. Remove any deposits (debris and dirt) from the tread. 3. Remove any deposits (debris or objects) stuck between the tires. DANGER HIGH-PRESSURE HAZARD The tires may explode if you try to remove objects that are stuck in them, which could cause death or serious personal injury. To remove any objects that are stuck in the tire, contact authorized personnel. 4. Check that no wheel nuts are missing or loose. 5. Check that the tires have the correct pressure according to the recommendations of the manufacturer. 6. Inflate or deflate the tires according to the relevant recommendations. Always take the ambient temperature into account. 89/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2.3 Checking the engine oil level WARNING IRRITATING SUBSTANCE HAZARD The machine contains several chemical substances which may cause skin irritations and allergies. Personal injury hazard if long-term skin contact. Avoid direct contact with skin when handling chemical substances. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. Use safety goggles. NOTE Make sure that the engine is switched off before checking the engine oil level. 2 1 Figure 26. Checking the engine oil level, Volvo engines 90/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 1 2 Figure 27. Checking the engine oil level, Cummins engines 1. To access the dipsticks and oil filling, open the engine hood. 2. Remove the dipstick (2) and dry it off with a clean cloth. 3. Put back the dipstick fully and remove again. The oil level must be between the minimum and maximum level indicators (in the operating temperature, at least 65°C or 149°F). 4. If necessary, remove the filler cap (1) and top up the oil. NOTE Only trained service personnel are allowed to fill oil. 5. Fill with the recommended oil. See Recommended fluids and lubricants (page 172). Make sure that the oil level is between the minimum and maximum marks on the dipstick. Do not fill above the maximum oil level. See maintenance data for the volume. 91/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2.4 Checking the DANA transmission oil level WARNING HOT FLUID HAZARD Risk of serious personal injury. Avoid spilling hot oil and do not touch hot surfaces. 1 2 Figure 28. Checking transmission oil level NOTE Park the machine on level ground in a safe working area. 1. Start the engine. 2. Run the engine until it has reached operating temperature 82–93° C (180–200° F). NOTE Oil temperature must be at least 65° C (149° F). 3. Open the hatch for the dipstick (1) and the oil filling (2). 4. Remove the dipstick (1) and dry it off with a clean and lint free cloth. 5. With the engine idling, insert the dipstick (1) fully. 6. Remove the dipstick (1) again. 7. Check that the oil level is between the minimum and maximum level indicators. 8. If the level is incorrect, contact your local service team. NOTE Only trained service personnel are allowed to top up transmission oil. 92/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.2.5 Checking the ZF transmission oil level WARNING HOT FLUID HAZARD Risk of serious personal injury. Avoid spilling hot oil and do not touch hot surfaces. 1 2 Figure 29. Checking the ZF transmission oil level NOTE Park the machine on level ground in a safe working area. 1. Start the engine and run until the oil has reached operating temperature (at least 65°C or 149°F). 2. Remove the dipstick (1) and dry it off with a clean and lint free cloth. 3. With the engine idling, put back the dipstick fully into the tube (2) and remove it again. The oil level must be between the minimum and maximum level indicators. 4. If level is low, contact your local service team. NOTE Only trained service personnel are allowed to top up transmission oil. 93/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2.6 Checking the coolant level, Volvo engines WARNING TOXIC SUBSTANCE HAZARD It is highly dangerous to drink ethylene glycol. Contact with skin or spray from the refill can cause skin irritation and eye damage. Do not drink ethylene glycol, and avoid contact with skin. WARNING HOT COOLANT HAZARD Opening the pressure chamber cap can cause serious personal injury. Never open the pressure chamber cap (1) when checking, or refilling coolant. NOTE Only authorized maintenance personnel are allowed to fill the coolant. 1 2 1. Check the level of the coolant on the level indicator (2). The level should always be above the minimum level. NOTE If the coolant level decreases much every day, notify the maintenance personnel. 94/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.2.7 Checking the coolant level, Cummins WARNING TOXIC SUBSTANCE HAZARD It is highly dangerous to drink ethylene glycol. Contact with skin or spray from the refill can cause skin irritation and eye damage. Do not drink ethylene glycol, and avoid contact with skin. NOTE Only authorized maintenance personnel are allowed to fill the coolant. 2 1 1. Check the level of the coolant. The level should be at maximum on the level indicator (1) of the coolant tank (2). NOTE If the coolant level decreases much every day, notify the maintenance personnel. 95/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2.8 Checking the hydraulic oil level WARNING HOT FLUID HAZARD Hot hydraulic oil may spray from the oil refill, which may cause a risk of serious personal injury. Do not fill hydraulic oil while the machine runs. 1 Before checking the hydraulic oil level, make sure that the mast and forks are lowered. The mast should also be tilted to the maximum rear position. 1. Check that the oil level is between the minimum and maximum level marks on the indicator (1) at the side of the hydraulic oil tank. NOTE When the oil is warm, the oil level raises. NOTE Only trained service personnel are allowed to fill the oil. 96/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.2.9 Checking the brake cooling oil level (option) WARNING HOT FLUID HAZARD Hot oil may spray from the oil refill, which may cause a risk of serious personal injury. Do not fill oil while the engine is running. NOTE Park machine on level ground in a safe working area. 1 High Low High Low 1. Check that the brake cooling oil level is between the minimum and maximum level marks of the indicator at the side of the brake cooling oil tank (1). 2. If level is low, contact your local service team. NOTE Only trained service personnel is allowed to top up the brake-cooling oil. 4.2.10 Checking the engine air filter, Volvo engines In sandy or dusty environments with a large number of particles, clean the engine air NOTE filter more frequently. Only authorized maintenance personnel are allowed to clean the air filter. 1 Figure 30. Checking the engine air filter 1. When the engine air filter (1) needs to be checked, a warning about air inlet pressure appears on the MD4 display. 97/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 2. If warning appears in the MD4 display, contact your local service team. 4.2.11 Checking the windshield washer level NOTE Park machine on level ground in a safe working area. 1 Figure 31. Windshield washer fluid tank 1. Check the windshield washer fluid level in the washer fluid tank (1). NOTE To see the level, open the lid. 2. If level is low, contact your local service team. NOTE Only trained service personnel are allowed to top up the windshield washer fluid. 98/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.2.12 Checking the fuel level DANGER IGNITION HAZARD Spilling fuel may start a fire, which can cause serious injury or death and can damage the machine. Spilling fuel can also damage the environment. Do not spill fuel. If air enters the fuel system, the engine stops. To avoid air being sucked into the fuel NOTE system, never run the machine until the fuel tank is empty. If air enters the fuel system, a service technician must bleed the fuel system. NOTE Turn off the engine before filling fuel. 1 Figure 32. Checking the fuel level 1. Check the fuel level (1) in the MD4 display. 2. If the level is too low, fill up the fuel. 99/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 2 Figure 33. Adding fuel 1. Clean the area around the filler cap (2). 2. Open the filler cap (2) on the fuel tank. 3. Fill with the recommended fuel. See Recommended fluids and lubricants (page 172). See maintenance data for volume. 4. Refit the filler cap (2), and tighten it. 4.2.13 Checking the AdBlue level WARNING HARMFUL SUBSTANCE HAZARD Causes irritation on skin or eye contact. Handle carefully, avoiding contact with skin and eyes. If you get AdBlue solution on your skin or eyes, quickly wash it off with soap and water. WARNING CORROSIVE SUBSTANCE HAZARD The AdBlue solution is corrosive towards certain metals such as copper and aluminum, which is used in harnesses, cables and connectors. Do not allow the AdBlue solution to come into contact with any parts that are made of copper or aluminum. Corrosion starts and progresses rapidly. AdBlue information for Volvo stage V engines is found here, Selective catalyst reduction NOTE (SCR) - Volvo stage V (page 111), and for Cummins stage IV engines here, Selective catalyst reduction (SCR) - Cummins engines (page 116). AdBlue level must be more than 10%. If the AdBlue level becomes less than 8%, the NOTE engine generates an error code which must be restored by Volvo. If the AdBlue level is less than 23%, the torque of the engine starts to derate, which NOTE reduces the capacity of the machine. In temperatures below -11°C (12°F), the AdBlue solution freezes. Do not store below -11°C NOTE (12°F), recommended storing temperature is approximately 20°C (room temperature). 1. Start the engine. 100/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 2. All Main pages show the AdBlue level (1) as percentage of the total tank volume. 1 3. If the level is too low, open the hatch to access the AdBlue tank. NOTE When the level is too low, the symbol for AdBlue level (1) becomes red. 2 4. Clean the area around the AdBlue tank cap (2). 5. Open the AdBlue tank cap (2) and fill with the recommended AdBlue solution. See maintenance data for maximum volume. 6. Refit the AdBlue tank cap. 7. Close the hatch for AdBlue. 101/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2.14 Check the soot level 1 2 Figure 34. Emission page 1. Check the soot level (1) in the MD4 display. 2. Check the reason and severity of the soot level (2). 3. Perform a parked regeneration when needed. NOTE For Volvo engines, see Parked regeneration - Volvo stage V (page 113). 4.2.15 Adjusting the operator's seat DANGER UNCONTROLLED MOVEMENT HAZARD During an accident, not wearing the seat belt could result in serious personal injury or death. Always fasten the seat belt before driving. For optimum safety, and ergonomics, always adjust the seat to the individual preferences before starting the machine. Check and replace or repair if you notice any of the following: • cut or frayed straps • worn or damaged hardware, including anchor points • buckle or retractor malfunction • loose stitching 102/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.2.15.1 Adjusting the BE-GE operator's seat Be-Ge 91-series 1 3 8 2 3 4 5 7 6 Figure 35. Controls for the BE-GE operator's seat 1. Headrest (option) 5. Height and weight adjustment 2. Backrest adjustment 6. Quick-release 3. Integrated 3-point seat belt (option) 7. Length adjustment 160 mm (6.30 in) 4. Seat cushion angle adjustment 8. Lumbar adjustment 103/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions Be-Ge 92-series 1 3 7 2 3 4 6 5 Figure 36. Controls for the BE-GE operator's seat 1. Headrest (option) 5. Height and weight adjustment 2. Backrest adjustment 6. Length adjustment 160 mm (6.30 in) 3. Integrated 3-point seat belt (option) 7. Lumbar adjustment 4. Seat cushion angle adjustment 104/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions Be-Ge 31-series 1 3 9 2 3 4 5 6 7 8 Figure 37. Controls for the BE-GE operator's seat 1. Headrest (option) 6. Height adjustment 2. Quick-release backrest adjustment 7. Seat cushion angle adjustment 3. Integrated 3-point seat belt (option) 8. Length adjustment 210 mm (8.27 in) 4. Air controlled backrest functions 1) 9. Seat cushion length adjustment 5. Shock absorber 1)Heating and airvent (option) 105/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2.15.2 Adjusting the Isringhausen operator's seat 1 1 8 2 7 3 6 5 4 Figure 38. Controls for the Isringhausen operator's seat 1. Integrated 3-point seat belt 5. Horizontal adjustment 2. Backrest adjustment 6. Weight and height adjustment 3. Integrated pneumatic system (IPS) 7. Seat cushion adjustment 4. Adjustable vertical shock absorber 8. Tilt adjustment 106/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.2.15.3 Adjusting the Grammer operator's seat 1 2 3 9 4 8 7 6 5 Figure 39. Controls for the Grammer operator's seat 1. Headrest (option) 6. Height adjustment 2. Seat heating 7. Shock absorber (adjustable) 3. Adjustable backrest angle 8. Forward and backward adjuster (170 mm) 4. Integrated 3-point seat belt 9. Adjustable seat cushion depth and angle 5. Forward and backward isolator (lockable) 1) 1)Reduces horizontal vibration in the direction of travel, for a more comfortable ride on tough terrain. 107/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.2.16 Adjusting the steering wheel Figure 40. Controls for the steering wheel 1. Pull lever (1) upwards to adjust the height of the steering wheel. 2. Push lever (1) downwards to adjust the tilt of the steering wheel. 3. Step on the pedal (2) to adjust the angle of the steering column. 4.3 Hydraulic long life (HLL) filter (option) 4.3.1 Placement of the hydraulic long life (HLL) filter 1 Figure 41. Placement of filter, SMV 10-16 108/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 1 Figure 42. Placement of filter, SMV 18-60 1. Placement of the HLL filter 4.3.2 Checking the HLL filter 1 Figure 43. Pressure indicator The pressure indicator (1) shows the status of the HLL filter, when the machine is on. If the indicator points towards the red area between service intervals, contact authorized maintenance personnel. 4.4 Engine After-treatment System (EATS) - Volvo stage V The Engine After-treatment System (EATS) display page shows information concerning the "Selective Catalytic Reduction" system (SCR). The SCR system includes information about "Nox Control Diagnostics" (NCD) and "Diesel Particle Filter" system (DPF) including "Particle Control Diagnostics" (PCD). 109/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 1 2 3 Figure 44. Machine overview page - Volvo stage V 1. Navigate to the Machine overview page (1). 2. Navigate to the Emission page (2). The EATS display page can also be accessed by clicking the warning symbols (3) in the NOTE bottom frame. 1 2 3 4 5 6 7 11 10 8 9 Figure 45. Emission page - Volvo stage V 1. AdBlue level indication 2. Soot level indication 3. Ash level indication 4. Parked regeneration "start" button 5. Parked regeneration "cancel" button 6. Reason and severity indication AdBlue level 7. Reason and severity indication soot level DPF 8. Engine diagnostics button 110/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 9. Warning symbols "Parked regeneration", "Parked regeneration cancel", and "AdBlue level" warning. 10. Engine warning 11. Engine stop NOTE When the ash level indication (3) reaches 80%, the filter needs to be changed. 4.4.1 Selective catalyst reduction (SCR) - Volvo stage V Nox is one of the residual products during the combustion of diesel fuel. To reduce the Nox levels that the engine is fitted with an SCR system. The SCR system converts Nox into nitrogen and water using AdBlue. NOTE If the AdBlue level is 0, the SCR system is not able to reduce the Nox levels. 1 2 1. AdBlue level indication 2. Reason and severity indication AdBlue level Nox control diagnostics (NCD) - Reason and severity AdBlue is essential for the aftertreatment system (EATS) and is a part of the NCD. On the emission page, the reason and severity level codes are displayed with the letters R and S. An NCD reason (R) value of 1 indicates a low AdBlue level. The NCD severity value (S) increases as the AdBlue level decreases. NOTE If the reason (R) has a value other than 0 or 1, contact an authorized dealer. Figure 46. AdBlue level and severity values There are four levels of severity depending on the AdBlue level and time: 111/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions Table 6. Nox control diagnostics (NCD) Nox control diagnostics (NCD) – Low AdBlue level AdBlue Level < 15% < 6% < 6% < 6%> 7 min Severity 1 3 4 5 Active warning symbols Solid amber Flashing amber Flashing amber Flashing amber Solid amber Solid red Solid red Solid red 50% torque and 25% torque 25% torque Derate None 40% RPM reduction reduction reduction Recommended Refill AdBlue Refill AdBlue Refill AdBlue Refill AdBlue action 4.4.2 Diesel Particulate Filter (DPF) - Volvo stage V 1 2 3 Figure 47. EATS emission page Volvo stage V 1. Soot level indication (1). 2. Ash level indication (2) 3. Reason and severity soot level DPF (3) Passive regeneration Soot is one of the residual products during the combustion of diesel fuel. The engine continuously strives to maintain the passive regeneration, which maintains a slow accumulation of soot in the DPF. 112/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions The passive regeneration is sufficient to maintain an acceptable level of soot in the DPF under normal circumstances. If the engine operates or idle at low RPM or is unable to reach a normal working NOTE temperature during operation, soot in the engine accumulates faster. NOTE When the ash level indication (2) reaches 80%, the filter needs to be changed. Particle Control Diagnostics (PCD) The engine sends information about the status of the particulate filter. On the emission page, the error code is displayed with the letters R and S. R shows the reason of the error and S shows the severity level. If an error occurs, different notifications are triggered depending on the severity level. Soot accumulation is normal and gradual over time, it is therefore not part of the PCD. The R (reason) and S (severity) next to the DPF symbol should always show the value 0. Figure 48. PCD reason and severity values NOTE If R (reason) has a value other than 0, contact an authorized workshop. 4.4.3 Parked regeneration - Volvo stage V WARNING IGNITION HAZARD When a parked regeneration is performed, the exhaust gas temperature may exceed 500°C. If there are flammable or combustible materials, on or near the machine, the exhaust gas can cause a fire. Examples of such materials are paper, saw dust or fuel. When performing a parked regeneration, the machine must be positioned in a well- ventilated area away from flammable material. If possible, the machine should be parked on gravel. Over time the DPF (Diesel Particulate Filter) will accumulate soot. The time that it takes depends on the machine operation. Performing a parked regeneration burns the soot and cleans the filter. During the regeneration, the engine RPM gradually increases to 1400 RPM. During the NOTE regeneration, the parking brake cannot be released and the hydraulic functions are disabled. The procedure takes about 45 min, but can vary from 20–60 min depending on the current engine temperature and soot level. The engine RPM decreases to idle RPM and normal operation can be resumed when the regeneration is completed. Operating or idling at low RPM and below normal operating engine temperatures causes NOTE the soot in the DPF to accumulate faster. The increasing level of soot makes the engine struggle to maintain the passive regeneration. When the soot level is 80%, the parked regeneration can only be initiated by "Volvo NOTE Penta" service dealers using VODIA (Volvo diagnostics). 113/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 1 2 3 4 1. Soot level indication bar 2. Parked regeneration "start" button 3. Parked regeneration "cancel" button 4. Reason and severity indication soot level DPF (Diesel Particulate Filter) To initiate a parked regeneration: 1. Position the machine in a safe location. 2. Check the fuel and AdBlue levels, top up if needed. 3. Select neutral gear. 4. Activate the parking brake. 5. Press the regeneration "start" button (2) for 2 s. If an emergency occurs, press and hold the "cancel" button (3) for 0.1 s to stop the NOTE parked regeneration. The machine resumes normal operation. Always wait for the parked regeneration to complete. The procedure can be stopped four times in a row without completion. After five consecutive stops, the next parked NOTE regeneration can only be activated by a Volvo Penta dealer using VODIA (Volvo diagnostics). There are four different intervals of severity depending on the soot level: 114/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions Table 7. Soot level severity Soot level 0%–60% 61%–69% 70%–79% 80%–100% Torque limit No No No Yes Parked No Yes Yes No regeneration enabled Active warning None symbols Solid amber Flashing amber Flashing amber Solid amber Solid red Contact Start Recommended Time to start authorized No action. regeneration action regeneration. workshop immediately. immediately. 4.5 Engine aftertreatment System - Cummins engines The Engine After-treatment System (EATS) display pages show information concerning the "Selective Catalytic Reduction" system (SCR). The SCR system includes information about "Nox Control Diagnostics" (NCD) and "Diesel Particle Filter" system (DPF) including "Particle Control Diagnostics" (PCD). 1 2 3 Figure 49. Machine overview page 1. Navigate to the Machine overview page (1). 2. Navigate to the Emission page (2). The display page for the engine aftertreatment system can also be accessed by clicking NOTE the warning symbols in the bottom frame (3). 115/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 1 2 3 4 8 7 5 6 Figure 50. Emission page 1. AdBlue/DEF (Diesel Exhaust Fluid) level indication 2. Soot level indication 3. Parked regeneration "start" button 4. Parked regeneration "cancel" button 5. Engine diagnostics button 6. Warning symbols "Parked regeneration", "Parked regeneration cancel", and "AdBlue/DEF level" warning. 7. Engine warning 8. Engine stop 4.5.1 Selective catalyst reduction (SCR) - Cummins engines Applicable for B 6.7 and X12 EU stage V / tier 4f, QSB 6.7 tier 4f If the AdBlue/DEF level is 0, the SCR system is not able to reduce the NOx levels. High NOTE NOx levels reduce and limits the performance. Nitrogen Oxide (NOx) is one of the residual products during the combustion of diesel fuel. To reduce the NOx levels that the engine is fitted with an SCR system. The SCR system converts NOx into nitrogen gas (N2) and water using AdBlue/DEF (Diesel Exhaust Fluid). NOx control diagnostics (NCD) 116/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions NOx control diagnostics (NCD) – Low AdBlue/DEF level AdBlue/DEF < 10% < 5% < 2.5% < 0% Level Severity 1-2 3 4 5 Active warning symbols Solid amber Flashing amber Flashing amber Flashing amber Solid amber Solid amber Solid red Solid red Solid red No torque (1) 50% torque (3) 75% torque and no engine and 40% engine Derate None reduction and RPM (2) RPM (4) Engine idle RPM reduction reduction Recommended Refill Refill Refill Refill action AdBlue/DEF AdBlue/DEF AdBlue/DEF AdBlue/DEF (1) Starts to derate 5 min before reaching next severity level, down to 50% reduction. (2) Starts to derate 5 min before reaching next severity level, down to 40% reduction. (3) Starts to derate 5 min before reaching next severity level, down to 75% reduction. (4) Starts to derate 5 min before reaching next severity level, down to "Engine idle RPM". 117/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.5.2 Diesel Particulate Filter (DPF) - Cummins engines Applicable for B 6.7 and X12 EU stage V / tier 4f 1 2 3 Figure 51. Emission page 1. Soot level indication. 2. Parked regeneration "start" button. 3. Parked regeneration "cancel" button. Soot is one of the residual products during the combustion of diesel fuel. The engine control module (ECM) continuously controls the soot load in the DPF. The soot levels are shown on the display page and are presented on the soot level indicator. Above the indicator, the DPF symbol is displayed. When the different levels in the DPF are reached, they are transmitted to the VCU (Vehicle Control Unit). If the engine operates or idle at low RPM or is unable to reach a normal working NOTE temperature during operation, soot in the engine accumulates faster. The following image shows the approximate soot level indications. Full High Medium Low Empty Passive regeneration A passive regeneration can be initiated by the ECM (Engine Control Module). Usually, the passive exhaust system cleaning can be performed while the machine performs its normal functions and remains unnoticeable to the operator. The passive regeneration provides the least disruption to the productivity of the machine. 118/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.5.3 Parked regeneration - Cummins engines Applicable for B 6.7 and X12 EU stage V / tier 4f WARNING IGNITION HAZARD When a parked regeneration is performed, the exhaust gas temperature may exceed 500°C. If there are flammable or combustible materials, on or near the machine, the exhaust gas can cause a fire. Examples of such materials are paper, saw dust or fuel. When performing a parked regeneration, the machine must be positioned in a well- ventilated area away from flammable material. If possible, the machine should be parked on gravel. Operating or idling at low RPM and below normal operating engine temperatures causes NOTE the soot in the DPF (Diesel Particulate Filter) to accumulate faster. The increasing level of soot makes the engine struggle to maintain the passive regeneration. Always wait for the parked regeneration to complete. If the regeneration is interrupted two times within 30 min, a warning is shown in the display unit. If the regeneration is NOTE canceled three times within 30 min, or is interrupted five times, it is no longer possible to start regeneration using the display unit. Contact with an authorized service technician is required. If the button for cancel regeneration is pressed, both the automatic and the parked regeneration is disallowed. If the button is pressed when regeneration is active, NOTE regeneration is stopped. It is recommended by the engine supplier that the "cancel" button is only used when high exhaust temperatures may cause a hazardous condition. During the regeneration, the engine RPM gradually increases to 1400 RPM. During the NOTE regeneration, the parking brake cannot be released and the hydraulic functions are disabled. It is not possible to activate forward or reverse gear. Over time the DPF (Diesel Particulate Filter) will accumulate soot. The time that it takes depends on the machine operation. Performing a parked regeneration burns the soot and cleans the particulate filter. The procedure takes about 45 min, but can vary from 20–60 min depending on the current engine temperature and soot level. The engine RPM decreases to idle RPM and normal operation can be resumed when the regeneration is completed. 119/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 1 2 3 1. "Soot level indication" bar 2. Parked regeneration "start" button 3. Parked regeneration "cancel" button If high levels of soot are indicated, initiate a parked regeneration: 1. Position the machine in a safe location. 2. Check the fuel and AdBlue/DEF levels, top up if needed. 3. Select neutral gear. 4. Activate the parking brake. 5. Press the regeneration "start" button (2) for 2 s. If an emergency occurs, press and hold the "cancel" button (3) for 0.1 s to stop the NOTE parked regeneration. The machine resumes normal operation. If regeneration is active, the indication light below the start regeneration button is lit. If regeneration is not possible, due to low soot levels or if the "cancel" button has been pressed, the regeneration button is grayed out. 120/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions If regeneration has been canceled, the indication light below the cancel button is lit. There are four different intervals of severity depending on the soot level: Table 8. Soot level severity Soot level 0%–60% 61%–69% 70%–79% 80%–100% Reduction and No No No Yes Torque limit Parked No Yes Yes No regeneration enabled Active warning None symbols Solid amber Flashing amber Flashing amber Solid amber Solid amber Solid red Contact Start Recommended Time to start authorized No action. regeneration action regeneration. workshop immediately. immediately. 4.5.4 Diesel Oxidation Catalyst (DOC) - Cummins engines Applicable for QSB 6.7 tier 4f Diesel Oxidation Catalyst (DOC) is an aftertreatment component that converts carbon monoxide (CO) and hydrocarbons into carbon dioxide (CO2) and water vapor. DOC works in a passive mode and require no active regeneration or other special requirements. The DOC component breaks down pollutants in the exhaust stream from the engine. DOC also reduces particulate matter (PM) through a chemical reaction that requires no cleaning or maintenance. Exhaust flows through the Engine Aftertreatment System (EATS), and passes from the turbo through the DOC. Even after the DOC collects particles from the harmful substances in the exhaust, it still contains Nitrogen oxide (NOx). NOx levels are reduced by using AdBlue/DEF (Diesel Exhaust Fluid). See Selective catalyst reduction (SCR) - Cummins engines (page 116). 121/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.6 Using the cabin heating and ventilation 1 2 1. Fan speed 2. Heat control 1. To select the desired fan speed, turn the left handle (1). 2. To control the temperature, turn the right handle (2). 122/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.7 Using the cabin ventilation (option) 1 2 3 4 5 6 7 8 Figure 52. Cabin ventilation A lamp lights up when a function (2, 3, 5, 6) is active. Press again to deactivate. 1. Fan speed 5. Display outside temperature 2. Air recirculation 6. Defrost 3. Air conditioning 7. Temperature control - 4. Temperature display 8. Temperature control + The cabin temperature is controlled by a heating/air conditioning unit with a motorized water valve and an external air flap. The temperature display (4) shows the inside temperature you have set for the cabin. You can set the value 18°C…28°C (corresponding to 64°…82°F). Set the temperature by pressing the - and + buttons (7, 8). Press (5) to display the outside temperature on the 4-digit display (4). To switch the unit of temperature between Celsius and Fahrenheit, press (5) for more than 20 s. Controls may vary according to customer options. Tips for working with the air conditioning: • To reduce humidity in the cabin, operate the machine with the air conditioning system on. • Recirculated air helps to cool down the cabin faster. • When driving and with normal humidity, use external air intake. • To reduce fog build-up during humid weather, and ice during cold weather, use the defroster. 4.8 Driver login (option) If the machine is shut down and restarted, the login code of the operator must be NOTE reentered. 1. When opening one of the Main pages, a pop-up screen (1) appears. 123/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 2 1 2. Press Enter PIN (2). 3 3. Enter the personal login code and press (3). 4.9 Changing the operator If the operator changes, the login code of the new operator must be entered. Figure 53. Operator's button on the right side 1. On any of the Main pages, tap the button on the right side to open the Operator’s menu. 124/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions Driver 11 1 2. Press the driver selection button (1) , a drop-down menu opens. Driver 13 2 3 3. Select your driver's number from the drop-down menu, for instance, Driver 13 (2). 4. A pop-up window opens. Press Enter PIN (3). 125/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions Driver 13 4 5. Enter your personal login code and press (4) Now you can start the machine. 4.10 Break-in period The machine can be driven at full speed right from the start. However, prolonged maximum loading of the hydraulic system and transmission must be avoided during the first 50 hours of operation. After the first 150 hours, perform the first service. For more information, see the maintenance instruction. 4.11 Steering and braking 4.11.1 Steering To minimize unnecessary wear and tear to the tires, turn the steering wheel only when the machine is moving. 126/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.11.2 Using the electrical mini-wheel steering (option) DANGER MOVING MACHINE HAZARD Losing control of the steering system of the machine can cause material damage, personal injury, or death. If the system detects a fault in the electrical mini-wheel steering system, a warning buzzer sounds in the cabin. The operator must then use the ordinary steering wheel. DANGER MOVING MACHINE HAZARD Losing control of the steering system of the machine can cause material damage, personal injury, or death. If any faults or malfunctions with the mini-wheel steering system is detected, the machine must immediately be taken out of use. Maintenance staff must be contacted. The mini-wheel is an ergonomic feature that helps to reduce stress on the shoulders and back of the operator. 1 2 Figure 54. Mini-wheel steering 1. Mini-wheel steering 2. F-N-R switch 127/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 2 1 Figure 55. F-N-R mini-wheel steering 1. Mini-wheel steering 2. F-N-R switch 1 2 Figure 56. Dome lever steering 1. Lever steering 2. F-N-R switch 128/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 1 2 Figure 57. Lever steering 1. Lever steering 2. F-N-R switch It is always possible to steer the machine with the ordinary steering wheel. When the NOTE ordinary steering wheel is in use, the mini-wheel steering is deactivated. The main steering wheel retains priority over mini-wheel steering in case you must grab NOTE it suddenly. 3 3 1. To activate mini-wheel steering, press the button (3). 2. To deactivate mini-wheel steering, press the button (3) again. NOTE The F-N-R switch is disabled when the mini-wheel steering function is deactivated. 129/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.11.3 Force neutral when braking The function "force neutral when braking" helps avoid abnormal wear on the brakes. When the driving speed is higher than 4 km/h, and the operator presses the brake pedal the gear is forced into neutral. When the operator releases the brake, the gear is reactivated. NOTE When using the inching brake function, "force neutral when braking" is not activated. 130/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.11.4 Activating the declutch 3 1 2 Figure 58. Activating the declutch, cabin with levers 3 1 2 Figure 59. Activating the declutch, cabin with joystick The declutch switch (1) disengages the transmission, and enables the operator to control the hydraulics while maintaining a high engine RPM. During stacking maneuvers, this function prevents overheating of the engine, transmission, or brakes. The additional benefits are that the reverse or forward gear can remain activated. 1. To activate the declutch, press the declutch switch (1). 2. If you press the declutch switch (1) at the same time as the brake pedal (2), the brakes are applied. When you brake using only the brake pedal (2), the declutch is not activated. If the gear switch (3) is in forward or reverse position, the transmission is activated again NOTE when releasing the pressure on the declutch switch (1). 131/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.11.5 Activating the declutch, with pressure switch (option) 3 Figure 60. Activating the declutch with pressure switch The declutch with pressure switch disengages the transmission depending on the brake pressure. When the brake pressure exceeds approximately 30 bar, the transmission disengages (Neutral). This function enables the operator to control the hydraulics while maintaining a high engine RPM without overheating the engine, transmission, or brakes during stacking maneuvers. 1. To activate the pressure switch, press either the left or the right brake pedal (2). 2. Control the lifting speed by pressing the accelerator pedal (1). If the gear switch (3) is in forward or reverse position, the transmission is reactivated NOTE when the brakes are released. 4.11.6 Activating the inching function (option) 2 1 Figure 61. Activating the inching function The inching function disengages the transmission depending on, and parallel to the brake pressure. The inching function enables a smooth propulsion in parallel with an effective lifting speed. 1. To activate the inching function, press either the left or the right brake pedal (2). 132/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 2. Control the lifting speed by pressing the accelerator pedal (1). NOTE The higher brake pressure, the lower propulsion. When using the inching function, "force neutral when braking" is not activated. Force NOTE neutral when braking (page 130) 4.11.7 Parking WARNING RISK OF UNINTENDED MOVEMENT The parking brake can fail and cause unintended movement. Park the machine on level ground. Before parking the machine: • Make sure that the forks are fully lowered. • Tilt the mast forward, the fork tips must touch the ground. • Park the machine on level ground. To hold the machine still while working on slopes with up to 15% inclination, the parking NOTE brake can be used. 1. Use the service brake to bring the machine to a standstill. 2. Select neutral gear. 3. Activate the parking brake. 4. Turn off the ignition. 5. Wait until the AdBlue pump has stopped. NOTE After parking the machine, make sure to switch off the battery main switch. 133/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.11.8 Activating the parking brake Figure 62. Parking brake, cabin with levers 1 If the operator leaves the seat without activating the parking brake, an audio signal is activated. Check the function of the parking brake daily. Contact your authorized dealer, or NOTE maintenance personnel if the parking brake does not function properly. If there is doubt, they can ensure that the parking brake is in a safe condition to use. 1. Bring the machine to a standstill, using the service brake. 2. Select the neutral gear. 3. Press (1) to activate the parking brake. 4.11.9 Automatically applied parking brake (option) The parking brake is activated automatically, when there is no signal from the seat switch sensor. The machine must be stationary, for the parking brake to be activated. 134/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 1 To release the parking brake again, the parking brake button (1) on the keypad must be pressed. 4.11.10 Differential lock function (option) WARNING RISK OF DAMAGE TO THE MACHINE Wrong usage can damage the axle drive line parts Only use the function when operating with low and bad traction (when driving in snow, ice, or mud). Do not use for long-distance driving. Only apply the differential lock when the machine stands still. Do not drive with full engine power. No steering is allowed when the differential lock is applied. Only use the differential lock when driving forwards. The differential lock function enables the possibility to have the same propulsion power and speed on all drive wheels. The differential lock function can be used to stabilize the forward propulsion when operating with bad and low traction (such as snow, ice, or mud). The following symbol (2) is shown in the display when the differential lock function is activated: 2 135/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 1. Slow down the machine to a standstill. 2. Press the activation button for the differential lock (1). 3. Drive slowly forwards max speed 5 km / hour. 4. Slow down the machine to a standstill. 5. Press the activation button (1) again to deactivate the differential lock. 4.12 Sideways sliding cabin DANGER PERSONAL INJURY HAZARD When the cabin is sideways positioned, the distance to the ground is high. A fall from this height, can cause serious personal injury or death. If the cabin is sideways positioned, do not exit the cabin on the right side. In an emergency situation, when the left door is blocked, use the emergency hammer and exit through the rear window. WARNING PERSONAL INJURY HAZARD If walking in the area to the right of the cabin, when the cabin is sideways positioned, there is a risk of tripping. Tripping causes a risk of serious personal injury. Be careful when moving in this area, preferably return the cabin to normal position before exiting the cabin. WARNING RISK OF DAMAGE When moving the cabin sideways, there is a risk of colliding with objects or persons in the surrounding area. There is a risk of personal injury and damage to the machine. Make sure that there is enough space to slide the cabin sideways. Make sure that there are no personnel near the area when moving the cabin. WARNING LIMITED VISIBILITY HAZARD The working range of the machine is large and visibility from the operator’s cabin is limited. Risk of serious personal injury and damage to the machine Before you start to move the machine, check that the road ahead is free and that you have an unobstructed view. If the view forwards is obstructed, use the sideways sliding feature to change the position of the cabin. If the view is still obstructed, drive in reverse. 136/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions The cabin must be in end position, either in normal position, or in sideways position to NOTE be able to operate the machine. The sideways sliding cabin function is an option which enables the operator to change the position of the cabin. The feature can be used when the view is obstructed when operating the machine. The function is hydraulic, and the following criteria must be fulfilled move the cabin: • Engine runs • Parking brake is engaged 1 1. Use the switch (1) to move the cabin sideways. The cabin moves proportionally depending on the angle of the switch. When the switch NOTE is released, the cabin movement stops. 2 137/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 2. Cabin in normal position (2). 3 3. Cabin positioned sideways (3). 138/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.13 Using the 180° rotating seat (option) WARNING PERSONAL INJURY HAZARD If the operator is not correctly positioned in the seat, the rotating movement could cause personal injury. When rotating the seat, wear a seat belt, and make sure that legs and arms are safely positioned. Make sure that seat, and backrest settings does not interfere, when rotating the operator seat. WARNING CRUSH INJURY HAZARD If there are several persons in the cabin when rotating the seat, there is a risk of personal injury due to the rotating movement. There is a risk of getting pinned between the seat and the cabin. When rotating the seat, the operator must make sure that there are no other persons in the cabin. When rotating the seat, the operator must make sure that there are no other items, such as bags, or jackets, in the cabin. Make sure to not release the hand and foot switches before the seat is fully rotated to 180°. If any of the switches are released too early, the seat returns to either a forward or NOTE reverse position. Depending on the position of the seat when releasing the switches, the seat can also stop between end positions. If so, the parking brake cannot be released and a warning is shown in the display. When the seat rotates, the hydraulic functions are disabled. When the seat is fully rotated NOTE to end direction, facing forwards, the hydraulic functions are enabled. When the seat is fully rotated to end direction, facing backwards, the hydraulic functions are disabled. 1) When equipped with "Armrest inclination sensor" (option), it is not possible to rotate the NOTE seat when the armrest inclination is more than 45°. 1) All hydraulic functions, can be activated in the settings. For more information, contact Konecranes Lift Trucks, or an authorized dealer. Figure 63. Rotating seat in forward driving position (left) and reverse driving position (right) 139/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions The rotating seat option allows the operator to rotate the seat 180° for reverse driving. As this feature eliminates the need for reversing, it decreases strain and stress on the operator. Rotating seat also gives a better view of the rear and increases safety when driving. The steering wheel rotates together with the seat, but there are pedals on both sides of the cabin. When the seat is rotated, the following changes take place: • The turning directions of the steering wheel adapt to the new driving direction. • The lights adapt to the new driving direction. • The gear switch adapts to the new driving direction. 2 1 1. Bring the machine to a standstill. 2. Make sure that the machine is in neutral. 3. Apply the parking brake. 4. Press both feet against the two switches (1) under the seat. 5. Activate the switch (2) for seat rotation on the armrest. 6. Keep pressing the switches (1) and (2) until the seat has rotated fully to 180°. 7. Release the switches (1) and (2). The machine can now be driven in the opposite direction. If the accelerator pedal is not pressed within 10 s, the parking brake must be disengaged manually, by pressing the parking brake button. When finished, rotate the seat back to the original position by following the same procedure. 140/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.14 Operating 4.14.1 Daily inspection before operation (option) Daily inspection 2 • Check the battery main switch • Check lifting equipment, forks and lifting chains • Check the tire pressure, condition, rims and wheel nuts • Check the engine oil level 1 • • Check the transmission oil level Check the coolant level • Check the hydraulic oil level • Check the grease level in the container for the automatic lubrication system (option) • Check the MD4 warnings for clogging of engine air filter (option) • Check the windshield washer fluid level • Check the fuel level • Check the AdBlue level (when applicable) • Check that the mirrors are clean and adjust them. Clean the rearview camera (option) • Check the seat adjustments • Check the functionality of the brake system • Check the functionality of the steering system • Check the functionality of the hydraulic system • Check the lights and horn • Check the climate unit (option) settings When starting the machine for the first time each day, a checklist is displayed. The operator must go through the list and confirm that the machine functions as expected before the engine can be started. Press the check mark button (1) to confirm the functions. If a fault is detected during the inspection, press the cross button (2). If a fault is detected, evaluate the problem, contact maintenance personnel if needed. NOTE When the problem is solved, start the machine again. If the machine passes all the tests, and the inspection is confirmed, it is possible to start the engine. The status of the inspection is transmitted to TRUCONNECT®. When no status is uploaded, the machine sends “No status” to TRUCONNECT®. 4.14.2 Operating - general information To be able to start the machine, the operator needs to be identified. The machine can be started in the following ways: • Ignition key - for more information see: Starting the engine (page 142) • Ignition key and driver login with code - for more information see: Driver login (option) (page 123) • RFID - for more information see: Starting the engine, with RFID tag (option) (page 144) 141/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.14.3 Starting the engine WARNING TOXIC SUBSTANCE HAZARD Breathing diesel engine exhaust exposes you to chemicals that may cause cancer, birth defects or other reproductive harm. Never run the engine in unventilated places. Use fume extraction. Do not keep the engine idling, except when necessary. Do not modify or tamper with the exhaust system. Figure 64. Starting the engine, cabin with levers 142/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions Figure 65. Starting the engine , cabin with a joystick 1. Position yourself in the operator’s seat. 2. Ensure that the gear switch (1) is in neutral. 3. Insert the ignition key (2). 4. Turn the key clockwise. 5. Wait until the display shows the home page. 6. Press the start button (3). The engine starts. 143/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.14.4 Starting the engine, with RFID tag (option) WARNING TOXIC SUBSTANCE HAZARD Breathing diesel engine exhaust exposes you to chemicals that may cause cancer, birth defects, or other reproductive harm. Never run the engine in unventilated places. Use fume extraction. Do not keep the engine idling, except when necessary. Do not modify or tamper with the exhaust system. The RFID (Radio-frequency identification) tag identifies the operator and is used to start and stop the machine. If the RFID tag is used, it replaces the ignition key, there can be up to 200 individual tags/machine. 1. Position yourself in the operator’s seat. 2. Ensure that the gear switch is in the neutral gear. 3 2 2 START 1 1 3. Lift the cover of the armrest (1). 4 4. Swipe the RFID tag (4) over the RFID reader (2). 5. Wait until the display shows the home page. 6. Press the start button (3). The engine starts. 144/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.14.5 Stopping the engine WARNING RISK OF DAMAGE TO THE MACHINE If you do not let the turbo slow down before turning off the engine, there is a risk of turbo damage. Allow the engine to idle for a few minutes before turning of the engine. Use the emergency stop only in an emergency situation. For more information, see NOTE Emergency stopping (page 34). 4 2 1 1. Release the accelerator pedal (1). 2. Apply the service brakes (2) and bring the machine to a standstill. 3. Select the neutral gear (4). 4. Activate the parking brake (3). See Activating the parking brake (page 134). 5. Let the engine idle for a few minutes. 6. To stop the engine, press the start/stop button (5). 5 145/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 7. Turn the ignition key anti-clockwise. The engine and the ignition are now both NOTE turned off. 8. If you leave the machine unsupervised, turn off the battery main switch. For more information, see Battery main switch (page 35) NOTE Do not turn off the battery main switch before the engine has stopped. If the machine has en engine that uses diesel exhaust fluid (DEF) solution (AdBlue), turn off the engine, but do not turn off the battery main switch. Wait for the DEF pump to NOTE finish pumping back all the fluid from the hoses to the DEF tank before turning off the battery main switch (1). 4.14.6 Stopping the engine, with RFID tag (option) WARNING RISK OF DAMAGE TO THE MACHINE If you do not let the turbo slow down before turning off the engine, there is a risk of damaging the turbo. Allow the engine to idle for a few minutes before turning off the engine. Use the emergency stop only in an emergency situation. For more information, see NOTE Emergency stopping (page 34). Figure 67. Stopping the engine 1. Release the accelerator pedal (1). 2. Apply the brakes (2) and stop the machine. 146/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 3 4 5 2 START 1 6 3. Activate the parking brake (3). 4. Ensure that the gear switch is in the neutral gear. 5. To stop the engine, press the start/stop button (4). 6. Lift the cover of the armrest (6). 7 7. Swipe the RFID tag (7) over the RFID reader (5) to switch off the ignition. NOTE The machine must be in a standstill to use the RFID tag (7) to switch off the ignition. If you leave the machine unsupervised, switch off the battery main switch. Battery main NOTE switch (page 35) NOTE Do not turn off the battery main switch before the engine has stopped. 147/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.14.7 Operating the machine DANGER RISK OF TIPPING If driving with the load placed higher than the recommended transport position, the machine can roll or tip. Risk of death, serious injury and damage to the machine. If needed, reverse from stack, and lower the load to transport position before driving away. WARNING RISK OF DAMAGE TO MACHINE HAZARD Keeping the machine idling or operating at low load for long periods of time may cause oil leak, increased levels of soot, and damage the engine. Do not keep the machine idling or operating at low load for long periods of time. WARNING SIDEWAYS TILTING HAZARD Driving on uneven terrain may damage the machine. Driving on surfaces with insufficient support may cause the machine to roll or sink. Risk of serious personal injury and damage to the machine. Drive the machine only on level ground that is intended for the total weight and ground pressure of the machine. Figure 68. Do not drive on uneven terrain WARNING HIGH-VOLTAGE HAZARD Electric arcing can cause burns or electrocution even without direct contact with the power line. Be careful when operating the machine near electricity power lines. WARNING LIMITED VISIBILITY HAZARD The working range of the machine is large and visibility from the operator’s cabin is limited. Risk of serious personal injury and/or damage to the machine. Before you start to move the machine, check that the road ahead is free and that you have an unobstructed view. 148/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions WARNING RISK OF LOAD DROP Driving downhill on slopes carrying a load, can lead to a load drop. This can damage the machine and can lead to serious personal injury. If carrying a load, always drive downhill in reverse. WARNING TIPPING AND COLLISION HAZARD If you drive on slopes greater than 15%, the brakes may fail to stop the machine and machine may roll. Risk of serious personal injury and damage to the machine. Do not drive on slopes greater than 15%. If you must drive the machine along greater slopes, contact your Konecranes Lift Trucks NOTE authorized dealer. Figure 69. Do not drive on slopes steeper than 15% • The machine is not intended for off-road driving. • The machine is not equipped with wheel suspension. • Always adjust your method of driving to the condition of the road (bumps, and so on), to hazards within the working area and the load. • The indicated hill-climbing capacity of the machine in the data sheet is based on the pulling power of the machine. It applies only to driving over obstacles and minor irregularities in ground level. If leaving the seat when operating the machine, the transmission is forced into neutral. The gear must be reactivated when returning. Due to the "Operator presence" function, NOTE the operator must sit in the seat to activate the seat switch for the propulsion and the hydraulics. 1. Start the engine. 2. Lift just enough to still maintain a clear view above the load. If the load is so large it obstructs your view, drive the machine in reverse for better visibility. 3. Hold the steering wheel steady. Always use the whole of your hand to hold the wheel knob. 149/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.14.8 Driving forwards For more information regarding transport position of the forks, see Lifting and driving NOTE with a load (page 161). Figure 70. Driving controls, cabin with levers 150/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions Figure 71. Driving controls, cabin with joystick(option) 1. Press the brake pedal (1). To avoid damage and prevent the transmission from overheating, always start in the first NOTE or second gear. 2. Release the parking brake (2). 3. Select forward (3). 4. Release the brake pedal (1). 5. Press the accelerator pedal (4) slowly. When starting uphill, hold the machine still using the brake pedal (4), until you have NOTE sufficient pulling power. 151/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.14.9 Stopping the machine For more information regarding position of the forks when parking, see NOTE Parking (page 133). 4 3 2 1 Figure 72. Driving controls, cabin with levers 152/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4 3 2 1 Figure 73. Driving controls, cabin with joystick(option) 1. Take your foot off the accelerator pedal (1). 2. Press the brake pedal (2) and stop the machine in a gentle, controlled manner. WARNING FORWARD TIPPING HAZARD Sudden braking and acceleration may cause the machine to roll or tip. Risk of serious personal injury and damage to the machine. Avoid violent acceleration and braking. RISK OF PROPERTY DAMAGE NOTICE Do not use the transmission as a brake. 3. Select the neutral gear (4). 4. When the machine has stopped, activate the parking brake (3) before releasing the brake pedal. 153/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.14.10 Driving in reverse DANGER MOVING VEHICLE HAZARD Reversing without a direct view in the reverse direction may cause death, serious personal injury, or damage to property. Only drive in reverse when you have a direct and unobstructed view in the reverse direction. Figure 74. Driving controls, cabin with levers 154/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions Figure 75. Driving controls, cabin with joystick 1. Press the brake pedal (1). To avoid damage and prevent the transmission from overheating, always start in the first NOTE or second gear. 2. Release the parking brake (2). 3. Select reverse (3). 4. Release the brake pedal (1). 5. Press the accelerator pedal (4) slowly. NOTE Make sure that there is a direct view in the reverse direction. When starting uphill, hold the machine still using the brake pedal (4) until you have NOTE sufficient pulling power. 155/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.15 Mounting the attachment - ELME 815 4.15.1 Parts of the attachment 4 5 10 1 9 2 3 6 8 7 1. Fork in standard position 7. Fork in inverted position 2. Fixation for the safety and mounting 8. Safety and mounting bracket (inverted bracket (std position) position) 3. Safety and mounting bracket (std position) 9. Safety edge on bracket (inverted position) 4. Safety edge on bracket (std position) 10. Lower fixation point (inverted position) 5. Upper fixation point (std position) 6. Fixation for the safety and mounting bracket (inverted position) 4.15.2 Mounting the attachment - forks in standard position WARNING RISK OF DAMAGE TO THE MACHINE If the attachment is not fixated correctly on the forks, there is risk of dropping the attachment. Dropping the attachment can damage the machine and the surrounding area. Make sure to use the upper fixation points and position the mounting brackets with the safety edge upwards. 156/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 1 1. Insert the forks (1) in the pockets on the attachment. 4 5 1 2 3 2. Secure the forks (1) with the mounting brackets (3). NOTE The safety edge (4) on the mounting brackets (3) must be positioned upwards. Use the upper fixation points (5) for the mounting brackets (3) when using forks in NOTE standard position (1). 3. Secure the mounting brackets (3) with the fixations (2). 157/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 4.15.3 Mounting the attachment - forks in inverted position WARNING RISK OF DAMAGE TO THE MACHINE If the attachment is not fixated correctly on the forks, there is risk of dropping the attachment. Dropping the attachment can damage the machine and the surrounding area. Make sure to use the lower fixation points and position the mounting brackets with the safety edge downwards. 7 158/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 1. Insert the forks (7) in the pockets on the attachment. 10 9 6 7 8 2. Secure the forks (7) with the mounting brackets (8). NOTE The safety edge (9) on the mounting brackets (8) must be positioned downwards. Use the lower fixation points (10) for the mounting brackets (8) when using forks in NOTE inverted position (7). 3. Secure the mounting brackets (8) with the fixations (6). 4.15.4 Connecting the hydraulic quick couplings WARNING RISK OF MALFUNCTION The hydraulics may not work properly if the hydraulic hoses are not connected correctly. Make sure to attach the quick couplings for the hydraulics to the corresponding connections on the carriage. 159/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 2 1 3 Figure 76. Hydraulic quick couplings - ELME 815 1. Select the hydraulic quick couplings from the hose package (1) on the attachment. 2. Remove the four yellow protection plugs (3) from the quick couplings. 3. Connect the quick couplings (2) for the hydraulics to the corresponding connection on the carriage. NOTE Always reattach the protection plugs (3) when disconnecting the quick couplings. 4.15.5 Connecting the electric contact 3 2 1 4 Figure 77. Electric contact - ELME 815 160/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 1. Select the electric contact (3) from the hose package (1). 2. Remove the protection lids (4) from the electric box (2) on the carriage, and from the electric contact (3) on the hose package (1). 3. Connect the electric contact (3) to the electric box (2) on the carriage. Always reattach the protection lids (4) when disconnecting the electric contact (3) from NOTE the electric box (2). 4.16 Lifting and driving with a load DANGER UNCONTROLLED MOVEMENT HAZARD If the machine moves unexpectedly, it could result in personal injury, death, or damage to the equipment. To stop any unexpected movement, push the emergency stop button. WARNING RISK OF TIPPING If activating the emergency stop when driving, the parking brake is activated. This safety maneuver can cause the load to rapidly slide forwards, and cause imbalance or cause a load drop. Drive slowly and follow the recommendations for Transporting a load (page 163). 4.16.1 Lifting a load DANGER MOVING VEHICLE HAZARD Reversing without a direct view in the reverse direction may cause death, serious personal injury, or damage to property. Only drive in reverse when you have a direct and unobstructed view in the reverse direction. 1. Drive forward towards the load. If the load is not centered, the operator must take extra precautions to center the load on the forks. If the operator does not take the precautions that are recommended above, the load can NOTE move unexpectedly. Avoiding to take precautions could cause the load to fall or move towards the mast and carriage. To center the load also reduces the stress on the lifting equipment. 161/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 2. Raise or lower the forks to the correct height. 3. Place the mast in its vertical position. 4. Carefully push the forks under the load until the fork shafts touch the load. 5. Raise the forks until the load rests on the forks. A = 20–40 cm (8–16 in). Raise only so much that the load is free from the surface. Check that the weight of the NOTE load is centered in regards to the mast and the machine. Sideshift the forks to adjust the weight balance if necessary. 6. Tilt the mast backwards. 7. Reverse the machine until the load is free from the front of the stack. B = 20–40 cm (8–16 in). NOTE Make sure that there is a direct view in the reverse direction. 162/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 8. Lower the load to the transport position. Distance between the forks and the ground should be 30 cm (11.8 in) or 50 cm (19.6 in) NOTE depending on the size of the machine. See Transporting a load (page 163) for more information. 4.16.2 Transporting a load DANGER MOVING VEHICLE HAZARD Reversing without a direct view in the reverse direction may cause death, serious personal injury, or damage to property. Only drive in reverse when you have a direct and unobstructed view in the reverse direction. WARNING FALLING LOAD HAZARD Load and attachment may drop and lead to serious personal injury or death. Do not allow anyone to stand or walk under the elevated part of the machine whether it is empty or loaded. Never park or leave a machine with raised load unsupervised. WARNING COLLISION HAZARD Driving with the forks or load in the raised position could result in serious personal injury or death. Never drive with the forks or load in the raised position. WARNING RISK OF LOAD DROP Driving downhill on slopes carrying a load, can lead to a load drop. This can damage the machine and can lead to serious personal injury. If carrying a load, always drive downhill in reverse. 163/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions • Do not drive with the load displaced sideways (for example, by side maneuvering). • Tilt the mast backwards. • Transport the load close to the ground. In transport position, the distance between the forks and the ground should be: ◦ 30 cm (11.8 in) for machines up to 10 T. NOTE ◦ 50 cm (19.6 in) for machines larger than 10 T. ◦ 30 cm (11.8 in) when lifting containers with fork pockets (machines up to 10 T). ◦ 50 cm (19.6 in) when lifting containers with fork pockets (machines larger than 10 T). When handling containers, using an attachment, the bottom of the lifted container should NOTE be at eye height. • Avoid driving on slopes or uneven surfaces when transporting a load. • Always drive with the load turned upwards on a slope. Never drive across, or turn on a slope. • Never drive with raised forks, or a raised load above the recommendations for transport position. • If the view is reduced, ask someone to guide you. • If the load has been stacked so high that it prevents a forward view, drive the machine in reverse. NOTE Make sure that there is a direct view in the reverse direction. If the load is transported a longer distance, check the height of the load every now and NOTE then. 164/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.16.3 Unloading a load DANGER COLLISION HAZARD Driving with the forks or load in the raised position could result in serious personal injury or death. Never drive with the forks or load in the raised position, or with a raised load above 30 cm (11.8 in), or 50 cm (19.6 in) depending on the size of the machine. See Transporting a load (page 163) for more information. DANGER MOVING VEHICLE HAZARD Reversing without a direct view in the reverse direction may cause death, serious personal injury, or damage to property. Only drive in reverse when you have a direct and unobstructed view in the reverse direction. DANGER UNCONTROLLED MOVEMENT HAZARD If the machine moves unexpectedly, it could result in personal injury, death, or damage to the equipment. To stop any unexpected movement, push the emergency stop button. WARNING RISK OF TIPPING If activating the emergency stop when driving, the parking brake is activated. This can cause the load to rapidly slide forwards, and cause imbalance or cause a load drop. Drive slowly and follow the recommendations for Transporting a load (page 163). 1. Drive up to the stack or unit on which you want to unload as precisely as possible. 2. Raise the fork carriage to the correct height. 165/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 3. Place the load vertically. 4. Carefully drive up to the stack. 5. Lower the load. To avoid scratching the load (depending on the weight of the load), tilt slightly forward. The mast and forks should be vertical and horizontal before reversing from the stack. 6. Carefully reverse from the stack. Ensure that the forks are free. NOTE Make sure that there is a direct view in the reverse direction. 7. Lower the forks to the transport position. Tilt the mast backwards. Distance between the forks and the ground should be 30 cm (11.8 in) or 50 cm (19.6 in) NOTE depending on the size of the machine. See Transporting a load (page 163) for more information. 166/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 4.17 Emergency lowering, general DANGER FALLING LOAD HAZARD Danger of serious personal injury, death, or damage to the vehicle. The mast and carriage descend fast, about 1 m/s. Ensure that the carriage and the mast can be lowered without hindrance. Ensure that there are no people or items underneath or near the forks. Emergency lowering must be performed by trained service personnel. DANGER FALLING LOAD HAZARD Danger of serious personal injury, death, or damage to the vehicle. If the locking screw and the locking nuts are repositioned wrongly, the mast and carriage can descend unexpectedly during operation. Ensure that the locking screw is returned to the exact same position when restored. This task must be performed by trained service personnel. The machine is equipped with hydraulic assistance. If the engine stops or if a fault occurs in the hydraulics preventing the assistance from working, you cannot lower using the maneuvering levers. The directional control valve is therefore equipped with a mechanical control that allows manual lowering. 4.17.1 Emergency lowering for SMV 10-16 - L90 main valve NOTE The emergency lowering locknut is located behind the hoses. Figure 78. L90 view from above (look for the 90-degree hydraulic coupling placed horizontally) 167/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 1 2 Figure 79. L90 view from side, left side, behind NOTE The locking screw (2) is the one nearest to the 90-degree hydraulic coupling. 1. Tilt the cabin upwards. 2. Loosen the locknut (1). 3. Open the locking screw (2) with an Allen wrench. NOTE The mast and carriage descends rapidly. When the mast has been lowered, it is not possible to raise it again until the engine runs and the hydraulics works correctly. Always count the turns when loosening the locknut (1) and locking screw (2). Always NOTE reset the locknut (1) and locking screw (2) to their original position, after emergency lowering is performed. 4.17.2 Emergency lowering for SMV 18-60 - K220/L90 main valve 2 1 Figure 80. K220/L90 main valve 1. Tilt the cabin upwards. 168/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Operating instructions Operating Instructions 2. Loosen the locknut (1). 3. Open the locking screw (2) with an Allen wrench. NOTE The mast and carriage descends rapidly. When the mast has been lowered, it is not possible to raise it again until the engine runs and the hydraulics works correctly. Always reset the locknut (1) and locking screw (2) to their original position, after NOTE emergency lowering is performed. 4.18 Towing WARNING RUN OVER HAZARD If the engine, the electrical system or the hydraulic system is broken, the parking brake may need to be released manually to tow the machine. In this situation, the machine has no brakes or steering capability, which may lead to serious personal injury and damage to the machine. When towing the machine, the engine must idle, or a vehicle with sufficient braking capacity to stop both vehicles must be used. WARNING MOVING VEHICLE HAZARD When towing the machine, there is a risk that the machine becomes unattached from the towing vehicle. It can lead to serious personal injury and damage to the machine. Do not exceed the towing capacity of the transporting vehicle. NOTE Only trained and authorized personnel are allowed to tow the machine. If possible, the engine should idle when being towed. If not, the hydraulic brake system, and servo-assisted steering system cannot be used. If idling is not possible, release the hydraulic parking brake manually. After the hydraulic parking brake is released, the machine has no brakes. To stop both vehicles when towing the machine, use a vehicle with sufficient brake capacity. Use a towing bar if possible. 1. Attach the towing bar to the machine. Use the rear towing peg, if applicable, when fitting a sturdy towing bar on the machine. NOTE Otherwise use slings and secure them around the back counterweight when towing. 169/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions 4 Operating instructions 2. Remove the propshaft (1). 3. Release the parking brake manually. 170/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX I: Fuel and oil recommendations Operating Instructions APPENDIX I: FUEL AND OIL RECOMMENDATIONS Quality of the engine oil Depending on engine type, the engine oil must comply with one of the following oil classifications: • Volvo VDS-4.5 • Volvo VDS-4 • Volvo VDS-3 • CES20081 / ACEA E9 / API CJ-4 • CES20071 / ACEA E5 / API CH-4 • ACEA E5 / API CI-4 Table 9. Oil classifications according to engine type Oils Engine CES20081 / CES20071 / ACEA E5 / VDS-4.5 VDS-4 VDS-3 ACEA E9 / ACEA E5 / API CI-4 API CJ-4 API CH-4 Volvo TAD 581, 881, 883, 1181 X VE Volvo TAD 571, 871, 873, 1171, X 1371 VE Volvo TAD 541, 551, 841, 851, X 853, 1141, 1151 VE Cummins QSB 6.7 T4, B 6.7, X X12 1) Cummins QSB 6.7, QSM 11 X 1) For Cummins B 6.7 and X12 engines, SAE 15W-40 must be used. Check with your oil supplier that your oil meets these demands. For engines that do not use fuel with low sulphur content, the TBN (Total Base Number) value should be at least 12 according to ASTM 2896. Check with your oil supplier that your oil meets these demands. Depending on operating conditions, and the quality of the oil and fuel, the intervals between changing the oil may vary in length. The engine oil must be replaced within a maximum operation time of one year. If the machine is parked in cold weather, the viscosity of the oil can vary according to the temperature. Therefore the ambient temperature is vital to the choice of the engine oil viscosity range (see following figure). NOTE If the machine is warm, the oil is also warm. Changing the oil due to a change in season may be avoided by using multi-grade oils. Specified intervals for changing the oil also apply to multi-grade oils. No oil additives should be added to the recommended oils. Using such additives may NOTE invalidate the engine warranty. Avoid mixing different brands of oil. The temperature ranges for adjacent SAE classes overlap, so you do not need to replace the oil when short-term temperature changes occur. To ensure trouble-free cold starts, select the SAE class according to the ambient NOTE temperature. 171/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions APPENDIX I: Fuel and oil recommendations Figure 81. Oil temperature ranges Extended oil change interval Extended oil change interval may differ when using synthetic fluids. To determine a baseline, appropriate change intervals should be determined for each engine by measuring oil oxidation and wear metals over time. Wear metals analysis can provide useful information, but an engine should not be removed from service based solely on this analysis. For more information contact Konecranes Lift Trucks, an authorized dealer, or the engine supplier. Recommended fluids and lubricants Diesel fuel It is recommended to use diesel fuel HVO 100, which complies with the following classification: • EN 15940 Class A If using other diesel fuels than HVO 100, they must comply with one of the following classifications: • EN 590 • ASTM D 975 No 1-D or 2-D For Tier 4F, stage 4 and stage 5 engines ULSD (Ultra-Low Sulfur Diesel) fuel must be used (sulphur content below 15 mg/kg). For more information, contact the engine manufacturer, or an authorized representative. As the ambient temperature falls, the flow characteristics of the diesel fuel are reduced NOTE and paraffin begins to precipitate, i.e the diesel is gelling in cold temperatures. Use the correct diesel quality according to the ambient temperature. Using additives to improve the flow is not recommended. Additives may reduce the NOTE capacity to start from cold. Biodiesel (FAME) Vegetable oil esters (Fatty Acid Methyl Esters, FAME), also called "biodiesel", are increasingly available as a blending component in diesel fuels. The engine manufacturer accepts the same FAME content as in major on-road fuels EN590 and ASTM D975. The maximum FAME content is 7%, without any specific extra service requirements. For more information, contact the engine manufacturer, or an authorized representative. Higher FAME blends negatively impact performance, emissions, and fuel consumption. It NOTE also affects negatively the function of the SCR engines exhaust after treatment system. 172/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX I: Fuel and oil recommendations Operating Instructions AdBlue solution Only use an AdBlue solution that fulfills the ISO 22241 standard. The AdBlue solution consists of deionized water that is mixed with 32.5% urea. Table 10. Engines using AdBlue solution Engine family Engine VOLVO TAD 571 VE TAD 871 / 873 VE TAD 1171 VE TAD 1371 VE TAD 581 VE TAD 881 / 883 VE TAD 1181 VE CUMMINS QSB 6.7 1) / B 6.7 / X12 1) EU stage 4 / US tier 4f Transmission oil DANA transmission: ATF Dexron III ZF transmission: Mineral oil -based engine oil (API CD/CE/CF-4/CF/CG-4/CH-4/ CI-4/SF/SG/SH/SJ/SL or ACEA, categories A, B, E). Viscosity degrees: SAE 20W-20 / 30 / 10W-30 / 10W-40 / 15W-30 / 15W-40 / 20W-40. For more information, see the ZF recommended oil list TE-ML 03. Table 11. ZF Transmission: Approved and recommended oil types Lubricant class Oil type / viscosity Temperature 03C, 03M ATF (Automatic transmission fluids) -40°C 03F UTTO in accordance with JDM 20D / John Deere Low -40°C Viscosity Hy-Gard 03E, 03G, 03H UTTO -30°C 03K SAE 0W-30, 0W-40 -40°C 03B, 03C, 03K SAE 5W-30, 5W-40 -35°C 03A, 03B, 03C, 03K SAE 10 W, 10W-30, 10W-40 -30°C 03A, 03C, 03K SAE 15W-30, 15W-40 -25°C 03A, 03C, 03K SAE 20W-20, 20W-40 -20°C 03A, 03C, 03K SAE 30 -10°C Oil change interval Drain and refill the system every 1000 h for average environmental and duty cycle conditions. Severe or sustained high operating temperature or dusty environments cause accelerated deterioration or contamination. Judgment must be used to determine the required change intervals for extreme conditions. For more information, contact your local authorized dealer. Drive axle oil Axle housing / Hub assembly / Drive Assembly API GL.5 SAE 90 173/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions APPENDIX I: Fuel and oil recommendations Table 12. Oil filling quantities Drive Width Planetary Model Brake Differential Hub axle (mm) gear FLT 10-16 D81 2274 PL478 NLB5340 19 l (5.02 US gal) 2.3 l (0.6 US gal) FLT 18-25 D91 2717 PL488 NLB4460 31 l (8.2 US gal) 3.2 l (0.8 US gal) FLT 28-33 D91 3015 PL408 NLB6460 36.5 l (9.6 US gal) 3.7 l (0.97 US gal) FLT / LCH 37-50 D102 3807 PL341 NLB8460 72 l (19 US gal) 11 l (2.9 US gal) FLT / LCH 37-50 D102 3431 PL341 NLB8460 58 l (15.3 US gal) 11 l (2.9 US gal) LCH 52 D102 4549 PL341 NLB8460 121 l (31.9 US gal) 12.5 l (3.3 US gal) FLT / LCH 52-55 D106 3807 PL341 NLB8460 85 l (22.4 US gal) 11 l (2.9 US gal) FLT 60-55 D111 4188 PL545 NLB6650-1 108 l (28.5 US gal) 12.5 l (3.3 US gal) ECH 80 D81 3218 PL478 NLB5340 39 l 10.3 US gal) 2.3 l (0.6 US gal) ECH 90/100 D81 3713 PL488 NLB6340 45 l (11.9 US gal) 3.5 l (0.9 US gal) ECH 90/100 D91 4218 PL488 NLB6340 45 l (11.9 US gal) 3.5 l (0.9 US gal) ECH 90/100 *) D91 4203 PL489 NLB4460 66 l (17.4 US gal) 3.2 l (0.8 US gal) RST 108 D81 3713 PL488 NLB6340 45 l (11.9 US gal) 3.5 l (0.9 US gal) RST 2518 D91 3015 PL408 NLB6460 36.5 l (9.6 US gal) 3.7 l (0.97 US gal) RST 4127-4638 D102 3807 PL341 NLB8460 72 l (19 US gal) 11 l (2.9 US gal) RST 4537-4644 D106 3807 PL341 NLB8460 85 l (22.4 US gal) 11 l (2.9 US gal) RST 4646 D111 4188 PL545 NLB6650-1 108 l (28.5 US gal) 12.5 l (3.3 US gal) *) = with clamped wheel rims The volumes are strictly recommendations. If you have any doubts, contact your NOTE Konecranes Lift Trucks authorized dealer for advice. Hydraulic oil For machines without separate brake cooling tank Universal Tractor transmission oil (UTTO) The oil must comply with one of the following classifications: • John Deere: JD20C • Massey Ferguson: MF1141/MF1135/ MF1143 • ZF: TE-ML 03E/TE-ML 05F/TE-ML 06K For machines with separate brake cooling tank (option) DIN 51524 Part 2 HLP and Part 3 HVLP Use hydraulic oil from a well-known oil company for mobile applications. Viscosity Temperature range SHS 32 -30°C...+10°C (-22°F...+50°F) SHS 46 -20°C...+50°C (-4°F...+122°F) SHS 68 ±0°C...+50°C (+32°F...+122°F) Brake cooling oil (option) Universal Tractor transmission oil (UTTO) The oil must comply with one of the following classifications: 174/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX I: Fuel and oil recommendations Operating Instructions • John Deere: JD20C • Massey Ferguson: MF1141/MF1135/ MF1143 • ZF: TE-ML 03E/TE-ML 05F/TE-ML 06K Grease Multipurpose type E.P. according to NLGI Grade 2. Coolant WARNING HARMFUL SUBSTANCE HAZARD Using wrong coolant may damage the machine. Use the recommended coolant and never mix different coolants. WARNING TOXIC SUBSTANCE HAZARD It is highly dangerous to drink ethylene glycol. Contact with skin or spray from the refill can cause skin irritation and eye damage. Do not drink ethylene glycol and avoid contact with skin. Use only ethylene glycol-based coolants with an additive that prevents corrosion. Do not mix different coolant types with each other. Do not mix the coolant with antifreeze that contains ethanolamine. Table 13. Coolants for Volvo engines Engine Coolant VOLVO TAD 541, 551 VE VOLVO TAD 571 VE VOLVO TAD 581 VE VOLVO TAD 841 VE VOLVO TAD 851 VE VOLVO TAD 871, 873 VE Volvo Penta Coolant VCS-2 and VCS-2 Ready Mixed VOLVO TAD 881, 883 VE VOLVO TAD 1141, 1151 VE VOLVO TAD 1171 VE VOLVO TAD 1181 VE VOLVO TAD 1371 VE Table 14. Coolants for Cummins engines Engine Coolant CUMMINS QSB 6.7-C240 CUMMINS B 6.7 To comply with Cummins CES 14603 CUMMINS QSM 11-C335 Recommended: Cummins ES Compleat EG CUMMINS X12 175/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions APPENDIX I: Fuel and oil recommendations Liquid antifreeze at the lowest Percentage of volume mixture liquid Mixture of antifreeze and water temperature antifreeze -12°C (10.4°F) 25 1:3 -18°C (-0.4°F) 30 1:2 -25°C (-13°F) 40 1:1.5 -37°C (-34.6°F) 50 1:1 -60°C (-76°F) 66 2:1 176/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX II: Fuses and relays Operating Instructions APPENDIX II: FUSES AND RELAYS Fuses Fuses are located behind the operator's seat in the cabin and in the battery compartment on the right side of the machine. Figure 82. Location of fuses 101 121 141 163 185 190 120 140 162 184 Figure 83. Numbering order of the fuses 177/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions APPENDIX II: Fuses and relays Table 15. Fuses and their function (Functions may vary depending on machine model and chosen options) Number Size Function F101 7.5 A Cabin heating F102 7.5 A Option F103 7.5 A Option F104 7.5 A Central lubr. pump chassis F105 10 A Converter 12-V option F106 7.5 A Reverse light F107 7.5 A Working light extra 2 F108 7.5 A PCB 48-PIN STD D F109 7.5 A PCB 48-PIN STD D F110 7.5 A PCB 48-PIN STD D F111 7.5 A PCB 48-PIN STD D F112 7.5 A Clutch for HVAC compressor F113 5A Position light right F114 5A Position light left F115 7.5 A High beam F116 7.5 A Low beam F117 15 A Seat suspension air compressor F118 7.5 A Reverse alarm in the front F119 7.5 A Working lights extra 1 F120 10 A Option F121 7.5 A Working light mast, right F122 7.5 A Working light mast, left F123 10 A Main fuse for the lights, F115 and F116 F124 5A ACR RFID keyless ignition F125 5A Battery clock (RTC) F126 7.5 A Ignition F127 7.5 A Beacon F128 7.5 A Power supply controller F129 7.5 A Hazard F130 10 A HV/AC condensor blower 1 F131 10 A HV/AC condensor blower 2 F132 10 A HV/AC condensor blower 3 F133 7.5 A K128 Door open switch F134 5A Reading light F135 15 A Rear window heating F136 7.5 A RCU F137 7.5 A Diagnostic, PCB connector F138 7.5 A CAN extra, PCB connector F139 5A Turn signal F140 7.5 A PCB 48-PIN STD D F141 7.5 A PCB 48-PIN STD D F142 7.5 A Rearview mirror heater F143 5A I/O units in the armrest, XC21, XC21 OPT C1, XC21 OPT C2 F144 7.5 A Seat heater F145 7.5 A MD4 178/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX II: Fuses and relays Operating Instructions Table 15. Fuses and their function (Functions may vary depending on machine model and chosen options) (Continued) Number Size Function F146 5A TRUCONNECT® modem F147 5A RFID nearguard 2 F148 5A Tire pressure gateway F149 10 A Connection for computer F150 5A RFID nearguard 1 F151 7.5 A Main fuse for position light (F113, F114) and brake lights F152 5A Alcohol ignition interlock F153 10 A 24 V dashboard F154 5A GSM G2 modem F155 10 A 12 V reverse camera F156 10 A 12 V dashboard F157 10 A 24 V roof F158 7.5 A Converter roof F159 10 A 12 V roof F160 7.5 A 12 V radio F161 15 A Working light roof (option) F162 15 A Working light roof (option) F163 10 A Wiper rear/roof/front washer F164 7.5 A PCB 48-PIN STD E F165 7.5 A PCB 48-PIN STD E F166 7.5 A Converter F167 7.5 A Converter 2 rear wall F168 15 A Horn F169 7.5 A PCB 48-PIN STD E F170 7.5 A PCB 48-PIN STD E F171 7.5 A PCB 48-PIN STD E F172 7.5 A PCB 48-PIN STD E F173 7.5 A Fuel heater F174 7.5 A Option F175 7.5 A Option F176 15 A Electrical seat column F177 7.5 A Option F178 7.5 A Particle detecting monitor (PDM) F179 10 A XA2 OPT, external expansion unit in the chassis F180 10 A XA2-STD, external expansion unit in the chassis F181 10 A Connection for computer F182 7.5 A Reverse camera F183 5A HVAC controller F184 15 A HVAC blower F185 3A Spare fuse F186 5A Spare fuse F187 7.5 A Spare fuse F188 10 A Spare fuse F189 15 A Spare fuse F190 - Fuse test 179/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions APPENDIX II: Fuses and relays Fuses and relays in the battery compartment DANGER EXPLOSION HAZARD Short-circuiting the battery may cause a fire or explosion, which can cause a risk for serious injury or death. DANGER CORROSIVE SUBSTANCE HAZARD The battery contains corrosive acid that may cause a risk for serious injury or death. Always use the necessary protective equipment. DANGER EXPLOSION HAZARD Batteries generate explosive hydrogen when charged, or when being jump-started, which may cause a risk for serious injury or death. Always use the necessary protective equipment. Ensure that there is good ventilation and avoid sparking. WARNING ELECTRICAL HAZARD The battery main switch disconnect does not cut the power to the alternator. To reduce the risks of electric shock and personal injury always remove jewelry and conductive material before working on the electrical system. Always disconnect the ground (minus) cable at the battery when working near or on the alternator. WARNING TIPPING OVER HAZARD Turning off the battery main switch while the machine is moving applies the parking brake and the machine may tip over. The software in the control unit can get damaged. Do not turn it off while the engine is running. 180/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX II: Fuses and relays Operating Instructions 1 3 2 1 Figure 84. Fuses and relays in the battery compartment 1. Fuses F51–F58, F71-78, F92-F98 (1) 2. Relay K32 (2), behind the three fuse lines 3. Fuses F61-F62, F80 Figure 86. Numbering order of the fuses Table 16. Fuses and their functions (Functions may vary depending on machine model and chosen options) Number Size Function F51 10 A MD4 internal clock (IQAN-MD4 RTC) F52 20 A Starter for Scania DC13 EU4/Cummins QSB (15A) F53 20 A Scania DC13 EU4 AdBlue control unit/Cummins QSB (15 A) F54 7.5 A Cummins QSB (15 A) F55 7.5 A Fuel heater (Cummins 20A) F56 7.5 A TCU battery power supply (DANA) F57 20 A Scania DC13 EU4, VOLVO 660/760 (10A) /Cummins QSB (15A) F58 20 A Scania DC13 EU4/Cummins QSB (15A) 181/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions APPENDIX II: Fuses and relays Table 16. Fuses and their functions (Functions may vary depending on machine model and chosen options) (Continued) Number Size Function F61 100 A Main fuse 15 ignition F62 60 A Main fuse 30 battery F71 7.5 A Option F72 7.5 A Option (fuel shut-off) (seat suspension air compressor 15 A) F73 7.5 A Option F74 10 A Engine ignition F75 7.5 A DANA/ZF transmission control unit (TCU) ignition power supply F76 25 A Hydraulic oil cooler F77 20 A Scania DC13 EU4 exhaust gas recirculation valve (EGR) F78 - Option F80 70 A Cummins engine starter F81 100 A Cummins intake air heater F91 10 A Attachment lights F92 10 A Chassis 48-pin STD F F93 10 A Chassis 48-pin STD F F94 10 A Chassis 48-pin STD F F95 10 A Chassis 48-pin STD F F96 10A Chassis 48-pin STD F F97 10A Chassis 48-pin STD F F98 10 A Power supply, attachment Relays Relays K32, K35, and K36 are mounted next to the main fuses in the battery compartment. K101-K135 are mounted behind the operator seat in the cabin. Figure 87. Relay location K101-K135 182/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX II: Fuses and relays Operating Instructions 135 117 118 119 120 121 122 123 124 116 115 125 126 114 127 128 113 129 130 112 131 132 111 133 134 110 109 108 107 104 103 102 101 106 105 Figure 88. Relays K101-135 Table 17. Relay functions (Functions may vary depending on machine model and chosen options) Number Function K31 Volvo 620, 722, Engine starter K32 Q1 ignition K33 Ground support for K31 K35 Engine shut-off for Volvo engines (Engine starter Cummins QSB and QSM) K36 Fuel heater K63 Starter lockout Cummins K64 Intake air heater Cummins K65 DEF hose heating 1 Cummins K66 DEF hose heating 2 Cummins K67 DEF hose heating 3 Cummins K68 DEF heater relay K101 Pre-heating power supply for HVAC (heating, ventilation, air-conditioning) K102 Signal for HVAC (heating, ventilation, air-conditioning), engine running with cabin doors closed K103 Brake lights K104 Inverted road light (turnable seat) K105 ACR RFID keyless ignition 183/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Operating Instructions APPENDIX II: Fuses and relays Table 17. Relay functions (Functions may vary depending on machine model and chosen options) (Continued) Number Function K106 Working light mast F121 and F122 K107 Working light extra 1 K108 Front alarm K109 Door switch K110 Low beam K111 High beam K112 Clutch for HVAC compressor K113 Blinker right K114 Blinker left K115 Working light extra 2 K116 Backup Light/Right K117 Central lubrication pump chassis K118 Option K119 Option K120 RCU 3 K121 Working light roof F161, F162 K122 Windshield wiper motor roof K123 Windshield wiper motor rear K124 Rear/front window washer motor K125 Rear window heating K126 Windshield wiper motor front, 1st speed K127 Rear/front window washer motor K128 Windshield wiper motor front, 2nd speed K129 Horn K130 Fuel heater K131 RCU 1 K132 RCU 2 K133 Option K134 Communication radio K135 Hazard K201 Attachment lights (opt) 184/184 DOC2730881A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved.  Maintenance Instructions Forklift SMV 10-65, Gen C MIFLTC_RevE Original Instructions 24 May 2024 Document ID: DOC2726785A / en-US This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Internal reference: X166890 en-US / E Contact information Contact the manufacturer’s local representative or Konecranes Lifttrucks AB Anders Anderssons väg 13 285 35 Markaryd SWEDEN Tel. +46 433 733 00 For UK, contact: Konecranes Demag UK Ltd Coalfield Way LE65 1NF Asby De La Zouch UNITED KINGDOM www.kclifttrucks.com Table of contents Maintenance Instructions TABLE OF CONTENTS 1 INTRODUCTION.............................................................................................................9 1.1 About this document.................................................................................................... 9 1.1.1 Use of the document......................................................................................... 9 1.1.2 Terminology.......................................................................................................9 1.1.3 Abbreviations.................................................................................................. 10 1.1.4 Copyright notice.............................................................................................. 11 1.1.5 Available technical documents........................................................................ 11 1.1.6 Feedback on documents................................................................................. 11 1.2 About this product...................................................................................................... 12 1.2.1 Use of the product ..........................................................................................12 1.2.2 Conditions of warranty.................................................................................... 12 1.2.3 Identification of the product............................................................................. 13 1.2.4 Standards and directives.................................................................................14 1.2.5 Declaration of conformity.................................................................................15 2 SAFETY AND ENVIRONMENT.................................................................................... 17 2.1 Safety messages and symbols.................................................................................. 17 2.1.1 Signal words................................................................................................... 17 2.1.2 Hazard symbols.............................................................................................. 17 2.1.3 Mandatory action symbols...............................................................................20 2.1.4 Prohibited action symbols............................................................................... 21 2.1.5 Safety and information labels on the product...................................................21 2.1.6 Location of the safety and information labels...................................................22 2.2 Responsibilities of the operational manager............................................................ 28 2.2.1 Preventing work-related hazards.....................................................................28 2.2.2 Preventive maintenance..................................................................................28 2.2.3 Personal protective equipment........................................................................ 29 2.2.3.1 Fall protection............................................................................................. 30 2.2.4 Incident reporting............................................................................................ 30 2.3 Limitations of the product.......................................................................................... 31 2.3.1 Operating conditions....................................................................................... 31 2.3.2 Inclination angles............................................................................................ 31 2.3.3 Lift truck danger zones, general...................................................................... 32 2.3.4 Tire explosion danger zone............................................................................. 32 2.3.5 Prohibited use................................................................................................. 34 2.3.6 Changes to the product................................................................................... 34 2.4 Emissions.................................................................................................................... 36 2.4.1 Noise...............................................................................................................37 2.4.2 Vibration .........................................................................................................37 2.5 Protective measures................................................................................................... 38 2.5.1 Emergency stopping....................................................................................... 38 2.5.2 Battery main switch......................................................................................... 39 2.5.3 Releasing the hydraulic pressure ................................................................... 41 2.5.4 Fire safety....................................................................................................... 41 2.5.5 Emergency exits..............................................................................................42 2.5.6 Mounting, and dismounting the machine......................................................... 43 2.5.7 Locking the cabin door in open position.......................................................... 43 2.5.8 Personnel requirements.................................................................................. 44 2.6 Environmental information.........................................................................................45 2.6.1 Energy consumption....................................................................................... 45 2.6.2 Product lifecycle stages...................................................................................45 2.6.2.1 Production of materials and components.................................................... 46 2.6.2.2 Equipment manufacturing and assembly.....................................................46 3/262 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Maintenance Instructions Table of contents 2.6.2.3 Use phase, including maintenance and modernization................................47 2.6.2.4 Dismantling and handling waste material.................................................... 47 2.6.2.5 Deliveries between each stage....................................................................48 2.6.3 Notice on the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH)....................................................................................... 49 2.7 Storage information.................................................................................................... 49 2.7.1 Storage........................................................................................................... 49 2.7.2 Alternative storage, up to two months............................................................. 50 2.7.3 Alternative storage, longer than two months....................................................51 3 TRANSPORT AND TOWING........................................................................................53 3.1 Lifting the machine - General safety..........................................................................53 3.2 Lifting points SMV 10-25.............................................................................................54 3.3 Lifting points SMV 28-65.............................................................................................55 3.4 Rear top lifting ears SMV 10-25 (option)....................................................................56 3.5 Lifting the machine without the mast........................................................................ 58 3.6 Lifting the mast........................................................................................................... 59 3.7 Towing..........................................................................................................................60 3.8 Transportation.............................................................................................................60 3.8.1 Securing the rear end......................................................................................61 3.8.2 Securing the front end - machines without mast..............................................61 3.8.3 Securing the front end - machines with mast...................................................62 4 SERVICE AND MAINTENANCE INSTRUCTIONS....................................................... 63 4.1 Maintenance safety information.................................................................................63 4.2 Reset service hour counter........................................................................................ 64 4.3 RFID - Adding an operator (option)............................................................................65 4.4 Electric welding...........................................................................................................68 4.5 Jump-starting.............................................................................................................. 69 4.6 Tilting the cabin...........................................................................................................70 4.6.1 Manual cabin tilting......................................................................................... 71 4.6.2 Electrical cabin tilting (option)..........................................................................72 4.7 Releasing the hydraulic accumulator pressure........................................................ 73 4.8 Changing the wheels.................................................................................................. 74 4.8.1 Before changing the wheels............................................................................ 74 4.8.2 Positioning the jack......................................................................................... 75 4.8.3 Deflating the tire..............................................................................................76 4.8.4 Inflating the tire............................................................................................... 78 4.8.5 Dismantling the outer drive wheel, general......................................................80 4.8.5.1 Dismantling the outer drive wheel, wheels without clamp units....................80 4.8.5.2 Dismantling the outer drive wheel, wheels with clamp units........................ 81 4.8.6 Dismantling the inner drive wheel....................................................................82 4.8.7 Mounting the inner drive wheels......................................................................83 4.8.8 Mounting the outer drive wheel....................................................................... 83 4.8.8.1 Mounting the outer drive wheel, wheels without clamp units....................... 83 4.8.8.2 Mounting the outer drive wheel, wheels with clamp units............................ 84 4.8.9 Dismantling the steer wheel, general...............................................................86 4.8.9.1 Dismantling the steer wheels, wheels without clamp units...........................86 4.8.9.2 Dismantling the steer wheels, wheels with clamp units............................... 87 4.8.10 Mounting the steer wheels.............................................................................. 88 4.8.10.1 Mounting the steer wheels, wheels without clamp units.............................. 88 4.8.10.2 Mounting the steer wheels, wheels with clamp units................................... 89 4.9 Tightening the bolted joints....................................................................................... 90 4.9.1 Tightening torque............................................................................................ 90 4/262 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Table of contents Maintenance Instructions 4.9.2 Tightening the wheel nuts................................................................................91 4.9.3 Tightening the bolts in the propshaft................................................................92 4.9.4 Tightening the bolts in the engine and transmission mounting.........................93 4.9.5 Tightening the bolts in the drive axle suspension............................................ 94 4.9.6 Tightening the bolts in the hydraulic pumps.....................................................95 4.9.7 Tightening the bolts in the cabin suspension................................................... 95 4.9.8 Tightening the bolts in the counterweights.......................................................97 4.9.9 Tightening the bolts in the steer axle............................................................... 98 4.10 Lubricating the machine.............................................................................................98 4.10.1 General lubrication rules................................................................................. 98 4.10.2 Lubricating the steer axle................................................................................ 99 4.10.3 Lubricating the hinges................................................................................... 100 4.11 Lubricating the mast................................................................................................. 101 4.12 Lubricating the fork rollers.......................................................................................102 4.13 Lubricating the attachment...................................................................................... 103 4.13.1 Attachment lubrication points - ELME 815 Toplift...........................................103 4.13.2 Lubricating the wear pads for main beams and extending beams................. 104 4.13.3 Lubricating extension beams and twistlocks..................................................104 4.13.4 Lubricating extension cylinder support wear pads and tracks........................ 104 4.13.5 Lubricating the fork frame - ELME 815.......................................................... 105 4.13.6 Lubricating stop cylinders - ELME 815 (option)............................................. 106 4.14 Maintenance common to all engines....................................................................... 106 4.14.1 Cleaning and draining the fuel tank, all engines............................................ 106 4.14.2 Cleaning the engine air filter's coarse separator............................................107 4.14.3 Cleaning and changing the engine air filter, all engines................................. 109 4.14.4 Changing the safety cartridge, all engines..................................................... 111 4.14.5 Checking the air intake system, all engines................................................... 112 4.14.6 Checking the coolant system, Volvo engines.................................................113 4.14.7 Checking the coolant system, Cummins engines...........................................114 4.14.8 Changing the coolant, Volvo engines.............................................................115 4.14.9 Changing the coolant, Cummins engines...................................................... 117 4.14.10 Cleaning the radiator, intercooler, and oil coolers, all engines........................119 4.14.11 Checking the valve clearance, all engines.....................................................120 4.14.12 Checking the fuel system and fuel injectors, all engines................................120 4.14.13 Checking the exhaust system, all engines.....................................................121 4.15 Maintaining the Volvo engines................................................................................. 122 4.15.1 Bleeding the fuel system: Volvo 5- and 8-liter engines.................................. 122 4.15.2 Bleeding the fuel system: Volvo 11 and 13-liter engines................................ 123 4.15.3 Draining the fuel prefilter: Volvo 5- and 8-liter engines.................................. 127 4.15.4 Draining the fuel prefilter: Volvo 11- and 13-liter engines...............................128 4.15.5 Changing the fuel prefilter: Volvo 5- and 8-liter engines.................................129 4.15.6 Changing the fuel prefilter: Volvo 11- and 13-liter engines ............................ 130 4.15.7 Changing the fuel filter: Volvo 5- and 8-liter engines......................................132 4.15.8 Changing the fuel filter: Volvo 11- and 13-liter engines ................................. 134 4.15.9 Changing the AdBlue filters, Volvo................................................................ 135 4.15.9.1 Changing the AdBlue pump filter...............................................................135 4.15.9.2 Changing the AdBlue breather filter...........................................................138 4.15.9.3 Changing the AdBlue armature (level) filter............................................... 139 4.15.10 Changing the Volvo engine oil....................................................................... 141 4.15.11 Changing the engine oil filter: Volvo 5- and 8-liter engines............................ 142 4.15.12 Changing the engine oil filter: Volvo 11- and 13-liter engines.........................143 4.15.13 Changing the crankcase breather filter..........................................................144 4.15.14 Checking the Volvo drive belt........................................................................ 146 4.15.15 Checking the Volvo vibration damper............................................................ 148 4.15.16 Checking the Volvo water pump.................................................................... 148 4.16 Maintaining the Cummins engines.......................................................................... 149 5/262 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Maintenance Instructions Table of contents 4.16.1 Bleeding the fuel system - QSB 6.7...............................................................150 4.16.1.1 Bleeding the fuel prefilter - QSB 6.7 and B 6.7.......................................... 150 4.16.1.2 Bleeding the distributor pump - QSB 6.7................................................... 152 4.16.1.3 Bleeding the fuel filter - QSB 6.7 and B 6.7............................................... 153 4.16.2 Bleeding the fuel system - QSM 11............................................................... 155 4.16.3 Bleeding the fuel system - X12......................................................................156 4.16.3.1 Bleeding the fuel prefilter - X12................................................................. 156 4.16.3.2 Bleeding the fuel filter - X12...................................................................... 157 4.16.4 Draining the fuel prefilter - X12......................................................................158 4.16.5 Changing the fuel prefilter - QSB 6.7 and B 6.7.............................................160 4.16.6 Changing the fuel prefilter - X12....................................................................162 4.16.7 Changing the AdBlue filters, Cummins.......................................................... 163 4.16.7.1 Changing the AdBlue pump filter...............................................................135 4.16.7.2 Changing the AdBlue pump filter, B 6.7 and X12.......................................167 4.16.7.3 Changing the AdBlue tank filter................................................................. 168 4.16.8 Changing the Cummins engine oil.................................................................171 4.16.9 Changing the Cummins engine oil filter......................................................... 173 4.16.10 Changing the Cummins fuel filter.................................................................. 175 4.16.11 Checking the Cummins drive belt..................................................................177 4.16.12 Checking the Cummins cooling fan............................................................... 180 4.16.13 Checking the Cummins vibration damper...................................................... 182 4.16.14 Checking the Cummins water pump..............................................................182 4.17 Maintaining the DANA transmissions......................................................................183 4.17.1 Changing the DANA transmission oil.............................................................183 4.17.2 Changing the DANA transmission oil filter..................................................... 186 4.17.2.1 DANA TE17 transmission oil filter............................................................. 186 4.17.2.2 DANA TE14 and TE30 transmission oil filter............................................. 187 4.17.3 Checking the DANA transmission breather................................................... 188 4.17.4 Calibrating the DANA transmission............................................................... 189 4.17.4.1 Heating up the DANA transmission........................................................... 189 4.17.4.2 Activating the DANA transmission calibration............................................191 4.18 Maintaining the ZF transmissions............................................................................192 4.18.1 Changing the ZF transmission oil.................................................................. 193 4.18.2 Changing the ZF transmission oil filter.......................................................... 194 4.18.2.1 Changing the ZF 191 transmission oil filter................................................194 4.18.2.2 Changing the ZF 261/311 transmission oil filter......................................... 194 4.18.3 Checking the ZF transmission breather.........................................................196 4.18.4 Calibrating the ZF transmission.....................................................................196 4.18.4.1 Heating up the ZF transmission.................................................................196 4.18.4.2 Activating the ZF transmission calibration................................................. 197 4.19 Maintaining the drive axle.........................................................................................198 4.19.1 Checking the drive axle oil level.................................................................... 198 4.19.2 Changing the drive axle oil............................................................................ 199 4.19.2.1 Changing the drive axle oil - hub............................................................... 199 4.19.2.2 Changing the drive axle oil - differential.....................................................200 4.19.3 Checking the drive axle breather...................................................................200 4.19.4 Measuring the parking brake pressure.......................................................... 201 4.19.5 Adjusting the parking brake...........................................................................202 4.19.6 Manually releasing the parking brake............................................................ 203 4.19.7 Bleeding the parking brake............................................................................204 4.20 Maintaining the steer axle.........................................................................................205 4.20.1 Checking the steer axle bearings.................................................................. 205 4.20.2 Adjusting the wheel bearings.........................................................................206 4.20.3 Adjusting the spindle bearings.......................................................................207 4.21 Maintaining the hydraulic system............................................................................ 208 4.21.1 Changing the hydraulic oil ............................................................................ 208 4.21.2 Starting the hydraulic pumps......................................................................... 209 6/262 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Table of contents Maintenance Instructions 4.21.3 Changing the hydraulic oil filter..................................................................... 210 4.21.4 Hydraulic long life (HLL) filter (option)........................................................... 213 4.21.4.1 Placement of the hydraulic long life (HLL) filter......................................... 213 4.21.4.2 Checking the HLL filter.............................................................................. 214 4.21.4.3 Changing the hydraulic long life (HLL) filter (option).................................. 214 4.21.5 Changing the hydraulic tank breather filter.................................................... 217 4.21.5.1 Replace filter element in the breather filter housing...................................218 4.21.6 Changing the brake cooling oil ..................................................................... 218 4.21.7 Changing the brake cooling oil filter ..............................................................219 4.21.8 Changing the breather filter for the brake cooling oil tank .............................219 4.22 Maintaining the mast and fork carriage................................................................... 220 4.22.1 Checking the mast and fork carriage............................................................. 220 4.22.2 Checking the fork arms................................................................................. 221 4.22.3 Checking the clearance between the mast and fork carriage........................ 222 4.22.4 Checking the fork shaft system (option)........................................................ 222 4.22.5 Checking the lift chains................................................................................. 223 4.22.6 Adjusting the lift chains..................................................................................224 4.23 Maintaining the machine.......................................................................................... 225 4.23.1 Cleaning the machine....................................................................................225 4.23.2 Changing the internal cabin air filter.............................................................. 226 4.23.3 Changing the external cabin air filter............................................................. 227 4.23.4 Checking the battery..................................................................................... 228 4.23.5 Changing the batteries.................................................................................. 229 4.23.6 Checking the weld constructions................................................................... 232 4.23.7 Changing the windshield wipers.................................................................... 232 5 MAINTENANCE SCHEDULE..................................................................................... 233 5.1 Commissioning inspection.......................................................................................233 5.2 Commissioning service............................................................................................ 233 5.3 Daily maintenance ....................................................................................................233 5.4 Maintenance points after the first 150 operating hours......................................... 235 5.5 Regular service......................................................................................................... 236 5.6 Maintenance data...................................................................................................... 248 APPENDIX I: FUEL AND OIL RECOMMENDATIONS........................................................... 249 Quality of the engine oil...............................................................................................249 Extended oil change interval....................................................................................... 250 Recommended fluids and lubricants............................................................................250 APPENDIX II: FUSES AND RELAYS..................................................................................... 255 Fuses.......................................................................................................................... 255 Relays.........................................................................................................................260 7/262 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. Maintenance Instructions Table of contents 8/262 This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved. 1 Introduction Maintenance Instructions 1 INTRODUCTION 1.1 About this document This maintenance instruction offers guidance to enable safe and efficient maintenance of the equipment. Taking the time to read this document helps to prevent damage to the equipment, and, most importantly, keep the personnel safe. The equipment is safe when used correctly. However, there are many potential hazards that are associated with incorrect operation and maintenance. These hazards can be avoided with knowledge about how to recognize and anticipate them. This document increases the awareness of the responsibilities regarding the equipment. Following the content of this document will ensure that the equipment is kept in a safe operating condition throughout its lifetime. This document is not intended as a substitute for proper training but provides recommendations and methods for safe and efficient operation and maintenance. The operational manager must ensure that operators are properly trained before operation. They must always comply with all the applicable and prevailing safety, as well as other standards, rules, and regulations. 1.1.1 Use of the document Every person that is exposed to the equipment must, before operating, servicing and maintaining such products, read, and understand the contents of this document. Also to strictly adhere and conform their conduct with and to the information, recommendations, and warnings that are provided in this document. NOTE Keep the maintenance instructions in a safe and accessible location for future reference. WARNING IGNORING INSTRUCTIONS HAZARD Failure to follow the given instructions could cause death or serious injury. Read and understand the contents of this document before operating, servicing, and maintaining the equipment. The manufacturer makes absolutely no warranty whatsoever regarding the contents of this document, express or implied, whether arising by operation of law or otherwise. This includes, but are not limited to, any implied warranties of merchantability or fitness for a particular purpose. 1.1.2 Terminology All brand names, product names, and trademarks that are used in this document are registered trademarks of their respective owners. The following terms and definitions may have been used in this document: 9/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 1 Introduction Authorized dealer Company, or person authorized by Konecranes Lifttrucks AB to carry out service actions, and represent the manufacturer. Authorized Persons who have the necessary training and who are authorized by personnel Konecranes Lifttrucks AB or their representative to carry out operation, or service actions. Manufacturer Refers to Konecranes Lifttrucks AB, or supplier of part when otherwise specificed. Operational Person, or persons, with different areas of responsibility at the working manager site where the machine is used. The areas of responsibility include, but are not limited to risk assessments, daily operations and maintenance tasks. Battery A compartment containing the 24V batteries and fuses, which are compartment found on the right side of the machine. CE marking The CE marking of the machine is displayed on the lifting capacity plate. The symbol indicates that the machine complies with the appropriate CE regulations. Check A visual and functional assessment (not a test) of the machine without dismantling it. Touch screen A touch screen where the user receives information, and enter display commands by touching designated areas on the screen. TRUCONNECT® TRUCONNECT® is a suite of remote service products and applications to support maintenance operations and drive improvements in safety and productivity. The collected data from the machines can be viewed at yourKONECRANES customer portal. 1.1.3 Abbreviations The following abbreviations and shortenings can occur in this document: Abbreviation Description Abbreviation Description Automated determination of the filling paramaters AEB LV Low Voltage (Automatisiertes Ermitteln der Befüllparameter) COG Center Of Gravity NCD Nox Control Diagnostics DEF Diesel Exhaust Fluid PCB Printed Circuit Board DOC Diesel Oxidation Catalyst PCD Particle Control Diagnostics Personal Protective DPF Diesel Particulate Filter PPE Equipment Engine After-treatment EATS PPS Power Pile Slope System Radio Frequency ECM Engine Control Module RFID Identification Electric Magnetic EMC SCR Selective Catalyst Reduction Compatibility FGO Function Group Output SWL Safe Working Load 10/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 1 Introduction Maintenance Instructions Abbreviation Description Abbreviation Description Tire Pressure Monitoring HLL Hydraulic Long-Life TPMS System Heating, ventilation, and air HVAC ULSD Ultra-Low Sulphur Diesel conditioning International Organization for ISO VCU Vehicle Control Unit Standardization LC Load Center 1.1.4 Copyright notice This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Konecranes © 2024. All rights reserved. 1.1.5 Available technical documents For this equipment, there are technical documents that serve different purposes and audiences. Contact your supplier if you require any of the documents that are listed here. Operating instructions Describes the responsibilities of the operator and the operating instructions, along with some mandatory daily maintenance tasks and safety information. The operating instruction must be stored in the cabin of the truck. Maintenance instructions Describes maintenance tasks such as lubrication and oil change and the recommended safety instructions. Technical instructions Describes in greater detail the hydraulic and electrical systems, vehicle control unit, and other components of the machine and its software. Spare part catalogue Includes part numbers of all components for the supplied parts, drawings, and exploded views. Supplier documentation Describes components that are assembled on the machine, and provided by approved suppliers to the manufacturer. This includes component-specific documents, for example, for installation, operation, and maintenance. NOTE Store documents in a safe, dry place where they can be easily located when required. 1.1.6 Feedback on documents As the goal is constant improvement, this document may be updated or revised to provide operational managers and maintenance personnel with the most accurate information currently available. Current versions of instructions can be found at document portal www.kclifttrucks.com. To communicate any inaccuracies or omissions, or to provide general feedback or suggestions regarding the quality of this document, send an email to [email protected]. 11/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 1 Introduction 1.2 About this product 1.2.1 Use of the product The machine is designed to perform lifting and transporting of loads within the limits that are specified in the machine's lifting capacity plate. For more information, see the machine's lifting capacity plate in front of the left side cabin door. Contact the manufacturer or manufacturer's representative in case of doubt. 1.2.2 Conditions of warranty The terms under which seller's equipment and/or services are warranted are defined pursuant to the warranty set forth in the contract between seller and customer for seller's products and/or services and, if not so set forth, the warranty for seller's products and/or services is seller's standard warranty in effect at the time of sale, a copy of which is available from seller upon request. THE FOREGOING REPRESENTS THE SOLE AND EXCLUSIVE WARRANTY GIVEN BY SELLER AND IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, ARISING BY OPERATION OF LAW OR OTHERWISE, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Seller provides no warranties for products manufactured or services provided by parties other than seller ("Third Party Products"). Third Party Products may be warranted separately by their respective manufacturers or such other parties from whom seller purchases such Third Party Products and seller shall, to the extent possible, assign to you whatever rights seller may obtain under any such warranties. Modifying any seller product or incorporating any Third Party Product into any seller product or service without the seller's approval invalidates the warranty. Seller does not accept, shall not have any responsibility and disclaims any liability for accidents, injury or physical or property damage arising as a consequence of such unauthorized modifications and/or incorporation of Third Party Products. Further, each of the following invalidates any warranty of seller and relieves seller from any responsibility to repair or replace any seller product due to a failure to operate and/or maintain seller products in accordance with the applicable manuals, instructions, guides, recommendations, and any other manuals, guidelines or recommendations of seller concerning the maintenance and operation of seller products that may be communicated to you from time to time; damage or defects caused by side-pulling of load, shock loading, excessive jogging, eccentric loading or overloading, accidental occurrence, improper repair, improper handling or storage of products, chemical exposure, abnormal operating conditions, or any other cause that in seller's sole discretion is not attributable to defects in the material and workmanship of seller’s product. The applicable seller manuals, instructions, guidelines, and recommendations must be strictly complied with by customer which may include, by way of example and not by limitation, installation and commissioning instructions, owner's manuals, operator's/user’s manuals, operating and maintenance instructions and user's guides. SELLER SHALL HAVE NO LIABILITY TO YOU OR ANY END USER OF PRODUCTS FOR LOST PROFITS OR FOR INDIRECT, SPECIAL, CONSEQUENTIAL, EXEMPLARY OR INCIDENTAL DAMAGES OF ANY KIND WHETHER ARISING IN, CONTRACT, TORT, PRODUCT LIABILITY, STRICT LIABILITY OR OTHERWISE, EVEN IF SELLER WAS ADVISED OF THE POSSIBILITY OF SUCH LOST PROFITS OR DAMAGES. SELLER’S LIABILITY IS LIMITED TO THE AMOUNT OF YOUR DIRECT DAMAGES UP TO THE AMOUNT OF THE CONTRACT PRICE AND IN NO EVENT SHALL SELLER BE LIABLE TO YOU FOR ANY DAMAGES WHATSOEVER IN EXCESS OF THE TOTAL PRICE PAID BY YOU FOR THE APPLICABLE SELLER PRODUCTS. YOU HEREBY WAIVE ANY CLAIM THAT THE EXCLUSIONS OR LIMITATIONS IDENTIFIED HEREIN DEPRIVE YOU OF AN ADEQUATE REMEDY OR CAUSES YOUR AGREEMENT WITH SELLER TO FAIL OF ITS ESSENTIAL PURPOSE. YOU SHALL BE ENTITLED TO NO OTHER REMEDY OTHER THAN THOSE IDENTIFIED IN THE CONTRACT BETWEEN YOU AND SELLER OR SELLER’S STANDARD 12/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 1 Introduction Maintenance Instructions WARRANTY, WHICHEVER IS APPLICABLE, WITH RESPECT TO THE PROVISION OF PRODUCTS BY SELLER REGARDLESS OF THE FORM OF CLAIM OR CAUSE OF ACTION, WHETHER BASED IN AGREEMENT, NEGLIGENCE, STRICT LIABILITY OR OTHERWISE. UNLESS OTHERWISE REQUIRED BY MANDATORY LAW, SELLER DISCLAIMS ALL WARRANTIES RELATING TO THE CONTENTS OF THIS DOCUMENT, EXPRESS OR IMPLIED, ARISING BY OPERATION OF LAW OR OTHERWISE. 1.2.3 Identification of the product 1 2 3 4 5 6 7 8 Figure 1. Plates and serial numbers 1. Mast serial number 6. Transmission serial number 2. Lifting capacity plate 7. Engine serial number 3. Fork carriage number 8. Steer axle serial number 4. Drive axle serial number 5. Chassis serial number (punched into the frame) NOTE The appearance may deviate from the delivered product depending on model size. 13/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 1 Introduction 1.2.4 Standards and directives This product has been designed and manufactured to conform to the following standards and directives: • Health and safety: EU: Machinery directive 2006/42/EC UK: Supply of Machinery (Safety) Regulations 2008 S.I. 2008:1597 ◦ EN ISO 3691-1:2015/A1:2020. "Industrial trucks – Safety requirements and verification - Part 1: Self-propelled industrial trucks, other than driverless trucks, variable-reach trucks, and burden-carrier trucks". ◦ ISO/TS 3691-8:2012,IDT. Industrial trucks – Safety requirements and verification. Regional requirements for countries outside the EC. ◦ EN 16307-1:2013+A1:2015. "Safety requirements and verification. Supplementary requirements for self-propelled industrial trucks, other than driverless trucks, variable-reach trucks, and burden-carrier trucks" (EU/EFTA market). ◦ EN 13059+A1:2008. "Safety of industrial trucks. Test methods for measuring vibration" (EU/EFTA market). ◦ EN 12053+A1: 2008. "Safety of industrial trucks. Test methods for noise emission" (EU/ EFTA market). ◦ EN 1175-2+A1:2010 “Safety of industrial trucks – Electrical Requirements - Part 2: General requirements of internal combustion engine powered trucks“. • EMC: EU: 2014/30/EU UK: Electromagnetic Compatibility Regulations 2016 S.I. 2016:1091 ◦ EN 12895:2015+A1:2019. Industrial trucks - Electromagnetic compatibility. • Emissions: EU: 2016/1628/EC (EU/EFTA market, stage 4, and 5 engines). UK: The Non-Road Mobile Machinery (Type-Approval and Emission of Gaseous and Particulate Pollutants) Regulations 2018 2018 No. 764 • 2016/1628/EU “REGULATION (EU) 2016/1628 OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 14 September 2016 on requirements relating to gaseous and particulate pollutant emission limits and type-approval for internal combustion engines for non-road mobile machinery, amending Regulations (EU) No 1024/2012 and (EU) No 167/2013, and amending and repealing Directive 97/68/EC" Declaration of conformity and other certificates are included in the delivery package. Manufacturer reserves the right to modify the design and material specifications without NOTE prior notice. Applicable sections of EN13155 are used for all lifting ears on the machine. 14/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 1 Introduction Maintenance Instructions 1.2.5 Declaration of conformity EC DECLARATION OF CONFORMITY OF THE MACHINERY (Machinery Directive 2006/42/EC, Annex II, sub. A) Manufacturer: Konecranes Lifttrucks AB Anders Anderssons väg 13, P.O. Box 103 SE-28523 MARKARYD SE Name and address of the person authorised to compile the technical file: XXXXX XXXXX Anders Anderssons väg 13, P.O. Box 103 SE-28523 MARKARYD SE The manufacturer declares that Description: Forklift Model: XXXXX Serial number: XXXXX • Is in conformity with the relevant provisions of the DIRECTIVES OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL: - of May 17, 2006, "relating to machinery" 2006/42/EC - of February 26, 2014, "relating to electromagnetic compatibility" 2014/30/EU - Directive 2000/14/EC as amended by Directive 2005/88/EC on the noise emission in the environment by equipment for use outdoors and fulfils the requirements of the following harmonised standards: • regarding Machinery Directive: EN ISO 3691-1 • regarding EMC Directive: EN 12895 Place and date of issue MARKARYD DD.MM.YYYY Signature: Anders Nilsson Technical Director Konecranes Lift trucks Figure 2. EC Declaration of conformity of the machinery (template) 15/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 1 Introduction UK DECLARATION OF CONFORMITY OF THE MACHINERY (Supply of Machinery (Safety) Regulations 2008, Annex II, sub. A) Manufacturer: Konecranes Lifttrucks AB Anders Anderssons väg 13, P.O. Box 103 SE-28523 MARKARYD SE Name and address of the person authorised to compile the technical file: XXXXX XXXXX Coalfield Way LE65 1NF Ashby De La Zouch UK The manufacturer declares that Description: Forklift Model: XXXXX Serial number: XXXXX • is in conformity with the relevant provisions of statutory instruments - Supply of Machinery (Safety) Regulations 2008 No.1597 - Electromagnetic Compatibility Regulations 2016 No.1091 - Noise emission in the environment by Equipment for use Outdoors Regulations 2001 No.1071 and fulfils the requirements of the following designated standards: • regarding 2008 No. 1597: EN ISO 3691-1 • regarding 2016 No. 1091: EN 12895 Place and date of issue MARKARYD DD.MM.YYYY Signature: Anders Nilsson Technical Director Konecranes Lift trucks Figure 3. UK Declaration of conformity of the machinery (template) 16/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions 2 SAFETY AND ENVIRONMENT 2.1 Safety messages and symbols 2.1.1 Signal words The following signal words and symbols are used to identify safety messages in these instructions. Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation that, if not avoided, could result in damage to property or environment. 2.1.2 Hazard symbols Hazard symbols are used to indicate the type of the hazard and the potential consequences. Hazard symbols are indicated by a yellow triangle with black symbols and a black triangle band. All personnel working on or in proximity of the machine must understand and follow the information that is given in all hazard symbols. General hazard symbol General hazard The general hazard symbol identifies important safety messages in this document. When you see this symbol, carefully read and understand the message that follows, and inform other users when necessary. 17/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment Mechanical hazard symbols Moving vehicle Sideways tipping Forward or backward Run over hazard hazard hazard tipping hazard Moving parts hazard Falling load hazard Slipping hazard Hanging load hazard Crushing hazard Crushing hand Flying objects to face Flying objects hazard hazard hazard Skin injection hazard Electrical hazard symbols Electrical hazard Material hazard symbols Hot liquid hazard Explosion hazard Harmful substance High-pressure hazard hazard Ignition hazard Corrosive chemical Pressurized gas Hazardous or substance hazard hazard poisonous material hazard 18/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions Thermal hazard symbols Hot surface hazard Slippery when frozen hazard Noise hazard symbols Noise hazard Laser hazard symbols Laser hazard Ergonomic hazard symbols Lifting hazard 19/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment 2.1.3 Mandatory action symbols Mandatory action symbols specify actions to be taken to avoid a hazard. Mandatory actions are indicated by blue circle with white symbols. All personnel working on or in proximity of the machine must understand and follow the information that is given in all mandatory action symbols. Wear approved safety Wear approved Wear approved Wear approved safety gloves hearing protectors protective clothing shoes Wear approved safety Wear approved hard Wear approved high Wear approved eye harness hat visibility clothing protector Disconnect Apply indicator for Use jack Alarm horn equipment from pin-hole leak test power source Read instructions Two persons for Wear approved Use seat belt handling respirator 20/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions 2.1.4 Prohibited action symbols Prohibited action symbols indicate actions that are prohibited in order to avoid a hazard. Prohibited actions are indicated by a red circle with a red diagonal line across the circle. The action that is prohibited is always in black. All personnel working on or in proximity of the machine must understand and follow the information that is given in all prohibited action symbols. General prohibition Do not walk or stand Do not weld No open fire here Do not smoke Do not modify Do not test for leak Do not touch with hands Restrict access 2.1.5 Safety and information labels on the product The safety and information labels communicate the following: • Level of risk that is based on the signal word Danger, Warning, or Notice • Type of hazard, such as cutting parts, hanging load, hot surface, live parts • Consequence of hazard, such as cutting, injection, crushing, burn, electric shock • How to avoid the hazard Always keep safety and information labels visible, and check the condition of the labels daily. Before operating the machine, replace labels that are damaged, have come loose, NOTE or do not meet the readability requirements for safe viewing distance. New safety and information labels can be ordered from the manufacturer of the machine. 21/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment 2.1.6 Location of the safety and information labels 1 5 6 7 4 8 10 3 1 9 1 12 2 26 25 11 12 1 13 13 21 20 19 18 15 14 22 16 23 17 24 Figure 4. Location of the safety and information labels 1. Lifting point 14. Accumulator pressure 2. Engine oil 15. Hydraulic oil 3. Transmission oil 16. Diesel fuel 4. Fuses and relays, PCB 17. Brake cooling oil 5. Emergency exit only 18. Do not step here 6. Seat belt 19. Remove pressure before demounting tire 7. In case of rollover 20. Read operating instructions first 8. Working zone 21. Battery main switch 9. Crush injury risk 22. Cab tilting 10. Injection hazard 23. Fuses and relays, battery compartment 11. Do not stand under or on lifted load 24. Warning-Acid and explosion risk 12. Tire pressure 10 bar (1.0 MPa)*) 25. Crushing risk by tire 13. Tie down point when transporting the 26. Machine working zone machine *) Sign present above all tires. 22/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions Table 1. Labels 1. Lifting point 2. Engine oil 3. Transmission oil 4. Fuses and relays, PCB 5. Emergency exit only 23/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment Table 1. Labels (Continued) 6. Seat belt 7. In case of rollover This sticker shows what the operator must do in case of rollover. Do not jump out of the cabin in case of rollover. Brace feet against the floor and hold on tightly to the steering wheel. Climb out of the machine when it has stopped moving. 8. Working zone 9. Crush injury risk 24/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions Table 1. Labels (Continued) 10. Injection hazard 11. Do not stand under or on lifted load. 12. Tire pressure 10 bar (1.0 MPa) 13. Tie down point for loading the machine for transport Secure the machine here when loading it for transport. 14. Accumulator pressure Warning, read instructions in the manual. 25/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment Table 1. Labels (Continued) 15. Hydraulic oil 16. Diesel fuel 17. Brake cooling oil 18. Do not step here 19. Remove pressure before demounting tire 20. Warning - Read operating instructions first 21. Battery main switch 26/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions Table 1. Labels (Continued) 1 2 22. Cab tilting 23. Fuses and relays, battery compartment 24. Warning - Acid and explosion risk 25. Crushing risk by tire 26. Machine working zone 27/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment 2.2 Responsibilities of the operational manager 2.2.1 Preventing work-related hazards The operational manager must ensure that operators, and maintenance personnel have sufficient knowledge of the work-related hazards, and the ways to avoid the hazards. The operational manager must ensure to inform the operator that a local risk assessment always must be performed before every work phase or shift. The assessment ensures that the operator stops and thinks about what to do before starting to work. • Identify potential hazards that could affect the operator, other personnel, the environment, the product, or work methods while performing the task • Assess the risks and implement the actions that are required to eliminate or reduce the risks Only personnel with sufficient competence are allowed to operate the machine, and carry out other tasks on the machine. The responsibilities of the operational manager are, for example, to: • Provide training and orientation. • Validate training methods. • Verify competence and skills. • Monitor and evaluate user performance regularly. • Provide fire-fighting equipment. • Make sure that the working site has guidelines on how to prevent fires. • Make sure that the working site has guidelines to follow concerning fire-fighting. • Make sure that the working site has guidelines on how to operate the machine during strong wind. • Make sure that the instructions from Konecranes Lift Trucks are accessible and up to date. • Make a risk assessment of the work site, for example, regarding height limitations, door openings, overhead powerlines, and ground conditions. • Make sure that the work site follows all local rules and regulations. 2.2.2 Preventive maintenance WARNING MACHINE MALFUNCTION HAZARD Failure to regularly and properly maintain the product can result in death, injury, or damage. Do not allow the product to be used if it is not in proper condition or if it has not been maintained correctly. Contact an authorized service agent or manufacturer's representative immediately if there are doubts. WARNING MACHINE NON-COMPLIANCE Replacing components with non-genuine components, or components not authorized by Konecranes Lift Trucks, can affect the safety of the machine. This is considered as a modification of the machine and therefore voids Konecranes' liability as manufacturer. The party that performed the modification will thereafter legally be liable for the safety of the modified machine, and the related CE marking. For any clarification always contact your authorized Konecranes Lift Trucks representative. 28/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions RISK OF PROPERTY DAMAGE Only use genuine spare parts or materials and lubricants that are approved by the NOTICE product manufacturer or manufacturer's representative. For more information, see the spare part catalogue and section Fuel and oil recommendations (page 249). Scheduled inspections and preventive maintenance are essential for keeping the product in safe working condition. Here are some general guidelines for preventive maintenance. • It is the responsibility of the operational manager to organize maintenance inspections regularly. These inspections are to ensure long-term safety, reliability, durability, operability, and warranty for the product. • The operational manager must keep a record (log book) of all maintenance activities and usage relating to the product. • Maintenance must be carried out at different intervals and by authorized personnel who are qualified for the individual task. • Daily checks and minor lubrication must be carried out by operators or maintenance personnel. These checks are important for catching small faults before they become major faults and causes breakdowns. • Other maintenance actions must be done by service personnel that are authorized by the operational manager. • Replacement parts and materials must comply with the specifications that are defined by the product manufacturer. It is the responsibility of the operational manager to ensure that only genuine replacement parts, and components that are approved by the manufacturer are used. • Keep this document in a safe, accessible location during the whole lifetime of the product. 2.2.3 Personal protective equipment For safety, all personnel working in or near the machine are required to wear personal NOTE protective equipment (PPE). This section proposes personal protective equipment to ensure the safety of all personnel working in or near the machine. Follow the local regulations and requirements NOTE of the working environment. Use only approved and accepted personal protective equipment. Operators and anyone near and around the product must wear the following items: • Safety shoes • High-visibility clothing Various types of PPE are available as listed, depending on the situation, other types of PPE than listed can be required. It is the responsibility of the operational manager to make sure that all local PPE requirements are followed. • Hard hat • Eye protection • Ear protection • Respirator • Safety gloves • Protective clothing • Safety harness when working at heights Do not wear loose clothing or jewelry that can get caught on controls or pulled into moving parts of the product. Do not wear jewelry or metal accessories such as watches when working with or near the electrical system or the batteries. Tie back long hair. Long hair can get entangled. Select the appropriate clothing for each task, for example: 29/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment • Wear fire-resistant clothing when welding, flame cutting, or using an angle grinder. • Tear-resistant clothing must resist damage from sharp edges in the steel structure. • Wear anti-static clothing when working on electrical circuits so that components do not get damaged by a discharge of static electricity. • Always use safety goggles when working with high voltage or pressurized fluids. • When working with lubricants, clothing must prevent direct skin contact with the lubricant. • Choose clothing with consideration to the temperature at the working site, and stay hydrated. 2.2.3.1 Fall protection While personnel installs, inspects, or do maintenance work at heights, they must follow fall protection procedures as required by local regulations. Fall prevention practices and equipment aim at protecting personnel working on or around the equipment. If the equipment does not have a service platform or guardrail, personnel must use a properly fitted safety harness. The safety harness is attached to the dedicated fixing points on a building or equipment to prevent falls. If dedicated fall protection fixing points are missing, it is the operational manager's responsibility to make sure that suitable and secure fixing points are available. If not possible it is necessary for the operational manager to provide an appropriate manlift. If ladders must be used, personnel must practice setting and securing the ladders before using them for actual work. Fall protection system has four components: • Safety harness: Safety harness helps to prevent employees to get hurt in a fall. • Lanyard belt: Lanyard belt is connected to the anchor point and is attached to the safety harness. Lanyard belts are shock absorbing, which means that they slow down and eventually stop a fall. • Snap hook: Snap hooks connect the D-ring to the safety harness. Snap hooks must be double locking. To connect only one snap hook to one D-ring, is the basic rule. • Anchorage point: Anchorage point is the point to which personal fall protection equipment is attached. The point must be capable of supporting at least 2,268 kg (5,000 lb) for each employee. If there is any doubt about the strength of the attachment point, find an alternative point that can support the worker. A typical fall protection program may include: • Documented and established site policies and procedures • Conducting site assessments for fall hazards • Selection of the proper fall protection system and equipment • Training on fall protection procedures and the proper use of fall protection systems • Inspection and proper maintenance of fall protection equipment • Measures to prevent falling objects • Rescue plans If necessary, contact your supplier or service organization for assistance with designing your fall protection program. For more information about lifting operations and equipment, see "Lifting Operations and Lifting Equipment Regulations" (LOLER). 2.2.4 Incident reporting Product safety issues that you must report are events in which the manufacturer's product has been involved in an accident or near-miss incident. Contact your local manufacturer's representative immediately to report any safety-related feedback, such as unauthorized modifications, missing instructions and safety labels, neglected maintenance, or misuse. Reporting is mandatory to ensure safe working conditions for employees, to provide information for the risk assessment process, and to initiate product and work procedure improvements. 30/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions 2.3 Limitations of the product 2.3.1 Operating conditions Thunderstorm When in danger of being struck by lightning, operating or being close to the machine is strongly discouraged. Protection from lightning during work must be managed by the workplace risk assessment that is made by the operational manager. Following a lightning strike (or if you suspect the machine has been struck) the machine must be checked by authorized personnel. The check must follow the instructions of the daily maintenance. Surfaces Do not operate the machine on uneven surfaces or in unstable conditions. NOTE Do not drive on slopes that are greater than 15%. 2.3.2 Inclination angles WARNING TIPPING AND COLLISION HAZARD If you drive on slopes greater than 15%, the parking brake may fail and risk of tipping increases considerably. Risk of serious personal injury and damage to the machine. Do not drive on slopes greater than 15%. WARNING RISK OF LOAD DROP Driving downhill on slopes carrying a load, can lead to a load drop. This can damage the machine and can lead to serious personal injury. If carrying a load, always drive downhill in reverse. If you must drive the machine along greater slopes, contact your Konecranes Lift Trucks NOTE authorized dealer. NOTE Do not drive on slopes that are greater than 15%. Figure 5. Do not drive on slopes greater than 15% 31/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment 2.3.3 Lift truck danger zones, general DANGER MOVING MACHINERY HAZARD The moving machine and its moving parts can cause death or serious injury. While the machine operates, unauthorized personnel should never enter or be within the danger zone. During operation, the authorized personnel working within the danger zone and the operator must constantly communicate verbally or visually to stay aware of each other. The following images show the danger zones surrounding the machine and its parts. 15 m/16 yd Figure 6. General danger zone 2.3.4 Tire explosion danger zone DANGER HIGH-PRESSURE HAZARD The tires may explode when you inflate or deflate them, or in case of fire. Standing inside the tire explosion danger zone during a tire explosion can cause death or serious injury. Always stand to the side of the wheel when deflating or inflating tires, see "tire explosion danger zone" illustration. Use safety glasses. The tire explosion danger zone follows the positioning of the wheels. The illustration NOTE applies when the wheels are in line with the machine. 32/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions 120° 120° 50 yd m/ 55 55 m/ yd 50 50 d 5y m/5 m/5 5y 50 d 120° 120° Figure 7. Tire explosion danger zones 33/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment 2.3.5 Prohibited use WARNING MACHINE MALFUNCTION HAZARD Using the machine outside the limits of its capacity or operating conditions could cause malfunction of the equipment. Unauthorized usage could lead to death, severe injury, or property damage. Do not use the machine outside the limits of its capacity or operating conditions. The misuse of the equipment includes, but is not limited to: • Lifting or transporting people. • Driving with the load above transport position. • Driving with heavy loads in slings. • Driving with swinging load. • Having passengers in the cabin 1) • Driving on uneven terrain • Exceeding the load limit, which is shown on the lifting capacity plate • Adding extra counterweights • Driving uphill and downhill on slopes with an inclination over 15%. • Using tools that are not approved by the manufacturer. • Using the low-voltage battery switch when the machine is in motion. • Overriding any safety systems. • Using the emergency stop in a none emergency situation. NOTE Only use the emergency stop in an emergency situation. 1) If a truck is equipped with an optional trainer's seat, another person is allowed to sit there, as long as the person uses the seat belt. For more information, see the lifting capacity plate of the machine, and, if applicable, lifting capacity plates on attachments. Contact the manufacturer or the representative for the manufacturer if there are any doubts. 2.3.6 Changes to the product DANGER MACHINE MALFUNCTION HAZARD Unauthorized changes, or modifications to the product can lead to death, severe injury, or property damage. Always contact Konecranes Lift Trucks, or an authorized representative to get a written approval in advance for any product change or modification. 34/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions DANGER MACHINE MALFUNCTION HAZARD Changes, and modifications without proper risk assessment, can lead to death, or serious personal injuries. It can also damage property, or the environment. Unauthorized modifications void the warranty and responsibility of the manufacturer. Perform a risk assessment, which eliminates, or reduces risks, and considers appropriate safety measures. WARNING MACHINE MISUSE HAZARD Adding and using equipment that is not supplied with the machine, can cause the products to malfunction. Risk of serious personal injury and damage to the machine. If using equipment that was not supplied with the machine, an authorized dealer must approve the combination and use of the equipment. The authorized dealer must ensure that safe operations can be guaranteed concerning lifting capacity, stability, and visibility. WARNING MACHINE NON-COMPLIANCE Replacing components with non-genuine components, or components not authorized by Konecranes Lift Trucks, can affect the safety of the machine. This is considered as a modification of the machine and therefore voids the liability of Konecranes as a manufacturer. The party that performed the modification will thereafter legally be liable for the safety of the modified machine, and the related CE marking. For any clarification always contact your authorised Konecranes Lift Trucks representative. All modifications and corrections that are not authorized in the product documents or which may affect the maintenance, operation, safety, and availability of the product must be approved in writing by Konecranes Lift Trucks before implementation. Approval requires a risk assessment which consider any new risks that the changes and modifications may bring. All safety and information labels on the machine, must be updated to match the machine after any modifications. To avoid using obsolete spare parts, always check the specific spare parts catalogue for the machine. For the latest version, contact Konecranes Lift Trucks spare parts department. If a modification or correction has been implemented without the permission from Konecranes Lift Trucks, its effect on warranty liability is considered case-by-case. Thus, the warranty application may be rejected altogether. If a modification, or alteration is considered necessary, contact an authorized dealer, or the organization that manufactured, and designed the product. No modification is permitted, unless the written approval from the manufacturer is obtained. Before doing any modifications, the following information must be sent to Konecranes Lift Trucks. • Product model and type • Serial number of product • Description of the modification or correction 35/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment • Related blueprints • Related photos • And other material, if necessary The manufacturer then approves, or rejects the modifications in writing. 2.4 Emissions The noise and vibration levels are checked according to industry standards. This is to make sure that the operator's have a healthy environment while operating the machine. 36/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions 2.4.1 Noise Measured sound levels WARNING NOISE HAZARD Continuous exposure to noise above 80 dB(A) can cause hearing impairment, and make the operator tired and unfocused. Wear approved hearing protectors. The noise values were measured according to the harmonized standard EN12053 – A1:2008, following the conditions described therein, by a notified body. The noise values are reported according to ISO4871:2009. The specified equipment has been assessed in accordance with Directive 2000/14/EC (amended by Directive 2005/88/EC), annex VI by notified body 0404, RISE SMP Svensk Maskinprovning AB (The Swedish Machinery Testing Institute). Declared dual-number noise emission values In accordance with ISO4871:2009 Lift mode Idle mode Drive mode Total Time proportion factors of the operating cycle (%) - 0.18 0.58 0.24 1 ref. EN12053+A1:2008 A-weighted emission sound pressure level 75 74 76 76 at the operator position LpAZ (dB) Uncertainty (dB) 1 1 1 1 C-weighted peak emission sound < 130 < 130 < 130 < 130 pressure level Measured sound power level in an 102 operational cycle (A- weighted) Guaranteed sound power level in an 104 operational cycle (A- weighted) Measured on 16-33 ton forklifts, for other sizes, the values may vary slightly. Where the time proportion factors are used in defining the operational cycle, they are as defined in EN12053+A1:2008. 2.4.2 Vibration The whole-body vibration has been measured according to the harmonized standard EN13059:2008, following the conditions described therein, by a notified body. • Measured whole body vibration: below 0.9 m/s₂ • Overall uncertainty of the measurement: 1 m/s₂ 37/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment The reported expanded uncertainty is based on a standard uncertainty that is multiplied by a coverage factor K = 2. For a normal distribution, this value provides a level of confidence of approx. 95%. The standard uncertainty has been determined in accordance with EA publication EA-4/16/2003. 2.5 Protective measures 2.5.1 Emergency stopping DANGER UNCONTROLLED MOVEMENT HAZARD If the machine moves unexpectedly, it could result in personal injury, death, or damage to the equipment. To stop any unexpected movement, press the emergency stop button. WARNING FORWARD TIPPING HAZARD If the emergency stop is used when the machine moves, the machine may tip over. Risk of serious personal injury and damage to the machine. Only use the emergency stop in an emergency. Do not operate the equipment without knowing the location of the emergency stop NOTE buttons. After the emergency stop button (1) is pressed, all functions are cut out, the parking brake is activated and the engine stops. In normal operation, do not use the emergency stop button to stop the machine. Instead, use the brake pedal. Only use the emergency stop button in an emergency situation. Routinely using the NOTE emergency stop button increases wear on the product and can cause a breakdown. After each time the emergency stop is used, a daily maintenance must be performed to check the overall function of the machine. If the machine moves when pressing the emergency button, the condition of the parking brake disc and pads must also be checked. Contact authorized service personnel for the check-up. Figure 8. Emergency stop inside the cabin 38/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions Emergency stop on the outside of the machine 1 2.5.2 Battery main switch DANGER EXPLOSION HAZARD Short-circuiting the battery may cause a fire or explosion, which can cause a risk of serious injury or death. To reduce the risks of fire, explosion, electric shock and personal injury, always remove jewelry and conductive material before working on the electrical system. DANGER EXPLOSION HAZARD Batteries generate explosive hydrogen when charged, which can cause a risk of serious injury or death. Always use the necessary protective equipment. Ensure that there is good ventilation and avoid sparking. 39/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment DANGER ELECTRIC SHOCK HAZARD If the engine is on, there may still be voltage present in some parts, even when the battery main switch is turned off. The main switch does not cut the power from the alternator. This causes a risk of electric shocks, which can lead to death or serious personal injury. To reduce the risks of electric shock and personal injury always remove jewelry and conductive material before working on the electrical system. Always disconnect the ground (minus) cable at the battery when working near or on the alternator. Be aware of the battery main switch functionality. WARNING TIPPING OVER HAZARD If the battery main switch is turned off when the machine moves, the parking brake is activated. The machine may tip over, causing a risk of serious personal injury and damage to the machine. Unless there is an emergency situation, do not turn off the battery main switch when the engine runs. NOTE Do not operate the machine without knowing the location of the battery main switch (1). If the machine has an engine that uses diesel exhaust fluid (DEF) solution (for example AdBlue), turn off the engine, but do not turn off the battery main switch. Wait for the DEF NOTE pump to finish pumping back all the fluid from the hoses to the DEF tank before turning off the battery main switch (1). The required time varies slightly between different engine models. NOTE Remove the main switch handle when parking the machine. The battery main switch is found on the right-hand side of the machine, near the battery compartment. The machine can only be operated when the power is turned on. 1 Figure 9. Battery main switch 40/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions 2.5.3 Releasing the hydraulic pressure WARNING HIGH-PRESSURE HAZARD The hydraulic system contains hydraulic accumulators to maintain the brake function during a possible engine failure. Risk of serious personal injury. Only authorized maintenance personnel are permitted to loosen any hydraulic hoses. Before maintaining or servicing the hydraulics of the machine: - Always lower the mast and fork carriage to the bottom position. - If maintaining the brake system, always ensure that the accumulator pressure for the hydraulics is released before loosening any hydraulic hoses in the brake circuit. - Make sure that no other hydraulic hoses or components are pressurized before loosening any hoses. For more information about releasing the hydraulic pressure, see Releasing the hydraulic accumulator pressure (page 73). 2.5.4 Fire safety DANGER FIRE AND EXPLOSION HAZARD Ignition sources together with combustible materials can cause fire. If these risks are not avoided, they could lead to death or severe injury. Smoking, open flames, and sparks are examples of ignition sources. Fuel is an example of combustible material. Ignition sources are prohibited near the machine. During maintenance, follow appropriate fire prevention and protection measures. Measures include but are not limited to trained personnel and proper fire extinguishing equipment. Before starting any maintenance or repairs that require ignition sources, carry out a proper risk assessment to control the risk. 120° 120° 50 yd m/ 55 55 m/ yd 50 50 d 5y m/5 m/5 5y 50 d 120° 120° 41/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment In case of fire, approach the machine from the front or the back. If possible, always avoid NOTE the tire explosion danger zones. • Smoking and open fire are prohibited near the product. • Access to all fire-fighting equipment must be granted always, especially during maintenance and repair works. Fire-fighting equipment is not a standard part of the machine. It is the responsibility of NOTE the operational manager to make sure that fire-fighting equipment is available. • All fire-fighting equipment must be inspected and serviced regularly, according to local regulations. • Damaged fire-fighting equipment and used fire extinguishers must be replaced immediately. • Know the various types of fires and the appropriate fire-fighting methods. Various fires must not be extinguished with water. Special extinguishing agents, dry powders, or deoxygenating agents are required. • It is the responsibility of the operational manager to make sure that the working site has guidelines to follow concerning fire-fighting. • All personnel must be aware of the guidelines and trained regularly in fire-fighting methods. It is strongly suggested that guidelines, and training is performed in cooperation with NOTE local authorities, and rescue organizations. 2.5.5 Emergency exits The cabin door on the left-hand side is the main emergency exit. If the left-hand side door is blocked, use the right-hand side door. If both the left and right doors are blocked, use the emergency hammer (option) to smash the rear window to exit the cabin. Using the emergency hammer (Option) 1. Pull the emergency hammer from its mounting above the rear window. WARNING FLYING OBJECTS TO FACE HAZARD Breaking glass may fly into your face and eyes. Shield your eyes and face with your other arm while breaking the window with the hammer. 2. Smash the rear window with the hammer. 3. Use the hammer to scrape the remaining glass. 4. Exit the cabin through the rear window. 42/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions 2.5.6 Mounting, and dismounting the machine WARNING SLIPPING HAZARD Failing to maintain three points of contact can cause serious injury or death. Maintain three points of contact when mounting, or dismounting the machine. Three points of contact are either two hands, and one foot, or two feet, and one hand. NOTE Climb on and off only when the machine is stationary. NOTE Do not jump from the steps to the ground. Following this procedure reduces the risk of falling, and decreases wear on back, and NOTE knees. 1. Face the steps, when mounting, or dismounting the machine. The cabin entrance is on the left side of the machine. 2. Maintain three points of contact until reaching the cabin, or ground. 2.5.7 Locking the cabin door in open position 1. To fasten the cabin door in open position, open the cabin door and push it into the lock. 43/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment 2. To unlock the door from open position, press the handle on the inside of the cabin door. 2.5.8 Personnel requirements DANGER SPECIALIST SKILLS REQUIRED Incompetent operation and maintenance could cause death or severe injuries. Operation and maintenance procedures require professional skills and special training regarding the tasks and working methods. Do not operate the equipment or do any maintenance tasks without proper training. Always follow the instructions. Use appropriate personal protective equipment, depending on the task. 44/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions To avoid hazardous situations and dangerous consequences, leave all operation and maintenance work to authorized personnel. Tasks that are mentioned are examples of tasks which are allowed only for authorized personnel. Instructions for safe handling and other risks that are related to the tasks, can be found in the following chapters. Tasks that require special technical skills and training include, but are not limited to: 1. Hydraulic system maintenance 2. Electric system maintenance 3. Battery maintenance 4. Tire maintenance 5. Changing parameters in the control system 2.6 Environmental information Environmental impacts have been taken into account when designing and manufacturing this product. To prevent environmental risks during use, follow the instructions and local regulations for disposal of waste material. Proper use and maintenance improve the environmental performance of this product. 2.6.1 Energy consumption Energy consumption during the use phase has the biggest environmental impact. Diesel fuel is needed for lifting, transporting, lighting, heating, cooling, and other optional components that are part of the machine. Konecranes machines minimize the use of fuel in the following ways: • Engineering diesel engines with the best possible fuel efficiency and lowest emission levels. • Engine downsizing. • Fuel saving transmission features, like lock-up and continuously variable transmission. • Using load-sensing hydraulic systems, so no hydraulic flow (with resulting energy losses) is created unless it is needed by an actual load command. • ECO-driving supports the operators so they can minimize fuel consumption by reducing the harshness of operations. • Connectivity for the operational managers to optimize the use and operational efficiency of their machine fleet by: ◦ maximizing time driving with payload ◦ minimizing travelling distances over the yard ◦ select the most suitable machine capacity for specific lifting needs ◦ monitoring the right tire pressure for the lowest rolling resistance in connected machines • Eliminating idling time with: ◦ automatic start and stop • Means to optimize the preventive maintenance of the machines, to ensure long-term fuel efficiency. 2.6.2 Product lifecycle stages The environmental impact of a Konecranes machine is taken into account for the whole lifecycle of the vehicle. “Lifecycle” refers to the extraction and processing of raw materials, the production of components, manufacturing, use, and maintenance. "Lifecycle" also refers to disposal of the product and the transportation that is involved from one stage to the next. Each stage of the lifecycle has a different impact on the environment. The two most significant environmental impacts of the machines are the energy consumption during the use phase (in particular, the effects of diesel emissions) and the raw materials and component production (in particular, the effects of steel production). The significance of energy consumption depends on actual usage, including operating time, efficiency of operations, and load collective. Product lifecycle stages include: 45/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment • Production of materials and components • Equipment manufacturing and assembly • Use phase, including maintenance, repairs, and modernization • Dismantling and recycling of waste materials • Transports between each stage Figure 10. Product lifecycle stages 2.6.2.1 Production of materials and components 84%–92% of machine materials are metals, and rubber tires form 3%–9%. The rest of the materials include electrical and electromechanical components, fluids (hydraulic oil, diesel fuel, and grease), plastic, and glass. The main raw material is steel. The most significant environmental impacts of steel production are the use of raw materials and energy, as well as carbon dioxide and particle emissions. More than 75% of the steel content can be manufactured from recycled steel scrap. Lubricants, which are used from factory on the products, are industrial hydrocarbons. Table 2. Materials used in Konecranes machines Konecranes Lift Trucks Konecranes Liftace Forklift Forklift, Empty Laden Reach Forklift Empty Reach electric container container stacker container stacker handler handler handler Steel 88% 84% 91% 90% 92% 88% 92% 92% Rubber 6% 6% 4% 5% 3% 6% 3% 3% Copper <1% <2% <1% <1% <1% <1% <1% <1% Electronics <1% <4% <1% <1% <1% <1% <1% <1% Fluids <2% <2% <2% <2% <2% <2% <2% <2% Polymers <1% <1% <1% <1% <1% <1% <1% <1% Others <1% <1% <1% <1% <1% <1% <1% <1% 2.6.2.2 Equipment manufacturing and assembly Production mainly involves assembling of machines and some installations. Welding is only carried out for complementing or repair work. Surface treatment for reconditioning is conducted to a lesser extent. Testing of machines is carried out outdoors after assembly, before delivery. 46/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions The most significant environmental impact is the energy consumption, and diesel emissions during test-driving. To decrease the impact, Konecranes Lift Trucks is using HVO100 bio diesel. It is recommended that HVO100 bio diesel is used generally to decrease the environmental footprint. There are also some lower impacts from the chemicals that are used, like paints, oils and fuels. The waste from the production is disposed of, according to local regulations. Examples of waste are wood, plastic, and paper as well as hazardous waste such as residue of paint, and waste oil. 2.6.2.3 Use phase, including maintenance and modernization Most significant environmental impacts of machines are the energy consumption during the use phase (in particular, the effects of diesel emissions). Konecranes machines minimize the use of fuel, as described in "Energy consumption". Timely repairs and proper maintenance support each machine’s efficiency, safety and, performance which contributes to less environmental impact. The optional hydraulic long-life (HLL) filter removes small particles, reduces the water in the oil, and extends the life of the hydraulic oil. This filter increases the amount of time between hydraulic oil replacements. With the option TRUCONNECT® Smart Connected Lift Trucks the customer can plan service on real machine use, which in most situations extend service intervals. A sensor for monitoring the status of the hydraulic oil, and estimate the remaining life of the oil, can also be provided. The monitoring of the hydraulic oil status prevents unnecessary hydraulic oil replacement. Certain major components like diesel engine, transmission, and some electronics can be restored to like-new condition. Konecranes Service offers restored spare parts, where the old part is requested back (as core unit for later renovation). This restoration process extends the useable machine life and reduced the environmental impact. 2.6.2.4 Dismantling and handling waste material Konecranes Lifttrucks strive to optimize all packaging to minimize waste and to follow the EU waste hierarchy. The most preferable actions are: prevention, reuse, recycle, burning of material to recover the energy in the material, and as a final resort, safe disposal as landfills. Waste material from dismantling shall be handled and disposed according to local regulations. As waste regulations and types of available recovery and disposal methods vary regionally, no general detailed guidance can be given. Dismantling should always be planned and executed by authorized personnel. A local risk assessment must be performed in advance. Depending on available recovery and disposal methods, wood can be recycled and reused but is the responsibility of the customer. Plastic waste is collected and, depending on the infrastructure, recycled, burned to recover the energy in the material, or as a final resort, safely disposed as landfills. NOTE Always use licensed recycling companies. The following list provides proposals for adequate waste handling methods. 47/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment Table 3. Proposed waste handling methods (example for EU states) Proposed waste handling methods (example of EU states) Material Handling method Metals Material recycling, multi-metal scrap recycling. Rubber tires Recycle rubber according to local regulations. Whenever possible, return the used rubber tires to the tire supplier for recycling. Electronics and Some electrical parts may be treated as hazardous waste. electromechanical components Collect and recycle the electronics and electromechanical components separately. Use e-waste management. Batteries Batteries and other energy storage components may contain hazardous substances. Collect these items separately and recycle according to local regulations. Fluids, Recycling, hazardous waste management accumulators, oil filters Plastics and Recycle plastic as material, burn to recover the energy in the material, or polymers deliver it to a landfill site. Chemicals Never spill chemicals, such as oil, grease, and other liquids, onto the ground, soil, or sewage. Store waste oil and grease in containers that are indicated for the purpose. More detailed information on chemical handling as waste can be found in the chemical safety data sheet. The data sheet is available from the manufacturer of the chemical. Packing materials Reuse or recycle packing materials, such as plastics, wood, and cardboard. Glass Recycle glass according to local regulations. 2.6.2.5 Deliveries between each stage Materials and components are provided by various suppliers worldwide, however steel structure is primarily sourced from local vendors to reduce the transportation need. It is an ethical, environmental, and employee-related principle that is applied. Shipment of materials to the respective factories is primarily by road transport, and containerized whenever feasible. Before shipment, each machine is partly dismantled, depending on dimensional and/or weight constraints for road transportation. The shipment of a machine to local and regional customers is usually by road from the factory. When shipment is to more remote customers or the shipping route involves waterways, sea transport is often involved. By sea, Ro-Ro type ships are used (where the machine drives onto the ship). 48/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions 2.6.3 Notice on the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH) Konecranes is fully aware of its obligations under Regulation (EC) No 1907/2006 of the European Parliament and of the Council of 18 December 2006 concerning the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH), and under the UK REACH in the United Kingdom. Twice a year the EU publishes a Candidate list of Substances of Very High Concern (“SVHC”) for Authorization. Producers and EU importers/UK importers have the duty to inform their EU/UK customers when a product contains SVHCs in a concentration above 0.1 % weight by weight. Some Konecranes products do include small quantities of SVHCs, such as lead which is typically used in brass and in certain electric components. These cases are exemptions, as there are currently no satisfactory alternatives available for such substances. We are actively searching for alternatives to substitute articles including SVHCs. For a list of SVHCs, please see https://www.konecranes.com/about/corporate-responsibility/konecranes-reach-notice. 2.7 Storage information 2.7.1 Storage The following chapter describes the recommended procedure for storage of machines. To preserve the condition of the stored machine, it must be driven regularly during storage. Preparation before storage Before storing the machine, make sure that all required services according to the NOTE maintenance schedule are performed. Be aware that some points in the storage handling process, must be performed by NOTE trained and authorized maintenance personnel. If using a pressure washer, never aim the water directly at radiators, air intakes, seals, NOTE rubber hoses, or electrical components. • Clean the machine • Perform daily maintenance check, see section "Daily maintenance" • Run all hydraulic functions and steer cylinders to end position and back again • Fill the fuel tank before storing the machine • Charge the battery • Lubricate the machine, see section "Regular service" • To prevent corrosion, apply a rust inhibitor to all the metallic surfaces • To protect the coating from corrosion, touch up painted surfaces • If possible, store the machine indoors or under a roof • If stored outside, it is recommended to cover the whole machine Maintenance during storage When driving the machine, the engine temperature must reach at least 80 degrees and NOTE the transmission must reach at least 65 degrees. To preserve the condition of the machine during storage, the following steps must be performed at least once a month. • Check the battery, charge if needed • Check for visible leakage under the machine. If needed, tighten all connections before filling any fluid • Bleed the fuel system, if needed, see section "Bleeding the fuel system" • Start the machine, and idle to warm up the engine 49/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment • Drive the machine for a while, both forwards and in reverse • Run all hydraulic functions and steer cylinders to end position and back again • Before parking the machine again, check the guidelines for "Preparation before storage". Perform the steps, if needed. Bringing out of storage • Check for visible leakage under the machine and on the ground. • Tighten all connections before filling any fluid, if needed • Perform daily maintenance check, see section "Daily maintenance" • Lubricate the machine, see section "Regular service" • Check the battery, charge if needed • Bleed the fuel system, if needed, see section "Bleeding the fuel system" • Start the machine, and idle to warm up the engine • When the engine has reached the required temperature, and while idling, check for visible oil, fuel, or coolant leakage • Test drive the machine, to make sure all systems function properly 2.7.2 Alternative storage, up to two months The following chapter describes the procedure for storage of machines that cannot be accessed or driven during storage. This way of storing the machine should only be used if necessary. See section "Storage" NOTE for the recommended procedure. Preparation before storage Before storing the machine, make sure that all required services according to the NOTE maintenance schedule are performed. Be aware that some points in the storage handling process, must be performed by NOTE trained and authorized maintenance personnel. If using a pressure washer, never aim the water directly at radiators, air intakes, seals, NOTE rubber hoses, or electrical components. • Clean the machine • Perform daily maintenance check, see section "Daily maintenance" • Run all hydraulic functions and steer cylinders to end position and back again • Fill the fuel tank • Fill up the windshield washer fluid • Fill the AdBlue/DEF tank, if applicable • Charge the battery • Lubricate the machine, see section "Regular service" • To prevent corrosion, apply a rust inhibitor to all the metallic surfaces • To protect the coating from corrosion, touch up painted surfaces • If possible, store the machine indoors or under a roof • If stored outside, it is recommended to cover the whole machine Bringing out of storage • If applicable, remove the cover from the machine • Check for visible leakage under the machine and on the ground. • Tighten all connections before filling any fluid, if needed • Perform daily maintenance check, see section "Daily maintenance" • Lubricate the machine, see section "Regular service" • Check the battery, charge if needed • Bleed the fuel system, if needed, see section "Bleeding the fuel system" • Check the condition of all rubber hoses, and retighten the hose clamps if necessary • Check that no oil, fuel, or coolant leakage occurs • Start the machine, and idle to warm up the engine 50/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 2 Safety and environment Maintenance Instructions • When the engine has reached the required temperature, and while idling, check for visible oil, fuel, or coolant leakage • Run all hydraulic functions and steer cylinders to end position and back again • Check for visible leakage also when using the hydraulic functions after storage • Test drive the machine, to make sure all systems function properly 2.7.3 Alternative storage, longer than two months The following chapter describes the procedure for storage of machines that cannot be accessed or driven during storage. This way of storing the machine should only be used if necessary. See section "Storage" NOTE for the recommended procedure. Preparation before storage Before storing the machine, make sure that all required services according to the NOTE maintenance schedule are performed. Be aware that some points in the storage handling process, must be performed by NOTE trained and authorized maintenance personnel. If using a pressure washer, never aim the water directly at radiators, air intakes, seals, NOTE rubber hoses, or electrical components. When performing the regular service, also consider the procedure for conserving the NOTE machine. • Clean the machine • Perform maintenance service according to the 500 hours schedule, see section "Regular service" • Run all hydraulic functions and steer cylinders to end position and back again • Apply a long-term rust inhibitor to the cylinder pistons • Drain any water and contamination from the fuel filters and fuel tank • Fill the fuel tank • Fill up the windshield washer fluid • Fill the hydraulic tank completely, to avoid corrosion above the maximum level • Empty the AdBlue/DEF tank, if applicable, and rinse it with distilled water • Disconnect, and charge the battery • Store the battery in a safe way • Loosen the fan belt • To prevent corrosion, apply a long-term rust inhibitor to all the metallic surfaces • To protect the coating from corrosion, touch up painted surfaces • Conserve the machine, see section "Conservation of the lubrication and fuel system" • Cover the air filter, exhaust pipe, and engine if necessary • If possible, store the machine indoors or under a roof • If stored outside, it is recommended to cover the whole machine 51/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 2 Safety and environment Conservation of the engine and fuel system WARNING RISK OF FIRE AND PERSONAL INJURY Conservation oils are flammable and are dangerous to inhale. Ensure good ventilation. Use a face mask when applying the conservation oil. • Drain the engine oil and fill with conservation oil just over the MIN marking on the dipstick • Connect the fuel suction and return hoses to a fuel can (app. 20 l) containing 1/3 conservation oil and 2/3 diesel fuel • Bleed the fuel system, see section "Bleeding the fuel system" • Start the engine and idle until about 2 l of the fluid in the fuel can have been used • Stop the engine and reconnect the fuel suction and return lines to the machine • Drain the excess fluid from the engine, see section "Cleaning and draining the fuel tank, all engines" • Put a note on the machine with the date, type of conservation and the conservation oil used Bringing out of storage • If applicable, remove the cover from the machine • Remove covers from air intake systems and exhaust systems • Remove the rust inhibitor • Check for visible leakage under the machine and on the ground. • Tighten all connections before filling any fluid, if needed • Check and adjust the hydraulic oil level, remove excess oil • Charge and reconnect the battery • Tighten the fan belt • Fill the AdBlue/DEF tank, if applicable • Perform maintenance service according to the 500 hours schedule, see section "Regular service" • Lubricate the machine, see section "Regular service" • Bleed the fuel system, if applicable, see section "Bleeding the fuel system" • Check the condition of all rubber hoses, and retighten the hose clamps if necessary • Check that no oil, fuel, or coolant leakage occurs • Start the machine, and idle to warm up the engine • When the engine has reached the required temperature, and while idling, check for visible oil, fuel, or coolant leakage • Run all hydraulic functions and steer cylinders to end position and back again • Check for visible leakage also when using the hydraulic functions after storage • Test drive the machine, to make sure all systems function properly 52/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Transport and towing Maintenance Instructions 3 TRANSPORT AND TOWING 3.1 Lifting the machine - General safety DANGER FALLING LOAD HAZARD When the machine is lifted, the machine or parts from the machine could fall. There is a risk of serious personal injury or death to people who stands or walks near or under the machine. Do not stand or walk near or under the machine when it is lifted. WARNING RISK OF DAMAGE TO THE MACHINE When the machine is lifted, it could fall. Visually check the lifting equipment and the lifting points for damages before lifting the machine. Use only lifting equipment and cranes which have sufficient lifting capacity. See the information on the lifting capacity plate from the manufacturer, for the weight of the lifted machine. Follow local regulations for lifting procedures and equipment. WARNING RISK OF DAMAGE TO THE LIFT SLINGS If the lift slings grind against the chassis, the lift slings can get damaged. Lift the machine with the lift slings positioned as straight as possible. The maximum allowed angle of the front lift slings for SMV 10-25 is 15 degrees. The maximum allowed angle of the front lift slings for SMV 28-65 is 10 degrees. The maximum allowed angles of the rear lift slings are: - 15 degrees forwards and backwards for SMV 10-25 - 10 degrees to the left and to the right for SMV 10-25 - 10 degrees forwards and backwards for SMV 28-65 - 5 degrees to the left and to the right for SMV 28-65 When the machine is lifted, the lift slings must not grind against any part of the machine. Protect the lift slings with some appropriate protection if contact with the chassis cannot be avoided. 53/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 3 Transport and towing 5° X. 1 MAX. 10° MAX. 10° MAX. 10° MAX. 10° MA 5° 5° MA X. 1 X. 1 X. 1 MA MA 5° Figure 11. Maximum allowed angles of the slings SMV 10-25 (Rear lifting ears optional for SMV 10-25) 0° X. 1 MA X. 5° MA X. 5 X. 5 ° MA X. 5 MA ° MA ° 0° MA X. 1 X. 1 0° MA 0° X. 1 MA Figure 12. Maximum allowed angles of the slings SMV 28-65 3.2 Lifting points SMV 10-25 NOTE Always inspect the lifting ears before lifting the machine. When lifting the machine, the lift slings must always be as vertical as possible, never NOTE exceed the recommended angles. See Lifting the machine - General safety (page 53). NOTE If the machine is equipped with a high mast, always use the lower front lifting points. 54/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Transport and towing Maintenance Instructions 5 3 4 2 2 1 Figure 13. Lifting points SMV 10-25 1. Attach two shackles on the rear lifting ears (1) at the counterweight. 2. Attach two shackles to either the upper or the lower front lifting points (2). 3. Attach lift slings to the shackles in the front and the rear. 4. Attach the lift slings to the lifting hook (3) and secure the safety lock (4). Figure 14. Rear lifting ears 5. To protect the slings when lifting the machine, place appropriate protection (5) between the lift slings and the chassis. When lifting the machine, always use the rear lifting ears (1). The lifting ears on the NOTE removable counterweight (if applicable) must not be used for lifting the complete machine. 3.3 Lifting points SMV 28-65 NOTE Always inspect the lifting ears before lifting the machine. 55/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 3 Transport and towing 3 4 2 1 2 Figure 15. Lifting points SMV 28-65 1. Attach two shackles on the top rear lifting ears (1) at the counterweight. 2. Attach two shackles to either the upper or the lower front lifting points (2). 3. Attach lift slings to the shackles in the front and the rear. 4. Attach the lift slings to the lifting hook (3) and secure the safety lock (4). When lifting the machine, always use the welded lifting ears (1), or the rear lifting ears. NOTE The lifting ears on the removable counterweight (if applicable) must not be used for lifting the complete machine. 3.4 Rear top lifting ears SMV 10-25 (option) WARNING RISK OF DAMAGE TO THE MACHINE The machine can be dropped when lifted. Visually check the lifting ears and the bolts for the lifting ears for damages before lifting the machine. There should not be any visible damage on either the lifting ears or the bolts for the lifting ears. NOTE If the machine is equipped with a high mast, always use the lower front lifting points. 56/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Transport and towing Maintenance Instructions 3 4 2 5 1 2 Figure 16. Lifting points when using optional lifting ears The bolts for the lifting ears (5) are tightened with an appropriate locking glue when NOTE delivered. If the bolts are not loose, they do not need to be retightened. 1. Attach two shackles on the top rear lifting ears (1) at the counterweight. 2. Attach two shackles to either the upper or the lower front lifting points (2). 3. Attach lift slings to the shackles in the front and the rear. 4. Attach the lift slings to the lifting hook (3) and secure the safety lock (4). When lifting the machine, always use the rear lifting ears (1). The lifting ears on the NOTE removable counterweight (if applicable) must not be used for lifting the complete machine. 57/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 3 Transport and towing 3.5 Lifting the machine without the mast WARNING RISK OF DAMAGE TO THE MACHINE Using shackles damages the bushings of the machine. Do not use shackles to lift the machine when the mast is dismounted. Instead, use appropriate lifting equipment which does not damage the bushings. NOTICE Be careful not to damage the suspension ears when lifting the machine. When the mast is dismantled, it is possible to use the mast suspension ears (5) as lifting points. 1. To lift the machine without the mast, attach appropriate lifting equipment to the mast suspension ears (5). 58/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Transport and towing Maintenance Instructions 3.6 Lifting the mast When lifting only the mast, the lower lifting point must be used. This lifting point can also be used when lifting the complete machine, if needed. 3 4 5 2 2 1 Figure 17. Lower lifting point - Mast 1. Attach two shackles on the lower front lifting points (1). 2. Attach lift slings to the shackles (2). 3. Thread the lift slings behind the top front beam (3). When lifting the complete machine, the lift slings must be threaded between the top front NOTE beam (3), and the mast. 4. Attach the lift slings to the lifting hook (4) and secure the safety lock (5). 59/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 3 Transport and towing 3.7 Towing WARNING RUN OVER HAZARD If the engine, the electrical system or the hydraulic system is broken, the parking brake may need to be released manually to tow the machine. In this situation, the machine has no brakes or steering capability, which may lead to serious personal injury and damage to the machine. When towing the machine, the engine must idle, or a vehicle with sufficient braking capacity to stop both vehicles must be used. WARNING MOVING VEHICLE HAZARD When towing the machine, there is a risk that the machine becomes unattached from the towing vehicle. It can lead to serious personal injury and damage to the machine. Do not exceed the towing capacity of the transporting vehicle. NOTE Only trained and authorized personnel are allowed to tow the machine. If possible, the engine should idle when being towed. If not, the hydraulic brake system, and servo-assisted steering system cannot be used. If idling is not possible, release the hydraulic parking brake manually. After the hydraulic parking brake is released, the machine has no brakes. To stop both vehicles when towing the machine, use a vehicle with sufficient brake capacity. Use a towing bar if possible. For more information, see Manually releasing the parking brake (page 203). 1. Attach the towing bar to the machine. Use the rear towing peg, if applicable, when fitting a sturdy towing bar on the machine. NOTE Otherwise use slings and secure them around the back counterweight when towing. 2. Remove the propshaft (1). 3. Release the parking brake manually. 3.8 Transportation RISK OF DAMAGE TO THE MACHINE NOTICE Do not exceed the load limits of the transporting vehicle. See the lifting capacity plate for the weight of the transported machine. 60/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 3 Transport and towing Maintenance Instructions RISK OF DAMAGE TO THE MACHINE NOTICE Check the total clearance height of the transporting vehicle and the transported machine. There can be low overpasses along the transportation route. 3.8.1 Securing the rear end 2 3 1 1. Engage the parking brake. 2. Place blocks (1) in front of and behind the wheels to prevent the truck from moving. 3. Hold the truck in place with two chains that are attached with shackles (2) to the eyes (3) beneath the counterweight. 3.8.2 Securing the front end - machines without mast 4 5 5 1. Attach two shackles to the front lifting eyes (4) positioned on the chassis. 2. Place blocks (5) in front of and behind the wheels to prevent the truck from moving. 61/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 3 Transport and towing 3.8.3 Securing the front end - machines with mast 3 1. Lower the mast and fork carriage. 2. Attach two lifting hooks (3) to the fork carriage to hold the truck in place. 3. Secure the cylinders with straps and cable ties. 62/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4 SERVICE AND MAINTENANCE INSTRUCTIONS 4.1 Maintenance safety information WARNING IRRITATING SUBSTANCE HAZARD The machine contains several chemical substances, which can cause skin irritation and allergies. Personal injury hazard when in prolonged contact with skin. When handling chemical substances, such as oils, hydraulic oils, fuel, grease, paint, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. WARNING BODY INJURY HAZARD Lifting or moving heavy components could cause musculoskeletal disorders and back strains. Use appropriate lifting equipment. Use power tools when possible instead of manual tools. WARNING TIPPING AND COLLISION HAZARD If a collision occurs, the machine can tip over. Risk of personal injury, and or damage to the machine. Evaluate the height of overhead structures concerning the mast position when driving and before entering maintenance buildings with the machine. Preventive maintenance and service must be carried out regularly and in accordance with the regulations that are supplied in the maintenance schedule. Maintenance must only be carried out by trained staff, dealers, or service technicians authorized by the operational manager, or Konecranes Lift Trucks. During the warranty period, maintenance must always be carried out by personnel authorized by Konecranes Lift Trucks. Maintenance must be carried out in accordance with the maintenance schedule. Before any service work, check that: • The machine is parked on firm, level ground. • The mast, and carriage are fully lowered, and the mast is tilted to vertical position. • The machine is blocked, so that it cannot move. • The engine is turned off and the ignition key removed. • The battery main switch is turned off, and the handle is removed. • The mast, and fork carriage have been secured, if they are in a raised position. • The machine is firmly secured if work must be carried out underneath when the machine is lifted. NOTE Make sure to use appropriate lifting equipment when handling heavy components. After every service, check the machine for leakage and carry out a test drive and an operational test on the machine. If applicable, check that TRUCONNECT® functions properly. Perform a daily maintenance check. 63/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions RISK OF DAMAGE TO THE MACHINE When the machine is used in extremely warm, cold, or dusty environments or in other NOTICE unfavorable conditions, it is more exposed. If so, the service must be carried out more frequently than the service and maintenance schedule recommends. Clean the area around each component before lubricating, changing filters, or repairing the hydraulic system. Use only clean receptacles when topping up lubricants, and other fluids. 4.2 Reset service hour counter WARNING RISK OF DAMAGE TO THE MACHINE If service is not performed according to the maintenance schedule, there is a risk of degradation and damage to the machine. Reset of the service hours must only be performed by trained maintenance personnel. Reset of the service hours must only be performed after each completed service of the machine. 1 2 Figure 18. Reset service hours After service is performed, the service hours (1) can be reset. The reset restarts the counter to the next service interval and removes all service reminders until the next interval is reached. 1. Perform service of the machine. 2. Press the reset button (2). 3. Enter the requested service code. 4. Press the reset button (2) for 5 s. 64/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.3 RFID - Adding an operator (option) 1. Start the ignition. 1 2. Go to the Machine overview page (1). 2 3 3. Press the RFID selection button (2). 65/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4. Enter the service code (3). 4 5. The Access card page (4) appears. 5 START 6 1 2 6. Lift the cover of the armrest (5). 66/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 7. Swipe the RFID tag over the RFID reader (6). 7 8 9 10 NOTE The ID-number of the operator appears in the top right corner (8). 8. Choose a number in the list (7), the colour changes to green. 9. Press the "plus" button (9) to add the ID-number (8) to the operator number (7) NOTE Press the "minus" button to remove an operator. 10. Press "confirm" (10). 11 11. If the warning message (11) appears, turn off the ignition to store the new settings. 67/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.4 Electric welding WARNING RISK OF FIRE While welding, molten particles can be projected and set fire to surrounding materials. Keep the working area clean and use appropriate protective gear. WARNING TOXIC FUMES HAZARD Breathing in the toxic fumes from welding can cause breathing difficulties and suffocation. Do not inhale the welding fumes. Use appropriate protection gear such as breathing mask. Only qualified and trained personnel may perform this action. RISK OF DAMAGE TO THE MACHINE NOTICE Follow these instructions when doing electric welding on the machine. Disconnect all battery connections, alternator connections, and all control units. NOTE All welding work must be performed by authorized welders. 1. Remove the battery connections. 2. Remove the connections to the alternator. 3. Disconnect all control units in, and on the machine. 4. Connect the welding clamp, close to the welding point. Never attach the welding clamp to the engine, or anywhere that enables the current to NOTE pass over a bearing, or a vibration damper. 5. When the welding is done, connect the alternator, and control units before connecting the batteries. 6. Perform a daily maintenance check. To ensure that everything works properly, test all functions before returning the machine NOTE to operation. 68/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.5 Jump-starting DANGER RISK OF ARCING AND EXPLOSION Touching the connections during a jump-start attempt can cause arcing and lead to serious personal injury or death. Do not touch the connections during a jump-start attempt. WARNING RISK OF EXPLOSIVE GAS When jump-starting the machine with a new battery, the empty battery is charged with a high effect. The high-effect charging causes the empty battery to release explosive gas. Always connect the black cable from the negative pole on the new battery to the chassis, as far away as possible from the empty battery. RISK OF DAMAGE TO THE MACHINE Jump-starting the machine with a quick charger, booster, power pack, or similar, can NOTICE cause a current surge and serious damage to the control units. Do not jump-start the machine with a quick charger, booster, power pack, or similar. NOTE To avoid risk of fire, keep the working area clean when performing a jump-start attempt. 1. Connect the red cable on the positive pole of the two auxiliary batteries to the positive pole of the discharged battery. 2. Connect the black cable that is on the negative pole of the two auxiliary batteries to a chassis point, away from the discharged battery. 3. When the engine starts, remove the cables in the reverse order. 69/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.6 Tilting the cabin WARNING FLYING OBJECTS HAZARD Loose objects can fall out of the cabin. If left open when tilting the cabin, the cabin doors may come off their hinges. Risk of serious injury and damage to the machine. Before the cabin is tilted, both cabin doors must be shut. Loose objects should be removed from the cabin. The mast should be vertical and the fork carriage in its lowest position. WARNING FALLING LOAD HAZARD If the cabin is not fully tilted, the cabin may fall and cause serious injury. If the cabin is not fully tilted, secure the cabin to prevent it from falling down. Take care if you must work underneath the cabin. WARNING MACHINE MISUSE HAZARD Risk of serious injury and damage to the machine. Do not drive the machine with the cabin partially or fully tilted. WARNING RISK OF DAMAGE TO THE MACHINE When tilting the cabin, it collides with the mast if the mast is tilted backwards. This can cause damage to the cabin. Do not tilt the cabin if the mast is tilted backwards. 1 2 All standard machines are equipped with manual cabin tilting (electrical cabin tilting is available as an option). 70/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.6.1 Manual cabin tilting 2 3 1 Figure 19. Manual cabin tilting 1. Warning sticker 2. Pump handle 3. Direction valve A warning sticker (1) is attached to the pump. Figure 20. Pump warning sticker 1. Open the hatch by using a special key. Hatch is found on the left side of the machine. 2. Fit the pump handle (2) in the direction valve (3). 3. To tilt the cabin upwards, turn the direction valve (3) clockwise. To turn the valve (3), use the bottom end of the pump handle (2). 4. Pump to tilt the cabin. 5. To tilt the cabin downwards, turn the direction valve (3) counter-clockwise. 6. Pump to tilt the cabin. 71/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.6.2 Electrical cabin tilting (option) 1 2 4 3 1. Warning sticker 2. Pump handle 3. Direction valve 4. Electrical tilt button A warning sticker (1) is attached to the pump. Figure 21. Pump warning sticker 1. Open the hatch by using a special key. Hatch is found on the left side of the machine. 2. Fit the pump handle (2) in the direction valve (3). 3. To tilt the cabin upwards, turn the direction valve (3) clockwise. To turn the valve (3), use the bottom end of the pump handle (2). 4. Press the electrical tilt button (4). 5. To tilt the cabin downwards, turn the direction valve (3) counter-clockwise. 6. Press the electrical tilt button (4). 72/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.7 Releasing the hydraulic accumulator pressure WARNING HIGH-PRESSURE HAZARD The hydraulic system contains a hydraulic accumulator to maintain the brake function during a possible machine failure. Risk of serious personal injury. Before performing maintenance or service on the hydraulics of the machine: - Always lower the mast to the bottom position. - Always ensure that the accumulator pressure for the hydraulic brake system is released before loosening any hydraulic hoses in the brake circuit. Be careful as high nitrogen pressure remain in the accumulator even after the oil pressure is released. 1. Locate the accumulator charging block. 2. Loosen the locknut using a wrench (1). 2 1 3. Loosen the drainage screw using an Allen key (2). After performing maintenance on the machine, make sure to tighten the drainage screw NOTE and locknut. 73/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.8 Changing the wheels DANGER HIGH-PRESSURE HAZARD The tires may explode when you deflate or inflate them, or in case of fire. Standing inside the tire explosion danger zone during a tire explosion can cause death or serious injury. Always stand to the side of the wheel when deflating or inflating tires, see "tire explosion danger zone" illustration. Use safety glasses. WARNING HIGH-PRESSURE HAZARD If the valve is broken, air cannot come out of the tire while deflating. If there is visual damage to the tire or rim, it may cause the tire to explode. To deflate the tire, drill a hole into the thread, as shown in the illustration. Only authorized and properly trained personnel are allowed to maintain and change the NOTICE wheels. NOTE When changing tires, always perform a dye penetration test on the rims. 4.8.1 Before changing the wheels Changing a wheel is a two-man operation. A support truck that is fitted with an attachment for the wheel (1) facilitates the work. 1 Figure 22. Support truck 1. Position the machine on even ground. 2. Lift the side of the machine and support the underside of the chassis according to recommendations. 74/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.8.2 Positioning the jack WARNING MOVING VEHICLE HAZARD. The machine can move if not parked on level ground and with the wheels firmly secured. If the machine moves, there is a risk of serious injury or death. Park the machine on level ground and firmly secure the wheels before jacking up the machine. Observe the following regulations before lifting the machine. • Specifications for tires: See machine card. • Specifications for rims: Use only rims that are approved by the manufacturer of the machine. • Other type of tires: The machine is designed to use pneumatic tires. Solid tires are used only in consultation with the manufacturer of the machine. NOTE Changing wheels is a two-man operation. 1 2 1. Block the drive wheels and position the jack underneath the steer axle (1) to lift the steer axle of the machine. 2. Block the steer wheels and position the jack underneath the drive axle (2) to lift the drive axle of the machine. 75/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.8.3 Deflating the tire DANGER HIGH-PRESSURE HAZARD The tires may explode when you deflate them. Standing inside the danger zone during a tire explosion causes death. Always stand beside the wheel when deflating or inflating tires, see "tire explosion danger zone" illustration. Wear appropriate safety glasses. DANGER HIGH-PRESSURE HAZARD If the valve mechanism shoots out at high pressure, it may cause serious personal injury or death. Make sure that no part of the body is in the trajectory of the valve mechanism. Wear appropriate safety glasses. WARNING HIGH-PRESSURE HAZARD If the valve is broken, air cannot come out of the tire while deflating. If there are visual damages on the tire or the rim, it may cause the tire to explode. To deflate the tire, drill a hole into the tread, as shown in the illustration. RISK OF PROPERTY DAMAGE When you deflate the tire, the high pressure and moisture of the air may cause the valve NOTICE to get covered with ice. Heat the valve with a heat gun. 76/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 120° 120° 50 yd m/ 55 55 m/ y 50 d 50 d 5y m/5 m/5 5y 50 d 120° 120° Figure 23. Tire explosion danger zone Only drill if the valve is broken and does not release air. It is only allowed to drill in the surface of the tread that has contact with the ground (shown in the picture). If only NOTE drilling in the contact surface of the tread, it is possible to reuse the tire when it has been repaired. Figure 24. Drilling a hole into the tread NOTE Recommended size of the drill bit, approximately 7-8 mm. Deflate as follows: 1. Unscrew the valve cap. 2. Unscrew the valve plug. Ensure that no part of the body is in the possible trajectory of the valve mechanism. 77/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.8.4 Inflating the tire DANGER HIGH-PRESSURE HAZARD The tires may explode while being inflated or if the maximum tire pressure is exceeded. Standing inside the danger zone during a tire explosion can cause death or serious injury. Never exceed the maximum tire pressure. Always stand aside the wheel when deflating or inflating tires, outside the tire explosion danger zone. Use safety glasses. Only authorized and properly trained personnel are allowed to maintain and change the NOTICE wheels. The recommended tire pressure is 10 bar at 20° Celsius. When checking the tire pressure, consider the temperature. The recommended tire pressure can vary depending on the temperature. If the machine is equipped with tire pressure monitoring system (TPMS), the 10-bar recommendation is monitored. Should the pressure drop too far or get too high, the operator gets a notification in the display unit. Always contact the manufacturer of the machine in advance for a written approval to use NOTE other tires. The maximum pressures that are specified by the tire manufacturer must never be exceeded. If using another rim or tire than the ones delivered with the machine, other NOTE pressure values could be valid. It is the responsibility of the operational manager to make sure that the machine has the correct safety labels if using other tires. 120° 120° 50 yd m/ 55 55 m/ yd 50 50 d 5y m/5 m/5 5y 50 d 120° 120° Figure 25. Tire explosion danger zone 78/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions Figure 26. Example of staying out of the tire explosion danger zone when inflating or deflating a tire • If using rims with clamps, never fit a tire or rim which is fully or partly inflated. All parts must be assembled before inflating the tire. • Rim components must never be assembled with hammer blows. • When the tire is deflated, disassemble the tire and check the rim for wear, cracks, and damage. Perform a dye penetration test on the rim. • It is important that all rim components comply with each other and are certified and approved for use on heavy-duty machines. • 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 machine. • If a safety cage is used, the tire can be inflated to maximum pressure. Otherwise the tire must be inflated until the bead is seated to the rim. • Never exceed the maximum pressures that are specified by the tire manufacturer. If using another rim or tire than the ones delivered with the machine, other pressure values could be valid. Contact Konecranes Lift Trucks for advice. Inflate the tire as follows: NOTE If using rims with clamps, always mount the tire to the machine before inflating the tires. 1. Check that locking rings and locking lugs (if applicable) are in place, and tightened with correct torque, before inflating the tire. 2. Connect the compressor line to the tire air valve. To prevent the entry of humidity which leads to corrosion, use a dryer filter on the NOTE compressor air line. 3. Check that all components are in place when bead seating pressure is achieved. NOTE Always stand beside the wheel when inflating the tire. 4. If using rims without clamps, mount the tire to the machine according to instructions. 5. Stand beside the wheel, inflate the tire to the maximum pressures specified by the tire manufacturer. NOTE The recommended tire pressure varies depending on the temperature. 79/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.8.5 Dismantling the outer drive wheel, general DANGER HIGH-PRESSURE HAZARD Fitting tires that are not approved by the manufacturer may cause a tire explosion, which can cause serious personal injury or death. When changing tires, only use tires which are approved by the manufacturer. DANGER HIGH-PRESSURE HAZARD The bead seat bands (2) and locking rings (3) may release and shoot off when the pressure changes. Risk of serious personal injury and death. Always release the air from both tires, before loosening or removing any wheel nuts or clamp units (if applicable). 1 2 3 Figure 27. Parts of the rim 1. Rim base 2. Bead seat band 3. Locking ring 4.8.5.1 Dismantling the outer drive wheel, wheels without clamp units 1. Jack up the drive axle. See: Positioning the jack (page 75) 2. Deflate both outer and inner wheel (if applicable). 3. Remove all but two of the nuts (1). 80/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 1 4. Use the support truck to support the weight of the outer wheel (3) on its forks. 5. Remove the two remaining nuts (1). 6. Lean the outer wheel (3) against the wheel support of the support truck (4). 7. Secure the wheel with a chain (5). 3 5 4 8. Reverse the support truck carefully and unload the outer wheel (3). 4.8.5.2 Dismantling the outer drive wheel, wheels with clamp units 1. Jack up the drive axle. See: Positioning the jack (page 75) 2. Deflate both outer and inner wheel (if applicable). 3. Remove all but two of the nuts (1) and clamp units (2). 81/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 2 1 1 2 4. Use the support truck to support the weight of the outer wheel (3) on its forks. 5. Remove the two remaining nuts (1) and clamp units (2). 6. Remove the outer clamp unit ring. 7. Lean the outer wheel (3) against the wheel support of the support truck (4). 8. Secure the wheel with a chain (5) to the support truck. 3 5 4 9. Reverse the support truck carefully and unload the outer wheel (3). 4.8.6 Dismantling the inner drive wheel 7 8 9 6 1. Remove the outer drive wheel. 2. Remove the spacer (6). 82/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 3. Make sure that the inner drive wheel (7) is deflated. 4. Use the forks of the support truck to support the weight of the inner drive wheel (7). 5. Lean the inner drive wheel (7) against the wheel support (8) and secure it with a chain (9). 6. Carefully reverse the support truck and unload the inner drive wheel (7). 4.8.7 Mounting the inner drive wheels 1. Load the inner drive wheel (7) onto the support truck and fasten it to the support. 6 7 2. Clean the contact surfaces. 3. Carefully drive the support truck to the required position and place the inner drive wheel (7) over the drive axle and the hub. 4. Straighten the wheel (7). 5. Lower the forks of the support truck until the inner drive wheel (7) is resting on the hub. 6. Carefully reverse the support truck. 7. Mount the spacer (6). 4.8.8 Mounting the outer drive wheel 4.8.8.1 Mounting the outer drive wheel, wheels without clamp units 1. Secure the wheel support (4) to the support truck. 2. Load the outer wheel (3) onto the wheel support (4). 3. Secure the wheel to the wheel support (4). 4. Carefully drive the support truck into position. 5. Place the outer wheel (3) over the hub. 83/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 3 4 6. Straighten the wheel (3). 7. To avoid putting too much weight on the drive axle, continue supporting the outer wheel (3). 8. To keep the rim in place, fasten two wheel nuts placed diagonally to each other. 9. Carefully reverse the support truck. 10. Tighten the wheel nuts crosswise, in the order 1-10 as shown in the figure. 1 8 6 9 3 10 4 5 7 2 For the required torque, see Tightening the wheel nuts (page 91). 11. Pump the tires according to the recommendations from the tire manufacturer. 4.8.8.2 Mounting the outer drive wheel, wheels with clamp units 1. Secure the wheel support (1) to the support truck. 2. Load the outer wheel (3) onto the wheel support (1). 3. Secure the wheel (3) to the wheel support (1). 4. Carefully drive the support truck into position. 5. Place the outer wheel (3) over the hub. 84/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 3 1 2 6. Straighten the wheel (3). 7. To avoid putting too much weight on the drive axle, continue supporting the outer wheel (3). 8. Fit the outer clamp unit ring (2). 9. To keep the rim in place, fasten two clamp units (5) and two wheel nuts (4). NOTE Place the clamp units (5) and the wheel nuts (4) diagonally to each other. 5 4 4 5 10. Carefully reverse the support truck. 11. Fasten the remaining clamp units (5). 12. Tighten the wheel nuts crosswise, in the order 1-24 as shown in the figure. 85/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 1 9 23 17 15 6 7 14 19 21 11 4 3 12 22 20 13 8 5 16 18 24 10 2 For required torque, see Tightening the wheel nuts (page 91). 13. Pump the tires according to the recommendations from the tire manufacturer. 4.8.9 Dismantling the steer wheel, general DANGER HIGH AIR PRESSURE If the air is not released from the tire, it can explode. Risk of serious injury or death. Release the air from the tire before dismantling. 4.8.9.1 Dismantling the steer wheels, wheels without clamp units 1. Jack up the steer axle. See Positioning the jack (page 75) 2. Deflate the tires. 3. Remove all but two of the nuts (1). 1 86/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4. To support the weight of the steer wheel (5), use the forks of the support truck. 5. Remove the remaining nuts. 6. Lean the steer wheel (5) against the wheel support (3). 7. Fasten the steer wheel with a chain (4). 3 4 5 8. Carefully reverse the support truck and unload the steer wheel (5). 4.8.9.2 Dismantling the steer wheels, wheels with clamp units 1. Jack up the steer axle. See: Positioning the jack (page 75) 2. Deflate the tire. 1 3. Remove all but two of the nuts (1) and clamp units. 3 4 2 4. To support the weight of the steer wheel (2), use the forks of the support truck. 87/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 5. Remove the remaining nuts and clamp units. 6. Lean the steer wheel (2) against the wheel support (3). 7. Fasten the steer wheel with a chain (4). 8. Carefully reverse the support truck and unload the steer wheel (2). 4.8.10 Mounting the steer wheels 4.8.10.1 Mounting the steer wheels, wheels without clamp units 3 4 5 1. Load the steer wheel (5) onto the support truck. 2. Secure the steer wheel (5) to the wheel support (3) with a chain (4). 3. Clean the contact surfaces. 4. Carefully drive the support truck into position. 5. Place the steer wheel (5) against the hub. 6. To support the weight of the steer wheel (5), use the forks of the support truck. 7. Fix and tighten two of the nuts (1) diagonal to each other. 1 8. Carefully reverse the support truck. 9. Fasten and tighten the remaining nuts (1) crosswise. For the required torque, see Tightening torque (page 90). 10. Pump the tires according to the recommendations of the tire manufacturer. 88/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.8.10.2 Mounting the steer wheels, wheels with clamp units 3 4 5 1. Load the steer wheel (5) onto the support truck. 2. Secure the steer wheel (5) to the wheel support (3) with a chain (4). 3. Clean the contact surfaces. 4. Carefully drive the support truck into position. 5. Place the steer wheel (5) against the hub. 6. To support the weight of the steer wheel (5), use the forks of the support truck. 7. Fix and tighten two of the clamp units (2) and nuts (1) diagonal to each other. 2 1 1 2 8. Carefully reverse the support truck. 9. Fasten and tighten the remaining clamp units (2) and nuts (1) in the correct sequence. For the required torque, see Tightening torque (page 90). 89/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 1 9 7 6 11 4 3 12 5 8 10 2 10. Pump the tires according to the recommendations of the tire manufacturer. 4.9 Tightening the bolted joints This chapter gives general informaton about the tightening torques for nuts and bolts, as well as more precise information about tightening torques for the nuts and bolts that are used in specific parts of the truck. 4.9.1 Tightening torque DANGER MACHINE MALFUNCTION HAZARD Failure to check the torque, can result in death, injury, or damage. Check the torque of the bolted joints during first service and on regular intervals. DANGER MACHINE MALFUNCTION HAZARD If lubricating the bolts before tightening them, the bolts are not properly fixated. Bolts which are not properly fixated, can cause accidents which can result in death, injury, or damage. The torques which are presented in the table apply only for dry bolts. Do not lubricate the bolts before tightening. The following table contains general tightening torque information for nuts and bolts in the truck. Check the following chapters for more precise information about tightening torques for NOTE the nuts and bolts of specific parts. Table 4. Tightening torques for untreated, unoiled, steel screw joints Millimeter bolts Inch bolts Thread M Tensile strength class Thread Tensile strength class UNC 8.8 10.9 12.9 8.8 10.9 12.9 6 9.8 Nm 14 Nm 17 Nm 1/4” 11 Nm 15 Nm 19 Nm 8 24 Nm 33 Nm 40 Nm 5/16” 22 Nm 31 Nm 38 Nm 90/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions Table 4. Tightening torques for untreated, unoiled, steel screw joints (Continued) Millimeter bolts Inch bolts 10 47 Nm 65 Nm 79 Nm 3/8” 38 Nm 54 Nm 68 Nm 12 81 Nm 114 Nm 136 Nm 7/16” 61 Nm 87 Nm 108 Nm 14 128 Nm 181 Nm 217 Nm 1/2” 93 Nm 131 Nm 163 Nm 16 197 Nm 277 Nm 333 Nm 9/16” 133 Nm 187 Nm 234 Nm 18 275 Nm 386 Nm 463 Nm 5/8” 183 Nm 259 Nm 323 Nm 20 385 Nm 541 Nm 649 Nm 3/4” 322 Nm 455 Nm 568 Nm 22 518 Nm 728 Nm 874 Nm 7/8” 516 Nm 729 Nm 909 Nm 24 665 Nm 935 Nm 1120 Nm 1” 772 Nm 1090 Nm 1360 Nm 27 961 Nm 1350 Nm 1620 Nm 1 1/8” 1090 Nm 1550 Nm 1930 Nm 30 1310 Nm 1840 Nm 2210 Nm 1 1/4” 1530 Nm 2160 Nm 2690 Nm 33 1770 Nm 2480 Nm 2980 Nm 1 3/8” 2020 Nm 2850 Nm 3550 Nm 36 2280 Nm 3210 Nm 3850 Nm 1 1/2” 2650 Nm 3750 Nm 4680 Nm 4.9.2 Tightening the wheel nuts DANGER MACHINE MALFUNCTION HAZARD Failure to check the torque, can cause the wheel nuts, and the rim to loosen, and destroy the hub. This can result in death, injury or damage. Check the torque of the wheels nuts as described. Check the torque of the wheel nuts daily for 14 days, or until the rim, clamp units, and nuts have settled in, and no more tightening is obtained. Perform these checks: • After a new delivery of machine • After the machine has been taken into use • After a wheel has been removed or replaced Figure 28. Drive wheel nuts 91/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions Figure 29. Steer wheel nuts Tighten the nuts crosswise according to the following table. Table 5. Drive wheel and steer wheel nuts torque Position Size Strength class Torque Clamps Drive axle M18x2 10.9 400 Nm Yes (295 lbf ft) Drive axle M22x1.5 10.9 768 Nm No (disc rim) (566.4 lbf ft) Steer axle M22x1.5 10.9 400 Nm Yes (295 lbf ft) Steer axle M22x1.5 10.9 700 Nm No (disc rim) (516.3 lbf ft) 4.9.3 Tightening the bolts in the propshaft 2 1 Figure 30. Propshaft SMV 10-18 92/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 2 1 Figure 31. Propshaft SMV 32-60 Select the correct torque according to the bolt size on the drive axle side (1) and the transmission side (2). Table 6. Propshaft torque Size Strength class Torque M14 8.8 128 Nm (94.4 lbf ft) M12 8.8 81 Nm (59.7 lbf ft) 4.9.4 Tightening the bolts in the engine and transmission mounting Check the condition of the rubber suspensions. If any wear and tear is discovered, replace the damaged parts. The engine mountings are accessible from the engine compartment, one on each side of the rear part of the engine. The transmission mountings are accessible from the engine compartment, one on each side of the transmission. 1 2 1 2 1 Figure 32. Engine mounting (left) and transmission mounting (right) 93/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions Table 7. Engine and transmission mounting torque Size Strength class Torque M20 8.8 385 Nm (284 lbf ft) M16 8.8 197 Nm (145.3 lbf ft) M16 10.9 277 Nm (204.3 lbf ft) 4.9.5 Tightening the bolts in the drive axle suspension WARNING RISK OF PROPERTY DAMAGE The bolts must be tightened in the order that is shown in the figure. There are four bolts on each side of the drive axle suspension. Select the correct torque from the table according to the bolt size. The screws, nuts, and washers must be installed dry. Do not use lubricants on the NOTE threads, or contact surfaces of the screws, nuts, or washers. 5 7 6 8 4 2 3 1 ° 60° 0 / 360° 60 60° 60° 60 ° ° 60 150° 120° Figure 33. Order to tighten bolts, including bolt angle torque The torque values in this table do not correspond to the standard torque values NOTE presented in the table in Tightening the bolted joints (page 90). Table 8. Drive axle suspension torque Size Method Strength class Torque M24 1 10.9 900 Nm (663.8 lbf ft) M30 1 10.9 1,550 Nm (1,143.2 lbf ft) M30 2 10.9 750 Nm (553.2 lbf ft) + 120° 94/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions Table 8. Drive axle suspension torque (Continued) Size Method Strength class Torque M36 1 10.9 3,000 Nm (2,212.7 lbf ft) M36 2 10.9 1,500 Nm (1,106.3) + 150° 4.9.6 Tightening the bolts in the hydraulic pumps 1 Figure 34. Hydraulic pumps Table 9. Hydraulic pumps torque Size Strength class Torque M12x40 8.8 81 Nm (59.7 lbf ft) 4.9.7 Tightening the bolts in the cabin suspension WARNING RISK OF DAMAGE TO THE MACHINE The suspension ears can get scrunched and damage the mounting brackets. When tightening the bolts, do not exceed the recommended torque values. WARNING RISK OF DAMAGE TO THE MACHINE When using the machine, the nuts and bolts of the front cabin suspension can come loose due to vibrations. The threads on the bolt must pass through the entire locking part of the nut. The torque value does not correspond to the standard torque value presented in the NOTE table at the beginning of the chapter. 95/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions Figure 35. Cabin suspension Cabin suspension - front 1. Place the bolt (1) with washers (2) in the suspension ears (3) and the mounting brackets. 2. Secure the bolt (1) with the locknut (4). NOTE The threads on the bolt (1) must pass through the entire locking part of the nut (4). 3. Tighten according to the recommended torque. Cabin suspension - rear 1. Apply Loctite to the bolt (1). 2. Thread the bolt (1) with washer (2) through the suspension ears (3) and the mounting brackets. 3. Secure the bolt (1) with the locking screw (5). 4. Tighten according to the recommended torque. Table 10. Cabin suspension torque Size Strength class Torque M24 12.9 100 Nm (73.8 lbf ft) 96/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.9.8 Tightening the bolts in the counterweights 1 2 3 4 Figure 36. Counterweights Select the right torque from the table according to the bolt size for the bolts of the counterweights (1), and (2). If equipped with counterweights on the steer axle, also check (3), and (4). Table 11. Counterweights torque Size Strength class Torque M24 8.8 665 Nm (490.5 lbf ft) M30 8.8 1,310 Nm (966.21 lbf ft) M36 8.8 2,280 Nm (1,682 lbf ft) 97/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.9.9 Tightening the bolts in the steer axle 1 2 Figure 37. Steer axle Tightening the bolts in the steer axle (1), and (2). Table 12. Steer axle torque Size Strength class Torque M36 8.8 2,280 Nm (1,682 lbf ft) M20 8.8 385 Nm (284 lbf ft) M30 8.8 1,310 Nm (966.2 lbf ft) 4.10 Lubricating the machine 4.10.1 General lubrication rules Follow these rules during lubrication: • Clean off old grease and clean grease nipples. • Lubricate until fresh grease protrudes. • Use only recommended grease. • All wear pads must be free of pressure for the grease to be able to penetrate. • Wear pads require frequent lubrication with a small amount of grease. Roller bearings require more grease less often. • Check the function and bearing slackness when lubricating. • Specified lubrication intervals apply in favorable conditions. More frequent lubrication is recommended in more demanding conditions, particularly of the wear pads. Examples of more demanding conditions can be dusty environments and heavy handling. For more information, see Recommended fluids and lubricants (page 250). 98/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.10.2 Lubricating the steer axle 1 3 3 Figure 38. Lubrication points 1. Remove any old grease and clean the grease nipples. 2. Lubricate the steering links (1), four points - two points on each steer link. 3. Lubricate the spindle bolts (2), one upper and one lower on each side. 4. Lubricate the wheel bearings (3), one on each side. Grease penetrates onto the inside. 99/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.10.3 Lubricating the hinges Figure 39. Lubrication points 1. Check and clean the hinges of the cabin door, battery hatch, and the hatch for the cabin tilting equipment. 2. Lubricate the hinges. To check that all parts of the hinges have been lubricated, open and close the hatches. 100/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.11 Lubricating the mast DANGER FALLING LOAD HAZARD Certain tasks require that the inner mast and carriage are raised. If you do not secure them, they may fall and cause serious injury or death. Secure the inner mast and carriage with a wooden block before starting work. 3 6 3 2 2 5 5 4 4 1 1 4 4 5 5 Figure 40. SMV 10-16 (left) and SMV 18-60 (right) mast lubrication points 1. Suspension shaft grease nipples 4. Side support reels 2. Tilt cylinder shafts 5. Mast wheels 3. Top support rollers 6. Chain wheels Do not use to much grease. Grease in the mast beams cause the rollers and wheels to NOTE slide instead of roll. Apply grease only to the bearings, not to the support rollers and mast wheels. Remember NOTE to lubricate on both sides of the mast. 1. Apply grease to the suspension shaft grease nipples (1). 101/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions The suspension shaft grease nipples (1) are accessible through the mast. Offload the shaft pins by lifting the mast either using a jack or a bench trestle and tilting it forwards. 2. Apply grease to the center of the tilt cylinder shafts (2). To offload the tilt cylinders, tilt the mast backwards. 3. Apply grease to the grease nipples of the top support rollers (3) on the outer mast. To reach the top support rollers (3), raise the mast. 4. Apply grease to the bearings of the side support reels (4) on the inner mast and the fork carriage. To reach the rollers, raise the carriage. The side support reels (4) of the fork carriage can be reached from the backside of the carriage. The side support reels (4) of the inner mast can be reached from the backside of the inner mast. 5. Apply grease to the bearings of the mast wheels (5) on the inner mast and the carriage. To reach the wheels, raise the carriage. The mast wheels (5) can be reached from the backside of the inner mast and carriage. 6. For SMV18-60: Apply grease to the chain wheels (6) through the grease nipples. 4.12 Lubricating the fork rollers 1 2 1 2 2 3 3 Figure 41. Fork rollers - lubrication points 1. Upper support rollers 2. Grease nipples 3. Lower support rollers Do not use too much grease. Grease in the carriage beams cause the rollers and wheels NOTE to slide instead of roll. Only apply grease through the grease nipples (2) to the bearings, not directly on the NOTE support rollers (1, and 3). 1. Apply grease through the grease nipples (2) for the upper support rollers (1). There are four upper support rollers (1) on each fork. 2. Apply grease through the grease nipples (2) for the lower support rollers (3). There are two lower support rollers (3) on each fork. 102/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.13 Lubricating the attachment 4.13.1 Attachment lubrication points - ELME 815 Toplift 3 3 1 2 2 1 4 5 5 4 1. Wear pads for main beams and extension 3. Stop cylinders beams 4. End beams and twistlocks 2. Extension cylinders 5. Fork frame and slew cylinders 103/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.13.2 Lubricating the wear pads for main beams and extending beams There are 20 or 24 lubrication points depending on model: 2 1 3 Figure 42. Lubrication points • Four tracks (1) on the inside of each main beam • Six tracks (2) on each extending beam • Two tracks (3) on the inside of each main beam 4.13.3 Lubricating extension beams and twistlocks NOTE Twistlocks on ELME New Generation (NG) are lubrication free. There are eight lubrication points: • One grease nipple in each end box (1) • One grease nipple in each sleeve (2) 1 2 Figure 43. Lubrication points 4.13.4 Lubricating extension cylinder support wear pads and tracks There are four lubrication points, two tracks in each extension beam. 104/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 1 Figure 44. Lubrication points 4.13.5 Lubricating the fork frame - ELME 815 There are 6 lubrication points: • Two greasing points on each slew cylinder, and one greasing point in the surface of the fork frame (4). 4 Figure 45. Lubrication points 105/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.13.6 Lubricating stop cylinders - ELME 815 (option) One grease nipple (1) on each stop cylinder. 1 100 m m 100 m m Figure 46. Lubrication points * * Locking plate shown in illustration. 4.14 Maintenance common to all engines 4.14.1 Cleaning and draining the fuel tank, all engines To collect the fuel, put a receptacle underneath the drain plug, and dispose of it in an NOTE environmentally responsible way. 2 1 Figure 47. Fuel tank 1. Check the tank for any leaks. 2. Place a receptacle underneath the tank. 3. Loosen the drain plug (1). 4. Drain the tank of any dirt and water through the drain plug (1). 5. When clear fuel comes through, refit the drain plug (1). Before refitting the drain plug, check the seal and change if needed. 106/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 6. Check the seal around the fuel cap (2), and change if needed. 4.14.2 Cleaning the engine air filter's coarse separator WARNING TOXIC SUBSTANCE HAZARD The engine air filter contains a significant number of dust particles, which may lead to breathing problems. If the filter element is damaged, the dust particles are also a major risk factor for engine damage. Always wear a face mask when servicing the air intake system. Do not inhale the dust particles. Consider the environment when carrying out this work. In sandy or dusty environments with many particles, clean the coarse separator more NOTE frequently. 2 1 Figure 48. Coarse separator, standard 2 Turbo II 1 Figure 49. Coarse separator, Turbo II (option) 1. Clean around the coarse separator (2). 2. Clean the clamp (1). 107/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 3. Remove the clamp (1) from the coarse separator (2). 4. Remove the coarse separator (2). 5. Clean the coarse separator (2) with air and remove the particles. 6. Dry the coarse separator (2) with a cloth. 7. Refit the coarse separator (2) and screw the clamp (1) in place. 108/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.14.3 Cleaning and changing the engine air filter, all engines WARNING TOXIC SUBSTANCE HAZARD The engine air filter contains a significant number of dust particles. If the filter element is damaged, it may lead to breathing problems. Always wear a protective mask when servicing the air intake system. Do not inhale the dust particles. Consider the environment when carrying out this work. WARNING RISK OF PROPERTY DAMAGE The engine air filter contains a significant number of dust particles. If the filter element is damaged, it causes a risk of damage to the engine. Always make sure that the engine air filter is cleaned and undamaged. Follow the "daily maintenance" instructions, and the maintenance schedule. RISK OF PROPERTY DAMAGE Do not clean the inside of the filter housing with compressed air. All maintenance on the NOTICE air intake system must be carried out while the engine is turned off. Do not use any liquids to clean the engine air filter, as it is a dry filter element. Cleaning the engine air filter always induce a risk of damaging it. After cleaning, the NOTE engine air filter has lower dust capacity than a new element. Clean or change the filter element when a warning about air inlet pressure appears on the MD4 display. Clean the area around the filter before opening the clamp units. 109/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4 3 2 1 Figure 50. Main filter element 1. Open all the clamp units (2) and remove the air filter cover (1). 2. Empty out the dust which has collected in the air filter cover (1). 3. Dry the air filter cover (1) using a damp cloth. 4. Remove the element (3) carefully. NOTE The safety cartridge inside the filter element (3), must stay in place. 5. Clean inside the filter housing (4) using a damp cloth. 6. Use a flashlight to check from the outside that there are no holes or cracks in the filter paper. 7. To clean the filter element (3), carefully blow compressed air of maximum 5 bar (72.5 psi) from the inside. Continue to blow until no more dust comes out. NOTE Do not use any liquids to clean the engine air filter, as it is a dry filter element (5). 8. After cleaning, write the date of cleaning on the filter element (3). 9. Discard the filter element (3) if it is damaged, or when it has been cleaned four times. 10. Put back the filter element (3) and close the air filter cover (1). 11. On the MD4 display, push (X) on the error message to close it. 110/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.14.4 Changing the safety cartridge, all engines NOTE Never clean the safety cartridge. Do not remove the safety cartridge unnecessarily. Replace the safety cartridge (1) if there has been any damage to the main filter. 1 2 3 Figure 51. Safety cartridge 1. Disassemble the filter element (2) as in Cleaning and changing the engine air filter, all engines (page 109). 2. Fit in a new safety cartridge (1). 3. Put back the filter element (2) and close the air filter cover (3). 111/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.14.5 Checking the air intake system, all engines The air intake system must be intact. Broken and leaking pipes shorten the life of the engine. Check the system regularly. 1 1 2 2 Figure 52. Air intake system 1. Check the hoses (1) for fissures and damage. If necessary, replace them. 2. Make sure that all hose clamps (2) are fit well. 3. Check that the filter housing is intact. 112/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.14.6 Checking the coolant system, Volvo engines For Volvo engines, there is a cover on the coolant tank. Turn the hand wheel (1) of the NOTE coolant tank cover anti-clockwise. Slide the cover back to gain access to the Volvo coolant tank. 1 Figure 53. Cover on Volvo cooling tank Figure 54. Cooling system, Volvo 1. To discover leaks and cracks, check all the hoses by pressing them. When in doubt, replace the hoses. 2. Check the radiator for damage and leaks, and that there are no deposits. 3. Check the functioning of the cabin heater. 4. Check the coolant in terms of: • Level • Freezing points • Any contaminations 5. Replace the coolant if it is not clean and clear. 6. If the coolant level is below minimum mark, top it up. 7. Check the rubber suspensions in the radiator mounting brackets at the bottom of the radiator. Replace the rubber mounts as necessary. 8. Make sure to tighten the fixing bolts. 113/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.14.7 Checking the coolant system, Cummins engines 1. To discover leaks and cracks, check all the hoses by pressing them. When in doubt, replace the hoses. 2. Check the radiator for damages and leaks, and that there are no deposits. 3. Check the functioning of the cabin heater. 4. Check the coolant in terms of: • Level • Freezing points • Any contaminations 5. Replace the coolant if it is not clean and clear. 6. If the coolant level is below minimum mark, top it up. 7. Check the rubber suspensions in the radiator mounting brackets at the bottom of the radiator. Replace the rubber mounts as necessary. 8. Ensure that the fixing bolts are tightened. 114/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.14.8 Changing the coolant, Volvo engines WARNING HOT FLUID HAZARD Hot coolant may spray from the refill, which may cause a risk of serious injury. Allow engine to cool and release pressure before opening the filler cap. Only authorized and trained service personnel is allowed to fill the coolant. WARNING HIGH-PRESSURE HAZARD The system may be under pressure even if it is not of the high-pressure type. The coolant may be under pressure and hot, which may cause serious injury. Open the filler cap slowly. WARNING HARMFUL SUBSTANCE HAZARD Using wrong coolant may damage the machine. Use the recommended coolant and never mix different coolants. For recommended coolants, see Fuel and oil recommendations (page 249). WARNING TOXIC SUBSTANCE HAZARD It is highly dangerous to drink ethylene glycol. Contact with skin or spray from the refill can cause skin irritation and eye damage. Do not drink ethylene glycol, and avoid contact with skin. WARNING HOT COOLANT HAZARD Opening the pressure chamber cap (1) can cause serious personal injury. Never open the pressure chamber cap (1) when checking, or refilling coolant. 115/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 2 1 3 4 1. Remove the filler cap (2) on the expansion tank (3). To ensure that the system is not pressurized when removing the filler cap (2) , only open NOTE 1/4 of a turn first. 2. Switch on the ignition to adjust the temperature for the cabin heater to maximum. 3. After adjusting the temperature, switch off the ignition again. 5 4. Place a receptacle under the drain valve (5). 5. To lead the coolant to the receptacle, connect a hose to the drain valve (5). 6. Open the drain valve (5). NOTE Be careful, risk of burning when opening the valve (5). 7. Drain the whole system, using the drain valve (5) on the side of the radiator. NOTE Drain the whole system, when replacing hoses and components in the system. 8. Close the drain valve (5). 9. Remove the hose from the drain valve (5). 10. Fill to the maximum level through the filler cap (2) on the expansion tank (3). 116/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 11. Start the engine, let it idle, and check for leaks. 12. Observe the level and fill as necessary. • When the operating temperature has been reached, the level stabilizes. • The tank (3) should be filled to the maximum. 13. Refit the filler cap (2). 4.14.9 Changing the coolant, Cummins engines WARNING HOT FLUID HAZARD Hot coolant may spray from the refill, which may cause a risk of serious injury. Allow engine to cool and release pressure before opening the filler cap. WARNING HIGH-PRESSURE HAZARD The system may be under pressure even if it is not of the high-pressure type. The coolant may be under pressure and hot, which may cause serious injury. Open the filler cap slowly. WARNING HARMFUL SUBSTANCE HAZARD Using wrong coolant may damage the machine. Use the recommended coolant and never mix different coolants. WARNING TOXIC SUBSTANCE HAZARD It is highly dangerous to drink ethylene glycol. Contact with skin or spray from the refill can cause skin irritation and eye damage. Do not drink ethylene glycol and avoid contact with skin. 1. Remove the filler cap (1) on the expansion tank (2). To ensure that the system is not pressurized when removing the filler cap (1), only open 1/4 of a turn first. 2. Switch on the ignition to adjust the temperature for the cabin heater to maximum. After adjusting the temperature, switch off the ignition. 117/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 3 3. Place a receptacle under the drain valve (3). 4. To lead the coolant to the receptacle, connect a hose to the drain valve (3). 5. Open the drain valve (3). NOTE Be careful, risk of burning when opening the valve. 6. Drain the whole system. Drain the whole system using the drain valve on the side of the radiator when replacing NOTE hoses and components in the system. 7. Close drain valve (3). 8. Remove the hose from the drain valve (3). 9. Fill through the filler cap (1) on the expansion tank (2) to the maximum level. 10. Start the engine, run on idle, and check for leaks. 11. Observe the level and fill as necessary. • When the operating temperature has been reached, the level stabilizes. • Level should be at the maximum level indicator (4) on the side of the expansion tank. 4 12. Refit the filler cap (1). 118/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.14.10 Cleaning the radiator, intercooler, and oil coolers, all engines WARNING HOT SURFACE HAZARD If you touch the radiator and coolers when they are hot, the heat may cause serious injury. Only clean the radiator and coolers when the engine has been turned off and cooled down. Do not apply cold water on hot surface. RISK OF PROPERTY DAMAGE If you use a high-pressure steam cleaner, it may damage the fins of the radiator, NOTICE intercooler, and oil coolers. Use compressed air. 1 2 3 4 Figure 55. Radiator 1. Intercooler (contains air from the turbo to 3. Oil cooler for brakes(not applicable for all the engine) models and sizes) 2. Engine radiator (contains engine coolant) 4. Transmission oil cooler To clean the radiator (2), intercooler (1), and oil coolers (3 and 4), use compressed air. 1. Blow against the direction of the fan. The radiator (2), intercooler (1), and oil coolers (3 and 4) must not be cleaned with high- pressure water. In extreme cases, solvents or a jet of steam can be used with great care. 2. Allow the solvent time to penetrate. Rinse off with water. 3. Run the engine warm so that surplus water evaporates and does not cause corrosion. 119/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.14.11 Checking the valve clearance, all engines The valve clearance must be checked and adjusted by a service technician who has the NOTICE necessary special equipment. The technician must be authorized by Konecranes Lift Trucks or by the engine manufacturer. Check the valve clearance when the engine is cold. Follow the instructions in the engine NOTE manufacturer’s instruction book. Figure 56. Valve clearance 4.14.12 Checking the fuel system and fuel injectors, all engines WARNING SKIN INJECTION HAZARD If the high-pressure fluid from the fuel injectors penetrates the skin, it may cause serious bodily injury or death. Never check leakage of the fuel system when the engine runs. Use protective gear such as safety gloves and protective wear. RISK OF DAMAGE TO THE MACHINE The fuel injectors must be checked and adjusted by a service technician who has the NOTICE necessary special equipment. The technician must be authorized by Konecranes Lifttrucks or by the engine manufacturer. 120/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions Figure 57. Fuel system and fuel injectors 1. Check the fuel system for leakage. 4.14.13 Checking the exhaust system, all engines WARNING HOT SURFACE HAZARD Touching the exhaust system while it is hot may cause serious injury. Wait until the exhaust system has cooled down before starting any maintenance work. NOTE Always check the exhaust system, if the engine or machine sounds changes. Figure 58. Exhaust system 1. Check the overall condition of the exhaust system. If leaking, replace the pipes or the muffler. 2. Check all joints. 3. Check the exhaust manifold. 4. Check the suspension of the muffler. Replace if necessary. 121/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 5. Start the engine. 6. Check for any leaks in the exhaust system. 4.15 Maintaining the Volvo engines This chapter includes the instructions specific to Volvo engines. 4.15.1 Bleeding the fuel system: Volvo 5- and 8-liter engines WARNING HIGH-PRESSURE HAZARD High-pressure fuel may cause serious personal injury. Never disconnect a fuel line or a component from a fuel pump that is to be bled. The fuel is highly pressurized and can penetrate the skin. NOTE Working with the fuel system requires special cleanliness. Check that there is sufficient fuel in the tank, and that the fuel taps are open (if NOTE applicable). NOTE To collect fuel, put a receptacle under the fuel filter. Take care of the excess fuel and store the used filter in a suitable container. Dispose of NOTE both in an environmentally responsible way. Bleed the system if it has run dry or after filter change. Bleed the fuel system with the NOTE hand pump on the fuel filter bracket. 1. Clean thoroughly around the bleeder nipple (2) and cap (1). 2. Remove the protective cap (1) on the bleeder nipple (2). 1 2 3. Connect a transparent hose (3) to the nipple (2). To collect the excess fuel, place the loose end of the hose (3) in a receptacle. 4. Loosen the nipple (2), at least two turns. 122/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 3 2 5. Bleed the fuel system by pumping up fuel with the hand pump (4) until air-free fuel flows out. Pump rapidly, to maintain pressure in the pump. 4 6. Tighten the bleeder nipple with torque 3.5 Nm, while air-free fuel flows out. 7. Wait for 15 s. and then repeat step 4 to 6. 8. Remove the hose (3). 9. Fit the protective cap (1) on the bleeder nipple (2). 10. Start the engine. NOTE If the engine does not run smoothly, repeat the procedure. 4.15.2 Bleeding the fuel system: Volvo 11 and 13-liter engines WARNING HIGH-PRESSURE HAZARD High-pressure fuel may cause serious personal injury. Never disconnect a fuel line or a component from a fuel pump that is to be bled. The fuel is highly pressurized and can penetrate the skin. NOTE Working with the fuel system requires special cleanliness. Check that there is sufficient fuel in the tank, and that the fuel taps are open (if NOTE applicable). NOTE To collect fuel, put a receptacle under the fuel filter. 123/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions Take care of the excess fuel and store the used filter in a suitable container. Dispose of NOTE both in an environmentally responsible way. Bleed the system if it has run dry, if the filter is changed, or after a longer downtime. In NOTE such a case, bleed the system with the hand pump on the fuel filter bracket. 1. Clean thoroughly around the filter before starting to bleed the filter. 2. Free the hand pump (1) from the fuel filter bracket. 2.1 Turn the fuel pump handle (1) counter-clockwise. 2.2 Pull upwards. 2.3 The hand pump (1) is now open. A 1 B C 3. Open the bleeder nipple (2). 4. To collect fuel, connect a hose and a receptacle to the other end of the hose. 2 124/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 5. Bleed the fuel system by pumping with the hand pump (1) until the fuel flows without air bubbles. 1 6. Close the nipple (2). Tightening torque: 3.5 Nm (2.6-lbf ft). 2 7. Remove the hose. 8. Replace the rubber cap. 9. Tighten the fuel pump handle (1). 9.1 Press the pump handle (1) downwards. 9.2 Turn the pump handle (1) clockwise. 9.3 The hand pump (1) is now closed. 125/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions A 1 B C 10. Wipe dry any spilled fuel. 11. Check that there is no leakage. 12. Start the engine. NOTE If the engine does not run smoothly, repeat the procedure. 126/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.15.3 Draining the fuel prefilter: Volvo 5- and 8-liter engines WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid fuel spillage, place a receptacle underneath the filter. NOTE Take care of the excess fuel and dispose of it in an environmentally responsible way. Figure 59. Fuel prefilter 1. Stop the engine. 2. Close the fuel tap if applicable. 3. To collect the water and fuel, put a receptacle under the fuel prefilter. 4. Open the drain valve (1) at the bottom of the water separator (2). 5. Drain the water contained in the water separator (2) into the receptacle. NOTE Do not drain the water separator (2) completely. 6. Tighten the drain valve (1) and open the fuel tap if applicable. 7. Start the engine. 8. Check that there is no leakage from fuel prefilter. 127/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions If the engine is not working properly, bleed the system. For more information, see NOTE "Bleeding the fuel system" for Volvo engines. 4.15.4 Draining the fuel prefilter: Volvo 11- and 13-liter engines WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. NOTE Working with the fuel system requires special cleanliness. Take care of the water and fuel and dispose of it in a safe, controlled, and NOTE environmentally responsible way. 1 1. To collect the water and fuel, put a receptacle under the fuel prefilter. 2. Open the drain valve (1) in the base of the fuel prefilter. 3. Tighten the drain valve (1) when fuel without water starts to run out. 128/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.15.5 Changing the fuel prefilter: Volvo 5- and 8-liter engines WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. If the machine is equipped with a fuel tap (option), close tap before proceeding with the NOTE change of the fuel filter. To collect the water and fuel, put a receptacle under the fuel filter. Store the used filter in NOTE a suitable container and dispose of it in an environmentally responsible way. 8 1 7 2 6 3 5 4 1. Clean thoroughly around the fuel prefilter (1) and water separator (2). 2. Disconnect the cable (4) from the water trap sensor (3). 3. To drain the filter, open the drain valve (5) at the bottom of the water separator (2). 4. Tighten the drain valve (5) again. 5. Remove the fuel prefilter (1) and the water separator (2). Put the used filter in a suitable container and dispose of it in an environmentally responsible way. 6. Lubricate the new O-ring (7) with diesel. 7. Screw the new filter (1) onto the mounting bracket (8) by hand, until it bottoms. 129/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions Tighten a further 1/2–2/3 turns. 8. Remove the water separator (2) from the old fuel prefilter (1). 9. Clean the upper section of the water separator (2) and the contact surfaces. 10. Lubricate the new rubber seal (6) with diesel. 11. Reattach the water separator (2) to the new filter (1). 12. Reconnect the cable (4) to the water trap sensor (3). 13. Open fuel taps, if applicable, and bleed the fuel system. For more information, see Bleeding the Volvo fuel system. 14. Start the engine and make sure that there is no leakage. If the engine is not working properly, bleed the system. For more information, see NOTE "Bleeding the fuel system" for Volvo engines. 4.15.6 Changing the fuel prefilter: Volvo 11- and 13-liter engines WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. NOTE Working with the fuel system requires special cleanliness. NOTE To collect the water and fuel, put a receptacle under the fuel filter. Take care of the water and fuel and dispose of it in a safe controlled manner. Store the NOTE used filter in a suitable container, and dispose of it in an environmentally responsible way. 1 2 1. Clean thoroughly around the fuel prefilter (1) and water separator (2). 2. Disconnect the cable from the water separator sensor. 3. Remove the fuel prefilter (1) from the mounting bracket. Collect any spilled fuel in a receptacle. 130/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4. Remove the water separator (2) from the fuel prefilter (1). 5. Clean the upper part of the water separator (2) with a soft rag. 6. Check that the drain hole in the water separator (2) is not clogged. 7. Install a new seal on the water separator (2). 8. Lubricate the seal with diesel fuel. 9. Reinstall the water separator (2) to the new filter. 10. Screw the new filter onto the mounting bracket by hand. The rubber seal should touch the mating surface. 11. Tighten another half turn, no more. 12. Reconnect the cable to the water separator sensor. 13. If necessary, bleed the fuel system. For more information, see Bleeding the Volvo fuel system. 14. Start the engine, check that there is no leakage. 131/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.15.7 Changing the fuel filter: Volvo 5- and 8-liter engines WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. WARNING IGNITION HAZARD Fuel spill onto a hot surface or an electrical component can cause a fire. Causing a risk of personal injury or death. When carrying out work on the fuel system, make sure that the engine is cold. Store the fuel soaked rags in a suitable container, so that they cannot cause fire. Dispose of them in an environmentally responsible way. RISK OF MATERIAL DAMAGE A leaking seal allows air to enter the system and thus prevent the flow of fuel from the NOTICE tank to the fuel pump. The wrong type of fuel filter may damage the fuel injection circuit. Always use original parts when replacing the filters. NOTE Replace the fuel filter when the engine is cold. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid spillage, place a receptacle underneath the filter. Take care of the excess fuel and dispose of it in a safe controlled manner. Store the used NOTE filter in a suitable container, dispose of it in an environmentally responsible way. 132/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 1 2 3 4 1. Clean around the filter cover (1) and filter housing (4). 2. Carefully remove the fuel filter cover (1). Be prepared to gather up fluid. The filter is still full of fuel and there is a risk of spillage NOTE when the cover is removed. 3. Remove the O-ring (2) and filter (3). Let the fuel drip off into a receptacle. 4. If the filter housing is empty, lubricate with diesel around the inner section of the filter sealing surface. 5. Lubricate the O-ring (2) with diesel before installing the filter cover. 6. Install the filter (3) in the filter cover. Make sure that the filter fits properly in the cover. 7. Install the filter cover (1) and filter (3) in the bracket. 8. Carefully screw in the cover (1) and check that the O-ring (2) does not get twisted. Relubricate the seal as necessary. Tighten the cover to: 25 Nm (18.4 lbf. ft.) 9. Bleed the fuel system. See Bleeding the fuel system for Volvo engines. 10. Start the engine, check that there is no leakage. NOTE If the engine is not working properly, bleed the system again. 133/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.15.8 Changing the fuel filter: Volvo 11- and 13-liter engines WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. WARNING IGNITION HAZARD Fuel spill onto a hot surface or an electrical component can cause a fire. Causing a risk of personal injury or death. When carrying out work on the fuel system, make sure that the engine is cold. Store fuel soaked rags so that they cannot cause fire. RISK OF MATERIAL DAMAGE A leaking seal allows air to enter the system and thus prevent the flow of fuel from the NOTICE tank to the fuel pump. The wrong type of fuel filter may damage the fuel injection circuit. Always use original parts when replacing the filters. Do not fill the new fuel filter with fuel before assembly. There is a risk that NOTICE contamination could get into the system and cause malfunctions or damage. NOTE Replace the fuel filter when the engine is cold. NOTE To avoid fuel spillage, place a receptacle underneath the filter. Take care of the excess fuel and dispose of it in a safe controlled manner. Store the used NOTE filter in a suitable container, dispose of it in an environmentally responsible way. 1 1. Clean around the fuel filter (1). 2. Remove the filter (1) with a suitable filter remover. Collect any spilled fuel in a receptacle. 3. Clean the filter mating surface on the mounting bracket. 4. Lubricate the seal with diesel fuel. 134/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 5. Install the new fuel filter. 6. Tighten the fuel filter in accordance with the instructions on the fuel filter. 7. If necessary, bleed the fuel system. For more information, see Bleeding the Volvo fuel system. 8. If a water separator is installed, change the water separator filter at the same time as the fuel filter. Clean inside the water separator with a soft rag. 4.15.9 Changing the AdBlue filters, Volvo 4.15.9.1 Changing the AdBlue pump filter This section is applicable for machines that are equipped with Volvo or Cummins QSB 6.7 engines. WARNING CORROSIVE SUBSTANCE HAZARD The AdBlue solution may cause skin and eye damage. It is corrosive towards certain metals such as copper and aluminum. Do not allow AdBlue solution to come in contact with other chemicals. Use safety gloves. If the AdBlue solution comes in contact with the skin or eyes, quickly wash it off with soap and water. Wait at least 2-5 min after the engine has been turned off to disconnect the battery NOTE negative terminal. By doing so, the automatic drainage and depressurization of the selective catalytic reduction system can take place. NOTE To avoid spillage, place a receptacle underneath the filter. Take care of the excess fluid and dispose of it in a safe controlled manner. Store the NOTE used filter in a suitable container, dispose of it in an environmentally responsible way. 1. Switch off the engine. 1 2. After 2-5 min, disconnect the battery negative terminal (1). 135/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 2 3. Place a receptacle under the filter cover (2). 4. Remove the filter cover (2), let AdBlue run into the receptacle. 3 4 5. Press the puller, which is supplied with the filter kit (3), into the filter hole until a click is heard. 6. Pull out the old filter (4). 7. Put the used filter (4) in a suitable container, and dispose of it in an environmentally responsible way. 136/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 2 6 5 8. Install the new filter (5). 9. Install the rubber gasket (6). 2 10. Reattach the filter cover (2). 11. Tighten the filter cover (2) using a torque wrench. NOTE Tightening torque is 20 + 5 Nm (14.8 + 3.68-lbf ft). 12. Reconnect the battery negative terminal (1). 13. Start the engine. 14. Check that there are no leaks. 15. Delete any error codes. 137/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.15.9.2 Changing the AdBlue breather filter WARNING CORROSIVE SUBSTANCE HAZARD The AdBlue solution may cause skin and eye damage. It is corrosive towards certain metals such as copper and aluminum. Do not allow AdBlue solution to come in contact with other chemicals. Use safety gloves. If the AdBlue solution comes in contact with the skin or eyes, quickly wash it off with soap and water. Wait at least 2-5 min after the engine has been turned off to disconnect the battery NOTE negative terminal. By doing so, the automatic drainage and depressurization of the selective catalytic reduction system can take place. NOTE To avoid spillage, place a receptacle underneath the filter. Take care of the excess fluid and dispose of it in a safe controlled manner. Store the NOTE used filter in a suitable container, dispose of it in an environmentally responsible way. NOTE The size and appearance of the tank can vary depending on machine model and size. 1 2 4 3 1. Breather filter 3. From tank 2. From sensor 4. Hose clamp How to replace the breather filter 1. Switch off the engine. 2. Disconnect the battery negative terminal (after 2-5 min). 3. Clean around the filter area. 4. Loosen the hose clamp (4). 5. Remove the breather filter (1) from the AdBlue tank. 6. Put the used filter in a suitable container and dispose of it in an environmentally responsible way. 7. Reverse the procedure to install the new breather filter. It is important that the new filter is installed in the exact same position as the removed NOTE filter. 138/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.15.9.3 Changing the AdBlue armature (level) filter WARNING CORROSIVE SUBSTANCE HAZARD The AdBlue solution may cause skin and eye damage. It is corrosive towards certain metals such as copper and aluminum. Do not allow AdBlue solution to come in contact with other chemicals. Use safety gloves. If the AdBlue solution comes in contact with the skin or eyes, quickly wash it off with soap and water. Wait at least 2-5 min after the engine has been turned off to disconnect the battery NOTE negative terminal. By doing so, the automatic drainage and depressurization of the selective catalytic reduction system can take place. NOTE To avoid spillage, place a receptacle underneath the filter. Take care of the excess fluid and dispose of it in a safe controlled manner. Store the NOTE used filter in a suitable container, dispose of it in an environmentally responsible way. The size and appearance of the armature filter can vary depending on machine model NOTE and size. 1. Switch off the engine. 2. Disconnect the battery negative terminal (after 2-5 min). 3. Clean around the hose connection area. 1 3 2 4. Remove the connector hoses (1). 5. Wrap a plastic bag around the connectors to protect them. 6. Remove the coolant hoses (2). 139/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 7. Remove the hose clamp (3). 4 8. Lift out the armature (4). 5 9. Remove the armature (level) filter (5). 10. Flush warm water through the armature to clean it. 11. Reverse the procedure to reinstall the new armature (level) filter. NOTE After reinstalling the new armature (level) filter (5), check the coolant level. 140/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.15.10 Changing the Volvo engine oil WARNING HOT FLUID HAZARD Hot engine oil may cause serious personal injury. To avoid burns, use care when opening the drain plug. NOTE Drain the oil when the engine is at the operating temperature, at least 65°C (149°F). NOTE To avoid spillage, place a receptacle under the filter. NOTE Take care of the excess oil and dispose of it in an environmentally responsible way. 1. Place a receptacle underneath the drain plug (1). 1 1 EU stage 3a/4 / US tier 3/4i/4f EU stage 5 2. Unscrew the drain plug (1). 3. Allow the oil to run out. 4. Check the seal for damage or deformation. If necessary, renew the seal. 5. Refit the drain plug (1). 6. Tighten up the drain plug (1). 7. Remove the filler cap (2). 2 3 8. Fill oil through the opening, use the recommended oil. 9. Check the oil level using the dipstick (3). Make sure that the oil level is between the minimum and maximum marks on the dipstick (3). Do not fill above the maximum oil level. 141/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 10. Refit the filler cap (2). 11. Check that there are no leaks from the drain plug (1) or the oil filter. 12. Start the engine. Check that there is no warning symbol for low oil pressure on the display. 13. Turn off the engine. Check the oil level after 5 min. 4.15.11 Changing the engine oil filter: Volvo 5- and 8-liter engines WARNING HOT OIL AND HOT SURFACES HAZARD Risk of personal injury. Use protective gloves. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid spillage, place a receptacle under the filter. Take care of the excess oil and dispose of it in a safe controlled manner. Put the filter in a NOTE suitable container, dispose of it in an environmentally responsible way. Drain the oil according to the instructions in Changing the engine oil. 1 2 3 4 1. Before opening the oil filter, clean around the filter cover (1) and the filter housing (4). 2. Clean around the oil filter (3). 3. Carefully remove the filter cover (1) together with the filter (3). 4. Remove the O-ring (2) and filter (3) from the cover (1). 5. Let the oil drip off into a receptacle. 6. Lubricate the new O-ring (2) and the gasket of the new filter (3) with new oil before installation. 142/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 7. Install the new filter (3) and new O-ring (2) in the filter cover (1). Make sure to install the filter correctly in the cover. 8. Install the filter cover (1) and filter (3) in the filter housing (4). 9. Tighten the cover to 40 Nm (29.5-lbf. ft.). 10. Fill with required volume of oil. See Fuel and oil recommendations (page 249). 11. Start the engine. Check that there is no oil leakage from the oil filter or drain plug. 12. Switch off the engine and check the oil level after a few minutes. 13. If necessary, top up with oil. 4.15.12 Changing the engine oil filter: Volvo 11- and 13-liter engines WARNING HOT OIL AND HOT SURFACES HAZARD Risk of personal injury. Use protective gloves. NOTE Working with the oil system requires special cleanliness. NOTE To avoid spillage, place a receptacle underneath the filter. Take care of the excess oil and dispose of it in a safe controlled manner. Put the used NOTE filter in a suitable container, and dispose of it in an environmentally responsible way. 2 4 3 1 1. Clean the oil filter bracket (2). 2. Remove all oil filters with a suitable oil filter extractor (1). 3. Clean the mating surface of the oil filter bracket. 3.1 Make sure to not leave any old oil seal remnants behind. 3.2 Carefully clean inside the protective rim on the oil filter bracket (2). 4. Put a thin layer of new engine oil on the seals of the new oil filters. 5. Install the new oil filters. 5.1 Tighten the two full-flow filters (3) 1/2–3/4 of a turn after they bottom. 5.2 Tighten the bypass filter (4) 3/4–1 turn after it bottoms. 143/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 6. Top up with engine oil, start the engine, and let it run for 20–30 s. See Fuel and oil recommendations (page 249). 7. Turn off the engine. 8. Check the oil level, and top up as required. 9. Check the seals around the oil filters. 4.15.13 Changing the crankcase breather filter The crankcase breather filter (1) is used on 5- and 8-liter Volvo engines (EU stage 4 and NOTE below). NOTE Always change the crankcase breather filter (1), it must not be cleaned and reused. Store the used filter in a suitable receptacle, and dispose of it in an environmentally NOTE responsible way. 1 Figure 60. Placement of crankcase breather filter (1) - Volvo TAD 571 VE 144/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions Changing the crankcase breather filter 2 3 4 5 1. Clean around the filter cover (2) and the filter housing (5). 2. Remove the filter cover (2), using a suitable tool. 3. Remove the filter element (3) from the filter housing (5). 4. Remove the O-ring (4). 5. Clean inside the filter cover (2) and filter housing (5) with a lint free cloth. 6. Lubricate the new O-ring, using clean engine oil. 7. Fit the new O-ring to the filter cover (2). 8. Insert the new filter element in the filter housing (5). 9. Reattach the filter cover (2) on to the filter housing (5). 145/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.15.14 Checking the Volvo drive belt NOTE If the drive belt is oily, worn, or damaged, it must be replaced. 1 2 3 Figure 61. EU stage 3a/4 / US tier 3/4i/4f 2 1 3 Figure 62. EU stage 5 - TAD 581, 583 VE 146/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 2 1 3 Figure 63. EU stage 5 - TAD 881, 883 VE 1 2 3 Figure 64. EU stage 5 - TAD 1181, 1183 VE 1. Check the belt (1) for cracks and wear. The belt (1) should be checked after operation, when it is hot. It should be possible to depress the belt (1) 3–4 mm (0.12–0.16 in) between the pulleys (2). 2. Check that the automatic belt tensioners (3) function and maintains the tension in the belt (1). 3. Check the idler pulleys (2) for damage. 147/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.15.15 Checking the Volvo vibration damper WARNING RISK OF DAMAGE TO THE MACHINE If the vibration damper does not function properly, it can lead to serious engine or drive line failure. Check the condition of the vibration damper regularly, follow the regular service schedule. Service must be performed by an authorized service technician. If service or replacement of parts is needed, contact your local dealer for more information. 1 Figure 65. Vibration damper 1. Check the vibration damper (1) for wear and damage. 4.15.16 Checking the Volvo water pump WARNING RISK OF DAMAGE TO THE MACHINE A leaking or damaged water pump can lead to serious engine or drive line failure. Check the condition of the water pump regularly, follow the regular service schedule. Service must be performed by an authorized service technician. If service or replacement of the water pump is needed, contact your local dealer for more information. 148/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 1 Figure 66. Water pump NOTE Location, and appearance can vary depending on size and model of the motor. 1. Check the water pump (1) for leaks, and wear. If dripping, or a steady flow of coolant or oil is found, the water pump (1) must be NOTE replaced. Contact your local authorized dealer for more information. 4.16 Maintaining the Cummins engines This chapter includes the maintenance instructions for the Cummins engines. 149/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.16.1 Bleeding the fuel system - QSB 6.7 4.16.1.1 Bleeding the fuel prefilter - QSB 6.7 and B 6.7 WARNING HIGH-PRESSURE HAZARD High-pressure fuel may cause serious personal injury. Never disconnect a fuel line or a component from a fuel pump that is to be bled. The fuel is highly pressurized and can penetrate the skin. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid fuel spillage, place a receptacle underneath the filter. NOTE Take care of the excess fuel, and dispose of it in an environmentally responsible way. Bleed the fuel system if it has run dry or after filter change. Bleed the fuel system with NOTE the hand pump on the fuel filter bracket. 2 1 Figure 67. Bleeding the fuel prefilter - QSB 6.7 150/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 1 2 Figure 68. Bleeding the fuel prefilter - B 6.7 1. Clean thoroughly around the bleeder nipples (2) and the fuel prefilter. 2. Open the bleeder nipples (2). 3. Place a receptacle underneath the fuel prefilter. 4. Bleed the fuel system by pumping up fuel with the hand pump (1) until air-free fuel flows out. NOTE Pump rapidly, to maintain pressure in the pump. 5. Close the nipples (2). NOTE Tightening torque 3.5 Nm (2.6-lbf ft). 6. Wipe dry any spilled fuel. 7. Start the engine and make sure that there is no leakage. NOTE If the engine does not run smoothly, repeat the procedure. 151/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.16.1.2 Bleeding the distributor pump - QSB 6.7 WARNING HIGH-PRESSURE HAZARD High-pressure fuel may cause serious personal injury. Never disconnect a fuel line or a component from a fuel pump that is to be bled. The fuel is highly pressurized and can penetrate the skin. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid fuel spillage, place a receptacle underneath the filter. NOTE Take care of the excess fuel, and dispose of it in an environmentally responsible way. Bleed the system if it has run dry or after filter change. Bleed the fuel system with the NOTE hand pump on the fuel filter bracket. 2 1 Figure 69. Bleeding the distributor pump - QSB 6.7 1. Clean thoroughly around the bleeder nipple (2) and the distributor pump. 2. Open the bleeder nipple (2). 3. Place a receptacle underneath the distributor pump. 4. Bleed the fuel system by pumping up fuel with the hand pump (1) until air-free fuel flows out. NOTE Pump rapidly, to maintain pressure in the pump. 5. Close the nipple (2). NOTE Tightening torque: 3.5 Nm (2.6-lbf ft). 6. Wipe dry any spilled fuel. 7. Start the engine and make sure that there is no leakage. NOTE If the engine does not run smoothly, repeat the procedure. 152/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.16.1.3 Bleeding the fuel filter - QSB 6.7 and B 6.7 WARNING HIGH-PRESSURE HAZARD High-pressure fuel may cause serious personal injury. Never disconnect a fuel line or a component from a fuel pump that is to be bled. The fuel is highly pressurized and can penetrate the skin. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid fuel spillage, place a receptacle underneath the filter. NOTE Take care of the excess fuel, and dispose of it in an environmentally responsible way. Bleed the system if it has run dry or after filter change. Bleed the fuel system with the NOTE hand pump on the fuel filter bracket. 2 1 Figure 70. Bleeding the fuel filter - QSB 6.7 153/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 2 1 Figure 71. Bleeding the fuel filter - B 6.7 1. Clean thoroughly around the bleeder nipples (2) and the fuel filter. 2. Open the bleeder nipples (2). 3. Place a receptacle underneath the fuel filter. 4. Bleed the fuel system by pumping up fuel with the hand pump (1) until air-free fuel flows out. NOTE Pump rapidly, to maintain pressure in the pump. 5. Close the nipples (2). NOTE Tightening torque 3.5 Nm (2.6-lbf ft). 6. Wipe dry any spilled fuel. 7. Start the engine and make sure that there is no leakage. NOTE If the engine does not run smoothly, repeat the procedure. 154/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.16.2 Bleeding the fuel system - QSM 11 WARNING HIGH-PRESSURE HAZARD High-pressure fuel may cause serious personal injury. Never disconnect a fuel line or a component from a fuel pump that is to be bled. The fuel is highly pressurized and can penetrate the skin. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid fuel spillage, place a receptacle underneath the filter. NOTE Take care of the excess fuel, and dispose of it in an environmentally responsible way. NOTE Bleed the system if it has run dry, if the filter is changed, or after a longer downtime. 1 Figure 72. Bleeding fuel filter - QSM 11 1. Clean thoroughly around the bleeder nipples (1). 2. Connect draining hoses to the bleeder nipples (1). NOTE To open the bleeder nipples (1), select a hose with a suitable connection. 3. To collect any excess fluid, place the opposite ends of the hoses in a receptacle. 4. Start the engine. 5. Bleed the fuel system until air-free fuel flows out. 6. Close the nipples (1). NOTE Tightening torque: 3.5 Nm (2.6-lbf ft). 7. Stop the engine. 155/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 8. Check that there is no leakage from the fuel filter. NOTE If the engine does not run smoothly, repeat the procedure. 4.16.3 Bleeding the fuel system - X12 4.16.3.1 Bleeding the fuel prefilter - X12 WARNING HIGH-PRESSURE HAZARD High-pressure fuel may cause serious personal injury. Never disconnect a fuel line or a component from a fuel pump that is to be bled. The fuel is highly pressurized and can penetrate the skin. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid fuel spillage, place a receptacle underneath the filter. NOTE Take care of the excess fuel, and dispose of it in an environmentally responsible way. Bleed the system if it has run dry or after filter change. Bleed the fuel system with the NOTE hand pump on the fuel filter bracket. 1 2 Figure 73. Bleeding the fuel prefilter - X12 1. Clean thoroughly around the bleeder nipple (2) and hand pump (1). 2. Open the bleeder nipple (2). 3. Place a receptacle underneath the fuel prefilter. 4. Bleed the fuel system by pumping up fuel with the hand pump (1) until air-free fuel flows out. NOTE Pump rapidly, to maintain pressure in the pump. 5. Close the nipple (2). NOTE Tightening torque: 3.5 Nm (2.6-lbf ft). 156/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 6. Remove the hose. 7. Wipe dry any spilled fuel. 8. Start the engine and make sure that there is no leakage. NOTE If the engine does not run smoothly, repeat the procedure. 4.16.3.2 Bleeding the fuel filter - X12 WARNING HIGH-PRESSURE HAZARD High-pressure fuel may cause serious personal injury. Never disconnect a fuel line or a component from a fuel pump that is to be bled. The fuel is highly pressurized and can penetrate the skin. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid fuel spillage, place a receptacle underneath the filter. NOTE Take care of the excess fuel, and dispose of it in an environmentally responsible way. Bleed the system if it has run dry or after filter change. Bleed the fuel system with the NOTE hand pump on the fuel filter bracket. 2 1 Figure 74. Bleeding the fuel filter - X12 1. Clean thoroughly around the bleeder nipple (2) and hand pump (1). 2. Open the bleeder nipple (2). 3. Place a receptacle underneath the fuel filter. 4. Bleed the fuel system by pumping up fuel with the hand pump (1) until air-free fuel flows out. NOTE Pump rapidly, to maintain pressure in the pump. 5. Close the nipple (2). 157/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions NOTE Tightening torque: 3.5 Nm (2.6-lbf ft). 6. Remove the hose. 7. Wipe dry any spilled fuel. 8. Start the engine and make sure that there is no leakage. NOTE If the engine does not run smoothly, repeat the procedure. 4.16.4 Draining the fuel prefilter - X12 WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. NOTE Working with the fuel system requires special cleanliness. NOTE To avoid fuel spillage, place a receptacle underneath the filter. NOTE Take care of the excess fuel, and dispose of it in an environmentally responsible way. 1 2 Figure 75. Fuel prefilter - X12 1. Stop the engine. 2. Close the fuel tap, if applicable. 158/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 3. To collect the water and fuel, put a receptacle under the fuel prefilter. 4. Open the drain valve (2) at the bottom of the water separator (1). 5. Drain the water contained in the water separator (1) into the receptacle. NOTE Do not drain the water separator (1) completely. 6. Tighten the drain valve (2) and open the fuel tap, if applicable. 7. If needed, bleed the system. For more information, see sections about "Bleeding the fuel system". 8. Start the engine. 9. Check that there is no leakage from the fuel prefilter. 159/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.16.5 Changing the fuel prefilter - QSB 6.7 and B 6.7 WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. To collect the water and fuel, put a receptacle under the fuel prefilter. Store the used filter NOTE in a suitable container and dispose of it in an environmentally responsible way. NOTE Working with the fuel system requires special cleanliness. 1 2 3 4 5 Figure 76. Fuel prefilter - QSB 6.7 and B 6.7 1. Close fuel taps, if applicable. 2. Clean thoroughly around the fuel prefilter (4) and the mounting bracket (1). 3. Disconnect the cable (5) from the fuel prefilter (4). 4. Remove the filter (4) from the mounting bracket (1). Put the used filter (4) in a suitable container and dispose of it in an environmentally responsible way. 5. Install a new seal (2) to the new filter. 6. Lubricate the new seal (2) with diesel fuel. 160/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 7. Lubricate the seal (3) on the new filter with diesel fuel. 8. Screw the new filter onto the mounting bracket (1) by hand, until it bottoms. Tighten a further 1/2–2/3 turns. 9. Reconnect the cable (5) to the fuel prefilter (4). 10. Open fuel taps, if applicable, and bleed the fuel system. For more information, see sections about "Bleeding the fuel system". 11. Start the engine and make sure that there is no leakage. 161/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.16.6 Changing the fuel prefilter - X12 WARNING HARMFUL SUBSTANCE HAZARD The machine contains several chemical substances, which may cause skin irritation and allergies. Risk of injury when in prolonged contact with skin. When handling lubricants and oils, avoid direct contact with the skin. Use safety gloves. Immediately wash skin that comes in contact with chemical substances. To collect the water and fuel, put a receptacle under the fuel prefilter. Store the used filter NOTE in a suitable container and dispose of it in an environmentally responsible way. NOTE Working with the fuel system requires special cleanliness. 1 2 3 4 6 7 8 5 Figure 77. Fuel prefilter - X12 1. Close fuel taps, if applicable. 2. Clean thoroughly around the fuel prefilter (3) and the water separator (6). 3. Disconnect the cables (8) from the water trap sensors (7). 162/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4. Remove the fuel prefilter (3) from the mounting bracket (1). 5. Remove the the water trap (6) from the filter (3). Put the used filter in a suitable container and dispose of it in an environmentally responsible way. 6. Clean the water trap (6) with a soft rag. Check that the drain hole (5) in the water trap (6) is not blocked. 7. Install a new O-ring (4) on the water separator (6). 8. Lubricate the O-ring (4) with diesel fuel. 9. Reinstall the water trap (6) to the new filter (3). 10. Lubricate the O-ring (2) with diesel fuel. 11. Screw the new filter (3) onto the mounting bracket (1) by hand, until it bottoms. Tighten a further 1/2–2/3 turns. 12. Reconnect the cables (8) to the water trap sensors (7). 13. Open fuel taps, if applicable, and bleed the fuel system. For more information, see sections about "Bleeding the fuel system". 14. Start the engine and make sure that there is no leakage. 4.16.7 Changing the AdBlue filters, Cummins 4.16.7.1 Changing the AdBlue pump filter This section is applicable for machines that are equipped with Volvo or Cummins QSB 6.7 engines. WARNING CORROSIVE SUBSTANCE HAZARD The AdBlue solution may cause skin and eye damage. It is corrosive towards certain metals such as copper and aluminum. Do not allow AdBlue solution to come in contact with other chemicals. Use safety gloves. If the AdBlue solution comes in contact with the skin or eyes, quickly wash it off with soap and water. Wait at least 2-5 min after the engine has been turned off to disconnect the battery NOTE negative terminal. By doing so, the automatic drainage and depressurization of the selective catalytic reduction system can take place. NOTE To avoid spillage, place a receptacle underneath the filter. Take care of the excess fluid and dispose of it in a safe controlled manner. Store the NOTE used filter in a suitable container, dispose of it in an environmentally responsible way. 1. Switch off the engine. 163/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 1 2. After 2-5 min, disconnect the battery negative terminal (1). 2 3. Place a receptacle under the filter cover (2). 164/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4. Remove the filter cover (2), let AdBlue run into the receptacle. 3 4 5. Press the puller, which is supplied with the filter kit (3), into the filter hole until a click is heard. 6. Pull out the old filter (4). 7. Put the used filter (4) in a suitable container, and dispose of it in an environmentally responsible way. 2 6 5 8. Install the new filter (5). 9. Install the rubber gasket (6). 165/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 2 10. Reattach the filter cover (2). 11. Tighten the filter cover (2) using a torque wrench. NOTE Tightening torque is 20 + 5 Nm (14.8 + 3.68-lbf ft). 12. Reconnect the battery negative terminal (1). 13. Start the engine. 14. Check that there are no leaks. 15. Delete any error codes. 166/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.16.7.2 Changing the AdBlue pump filter, B 6.7 and X12 WARNING CORROSIVE SUBSTANCE HAZARD The AdBlue solution may cause skin and eye damage. It is corrosive towards certain metals such as copper and aluminum. Do not allow AdBlue solution to come in contact with other chemicals. Use safety gloves. If the AdBlue solution comes in contact with the skin or eyes, quickly wash it off with soap and water. Wait at least 2-5 min after the engine has been turned off to disconnect the battery NOTE negative terminal. By doing so, the automatic drainage and depressurization of the selective catalytic reduction system can take place. NOTE To avoid spillage, place a receptacle underneath the filter. Take care of the excess fluid and dispose of it in a safe controlled manner. Store the NOTE used filter in a suitable container, dispose of it in an environmentally responsible way. 1. Switch off the engine. 1 2. After 2-5 min, disconnect the battery negative terminal (1). 3 2 3. Place a suitable receptacle under the pump (3). 167/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4. Clean around the filter cover (2) and the pump (3). 5. Unscrew the filter cover (2). Use a 46-mm socket. 3 6 4 7 5 2 6. Remove the O-ring (7). 7. Remove the frost protection device (6) and the filter (5). 8. Put the used filter (5) in a suitable container and dispose of it in an environmentally responsible way. 9. Wipe the pump (3) and threads (4) clean. 10. Fit the new filter. 11. Fit the new frost protection device. 12. Lubricate the threads (4). 13. Lubricate the new O-ring with AdBlue. 14. Fit the new O-ring in the filter cover (2). 15. Check that the frost protection device and O-ring are correctly fitted. 16. Reattach the filter cover (2) on the pump (3) and tighten to 80 Nm (59 lbf ft). 17. Reconnect the battery negative terminal (1). 4.16.7.3 Changing the AdBlue tank filter WARNING CORROSIVE SUBSTANCE HAZARD The AdBlue solution may cause skin and eye damage. It is corrosive towards certain metals such as copper and aluminum. Do not allow AdBlue solution to come in contact with other chemicals. Use safety gloves. If the AdBlue solution comes in contact with the skin or eyes, quickly wash it off with soap and water. Wait at least 2-5 min after the engine has been turned off to disconnect the battery NOTE negative terminal. By doing so, the automatic drainage and depressurization of the selective catalytic reduction system can take place. 168/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions NOTE To avoid spillage, place a receptacle underneath the filter. Take care of the excess fluid and dispose of it in a safe controlled manner. Store the NOTE used filter in a suitable container, dispose of it in an environmentally responsible way. 1. Switch off the engine. 1 2. Disconnect the battery negative terminal (1) after 2-5 min. 5 6 3 2 4 2 7 3. Disconnect the coolant supply and return (2). 4. Disconnect the AdBlue supply and return (3). 5. Disconnect the electrical connector (4). NOTE To prevent contamination, disconnect the connector (4) last. 6. To avoid contamination, cover the connector (4) and the exposed inlets and outlets (2 and 3) on the AdBlue tank assembly. 7. Loosen and remove the screws (5). 8. Remove the attachment plate (6). 169/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 9. Lift out the AdBlue tank assembly (7) from the tank. AdBlue tank assembly and filter - X12 11 10 9 8 AdBlue tank assembly and filter - QSB 6.7 and B 6.7 11 10 9 8 10. Remove the clip (8) from the inlet port. 11. Remove the AdBlue tank filter (9) from the inlet pipe (10). 12. Remove the O-ring (11). 13. Reverse the procedure to install the new AdBlue tank filter and O-ring. 170/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.16.8 Changing the Cummins engine oil WARNING HOT FLUID HAZARD Hot engine oil may cause serious personal injury. To avoid burns, be careful when opening the drain plug. NOTE Drain the oil when the engine is at the operating temperature, at least 65°C (149°F). NOTE Working with the oil system requires special cleanliness. Put the used filter in a suitable container, and dispose of it in an environmentally NOTE responsible way. 1 1 QSB 6.7 - EU stage 3a / US tier 3 QSB 6.7 - EU stage 4 / US tier 4f 1 1 B 6.7 - EU stage 5 / US tier 4f QSM 11 171/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 1 X12 1. To avoid spillage, place a receptacle underneath the drain hole. 2. Unscrew the drain plug (1). 3. Allow the oil to run out. 4. Check that the seal is undamaged. If necessary, renew the seal. 5. Fit the drain plug. 6. Tighten up the drain plug (1). 7. Remove the filler cap (2). 2 3 8. Pour oil through the opening. 9. Check the oil level using the dipstick (3). 10. Fill up to the maximum indicator level. 11. Refit the filler cap (2). 12. Start the engine. 13. Check that there is no warning symbol for low oil pressure on the display. 14. Check that there are no leaks from the drain plug or the oil filter. 15. Turn off the engine and check the oil level again after 5 min. 172/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.16.9 Changing the Cummins engine oil filter WARNING HOT OIL AND HOT SURFACES HAZARD Risk of personal injury. Use protective gloves. NOTE Working with the oil system requires special cleanliness. Put the used filter in a suitable container, dispose of it in an environmentally responsible NOTE way. 1 1 QSB 6.7 - EU stage 3a / US tier 3 QSB 6.7 - EU stage 4 / US tier 4f 1 1 B 6.7 - EU stage 5 / US tier 4f QSM 11 173/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 1 X 12 1. To avoid spillage, place a receptacle underneath the filter (1). 2. Clean around filter on the outside of the filter. 3. Remove and dispose of the old filter (1). 4. Clean the mating surface of the filter housing. 5. Lubricate the rubber seal with new oil and fit a new filter. 6. Secure the filter by hand. NOTE Never use tools. The filter could get damaged and the circulation obstructed. 7. Top up with engine oil, start the engine, and let it run for 20–30 s. 8. Turn off the engine, check the oil level, and top up as required. See Fuel and oil recommendations (page 249). 9. Check the seal around the oil filters. 174/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.16.10 Changing the Cummins fuel filter NOTE Working with the fuel system requires special cleanliness. Put the used filter in a suitable container, dispose of it in an environmentally responsible NOTE way. 1 1 QSB 6.7 - EU stage 3a / US tier 3 QSB 6.7 - EU stage 4 / US tier 4f 1 1 B 6.7 - EU stage 5 / US tier 4f QSM 11 1 X12 1. To collect any spilled fuel, place a receptacle under the fuel filter (1). 2. Clean around the fuel filter (1). 3. Remove the fuel filter (1) with a suitable filter remover. 4. Remove the thread adapter seal. Clean the gasket surface on the fuel filter head. 175/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 5. Lubricate the fuel filter gasket with clean engine oil. 6. Fill the new fuel filter (1) with clean diesel fuel. 7. Install the new thread adapter seal (included in the filter kit). 8. Install the filter (1) on the filter head. 9. Turn the filter (1) until the gasket contacts the filter head surface. 10. Tighten the fuel filter (1) in accordance with the instructions of the filter manufacturer. 11. Bleed the fuel system. See "Bleeding the Cummins fuel system". 12. Start the engine, check that there is no leakage. NOTE If the engine is not working properly, bleed the system again. 176/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.16.11 Checking the Cummins drive belt NOTE If the drive belt is oily, worn, or damaged, it must be replaced. 2 2 1 3 Figure 78. QSB 6.7 - EU stage 3a / US tier 3 2 2 1 3 Figure 79. QSB 6.7 - EU stage 4 / US tier 4f 177/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 2 1 2 3 Figure 80. B 6.7 - EU stage 5 / US tier 4f 2 1 2 3 Figure 81. QSM 11 178/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 2 1 3 Figure 82. X12 1. Check the belt (1) for cracks and wear. 2. Check that the automatic belt tensioners (3) function and maintain the tension in the belt. 3. Check the idler pulleys (2) for damage. 179/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.16.12 Checking the Cummins cooling fan WARNING EQUIPMENT: FAN DAMAGE HAZARD Risk of personal injury or equipment damage If a fan blade is damaged, it can cause the fan to fail, which can cause personal injury or property damage. Do not rotate the engine by pulling or prying on the fan. Use the accessory drive shaft or the crankshaft barring tool to rotate the crankshaft. WARNING EQUIPMENT: BENT FAN BLADE HAZARD Risk of personal injury or equipment damage A bent fan blade can cause the fan to fail, which can cause personal injury or property damage. Do not straighten a bent fan blade or continue to use a damaged fan. NOTE The fan must be visually inspected daily. Replace a damaged fan with a fan that has an identical part number. Any other fan must NOTE be approved by Cummins to be covered under warranty. 180/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions P.N. XXXXXX Figure 83. Original fan part number, Cummins 1. Check for cracks, loose rivets. 2. Check for bent or loose blades (1). 1 3. Check that the fan is securely mounted. 4. Tighten the capscrews if necessary. NOTE Refer to the engine manufacturer's specifications for capscrew torque. 181/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.16.13 Checking the Cummins vibration damper WARNING RISK OF DAMAGE TO THE MACHINE The silicone fluid in the vibration damper will harden after an extended operating time, and will cause the damper to not function properly. This can lead to serious engine or drive line failure. Check the condition of the vibration damper regularly, follow the regular service schedule. Service must be performed by an authorized service technician. If service or replacement of parts is needed, contact your local dealer for more information. 1 2 Figure 84. Vibration damper 1. Check the inner part (1) of the vibration damper for cracks, dents, or silicone fluid loss. 2. Check the outer part (2) of the vibration damper for cracks, deformations, or raising of the damper cover plate. 4.16.14 Checking the Cummins water pump WARNING RISK OF DAMAGE TO THE MACHINE A leaking or damaged water pump can lead to serious engine or drive line failure. Check the condition of the water pump regularly, follow the regular service schedule. Service must be performed by an authorized service technician. If service or replacement of the water pump is needed, contact your local dealer. 182/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 2 1 Figure 85. Water pump Check the drainage hole (2) on the water pump (1) for leakage of coolant or oil. If dripping or a steady flow of coolant or oil is found, the water pump (1) must be NOTE replaced. Contact your local authorized dealer for more information. If the drainage hole (2) is clogged, a small screwdriver or similar tool can be used to remove any debris. NOTE Always make sure that the drainage hole (2) on the water pump (1) is clear. 4.17 Maintaining the DANA transmissions 4.17.1 Changing the DANA transmission oil WARNING HOT OIL HAZARD Risk of serious personal injury. To avoid burns, use care in opening the drain plug. NOTE Replace the oil when it is at the operating temperature, 82–93° C (180–200° F). NOTE Working with the oil system requires special cleanliness. NOTE Take care of the excessive oil and dispose of it in an environmentally responsible way. 183/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 1 1 DANA TE14 DANA TE17 1 DANA TE30 (not available for all models) 184/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 2 3 Figure 86. DANA TE17 1. Place a receptacle underneath the drain plug (1). 2. Clean around the drain plug (1). 3. Remove the drain plug (1) and allow the oil to run out. 4. Check the seal on the drain plug (1). 5. Refit the drain plug (1). 6. Remove the filler cap (2). 7. Fill with the recommended oil to the maximum level indicator on the dipstick (3). For more information, see Recommended fluids and lubricants (page 250). 8. To fill the torque converter and pipes, turn on the engine. Let it idle for 1 min. 9. Check the level of the oil while the engine runs. 10. Fill up with oil to the minimum indicator. 11. Check the oil level again when the engines operating temperature has reached 82-93° C (180-200° F). Fill to the maximum level indicator. 185/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.17.2 Changing the DANA transmission oil filter RISK OF PROPERTY DAMAGE NOTICE Handle the filter with care. Do not fit a damaged filter. Make sure that no dirt or sludge penetrates into the transmission. NOTE Working with the oil system requires special cleanliness. NOTE To avoid spillage, place a receptacle under the filter. Take care of the excessive oil and dispose of it in a safe controlled manner. Put the used NOTE filter in a suitable container, and dispose of it in an environmentally responsible way. 4.17.2.1 DANA TE17 transmission oil filter 1 Figure 87. DANA TE17 1. Clean the outside of the filter unit. 2. Loosen the filters by hand or with a filter wrench. 3. Remove the filters. 4. Check the new filters and the seals. 5. Lightly lubricate the seals with oil. 6. Clean the mating surface of the filter housing (1). 7. Screw on the filters until the seal is in contact with the filter housing (1). Tighten another half turn, no more. 8. Start the engine, check that there are no leaks. 9. Check the oil level with the dipstick. 10. Switch off the engine. 186/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.17.2.2 DANA TE14 and TE30 transmission oil filter 1 2 3 4 Figure 88. DANA TE14 and TE30 1. Clean around the filter cover (1) and filter housing (3). 2. Remove the drain plug (4). 3. Remove the filter cover (1) with a suitable filter remover. 4. To collect any excess oil, place the filter (2) and the cover (1) in a suitable container. 5. Clean inside the filter (2) with a lint free cloth. 6. Inspect and lubricate the O-ring on the drain plug (4). 7. Insert the drain plug (4) again. 8. Insert the new filter into the filter cover (1). 9. Lubricate the O-ring on the filter cover (1) with clean transmission oil. 10. Screw the filter cover (1) back onto the filter housing (3). 11. Tighten the cover (1) with 35 Nm. 12. Start the engine. 13. Check that there are no leaks. 14. Check the oil level with the dipstick. 15. Switch off the engine. 187/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.17.3 Checking the DANA transmission breather 1 1 DANA TE14 (not available for all models) DANA TE17 1 DANA TE30 (not available for all models) 1. Clean the transmission breather (1) with a cloth. 2. Check that the transmission breather (1) is not clogged. 3. Replace if necessary. Unscrew the transmission breather (1) and replace with a new transmission breather. 188/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.17.4 Calibrating the DANA transmission 4.17.4.1 Heating up the DANA transmission WARNING RUN OVER HAZARD If the parking brake fails, the machine can start moving. If so, it can cause death, severe injury, and property damage. Check the parking brake and replace worn disk pads before heating and calibration. Heat up the transmission before the calibration procedure. When the heating mode is selected, the following functions are possible: • Forward or reverse can be selected when the parking brake is activated • Highest gear is selected automatically 1. Go to Machine overview > DANA transmission. 2. From the top-right panel, select Heating mode. 189/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 3. Make sure that you activate the parking brake and that it works properly. 4. If the parking brake fails, use the foot brake. 5. Select driving direction forward. 6. Run the engine at maximum RPM. 7. After about 15 s at maximum RPM, select neutral. 8. Continue at maximum RPM. 9. Keep the transmission in neutral at maximum RPM for another 15 s. The figure shows the heating cycle for the transmission. 10. Release the speed pedal and allow the engine to slow down to idle. 11. Repeat the procedure from step 3 until the transmission has reached a temperature of 80°C...90°C (176°F...190°F). 12. You can now calibrate the transmission. 190/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions When the converter output temperature exceeds 120°C (248°F), the engine is reduced to NOTE half RPM. 4.17.4.2 Activating the DANA transmission calibration WARNING RUN OVER HAZARD If the parking brake fails, the machine can start moving. Never leave your seat during calibration. If the parking brake fails, you can use the foot brake. The transmission calibration determines the amount of oil that is required to fill the clutch until the clutch starts to transfer torque. To activate the transmission calibration, the following conditions must be met: • Parking brake must be activated and work properly • Transmission oil temperature must exceed 70°C (150°F) • Engine RPM must be 800 RPM ± 200 RPM 1. Go to Machine overview > DANA transmission. 2. To enter the PIN code (2), press the panel (1). 1 2 3. Enter the service PIN code. 4. From the drop-down list, select Transmission calibration. 191/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 5. To start calibration, tap on Select. The calibration automatically calibrates all the clutches in the transmission. The calibration takes about 20 min to perform. If any problems occur during calibration, an error code appears on the display. 6. After finishing the calibration, turn off the ignition. 7. Wait for 5–10 s. 8. Turn on the ignition. After the restart, the new settings for gear shifting are in use. Remember to select "OFF" in the request code menu when you are finished with the NOTE calibration. 4.18 Maintaining the ZF transmissions This chapter includes the maintenance instructions for the ZF transmissions. 192/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.18.1 Changing the ZF transmission oil WARNING HOT FLUID HAZARD Risk of serious personal injury. Avoid spilling hot oil and do not touch hot surfaces. NOTE Replace the oil when it is at the operating temperature. NOTE Working with the oil system requires special cleanliness. 2 1 Figure 89. Changing the transmission oil 1. Place a suitable container under the drain plug. 2. Clean around the drain plug (1). 3. Remove the drain plug. 4. Allow the oil to drain. 5. Clean the drain plug. 6. Replace the O-ring on the drain plug. 7. Remove the filler cap (2). 8. Fill with the recommended oil to the maximum level indicator on the dipstick (2). 9. Run the engine on idle for 1 min to fill the torque converter and pipes. 10. Check the oil level when the engine has run for 1 min and then refill to the minimum indicator level. 11. Check the oil level again when the transmission has reached operating temperature. Fill to the maximum indicator level. See maintenance data for volume. 12. Put the dipstick and the filler cap (2) back again. 193/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.18.2 Changing the ZF transmission oil filter RISK OF PROPERTY DAMAGE NOTICE Handle the filter with care. Do not fit a damaged filter. Make sure that no dirt or sludge penetrates into the transmission. NOTE Working with the oil system requires special cleanliness. 4.18.2.1 Changing the ZF 191 transmission oil filter 1. Clean the outside of the filter unit. 2. To collect any excess oil, place a receptacle underneath the filters (1). 1 3. Loosen the filters (1) by hand or with a filter wrench. 4. Remove the filters (1). 5. Check the new filters (1) and the seals. 6. Lightly lubricate the seals with oil. 7. Screw on the filters (1) until the seal is in contact with the filter housing. Tighten another half turn, no more. 8. Start the engine, check that there are no leaks. 9. Check the oil level with the dipstick. 10. Switch off the engine. 4.18.2.2 Changing the ZF 261/311 transmission oil filter 1. Clean the outside of the filter unit. 2. Place a receptacle underneath the filters (1) to collect any oil. 194/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 1 3. Loosen the filters (1) by hand or with a filter wrench. 4. Remove the filters (1). 5. Check the new filters (1) and the seals. 6. Lightly lubricate the seals with oil. 7. Screw on the filters (1) until the seal is in contact with the filter housing, tighten the filter (1) one half turn by hand at the most. Cleaning the ZF 261/311 transmission oil strainer 8. Clean the transmission oil strainer (2), if available. 9. Carefully clean the outside of the oil strainer unit. 10. Place a receptacle under the oil strainer (2) to collect any oil. 2 11. Loosen the oil strainer (2). NOTE Make sure that no larger particles (metal pieces or similar) are stuck to the oil strainer (2). 12. Clean the oil strainer (2). 13. Slightly lubricate the oil strainer (2). 14. Fit the oil strainer (2). 15. Start the engine and check that there are no leaks. 16. Check the oil level with the dipstick. 17. Switch off the engine. 195/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.18.3 Checking the ZF transmission breather 1 Figure 90. ZF transmission breather 1. Clean the transmission breather (1) with a cloth. 2. Check that the transmission breather (1) is not clogged. 3. Replace if necessary. 4.18.4 Calibrating the ZF transmission 4.18.4.1 Heating up the ZF transmission WARNING UNCONTROLLED MOVEMENT HAZARD Risk of personal injury or damage to the machine. Only the service brake is in use. Use chocks to block the wheels. Heat up the transmission before the calibration procedure. 1. To monitor the transmission temperature, go to the Machine overview> 1 Transmission page. The transmission temperature displays on the right on the MD4 display (1). 2. Select manual gear shifting. 3. Select the highest gear. 4. Apply the service brake by using the brake pedal in the cabin. 5. Release the parking brake. 6. Select driving direction forward. 7. Run the engine at maximum RPM. 8. After about 15 s at maximum RPM, select neutral. 196/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 9. Continue at maximum RPM. 10. Keep the transmission in neutral at maximum RPM for another 15 s. The figure shows the heating cycle for the transmission. 11. Release the speed pedal and allow the engine to slow down to idle. 12. Repeat the procedure from step 6 until the transmission has reached a temperature of 80°C...90°C (176°F...190°F). 13. You can now calibrate the transmission. When the converter output temperature exceeds 125°C (257°F), the engine is reduced to NOTE half RPM. 4.18.4.2 Activating the ZF transmission calibration The transmission calibration determines the amount of oil that is required to fill the clutch until the clutch starts to transfer torque. To activate the transmission calibration, the following conditions are required: • Parking brake must be activated and work properly • Transmission oil temperature must exceed 70°C (158°F) 1. Start the calibration by pressing AEB on the Transmission page. AEB = Automatisiertes Ermitteln der Befüllparameter (Automated determination of the filling parameters). 197/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 2. The calibration takes 15–20 min. The grey progress bar shows when the calibration is complete. Click OK. 3. Switch off ignition. 4. Wait 5–10 s. before turning on the machine again. 5. Switch the machine back on. The new values are in use now. 4.19 Maintaining the drive axle 4.19.1 Checking the drive axle oil level NOTE Check the oil level in both hubs and the differential. 1. Park the machine on level ground. 2. Make sure the hub level mark (1) is horizontal and you can read the text "oil" on the hub. 2 1 3. Open the filling and level plugs (2) and check the oil level. 198/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions • If oil seeps out of the filling and level plug, there is enough oil. NOTE If a large amount of oil comes out, check for internal leakage. • If no oil seeps out, the oil level must be checked. NOTE Minimum oil level is at least 1 cm from the edge of the filling and level hole. 4. If there is not enough oil, refill oil to at least the minimum level. 5. Tighten the filling and level plug (2). 4.19.2 Changing the drive axle oil NOTE Change the oil in both hubs and the differential. NOTE Take care of the excess oil and dispose of it in an environmentally responsible way. Park the machine on level ground. 4.19.2.1 Changing the drive axle oil - hub 3 2 1 1. Make sure that the drain hole (3) is located in the highest position on the wheel. 2. Clean around the drain hole (3) and plug. 3. Remove the plug from the drain hole (3). 4. Fix a suitable hose in the drain hole (3). Use a hose that fits the threads in the the drain hole (3). 5. To reposition the drain hole (3), carefully drive the machine in any direction. Make sure that the drain hole (3) is located in the lowest position on the wheel. 6. Drain the oil through the hose into a receptacle. 7. Refit the plug into the drain hole (3). 8. Place the machine with the level mark (1) and the text "oil" in horizontal position on the hub. 9. Open the filling and level plug (2). 10. Fill the drive axle through the filling and level plug (2). 199/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions NOTE Minimum oil level is at least 1 cm from the edge of the filling and level hole. 11. Close the filling and level plug (2). 12. Repeat the procedure on the opposite side. 4.19.2.2 Changing the drive axle oil - differential 1 2 1. Clean around the drain plug (2). 2. Remove the drain plug (2). 3. Drain the differential through the drain plug (2). Drain the oil at operating temperature or overnight, as the oil is of high viscosity. 4. Refit the drain plug (2). 5. Open the filling and level plug (1). 6. Fill the drive axle through the filling and level plug (1). NOTE Minimum oil level is at least 1 cm from the edge of the filling and level hole. 7. Close the filling and level plug (1). 4.19.3 Checking the drive axle breather 1 1. Check that the drive axle breather is not clogged. 2. Replace if necessary. 200/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions Unscrew the drive axle breather (1) and replace with a new drive axle breather. 4.19.4 Measuring the parking brake pressure 1. Connect a pressure gauge (0–300 bar or 0–5000 psi) to the measuring point (1) marked PRM on the accumulator charging valve. 1 2. Start the engine and let it idle. 3. Release the parking brake. 4. Read the pressure. Check according to the machine card. 201/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.19.5 Adjusting the parking brake WARNING MOVING VEHICLE HAZARD. The machine can move if not parked on level ground and with the wheels firmly secured. If the machine moves, there is a risk of serious injury or death. Park the machine on level ground and firmly secure the wheels. Adjusting the parking brake is required after installing new brake pads or brake disc, after all repairs, and to improve braking performance. Adjust the parking brake when it is cold. The parking brake must be in the released condition while adjusting. 9 1 2 7 8 3 6 5 4 Figure 91. Parking brake 1. Spring 6. Dust cap 2. Lock ring 7. Screw cap 3. Locknut 8. Adjusting screw 4. Seal 9. Bleeder screw 5. Piston sealing 1. Park the machine on a level surface. NOTE To prevent the vehicle from moving, block the wheels. 2. To release the parking brake, press the parking brake switch. NOTE The parking brake pressure must be correct and the ignition must be on. 3. Remove the screw cap (7). 4. Loosen the locknut (3). Turn the adjusting screw (8) clockwise until both brake pads contact the brake disc. 5. Turn the adjusting screw counterclockwise to set the total clearance to 1–0.5 mm (0.04– 0.02 in). 6. Tighten the locknut (3). 7. Recheck the clearance. 202/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.19.6 Manually releasing the parking brake DANGER RUN OVER HAZARD If the engine is running, the service brake is working. If the engine is not running, only the parking brake is working. If it is released, the machine has no brakes. Risk of serious personal injury or death. To prevent the machine from moving, block the wheels. 3 8 7 Figure 92. Manually releasing the parking brake If hydraulic pressure is not available, the parking brake can be manually released as follows: 1. To prevent the machine from moving, block the wheels. 2. Remove the screw cap (7). 3. Loosen the locknut (3). 4. Turn the adjusting bolt (8) counterclockwise until the brake is released. 5. Tighten the locknut (3). Install and hand-tighten the screw cap. Before you return the machine to operation, adjust the parking brake, see Adjusting the NOTE parking brake (page 202). 203/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.19.7 Bleeding the parking brake When you loosen the hydraulic hose of the parking brake, bleed the parking brake to remove the air from the system. To obtain the correct functionality, all air in the brake cylinder must be vented out. 9 Figure 93. Bleeding the parking brake 1. Attach a clear tube to the bleeder screw (9). Insert the other end of the tube in a receptacle. 2. Apply hydraulic pressure to the parking brake. 3. Loosen the bleeder screw (9). 4. Continue to apply pressure until no air bubbles appear in the hydraulic oil in the receptacle. 5. Tighten the bleeder screw and release the pressure. 204/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.20 Maintaining the steer axle 4.20.1 Checking the steer axle bearings Check the wheel and spindle bearings regularly and always when the tires are replaced. It is important to check the steer axle bearing during running in. It is important that there is no play in the steer axle bearings, as they are exposed to heavy loads and shocks. Any play results sooner or later in bearing breakdown. Bearings are adjustable. For more information, see Adjusting the wheel bearings (page 206). Play in link bearings are acceptable to 1–2 mm (0.04–0.08 in) for each bearing. Link NOTE bearings are not adjustable. 2 3 1 Figure 94. Checking the steer axle bearings 1. To lift each side, use a jack. See Positioning the jack (page 75). 2. Check the plays when the wheel rises from the ground. 3. Check the spindle bearings by lifting the wheel with a crowbar (1). See Adjusting the spindle bearings (page 207). 4. Check the wheel bearings by prying the wheel vertically (2). See Adjusting the wheel bearings (page 206). 5. Check the link bearings by turning the wheels in the steering direction (3). 205/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.20.2 Adjusting the wheel bearings 5 4 3 2 1 NOTE For instructions on how to jack up the machine, see Positioning the jack (page 75). 1. Remove bearing cover (1) and gasket (2). 2. Check that the grease is clean and free from particles. If the the grease is not clean or free from particles, the reason for the play may be a damaged bearing. 3. Loosen the outer nut (3) and remove the lock washer (4). 4. Tighten the inner nut (5). First tighten the nut to 500 Nm (368. 78-lbf ft). 5. Rotate the hub ten revs anti-clockwise. The hub should only offer light resistance when rotating. A noise or irregular rotation NOTE means that the bearings are damaged. If so, the bearings must be replaced. 6. Repeat steps 4 and 5 once. 7. Tighten the inner nut (5) again to achieve the correct torque of 500 Nm (368. 78-lbf ft). 8. Mount the lock washer (4). 9. Tighten the outer nut (3) to achieve the correct torque of 300 Nm (162.3-lbf ft). 10. Lock the outer nut (3) using the lock washer (4). 11. Refit the gasket (2) and bearing cover (1). 206/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.20.3 Adjusting the spindle bearings 2 3 4 5 1 6 NOTE For instructions on how to jack up the machine, see Positioning the jack (page 75). The steer wheel may have to be removed to access the spindle and bearing. For NOTE instructions on how to remove the steer wheel, see Dismantling the steer wheels, wheels with clamp units (page 87). 1. Remove the steering link (1). 2. Remove the bearing cover (2) and gasket (3). 3. Check that the grease is clean and free from particles. If the the grease is not clean or free from particles, the reason for the play may be a damaged bearing. 4. Unscrew the upper nut (4) completely. Otherwise, you cannot reach 1000 Nm (737.6-lbf ft) with the lower nut. 5. Loosen the lock washer (5). 6. Check that the lower nut (6) is tightened. Tighten the stop screw with 35 Nm and Loctite. The correct torque is 1000 Nm (737.6-lbf ft). 207/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions The lower nut (6) is not used to preload the bearing. All bearing preload is adjusted with NOTE the upper nut (3). 7. Tighten the upper nut (4). The correct torque for KM12 and KM17 is 300 Nm (221.3-lbf ft), and for KM22 is 350 Nm (258.1-lbf ft). 8. Rotate or swing the spindle ten times to the end positions (left-right-left-right, and so on). 9. Tighten the upper nut (4) again. The spindle should only offer light resistance when turning. NOTE A noise or irregular rotation means that the bearing is broken. Replace the bearing. 10. Lock the upper nut (4) with the lock washer (5). 11. Refit a new gasket (3). 12. Refit the bearing cover (2). 13. Fill the bearing house with grease. 4.21 Maintaining the hydraulic system 4.21.1 Changing the hydraulic oil The filter should be changed when the hydraulic oil is changed. 2 1 Figure 95. Changing the hydraulic oil 1. Drain out the oil through the drain plug (1), using a receptacle. NOTE If the filters have been removed, soak up the oil through the filter housings. 2. Check the tank for cracks and signs of leakage. 3. Inspect the bottom of the tank through the inspection hatches for any deposits. 4. Clean the tank if needed. 5. Assemble the filters and covers if removed. 6. Fill up the hydraulic oil through the filling cap (2) in the filter cover, the oil flows through the filters. To make sure that the oil goes through the filters quickly, connect the oil pump to the NOTE filling cap (2). 208/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.21.2 Starting the hydraulic pumps RISK OF DAMAGE TO THE MACHINE NOTICE Air in the system may damage the hydraulic system. Never start the machine if the pumps are not air-bled. The machine is equipped with variable pumps. After servicing pumps or other parts of the hydraulic system, the pumps are started as follows. 1 2 3 Figure 96. Hydraulic pump 1. Disconnect hoses (1) and (2). 2. Unscrew pump plug (3). 3. Fill the three pump housings with the recommended hydraulic oil. 4. Refit the hoses (1), (2) and the pump plug (3). 5. Start the machine and raise the forks slowly. Any noise should disappear after a few seconds. If there is a consistent noise, which NOTE does not disappear after a few seconds, turn of the machine and check the hydraulic system. 209/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.21.3 Changing the hydraulic oil filter RISK OF DAMAGE TO THE MACHINE Changing the hydraulic oil filter without following these instructions may damage the NOTICE hydraulic system. Always follow these instructions when changing the hydraulic oil filter. NOTE To be able to check the oil, the forks must be lowered to ground level. The hydraulic oil filters are in the hydraulic tank. In smaller forklifts, the tank is located under the steps, in bigger ones, the tank is next to the steps. Table 13. Location of hydraulic tank and filter - smaller forklifts (SMV 10-16) Location of hydraulic tank Hydraulic oil filter components Figure 97. Hydraulic oil filter components 1. Filter cover 2. Filter housing 3. Hydraulic oil filter 4. Overflow valve 1. With smaller forklifts, remove the top step to access the hydraulic tank. 2. Clean around the filter cover (1). 210/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 3. Remove the filter cover (1). 4. Check the condition of the seal (5). 5. Remove the four screws (6) of the filter housing in the return chamber. 5 6 6. Remove the rim (7) of the filter housing. 7 7. Lift the complete filter housing from the hydraulic tank. Let it drain before disassembling it. NOTE With smaller forklifts, open the cabin door before you remove the filter housing. 8. After you have removed the filter housing, check the filter area for any deposits. 9. Remove the overflow valve (4) by pressing and turning it. 211/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 10. Take the filter from the filter housing. 11. Remove the hydraulic filter spring (8). 8 12. Remove the filters. 13. Check the filters for any deposits. Remove the deposits. 14. Clean the filter housing, using a lint free cloth. 212/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 15. Fit new filters, close with the overflow valve (4). Press and turn to the correct position. 16. Fit the filter housing in the tank. 17. Fit rim (7) and then put back the screws in the filter housing. 18. Fit the filter covers using new O-rings. 19. Fill with oil if the oil has been drained. 20. Start the machine and check for leakage. 21. Turn off the machine and check the oil level. For more information, see Starting the hydraulic pumps (page 209). 4.21.4 Hydraulic long life (HLL) filter (option) NOTE Working with the oil system requires special cleanliness. NOTE To avoid spillage, place a receptacle under the filter. Take care of the excessive oil and dispose of it in a safe controlled manner. Put the used NOTE filter in a suitable receptacle, and dispose of it in an environmentally responsible way. 4.21.4.1 Placement of the hydraulic long life (HLL) filter 1 Figure 98. Placement of filter, SMV 10-16 213/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 1 Figure 99. Placement of filter, SMV 18-60 1. Placement of the HLL filter 4.21.4.2 Checking the HLL filter 1 Figure 100. Pressure indicator The pressure indicator (1) shows the status of the HLL filter, when the machine is on. If the indicator points towards the red area between service intervals, the HLL filter must be changed. For more information, see Changing the hydraulic long life (HLL) filter (option) (page 214). 4.21.4.3 Changing the hydraulic long life (HLL) filter (option) If the pressure indicator (5) points towards the red area between service intervals, the NOTE filter must be changed. Otherwise, follow the regular service recommendations. See Regular service (page 236) 214/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 1 2 3 4 5 Figure 101. Parts of the HLL filter 1. Filter cover 4. Filter housing 2. Seal (O-ring) 5. Pressure indicator 3. Filter 1. Clean the surface around and on the filter housing (4) and cover (1). 2. To open the cover (1), turn it counterclockwise. 215/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 3. Lift the cover (1) and filter (3) slowly. NOTE Let the excess oil drip into the filter housing (4). 7 6 4. To collect any remaining oil, place the filter (3) and the cover (1) in a suitable container. 5. To remove the cover (1) from the filter (3), slide the cover outwards (6) and pull upwards (7). 6. Dispose of the filter (3) in a responsible way. 7. Remove and change the seal (2). 8 9 8. To attach the cover (1) to the new filter, move the filter downwards (8), and fit the pin in the filter. 216/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 9. Slide the cover (1) towards the middle (9). 10. Insert the new filter with the attached cover (1) into the filter housing (4). 11. To fixate the cover (1), turn it clockwise in the filter housing (4). 4.21.5 Changing the hydraulic tank breather filter 1 1 Remove breather filter, single Remove breather filter, double 2 2 Replace breather filter, single Replace breather filter, double 1. Clean around the breather filter housing. 2. Unscrew the breather filter (1). 3. Replace with a new breather filter (2). 217/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.21.5.1 Replace filter element in the breather filter housing 1 2 1 1. Clean around the filter cap (1). 2. Unscrew the filter cap (1). 3. Remove the filter cap (1). 4. Remove the filter element (2). 1 3 1 5. Add the new filter element (3). 6. Screw the filter cap (1) back on. 4.21.6 Changing the brake cooling oil NOTE Working on the oil system requires special cleanliness. 1 1. Clean around the breather filter (1). 2. Drain out the oil through the drain plug, using a receptacle placed underneath. Drain plug is found in the bottom of the tank. 3. To speed up the draining of the oil, remove the filler cap. 4. Fill up the brake cooling oil through the breather filter (1). 218/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.21.7 Changing the brake cooling oil filter NOTE Working on the oil system requires special cleanliness. To avoid spillage, place a receptacle underneath the filter. Store the used filter in a NOTE suitable container and dispose of it in an environmentally responsible way. 1 1. Clean around the filter (1). 2. Remove the old filter (1). 3. Clean the mating surface of the filter housing. 4. Lubricate the rubber seal and fit a new filter. 5. Secure the filter by hand. 4.21.8 Changing the breather filter for the brake cooling oil tank 1 1. Clean around the breather filter (1). 2. Unscrew the breather filter (1). 3. Replace with a new breather filter (1). 219/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.22 Maintaining the mast and fork carriage 4.22.1 Checking the mast and fork carriage Figure 102. Checking the mast and fork carriage Using a crowbar or a lever: 1. Check the play between the carriage and the inner mast. 2. Check the play between the inner and the outer mast. If there is a play exceeding 5 mm (0.2 in), seek the advice of the nearest authorized dealer. 220/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.22.2 Checking the fork arms WARNING RISK OF PROPERTY DAMAGE The forks can crack, become deformed, or break. Only specially trained personnel can inspect the forks for cracks. The inspection interval is one year. Only a company that is certified can do fork inspections. Do not rectify surface cracks and wear by welding, only an authorized dealer can evaluate if the forks can be repaired. 150 m m 1 1. Check the fork arms for the thickness of the fork blade, crack formation, and deformation. The wear on the fork blade must not exceed 10%, based on the stamped dimension on the fork (1). The wear on the fork blade is measured 150 mm (6 in) from the heal of the fork (1). NOTE Do not use the fork if it has any visible cracks. 2. Check for crack formations in the fork heal. Surface cracks are usually not longer than 5 mm (0.2 in). 3. If surface cracks are found, grind off about 0.5 mm (0.02 in). Use magnetic powder to check if the crack is still visible. NOTE Only a company that is certified to do fork inspections are allowed to perform this step. 4. Check the fork suspension for play. If the forks are in need of repair, contact an authorized dealer, that can evaluate if it is possible to repair the forks. 221/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.22.3 Checking the clearance between the mast and fork carriage 2 Between base plate on the outer mast and the fork carriage. 1. Lower the mast and carriage to their lowest position. Keep the mast in vertical position. 2. Check the space between the base plate on the outer mast and the fork carriage (2). NOTE The space must be 10 mm (0.4 in). 3. If the space is not 10 mm (0.4 in), readjust the lift chains equally. 4.22.4 Checking the fork shaft system (option) 3 2 1 3 Figure 103. Fork shaft system Check the fork shaft system as follows: 1. Check that the welding on the locking mechanism (1) is undamaged. 2. Check that the locking pin (2) is undamaged. 3. Check that the ball bearings, and rollers (3) are undamaged. 222/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.22.5 Checking the lift chains DANGER FALLING LOAD HAZARD If a chain breaks, the load can fall, and cause death, personal injury or damage to the machine. If in doubt, replace the chain. Always replace the full chain, do not join, or restore broken lift chains. Before inspection, clean the chains in their entire length. Always check the chains when without a load. 1 2 p + + + + p Figure 104. Lift chains For inspection intervals, see Regular service (page 236). 1. Check that the length of the chain has not increased by more than 3% compared to its original length. Measure the 25 links that are lifted first, counting from the chain wheel down towards the carriage. These 25 links are the part of the chain where the extension is the greatest and most often brake. 2. Compare with the value for the given chain sizes in the following table. 3. If the 3% limit is exceeded, replace the chain. Local regulations may require that the chain must be replaced when the length increases NOTE by 2%. Table 14. Length of 25 links of chain Parting (p) Length of 25 links for Length of 25 links at 2% Length of 25 links at 3% new chain extension extension 38.1 mm (1.5 in) 952.5 mm (37.5 in) 971 mm (38.2 in) 981 mm (38.6 in) 50.8 mm (2 in) 1270 mm (50 in) 1295 mm (51 in) 1308 mm (51.5 in) 63.5 mm (2.5 in) 1587.5 mm (62.5 in) 1619 mm (63.7 in) 1635 mm (64.37 in) 76.2 mm (3 in) 1905 mm (75 in) 1943 mm (76.5 in) 1962 mm (77.2 in) 4. Check the state of the lift chains, make sure that there are: 223/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions • No twisted pins. Normal pin position (1), and twisted pin postion (2). • No loose pins in the outside washers • No visible cracks in any washer (link section) • No visible mechanical damage • No visible cracks or damages on the chain attachments on mast and carriage • No jarring noise when the chain moves • No corrosion in the chain • No resistance when the chain bends over the chain wheel NOTE If any of these deviations are found, always replace the chains. 5. Lubricate the chains after inspection using a thin oil or lubrication spray. 4.22.6 Adjusting the lift chains NOTE Follow the same procedure, and adjust both lift chains simultaneously. 1 2 3 4 1. Adjust the lift chains with the adjusting nuts (1-4). When the mast is in the lowest position, the distance between the base plate of the outer NOTE mast, and the bottom of the carriage should be 10 mm. 2. Raise the carriage to 50 mm. 3. Place a 10 mm spacer on both sides, under the carriage. 4. Lower the carriage until it rests on the spacer. 5. Loosen the upper adjusting nut (2), and the upper locking nut (1). 6. Adjust both the lift chains with the lower adjusting nut (3), until both have the same tension. 7. Lock the lower locking nut (4), on both lift chains. 8. Raise the carriage with load. 9. Tighten the upper adjusting nut (2). 10. Lock the upper locking nut (1). 224/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.23 Maintaining the machine 4.23.1 Cleaning the machine WARNING HARMFUL SUBSTANCE HAZARD Risk of serious injury. Hot steam or aggressive degreasing agents must be used with great care. Protective clothing and eye protection must be worn. Figure 105. Cleaning the machine The length of time between cleaning sessions depends on the type of work that the machine carries out. If the machine is used in aggressive environments, it must be cleaned after it has been NOTE used. Examples of aggressive environments are: • salt water • fertilizers • chemicals • cement 1. Protect all electrical components and the air intake filter from steam, water, and so on, during cleaning. 2. Clean the areas around the oil filling and lubrication areas before servicing. 3. If using a degreasing agent when cleaning, allow sufficient time for it to penetrate. Rinse with a powerful jet of water afterwards. 4. After cleaning the engine, run the engine warm so that it dries. Check that no water that has penetrated has caused any faults. 5. Dispose of all used cleaning materials in an environmentally responsible way. 6. Always lubricate the machine after cleaning. For more information, see Lubricating the machine (page 98). 225/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.23.2 Changing the internal cabin air filter Take care when changing the air filter, the filter may contain unhealthy particles. Dispose NOTE of the old filter in an environmentally responsible way. The internal and external cabin air filters are under the dashboard on the right side of the cabin. 1. Loosen the screws to open the cabin ventilation system cover (1). The filter frame with the blue cabin air filter is revealed. 1 2. Loosen the screws on the filter frame and open it. 3. Pull out the filter gently to avoid dust in the climate unit and cabin. 4. Replace the filter in the frame. 5. Put back the filter frame and tighten the screws. 6. Close the cover on the cabin ventilation system and tighten the cover screws. 226/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4.23.3 Changing the external cabin air filter Take care when changing the air filter, the filter may contain unhealthy particles. Dispose NOTE of the old filter in an environmentally responsible way. The internal and external cabin air filters are under the right-hand dashboard. 1 Figure 106. Replacing the external cabin air filter 1. To open the "cabin ventilation" system cover (1), loosen the screws. The filter frame with the blue cabin air filter is revealed. 2 2. Loosen the screws on the filter frame (2). 3. To reveal the beige external air filter, remove the frame and the internal filter. 3 4. Loosen the screws on the external air filter frame (3). 227/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 5. Replace the filter element. 6. Replace the covers and fasten the frame screws again. 7. Remount the internal filter. 8. Close the cover of the cabin ventilation system and fasten the screws. 4.23.4 Checking the battery WARNING CORROSIVE SUBSTANCE HAZARD The battery contains corrosive acid that may cause a risk for serious injury or death. Always use the necessary protective equipment. WARNING ELECTRICAL HAZARD The main disconnect does not cut the power to the alternator. To reduce the risks of electric shock and personal injury always remove jewelry and conductive material before working on the electrical system. Always disconnect the ground (minus) cable at the battery when working near or on the alternator. WARNING TIPPING OVER HAZARD Turning off the battery main switch while the machine is moving applies the parking brake and the machine may tip over. The software in the control unit can get damaged. Do not turn off the battery main switch while the engine is running. The batteries are in the battery compartment. Figure 107. Battery compartment 1. Keep the batteries clean. 2. Remove corrosion from the battery connections and check that the cable connections are tightened. 3. Lubricate the battery terminals using acid-free grease. 228/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 4. Check the battery acid level. If necessary, fill with distilled battery water. 4.23.5 Changing the batteries DANGER RISK OF EXPLOSIVE GAS There can be explosive gas around the batteries, which can cause serious personal injury or death. Always disconnect the ground (minus) cable, when working with, or around the batteries. Never smoke, or have flammable, or combustible material near, when working with or around the batteries. DANGER CORROSIVE SUBSTANCE HAZARD The battery contains corrosive acid that can cause a risk for serious injury or death. Always use necessary protective equipment, such as eye-protector, and safety gloves. WARNING RISK OF ARCING AND ELECTRIC SHOCK Touching the connections during a battery change can cause arcing, and lead to serious personal injury or death. Do not touch the connections during the battery change. Always remove jewlery, and conductive material before working on the electrical system. Take care of the old batteries, and dispose of them in an environmentally responsible NOTE way. Before installing new batteries, check for damages, or leakage. Make sure that the NOTE batteries are charged. Check the cables for damages, replace if needed. Clean, and lubricate the battery poles. 229/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 1. Turn off the machine, and the ignition. 1 2. Turn off the battery main switch (1) 3. Clean the surface around the battery connections. 3 2 4. Disconnect the ground connection (2), the cable is marked with blue color. 5. Disconnect the "plus" connector (3), the cable is marked with red color. 4 230/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 4 Service and maintenance instructions Maintenance Instructions 6. Remove the connecting cable between the batteries (4). 7 6 5 7. Remove the locking pin for the battery attachment (5). 8. Remove the wing nut and the washer (6). 9. Remove the mounting bracket for the batteries (7). 8 10. Use the handles (8) to lift out the batteries from the battery compartment. NOTE When installing the new batteries, reverse the procedure. 231/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 4 Service and maintenance instructions 4.23.6 Checking the weld constructions To see if there are any visible signs of damage, deformation, metal fatigue, and so on, check the mast, chassis, and all welded parts. Check them at least once a year, more often if the machine is used in shift work or in tough environments with a frequent heavy load. If you have any doubts, contact your Konecranes Lift Trucks authorized dealer. Figure 108. Weld constructions 4.23.7 Changing the windshield wipers 1 2 3 Figure 109. Windshield wipers 1. Raise the wiper from the windshield. 2. Remove the nut (1). 3. Remove the blade (2) from the arm (3). 4. Insert the new blade (2) into the arm (3). 5. Refit the nut. 6. Lower the wiper back onto the windshield. 232/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 5 Maintenance schedule Maintenance Instructions 5 MAINTENANCE SCHEDULE 5.1 Commissioning inspection Always perform maintenance, lubrication, inspection, and daily maintenance according to the instructions in this document. Before starting up the machine for the first time, check the inspection points according to the warranty commissioning report. The warranty commissioning report must be filled in and returned to Konecranes Lifttrucks within one week from starting up the machine to make the warranty valid from the commissioning date. If the warranty commissioning report is not returned within one week, the warranty is valid from the day the machine was delivered by Konecranes Lifttrucks. 5.2 Commissioning service 1. Clean the machine. 2. Tighten the wheel nuts according to correct torque. 3. Check the pressure and condition of the tires. 4. Check the windshield washer level. 5. Check the fuel level. 6. Check the coolant level. 7. Check the transmission oil level. 8. Check the engine oil level. 9. Check the hydraulic oil level. 10. Check the functioning of the service and parking brake. 11. Check the functioning of the steering system. 12. Lubricate according to the lubrication chart 13. Check the functioning and the condition of the electrical system, lighting, instruments, switches, and safety system. 14. Check the functioning of the hydraulic system. 15. Check the drive axle oil level. 16. Check the condition of batteries. 17. Check the safety and condition of the operator's cabin, fuel and oil tanks, chassis, counterweights, lifting equipment, and attachment. 18. Check the condition of the paintwork and windows. 19. Compare the specifications with the customer's acceptance of order. 20. Check the ID and warning signs, compare against available documentation. 21. Check that the operating instruction is delivered with the machine. 22. If applicable, activate TRUCONNECT® with customer information in the portal. 5.3 Daily maintenance DANGER UNCONTROLLED MOVEMENT HAZARD If the machine moves unexpectedly, it could result in personal injury, death, or damage to the equipment. To stop any unexpected movement, press the emergency stop button. 233/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 5 Maintenance schedule WARNING MOVING PARTS HAZARD There is a risk of getting trapped by moving parts of the engine. There is also a cutting risk from moving parts of the engine. Do not open the hood or perform maintenance work while the engine runs. WARNING TOXIC SUBSTANCE HAZARD Breathing diesel engine exhaust exposes you to chemicals that may cause cancer, birth defects, or other reproductive harm. Never run the engine in unventilated places. Use fume extraction. Do not keep the engine idling, except when necessary. Do not modify or tamper with the exhaust system. WARNING IGNITION HAZARD During operation, parts of the machine can become very hot. If there are flammable or combustible materials, on or near any hot surfaces on the machine, there is a risk of fire. Examples of such materials are paper, or saw dust. Before taking the machine into operation, make sure that there are no flammable or combustible materials on or around any hot surfaces. Examples of hot surfaces can be the turbo, exhaust pipe, DPF, and so on. Visually inspect the machine for damage while going through the checklist during daily NOTE maintenance. NOTE Check the condition of the safety and information labels, replace if needed. After performing the daily maintenance tasks, start the machine and listen for any NOTE abnormal noise from the engine and transmission. If any abnormal noise is heard, contact maintenance personnel. Separate instructions on how to perform each task, can be found in the Operating NOTE Instructions. 1. Check the battery main switch 2. Check the wheel nuts and clamps. 3. Check the tire pressure and the condition of tires and rims (visible cracks and damages). 4. Check the engine oil level. 5. Check the transmission oil level. 6. Check the coolant level in all tanks. 7. Check the hydraulic oil level. 8. Check the brake cooling oil level (option, not available for all models). 9. Check the grease level in the two reservoirs for the automatic lubrication system (option). NOTE If automatic lubrication is installed (optional), there can be one or two tanks. 10. Check the MD4 warnings for clogging of engine air filter. 11. Check the windshield washer fluid level. 12. Check the fuel level. 13. Check the AdBlue level (when applicable). 14. Check the soot level (when applicable). 234/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 5 Maintenance schedule Maintenance Instructions 15. Check that the mirrors are clean and adjust them to make sure of good visibility. 16. Check that the windows are clean. 17. Clean the rearview camera (option). 18. Check for visual signs of leakage, around and under the machine 19. Check the seat adjustments and adjust if needed. 20. Check the steering wheel adjustments. 21. Check the service brake functionality. 22. Check the parking brake functionality. 23. Check the functionality of the steering system. 24. Check the hydraulic functions. 25. Check the electrical functions. 26. Check the climate unit (option) settings. 5.4 Maintenance points after the first 150 operating hours 1. Change the engine oil. 2. Change the engine oil filter. 3. Change the transmission oil. 4. Change the transmission oil filter. 5. Lubricate the machine. 6. Check the drive axle oil level. 7. Check the coolant level. 8. Check the coolant freezing point. 9. Check the engine drive belt. 10. Check the hydraulic oil level. 11. Check the battery condition. 12. Check the exhaust system. 13. Check (clean if necessary) the engine air filter and air intake. 14. Check the mast and carriage. 15. Check pressure and condition of the tires. 16. Tighten the wheel nuts to the correct torque. 17. Check the steer axle bearings. 18. Check and tighten the bolted joints. 19. Check the condition and functioning of the electrical system, lighting, instrumentation, switches, and safety system. 20. Check the safety and condition of the cabin, tanks, chassis, counterweights, lifting equipment, and attachments. 21. Check the condition of the paintwork and windows. 22. Check the functioning of the service and parking brake. 23. Check the functioning of the steering system. 24. Check the functioning of the hydraulic system. 25. If applicable, check that TRUCONNECT® functions properly. 235/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 5 Maintenance schedule 5.5 Regular service Table 15. Machine maintenance Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Contact your local authorized dealer for updates about the X X X X latest changes and service information Cleaning the machine X Lubricating hinges X X X X Changing the cabin air filters X X X X Tightening the bolted joints X X X X X Checking the battery X X X X Checking the condition of paintwork and windows X X X X Checking the safety and condition of the cabin, tanks, X X X X body, counterweights, lifting equipment, and attachment Checking the machine plate and the warning stickers X X X X Checking the weld constructions X X Checking for leaks X X X X Table 16. Engine maintenance Volvo TAD 581, 881, 883 VE Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1) X X X Changing the engine oil filter 1) X X X Draining the fuel prefilter X X X X X Draining the extra fuel prefilter (if applicable X X X X X Changing the fuel filter X X X Changing the fuel prefilter X X X Changing the extra fuel prefilter (if applicable X X X Changing the AdBlue-pump filter X X Changing the AdBlue breather filter X X Changing the AdBlue armature (level) filter X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X Checking the freezing point of the coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the coolant hoses X X X Replacing the drive belts X X 236/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 5 Maintenance schedule Maintenance Instructions Table 16. Engine maintenance Volvo TAD 581, 881, 883 VE (Continued) Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Checking for leaks X X X X Checking and adjusting the valve clearance X X Checking the cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of VDS4.5 1) More often if necessary. Table 17. Engine maintenance Volvo TAD 1181 VE Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1) X X X Changing the engine oil filter 1) X X X Draining the fuel prefilter X X X X X Draining the extra fuel prefilter (if applicable X X X X X Changing the fuel filter X X X Changing the fuel prefilter X X X Changing the extra fuel prefilter (if applicable X X X Changing the AdBlue-pump filter X X Changing the AdBlue breather filter X X Changing the AdBlue armature (level) filter X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X Checking the freezing point of the coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the coolant hoses X X X Replacing the drive belts X X Checking for leaks X X X X Checking and adjusting the valve clearance X X Checking the cable clamping X X Checking the exhaust system X X X X 237/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 5 Maintenance schedule Table 17. Engine maintenance Volvo TAD 1181 VE (Continued) Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of VDS4.5 1) More often if necessary. Table 18. Engine maintenance Volvo TAD 571, 871, 873 VE Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1), 2) X X X X Changing the engine oil filter 1), 2) X X X X Draining the fuel prefilter X X X X X Changing the fuel filter X X X Changing the fuel prefilter X X X Changing the crankcase filter X X X Changing the AdBlue-pump filter (AdBlue engines) X X Changing the AdBlue breather filter (AdBlue engines) X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter 1) X X X X X Changing the engine air filter 1) X X X Changing the safety filter X X X Checking the coolant level X X X X Checking the freezing point of the coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and hub X X X Checking the water pump for wear and leaks X X X Check the vibration damper on the front pulley X X X Check the cooling hoses X X X Replacing the drive belts X X Checking for leaks X X X X Checking and adjusting the valve clearance X X Checking cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of VDS4 1) More often if necessary. 2) 1000-hour service intervals require an approved oil analysis 238/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 5 Maintenance schedule Maintenance Instructions Table 19. Engine maintenance Volvo TAD 1171, 1371 VE Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1), 2) X X X Changing the engine oil filter 1), 2) X X X Changing the engine by-pass filter X X X X Draining the fuel prefilter X X X X X Changing the fuel filter X X X Changing the fuel prefilter X X X Changing the AdBlue-pump filter (AdBlue engines) X X Changing the AdBlue breather filter (AdBlue engines) X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter 1) X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X Change the coolant 3) X X X Checking the freezing point of the coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and hub X X X Checking the water pump for wear and leaks X X X Check the vibration damper on the front pulley X X X Check the cooling hoses X X X Replacing the drive belts X X Checking for leaks X X X X Checking and adjusting the valve clearance X X Checking cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of VDS4 1) More often if necessary. 2) 1000-hour service intervals require an approved oil analysis 3) Only valid for Volvo TAD 1371 VE Table 20. Engine maintenance Volvo TAD 541, 551 VE Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1), 2) X X X X Changing the engine oil filter 1), 2) X X X X Draining the fuel prefilter X X X X X 239/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 5 Maintenance schedule Table 20. Engine maintenance Volvo TAD 541, 551 VE (Continued) Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Draining the extra fuel prefilter X X X X X Changing the fuel filter X X X Changing the fuel prefilter X X X Changing the extra fuel prefilter X X X Changing the crankcase filter X X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X Checking the coolant level X X X X Checking the freezing point of the coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the cooling hoses X X X Replacing the drive belts X X Checking for leaks X X X X Checking and adjusting the valve clearance X X Checking the cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of VDS3. 1) More often if necessary. 2) 1000-hour service intervals require an approved oil analysis. Table 21. Engine maintenance Volvo TAD 841, 851, 853 VE Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1), 2) X X X X Changing the engine oil filter 1), 2) X X X X Draining the fuel prefilter X X X X X Draining the extra fuel prefilter X X X X X Changing the fuel filter X X X Changing the fuel prefilter X X X Changing the extra fuel prefilter X X X Cleaning and draining the fuel tank 1) X X 240/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 5 Maintenance schedule Maintenance Instructions Table 21. Engine maintenance Volvo TAD 841, 851, 853 VE (Continued) Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X Checking the freezing point of the coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the cooling hoses X X X Replacing the drive belts X X Checking for leaks X X X X Checking and adjusting the valve clearance X X Checking the cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of VDS3. 1) More often if necessary.. 2) 1000-hour service intervals require an approved oil analysis. Table 22. Engine maintenance Volvo TAD 1141, 1151 VE Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1), 2) X X X X Changing the engine oil filter 1), 2) X X X X Changing the engine by-pass filter X X X X Draining the fuel prefilter X X X X X Draining the extra fuel prefilter X X X X X Changing the fuel filter X X X Changing the fuel prefilter X X X Changing the extra fuel prefilter X X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X Checking the freezing point of the coolant 1) X X X X 241/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 5 Maintenance schedule Table 22. Engine maintenance Volvo TAD 1141, 1151 VE (Continued) Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the cooling hoses X X X Replacing the drive belts X X Checking for leaks X X X X Checking and adjusting the valve clearance X X Checking the cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of VDS3. 1) More often if necessary.. 2) 1000-hour service intervals require an approved oil analysis. Table 23. Engine maintenance Cummins X12 Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1) X X X X Changing the engine oil filter 1) X X X X Changing the fuel filter X X X X Changing the water separator X X X X Changing the Ad-Blue pump filter X Changing the Ad-Blue tank filter X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X Checking the freezing point of coolant 1) X X X X Checking the supplemental coolant additive (SCA) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X 242/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 5 Maintenance schedule Maintenance Instructions Table 23. Engine maintenance Cummins X12 (Continued) Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Checking the vibration damper on the front pulley X X X Checking the cooling hoses X X X Checking for leaks X X X X Checking and adjusting the valve clearance 2) X X Checking the cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of CES20081 / ACEA E9 / API CJ-4 1) More often if necessary.. 2) If using HVO 100 diesel fuel, valve clearance should be checked every 1000 hours. Table 24. Engine maintenance Cummins B 6.7 - EU stage 5 / US tier 4f Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1) X X X X Changing the engine oil filter 1) X X X X Changing the fuel filter X X X X Changing the water separator X X X X Changing the Ad-Blue pump filter X Changing the Ad-Blue tank filter X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Changing the coolant filter X X X X Checking the coolant level X X X X Checking the freezing point of coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Changing the coolant X X Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the cooling hoses X X X Checking for leaks X X X X Checking and adjusting the valve clearance X Checking the cable clamping X X Checking the exhaust system X X X X 243/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 5 Maintenance schedule Table 24. Engine maintenance Cummins B 6.7 - EU stage 5 / US tier 4f (Continued) Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of CES20081 / ACEA E9 / API CJ-4 1) More often if necessary. Table 25. Engine maintenance Cummins QSB 6.7 T4 Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1) X X X X Changing the engine oil filter 1) X X X X Changing the fuel filter X X X X Changing the water separator X X X X Changing the Ad-Blue pump filter X Changing the Ad-Blue tank filter X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X Checking the freezing point of coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the cooling hoses X X X Checking for leaks X X X X Checking and adjusting the valve clearance X Checking the cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of CES20081 / ACEA E9 / API CJ-4 1) More often if necessary. 244/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 5 Maintenance schedule Maintenance Instructions Table 26. Engine maintenance Cummins QSM 11-C335 Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1) X X X X Changing the engine oil filter 1) X X X X Changing the fuel filter X X X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X Checking the freezing point of coolant 1) X X X X Checking the supplemental coolant additive (SCA) X X X X Replacing the coolant filter 2) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the cooling hoses X X X Checking for leaks X X X X Checking and adjusting the valve clearance X X Checking the cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of CES20071 / ACEA E5 / API CH-4 1) More often if necessary. 2) Do not replace the coolant filter if the SCA concentration level is over three units. Table 27. Engine maintenance Cummins QSB 6.7-C260 Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the engine oil 1) X X X X Changing the engine oil filter 1) X X X X Changing the fuel filter X X X X Changing the water separator X X X X Cleaning and draining the fuel tank 1) X X Cleaning the engine air filter X X X X X Changing the engine air filter 1) X X X Changing the safety filter 1) X X X Checking the coolant level X X X X 245/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 5 Maintenance schedule Table 27. Engine maintenance Cummins QSB 6.7-C260 (Continued) Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Checking the freezing point of coolant 1) X X X X Cleaning the radiator, intercooler, and oil coolers X X X X Cleaning the coolant system and changing the coolant At 5000 hours or at least every two years Checking the air intake system X X X X X Checking the drive belts X X X X Checking the belt tensioner and idler pulleys X X X Checking the cooling fan and fan hub X X X Checking the water pump for wear and leaks X X X Checking the vibration damper on the front pulley X X X Checking the cooling hoses X X X Checking for leaks X X X X Checking and adjusting the valve clearance X Checking the cable clamping X X Checking the exhaust system X X X X Checking the engine and transmission mountings X X Checking the engine and transmission for abnormal noise X X Use minimum oil quality of CES20071 / ACEA E5 / API CH-4 1) More often if necessary. Table 28. Transmission maintenance Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the transmission oil 1) X X X Changing the transmission oil filter X X X Cleaning the transmission oil cooler: Cleaning the radiator, X X X X intercooler, and oil coolers Checking the transmission breather X X X X X Calibrating the transmission X X X X 1) Check oil level daily with engine idling, maintain oil level at full mark (temperature depending). Table 29. Drive axle maintenance Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the drive axle oil X Checking the drive axle oil level X X X X Checking the drive axle breather X X X X X Checking the condition and pressure of the tires X X X X X Tightening the wheel nuts X X X X X Adjusting the parking brake X X X X 246/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. 5 Maintenance schedule Maintenance Instructions Table 30. Steer axle maintenance Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Lubricating the steer axle X X X X Checking the steer axle bearings X X X Checking the condition and pressure of the tires X X X X X Tightening the wheel nuts X X X X X Table 31. Hydraulic system maintenance Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Changing the hydraulic oil 1) X X Changing the hydraulic oil filter X X X Changing the HLL (hydraulic long life) filter (machines with X X HLL filter) 2) Changing the hydraulic tank breathing filter X X Changing the brake cooling oil (machines with brake X X cooling oil) Changing the brake cooling oil filter (machines with brake X X cooling oil) Changing the hydraulic high pressure oil filter 3) X X Changing the breathing filter for the brake cooling oil tank X X (machines with brake cooling oil) Checking the hydraulic hoses X 1) If fitted with an HLL filter, the oil change interval can reach up to 12,000 hours. Oil analysis must be carried out every 1000 hours after the initial oil change at 4000 hours. 2) The filter element should be replaced as necessary when implied on the pressure indicator on the filter housing. 3) The high pressure filter is used on the Reachstacker, but is an option for all other models. Table 32. Mast and forks maintenance Maintenance points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Lubricating the mast X X X X Lubricating the fork shaft system X X X X Checking the mast and fork carriage X X X X Checking the fork arms X X X X Checking the fork shaft system X X X X Table 33. Functional test Testing points As necessary Every 500 Every 1000 Every 2000 Every 4000 h h h h Checking the function of the electrical system X X X X Checking the function of the steering system X X X X Checking the function of the hydraulic system X X X X Checking the function of the service and parking brake X X X X 247/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions 5 Maintenance schedule 5.6 Maintenance data Unit Material/oil/lubricant Volume VOLVO 541 / 551: 16 l (4.23 US gal) VOLVO 571: 16 l (4.23 US gal) VOLVO 581 / 583: 16 l (4.23 US gal) VOLVO 841 / 851: 27 l (7.13 US gal) VOLVO 871 / 873: 27 l (7.13 US gal) VOLVO 881 / 883: 27 l (7.13 US gal) Engine Engine oil VOLVO 1141 / 1151: 37 l (9.77 US gal)) VOLVO 1171: 37 l (9.77 US gal) VOLVO 1181: 37 l (9.77 US gal) VOLVO 1371: 36 l (9.51 US gal) CUMMINS QSM 11-C335 / X12: 37 l (9.77 US gal) CUMMINS QSB 6.7 / B 6.7: 16,7 l (4.41 US gal) CUMMINS QSB 4.5 T3: 13 l (3.43 US gal) Fuel tank Diesel 130–700 l (114–184.9 US gal) AdBlue tank AdBlue 30–60 l (7.9–15.8 US gal) Cooling system Glycol and water mixture 50–60 l (13.2–15.9 US gal) Hydraulic oil system (total volume) Hydraulic oil 150–900 l (39–237.8 US gal) Brake cooling oil tank (option) Brake cooling oil 110 l (29 US gal) See table "Oil filling quantities" in section "Recommended Drive axle Drive axle oil fluids and lubricants". DANA TE10: 25.6 l (6.8 US gal) DANA TE14: 27 l (7 US gal) DANA TE17: 25–30 l (6.6–7.9 US gal) DANA TE27 / TE32: 60–70 l (15.9–18.5 US gal) Transmission See fluid recommendations DANA TE30: 55 l (14.5 US gal) ZF 191: 25–30 l (6.6–7.9 US gal) ZF 261 / 311: 40–50 l (10.6–13.2 US gal) Always check with dipstick Tires Air See manufacturer's recommendations. 248/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX I: Fuel and oil recommendations Maintenance Instructions APPENDIX I: FUEL AND OIL RECOMMENDATIONS Quality of the engine oil Depending on engine type, the engine oil must comply with one of the following oil classifications: • Volvo VDS-4.5 • Volvo VDS-4 • Volvo VDS-3 • CES20081 / ACEA E9 / API CJ-4 • CES20071 / ACEA E5 / API CH-4 • ACEA E5 / API CI-4 Table 34. Oil classifications according to engine type Oils Engine CES20081 / CES20071 / ACEA E5 / VDS-4.5 VDS-4 VDS-3 ACEA E9 / ACEA E5 / API CI-4 API CJ-4 API CH-4 Volvo TAD 581, 881, 883, 1181 X VE Volvo TAD 571, 871, 873, 1171, X 1371 VE Volvo TAD 541, 551, 841, 851, X 853, 1141, 1151 VE Cummins QSB 6.7 T4, B 6.7, X X12 1) Cummins QSB 6.7, QSM 11 X 1) For Cummins B 6.7 and X12 engines, SAE 15W-40 must be used. Check with your oil supplier that your oil meets these demands. For engines that do not use fuel with low sulphur content, the TBN (Total Base Number) value should be at least 12 according to ASTM 2896. Check with your oil supplier that your oil meets these demands. Depending on operating conditions, and the quality of the oil and fuel, the intervals between changing the oil may vary in length. The engine oil must be replaced within a maximum operation time of one year. If the machine is parked in cold weather, the viscosity of the oil can vary according to the temperature. Therefore the ambient temperature is vital to the choice of the engine oil viscosity range (see following figure). NOTE If the machine is warm, the oil is also warm. Changing the oil due to a change in season may be avoided by using multi-grade oils. Specified intervals for changing the oil also apply to multi-grade oils. No oil additives should be added to the recommended oils. Using such additives may NOTE invalidate the engine warranty. Avoid mixing different brands of oil. The temperature ranges for adjacent SAE classes overlap, so you do not need to replace the oil when short-term temperature changes occur. To ensure trouble-free cold starts, select the SAE class according to the ambient NOTE temperature. 249/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions APPENDIX I: Fuel and oil recommendations Figure 110. Oil temperature ranges Extended oil change interval Extended oil change interval may differ when using synthetic fluids. To determine a baseline, appropriate change intervals should be determined for each engine by measuring oil oxidation and wear metals over time. Wear metals analysis can provide useful information, but an engine should not be removed from service based solely on this analysis. For more information contact Konecranes Lift Trucks, an authorized dealer, or the engine supplier. Recommended fluids and lubricants Diesel fuel It is recommended to use diesel fuel HVO 100, which complies with the following classification: • EN 15940 Class A If using other diesel fuels than HVO 100, they must comply with one of the following classifications: • EN 590 • ASTM D 975 No 1-D or 2-D For Tier 4F, stage 4 and stage 5 engines ULSD (Ultra-Low Sulfur Diesel) fuel must be used (sulphur content below 15 mg/kg). For more information, contact the engine manufacturer, or an authorized representative. As the ambient temperature falls, the flow characteristics of the diesel fuel are reduced NOTE and paraffin begins to precipitate, i.e the diesel is gelling in cold temperatures. Use the correct diesel quality according to the ambient temperature. Using additives to improve the flow is not recommended. Additives may reduce the NOTE capacity to start from cold. Biodiesel (FAME) Vegetable oil esters (Fatty Acid Methyl Esters, FAME), also called "biodiesel", are increasingly available as a blending component in diesel fuels. The engine manufacturer accepts the same FAME content as in major on-road fuels EN590 and ASTM D975. The maximum FAME content is 7%, without any specific extra service requirements. For more information, contact the engine manufacturer, or an authorized representative. Higher FAME blends negatively impact performance, emissions, and fuel consumption. It NOTE also affects negatively the function of the SCR engines exhaust after treatment system. 250/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX I: Fuel and oil recommendations Maintenance Instructions AdBlue solution Only use an AdBlue solution that fulfills the ISO 22241 standard. The AdBlue solution consists of deionized water that is mixed with 32.5% urea. Table 35. Engines using AdBlue solution Engine family Engine VOLVO TAD 571 VE TAD 871 / 873 VE TAD 1171 VE TAD 1371 VE TAD 581 VE TAD 881 / 883 VE TAD 1181 VE CUMMINS QSB 6.7 1) / B 6.7 / X12 1) EU stage 4 / US tier 4f Transmission oil DANA transmission: ATF Dexron III ZF transmission: Mineral oil -based engine oil (API CD/CE/CF-4/CF/CG-4/CH-4/ CI-4/SF/SG/SH/SJ/SL or ACEA, categories A, B, E). Viscosity degrees: SAE 20W-20 / 30 / 10W-30 / 10W-40 / 15W-30 / 15W-40 / 20W-40. For more information, see the ZF recommended oil list TE-ML 03. Table 36. ZF Transmission: Approved and recommended oil types Lubricant class Oil type / viscosity Temperature 03C, 03M ATF (Automatic transmission fluids) -40°C 03F UTTO in accordance with JDM 20D / John Deere Low -40°C Viscosity Hy-Gard 03E, 03G, 03H UTTO -30°C 03K SAE 0W-30, 0W-40 -40°C 03B, 03C, 03K SAE 5W-30, 5W-40 -35°C 03A, 03B, 03C, 03K SAE 10 W, 10W-30, 10W-40 -30°C 03A, 03C, 03K SAE 15W-30, 15W-40 -25°C 03A, 03C, 03K SAE 20W-20, 20W-40 -20°C 03A, 03C, 03K SAE 30 -10°C Oil change interval Drain and refill the system every 1000 h for average environmental and duty cycle conditions. Severe or sustained high operating temperature or dusty environments cause accelerated deterioration or contamination. Judgment must be used to determine the required change intervals for extreme conditions. For more information, contact your local authorized dealer. Drive axle oil Axle housing / Hub assembly / Drive Assembly API GL.5 SAE 90 251/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions APPENDIX I: Fuel and oil recommendations Table 37. Oil filling quantities Drive Width Planetary Model Brake Differential Hub axle (mm) gear FLT 10-16 D81 2274 PL478 NLB5340 19 l (5.02 US gal) 2.3 l (0.6 US gal) FLT 18-25 D91 2717 PL488 NLB4460 31 l (8.2 US gal) 3.2 l (0.8 US gal) FLT 28-33 D91 3015 PL408 NLB6460 36.5 l (9.6 US gal) 3.7 l (0.97 US gal) FLT / LCH 37-50 D102 3807 PL341 NLB8460 72 l (19 US gal) 11 l (2.9 US gal) FLT / LCH 37-50 D102 3431 PL341 NLB8460 58 l (15.3 US gal) 11 l (2.9 US gal) LCH 52 D102 4549 PL341 NLB8460 121 l (31.9 US gal) 12.5 l (3.3 US gal) FLT / LCH 52-55 D106 3807 PL341 NLB8460 85 l (22.4 US gal) 11 l (2.9 US gal) FLT 60-55 D111 4188 PL545 NLB6650-1 108 l (28.5 US gal) 12.5 l (3.3 US gal) ECH 80 D81 3218 PL478 NLB5340 39 l 10.3 US gal) 2.3 l (0.6 US gal) ECH 90/100 D81 3713 PL488 NLB6340 45 l (11.9 US gal) 3.5 l (0.9 US gal) ECH 90/100 D91 4218 PL488 NLB6340 45 l (11.9 US gal) 3.5 l (0.9 US gal) ECH 90/100 *) D91 4203 PL489 NLB4460 66 l (17.4 US gal) 3.2 l (0.8 US gal) RST 108 D81 3713 PL488 NLB6340 45 l (11.9 US gal) 3.5 l (0.9 US gal) RST 2518 D91 3015 PL408 NLB6460 36.5 l (9.6 US gal) 3.7 l (0.97 US gal) RST 4127-4638 D102 3807 PL341 NLB8460 72 l (19 US gal) 11 l (2.9 US gal) RST 4537-4644 D106 3807 PL341 NLB8460 85 l (22.4 US gal) 11 l (2.9 US gal) RST 4646 D111 4188 PL545 NLB6650-1 108 l (28.5 US gal) 12.5 l (3.3 US gal) *) = with clamped wheel rims The volumes are strictly recommendations. If you have any doubts, contact your NOTE Konecranes Lift Trucks authorized dealer for advice. Hydraulic oil For machines without separate brake cooling tank Universal Tractor transmission oil (UTTO) The oil must comply with one of the following classifications: • John Deere: JD20C • Massey Ferguson: MF1141/MF1135/ MF1143 • ZF: TE-ML 03E/TE-ML 05F/TE-ML 06K For machines with separate brake cooling tank (option) DIN 51524 Part 2 HLP and Part 3 HVLP Use hydraulic oil from a well-known oil company for mobile applications. Viscosity Temperature range SHS 32 -30°C...+10°C (-22°F...+50°F) SHS 46 -20°C...+50°C (-4°F...+122°F) SHS 68 ±0°C...+50°C (+32°F...+122°F) Brake cooling oil (option) Universal Tractor transmission oil (UTTO) The oil must comply with one of the following classifications: 252/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX I: Fuel and oil recommendations Maintenance Instructions • John Deere: JD20C • Massey Ferguson: MF1141/MF1135/ MF1143 • ZF: TE-ML 03E/TE-ML 05F/TE-ML 06K Grease Multipurpose type E.P. according to NLGI Grade 2. Coolant WARNING HARMFUL SUBSTANCE HAZARD Using wrong coolant may damage the machine. Use the recommended coolant and never mix different coolants. WARNING TOXIC SUBSTANCE HAZARD It is highly dangerous to drink ethylene glycol. Contact with skin or spray from the refill can cause skin irritation and eye damage. Do not drink ethylene glycol and avoid contact with skin. Use only ethylene glycol-based coolants with an additive that prevents corrosion. Do not mix different coolant types with each other. Do not mix the coolant with antifreeze that contains ethanolamine. Table 38. Coolants for Volvo engines Engine Coolant VOLVO TAD 541, 551 VE VOLVO TAD 571 VE VOLVO TAD 581 VE VOLVO TAD 841 VE VOLVO TAD 851 VE VOLVO TAD 871, 873 VE Volvo Penta Coolant VCS-2 and VCS-2 Ready Mixed VOLVO TAD 881, 883 VE VOLVO TAD 1141, 1151 VE VOLVO TAD 1171 VE VOLVO TAD 1181 VE VOLVO TAD 1371 VE Table 39. Coolants for Cummins engines Engine Coolant CUMMINS QSB 6.7-C240 CUMMINS B 6.7 To comply with Cummins CES 14603 CUMMINS QSM 11-C335 Recommended: Cummins ES Compleat EG CUMMINS X12 253/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions APPENDIX I: Fuel and oil recommendations Liquid antifreeze at the lowest Percentage of volume mixture liquid Mixture of antifreeze and water temperature antifreeze -12°C (10.4°F) 25 1:3 -18°C (-0.4°F) 30 1:2 -25°C (-13°F) 40 1:1.5 -37°C (-34.6°F) 50 1:1 -60°C (-76°F) 66 2:1 254/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX II: Fuses and relays Maintenance Instructions APPENDIX II: FUSES AND RELAYS Fuses Fuses are located behind the operator's seat in the cabin and in the battery compartment on the right side of the machine. Figure 111. Location of fuses 101 121 141 163 185 190 120 140 162 184 Figure 112. Numbering order of the fuses 255/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions APPENDIX II: Fuses and relays Table 40. Fuses and their function (Functions may vary depending on machine model and chosen options) Number Size Function F101 7.5 A Cabin heating F102 7.5 A Option F103 7.5 A Option F104 7.5 A Central lubr. pump chassis F105 10 A Converter 12-V option F106 7.5 A Reverse light F107 7.5 A Working light extra 2 F108 7.5 A PCB 48-PIN STD D F109 7.5 A PCB 48-PIN STD D F110 7.5 A PCB 48-PIN STD D F111 7.5 A PCB 48-PIN STD D F112 7.5 A Clutch for HVAC compressor F113 5A Position light right F114 5A Position light left F115 7.5 A High beam F116 7.5 A Low beam F117 15 A Seat suspension air compressor F118 7.5 A Reverse alarm in the front F119 7.5 A Working lights extra 1 F120 10 A Option F121 7.5 A Working light mast, right F122 7.5 A Working light mast, left F123 10 A Main fuse for the lights, F115 and F116 F124 5A ACR RFID keyless ignition F125 5A Battery clock (RTC) F126 7.5 A Ignition F127 7.5 A Beacon F128 7.5 A Power supply controller F129 7.5 A Hazard F130 10 A HV/AC condensor blower 1 F131 10 A HV/AC condensor blower 2 F132 10 A HV/AC condensor blower 3 F133 7.5 A K128 Door open switch F134 5A Reading light F135 15 A Rear window heating F136 7.5 A RCU F137 7.5 A Diagnostic, PCB connector F138 7.5 A CAN extra, PCB connector F139 5A Turn signal F140 7.5 A PCB 48-PIN STD D F141 7.5 A PCB 48-PIN STD D F142 7.5 A Rearview mirror heater F143 5A I/O units in the armrest, XC21, XC21 OPT C1, XC21 OPT C2 F144 7.5 A Seat heater F145 7.5 A MD4 256/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX II: Fuses and relays Maintenance Instructions Table 40. Fuses and their function (Functions may vary depending on machine model and chosen options) (Continued) Number Size Function F146 5A TRUCONNECT® modem F147 5A RFID nearguard 2 F148 5A Tire pressure gateway F149 10 A Connection for computer F150 5A RFID nearguard 1 F151 7.5 A Main fuse for position light (F113, F114) and brake lights F152 5A Alcohol ignition interlock F153 10 A 24 V dashboard F154 5A GSM G2 modem F155 10 A 12 V reverse camera F156 10 A 12 V dashboard F157 10 A 24 V roof F158 7.5 A Converter roof F159 10 A 12 V roof F160 7.5 A 12 V radio F161 15 A Working light roof (option) F162 15 A Working light roof (option) F163 10 A Wiper rear/roof/front washer F164 7.5 A PCB 48-PIN STD E F165 7.5 A PCB 48-PIN STD E F166 7.5 A Converter F167 7.5 A Converter 2 rear wall F168 15 A Horn F169 7.5 A PCB 48-PIN STD E F170 7.5 A PCB 48-PIN STD E F171 7.5 A PCB 48-PIN STD E F172 7.5 A PCB 48-PIN STD E F173 7.5 A Fuel heater F174 7.5 A Option F175 7.5 A Option F176 15 A Electrical seat column F177 7.5 A Option F178 7.5 A Particle detecting monitor (PDM) F179 10 A XA2 OPT, external expansion unit in the chassis F180 10 A XA2-STD, external expansion unit in the chassis F181 10 A Connection for computer F182 7.5 A Reverse camera F183 5A HVAC controller F184 15 A HVAC blower F185 3A Spare fuse F186 5A Spare fuse F187 7.5 A Spare fuse F188 10 A Spare fuse F189 15 A Spare fuse F190 - Fuse test 257/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions APPENDIX II: Fuses and relays Fuses and relays in the battery compartment DANGER EXPLOSION HAZARD Short-circuiting the battery may cause a fire or explosion, which can cause a risk for serious injury or death. DANGER CORROSIVE SUBSTANCE HAZARD The battery contains corrosive acid that may cause a risk for serious injury or death. Always use the necessary protective equipment. DANGER EXPLOSION HAZARD Batteries generate explosive hydrogen when charged, or when being jump-started, which may cause a risk for serious injury or death. Always use the necessary protective equipment. Ensure that there is good ventilation and avoid sparking. WARNING ELECTRICAL HAZARD The battery main switch disconnect does not cut the power to the alternator. To reduce the risks of electric shock and personal injury always remove jewelry and conductive material before working on the electrical system. Always disconnect the ground (minus) cable at the battery when working near or on the alternator. WARNING TIPPING OVER HAZARD Turning off the battery main switch while the machine is moving applies the parking brake and the machine may tip over. The software in the control unit can get damaged. Do not turn it off while the engine is running. 258/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX II: Fuses and relays Maintenance Instructions 1 3 2 1 Figure 113. Fuses and relays in the battery compartment 1. Fuses F51–F58, F71-78, F92-F98 (1) 2. Relay K32 (2), behind the three fuse lines 3. Fuses F61-F62, F80 Figure 115. Numbering order of the fuses Table 41. Fuses and their functions (Functions may vary depending on machine model and chosen options) Number Size Function F51 10 A MD4 internal clock (IQAN-MD4 RTC) F52 20 A Starter for Scania DC13 EU4/Cummins QSB (15A) F53 20 A Scania DC13 EU4 AdBlue control unit/Cummins QSB (15 A) F54 7.5 A Cummins QSB (15 A) F55 7.5 A Fuel heater (Cummins 20A) F56 7.5 A TCU battery power supply (DANA) F57 20 A Scania DC13 EU4, VOLVO 660/760 (10A) /Cummins QSB (15A) F58 20 A Scania DC13 EU4/Cummins QSB (15A) 259/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions APPENDIX II: Fuses and relays Table 41. Fuses and their functions (Functions may vary depending on machine model and chosen options) (Continued) Number Size Function F61 100 A Main fuse 15 ignition F62 60 A Main fuse 30 battery F71 7.5 A Option F72 7.5 A Option (fuel shut-off) (seat suspension air compressor 15 A) F73 7.5 A Option F74 10 A Engine ignition F75 7.5 A DANA/ZF transmission control unit (TCU) ignition power supply F76 25 A Hydraulic oil cooler F77 20 A Scania DC13 EU4 exhaust gas recirculation valve (EGR) F78 - Option F80 70 A Cummins engine starter F81 100 A Cummins intake air heater F91 10 A Attachment lights F92 10 A Chassis 48-pin STD F F93 10 A Chassis 48-pin STD F F94 10 A Chassis 48-pin STD F F95 10 A Chassis 48-pin STD F F96 10A Chassis 48-pin STD F F97 10A Chassis 48-pin STD F F98 10 A Power supply, attachment Relays Relays K32, K35, and K36 are mounted next to the main fuses in the battery compartment. K101-K135 are mounted behind the operator seat in the cabin. Figure 116. Relay location K101-K135 260/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. APPENDIX II: Fuses and relays Maintenance Instructions 135 117 118 119 120 121 122 123 124 116 115 125 126 114 127 128 113 129 130 112 131 132 111 133 134 110 109 108 107 104 103 102 101 106 105 Figure 117. Relays K101-135 Table 42. Relay functions (Functions may vary depending on machine model and chosen options) Number Function K31 Volvo 620, 722, Engine starter K32 Q1 ignition K33 Ground support for K31 K35 Engine shut-off for Volvo engines (Engine starter Cummins QSB and QSM) K36 Fuel heater K63 Starter lockout Cummins K64 Intake air heater Cummins K65 DEF hose heating 1 Cummins K66 DEF hose heating 2 Cummins K67 DEF hose heating 3 Cummins K68 DEF heater relay K101 Pre-heating power supply for HVAC (heating, ventilation, air-conditioning) K102 Signal for HVAC (heating, ventilation, air-conditioning), engine running with cabin doors closed K103 Brake lights K104 Inverted road light (turnable seat) K105 ACR RFID keyless ignition 261/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. Maintenance Instructions APPENDIX II: Fuses and relays Table 42. Relay functions (Functions may vary depending on machine model and chosen options) (Continued) Number Function K106 Working light mast F121 and F122 K107 Working light extra 1 K108 Front alarm K109 Door switch K110 Low beam K111 High beam K112 Clutch for HVAC compressor K113 Blinker right K114 Blinker left K115 Working light extra 2 K116 Backup Light/Right K117 Central lubrication pump chassis K118 Option K119 Option K120 RCU 3 K121 Working light roof F161, F162 K122 Windshield wiper motor roof K123 Windshield wiper motor rear K124 Rear/front window washer motor K125 Rear window heating K126 Windshield wiper motor front, 1st speed K127 Rear/front window washer motor K128 Windshield wiper motor front, 2nd speed K129 Horn K130 Fuel heater K131 RCU 1 K132 RCU 2 K133 Option K134 Communication radio K135 Hazard K201 Attachment lights (opt) 262/262 DOC2726785A / en-US / 24 May 2024 Copyright © 2024 Konecranes. All rights reserved. This document and the information contained herein, is the exclusive property of Konecranes and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes. Copyright 2024 © Konecranes. All rights reserved.  Käsikahvelkäru info https://www.vmh.sk/hpts-with-weight-system.html Lisa 2 19.05.2026 lepingu nr 2-2/26/607-2 juurde Julgeolekutingimused Riigihanke objekti asumisega Kaitseväe julgeolekualal teavitatakse lepingupartnerit alljärgnevatest tingimustest, õigustest ja kohustustest eesmärgiga selgitada lepingupartnerile poolte õigusi ja kohustusi julgeolekualaste nõuete täitmisel Kaitseväe julgeolekualal. 1. MÕISTED 1.1 Julgeoleku eest vastutav isik (edaspidi JEVI) - konkreetsel KV JOA-l asuva riigihanke objekti julgeolekualaste nõuete täitmise eest vastutav Kaitseväe allüksus või teenistuja. 1.2 Julgeolekualased nõuded - Kaitseväe julgeolekualale sisenemisel ja viibimisel kehtestatud üldised julgeolekunõuded (lisa 5) ning muudest õigusaktidest tulenevad Kaitseväe julgeoleku tagamiseks kehtestatud nõuded. 1.3 Kaitseväe julgeolekuala (edaspidi KV JOA) - Kaitseväe valduses olev territoorium, Kaitseväe laevad, lennuvahendid ja sõidukid. 1.4 Lepingupartneri kontaktisik - lepingu täitmise nõuete ja julgeolekualaste nõuete täitmise eest vastutav lepingupartneri ja/või tema alltöövõtja määratud isik. 1.5 Nõusolek – taustakontrolli tegemiseks vajalik eelnev kirjalik nõusolek, millega isik lubab Kaitseväel koguda enda kohta andmeid ja teha päringuid nõusoleku andmisest viie aasta jooksul (KKS § 416) (lisa 2 eesti keeles ja lisa 3 inglise keeles). 1.6 Riigi Kaitseinvesteeringute Keskuse (edaspidi RKIK) kontaktisik - lepingujärgne isik, kelle kaudu toimub lepingujärgsete kohustuste täitmise korraldamine ja lepingus ettenähtud teadete, nõuete ja teiste dokumentide edastamine. 1.7 Riigihanke objekt - lepingu täitmiseks ettenähtud Kaitseväe julgeolekualal paiknev tööpiirkond. 1.8 Taustakontroll - Kaitseväele teenuse osutamisega seotud isiku (edaspidi teenuseosutaja) KV JOA-le lubamise otsustamiseks läbiviidav kontroll Kaitseväe korralduse seaduse (edaspidi KKS) § 413 alusel ja KKS §-s 41⁵ viisil. 1.9 Taustakontrolli taotlus (e-kiri) - lepingupartneri kontaktisiku poolt esitatav taotlus teenuseosutajale taustakontrolli tegemise algatamiseks (lisa 1). 1.10 Teenuseosutaja - lepingupartneri ja/või tema alltöövõtja töötaja, kelle suhtes teostatakse taustakontrolli tema eelneval kirjalikul nõusolekul, seoses sissepääsuõiguse taotlemisega KV JOA-le. 1.11 Turvaala - konfidentsiaalse, salajase või täiesti salajase taseme riigisaladuse või salastatud välisteabe ja seda sisaldava salastatud teabekandja töötlemiseks lubatav ala. 1.12 Sissepääsutaotlus (e-kiri) - lepingupartneri kontaktisiku poolt esitatav taotlus teenuseosutaja KV JOA-le lubamiseks (lisa 4). 1.13 Sissepääsuõigus - õigus viibida KV JOA-l asuval riigihanke objektil seoses lepingu täitmisega. 1.14 Sissepääsuõigust omav isik - taustakontrolli läbinud isik, kelle sissepääs KV JOA-l asuvale riigihanke objektile on otsustatud ning kellel on õigus saatjata siseneda ja viibida KV JOA-l asuval riigihanke objektil seoses lepingu täitmisega. 1/3 2. LEPINGUPARTNERI ÕIGUSED JA KOHUSTUSED 2.1 Lepingupartneril, sh teenuseosutajal ja lepingupartneri kontaktisikul, on õigus riigihanke objekti JEVI-lt saada julgeolekualaste nõuete täitmiseks vajalikku informatsiooni ja teavet KV JOA-le sissepääsuõiguse saamise kohta. Konkreetse riigihanke objekti JEVI kontaktid edastab lepingupartnerile esimesel võimalusel RKIK-i kontaktisik. 2.2 Lepingupartner kohustub: 2.2.1 mitte planeerima KV JOA-le teenust osutama teatamiskohustusega välisriikide kodanikke. Teatamiskohustusega riikideks on lepingu sõlmimise hetkel siseministri 29.09.2023 käskkirja nr 1-3/112 alusel1: Armeenia Vabariik; Aserbaidžaani Vabariik; Hiina Rahvavabariik (sh Hongkongi ja Macau erihalduspiirkonnad); Iraani Islamivabariik; Kasahstani Vabariik; Kirgiisi Vabariik; Korea Rahvademokraatlik Vabariik; Tadžikistani Vabariik; Türkmenistan; Usbekistani Vabariik; Valgevene Vabariik; Venemaa Föderatsioon. Juhul kui nimetatud siseministri käskkirjas tehakse muudatusi, siis teavitatakse sellest lepingupartnerit ning vajadusel muudetakse käesolevaid julgeolekutingimusi; 2.2.2 tagama, et lepingupartneri kontaktisik esitab taustakontrolli taotluse (lisa 1 koos lisadega 2 ja/või 3) esimesel võimalusel, arvestades lepingus kokkulepitud töö teostamise alguskuupäeva ning taustakontrollile kuluvat aega (14 kalendripäeva), e- posti aadressile [email protected]; 2.2.3 tagama, et lepingupartneri kontaktisik lisab välismaalasele taustakontrolli algatamise taotlusele juurde: 2.2.3.1 koopia isikut tõendava dokumendi pildiga leheküljest, sh viisast vm Eestis viibimise seaduslikku alust kinnitavast dokumendist; 2.2.3.2 isiku kodukohariigi karistusregistri väljavõtte; 2.2.4 tagama, et lepingupartneri kontaktisik esitab sissepääsutaotluse (lisa 4) esimesel võimalusel, arvestades lepingus kokkulepitud töö teostamise alguskuupäeva ning sissepääsutaotluse menetlemiseks kuluda võivat mõistlikku aega, RKIK kontaktisiku või tema määratud isiku e-posti aadressile; 2.2.5 teavitama viivitamatult teenuseosutaja ennetähtaegse sissepääsuvajaduse lõppemisest KV JOA-le e-kirja teel Kaitseväe taustakontrolli [email protected] ja RKIK kontaktisikut; 2.2.6 täitma ja tagama teenuseosutaja julgeolekualaste nõuete järgimise KV JOA-l kehtestatud tingimustel ning tagama nende täitmise alltöövõtja poolt. 1 https://kapo.ee/sites/default/files/content_page_attachments/Teatamiskohustusega%20v%C3%A4lisriikideni mekirja%20kehtestamine_0.pdf 2/3 3. KAITSEVÄE ÕIGUSED JA KOHUSTUSED 3.1 Kaitseväel on õigus: 3.1.1 teha taustakontrolli Kaitseväele teenuse osutamisega seotud isikule KV JOA-le lubamise otsustamiseks; 3.1.2 anda või piirata taustakontrolli käigus ilmnenud asjaoludele tuginedes teenuseosutaja sissepääsuõigus KV JOA-le; 3.1.3 jätta taustakontrolli taotlus läbi vaatamata haldusmenetluse seaduses sätestatud korras2; 3.1.4 keelduda julgeolekukaalutlustel sissepääsuõiguse andmisest isikule, kellele ei ole taustakontrolli tehtud, kes ei läbinud taustakontrolli või kellele ei ole võimalik seda teha; 3.1.5 piirata või keelduda sissepääsuõiguse andmisest julgeoleku- ja turvaaladele kodakondsuseta või välisriigi kodakondsusega isikutele, lähtudes julgeolekukaalutlusest. 3.1.6 kontrollida riigihanke objektil kehtestatud julgeolekualastest nõuetest kinni pidamist sissepääsuõigust omava teenuseosutaja suhtes ning julgeolekualaste nõuete mittejärgimisel või nende rikkumisel keelata teenuseosutajal viibimine KV JOA-l. 3.2 Kaitsevägi kohustub: 3.2.1 teavitama taustakontrolli taotluse esitanud isikut kirjalikus taasesitamist võimaldavas vormis teenuseosutaja taustakontrolli tulemusest; 3.2.2 teavitama KV JOA-le sissepääsutaotluse esitanud isikut kirjalikus taasesitamist võimaldavas vormis teenuseosutajale sissepääsuõiguse saamisest, sh sellekohastest piirangutest; 3.2.3 tutvustama teenuseosutajale KV JOA-l paikneva riigihanke objektil kehtivaid julgeolekualaseid nõudeid; 3.2.4 teavitama RKIKi, kui teenuseosutaja ja/või lepingupartner rikub julgeolekutingimusi ega järgi riigihanke objektil kehtestatud julgeolekualaseid nõudeid (lisa 5); 3.2.5 teavitama vastavalt punktile 3.1.3 taotluse läbi vaatamata jätmisel kirjalikult. 4. LÕPPSÄTTED 4.1 Julgeolekutingimustes nimetatud kontaktisikud määratakse kindlaks hankelepingu sõlmimisel ja nende muutumisest teavitatakse pooli e-kirja teel. 4.2 Isikuandmete töötlemisel lähtutakse kehtivate õigusaktide nõuetest. 2 https://www.riigiteataja.ee/akt/106072023031#para14 3/3 LISA 1: Näidis Taustakontrolli taotlus (e-kiri) Taotlus saata e-posti aadressile [email protected] PEALKIRI: Taustakontrolli taotlus (linnaku ja objekti nimetus) ASUTUSESISESEKS KASUTAMISEKS TEKST: KAITSEVÄGI Juurdepääsupiirang kehtib alates dokumendi koostamise kuupäevast kuni vajaduse möödumiseni, kuid mitte kauem kui 75 aastat Alus: avaliku teabe seadus § 35 lg 1 p 12 Tere Seoses RKIK (lepingu nimi) lepinguga nr xxxxxxxxx, sõlmitud pp.kk.aaaa, edastan Kaitseväele taustakontrolli tegemiseks allolevate isikute andmed. Taustakontrolli dokumendid on lisatud e-kirja manusesse. Lisainfo on tabelis: Teenuse Teenuse Teenuse Teenuse osutamise Osutatav osutamise osutamine Eesnimi Perenimi Isikukood Ettevõte osutamise perioodi algus teenus perioodi lõpp turvaalal JAH/EI objekt pp.kk.aaaa pp.kk.aaaa Olen teadlik, et taustakontroll võib võtta nõuetekohase taotluse esitamisest aega kuni 14 kalendripäeva. Lugupidamisega Taotluse esitaja ees- ja perenimi Ametikoht Ettevõtte nimi Kontakttelefon, e-posti aadress 1/1 LISA 2: NÕUSOLEKUVORM (eesti keeles) ASUTUSESISESEKS KASUTAMISEKS Teabevaldaja: Kaitsevägi Juurdepääsupiirang kehtib alates dokumendi koostamise kuupäevast kuni vajaduse möödumiseni, kuid mitte kauem kui 75 aastat Alus: AvTS § 35 lg 1 p 12 KINNITATUD Kaitseväe juhataja 23.03.2026 käskkirjaga nr 0.1-3.1/26/63 Lisa 2 ISIKU NÕUSOLEK TAUSTAKONTROLLI TEOSTAMISEKS (ees- ja perekonnanimi) Isikukood: Luban Kaitseväel teostada minu suhtes taustakontrolli Kaitseväe korralduse seaduse (edaspidi KKS) § 413 alusel ning KKS § 41⁵ sätestatud viisil käesoleva nõusoleku andmisest viie aasta jooksul. Olen teadlik, et: 1. mul on õigus keelduda nõusoleku andmisest (KKS 416 lg 2 p 1); 2. mul on õigus keelduda selliste andmete esitamisest, mis võivad põhjustada minu teenistusest või ametikohalt vabastamise või töölepingu ülesütlemise või minu või minu lähedase või elukaaslase suhtes süüteo- või distsiplinaarmenetluse (KKS 416 lg 2 p 2); 3. mul on õigus taotleda minu kohta andmete kogumise või päringute tegemise lõpetamist (KKS 416 lg 2 p 3); 4. mul on õigus esitada minu kohta kogutud andmete kohta selgitusi (KKS 416 lg 2 p 4); 5. mul on õigus pöörduda oma õiguste kaitseks ja § 415 alusel kogutud andmete põhjal tehtud otsuse vaidlustamiseks kohtu, õiguskantsleri, Andmekaitse Inspektsiooni või töövaidluskomisjoni poole, et kontrollida, kas minu põhiõiguste ja -vabaduste tagamise põhimõtet ning hea halduse tava on järgitud (KKS 416 lg 2 p 5). 6. kui ma keeldun nõusoleku andmisest või taotlen andmete kogumise või päringute tegemise lõpetamist (KKS § 417), siis on see minu taustakontrolli lõpetamise aluseks (KKS § 413); 7. Kaitsevägi võib piirata minu õigusi töödeldavate isikuandmete suhtes (KKS § 41¹⁰ lg 3 ja lg 4). Olen teadlik, et Kaitseväe julgeolekualal(e) (s.o. Kaitseväe laevad, lennuvahendid, sõidukid ja Kaitseväe territoorium): 1. ei tohi viibida ilma Kaitseväe loata (KKS § 52 lg 1); 2. peab täitma Kaitseväes kehtivat korda ja Kaitseväe esindaja korraldusi (KKS § 52 lg 2); 3. ei tohi pilti või kujutist salvestada ja edastada (KKS § 563); 4. ei tohi kasutada osaliselt või täielikult automaatset või kaugjuhitavat sõidukit (KKS § 52 lg2, KKS § 562); 5. ei tohi kasutada agressioonisümboleid (KarS § 1511); 6. on Kaitseväel õigus teostada minu, minuga kaasas oleva eseme ja sõiduki turvakontrolli (KKS § 56); 7. peab sõiduki pardakaamera olema kaetud ja video-ja helisalvestus välja lülitatud (KKS § 52 lg 2); 8. ei tohi tuua kolmandaid isikuid ega lemmikloomi (KKS § 52 lg 2); 9. ei tohi tuua ega tarvitada alkoholi, narkootilist või psühhotroopset ainet ega viibida julgeolekualal selle tarvitamise kahtlusega või joobes (KKS § 52 lg 2); 1/2 10. ei tohi tuua relva, drooni, lõhke- ja süüteainet või -seadeldist või seda sisaldavat eset ja muud vahendit, mis võib ohustada alal viibivaid isikuid, tehnikat ja seadmeid. Loetelu ei ole lõplik, Kaitseväel on õigus hinnata kaasatoodu ohtlikkust ja seda julgeolekualale mitte lubada (KKS § 52 lg 2); Olen teadlik, et ma ei tohi avaldada mulle teatavaks saanud riigi- ja ärisaladust, salastatud välisteavet, Kaitseväe teenistujate perekonna- ja eraelulisi andmeid ning muud Kaitseväega seotud teavet ilma Kaitseväe kirjaliku loata (KKS § 52 lg 2). (päev, kuu, aasta) [ allkirjastatud digitaalselt ]3 3 lubatud allkirjastada ka paberkandjal 2/2 LISA 3: NÕUSOLEKUVORM (inglise keeles) FOR OFFICIAL USE ONLY Information owner: ESTONIAN DEFENCE FORCES Restrictions on access to information were enforced when this document was created and are valid as long as necessary but no longer than 75 years Legal grounds: Public Information Act clause 35 (1) 12) Annex 3 APPROVED With the 23.03.2026 Directive of the Commander of the Estonian Defence Forces No 0.1-3.1/26/63 AUTHORISATION FOR BACKGROUND CHECK (first and last name) Personal identification code: I hereby authorise the Estonian Defence Forces to perform a background check on me in accordance with section 413 of the Estonian Defence Forces Organisation Act and in the manner specified in section 415 of the Estonian Defence Forces Organisation Act during five years as of my authorisation. I am aware of the following conditions. 1. I have the right to refuse authorisation (clause 416 (2) 1) of the Estonian Defence Forces Organisation Act). 2. I have the right to refuse to disclose information that might cause me being released from service or my position, or my employment contract being terminated, or that might lead to an offence or disciplinary proceeding for my loved ones or partner (clause 416 (2) 2) of the Estonian Defence Forces Organisation Act). 3. I have the right to request the termination of data collection and inquiries about me (clause 416 (2) 3) of the Estonian Defence Forces Organisation Act). 4. I have the right to provide explanations about the information collected about me (clause 416 (2) 4) of the Estonian Defence Forces Organisation Act). 5. I have the right to turn to the court, the Chancellor of Justice, the Data Protection Inspectorate, and the labour dispute committee to protect my rights and dispute the decision made about me based on the information collected on the grounds of section 415 to confirm whether the principles of protecting my basic rights and freedoms, and the code of good administration behaviour were followed (clause 416 (2) 5) of the Estonian Defence Forces Organisation Act). 6. If I refuse authorisation or request that data collection and inquiries were terminated (section 417 of the Estonian Defence Forces Organisation Act), it serves as the basis to end my background check (section 413 of the Estonian Defence Forces Organisation Act). 7. The Estonian Defence Forces may restrict my rights to the personal data being processed (subsections 4110 (3) and (4) of the Estonian Defence Forces Organisation Act). 1/2 I am aware of the following rules that apply on the restricted area of the Estonian Defence Forces (including vessels, aircraft, vehicles, and the territory of the Estonian Defence Forces). 1. Staying on the restricted area is not allowed without the permission of the Estonian Defence Forces (EDF) (subsection 52 (1) of the Estonian Defence Forces Organisation Act). 2. Each person on the restricted area must follow the procedures in force in the Estonian Defence Forces and the orders given by a representative of the EDF (subsection 52 (2) of the Estonian Defence Forces Organisation Act). 3. It is not allowed to take pictures or other images on the restricted area, or forward such pictures or images (section 563 of the Estonian Defence Forces Organisation Act). 4. It is not allowed to use partially or entirely automatic or remote-controlled devices on the restricted area (section 562 of the Estonian Defence Forces Organisation Act). 5. It is not allowed to display symbols of aggression on the restricted area (section 1511 of the Penal Code). 6. The Estonian Defence Forces has a right to perform a security check on any person, personal item or vehicle on the restricted area (section 56 of the Estonian Defence Forces Organisation Act). 7. The board camera of a vehicle must be covered and any video and sound recording devices shut off on the restricted area (subsection 52 (2) of the Estonian Defence Forces Organisation Act). 8. It is not allowed to bring third persons or pets to the restricted area (subsection 52 (2) of the Estonian Defence Forces Organisation Act). 9. It is not allowed to bring or use alcohol, narcotic or psychotropic substances, nor be under the influence of such substances on the restricted area (subsection 52 (2) of the Estonian Defence Forces Organisation Act). 10. It is not allowed to bring a weapon, a drone, explosives, fuels or ignitions or anything that contains such substances, or any equipment that might endanger the people, technology and devices on the restricted area. This list is not conclusive, and the Estonian Defence Forces has the right to evaluate the hazards of any personal items and prevent any person from entering with a potentially dangerous item (subsection 52 (2) of the Estonian Defence Forces Organisation Act). 11. It is not allowed to disclose to any third persons the information made available to a person on the restricted area (subsection 52 (2) of the Estonian Defence Forces Organisation Act). (day, month, year) [ signed digitally ]4 4 Could also be signed on paper. 2/2 LISA 4: Näidis Sissepääsutaotlus (e-kiri) Taotlus saata lepingus määratud RKIK kontaktisiku või tema poolt määratud isiku e-posti aadressile. PEALKIRI: Sissepääsutaotlus (linnaku ja objekti nimetus) TEKST: ASUTUSESISESEKS KASUTAMISEKS KAITSEVÄGI Tere Juurdepääsupiirang kehtib alates dokumendi koostamise kuupäevast kuni vajaduse möödumiseni, kuid mitte kauem kui 75 aastat Alus: avaliku teabe seadus § 35 lg 1 p 12 Seoses RKIK (lepingu nimi) lepinguga nr xxxxxxxxx, sõlmitud pp.kk.aaaa, edastan sissepääsutaotluse. Lisainfo on manuses (NB! kasutada MS Exceli formaati): Teenuse Teenuse Sõiduki mark ja reg Teenuse Osutatav osutamise osutamise number Eesnimi Perenimi Isikukood Ettevõte osutamise teenus perioodi algus perioodi lõpp objekt pp.kk.aaaa pp.kk.aaaa Taotluse esitaja on teadlik, et: 1. taustakontrolli läbimine ei taga automaatset sissepääsu Kaitseväe julgeolekualale; 2. Kaitseväel on õigus piirata isikute sissepääsu Kaitseväe julgeolekualale. Lugupidamisega Taotluse esitaja ees- ja perenimi Ametikoht Ettevõtte nimi Kontakttelefon, e-posti aadress 1/1 LISA 5: Kaitseväe julgeolekualale sisenemisel ja viibimisel kehtestatud üldised julgeolekunõuded. Kaitseväe julgeolekualal viibimisel (KKS § 52 lg 3) peab täitma Kaitseväes kehtivat korda (sh tuleohutuse-, liiklemise- ja parkimise korda) ja Kaitseväe esindaja korraldusi (KKS § 52 lg 2), sealhulgas 1. Kaitseväe julgeolekualale on keelatud siseneda alkoholi, narkootiliste-või psühhotroopsete ainetega, tulirelvaga, lõhkematerjaliga, osaliselt või täielikult automaatse või kaugjuhitava lendava seadmega (droon, jmt), radioaktiivsete- ja kergesti süttivate ainetega või neid sisaldavate esemetega ja muude vahenditega, mis võivad ohustada isikut ennast või objektil viibivaid isikuid, tehnikat ja seadmeid; 2. Kaitseväe loata ei tohi Kaitseväe julgeolekualale tuua ega lubada kolmandaid isikuid; 3. Sõidukiga Kaitseväe julgeolekualale sisenedes on kohustuslik video- ja/või helisalvestavad sõidukaamerad katta, välja lülitada või eemaldada; 4. Kaitseväel on õigus turvakontrolli läbiviimiseks pidada kinni isikut (sealhulgas sõidukit) sisenemisel Kaitseväe julgeolekualale, viibimisel Kaitseväe julgeolekualal või väljumisel Kaitseväe julgeolekualalt ning kontrollida isikut (sealhulgas tema riietust või temaga kaasas olevat asja (sealhulgas sõidukit) vaatlemise ja kompimise teel või tehnilise vahendi või väljaõppe saanud teenistuskoera abil; 5. Kaitsevägi võib julgeoleku- või ohutuskaalutlustel ajutiselt keelata isikutele sissepääsu Kaitseväe julgeolekualale ja anda korralduse Kaitseväe julgeolekualal viibivatele isikutele Kaitseväe julgeolekualalt lahkuda või keelata sealt lahkumist; 6. Kaitseväe eelneva nõusolekuta on keelatud pildistamine, video- ja helisalvestamine Kaitseväe julgeolekualal ja -hoonetes ning nimetatud materjali jagamine/üleslaadimine mis tahes kujul ja keskkonnas; 7. Kaitseväe julgeolekualal on keelatud viibida alkoholi, narkootiliste- või psühhotroopsete ainete tarvitamise kahtlusega, -tunnustega või -joobes; 8. Kaitseväe julgeolekualal on keelatud kasutada (sealhulgas sõidukites) agressioonisümboleid. 1/1