Smv SC 4127 TA User manual

MODELRANGE REACH STACKER

SC 4127 - 4535 TA / SC 4023 - 4531 CA

SC4535

SC45

31 CA

Produced by Condesign Ljungby AB, Sweden

Instruction book SC - TA/CA

2Publ. nr 6053.411 0315

YOUR SMV LIFT-TRUCK

This user manual provides you with

the information you need to know

about starting, driving, servicing and

maintaining your SMV lift-machine.

Using and attending to the truck

properly will preserve its qualities

for a long and profitable working

life, and will make full use of its

applications.

The expressions "front", "back",

"right" and "left" indicate the position

in which the relevant component is

installed in the truck as seen from the

driving compartment.

Follow all instructions in the manual

on using the machine and carry out

maintenance and inspection as

described in the maintenance table on

a regular basis and at the correct time,

using the specified lubricant.

Maintenance must be carried out only

by qualified staff.

Above all, we would like to emphasise

the importance of following both the

general traffic regulations and the

guidelines in force for the use of lift-

machines and the prevention of

accidents at work.

The regulations in force for normal

and regular use of commercial lift-

machines must be strictly adhered to

by management, commercial operators

and service staff.

The user, not SMV, is responsible for

any dangers that may arise when the

machine is being used for applications

not approved by the manufacturer.

SMV lift-machines are designed for

the transport and lifting of loads

indicated on the load-bearing capacity

plate.

No alterations and, above all, no

additions or conversions may be made

to the machine without the permission

of the manufacturer.

The user instructions for additional

parts issued by the manufacturer apply

to those additional parts.

Technical remarks

SMV is constantly developing both the

design and manufacture of its

products. Illustrations and technical

details concerning the design, parts

and performance of the lift-machine

are subject to alteration as a result of

this technological development.

SMV therefore assumes no

responsibility on the basis of those

specifications, illustrations and

descriptions found in the user manual.

If you have any questions concerning

SMV lift-machine and ordering spares,

contact your nearest authorised dealer.

Take care to supply the correct address

for delivery.

If any repairs are needed, use only

SMV original spares. This is necessary

in order for your SMV machine to

retain its original technical standard.

When ordering spares, it is important

to indicate the item number found in

the spares list as well as the following

information:

Model:

Serial number/year of manufacture:

Delivery date:

When ordering spares for the

following units, you must indicate

their individual manufacturing

numbers:

Engine no.:

Boom no.:

The lift height of the boom:

Transmission no.:

Drive shaft no.:

When the lift-machine is delivered, the

details on the type plate should be

written in this user manual.

Delivery inspection

Every SMV lift-machine is carefully

inspected before it leaves the factory to

ensure that it is fully in order and is

fully equipped in accordance with the

order. Authorised SMV dealers are

then required to reinspect the machine

before it is delivered to the customer.

In order to avoid later complaints and

problems, the customer should also

check that the machine is in full

working order and is fully equipped

when it is delivered, with a receipt of

the acceptance/handover of the

machine from the dealer.

The following technical manuals

accompany every lift-machine:

1 Spares catalogue for the lift-machine

1 User manual for the lift-machine

1 Machine card

When contacting your

authorised dealer, always

indicate:

1. Machine designation

2. Machine serial number

3. Year of manufacture.

Publ. nr 6053.411 0315

Instruction book SC - TA/CA

SAFETY REGULATIONS

BEFORE OPERATION

Persons responsible, particularly

machine drivers and service staff,

must be instructed on the regulations

for normal and safe use of commercial

lift-machine which accompany this

manual. Follow the guidelines and

safety regulations applicable to:

- use of commercial machine

- roads and work places

- drivers (rights, obligations and

regulations for implementation)

- any extra equipment

- different types of vehicle

- service (maintenance and inspection)

- annual inspection for the prevention

of accidents.

The driver /(owner) or other persons in

positions of responsibility must ensure

that the above guidelines and safety

regulations are adhered to. When a

trained driver is about to operate the

truck, instruct him on:

- special functions of the SMV

machine extra equipment

- special operating applications.

Driving, manoeuvring and steering

should be practised until the driver is

fully acquainted with all these

operations.

Only after that stage can training in

stacking manoeuvres begin.

The stability of the machine in the

working area can only be guaranteed if

the correct procedures are followed.

Should the machine start to roll due to

unapproved manoeuvres or incorrect

driving, the full instructions supplied

must be followed.

Prevention of accidents

In some countries, lift-machines must

be inspected once a year by trained

staff in accordance with the prevention

of accidents regulations. Authorised

SMV dealers can supply information

on these.

We reserve the right to modify our

design and material specifications

without prior notice.

Safety regulations

*Follow national safety regulations.

*The truck must only be driven by those trained to do

so and who have the permission of the management.

*Remember: The national law on driving licences and

driving regulations always apply!

*Before starting up: Ensure that no person(s) or other

obstacles are in the way of the truck or its equipment.

*The truck must not be used if it has faulty brakes,

steering, lifting or other important functions.

*Passengers are not allowed.

* Lifting a person or persons is forbidden unless the

truck is equipped with an approved lift cage for this

purpose.

*Never exceed the lifting capacity of the truck - see

type plate and load diagram.

*The load should always be transported in a lowered

position.

*Always report damage and wear and tear affecting the

safety/function and life of the truck.

*The hydraulics of the truck is equipped with a high-

pressure hydraulic accumulator. Take great care when

working with the hydraulic system. Only service staff

with knowledge of the hydraulics may intervene here.

Instruction book SC - TA/CA

4Publ. nr 6053.411 0315

OUTLINE PICTURE OF THE LIFT TRUCK

DESCRIPTION

1. Lift boom

2. Attachment

3. Twistlocks

4. Damping cylinders 2 pcs

5. Tilt cylinders attachment 4 pcs

6. Lifting cylinders

7. Drive axle

8. Steer axle

9. Counterweight

10. Driver's cab

11. Trailer lift legs. (CA mod)

10 9

Publ. nr 6053.411 0315

Instruction book SC - TA/CA

ID PLATES AND SERIAL NUMBERS

1. Boom number

2. Load capacity plate

3. Attachment

4. Steer axle number

5. Engine number

6. Transmission number

7. Chassis number

8. Drive axle number

Instruction book SC - TA/CA

6Publ. nr 6053.411 0315

TECHNICAL DESCRIPTION

to the right of the driver. The joystick

regulates the functions for lifting,

lowering, boom in/out and the spreader.

The driver's cab fulfils international

safety standards, and is rubbermounted

to protect the driver from vibrations.

Entrance to the cab is on the left side

via the steps on the machine. When the

driver's seat is rotated through 90°, it is

also possible to exit the cab from the

right side.

All hydraulic controls for the lifting

functions are grouped on the console

to the right of the driver's seat.

The parking brake and the switch for

selecting additional electrical

equipment instruments, gauges and

warning lights together with the

switches for the direction indicators

and windscreen wipers are located on

the front mounted instrument panel.

Gear control lever on the steer shaft.

The electrical system is 24 V and has

two serial-connected 140 Ah heavy

duty batteries.

The steer axle is mounted in

"spherelastic" bushes which allow

sufficient wheel movements for

stability on uneven ground. The

parallel tierods are between the

steering cylinder and the wheel axles.

The brakes are operated by an oil-

cooled wet disc-braking system. The

foot brakes are controlled by the foot

brake valve which activates the drive

axle. The parking brake is controlled

electrically and activates a hydraulic

cylinder on the drive shaft.

The double hydraulic pumps are

mounted directly on the gearbox. The

system is divided into four circuits -

two for manoeuvring, one for servo

functions and one for steering. The

relief valves in the hydraulic circuits

are installed to prevent the system

from overloading.

The steering is fully servo-assisted. If

the engine should stall, it is still

possible to steer the truck without

servo assistance, although it is heavy

going.

Two control valves, mounted on the

chassis, are controlled from the cab by

a servo-assisted joystick control levers

TECHNICAL DESCRIPTION

Specification SC 4127 TA means:

SC = Silver Container handler

41 = 41 tons lift capacity in

first row

27 = 27 tons lift capacity in

second row

TA = Toplift attachment

CA = Combi attachment

The engine is a water-cooled, turbo-

charged 6-cylinder diesel engine. The

engine drives a four speed trans-

mission using a torque converter. The

gear selection is electrical with three or

four gears for driving front/back. The

torque converter is equipped with an

oil cooler which lies underneath the

radiator. The gearbox has a dis-

engaging valve controlled by the brake

pedal in the cab. This valve disengages

the gearbox so that the operator can

control the brakes whilst maintaining

a high engine speed during stacking

manoeuvres.

The front axle is driven by the gearbox

via an universally jointed drive shaft.

The axle is of the heavy duty double

reduction type. The primary reduction

is through the hypoid crown wheel and

pinion gear set, the differential gears

are carried within the centre of the

crown wheel. The secondary reduction

is achieved by a planetary gear set

within the wheel hub. The wheel hubs

are carried on taper roller bearings,

thus relieving the half shaft of any

loading other than driving torque.

Publ. nr 6053.411 0315

Instruction book SC - TA/CA

CONTENTS

YOUR SMV LIFT- TRUCK............................................ 2

SAFETY REGULATIONS .............................................. 3

OUTLINE PICTURE OF THE LIFT TRUCK............. 4

ID-PLATES AND SERIAL NUMBERS......................... 5

TECHNICAL DESCRIPTION ....................................... 6

CONTENTS ...................................................................... 7

CAB CONTROLS AND INDICATORS

Description ......................................................................... 8

DISPLAY FOR ELECTRONIC SYSTEM

Left-hand panel, Right-hand panel..................................... 9

BEFORE DRIVING

Adjusting the driver's seat ................................................ 10

Rear panel, steering wheel and the panel

adjustment control, daily maintenance and

service before operating ................................................... 11

Checking the oil level in the engine, checking the

oil level in the gearbox ..................................................... 12

Checking the air indicator ................................................ 12

Checking (topping up) the hydraulic oil level ................. 13

Checking the main circuit switch..................................... 13

Filling up the fuel, checking the condition of the

tyres and the tyre pressure................................................ 14

IQAN panel .................................................................15-23

Starting the engine............................................................ 24

Stopping the engine .......................................................... 24

OPERATING

Driving the machine forwards.......................................... 25

Stopping the machine, driving backwards ....................... 26

STEERING AND BRAKING

Steering, the disengaging switch, parking brake ............. 27

Emergency stop, emergency stop engine,

rear emergency exit .......................................................... 28

SLIDING CABIN AND VENTILATION

Sliding cabin, ventilation and cab filter ........................... 29

LIFTING LOADS

Capacity plates ................................................................. 30

Load diagram.................................................................... 31

OPERATING THE BOOM AND SPREADER

Manoeuvring the boom and spreader............................... 32

THE LAMPS OF THE SPREADER 33

LIFTING AND-DRIVING-WITH-CONTAINERS

Lifting and driving with load, releasing load..............34-37

SERVICE/MAINTENANCE

General information ......................................................... 38

TRANSPORT/TOWING

Lifting the machine, towing ............................................. 39

CLEANING

Cleaning the machine, cleaning radiator.......................... 40

CHANGING WHEEL...............................................41-43

DISASSEMBLING THE BOOM/SPREADER

Disassambling the spreader,

disassambling the boom ..............................................44-46

TIGHTENING BOLTED JOINTS

Tightening torque, torque table, tightening wheel

nuts, universal drive shaft ................................................ 47

Differential nuts, engine mounting, gearbox.................... 48

Drive axle suspension, hydraulic pumps,

cab fastening..................................................................... 49

Counterweights, steer axle ............................................... 50

LUBRICATION.............................................................. 52

Lubrication and maintenance points

General lubrication regulations ........................................ 53

LUBRICATION SPREADER ..................................54-55

Lubrication of the spreader .........................................56-61

LUBRICATION

Lubricating the steer axle, front and rear

section of the boom .......................................................... 56

Boom suspension, the drive shaft, door hinges ............... 61

CHANGING OIL AND FILTERS

Changing and topping up the engine oil,

Changing the turbo filter .................................................. 62

Cleaning the engine oil filter............................................ 63

Changing gearbox oil and oil filters,

changing the breathing filter .......................................64-65

Checking and changing the oil in the drive axle.............. 65

Changing return filter hydraulic oil, changing

hydraulic oil and the breathing filters .............................. 66

Changing fuel filter, bleeding the fuel system ................. 68

Cleaning/changing air filters, safety cartridge ............69-70

CHECKING AND OTHER MAINTENANCE

Checking the intake system and battery........................... 70

Windscreen wiper, checking the cooling system and the

coolant level ..................................................................... 71

Changing the coolant, checking the exhaust system for

leaks .................................................................................. 72

Valve clearance, checking the fuel injector, checking the

fuel system for leaks,........................................................ 73

Checking the fuel tank, checking the V-belts................... 74

Boom wear pads, main pads, side guide pads,

checking the boom and weld constructions ................75-77

Checking/adjusting steer axle bearing, wheel

bearing, spindle bearing ..............................................77-78

PARKING BRAKE ........................................................ 79

MAINTENANCE TABLE

Table of inspection hours ............................................80-81

MAINTENANCE DATA................................................ 82

FUEL AND OIL RECOMMENDATIONS

The quality and viscosity of the engine oil ...................... 83

The quality and viscosity of the gearbox oil.................... 84

FUEL AND HYDRAULIC OILS

Diesel fuel, hydraulic oil, gearbox oil, universal

grease, coolant, drive shaft oil, grease for

battery connections........................................................... 85

HYDRAULICS ............................................................... 86

ELECTRICAL SYSTEM ....................................... 87-115

TECHNICAL DATA ............................................. 116-117

NOTES.................................................................... 118-119

Instruction book SC - TA/CA

8Publ. nr 6053.411 0315

H 1076

CONTROLS AND INDICATORS IN THE CAB

DESCRIPTION

1. Steering wheel

2. Instrument panel with switches

3. Ignition switch

4. Emergency stop

5. Joystick

6. Adjustment steering wheel

7. Accelerator

8. Brake pedal

9. Declutch switch

10. Fan

11. Air condition

12. Heater

13. Recirculation

14. Display for EMC

15. Direction and gear selector

789

414 15

Publ. nr 6053.411 0315

Instruction book SC - TA/CA

21. Enginge electronic system (DSI 12)

22. Support legs up (optiona)

23. Support legs down (optiona)

24. Emergency switch

25. Ignition switch

26. Buzzer EMC (internally)

27. Additional engine stop (DSI 12)

28. Display EMC

DISPLAY FOR ELECTRONIC SYSTEM

H1089

123

12 13 14

16 18

DESCRIPTION

1. Parking brake

2. Working lights boom

3. Working lights attachment

4. Working lights optional

5. Road lights

6. Screen washer

7. Rear windscreen wiper

8. Roof wiper

9. Hazard

10. Rotating beacon (optional)

11. Joystick steering (optional)

12. Central lubrication (optional)

13. Central lubrication (optional)

14. Emergency lowering

15. Warning light EMC

16. Parking brake

17. Alternator

18. High beam

19. Directionals

20. Joystick steering (optional)

Instruction book SC - TA/CA

Publ. nr 6053.411 0315

H 022

BEFORE DRIVING

Adjusting the driver's seat

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

Weight adjustment is automatic.

- Adjust tilting of the seat cushion, by the hand wheel (2).

- Adjust tilting of the backrest with hand wheel (1).

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

- Adjust the lumbard support with hand wheel (5)

- Rotate the seat by pressing pedal (6) Option

- Adjust the height stroke limiter with handle (7)

Lever to the right - full stroke

Lever one step to left - stroke limited partially

Lever to the left - stroke fully limited

- Adjust the armrest with the hand wheel (8)

- To remove seat press pedal (9) Option

WARNING

Never drive the truck unless the seat is

locked in position.

H 021eca

H022

H021

H020

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