INSTRUKTIONSBOK

INSTRUCTION MANUAL
BETRIEBSANLEITUNG
 Chassi
Chassi 1
42120-57 Cabin
Hytt 2
3
Manufacturing No. Mast
Tillverkningsnr. Mast

78442046764 Fork carriage

Gaffelvagn 4
Steering system
Styranordning 5
Brake system
Bromssystem 6
Hydraulic system
Hydraulsystem 7
Air conditioning
Klimatanläggning 8
Electrical equipment
Elsystem 9
Engine
Motor 10
Cooling system
Kylsystem 11
Transmission
Transmission 12
Drive axle
Drivaxel 13
Miscellaneous equipment, technical data
and declaration of conformity
Övrig utrustning, Tekniska data
och EG-försäkran
14
Registers and abbreviations
Register och förkortningar 15
Foreword
Förord
INSTRUCTION MANUAL

Foreword
This instruction manual helps you to get to know and take care of your Svetruck. In the manual are the instruments
on the switch panel and the controls described. The book contains also all necessary sevice instructions so that your
Svetruck gets as long service life as possible.

The instructions are devided into the same system of groups as the spare parts list. Behind patch 14 is a Maintenance
Schedule. The Maintenance Schedule is devided into service intervals. At every new interval must the previous
service points be performed.

Are the operating conditions especially unfavourable or dusty it could be necessary to lubricate the machine more
often then declarated.

Always use the operating time gauge to decide the service intervals. Calender intervals (every day, every week, every
month etc.) could be used instead of following the operating time gauge if it gives a more suitable service schedule.

Safety
Yours and others safety depends on care and judgement when you operate and during maintenance. Most accidents
happens because the basic rules have been neglected. Therefore always follow the local safety rules. Many accidents
could be avoided if you never clean, lubricate or adjust while your Svetruck moves.

Anybody that uses a tool which we have not recommended, must be completely convinced that nobodys safety is
in danger or that the Svetruck becomes damaged and unable to use.

Problems and questions

If you get problems or have questions, don’t hesitate to contact us. We can help you and also give you the latest
news and information.

SVETRUCK AB
Box 321
341 26 Ljungby
Sweden
Phone: +46 (0)372 - 866 00
Fax: +46 (0)372 - 824 50
E-mail: info@svetruck.com

Edition 2 KM-144:GB
Page 1 (2)
INSTRUCTION MANUAL

General ”safety tips”

» Always lower the forks (container spreader, aggregate) to the ground, stop the engine, switch on the
parking brake and put stopping devices at the wheels.

» If the machine is parked the emergency brake mustn’t be set free, unless the wheels are blocked or the
machine is anchored in some other way.

» Use some kind of face protection if you use compressed air.

» Be careful when you handle hot oil or coolant as they can cause burns.

» Dry all lubrication nipples, lid and plugs before maintenance. Durt is in that way prevented to enter the
system.

» Run the engine in a well ventilated place.

» Keep inflammable material at a safe and suiatable place.

» Use the protection equippment that the conditions demand.

» Don’t ever let any incompetent be in the Svetruck while maintenance is performed.

Edition 2 KM-144:GB
Page 2 (2)
INSTRUCTION MANUAL

CE marking
Compliance certification is only required for trucks marketed in the European Union/European Economic Area.

With the European Union Declaration of Conformity statement, Svetruck AB certifies that, upon delivery, the truck
meets the applicable ”Essential health and safety standards” specified in the European Directives for Machinery.

A European compliance certificate, issued by Svetruck AB, is delivered with each truck to corroborate this. The
certificate also covers equipment manufactured by Svetruck AB.
The certificate must be handed over with the machine if it is sold.

If the truck is modified or parts are added without the permission of Svetruck AB, this can adversely affect the safety
of the truck which may make the European compliance certificate invalid.
The person who carries out changes that affect the safety of the machine is also responsible for these changes. If the
truck is used for other purposes or with other equipment than that specified in the documentation, its safety must
be assured in each individual case.

The compliance certificate must be kept in a safe place and be available for inspection by enforcement authorities.

Please refer to European Standard EN 1551.

Figure 836

Edition 1 KM-380:GB
Page 1 (1)
INSTRUCTION MANUAL

Type plate
5

3 2 1 1

3 2 1 1

3 2 1 1

3 2 1 1

3 2 1 1

4 4

Figure 2877

M Machine model
S/N Serial number
Y Year of manufacture
D/N Part number, e.g. 55 56 95, i.e. 55 = Volvo TAD750VE, 56 = ZF 4WG 210, 95 = Kessler D81
WB Wheel base
Q Lifting capacity
D Load centre
H Lift height
W Kerb weight (with no load)
ATT Unit serial number
h Load height, used when the machine is equipped with a container yoke
ERP Engine power (kW)

1, 3 & 4 Lifting capacity (Q) at the specified lift height (H) and load centre distance (D).
1, 2 & 4 Lifting capacity (Q) at the specified load height (h) and load centre distance (D).

5 Machine type: Empty container handler or Forklift

Edition 1 KM-575:GB
Page 1 (1)
INSTRUCTION MANUAL

Use
The truck may only be used for the purpose for which it was constructed, i.e. lifting and moving goods. The maximum
permitted lifting capacity and centre of mass distance are specified on the lifting capacity plate.

The user is responsible for any damage that may occur if the truck is used in any way other than that intended.

If additional equipment is fitted, it should be used in accordance with the instructions issued by the equipment
manufacturer.

If the truck is to be driven on public roads, it must be fitted to comply with current, local traffic regulations.

It is the responsibility of the owner to ensure that the truck has approved fire extinguishing equipment in compliance
with current regulations.

Edition 1 KM-381:GB
Page 1 (1)
INSTRUCTION MANUAL

Driving requirements
The truck may only be driven by drivers who have completed truck driver training, or an equivalent course of
training, and have the applicable authorisation.

The driver must hold a driving licence, driver’s certificate, or the equivalent, in compliance with the current
legislation and regulations of the country.

The driver must be fully aware of the risks that are involved in working with a truck and is responsible for ensuring
that the machine is used properly in accordance with manuals, safety instructions and legislation.

Edition 1 KM-382:GB
Page 1 (1)
INSTRUCTION MANUAL

Ban on driving
It is forbidden to drive or use the truck if:

» Safety equipment, such as rear view mirrors, headlights or reverse warning indicators are missing or do not
work.

» Brakes, steering or hydraulic systems do not work.

» Lifting and load-handling devices do not work.

» Tyres not approved by Svetruck AB have been fitted.

» Conversion, modification or changes have been made to the basic construction of the truck that can affect its
function and/or performance.

» Repairs, service or changes have been performed by someone who does not have the applicable authorisation
or requisite training.

Edition 1 KM-383:GB
Page 1 (1)
INSTRUCTION MANUAL

Visibility
Check that no one is in the way of the truck or its equipment before or when it is being driven. Always face the
direction in which you are driving and be particularly alert in areas where there might be people or machinery.

Adjust your driving speed to visibility conditions.

If loaded goods obstruct visibility, drive the truck with the load to the rear. If this is not possible, another person
should walk alongside the truck and give directions. Drive as slowly as possible and with great caution.

NOTE!
Visibility is restricted. Risk of human
injury and damage to property and
machinery. Adjust your speed!

Edition 1 KM-384:GB
Page 1 (1)
INSTRUCTION MANUAL

Hazard areas
The hazard area is the area covered by the movements of the truck, loading devices and goods. This also includes
the area reached by falling goods or loading devices that fall or are lowered.

Nobody should be within the hazard area except for the driver when working under normal conditions.

Edition 1 KM-385:GB
Page 1 (1)
INSTRUCTION MANUAL

Scope of documentation
You receive the following documents with a new machine
» Instruction Manual
» Spare Parts Catalogue
» Driver’s Manual

Additional copies can be ordered from Svetruck AB

SVETRUCK AB
Box 321
341 26 Ljungby
Sweden
Phone: +46 (0)372 - 866 00
Fax: +46 (0)372 - 824 50

Please specify the truck model and serial number when ordering.

Edition 1 KM-389:GB
Page 1 (1)
INSTRUCTION MANUAL

Spare parts
For service and repairs, we recommend that only original spare parts and replacement items from Svetruck AB
are used. The use of these spare parts will ensure the performance of the truck and its original technical standard.

When ordering a spare part, it is important to specify the model, serial number and year of manufacture of the truck,
as well as the item number shown in the spare parts catalogue.
The model, serial number and year of manufacture of the truck are printed on the type plate.

Edition 1 KM-390:GB
Page 1 (1)
INSTRUCTION MANUAL

Safety regulations
» Always read the operating manual before starting to use the truck.

» Take extreme care and use common sense when working with the truck. Incorrect operation can result in
human injury or damage to property or machinery.

» Always comply with traffic regulations, local safety instructions and other standards, guidelines and
regulations for the use of trucks.

» It is forbidden to carry passengers in the cab unless proper seating is provided.

» It is forbidden to carry passengers on the outside of the truck, e.g. on footsteps, tanks or screens.

» It is forbidden to use the truck to lift a person unless the truck has an approved lifting basket and safety
features.

» It is forbidden to be under lifted loads.

» Transport the load in the lowest possible position that allows good visibility and with sufficient backwards
tilting for optimum stability.

» The weight of the load must not, under any circumstances, exceed the manufacturer’s recommended maximum
load capacity.

Edition 2 KM-391:GB
Page 1 (1)
Cabin
Hytt 2
INSTRUCTION MANUAL

Lexan windows - maintenance

Use cleaning-agent for windows or ordinary washing-up liquid to clean the window.

IMPORTANT!
Solvent mustn't be used as a cleaning-agent.

Clean the windows twice a week or as often as the operating conditions demand.

» Remove the dust from the windows.

» Spray the cleaning-agent on the windows.

» Clean the windows with a completely clean towel.

Edition 2 KM-191:GB
Page 1 (1)
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INSTRUCTION MANUAL

Steering
The forklift has power steering, which means that there is no mechanical connection between the steering wheel
and the wheels steering the forklift. A hydraulic system is used to transfer steering wheel movement to the wheels
steering the forklift.

Never try to coast down a slope with the engine switched off. Since there is no hydraulic pressure, steering of the
truck will be extremely limited.

Edition 1 KM-91:GB
Page 1 (1)
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INSTRUCTION MANUAL

Steering wheel adjustments

The operator can adjust the steering wheel to his driving position. Use the lever next to the steering wheel
(Figure 658) to adjust the steering wheel.

» When the lever is pushed down, the steering wheel automatically tilts forwards. To adjust the steering wheel
to the desired position, tilt the steering wheel manually while holding the lever pushed down. Release the
lever at the desired position.

» Pull the lever upwards and hold it in position to manually adjust the height of the steering wheel. Pull the
steering wheel upwards or push it downwards. Release the lever at the desired position.

Lever for steering

wheel adjustment
Figure 658

Edition 2 KM-318:GB
Page 1 (1)
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INSTRUCTION MANUAL

Driver’s seat
General
The driver’s seat can be mechanically adjusted with height, incline and back support settings.
Optional neck rest, PVC fabric cover and fitted pull-on cover are also available.

Figure 827

F
E
D
C
B

Settings

A Length setting, distance to pedals

Pull the lever upwards to set in the required position. Release the lever to lock the seat in that position.

B Weight setting
Turn the control to the required weight setting.

C Height and incline setting

The front and rear edges of the seat can be set at different heights.
Pull the front control upwards to adjust the front edge of the seat upwards or downwards.
Pull the rear control upwards to adjust the rear edge of the seat upwards or downwards.

Edition 1 KM-412:GB
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INSTRUCTION MANUAL

D Seat belt

E Electric heating
Push the button to turn the electric seat heating on or off. The light comes on when the heating is on.

F Back support setting

Turn the control to the required back support setting.

G Neck rest (Optional)

Edition 1 KM-412:GB
Page 2 (2)
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INSTRUCTION MANUAL

Tilting the cab

All standard machines are equipped with a manual hydraulic cab tilting.
(Electro-hydraulic cab tilting is available as an option).

Before the cab is tilted - make sure that:

» The parking brake is applied
» The gear selector is set in neutral
» The stand is in a vertical position
» Both doors are closed
» Any loose objects in the cab are removed
» Any railings on the truck's right side are dismantled (32120-52120, S1150)

Tilting
» Dismantle the locking handle so that the cab is released from the frame.
» Use the tip of the pump handle and set the selector valve to right mode (clockwise).
» Manual hydraulic (std): Pump until the cab has reached the end position.
» Electro-hydraulic (optional): Hold the push button for electro-hydraulic cab tilting until the cab has reached
the end position.

NOTE!
The cab should always be tilted over its equilibrium position!
If space sideways is not enough, the cab should ALWAYS be
secured with bracing or the like against unintentional lowering!

WARNING!
Risk of pinching! Note that the cab fall on its own for
the last stretch when tipping!
Make sure the area is clear at least 2 meters to the
right side of the truck.

Figure 2879

Edition 1 KM-572:GB
Page 1 (2)
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INSTRUCTION MANUAL

Lowering
» Use the tip of the pump handle and set the selector valve to left mode (counterclockwise).
» Manual hydraulic (std): Pump all the way until the cab rests against the frame.
» Electro-hydraulic (optional): Hold the push button for electro-hydraulic cab tilting until the cab is resting
against the frame.

WARNING!
Risk of pinching! Note that the cab fall
on its own for the last 100-200 mm!

» Mount the locking handle so that the cab is locked to the frame.

Figure 2880

NOTE!
The cab should always be completely lowered
during driving.
The machine cannot be operated with the cab
partially in raised position.

Edition 1 KM-572:GB
Page 2 (2)
2
Mast
Mast 3
INSTRUCTION MANUAL

Mast
To disassemble
We recommend you to control the whole mast when you are going to repair something on the mast. When the
mast is disassembled you should especially control the tube roller.

» Disassemble the fork carriage. See group 4, Fork carriage.

» Position the mast as high as possible.

» Unfasten the suction tubes on both lift cylinders and plug them to the tank.

» Lower the mast to its lowest position, unfasten the suction tubes and plug them.

» Unfasten the lifting cylinders’ pressure tubes. Plug tubes and connections.

» Tilt the mast to vertical position.

» Fasten a lifting chain from a traverse around the beam of the outer mast or, if available, in the lifting rings.
See figure 46.

IMPORTANT!
Before the pins of the tilt cylinders are unfastened, secure
the cylinders to make sure that they can't fall down.

Traverse

Inner mast

Lifting chain

Outer mast

Figure 46

Edition 2 KM-51:GB
Page 1 (2)
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INSTRUCTION MANUAL

» Unfasten the tiltcylinders from the outer mast by first removing the split pins. Then knock out the pins.
See figure 45.

IMPORTANT!
When the pins are being disassembled the
mast must not hang or push on the pins.

» Disassemble the mast by first removing the split pins. Then knock out the pins. See figure 45.

» Rise the mast.

» Reverse the forklift and put down the mast.

Tilting ear

Bearing
Lock ring
Pin
Split pin

Mounting ear

Pin
Split pin
Figure 45

To assemble
You assemble the mast in the reconversed order of disassemble. When the mast is assembled it’s very important to
check that there isn’t any hydraulic leakage.

Edition 2 KM-51:GB
Page 2 (2)
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INSTRUCTION MANUAL

Chains
Conscientious maintenance and lubrication are required if the characteristics are to remain valid.

The chains have a silver label with a label number. The label number tells you all relative data of the material used,
even including the material used, and the material supplier’s name. If required you can also examine all production
and inspection data applicable to the label No. All this data is kept available for a period of ten years.

Adjustment
The chains must be adjusted so that the forks don’t reach the ground when they are in their lowest position. It’s very
important that the chains are adjusted exactly the same on both sides.

When the adjustment is done you must fasten the chain tightener’s lock nut properly.

Chain

Split pin

Pin

Chain tightener

Spacer

Lock nut

Figure 56

Edition 1 KM-71 B:GB

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INSTRUCTION MANUAL

Maintenance

Maintenance intervals
Chains should be relubricated and inspected after every 250 hours of operation; this should already be done after
100 hours of operation if the chains are subjected to extreme soiling and very high continous loads.
We recommend different lubrication oils further on.

Noisy operation
Dry friction occurs in the chain’s joints if high-pitched squeaking or low-pitched creaking noises occur. These arise
exclusively from a lack of lubricant in the chain’s joints. Metallic friction then occurs during movment of the joint
into and out of the deflection wheel.

Metallic friction can also possibly lead to stick-slip effects. This backward slipping in the chain joint leads to
unharmonious movement.

Surface rust
Surface rust is easily recognizable by brown discolouration of the link plates. This exteriour phenomenon is
unfortunately not only an optical affair. The accompanying pitting, which always goes hand in hand with rust, is
dangerous. Pittings consist of small craters. They form on all parts of the chain if it has a lack of lubrication or even
the wrong lubrication. Pittings are the starting points of premature fatigue fractures.

Figure 104

Joint rust
Friction corrosion leads to red-brown discolouration of the joint zones. Joint rust is also frequently referred to as
”bleeding” of the chain and may occur as the result of a general lack of lubrication. It may also occur when using
greases or thickening oils which are not capable of penetrating into the joint.

Stiff joints
If the links of the chain do not assume a streched position again after leaving the deflection wheel, then the chain
joint is not operable. This penomenon may be caused by cold welding, joint corrosion or briquetting.

Figure 109

Edition 1 KM-71 B:GB

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INSTRUCTION MANUAL

Twisted pins
Twisted pins are a further indication of inadequate chain lubrication and are considered to be a consequence of stiff
joints. If this occurs, blockage of the joints has advanced to such an extent that the press fits between the chain’s
pins and outer links have been overcome.

Twisted pins are easy to recognize. Their flattened rivet surfaced on the face sides deviate form the arrangement
produced at the factory.

Figure 110

Loose chain pins

Chains which show loose pins in the outer links’ press fits produce a direct risk of tearing of the chain. Loose chain
pins are a direct consequence of ”stiff joints” and ”twisted pins”.

Figure 105

Inadmissible exterior wear

Examine whether the chain’s link plates have inadmissible exterior wear, e.g. as the result of direct rubbing against
mast sections or in the contact with deflection rollers.

Figure 108

Edition 1 KM-71 B:GB

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INSTRUCTION MANUAL

Damage
Do the chain’s link plates exhibit impact markings or other deformations?

Figure 111

Broken link plates

Broken link plates are indicted by "opening" of the effected link plate in the area of its head or by absence of the
head portion. This is the result of fatigue fractures caused by an overload. Corrosion may also trigger such fractures.

Figure 107

Broken pins
These generally occur mainly as the result of corrosion in the chain joint. On the pins, such corrosion leads to
pitting. In turn this is the starting point for fatigue fractures. It lies in the character of this phenomenon that several pin
fractures may occur shortly after one another in such cases because all chain pins are subject to identical conditions
in terms of corrosion, load on shock absorption and therefore a reduction in fatigue strength, essentially caused by
corrosion. It is therefore natural that several broken pins will be found when dismantling such a chain. Thorough
inspection is therefore advisable.

A thorough inspection could be difficult to perform if the chain is covered with a thick grease layer. In such cases
no reliable result will be obtained without thorough cleaning beforehand.

Figure 106

Edition 1 KM-71 B:GB

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INSTRUCTION MANUAL

Soiling
Chains are not reliably lubricated if they are soiled to such an extent that the oil applied for lubrication cannot
penetrate directly down to the joint. Applied grease also effectively prevents oil from penetrating to the joints.

Figure 100

Chain elongation
Even if a chain has been lubricated optimally, it will not be possible to avoid elongation during the course of the
years. This is caused exclusively by wear in the chain’s joints. The wear merely effects the area of the chain which
is guided over the deflection wheel. Thus, when measurnig wear, only this area needs to be measured.

As specified in the current standards, chain is considered to be worn if it has become elongated by 3% (30 mm per
meter). If safety requirments are very crucial or if the possible risk depends on one single chain, we consider it
necessary to replace the chain after only 2% elongation (20 mm per meter).

To measure elongation as the result of wear, move the part of the chain which passes over the deflection wheel into
the streched zone. Then measure a section approximately 1 meter in length using a ruler. It is always best to measure
from the bottom edge of one pin to another. The number of pitches in the measured zone, multiplied by the chain
pitch, results in the nominal dimension. See the table on page 6 for the exakt dimensions.

If a new chain is available, the elongation resulting from wear can also be determined by comparison. This 3%
elongation has been reached if the chain in operation has reached a length with 33 links which corresponds to 34
links on a new chain.

A second measurement must be carried out if it becomes clear during the above-mentioned measurement that
differing degrees of elongation from wear have occurred within the sections chosen for measurement. This second
measurement should cover only the section with the maximum elongation. Here also, the length increase must not
exceed 3%.

Figure 101

Edition 1 KM-71 B:GB

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INSTRUCTION MANUAL

Hydrogen brittlement
If heat treated (hardened) materials are subjected to free hydrogen (chemical designation H), the material reading
absorbs this substance from the environment. This absorbtion leads to destruction of the tempering steel’s
molecular structure. All chains and roller bearings are affected by this phenomenon.

Such fractures are, however, unavoidable if the atmosphere contains free hydrogen. Brittle fractures can also be
caused directly by cleaning chains or by using cleaning agents containing chlorine. Cold cleaning and jet blasting
of chains may result in such phenomena.

Figure 114

Pitch dimensions - Wippermann

Load (ton) Pitch (") Pitch (mm) Lacing

32 2 50,80 8x8

37-45 2 1/2 63,50 8x8

Table 3:1:B

Edition 1 KM-71 B:GB

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INSTRUCTION MANUAL

Lubrication
By correct and adequate chain lubrication, phenomena as described are prevented from occuring at all.
Lubrication also crucially influences chain elongation. As shown in the diagram below, the lifetime of an adequately
lubricated chain is 60 times longer than that of a dry-running chain. Even temporary dry-running, however, will
shorten the lifetime of a chain by a factor of twelve.

Elongation from wear as a function of lubrication and operating time.

Permissible
chain length
30

b
a

20

14

10
c
6
d
1 e
0,5 Operating time
0 Figure 99

Curve
a. Dry running
b. Lubrication once without relubrication
c. Temporary dry running (relubrication after too long a period)
d. Inadequate lubrication
e. Adequate lubrication

Elongation from wear

Curve a = 30 mm
Curve b = 14 mm
Curve c = 6 mm
Curve d = 1 mm
Curve e = 0,5 mm

Edition 1 KM-71 B:GB

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INSTRUCTION MANUAL

Incorrect lubrication
As proven by statistical analyses, 60% of all chain defects can be ascribed to incorrect lubrication. Thus, users might
think they have lubricated their chains well but nevertheless friction corrosion, twisted pins, metallic friction, stiff
joints, noisy operation and pitting may occur.

This is always the case whenever the applied lubrication product adheres only on the exterior, and has not penetrated
down to the chain’s joints.

Lubrication products with thinner

Chain manufacturers apply a corrosion protection and lubrication grease to their chains at the works. These are
applied in a warm bath. When these chains are now put to use, a certain depositiong of dust on the surface can be
expected. This stiffens the existing outer grease layer even more.

If a lubricant with a stiff basic viscosity is now sprayed onto the chain, having been temporarily made liquid by a
solvent, the following occurs: The existing outer grease layer is partly dissolved externally. This is where the thinner
is alreadey used up. No new lubricant penetrates into the joint of the chain. Merely the outer layer of grease is built
up again and now picks up soiling even more.

Condensation rust
When chains are covered homogeneously with a viscous exterior layer of grease, cavity formation may partly occur in
the joints as the result of joint movement. New lubrication is not capable of penetrating through because, as we have
seen above, it is not capable of flowing adequately and the newly applied grease has led only to additional stiffening.

If chains lubricated in this way are subjected to extreme temperature cycles, condenstae collects in the chain’s joints.
Particularly those chains which are directly subjected to sunlight during the day and which then cool off substantially
later on (at night) as well as those chains which operate inside and alternately outside of cold rooms, are especially
effected here. The result is joint corrosion which in turn, leads to stiff joints. Particularly new chains which, as we
know have a very low joint play, then tend towards jamming from rust.

Further consequences are pitting in the joint portions. In turn this triggers off premature fatigue fractures.

Figure 115

Edition 1 KM-71 B:GB

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INSTRUCTION MANUAL

Correct lubrication of chains

Chains are lubricated correctly and are in a perfect condition if:
» No exterior soiling adheres to them
» The finger is wetted with oil when the chain is touched

When lubricating chains with oil, it is in no way necessary to apply such large quantities that the oil will drip off.

Correct preservation of chains

Chains are automatically preserved properly if lubricated correctly. This means that corrosion and pitting will be
impossible.

Correct cleaning of chains

If a chain has become externally so soiled during operation that thorough penetration of the lubricating oil is not
guaranteed, then the chain must be cleaned. This must be done only with paraffin derivates such as diesel fuel.

We must warn against cleaning with steam jets, the use of cold cleansing agents or even caustic and acidic agents.
These may lead to direct chain damage.

Chain cleaning using steam jet equipment

Substantial soiling of lifting chains may occur at short intervals under specific conditions of use, e.g. in artificial
fertilizer plants or when bagging cement and other dusty products. If recourse is taken to cleaning with steam jet
equipment under such operating conditions, then this should be done exclusively without the use of aggressive or
caustic cleaning agents or agents containing clorine. The chain has not only been cleand but also totally ”degreased”.
In this condition it is subject to the risk of fast and dangerous corrosion. The film of water remains longest particularly
in the chain joint between the contact faces of the link bore and pin surface, and then produces corrosion and pitting.

Pure water or steam is the agent shich will produce the least damage.

Cleaning method optimization when using jet equipment

We recommend the following procedure if such a cleaning method cannot be avoided.

» Cleaning - Clean the chain with steam of hot water, using no additives whatever.

» Commpressed air - Immediately after cleaning, remove the water from the surface of the chain and from
inside the joints using compressed air. Move the chain several times while doing so.

» Spraying - Then immediately spray a preservative and lubricant on the chain. Also when doing so, move
the chain an adequate number of times to ensure that the product used will actually be capable of penetrating
down to the joint.

» Products to be used - use only products here which have the following characteristics; adequate creep
abilities, adquate corrosion protection and lubrication ability, ability to penetrate under water, continuously
viscous after application also, good adhesion and build up a protective film with a layer thickness adequate
for withstanding late mechanical aggressions (pelting rain, hail).

Edition 1 KM-71 B:GB

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INSTRUCTION MANUAL

Correct lubricant - selection and application criteria

To attain effective lubrication, an adequate quantity of a liquid lubrication product must be brought into chain joints
during each lubrication operation.

The cross - sections of roller chains’ and leaf chains’ joints clearly show that the lubrication product has to penetrate
through a long distance between narrow link plate gaps to reach its most important destination, the chain joint.

Figure 103

Another task of the lubricating oil is to ensure adequate protection against corrosion. This is done by wetting of the
surfaces with an adequate layer thickness.

Equipment using lifting chains which is subjectd to all weather conditions outdoors naturally requires slightly more
care.

Oil

Figure 102

Type of lubricant
A fluid mineral, machine or engine or sythetic oil should be used.

Viscosity
The lubricant oil’s viscosity should be chosen so that it will remain fluid at all occuring ambient temperatures.
Therefore, under usual and normal temperature conditions lubricating oils with a viscosity from SAE 20 to SAE 40
(50-2000 mm²/s at 40° C) are suitable. We recommend ”BP tooth grease MOG”.

Use of spray cans

If you wish to use spray cans to lubricate chains, make sure that the basic requirement is fulfilled her also, i.e. a
viscosity must set in after evaporation of the thinner which still conforms to the above requirement.

Edition 1 KM-71 B:GB

Page 10 (11)
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INSTRUCTION MANUAL

Recommended lubrication products

» Rexnord high-performance chainspray
» Structovis FHD
» Viscogen KL 23
» Mobilarma 524
» DEA DX transmission oil ST 80
» Esso transmission oil ST 80
» Molykote GO 220
» Hotemp Plus
» Shell Tonno oil T 220
» BP Energol transmission oil 80

Equivalent lubrication products from other manufacturers can naturally also be used if they fulfil the above
mentioned requirements.

Lubrication methods
The lubrication product can be applied using a brush or compressed air spray devices.

Chain replacement
If it should ever be necessary to replace a chain responsible users will make use of a quality product which fulfils
all demands which have to be placed on a saftey element.

If two chains are used on the equipment concerned as a pair:

» Use only spare parts form the same product as the worn out chain.
» Before driving out the pins, rivet heads must be ground off to avoid damaging the moving inner link plates
in the bores.
» Only new outer link plates and new pins may be used for repair because fatigue strength and thus operating
safety depend crucially on the use of link plates with unscored bores and an adequate press fit.
» When replacing chains, the connecting pins between the chain anchor and chain should also be renewed in
all cases. These are subject to high impact loads. This preventive replacement ensures that premature fatigue
fracture in relation to the new chain will be prevented.
» When carrying out repairs, manual riveting using a hammer is sometimes unavoidable. It is obvious that, for
safety reasons, extreme caution must be observed here.

Firstly it is necessary to wear protective goggles because the possibility of partial splintering from the pin heads
cannot be excluded. Pay attention to avoiding damage to the outer link plates because this may result in fatigue
fractures. Only moderate deformation of the pin head is required for riveting because essential securing of the pin
in the outerlink plate to prevent lateral migration and torsion must be provided by the press fit. During assembly and
when reveting the pin, pay attention to the fact that, on the one hand, adequate ply must be provided between the
link plates to guarantee mobility of the links while, on the other hand, the pin overhang must be enough to ensure
a rivet head which complies with specifications.

Generally
When installing new chains or when overhauling equipment, it is essential that paint does not come into contact
with the chains. This would merely prevent the chain joint from being effectively lubricated. Painted chains prevent
penetration by the lubricating oil.

Lifting chains are safety elements and great effort is put into their manufacture. In your hands, however, the degree
to which they will prove their worth depends substantially on proper maintenance and lubrication.

Edition 1 KM-71 B:GB

Page 11 (11)
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INSTRUCTION MANUAL

Chain rollers
Change of chain roller

» Remove the lifting chain.

» Unscrew the lubricating nipple. See figure 35.

Nipple
Shims

Washer
Bearing
Bearing
Washer
Chain roller
Split pin
Shims
Axle

Mast

Figure 35

» Check that the axle is undamaged, works properly and that it’s free from pollution.

» Place a new chain roller, the washers, the shims and the bearings. The chain roller should be shimed in so
that there isn’t any play. It shouldn’t be able to move the chain roller from one side to the other. The chain
should run in the middle of the new chain roller.

» Fasten the lubricating nipple.

» Lubricate the new chain roller.

Edition 1 KM-44:GB
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INSTRUCTION MANUAL

Lifting and transporting loads

WARNING!

» Transporting loads involve considerable risks.

» Risk of rolling and tipping over! Risk of damage to load and

property! Mortal danger!

» Respect the lifting capacity of the machine and be very careful

when handling loads.

» The machine should only be driven on even ground designed

to support the total weight of the machine and its surface
pressure.

» Do not tilt the mast forwards when the load is not suspended
above a stack. The stack prevents the machine from tipping
over.

» Be careful when lifting loads in strong winds!

» The load could become unstable, causing the machine to roll over!

» Do not allow anyone to enter under a suspended load. Persons

should also not remain in the vicinity of the truck’s work area.
Mortal danger!

» Only transport loads in the transport position.

Pay attention while driving; pay attention to clearance widths
and heights to prevent the mast/carriage/load from colliding
with poles, cables, etc.

» Loads should never be transported in a high position as this may

cause the machine to tip or roll over. There is a risk that
property could become damaged! Mortal danger!

» Transport the load facing upwards when ascending or

descending slopes; never drive across or turn on an incline.

» Avoid sudden braking and acceleration!

» Adapt the speed to prevent the risk of rolling or tipping over.

» If an accident does happen:

Do not try to jump off the machine if it tips or rolls over.
Remain inside the machine, brace yourself and grip the
steering handle tightly. Lean away from the tipping direction.
Only jump off the machine once it has stopped moving.

Edition 1 KM-583:GB
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INSTRUCTION MANUAL

General
Precautions when handling loads with a fork lift truck:
» Before commencing with the task at hand, check the lifting capacity of the forks/lifting attachment.

Load chart
If you are unsure whether your Svetruck machine is able to lift the intended load, this load chart can help you
with determining the maximum load. Pay attention to the fork/lifting attachment capacity.

» Estimate the centre of gravity of the load.

» Look up the position of the centre of gravity in the load chart. Proceed upwards in the chart to the line for
the model number of your Svetruck. Then move left in the chart and read the lifting capacity on the vertical
axis for this centre of gravity position.

See the examples below:

t
18
17
16
15
14
13
12
11
10
9
8 1860
7 1660
1560
6 13660
5 1260
1060
4 960
3 860
2
1
mm
600 900 1200 1500 2000 2500 Figure 643

WARNING!
» The machine's load capacity is limited. See
the type plate and load chart.
» Never exceed the maximum lifting capacity.
» Risk of rolling and tipping over!

Edition 1 KM-583:GB
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INSTRUCTION MANUAL

Lifting techniques with forks

» Carefully and as precisely as possible approach with the truck to the load to be lifted. (machine centre
towards the load’s centre of gravity).

» Slightly tilt the mast forwards.

WARNING!
» Never handle unstable and loosely laden goods.
» Make sure the load is securely positioned for lifting.
» Never tilt the mast forwards when holding a load.

» Lower or raise the forks to the correct height, adjust fork spreading/sideshift and insert the forks under the
load until the fork heels almost touch the load.

» Make sure the load’s centre of gravity is centred between the forks. If necessary, adjust using the sideshift
feature.

» Lift the forks until the load is suspended.

» Slightly tilt the mast backwards.

» Slowly reverse the truck from the pick-up site until the load is clear.

WARNING!
» Do not allow anyone to enter under a suspended
load. Persons should also not remain in the vicinity
of the truck’s work area.
» Risk of injury. Mortal danger!

» Adjust the mast to the transport position for optimum stability and lifting height. See the next section.

» If the truck seems heavier on one side, it will be necessary to adjust the load’s centre of gravity in relation to
the truck. In this case lower the load and correct the centre of gravity using the sideshift feature. If it is not
possible to sufficiently correct the load using the sideshift feature, the load should instead be repositioned and
lifted anew.

Edition 1 KM-583:GB
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INSTRUCTION MANUAL

During transport

IMPORTANT!
Adapt driving and travel speeds to ambient
conditions, such as the load, weather, wind,
visibility, temperature, etc.

Figure 2935

» Transport the load in the transport position for optimum stability, i.e. with the load kept as low and as far in as
possible without obstructing the view of the operator. Never drive with the load kept higher than the operator’s
line of sight. Transport the load as low as possible and with an unobstructed view.

» 
To stabilize the load and prevent it from becoming displaced or slide off when braking, tilt the mast sufficiently
backwards.

» The truck should only be driven on even ground designed to support the total weight of the truck and its
surface pressure.

IMPORTANT!
Make sure there is sufficient clearance under
overhead installations, power lines, lights, doors,
piping, etc.

IMPORTANT!
Before putting the truck in motion, the operator
should lean to both sides, forwards and
rearwards, to check all dead angles.

Edition 1 KM-583:GB
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INSTRUCTION MANUAL

IMPORTANT!
Transport the load in the lowest possible position that allows good
visibility and with sufficient backwards tilting for optimum stability.
Never drive with the load kept higher than the operator’s line of sight.

Transport position

Figure 2936 Figure 2937

» In case of even road surfaces, keep the truck’s forks at a height where the cargo is clear of the ground, and in
case of uneven surfaces and considerable inclines keep the forks sufficiently high to enable the load to clear
any obstacles.

» Transport the load facing upwards when ascending or descending slopes; never drive across or turn on an
incline.
When driving the truck without any load, the mast/carriage should face down on inclines.

» Always brake and accelerate with care when transporting loads. The truck could tip over forwards in case of
sudden braking and reverse acceleration.

» Pay special attention in freezing weather since the load then easily can slide off the forks.

» Do not transport a laterally uneven load (compensate by using the sideshift feature). The load’s centre of
gravity should be positioned on an extension of the truck’s centre line.

» If the truck starts to sway, braking will not help. Instead this will aggravate swaying and the truck could tip
over forwards.

» The truck’s lateral stability and tip-over stability frontwards will be considerably worse when transporting
loads at high positions.

Figure 2943

Edition 1 KM-583:GB
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INSTRUCTION MANUAL

Unstacking loads

» Carefully and as precisely as possible approach with the truck to stack or site where the load should be set
down.

» Lift the fork carriage to a sufficient height for setting down the load.

» Carefully drive forwards until the load is over the unloading site.

» Tilt the mast forwards until it is vertical.

» Slowly lower the load and make sure it is stable on the unloading site, e.g. on the ground or on top of the
stack.

» If a load has not been completely or only partially released, there is a risk it could be pulled back and fall
down when the truck reverses.

» If necessary tilt the mast slightly forwards.

» Slowly reverse the truck from the unloading site and lower the forks to the transport position.

Edition 1 KM-583:GB
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INSTRUCTION MANUAL

Lift cylinder
Forklifts that lift 18 ton and more have no seal kit, as the figure shows. They have a brass piston seal instead.

If there is oil leakage in the lift cylinder, you must change the seal that’s placed in the piston head. You don’t need
to change the brass piston seal.

Seal kit
(here: brass
piston seal) Plug Cylinder

Piston rod

Figure 50
Spacer
O-ring
Piston head
Piston head seal
Scraper ring

Edition 3 KM-67:GB
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INSTRUCTION MANUAL

Change of piston head seal

» Remove the bolts that fastens the piston head to the cylinder.

» Remove the piston head from the piston rod.

» Change the piston head’s o-ring and scraper ring.

» Remove the piston head seal and replace it with a new. It’s easier if you wrap the seal. See figure 617.

» Check that the piston head is clean and undamaged. Put it back into the cylinder and fasten it with the bolts.

Piston head seal

Wrapped seal

Piston head

Figure 617

Edition 3 KM-67:GB
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INSTRUCTION MANUAL

Tilt cylinders
Change of gaskets
The procedure is the same as for the fork carriage’s hydraulic cylinders. Secure the mast and unfasten one
cylinder at a time.

When you put back the tiltcylinders it’s very important that they have the same length. Measure therefore the distance
between the tiltcylinders’ links at full deflection. The distance must be exactly the same on both
cylinders.

IMPORTANT!
Work at a clean place and observe great cleanliness.

WARNING!
Sharp objects can damage the seal and the piston.

» Disconnect the cylinder’s hydraulic tubes and plug them with special plastic plugs.

» Remove the split pin and then the pin, at both ends of the cylinder. See figure 49.

Gaskets Cylinder

Piston

Piston seal Spacer

Scraper
O-ring
Piston head

Pin Bolt
Lock nut
Split pin Figure 49

Edition 2 KM-58:GB
Page 1 (2)
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INSTRUCTION MANUAL

» Unfasten the lock nut.

» Unfasten the attachment and remove it.

» Remove the lock nut.

» Remove the bolts that holds the piston head and remove the piston head.

» Pull out the piston.

» Note in which order the gaskets are placed.

» Remove the old gaskets.

» Clean first and then heel on the new gaskets. If they are hard to handle it’ll help if you warm them up
carefully in hot water.

» Change the gasket from the piston head and replace the gasket with a new gasket. It’ll help if you wrap
the gasket. See figure 618.

Piston seal

Piston head

Figure 618

» Check that the piston is clean and isn't damaged. Put back the piston in the cylinder.

» Check that the piston head is clean and not damaged. Put it back in the cylinder and fasten with the bolts.

» Screw on the nut so far that the attachment can be totally screwed on.

» Screw on the attachment and lock with the nut.

» Put back the tiltcylinder and fasten with the pin and split pin.

Edition 2 KM-58:GB
Page 2 (2)
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INSTRUCTION MANUAL

Rollers
Change of rollers
The procedure is the same as for the fork carriage's rollers.

» Remove the fork carriage from the mast. See Group 4, Fork Carriage.

» Unscrew the four socket head cap screws which fastens the washer to the axle pin. See figure 64.

Figure 64

Nipple Axle pin

Bearing
Roller
Bearing
Shims
Lock washer

Screw

Edition 1 KM-53:GB
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INSTRUCTION MANUAL

» Remove the washer and the shims.

» Remove the roller from the axle pin. Use a withdrawing tool.

» Clean the axle pin. Check that the pin is free from burrs. Check also that the lubricating canals and the
lubricating nipple are free from dirt and that they work properly.

» Knock in the new roller. Use a piece of a board or a club. It's easier if you lubricate the axle pin.

» Put back the washer with one or more shims, so that there is no backlash.

» Check that the new roller turns without any play. If the roller turns slowly you must put more shims.

» Lubricate the new roller via the nipple.

Edition 1 KM-53:GB
Page 2 (2)
3
Fork carriage
Gaffelvagn 4
INSTRUCTION MANUAL

Support roller
Change of suppport roller
To make it easier to lubricate the support roller, the lubrication nipple on the lower support roller is lengthened.

» Remove the fork carriage. See Group 4 Fork carriage.

» Unscrew the lubrication nipple with the elbow adapter, from the axle. See figure 201.

Attachment
Stopscrew
Shim

Bearing
Washer

Axle Lockring
Lockring Washer
Bearing
Elbow adapter Support roller
Spacer
Shim
Attachment

Lubrication nipple Figure 201

Lubrication nipple
Lengthened nipple

» Remove the lockrings on both sides of the axle.

» Unfasten the stopscrew, which fastens the axle to the rear support roller attachment, so that the axle can be
knocked out.

» Very carefully, knock out the axle so that the support roller becomes loose. Take care of the washers and
the shims. The support roller is shimmed to be centered.

» Shim in the new support roller at the same time as you knock in the axle. It’s easier if you put some oil on
the axle.

» Check that the support roller rolls easily without any play.

» Fasten the stopscrew, which holds the axle to the rear support roller attachment.

» Replace the lockrings on both sides of the axle.

» Replace the lubrication nipple with its adapter, on the axle.

» Lubricate the new support roller.

Edition 1 KM-185:GB
Page 1 (1)
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INSTRUCTION MANUAL

Rollers
Change of roller

» Remove the fork carriage from the mast. See Group 4, Fork Carriage.

» Unscrew the four screws that fasten the washer at the axel pin. See figure 196.

Lubrication nipple
Axle pin

Bearing

Roller

Bearing
Shim
Washer

Screw

Figure 196

» Remove the washer and the shims.

» Remove the roller from the axle pin. Use a withdrawing tool.

» Clean the axle pin and check that the pin is free from burrs. Also check that the lubricating nipple and
the lubricating canals are free from dirt and that they work properly.

» Carefully knock in the new roller on the axle pin. It’s easier if you lubricate the axle pin.

» Replace the washer with one or more shims so there is not any play.

» Check that the roller turns easily without any play. If the roller turns slowly you must add more shims.

» Lubricate the new roller via the nipple.

Edition 1 KM-183:GB
Page 1 (1)
4
Steering system
Styranordning 5
INSTRUCTION MANUAL

Tyres
Generally
The tyres’ characteristics and the air pressure in the tyres have a conclusive influence on the forklift’s road manners.
To make the forklift's stability as good as possible, the air pressure mustn’t be below the pressure that is
recommended in the table. It is important that the tyres on the same axle have the same air pressure.

Tyres that have been used with too low a pressure or without any pressure at all can have serious damages on its
walls, which you can’t see from the outside. If a tyre has been used without any pressure, it should be discarded.

Water in the tyres is not good. Water could enter the tyre together with compressed air or if the tyre is placed outside
in the rain. The body becomes damaged and vibration problems occur.

You should avoid using different types of tyres from different manufactures, on the same forklift. It’s especially
important that the tyres on the same axle are equivalent. The tyres mustn’t have considerably uneven wear.

Pumping
To avoid accidents you should stand behinde the tyre when you pump it. Use a self-adhering nozzle. See figure 172.
The valve cap protects the valve from dust and dirt. If the valve cap is missing, it should immediately be replaced.
Check the forklifts air pressure regularly (approximately every second week). Also check the wheel nuts torque.
See Wheel nuts group 5, which torque the nuts should have.

When you pump the tyres, also check the tyres with regards to foreign objects, cracks or bumps. If you find any
damage, please contact your tyre supplier regarding the possibility of repair.

Figure 172

Edition 2 KM-192:GB
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INSTRUCTION MANUAL

Pressure - tyres
Forklift Tyre Air pressure (front) Air pressure (rear)

ton " kPa PSI kPa PSI

18120-25120 14.00 x 24 1000 145 1000 145

28120-34120 16.00 x 25 1000 145 1000 145

37120-50120 18.00 x 25 1000 145 1000 145

S1150 18.00 x 33 1000 145 1000 145

Forklift Tyre (front) Tyre (rear) Air pressure (front) Air pressure (rear)

ton " " kPa PSI kPa PSI

TMF 12/9 16.00 x 25 16.00 x 25 1000 145 1000 145

TMF 15/11 18.00 x 25 16.00 x 25 1000 145 1000 145

TMF 25/18 18.00 x 25 18.00 x 25 1000 145 1000 145

TMF 28/21 18.00 x 33 18.00 x 25 1000 145 1000 145

This is a recommendation for genuine Svetruck tyres.

Replacement tyres should be approved by Svetruck for
the warranty and service agreement to remain in effect.

Edition 2 KM-192:GB
Page 2 (2)
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INSTRUCTION MANUAL

Wheel nuts
Tightening torque
Wheel nuts must always be tightened to a specific torque. The tightening torque should be checked regularly.
Tighten crosswise to the recommended torque.

NOTE!
If wheel nuts work loose while the vehicle is in motion, this can cause
damage to the wheel hub. With new wheels, the nuts must be
retightened after 4 to 5 hours. Check and retighten wheel nuts until they
are all properly torqued (for the first 50 hours of operation)!

WARNING!
The removal and installation of tires and wheels must always
be carried out by a qualified mechanic or a certified firm as
this work poses a risk to health and safety.

860-1890, ECS (Nm) (lbf ft)

Steering axle 650 480
Drive shaft D81 650 480

18120-34120 (Nm) (lbf ft)

Steering axle 500-550*1 370-405*1
Steering axle 650*2 480*2
Drive shaft D91 350 260

32120-52120, S1150, TMF 12/9-15/11 (Nm) (lbf ft)

Steering axle 500-550*1 370-405*1
Steering axle 650*2 480*2
Drive shaft D102 350 260

TMF 25/18-28/21 (Nm) (lbf ft)

Steering axle 500-550*1 370-405*1
Steering axle 650*2 480*2
Drive shaft D106 350 260

*1
= English thread, 7/8"UNF
*2
= Metric thread, M22x1,5

Edition 4 KM-441:GB
Page 1 (1)
5
Brake system
Bromssystem 6
LIST NO. 105996

Description Benennung

Hydraulic system Hydraulisches System

(Pos. 1-34, 120-127) (Pos. 1-34, 120-127)

1 Hydraulic tank Hydrauliktank

2 Hydraulic pump Hydraulikpumpe
3 Hydraulic filter Hydraulikfilter
4 Priority valve Prioritätsventil
5 Steering control unit Lenkungskontrolleinheit
6 Pressure control orbitrol Druckbegrenzungs Orbitrol
7 Steering cylinder Lenkzylinder
8 Vavle bank gearbox Ventilplatte Getriebe
9 Gear shifting cyl fwd / rev Schaltenzylinder vorwärts / rückwärts
10 Gear shifting cyl 1, 2, 3 Schaltenzylinder 1, 2, 3
11 Forkposition cylinder Zinkenverstellungzylinder
12 - Pressure switch - Druckschalter
- Lowering stop - Senkbremse
13 Nonreturn valve, liftcylinder Rückschlagventil, Hubzylinder
14 Distribution block, liftcylinder Distributionblock, Hubzylinder
15 Accumulator, liftcylinder Akkumulator, Hubzylinder
16 Lowering control valve Senkbremsventil
17 Lift cylinder Hubzylinder
18 Pressure control valve Druckkontrollventil, neigen
19 Tilt cylinder Neigungezylinder
20 Directional control valve, 2 section Richtungsventil, 2 Sektion
21 Directional control valve, no lift Richtungsventil, nicht heben
22 Directional control valve, no lowering Richtungsventil, nicht senken
23 Directional control valve, 4 section Richtungsventil, 4 Sektion
24 Directional control valve, aggregate Richtungsventil Aggregat
25 Pilot control valve Servoventil
26 Directional control valve, no tilt fwd. Richtungsventil, nicht neigen, vorwärts
27 Pilot control valve, quick lift Servoventil, schnell heben
28 Supply unit Versorgungseinheit
29 Nonreturn valve, steering Rückschlagventil, Steuerung
30 Flow divider valve Mengenteilerventil
31 Three way valve Dreiwegeventil

105996:GB/DE
Page 1 (4)
LIST NO. 105996

32 Side shift cylinder Seitenscheiberzylinder

33 Shuttle valve Wechselventil
34 Directional control valve load gauge Richtungsventil welle
120 Weight indicator Gewichtsanzeiger
121 Flow control valve, accumulator Strömungsventil, Akkumulator
122 Throttling non return valve, side shift Drossel Rückschlagventil, seitenschub
123 Non return valve, side shift Rückschlagventil, seitenschub
124 Block Block
125 Pressure control valve Druckkontrolventil
126 Throttle valve Drosselventil
127 Selector valve Wahlventil

Wet Brakes, Cooling system Ölgekühlte Bremse, Ölkühlungsystem

(Pos. 35-41) (Pos. 35-41)

35 Tank brake cooling system Tank Bremskühlung

36 Air cleaner Luftfilter
37 Hydraulic pump brake system Bremshydraulikpumpe
38 Pressure relief valve Druckreglerungsventil
39 Oil cooler Ölkühler
40 Restriction Drosselung
41 Brake discs drive shaft Bremslamellen Antriebswelle

Wet Brakes, operating system Ölgekühlte Bremse Betriebsystem

(Pos. 42-55) (Pos. 42-55)

42 Pressure control valve, charging Druckbegrenzerventil Ladung

43 Pressure control valve Druckbegrenzerventil

44 Nonreturn valve Rückschlagklappe

45 Drain valve Ablassventil

46 Low pressure switch, indicator lamp Unterdruckschalter, Kontrollampe

47 Pressure switch, charging Druckschalter, Ladung

48 Accumulator Akkumulator

49 Direct. cont. Valve, parking brake Richtungsventil, Festellbremse

50 Pressure switch, indicator lamp parking brake Druckschalter, Kontrollampe, Festellbremse

51 Parking brake Festellbremse

52 Quickloading valve Schnellade Ventil

105996:GB/DE
Page 2 (4)
LIST NO. 105996

53 Brake cylinders, drive shaft Bremszylinder, Antriebswelle

54 Brake pedal valve Bremspedal
55 Stop light switch Stopplichtschalter
56 Sequence valve Stufenventil
57 Adjustable. pressure valve Einstellbares Druckventil
58 Caliper, steering wheel Bremssattel, Lenkrad
59 Proportional steering valve Proportional Steuerventil
60 Hydraulic steering pump Hydraulikpumpe, Steuerung
61 Directional control valve, 1 section Richtungsventil, 1 Sektion
62 Directional control, 5 section Richtungsventil, 5 Sektion
63 Seated control valve twistlock Sitztkontrollventil, Twistlock
64 Tilting control valve Neigungs Kontrollventil
65 Extension cylinder Ein / Ausfahren Zylinder
66 Pilot operated check valve, twistlock Vorsteuerventil, Twistlock
67 Twistlock cylinder Twistlockzylinder
68 Forkleveling cylinder Niveauausgleich Zylinder
69 Single cylinder Einzelzylinder

TMF TMF
(Pos. 70-109) (Pos. 70-109)

70 Return line filter Rücklauffilter

71 Pressure relief valve, oil return pipe Druckreglerungsventil, Ölrückführung
72 Telescope cylinder Teleskop Zylinder
73 Directional control valve, 3 section Richtungsventil, 3 Sektion
74 Pilot control valves, main control Versteuerventil, Hauptventil
75 Swivel Drehwerk
76 Grapple cylinder Greiferzylinder
77 Restrictor check valve, damping cylinder Strömungsventil, Dämpfungzylinder
78 Pressure control valve, damping cylinder Druckkontrollventil, Dämpfungzylinder
79 Venturi, damping cylinder Drossel, Dämpfungzylinder
80 damping cylinder Dämpfungzylinder
81 Tilt cylinder, grapple Neigungzylinder, Greifer
82 Pressure limiter, tilt Druckbegrenzer, Neigungzylinder
83 Pressure relief / subsequent filling valve Druckbegrenzung / Nachfüllungventil
84 Sector valve Sektionsventil

105996:GB/DE
Page 3 (4)
LIST NO. 105996

85 Flow control valve, tilt Strömungsregelventil, Neigung

86 Flow control valve, rotary unit Strömungsventil, Dreheinheit
87 Pressure control valve, rotary unit Druckkontrollventil, Dreheinheit
88 Rotary motor Drehmotor
89 Pressure relief valve, log pusher Druckreglerungsventil, Stammschieber
90 Log pusher cylinder Stammschieberzylinder
91 Back pressure valve, log pusher Gegendruckventil, Stammschieber
92 Deactivating valve, lift Abshcaltventilventil, Hub
93 Pressure switch, deactivating valve Druckschalter, Abschaltventil
94 Hydraulic filter, pilot line Servofilter
95 Charging valve accumulator Ladungsventil Akkumulator
96 Pressure unloading valve Druckentlastungsventil
97 Locking reverseable heat Arretierung drehbaren Fahrersitz
98 Flow control valve Strömungsventil
99 Distribution block, reversable seat Distributionblock, drehbaren Fahrersitz
100 Hydrailc pump, fan Hydraulikpumpe, Kühllüfter
101 Restriction Drosselung
102 Termostat valve Thermostatventil
103 Cut-off valve Absperrventil
104 Non return valve, fan Rückschlagventil, Kühlluftfilter
105 Fan motor Lüfter Motor
106 Test nipple Testnippel
107 Directional control valve, fan reverse Richtungsventil, Lüfterumkerung
108 Pressure relief valve, fan Druckreglerungsventil, Lüfter
109 Servofilter Servofilter

Airhydraulic Brakes Lufthydraulische Bremsen

(Pos. 110-119) (Pos. 110-119)

110 Master cylinder (air to oil) Hauptzylinder (Luft zu Öl)

120 Weight indicator Gewichtindikator

121 Flow control valve, accumulator Strömungsventil, Akkumulator

122 Pressure limit valve, grapple Druckbegrenzungsventil, Greifer

105996:GB/DE
Page 4 (4)
 DOCUMENT NO.:

107877:GB
CREATED EDITION DATE PAGE
EH LIST NB 13 010330 1/ (2)

EH1 Gearbox solenoids EH2 Pressure switch, brake pressure charging

EH3 Charging valve EH4 Low-pressure switch/sensor, brakes

EH5 Parking brake sensor, standard EH5A See EH5

EH5B See EH5 EH5C Parking brake sensor, hydraulic control

EH5D Parking brake sensor, warning system override EH6 Parking brake solenoid

EH7 Magnetic valve, lever operation EH8 Solenoid, lift blocking

EH9 Pressure switch, lift blocking EH10 Cut-off valve, hydrostatic fan reversal

EH11 Magnetic valve, hydrostatic fan reversal EH12 Solenoid, roller buffer down

EH13 Solenoid, roller buffer up EH14 Solenoid, clockwise rotation

EH15 Solenoid, counter-clockwise rotation EH16 Solenoid, tilt out (grapple, mast)

EH17 Solenoid, tilt in (grapple, mast) EH18 Solenoid, telescope extension

EH19 Solenoid, telescope retraction EH20 Solenoid, lifting

EH21 Solenoid, lowering EH22 Solenoid, open grapple

EH23 Solenoid, close grapple EH24 Brake light switch

EH25 Solenoid, scale EH26 Solenoid, 2-speed lifting (fast lifting)

EH27 Brake light switch solenoid, lifting system EH28 Lowering blocking valve, spreader
accumulator

EH29 Lifting lock valve, spreader EH30 Sensor, lowering blocking

EH31 Solenoid, side shift left EH32 Solenoid, side shift right

EH33 Solenoid, fork spreading out (open clamping arm) EH34 Solenoid, fork spreading in (close clamping arm)

EH35 Solenoid, extra EH36 Solenoid, levelling down

EH37 Solenoid, levelling up EH38 Solenoid, spreader lock piston

EH39 Solenoid, charging valve EH40 Pressure switch, pre-charging pressure (hydraulic
brakes)

EH41 Relief valve, 2-speed lifting (fast lifting) EH42 Solenoid, differential gear

EH43 Solenoid, sander EH44 Selector valve

EH45 Solenoid, servo pressure accumulator EH46 Tilt blocking valve

EH47 Lifting sensor, tilt blocking EH48 Pressure switch, load warning

EH49 Relief valve, see hydraulic diagram 108235 EH50 Load pressure switch (pump control)

EH51 Servo pressure switch EH52 See hydraulic diagram 110451

EH53 Electrohydraulic steering left EH54 Electrohydraulic steering right

EH55 Solenoid, log pusher out/side-flip out EH56 Solenoid, log pusher in/side-flip in

EH57 Pressure switch, emergency steering pump EH58 Solenoid, optional spreader (lock)
 DOCUMENT NO.:

107877:GB
CREATED EDITION DATE PAGE
EH LIST NB 13 010330 2/ (2)

EH59 Solenoid, optional spreader (unlock) EH60 Solenoid, right fork spreading

EH61 Solenoid, left fork spreading EH62 Equalizing solenoid

EH63 Pressure switch/sensor, inching EH64 Pressure switch, load pressure

EH65 Pressure switch, Orbitrol EH66 Solenoid, left clamp open

EH67 Solenoid, left clamp close EH68 Solenoid, right clamp open

EH69 Solenoid, right clamp close EH70 Solenoid, retardation braking

EH71 Temperature sensor, hydraulic oil tank EH72 Temperature sensor, transmission converter

EH73 Temperature sensor, hydraulic oil servo EH74 Pressure switch, transmission

EH75 Pressure switch, tilt EH76 Pressure switch, lifting servo

EH77 Brake oil temperature sensor EH78 Pressure switch, braking deceleration

EH79 Pressure switch, hydrostatic fan EH80 Drain valve, fan reversal

EH81 Solenoid, cab tilt up EH82 Solenoid, cab tilt down

EH83 Solenoid, roller buffer hitch EH84 Pressure switch, large controller

EH85 Pressure switch, small controller EH86 Cab tilt up

EH87 Cab tilt down EH88 Solenoid, lifting (small)

EH89 Hydrostatic fan EH90 Solenoid, servo pressure accumulator (extra)

EH 91 Solenoid, release of the parking brake EH 92

INSTRUCTION MANUAL

Cooling oil tank - hydraulic brakes

Check the brakes cooling oil level and the breather every 10th hour of operation or every day. The tank is placed on
the right side of the forklift. You can check the oil level on the level indicator, that is placed on the side of the tank.
There is a breather and an oil refiller tube on the top of the tank. See figure 133.

Breather

Filling plug

Level indicator

Figure 133

Cooling oil level check

Check the oil level when the oil is cold. The oil level shall reach up to at least half the level indicator, but never
above the max level.

Breather
The filter must be replaced every 1000 hour of operation or every 5th month.

» Clean the lower edge of the old filter, so that dirt particles don’t fall down in the tank.

» Remove the filter and discard it.

» Replace the old filter with a new one.

Edition 6 KM-149:GB
Page 1 (2)
6
INSTRUCTION MANUAL

Oil
You must change oil every 4000 hour of operation or every second year. Refer to Maintenance chart under Group
14 in the Instruction Manual, to get the right oil quality.

WARNING!
Hot oil in contact with the skin could cause burns.

» Place a vessel under the bottom plug.

» Unscrew the bottom plug and empty the tank.

» Check that the seal is not worn and then fasten the plug.

» Fill the tank to the right level.

» Start the engine and let it run at an idle speed.

» Check the level and fill with more if necessary.

Tank volumes

Svetruck Volume (liters) Volume (US gallon)

32120-50120
TMF 12/9 184 48.6
TMF 15/11

50120-52120
225 59.4
(Wheelbase 6000)

TMF 25/18
300 79.3
(Wheelbase 5700)

TMF 25/18
TMF 28/21 365 96.4
(Wheelbase 6000)

Edition 6 KM-149:GB
Page 2 (2)
6
ADDITION

Charging the piston accumulator

with the CGH-3000 charger
» Connect the hexagonal fitting (A) to the nitrogen (N2 ) bottle. See Figure 560.

» Disassemble the protective clamp and screw on the swivel nut (B) by hand until the gas can no longer escape.
Then screw the upper hexagon on the accumulator’s gas valve anti-clockwise as far as it will go (the gas can
pass freely through the valve). Some small piston accumulators have a gas valve without a hexagon, but with a
spring-loaded seat valve instead. Screw the pin (C) clockwise to achieve free passage through the gas valve.

» Open the nitrogen bottle’s valve carefully, so that the piston slowly sinks to the bottom of the accumulator.
Check this before the accumulator is filled to the desired charging pressure (P0 ).

» Close the nitrogen bottle’s valve. Wait for 5 minutes. Check the pressure. If the pressure is too high, release gas
out through the ventilating valve (D).

» NOTE! Remember that the pressure in the accumulator drops when the compressed gas cools down. Charge to
approximately 20% above the required pressure.

» Screw the upper hexagon on the gas valve clockwise as far as it will go, and the pin (C) anti-clockwise as far as
it will go. Unscrew the swivel nut. Check for leakage in the valve or the sealing surface against the accumulator
lid (using leak detector spray or soap water).

» Install the protective cover and the protective clamp.

» Remove the hexagonal fitting (A) from the nitrogen bottle.

C
D

B Figure 560
Charger.

Issue 1 KM-333:GB
Instruction manual
SE
Piston
NO accumulators
2

GB 3

SE 9

DK 15

NO 21

FI 27

DE 33

FR 39

CE approved as per PED 2014/68/EU
PL 45
© Copyright PMC CYLINDERS AB 2013
All rights reserved. Reproduction, including extracts,
only by consent of PMC CYLINDERS. PMC CYLINDERS
reserves the right to change constructions and other
data in this manual without prior notification.
Manual issue 20-10-2016. Rev. 5.
1
2
1. Introduction
PMC Cylinder’s piston accumulators in
the PAC and PAS series are CE-marked
and approved for use within the EU and
have been checked in accordance with
the procedures in modules B (prod. type)
and D, according to the EU-directive
2014/68/EU on pressure equipment.
Read the instruction book carefully
prior to use. Take particular note of
warning texts before using the piston
accumulator. Incorrect use can involve
the risk of injury and accidents, possibly
fatal.
N.B.
The user is wholly responsible for
ensuring that applicable regulations are
adhered to, and only personnel with the
necessary training are allowed to work,
install and maintain the piston
accumulator.
The regulations for the commissioning
and use of the piston accumulator that
are applicable at the installation site must
be observed.
The manual can be downloaded from
www.pmccylinders.se.
Store the manual for easy access when
required.
2. Delivery
Warning
Piston accumulators that have been
damaged during transport must not be
used.
All transport of gas-filled piston
accumulators must be performed with
the greatest possible care, and all
applicable transport regulations for gas-
filled products must be complied with.
Only approved lifting equipment may be
used for transport and handling.
The piston accumulator is delivered
GB
either:
 Pre-charged with nitrogen gas (N₂) at
a pressure of max 2 bar in order to
prevent corrosion and to prevent the
piston from moving during transport.
This is not counted as pre-charged
and is not specified on the piston
accumulator’s label.
 Pre-charged with nitrogen (N₂) at a
pressure specified by the customer.
This pressure is declared on the label
on the piston accumulator.
3
2.1 Marking
Marking is information that is stamped
onto the piston accumulator, and labels.
The user is responsible for controlling
that all marking on the piston
accumulator is intact and completely
legible. It is strictly prohibited to alter
or remove marking, and damaged
marking must always be replaced.
Contact the supplier.
The sticker on the piston accumulator
usually specifies the pre-charged
pressure but it is not always filled in as it
may have been pre-charged after
delivery by the manufacturer.
2.2 Reception control
 Always check that a delivery
corresponds with the order.
 Check any damage to the packaging if
there is a risk that the piston
accumulator has been damaged.
 Check any damage to the surface.
 Check any other damage to the piston
accumulator and accessories.
 Check that the declaration of
conformity corresponds with the
marking on the piston accumulator.
4
2.3 Handling
Warning
Always use suitable protective
equipment when handling heavy
piston accumulators.
Be careful not to damage the piston
accumulator (surface, accessories etc) in
any way.
To erect large piston accumulators, use
suitable lifting equipment and lifting
straps. Ensure that the piston
accumulator is balanced.
End caps on large piston accumulators
have threaded holes for lifting eyes for
use when erecting.
2.4 Storage
The piston accumulator is in preserved
form on delivery (greased, plugged and
filled with nitrogen). It can be stored for
up to two years in a dry, cool place out of
direct sunlight.
If the piston accumulator is stored for
more than two years, all seals must be
changed before being taken into
operation.
If the piston accumulator is stored for
more than three months and is pre-
charged to >5 bar, the pressure must be
reduced to a maximum of 5 bar.
Pre-charged piston accumulators must
be stored in a safe place, protected from
collision and fire, which can cause
explosions.
3. Installation
Warning
No welding, riveting or soldering work
or mechanical work may be performed
on the piston accumulator, to avoid the
risk of explosion.
Warning
Be extra careful when installing
equipment on the gas side of the piston
accumulator. The piston accumulator
may be pre-charged.
Different regulations can apply to the use
and installation of the piston accumulator
in different countries. Before installation
and use, find out which national
regulations are applicable in the country
in which the piston accumulator is to be
used.
The piston accumulator can be installed
in any position. To reduce the risk of
wear and tear, installation in a vertical
position is recommended, with the fluid
port downwards.
The following are strictly prohibited:
 To weld, rivet or solder components
onto the piston accumulator.
 To perform any measure that can
affect the accumulator’s mechanical
properties.
 To alter the accumulator without the
consent of PMC Cylinders.
Ensure that the fluid is suitable for the
equipment.
Ensure that the highest permissible
pressure of the piston accumulator is the
same or higher than that of the hydraulic
circuit.
Check the environmental conditions and
protect the equipment as required.
Ensure that there is a space of approx.
200 mm above the gas valve to allow the
pre-charging and control equipment to be
mounted.
All markings must remain visible.
When piston position indicator is used, it
must always be properly secured and
mounted vertically with the fluid port
downwards.
The PMC Cylinders has an accessory
range of clamps and brackets for
securing the piston accumulator during GB
installation. (See separate data sheet.)
In the case of small piston accumulators
up to approx. 10 kg, securing with two
clamps is recommended. In the case of
heavier units, the number of clamps
depends on the size and type of piston
accumulator, and use of a supporting
bracket is recommended, to relieve the
weight.
Use suitable connections that are
intended for hydraulic systems and
ensure that the correct tightening torque
is used.
3.1 Safety equipment
We recommend installation of safety
equipment on the fluid side and the gas
side, to limit the pressure in the piston
accumulator.
We recommend a burst disc or spring-
loaded relief valve on the gas side. Both
of these open at a pre-set pressure
irrespective of the reason for the high
pressure.
We recommend use of a safety block
with a safety/pressure-reducing valve on
the fluid side.
5
3.2 Pre-charging
Warning
The piston accumulator must only be
filled with nitrogen gas (N₂). Risk of
explosion if oxygen or air is used.
Check that the pre-charging pressure of
the gas is correct for the unit.
The quality of the nitrogen gas is
important for the unit’s performance and
length of life. Industrial quality is
sufficient. Use nitrogen gas with a
minimum purity value of 99.95% (class
4.0 or better).
3.3 Gas valve
Opens and closes when the pre-charging
equipment’s connection thread is being
assembled or dismantled. The hollow pin
in the nozzle of the pre-charging
equipment opens the valve. The valve is
otherwise shut.
N.B.
If the gas valve has a hex operating
nut, use torque 6-7 Nm to close it.
6-7 Nm
Use the pre-charging equipment to drain
or fill the nitrogen gas.
6
4. Start-up
If air needs to be vented from the piston
accumulator prior to use, this must be
done at the oil-side connection.
Before the accumulator is used, it must
be correctly pressurized, with the
pressure being calculated in accordance
with the device’s operational data.
The permitted working pressure and
working temperature depend on the
materials used in the accumulator and
are specified in the marking on the
product.
The accumulator must be assembled in
such a way that safety can be
guaranteed in the event of vibrations or
possible breaks in connecting pipes etc.
Before pressurizing, check:
 that the piston accumulator has been
correctly installed;
 that equipment such as gas valves,
bursting discs and pipe connections
have been properly tightened and
that all components have been
correctly threaded;
 that there is no leakage after
pressurizing. If leaking has occurred,
tighten the connection in question. If
the product still leaks, contact PMC
Cylinders.
 that attachments do not put strain on
the accumulator.
5. Maintenance
5.1 General maintenance
To ensure long, problem-free usage, the
following maintenance measures should
be performed regularly.
Check:
 the pre-charging pressure of the
nitrogen gas regularly during the first
weeks of usage, and thereafter at
appropriate intervals (see item 5.2).
When filling with nitrogen gas, ensure
it is sufficiently clean;
 that connections have been tightened
and are free of leakage;
 the performance of the safety and stop
blocks;
 the mounting brackets;
 the accumulator ocularly at regular
intervals to look for any damage due
to corrosion, or any other deformation.
External corrosion must be dealt with
immediately and is not permissible.
Minor external corrosion is repaired by
painting;
 that the marking on the accumulator is
legible. If the accumulator is worn,
contact the supplier.
5.2 Frequency of checks
We recommend the following intervals
between testing of the pre-charged
pressure:
 directly after installation
 one week after installation
 six weeks after installation
Thereafter, in the case of normal
operations, once every six months and,
in the case of high working temperatures,
once a month.
5.3 Leakage
Leakage can occur if the fluid leaks over
GB
to the gas side or the gas leaks over to
the fluid side. Gas pressure that is too
low can be an indication of an external or
an internal gas leakage.
Internal leakage
Gas pressure that is too high can be an
indication that fluid is leaking to the gas
side. Gas pressure that is too low can be
an indication that gas is leaking over to
the fluid side.
Internal leakage can be caused by:
 the piston seal being worn or
damaged
 the cylinder’s inner surface being
damaged
Worn and damaged seals should be
replaced with original seals and
damaged cylinders must be inspected by
skilled, authorized personnel in order to
judge whether the damage can be
repaired or whether the cylinder must be
replaced (see item 7. Service).
7
External leakage
Gas pressure that is too low can be an
indication of external leakage. Fluid can
leak out from the fluid side or gas from
the gas side.
External leakage can be caused by:
 the end-cap seal being worn or
damaged.
7. Service
Warning
The user is wholly responsible for
ensuring that applicable regulations
are adhered to, and only personnel
with the necessary training are allowed
to perform service work on the piston
accumulator.

 the seal surface in the thread of the

seal being damaged. Warning
Be extra careful when dismantling and
 the cylinder being damaged at the
assembling equipment on the gas side
seal.
of the piston accumulator. The piston
accumulator must be depressurized!
 the valve not being sufficiently
tightened or being damaged.

Worn and damaged seals should be Warning

replaced with original seals and
damaged end-cap or accumulator pipe
must be inspected by skilled, authorized
personnel in order to judge whether the
damage can be repaired or whether
replacements are needed. If the valve is
damaged, replace the gas valve. For
safe dismantling, see item 7. Service.
The oil can retain heat for a while after
switching off.
Never drain the gas side by opening the
gas valve or other connections. The gas
valve or other parts can shoot out.

Rapid release of gas can involve a

6. Length of life
suffocation risk. Ensure that there is
good ventilation.
The life of the piston accumulator is
limited. The length of life depends on
If information regarding dismantling and
pressure amplitude and number of
repairs is required, contact PMC
pressure cycles.
Cylinders.
Use only PMC Cylinders’ original
The permitted number of load switches is
components.
specified in the conformity
documentation. These data are required
Service, checks and repairs can be
in order to decide the length of life of the
performed at PMC Cylinders’ factory in
accumulator. The lifetime is dependent
Vaggeryd.
on the working conditions in the hydraulic
system.

8
1. Introduktion
PMC Cylinders kolvackumulatorer i serie
PAC och PAS är CE-märkta och
godkända för användning inom EU och
genomgått kontroll enligt procedurerna i
modulerna B (prod. type) och D, i
enlighet med EU-direktivet 2014/68/EU
avseende tryckutrustning.
Läs igenom instruktionsboken
noggrant innan användning.
Observera särskilt varningstexter före
användning av kolvackumulatorn.
Felaktig användning kan innebära stor
risk för olyckor och personskada eller
möjligen dödsfall.
OBS!
Användaren bär hela ansvaret för att
säkerställa att gällande föreskrifter följs
och endast personal med erforderlig
utbildning tillåts arbeta, installera och
underhålla kolvackumulatorn.
De föreskrifter för drifttagning och
användning av kolvackumulatorn som
gäller på installationsplatsen måste
beaktas.
Instruktionsbok kan laddas ner från
www.pmccylinders.se.
Förvara manualen så att den finns till
hands vid behov.
2. Leverans
Varning
Kolvackumulatorer som skadats under
transport får inte användas.
All transport av gasfylld kolvackumulator
måste utföras med största möjliga
försiktighet och följa alla gällande
transportföreskrifter för gasfyllda
produkter.
Endast godkänd lyftutrustning får
användas för transport och hantering.
Kolvackumulatorn levereras antingen:
 Förladdad med kvävgas (N₂) vid
leverans till ett tryck av max 2 bar för
att förhindra korrosion och att
förhindra att kolven rör sig på oönskat
sätt under förflyttning. Detta räknas SE
inte som förladdat och anges inte på
kolvackumulatorns dekal.
 Förladdad med kvävgas (N₂) till det
tryck som anges av kunden. Detta
tryck står på dekalen som finns på
kolvackumulatorn.
2.1 Märkning
Märkning består av stämplad information
på kolvackumulatorn samt dekal.
Användaren är ansvarig för att
kontrollera att all märkning på kolv-
ackumulatorn är intakt och fullt läsbar.
Det är strängt förbjudet att ändra eller
avlägsna märkning och skadad märkning
måste alltid ersättas. Kontakta
leverantören.
Kolvackumulatorns märkdekal ange
normalt förladdningstrycket men är inte
alltid ifyllt då förladdningen kan ha utförts
efter leverans från tillverkaren.
9
2.2 Mottagningskontroll 2.4 Förvaring

 Kontrollera alltid att order och leverans Kolvackumulatorn levereras konserverad

överensstämmer.
 Kontrollera eventuella skador på
emballage där det finns risk för att
kolvackumulatorn har tagit skada.
 Kontrollera eventuella skador på
lackering.
(insmord, pluggad och kvävgasfylld).
Den kan förvaras i upp till två år om det
sker på en torr, sval plats och skyddad
mot direkt solljus.
Om kolvackumulatorn lagras längre än
två år måste alla tätningar bytas ut före
drifttagande.

 Kontrollera eventuella övriga skador Om kolvackumulatorn lagras mer än tre

på kolvackumulatorn och tillbehör.
 Kontrollera att överensstämmelse-
deklaration överensstämmer med
kolvackumulatorns märkning.
2.3 Hantering
månader och är förladdade över 5 bar
måste trycket reduceras till som högst 5
bar.
Förladdad kolvackumulator måste
förvaras på en säker lagerplats skyddad
mot påkörning och brand som kan
orsaka explosion.

Varning
Använd alltid lämplig skyddsutrustning
vid hantering av tunga kolv-
ackumulatorer.

Var försiktig så att kolvackumulatorn

(lackering, tillbehör m m) inte skadas i
något avseende.

För att resa större kolvackumulatorer

använd lämplig lyftanordning och
lyftstroppar eller liknande. Se till att
kolvackumulatorerna är balanserade.

Ändlock på större kolvackumulatorer är

försedda med gängade hål avsedda för
lyftöglor för användning vid resning.

10
3. Installation
Varning
Inget svetsnings-, nitnings- eller
lödningsarbete eller mekaniskt arbete
får utföras på kolvackumulatorn då
explosionsrisk föreligger.
Varning
Var extra försiktig vid montering av
utrustning på kolvackumulatorns
gassida. Kolvackumulatorn kan vara
förladdad.
Installationen och kolvackumulatorns
användning kan regleras av olika
föreskrifter i olika länder. Ta därför reda
på före installation och användning vilka
nationella regler som gäller för det land
som kolvackumulatorn ska användas i.
Kolvackumulatorn kan monteras i vilket
läge som helst. För att minska risken för
slitage rekommenderas vertikal
montering med vätskeanslutningen
nedåt.
Följande är strängt förbjudet:
 Att svetsa, nita eller löda fast några
komponenter vid kolvackumulatorn.
 Att utföra någon åtgärd som kan
påverka kolvackumulatorns
mekaniska egenskaper.
 Att ändra kolvackumulatorn utan
godkännande av PMC Cylinders.
Kontrollera att vätskan passar
utrustningen.
Kontrollera att kolvackumulatorns högsta
tillåtna tryck är samma eller högre än
hydraulkretsens högsta tillåtna tryck.
Kontrollera miljöförhållandena, och vid
behov skydda utrustningen.
Se till att det finns utrymme på ca 200
mm ovanför gasventilen för att kunna
montera förladdnings- och
kontrollutrustning.
Låt all märkning vara synlig.
När kolvlägesindikering används skall
den alltid vara ordentligt fixerad och
monteras vertikalt med
vätskeanslutningen nedåt.
PMC Cylinders har ett sortiment av
klamrar och konsoler som tillbehör för att
fixera kolvackumulatorn vid installation.
(se separat datablad).
För små kolvackumulatorer upp till ca 10
kg rekommenderas fixeringen med två
klamrar och vid tyngre enheter bestäms
antalet klamrar beroende på storlek och
typ av kolvackumulator samt
rekommenderas att använda stödkonsol
SE
som avlastar dess vikt.
Använd lämpliga anslutningar anpassade
för hydraulsystem och att åtdragning
sker med rätt moment.
3.1 Säkerhetsutrustning
Vi rekommenderar installation av
säkerhetsutrustning på både vätske- och
gassidan som begränsar trycket i kolv-
ackumulatorn.
På gassidan rekommenderas
sprängbleck eller fjäderbelastad
säkerhetsventil. Båda öppnar vid ett
förinställt tryck oavsett orsak till det höga
trycket.
På vätskesidan rekommenderas
användning av säkerhetsblock med
säkerhets- eller tryckreduceringsventil.
11
3.2 Förladdning
Varning
Kolvackumulatorn får endast fyllas med
kvävgas (N₂). Att använda syrgas eller
luft medför explosionsrisk.
Kontrollera att gasens förladdningstryck
är korrekt för enheten.
Kvaliten på kvävgasen är viktig för dess
funktion och livslängd, industrikvalitet är
tillräcklig, Använd kvävgas med ett lägsta
renhetsvärde på 99,95 % (klass 4.0 eller
bättre).
3.3 Gasventil
Öppnas och stängs i samband med att
förladdningsutrustningens anslutnings-
gänga monteras respektive demonteras.
Den ihåliga tappen i förladdnings-
utrustningens munstycke öppnar
ventilen. I övrigt är ventilen stängd.
OBS
Om gasventilen har en mutter, stäng
med moment 6-7 Nm.
6-7 Nm
Använd förladdningsutrustningen för att
dränera eller fylla kvävgas.
12
4. Drifttagning
Om kolvackumulatorn behöver avluftas
innan användning skall avluftning ske på
oljesidans anslutning.
Kolvackumulatorn måste fyllas till önskat
tryck beräknat efter anläggningens
driftdata innan kolvackumulatorn tas i
bruk.
Det tillåtna arbetstrycket och arbets-
temperaturen beror på vilka material
som använts i kolvackumulatorn och
framgår av märkningen på produkten.
Kolvackumulatorn ska monteras så att
säkerheten kan garanteras i händelse av
vibrationer eller eventuella brott i
anslutna ledningar.
Kontrollera före trycksättning att:
 Kolvackumulatorn är korrekt
installerad.
 All utrustning såsom gasventil,
sprängbleck samt röranslutningar är
ordentligt åtdragna och att inga
komponenter dragits snett.
 Efter trycksättning kontrollera så inget
läckage förekommer. Vid läckage dra
åt aktuell anslutning. Om produkten
inte blir tät kontakta PMC Cylinders.
 Fästanordningar inte utövar någon
belastning på kolvackumulatorn.
5. Underhåll
5.1 Råd för det allmänna
underhållet
För att säkerställa lång och problemfri
användning bör följande underhålls-
åtgärder genomföras regelbundet.
Kontrollera:
 kvävgasens förladdningstryck
regelbundet under de första veckornas
användning, och därefter med
lämpliga intervaller (se 5.2). Vid
påfyllning av kvävgas säkerställ att
den har tillräcklig renhet
 att anslutningar är åtdragna och
läckagefria
 säkerhets- och avstängningsblockens
funktion
 fästelementen
 kolvackumulatorn okulärt med jämna
mellanrum för att upptäcka eventuella
skador p g a korrosion eller annan
deformation. Utvändig korrosion
måste åtgärdas omgående och tillåts
ej. Mindre ytlig korrosion åtgärdas
genom ommålning.
 märkning på kolvackumulatorn så att
den är läsbar. Vid slitage, kontakta
leverantören.
5.2 Kontrollfrekvens
Vi rekommenderar följande
kontrollintervaller för test av
förladdningstrycket:
 Direkt efter installationen
 En vecka efter installationen
 Sex veckor efter installationen
Därefter kontroll vid normal drift en gång
per halvår och vid intensiv drift och vid
höga arbetstemperaturer varje månad.
5.3 Läckage
Läckage kan uppstå om vätskan läcker
över till gassidan eller att gasen läcker
över till vätskesidan. För lågt gastryck
kan tyda på externt eller internt gas-
läckage.
Internt läckage
För högt gastryck kan tyda på att vätska
läcker till gassidan. För lågt gastryck kan
tyda på att gas läcker över till vätske-
sidan.
Interna läckaget kan bero på att:
 Kolvtätningen är sliten eller skadad
 Cylinderrörets inre yta är skadad
Slitna och skadade tätningar byts till
originaltätningar och skadat cylinderrör SE
ska besiktigas av kunnig och behörig
personal för att bedöma om skadan kan
repareras eller måste bytas ut (se pkt 7.
Service).
Externt läckage
För lågt gastryck kan tyda på externt
läckage. Vätska kan läcka ut vid vätske-
sidan eller gas vid gassidan.
Externt gasläckage kan bero på att:
 Tätningen på ändlocket är sliten eller
skadad.
 Tätningsytan i spåret för tätningen kan
vara skadat.
 Cylinderröret vid tätningsläget kan
vara skadat.
 Ventilen är ej åtdragen eller skadad.
Slitna och skadade tätningar byts till
originaltätningar och skadat ändlock eller
ackumulatorrör ska besiktigas av kunnig
och behörig personal för att bedöma om
skadan kan repareras eller måste bytas
ut. Om ventilen är skadad byt gas-
ventilen. För säker demontering se pkt 7.
Service.
13
6. Livslängd 7. Service

Kolvackumulatorn har en begränsad

livslängd. Livslängden är beroende av
tryckamplitud och antalet tryckcykler.
I överensstämmelsedokumentationen
anges tillåtet antal lastväxlingar. Dessa
data behövs för att bestämma kolv-
ackumulatorns livslängd som är
beroende av arbetsbetingelserna i
hydraulsystemet.
Varning
Användaren bär hela ansvaret för att
säkerställa att gällande föreskrifter
följs och endast personal med
erforderlig utbildning tillåts utföra
service på kolvackumulatorn.

Varning
Var extra försiktig vid demontering
och montering av utrustning på kolv-
ackumulatorns gassida.
Kolvackumulatorn måste vara trycklös!

Varning
Oljan kan vara varm en tid efter
avstängning.

Dränera aldrig gassidan genom att lossa

på gasventilen eller andra anslutningar.
Gasventil eller annan utrustning kan
skjutas ut.

Snabb tömning av gas kan leda till

kvävningsrisk. Säkerställ god ventilation.

Vid behov av information om

demontering och reparation kontakta
PMC Cylinders.

Använd endast PMC Cylinders

originalkomponenter.

Service, kontroller och reparationer kan

utföras på PMC Cylinders fabrik i
Vaggeryd.

14
1. Introduktion
PMC Cylinders stempelakkumulatorer i
serie PAC og PAS er CE-mærkede og
godkendt til brug i EU og har
gennemgået kontrol iht. procedurerne i
modul B (prod. type) og D i EU-direktiv
2014/68/EU vedrørende trykbærende
udstyr.
Læs instruktionsbogen omhyggeligt
igennem før brugen. Vær særligt
opmærksom på advarselstekster før
anvendelse af stempelakkumulatoren.
Fejlagtig anvendelse kan indebære store
risici for ulykker og personskader eller
eventuelt dødsfald.
OBS!
Brugeren har det fulde ansvar for at
sikre, at gældende forskrifter følges, og
kun personale med den nødvendige
uddannelse har tilladelse til at arbejde
med, installere og vedligeholde
stempelakkumulatoren.
De forskrifter for ibrugtagning og
anvendelse af stempelakkumulatoren,
som gælder på installationsstedet, skal
respekteres.
Instruktionsbog kan downloades på
www.pmccylinders.se.
Opbevar manualen, så den er
tilgængelig ved behov.
2. Levering
Advarsel
Stempelakkumulatorer, som er blevet
beskadiget under transport, må ikke
anvendes.
Al transport af gasfyldte
stempelakkumulatorer skal udføres med
størst mulige forsigtighed og overholde
alle gældende transportforskrifter for
gasfyldte produkter.
Kun godkendt løfteudstyr må anvendes
til transport og håndtering.
Stempelakkumulatoren leveres enten:
 Forladet med kvælstofgas (N₂) ved
levering til et tryk af maks. 2 bar for at
forebygge korrosion og forhindre, at
stemplet bevæger sig på en uønsket
måde under transporten. Dette regnes
ikke som egentlig forladning og DK
angives ikke på stempel-
akkumulatorens overføringsmærkat.
 Forladet med kvælstofgas (N₂) til det
tryk, som er angivet af kunden. Dette
tryk er angivet på stempel-
akkumulatorens overføringsmærkat.
15
2.1 Mærkning
Mærkning består af stemplet information
på stempelakkumulatoren samt
overføringsmærkat.
Brugeren er ansvarlig for at kontrollere,
at al mærkning på stempel-
akkumulatoren er intakt og fuldt læselig.
Det er strengt forbudt at ændre eller
fjerne mærkning, og beskadiget
mærkning skal altid udskiftes. Kontakt
leverandøren.
Stempelakkumulatorens overførings-
mærkat angiver normalt forladnings-
trykket, men er ikke altid udfyldt,
eftersom forladningen kan være udført
efter levering fra producenten.
2.2 Modtagelseskontrol
 Tjek altid, at ordre og leverance
stemmer overens.
 Tjek eventuelle skader på emballage,
hvor der er risiko for, at stempel-
akkumulatoren har taget skade.
 Tjek eventuelle skader på lakering.
 Tjek eventuelle øvrige skader på
stempelakkumulator og tilbehør.
 Tjek at overensstemmelseser-
klæringen svarer til stempel-
akkumulatorens mærkning.
16
2.3 Håndtering
Advarsel
Brug altid egnet beskyttelsesudstyr
ved håndtering af tunge stempel-
akkumulatorer.
Vær forsigtig, så stempelakkumulatoren
(lakering, tilbehør mv.) ikke på nogen
måde bliver beskadiget.
Til at rejse større stempelakkumulatorer
anvendes passende løftegrej og
løftestropper eller lignende. Sørg for at
stempelakkumulatorerne er
afbalancerede.
Endelåg på større stempelakkumulatorer
er forsynede med gevindhuller beregnet
til løfteøjer til brug ved rejsning.
2.4 Opbevaring
Stempelakkumulatoren leveres
konserveret (indsmurt, tilproppet og fyldt
med kvælstofgas). Den kan opbevares i
op til to år, hvis det sker et tørt, køligt
sted beskyttet mod direkte sollys.
Hvis stempelakkumulatoren opbevares
længere end to år, skal alle pakninger
udskiftes, før den tages i brug.
Hvis stempelakkumulatoren opbevares
mere end tre måneder og er forladet til et
tryk over 5 bar, skal trykket reduceres til
maksimalt 5 bar.
En forladet stempelakkumulator skal
opbevares et sikkert sted beskyttet mod
påkørsel og brand, som kan forårsage
eksplosion.
3. Installation
Advarsel
Intet svejse-, nitte- eller loddearbejde
eller mekanisk arbejde må udføres på
stempelakkumulatoren, da der
foreligger eksplosionsrisiko.
Advarsel
Vær ekstra forsigtig ved montage af
udstyr på stempelakkumulatorens
gasside. Stempelakkumulatoren kan
være forladet.
Installationen og stempelakkumulatorens
anvendelse kan være reguleret af
forskellige forskrifter fra land til land. Før
installation og anvendelse skal det derfor
undersøges, hvilke nationale regler der
gælder for det land, som stempel-
akkumulatoren skal anvendes i.
Stempelakkumulatoren kan monteres i
en hvilken som helst stilling. For at
mindske risikoen for slitage, anbefales
vertikal montering med væske-
tilslutningen nedad.
Følgende er strengt forbudt:
 At svejse, nitte eller lodde nogle
komponenter fast på stempel-
akkumulatoren.
 At udføre nogle indgreb, som kan
påvirke stempelakkumulatorens
mekaniske egenskaber.
 At ændre stempelakkumulatoren
uden godkendelse fra PMC
Cylinders.
Tjek at væsken passer til udstyret.
Tjek at stempelakkumulatorens
maksimalt tilladte tryk er det samme som
eller højere end det hydrauliske
kredsløbs tilladte maksimaltryk.
Tjek miljøforholdene, og beskyt om
nødvendigt udstyret.
Sørg for at der er ca. 200 mm frirum over
gasventilen, så der kan monteres
forladnings- og kontroludstyr.
Lad al mærkning være synlig.
Når der anvendes stempelpositions-
indikering skal den altid være ordentligt
fikseret og monteret vertikalt med
væsketilslutningen nedad.
PMC Cylinders har et sortiment af
klemmer og konsoller som tilbehør til
fiksering af stempelakkumulatoren ved
installation
(se særskilt datablad).
Til små stempelakkumulatorer på op til
ca. 10 kg anbefales fiksering med to
klemmer, og ved tungere enheder
fastlægges antallet af klemmer ud fra
stempelakkumulatorens størrelse og
type; derudover anbefales brugen af
støttekonsoller for at aflaste dens vægt. DK
Anvend passende tilslutninger, som er
tilpasset til hydrauliske systemer, og sørg
for at de tilspændes med det korrekte
moment.
3.1 Sikkerhedsudstyr
På både væske- og gassiden anbefaler
vi installation af sikkerhedsudstyr, som
begrænser trykket i stempel-
akkumulatoren.
På gassiden anbefales en brudskive
eller en fjederbelastet sikkerhedsventil.
Begge åbner ved et forindstillet tryk
uanset årsagen til det høje tryk.
På væskesiden anbefales det at
anvende sikkerhedsblok med
sikkerheds- eller trykreduktionsventil.
17
3.2 Forladning
Advarsel
Stempelakkumulatoren må kun fyldes
med kvælstofgas (N₂). Anvendelse af ilt
eller luft medfører eksplosionsrisiko.
Tjek at gassens forladningstryk er korrekt
for enheden.
Kvaliteten på kvælstofgassen er vigtig for
dens funktion og levetid, industrikvalitet
er tilstrækkelig. Brug kvælstof med en
laveste renhedsværdi på 99,95 %
(klasse 4.0 eller bedre).
3.3 Gasventil
Åbnes og lukkes i forbindelse med, at
forladningsudstyrets tilslutningsgevind
monteres eller demonteres. Den hule tap
i forladningsudstyrets mundstykke åbner
ventilen. I andre sammenhænge er
ventilen lukket.
OBS
Hvis gasventilen har en møtrik, spænd
med drejningsmoment 6-7 Nm.
6-7 Nm
Forladningsudstyret bruges til at aftappe
eller påfylde kvælstof.
18
4. Idriftsætning
Hvis stempelakkumulatoren skal udluftes
før brugen, skal udluftningen ske på
oliesidens tilslutning.
Stempelakkumulatoren skal fyldes til
ønsket tryk beregnet efter anlæggets
driftsdata, før stempelakkumulatoren
tages i brug.
Det tilladte arbejdstryk og arbejds-
temperaturen afhænger af, hvilke
materialer der er anvendt i stempel-
akkumulatoren og fremgår af produktets
mærkning.
Stempelakkumulatoren skal monteres
således, at sikkerheden kan garanteres i
tilfælde af vibrationer eller eventuelle
brud i de tilsluttede ledninger.
Før tryksætning skal det kontrolleres at:
 Stempelakkumulatoren er korrekt
installeret.
 Alt udstyr såsom gasventil, brudskive
samt rørtilslutninger er korrekt
tilspændt, og at ingen komponenter er
trukket skæve.
 Efter tryksætning kontrolleres det, at
der ikke forekommer lækage. I tilfælde
af lækage tilspændes den
pågældende tilslutning. Hvis produktet
ikke kan gøres tæt, kontaktes PMC
Cylinders.
 Fæsteanordninger ikke udøver nogen
belastning på stempelakkumulatoren.
5. Vedligeholdelse
5.1 Råd om generel
vedligeholdelse
For at sikre lang og problemfri
anvendelse bør følgende
vedligeholdelsesforanstaltninger
gennemføres med jævne mellemrum.
Følgende tjekkes:
 Kvælstofgassens forladningstryk
tjekkes jævnligt i løbet af de første
ugers anvendelse, derefter med
passende mellemrum (se 5.2). Ved
påfyldning af kvælstofgas sikres det,
at den har tilstrækkelig renhed.
 At tilslutninger er tilspændte og
lækagefri
 Sikkerheds- og afspærringsblokkens
funktion
 Befæstigelseselementer
 Visuel inspektion af stempel-
akkumulatoren med jævne mellemrum
for at opdage eventuelle skader pga.
korrosion eller anden deformation.
Udvendig korrosion skal omgående
udbedres og er ikke tilladt. Mindre
omfattende, overfladisk korrosion
udbedres ved overmaling.
 At mærkning på stempelakkumulatoren
er læselig. Ved slitage kontaktes
leverandøren.
5.2 Kontrolhyppighed
Vi anbefaler følgende kontrolintervaller
for test af forladningstrykket:
 Umiddelbart efter installationen
 En uge efter installationen
 Seks uger efter installationen
Derefter kontrol en gang hvert halve år
ved normal drift, og hver måned ved
intensiv drift eller høje driftstemperaturer.
5.3 Lækage
Lækage kan opstå, hvis væsken lækker
over til gassiden, eller gassen lækker
over til væskesiden. For lavt gastryk kan
tyde på ekstern eller intern gaslækage.
Intern lækage
For højt gastryk kan tyde på, at væske
lækker til gassiden. For lavt gastryk kan DK
tyde på, at gas lækker over til væske-
siden.
Intern lækage kan skyldes at:
 Stempelpakningen er slidt eller
beskadiget
 Cylinderrørets indvendige overflade er
beskadiget
Slidte og beskadigede pakninger skiftes
med originalpakninger, og et beskadiget
cylinderrør skal inspiceres af kompetent
og autoriseret personale med henblik på
vurdering af, om skaden kan repareres
eller røret skal udskiftes (se pkt. 7.
Service).
19
Ekstern lækage
For lavt gastryk kan tyde på ekstern
gaslækage. Væske kan lække ud ved
væskesiden eller gas ved gassiden.
Ekstern gaslækage kan skyldes at:
 Pakningen på endelåget er slidt eller
beskadiget.
7. Service
Advarsel
Brugeren har det fulde ansvar for at
sikre, at gældende forskrifter følges,
og kun personale med den nødvendige
uddannelse har tilladelse til at udføre
service på stempelakkumulatoren.

 Pakningsfladen i noten til pakningen

kan være beskadiget. Advarsel
Vær ekstra forsigtig ved demontering
 Cylinderrøret ved pakningslejet kan
og montering af udstyr på stempel-
være beskadiget.
akkumulatorens gasside. Stempel-
akkumulatoren skal være gjort trykløs!
 Ventilen er ikke tilspændt eller
beskadiget.

Slidte og beskadigede pakninger skiftes Advarsel

med originalpakninger, og et beskadiget
endelåg eller akkumulatorrør skal Olien kan være varm et stykke tid efter
inspiceres af kompetent og autoriseret afspærring.
personale med henblik på vurdering af,
om skaden kan repareres eller der skal
foretages udskiftning. Hvis ventilen er Tøm aldrig gassiden ved at åbne
beskadiget, udskiftes gasventilen. Se gasventilen eller andre tilslutninger.
punkt 7. Service for sikker demontering. Gasventil eller andet udstyr kan blive
skudt ud.
6. Levetid
Hurtig udtømning af gas kan føre til
kvælningsrisiko. Sørg for god ventilation.
Stempelakkumulatoren har en
begrænset levetid. Levetiden afhænger
Ved behov for information om
af trykamplitude og antallet af trykcykler.
demontering og reparation kontaktes
PMC Cylinders.
I overensstemmelsesdokumentationen er
antallet af tilladte belastningsændringer
Brug kun originale komponenter fra
angivet. Disse data er nødvendige for at
PMC Cylinders.
bestemme stempelakkumulatorens
levetid, som afhænger af arbejds-
Service, kontrol og reparation kan
betingelserne i det hydrauliske system.
udføres på PMC Cylinders fabrik i
Vaggeryd.

20
1. Introduksjon
PMC Cylinders stempelakkumulatorer i
seriene PAC og PAS er CE-merkede og
godkjente for bruk i EU og har
gjennomgått kontroll ifølge prosedyrene i
modulene B (prod. type) og D, i samsvar
med EU-direktivet 2014/68/EU om
trykkutstyr.
Les nøye gjennom instruksjonsboken
før utstyret tas i bruk. Vær spesielt
oppmerksom på varseltekster før bruk av
stempelakkumulatoren. Feil bruk kan
innebære stor fare for ulykker og person-
skade eller til og med dødsfall.
OBS!
Brukeren bærer hele ansvaret for å sikre
at gjeldende forskrifter følges og at bare
personale med påkrevd utdanning får
arbeide med, installere og vedlikeholde
stempelakkumulatoren.
Man må følge de forskrifter for
idriftsetting og bruk av stempel-
akkumulatoren som gjelder på
installasjonsstedet.
Instruksjonsbok kan lastes ned fra
www.pmccylinders.se.
Oppbevar instruksjonsboken slik at den
er tilgjengelig ved behov.
2. Leveranse
Advarsel
Stempelakkumulatorer som er blitt
skadet under transport, må ikke brukes.
All transport av gassfylte stempel-
akkumulatorer må utføres med størst
mulig forsiktighet og følge alle gjeldende
transportforskrifter for gassfylte
produkter.
Det må kun brukes godkjent løfteutstyr
ved transport og håndtering.
Stempelakkumulatoren leveres enten:
 Forhåndsfylt med nitrogengass (N₂)
ved leveranse til et trykk på maks. 2
bar for å forhindre korrosjon og for å
unngå at stemplene beveger seg på
uønsket måte under forflytning. Dette
regnes ikke som forhåndsfylt og angis
ikke på stempelakkumulatorens
merkeetikett.
 Forhåndsfylt med nitrogengass (N₂) til
det trykket som angis av kunden. NO
Dette trykket står på merkeetiketten
som finnes på stempelakkumulatoren.
2.1 Merking
Merking består av stemplet informasjon
på stempelakkumulatoren samt
merkeetikett.
Brukeren er ansvarlig for å kontrollere at
all merking på stempelakkumulatoren er
intakt og fullt lesbar. Det er strengt
forbudt å endre eller fjerne merking, og
skadet merking må alltid erstattes.
Kontakt leverandøren.
Stempelakkumulatorens merkeetikett
angir vanligvis det forhåndsfylte trykket,
men er ikke alltid utfylt siden forhånds-
fyllingen kan ha blitt utført etter leveranse
fra produsenten.
21
2.2 Mottakskontroll 2.4 Oppbevaring

 Kontroller alltid at ordre og leveranse Stempelakkumulatoren leveres

stemmer overens.
 Kontroller eventuelle skader på
emballasje der det er risiko for at
stempelakkumulatoren har fått skader.
 Kontroller eventuelle skader på
lakkering.
konservert (innsmurt, plugget og fylt ned
nitrogengass). Den kan oppbevares i
opptil to år dersom det skjer på et tørt,
svalt sted og beskyttet mot direkte sollys.
Hvis stempelakkumulatoren lagres mer
enn to år, må alle tetninger byttes ut før
idriftsetting.

 Kontroller eventuelle øvrige skader på Hvis stempelakkumulatoren lagres mer

stempelakkumulatoren og tilbehøret.
 Kontroller at samsvarserklæringen
stemmer overens med stempel-
akkumulatorens merking.
2.3 Håndtering
enn tre måneder og er forhåndsfylt til
over 5 bar, må trykket reduseres til høyst
5 bar.
Forhåndsfylt stempelakkumulator må
oppbevares på en sikker lagerplass
beskyttet mot påkjørsel og brann som
kan forårsake eksplosjon.

Advarsel
Bruk alltid egnet verneutstyr ved
håndtering av tunge
stempelakkumulatorer.

Vær forsiktig slik at stempel-

akkumulatoren (lakkering, tilbehør m.m.)
ikke blir skadet på noen måte.

Bruk egnet løfteanordning og løfte-

stropper eller lignende for å reise opp
større stempelakkumulatorer. Sørg for at
stempelakkumulatorene er balanserte.

Endelokkene på større stempel-

akkumulatorer er utstyrt med gjengede
hull beregnet på løftekroker som brukes
når akkumulatorene skal reises opp.

22
3. Installasjon
Advarsel
Det må ikke utføres sveising, nagling
eller lodding eller annet mekanisk
arbeid på stempelakkumulatoren. Det
kan medføre eksplosjonsfare.
Advarsel
Vær ekstra forsiktig ved montering av
utstyr på stempelakkumulatorens
gasside. Stempelakkumulatoren kan
være forhåndsfylt.
Installasjon og bruk av stempel-
akkumulatorer kan være regulert av ulike
forskrifter i ulike land. Før installasjon og
bruk må du derfor finne ut hvilke
nasjonale regler som gjelder i det landet
der stempelakkumulatoren skal brukes.
Stempelakkumulatoren kan monteres i
en hvilken som helst posisjon. For å
minske faren for slitasje anbefales
vertikal montering med væske-
tilkoblingen nedover.
Følgende er strengt forbudt:
 Å sveise, nagle eller lodde fast
komponenter ved
stempelakkumulatoren.
 Å utføre arbeid som kan påvirke
stempelakkumulatorens mekaniske
egenskaper.
 Å endre stempelakkumulatoren uten
godkjenning fra PMC Cylinders.
Kontroller at væsken passer til utstyret.
Kontroller at stempelakkumulatorens
høyeste tillatte trykk er det samme eller
høyere enn hydraulikkretsens høyeste
tillatte trykk.
Kontroller miljøforholdene, og beskytt
utstyret ved behov.
Sørg for at det er ca. 200 mm fri plass
over gassventilen for å kunne montere
forhåndsfyllings- og kontrollutstyr.
La all merking være synlig.
Når stempelposisjonsindikering brukes,
skal den alltid være ordentlig festet og
monteres vertikalt med væske-
tilkoblingen nedover.
PMC Cylinders har et sortiment av
klamrer og konsoller som tilbehør for å
feste stempelakkumulatoren ved
installasjon (se separat datablad).
For små stempelakkumulatorer på opptil
ca. 10 kg anbefales det festing med to
klamrer. Ved tyngre enheter bestemmes
antallet klamrer avhengig av stempel-
akkumulatorens størrelse og type samt
at det anbefales å bruke en støttekonsoll
som avlaster vekten.
Bruk egnede tilkoblinger tilpasset for
hydraulikksystemer og sørg for at
tiltrekking skjer med rett moment. NO
3.1 Sikkerhetsutstyr
Vi anbefaler installasjon av sikkerhets-
utstyr på både væske- og gassiden som
begrenser trykket i stempel-
akkumulatoren.
På gassiden anbefales sprengplate eller
fjærbelastet sikkerhetsventil. Begge
åpner seg ved et forhåndsinnstilt trykk
uansett hva som er årsaken til det høye
trykket.
På væskesiden anbefales det bruk av
sikkerhetsblokk med sikkerhets- eller
trykkreduksjonsventil.
23
3.2 Forhåndsfylling
Advarsel
Stempelakkumulatoren må bare fylles
med nitrogengass (N₂). Bruk av
oksygengass eller luft medfører
eksplosjonsfare.
Kontroller at gassens forhåndsfylte trykk
er korrekt for enheten.
Kvaliteten på nitrogengassen er viktig for
dens funksjon og levetid. Industrikvalitet
er tilstrekkelig. Bruk nitrogengass med
en laveste renhetsverdi på 99,95 %
(klasse 4.0 eller bedre).
3.3 Gassventil
Åpnes og stenges i forbindelse med at
forhåndsfyllingsutstyrets tilkoblings-
gjenge monteres eller demonteres. Den
hule tappen i forhåndsfyllingsutstyrets
munnstykke åpner ventilen. For øvrig er
ventilen stengt.
OBS
Hvis gassventilen har en mutter, stram
med dreiemoment 6-7 Nm.
6-7 Nm
Bruk forhåndsfyllingsutstyret for å
drenere eller fylle nitrogengass.
24
4. Idriftsetting
Hvis stempelakkumulatoren må avluftes
før bruk, skal det skje på oljesidens
tilkobling.
Stempelakkumulatoren må fylles til
ønsket trykk beregnet etter anleggets
driftsdata før den tas i bruk.
Det tillatte arbeidstrykket og arbeids-
temperaturen avhenger av hvilke
materialer som er brukt i stempel-
akkumulatoren og fremgår av merkingen
på produktet.
Stempelakkumulatoren skal monteres
slik at sikkerheten kan garanteres ved
vibrasjoner eller eventuelle brudd i
tilkoblede ledninger.
Kontroller før trykksetting at:
 Stempelakkumulatoren er korrekt
installert.
 Alt utstyr som gassventil, sprengplate
samt rørtilkoblinger er ordentlig
tiltrukket og at ingen komponenter er
strammet skjevt.
 Etter trykksetting kontroller at det ikke
finnes lekkasjer. Ved lekkasje trekk til
den aktuelle tilkoblingen. Hvis
produktet ikke blir tett, kontakt PMC
Cylinders.
 Festeanordninger ikke utøver noen
belastning på stempelakkumulatoren.
5. Vedlikehold
5.1 Råd for generelt vedlikehold
For å sikre lang og problemfri bruk bør
følgende vedlikeholdstiltak gjennomføres
regelmessig.
Kontroller:
 nitrogengassens forhåndsfylte trykk
regelmessig de første ukene
akkumulatoren brukes, og deretter
med egnede intervaller (se 5.2). Ved
påfylling av nitrogengass kontroller at
den har tilstrekkelig renhet
 at tilkoblinger er tiltrukket og fri for
lekkasjer
 sikkerhets- og avstengningsblokkens
funksjon
 festeelementene
 stempelakkumulatoren visuelt med
jevne mellomrom for å oppdage
eventuelle skader pga. korrosjon eller
annen deformasjon. Utvendig
korrosjon må utbedres omgående og
er ikke tillatt. Mindre overflatekorrosjon
utbedres ved å male på nytt.
 merking på stempelakkumulatoren slik
at den er lesbar. Ved slitasje, kontakt
leverandøren.
5.2 Kontrollfrekvens
Vi anbefaler følgende kontrollintervaller
for test av det forhåndsfylte trykket:
 Rett etter installasjonen
 En uke etter installasjonen
 Seks uker etter installasjonen
Deretter kontroll ved normal drift en gang
per halvår og ved intensiv drift og ved
høye arbeidstemperaturer hver måned.
5.3 Lekkasje
Lekkasje kan oppstå om væsken lekker
over til gassiden eller ved at gassen
lekker over til væskesiden. For lavt gass-
trykk kan tyde på ekstern eller intern
gasslekkasje.
Intern lekkasje
For høyt gasstrykk kan tyde på at det
lekker væske til gassiden. For lavt gass-
trykk kan tyde på at det lekker gass over
til væskesiden.
Intern lekkasje kan skyldes at:
 Stempeltetningen er slitt eller skadet
 Sylinderrørets indre overflate er
skadet
Slitte og skadde tetninger byttes til
originaltetninger. Skadet sylinderrør skal
besiktiges av utdannet og kompetent
personale for å bedømme om skaden
kan repareres eller om røret må byttes ut
(se pkt 7. Service).
Ekstern lekkasje NO
For lavt gasstrykk kan tyde på ekstern
lekkasje. Væske kan lekke ut ved
væskesiden eller gass ved gassiden.
Ekstern gasslekkasje kan skyldes at:
 Tetningen på endelokket er slitt eller
skadet.
 Tetningsflaten i sporet for tetningen er
skadet.
 Sylinderrøret ved tetningsposisjonen
er skadet.
 Ventilen er ikke tiltrukket eller den er
skadet.
25
Slitte og skadde tetninger byttes til
originaltetninger. Skadet endelokk eller
akkumulatorrør skal besiktiges av
utdannet og kompetent personale for å
bedømme om skaden kan repareres eller
om lokket/røret må byttes ut. Hvis
ventilen er skadet, bytt gassventilen. For
sikker demontering se pkt 7. Service.
6. Levetid
7. Service
Advarsel
Brukeren bærer hele ansvaret for å
sikre at gjeldende forskrifter følges og
at bare personale med påkrevd
utdanning får utføre service på
stempelakkumulatoren.

Stempelakkumulatoren har en begrenset

levetid. Levetiden avhenger av trykk- Advarsel
amplitude og antallet trykksykluser.
Vær ekstra forsiktig ved demontering
og montering av utstyr på stempel-
I samsvarsdokumentasjonen angis det
akkumulatorens gasside. Stempel-
tillatte antallet lastvekslinger. Disse
akkumulatoren må være trykkløs!
dataene behøves for å bestemme
stempelakkumulatorens levetid som er
avhengig av arbeidsbetingelsene i
hydraulikksystemet. Advarsel
Oljen kan være varm en tid etter
avstengning.

Drener aldri gassiden ved å løsne på

gassventilen eller andre tilkoblinger.
Gassventilen eller annet utstyr kan
skytes ut.

Rask tømming av gass kan føre til

kvelningsfare. Sørg for god ventilasjon.

Ved behov for informasjon om

demontering og reparasjon, kontakt
PMC Cylinders.

Bruk bare originalkomponenter fra

PMC Cylinders.

Service, kontroller og reparasjoner kan

utføres på PMC Cylinders’ fabrikk i
Vaggeryd, Sverige.

26
1. Johdanto
PMC Cylinders sarjan PAC ja PAS
mäntäakut on CE-merkitty ja hyväksytty
käytettäviksi EU:ssa ja tarkastettu
painelaitteita koskevan EU-direktiivin
2014/68/EU moduulien B (prod. type) ja
D mukaisesti.
Lue käyttöohje huolellisesti ennen
käyttöä. Huomioi erityisesti
varoitustekstit ennen mäntäakun käyttöä.
Virheellinen käyttö voi aiheuttaa vakavan
onnettomuuden tai henkilövahingon, tai
mahdollisesti kuoleman.
HUOM!
Käyttäjä on itse vastuussa voimassa
olevien määräysten noudattamisesta, ja
vain tarvittavan koulutuksen saanut
henkilöstö saa käyttää, asentaa ja
huoltaa mäntäakkua.
Asennuspaikalla voimassa olevia
mäntäakun käyttöönottoa ja käyttöä
koskevia määräyksiä on noudatettava.
Käyttöohjeen voi ladata osoitteesta
www.pmccylinders.se.
Säilytä käyttöohjetta niin, että se on
tarvittaessa saatavilla.
2. Toimitus
Varoitus
Kuljetuksen aikana vahingoittuneita
mäntäakkuja ei saa käyttää.
Kaasutäytteisen mäntäakun
kuljetuksessa on toimittava äärimmäisen
varovasti ja noudatettava kaasutäytteisiä
tuotteita koskevia kuljetusmääräyksiä.
Kuljetuksessa ja käsittelyssä saa käyttää
ainoastaan hyväksyttyjä nostolaitteita.
Mäntäakku toimitetaan joko:
 Esitäytettynä typpikaasulla (N₂) ennen
toimitusta enintään 2 barin
paineeseen korroosion sekä männän
epätoivotun liikkumisen estämiseksi
siirron aikana. Mäntäakkua ei tällöin
lasketa esitäytetyksi eikä esitäyttöä
ole merkitty akun tyyppikilpeen.
 Typpikaasulla (N₂) esitäytettynä
asiakkaan ilmoittamaan paineeseen.
Tämä paine on merkitty mäntäakun
tyyppikilpeen.
2.1 Merkintä
Merkintä koostuu mäntäakkuun sekä FI
tyyppikilpeen leimatusta tiedosta.
Käyttäjän velvollisuus on tarkistaa, että
mäntäakun kaikki merkinnät ovat ehjät ja
täysin luettavissa. Merkinnän muuttaminen
tai poistaminen on ankarasti kielletty ja
vioittunut merkintä on aina uusittava. Ota
yhteys toimittajaan.
Mäntäakun tyyppikilvessä ilmoitetaan
yleensä esitäyttöpaine, mutta sitä ei ole
aina merkitty, sillä esitäyttö on voitu
tehdä tehtaalta toimittamisen jälkeen.
27
2.2 Vastaanottotarkastus 2.4 Säilytys

 Tarkasta aina, että toimitus on Mäntäakku toimitetaan säilytystä varten

tilauksen mukainen.
 Tarkasta pakkauksen mahdolliset
vauriot, jos on olemassa vaara, että
mäntäakku on vaurioitunut.
käsiteltynä (voideltuna, tulpattuna ja
typpikaasulla esitäytettynä). Sitä voidaan
säilyttää jopa kaksi vuotta, mikäli säilytys
tapahtuu kuivassa, viileässä paikassa ja
auringonvalolta suojattuna.

 Tarkasta maalipinnan mahdolliset Jos mäntäakkua varastoidaan yli kaksi

vauriot.
 Tarkasta mäntäakun ja lisävarusteiden
muut mahdolliset vauriot.
 Tarkasta, että
vaatimustenmukaisuusvakuutus
vastaa mäntäakun merkintää.
2.3 Käsittely
Varoitus
Käytä aina sopivia suojavarusteita
raskaita mäntäakkuja käsiteltäessä.
vuotta, on kaikki tiivisteet vaihdettava
ennen käyttöönottoa.
Jos mäntäakkua varastoidaan yli kolme
kuukautta ja se on esitäytetty yli 5 barin
paineeseen, on paine alennettava
korkeintaan 5 bariin.
Esitäytettyä mäntäakkua täytyy säilyttää
turvallisessa varastointipaikassa
suojassa törmäyksiltä ja tulipaloilta, jotka
voivat aiheuttaa räjähdyksen.

Varo vaurioittamasta mäntäakkua

(maalipintaa, lisävarusteita ym.).

Suuria mäntäakkuja nostettaessa on

käytettävä sopivaa nostolaitetta ja
nostoliinoja tai vastaavia. Varmista, että
mäntäakut ovat tasapainossa.

Suurten mäntäakkujen päätylaipoissa on

nostokorvakkeille tarkoitetut kierrereiät
nostoja varten.

28
3. Asennus
Varoitus
Mäntäakkua ei saa käsitellä
hitsaamalla, niittaamalla, juottamalla tai
mekaanisesti, sillä käsittelyt aiheuttavat
räjähdysvaaran.
Varoitus
Ole erityisen varovainen asennettaessa
laitteita mäntäakun kaasupuolelle.
Mäntäakku voi olla esitäytetty.
Mäntäakun asennus- ja
käyttömääräyksissä voi olla
maakohtaisia eroja. Selvitä sen vuoksi
ennen asennusta ja käyttöä, mitkä
kansalliset määräykset ovat voimassa
siinä maassa, jossa mäntäakkua on
tarkoitus käyttää.
Mäntäakku voidaan asentaa vapaasti
haluttuun asentoon. Kulumisvaaran
vähentämiseksi on suositeltavaa asentaa
mäntäakku pystyasentoon niin, että
nesteliitäntä tulee alaspäin.
Seuraavat ovat ankarasti kiellettyjä:
 Osien kiinnittäminen hitsaamalla,
niittaamalla tai juottamalla
mäntäakkuun.
 Kaikki toimenpiteet, jotka voivat
vaikuttaa mäntäakun mekaanisiin
ominaisuuksiin.
 Muutosten tekeminen mäntäakkuun
ilman PMC Cylinders hyväksyntää.
Tarkasta, että neste sopii laitteille.
Tarkasta, että mäntäakun suurin sallittu
paine on sama tai korkeampi kuin
hydraulipiirin suurin sallittu paine.
Tarkasta ympäristöolosuhteet ja suojaa
tarvittaessa laitteet.
Varmista, että kaasuventtiilin yläpuolella
on noin 200 mm vapaata tilaa esitäyttö-
ja mittauslaitteen asennusta varten.
Jätä kaikki merkinnät näkyviin.
Käytettäessä männän asennonilmaisinta
akku on aina kiinnitettävä kunnolla ja
asennettava pystyasentoon nesteliitäntä
alaspäin.
PMC Cylinders lisävarustevalikoimassa
on kiinnikkeitä ja kannattimia mäntäakun
kiinnittämistä varten. (Ks. erillinen esite).
Pienet, enintään 10 kg mäntäakut, on
suositeltavaa kiinnittää kahdella
kiinnikkeellä. Raskaampien yksiköiden
osalta päätetään kiinnikkeiden määrä
mäntäakun koon ja tyypin mukaan.
Lisäksi on suositeltavaa käyttää
tukikannatinta, joka keventää akun
painoa.
Käytä sopivia hydraulijärjestelmälle
sovitettuja liitäntöjä ja kiristä liitännät
FI
oikeaan momenttiin.
3.1 Turvalaitteet
Suosittelemme mäntäakun painetta
rajoittavien turvalaitteiden asentamista
sekä neste- että kaasupuolelle.
Kaasupuolella on suositeltavaa käyttää
varokalvoa tai jousikuormitteista
varoventtiiliä. Molemmat avautuvat
säädetyssä paineessa riippumatta
paineen kohoamisen syystä.
Nestepuolella on suositeltavaa käyttää
varo- tai paineenalennusventtiilistä
koostuvaa turvalohkoa.
29
3.2 Esitäyttö
Varoitus
Mäntäakun saa täyttää vain
typpikaasulla (N₂). Happikaasun tai
ilman käyttö aiheuttaa räjähdysvaaran.
Tarkasta, että kaasun esitäyttöpaine on
oikea yksikölle.
Typpikaasun laatu on tärkeää sen
toiminnalle ja kestoiälle, teollisuuslaatu
on riittävä. Käytä typpikaasua, jonka
puhtausarvo on vähintään 99,95 %
(luokka 4.0 tai parempi).
3.3 Kaasuventtiili
Avautuu/sulkeutuu esitäyttölaitteen
liitäntäkierteen kiinnityksen/irrotuksen
yhteydessä. Esitäyttölaitteen suuttimessa
oleva ontto tappi avaa venttiilin. Muulloin
venttiili on kiinni.
HUOM
Jos kaasu venttiili on mutteri, kiristää
vääntömomentti 6-7 Nm.
6-7 Nm
Käytä esitäyttölaitetta typpikaasun
tyhjennykseen ja täyttöön.
30
4. Käyttöönotto
Jos mäntäakku täytyy ilmata ennen
käyttöä, on ilmanpoisto tehtävä
öljypuolen liitännästä.
Mäntäakku täytyy ennen käyttöönottoa
täyttää haluttuun paineeseen, joka
lasketaan laitteiston käyttötiedoista.
Sallittu käyttöpaine ja käyttölämpötila
riippuvat siitä, mitä materiaaleja
mäntäakussa on käytetty, ja ne käyvät
ilmi tuotteen merkinnästä.
Mäntäakku on asennettava niin, että
turvallisuus voidaan taata, mikäli
liitosjohdot värähtelevät tai mahdollisesti
rikkoontuvat.
Tarkasta ennen paineistusta, että:
 Mäntäakku on asennettu oikein.
 Kaikki varusteet, kuten kaasuventtiili,
varokalvo sekä putkiliitännät on
kunnolla kiristetty eikä yhtään
komponenttia ole kiristetty kieroon.
 Paineistuksen jälkeen on tarkistettava,
ettei vuotoja ole. Mikäli liitännässä
havaitaan vuoto, on liitäntä
kiristettävä. Jos tuotteesta ei saada
tiivistä, on otettava yhteys PMC
Cylinders.
 Kiinnityselimet eivät kuormita
mäntäakkua.
5. Kunnossapito 5.3 Vuodot

5.1 Ohjeita yleiseen Vuoto voi syntyä, jos nestettä pääsee

kaasupuolelle tai kaasua nestepuolelle.
kunnossapitoon
Liian matala kaasun paine voi olla
merkkinä ulkoisesta tai sisäisestä
Pitkän ja ongelmattoman käytön
kaasuvuodosta.
varmistamiseksi on seuraavat
kunnossapitotoimet suoritettava
Sisäinen vuoto
säännöllisesti.
Liian korkea kaasun paine voi olla
Tarkasta:
merkkinä nestevuodosta kaasupuolelle.
Liian matala kaasun paine voi olla
 typpikaasun esitäyttöpaine
merkkinä kaasuvuodosta nestepuolelle.
säännöllisesti ensimmäisten
käyttöviikkojen aikana ja sen jälkeen
Sisäisen vuodon syy voi olla:
sopivin välein (ks. 5.2). typpikaasua
lisättäessä, että se on riittävän
 Männäntiiviste on kulunut tai vioittunut
puhdasta
 että liitännät on kiristetty ja tiiviit  Sylinteriputken sisäpinta on vioittunut

 turva- ja sulkulohkon toiminta Kuluneiden ja vioittuneiden tiivisteiden

 kiinnityselimet
 mäntäakku silmämääräisesti
määräajoin mahdollisten korroosiosta
tai muusta syystä aiheutuneiden
vaurioiden havaitsemiseksi.
Ulkopinnan korroosio on poistettava
välittömästi eikä sitä saa esiintyä.
Pieni pintakorroosio korjataan
uusintamaalaamalla.
tilalle vaihdetaan alkuperäistiivisteet ja
asiantuntijan on tarkastettava, voidaanko
vaurio korjata vai tarvitaanko vaihto (ks.
kohta 7 Huolto).
Ulkoinen vuoto
Liian matala kaasun paine voi olla
merkkinä ulkoisesta vuodosta. Nestettä
voi vuotaa nestepuolelta tai kaasua

 Mäntäakun merkintä niin, että se on

luettavissa. Mikäli kulumista ilmenee,
kaasupuolelta.

Ulkoisen vuodon syy voi olla:

FI
on otettava yhteys toimittajaan.
 Päätylaipan tiiviste on kulunut tai
5.2 Tarkastusvälit vioittunut.

Suosittelemme seuraavia tarkastusvälejä  Uran tiivistepinta on vioittunut.

esitäyttöpaineen tarkastukselle:
 Sylinteriputki on vaurioitunut
 Heti asennuksen jälkeen tiivistyskohdasta.
 Yksi viikko asennuksen jälkeen
 Venttiiliä ei ole kiristetty tai se on
 Kuusi viikkoa asennuksen jälkeen vioittunut.

Sen jälkeen tarkastus normaalikäytössä

puolivuosittain ja voimakkaassa käytössä
ja korkeissa käyttölämpötiloissa
kuukausittain.

31
Kuluneiden ja vioittuneiden tiivisteiden
tilalle vaihdetaan alkuperäistiivisteet ja
asiantuntijan on tarkastettava, voidaanko
päätykannen tai akkuputken vaurio
korjata vai tarvitaanko vaihto. Jos
kaasuventtiili on vaurioitunut, se on
vaihdettava. Turvallinen irrotus, katso
kohta 7. Huolto.
7. Huolto
Varoitus
Käyttäjä on itse vastuussa voimassa
olevien määräysten noudattamisesta,
ja vain tarvittavan koulutuksen saanut
henkilöstö saa huoltaa mäntäakkua.

6. Kestoikä

Mäntäakun kestoikä on rajallinen. Varoitus

Kestoikä riippuu paineamplitudista ja
painesyklien määrästä.
Yhdenmukaisuusasiakirjoissa ilmoitetaan
sallittu kuormanvaihtojen määrä. Näiden
tietojen avulla määritetään mäntäakun
kestoikä, joka riippuu
hydraulijärjestelmän käyttöolosuhteista.
Ole erityisen varovainen mäntäakun
kaasupuolen laitteita irrotettaessa ja
asennettaessa. Mäntäakun on oltava
paineeton!
Varoitus
Öljy voi olla kuumaa vielä jonkin aikaa
sulkemisen jälkeen.

Älä koskaan tyhjennä kaasupuolta

avaamalla kaasuventtiiliä tai muita
liitäntöjä. Kaasuventtiilit tai muu varuste
voi sinkoutua irti.

Kaasun nopea tyhjennys voi aiheuttaa

tukehtumisvaaran. Varmista hyvä
ilmanvaihto.

Purkamista ja korjausta koskevia tietoja

saa tarvittaessa PMC Cylinders.

Käytä vain PMC Cylinders

alkuperäisosia.

Huolto, tarkastukset ja korjaukset

voidaan tehdä PMC Cylinders tehtaalla
Vaggerydissä.

32
1. Einleitung
Die Kolbenspeicher der PMC Cylinders,
Serie PAC und PAS, tragen das CE-
Zeichen und sind für den Einsatz in der
EU zugelassen. Sie sind gemäß der
Verfahren, wie sie in den Abschnitten B
(prod. type) und D der EU-Richtlinie
2014/68/EU für Druckgefäße
vorgeschrieben sind, geprüft.
Vor Verwendung die
Betriebsanleitung sorgfältig lesen.
Warnhinweise vor Einsatz der
Kolbenspeicher besonders beachten!
Falsche Anwendung kann
möglicherweise zu tödlichen
Verletzungen sowie Unfällen führen.
N.B.
Der Anwender ist für die Einhaltung der
zutreffenden Vorschriften in vollem
Umfang verantwortlich. Nur
entsprechend geschultes Personal darf
mit Kolbenspeichern umgehen, sie
einbauen und warten.
Vorschriften für die Inbetriebnahme,
Übergabe und Wartung, die am
Einsatzort gelten, sind einzuhalten.
Die Betriebsanleitung kann von
www.pmccylinders.se heruntergeladen
werden.
Die Betriebsanleitung muss frei
zugänglich sein.
2. Lieferung
Achtung!
Während des Transports beschädigte
Kolbenspeicher dürfen nicht
verwendet werden.
Jeden gasgefüllten Kolbendruckspeicher
so sorgfältig wie möglich transportieren,
alle geltenden Transportvorschriften für
gasgefüllte Erzeugnisse einhalten
Nur zugelassene Hebezeuge für
Transport und Handhabung verwenden.
Kolbenspeicher werden geliefert
entweder
 vorgespannt mit Stickstoff (N₂) bei
einem maximalen Druck von 2 bar, um
Korrosion
sowie Bewegung der Kolben während
des Transports zu verhindern. Das
heißt aber nicht, dass sie vorgefüllt
sind,und es gibt dazu auch keine
Angabe auf dem Typenschild des
Kolbenspeichers, oder
 mit Stickstoff,mit einem vom Kunden
vorgegebenen Druck,vorgespannt.
Dieser Druck ist auf dem Typenschild
des Kolbenspeichers angegeben.
DE
33
2.1 Markierung
Die Markierung ist eine Angabe, die
sowohl auf dem Kolbenspeicher
eingestempelt als auch auf dem
Typenschild zu finden ist.
Der Anwender hat die Markierung auf
dem Kolbenspeicher auf Vollständigkeit
und Lesbarkeit zu überprüfen. Es ist
streng verboten, Markierungen zu
ändern oder zu entfernen. Beschädigte
Markierungen sind in jedem Fall zu
ersetzen. Den Lieferer kontaktieren.
Der Aufkleber am Kolbenspeicher gibt
normalerweise den tatsächlichen
Vorspanndruck an. Es kommt aber vor,
dass der Kolbenspeicher bei der
Auslieferung durch den Hersteller nicht
vorgespannt worden ist.
2.2 Wareneingangskontrolle
 Immer überprüfen, ob die Lieferung
mit dem Auftrag übereinstimmt.
 Die Verpackung auf Beschädigung
prüfen. Der Kolbenspeicher könnte
beschädigt sein.
 Die Oberfläche auf Beschädigung
prüfen.
 Den Kolbenspeicher und das Zubehör
auf mögliche Beschädigung prüfen.
 Überprüfen, dass die
Konformitätserklärung mit den
Angaben auf dem Kolbenspeicher
übereinstimmt.
34
2.3 Handhabung
Achtung!
Immer die passende Schutzausrüstung
bei der Handhabung von schweren
Kolbenspeichern anlegen.
Sorgfältig darauf achten, dass der
Kolbenspeicher (Oberfläche, Zubehör,
usw.) in keiner Weise beschädigt ist.
Zum Aufstellen langer Kolbenspeicher
geeignetes Hebezeug und Anschlagseile
benutzen. Kolbenspeicher nur im
Gleichgewicht transportieren.
Schutzkappen von langen
Kolbenspeichern besitzen zum Aufstellen
Gewindebohrungen für Augenschrauben.
2.4 Lagerung
Ein Kolbenspeicher ist bei der Lieferung
konserviert (gefettet, verschlossen und
mit Stickstoff gefüllt). Er kann bis zu zwei
Jahre in trockener, kühler Umgebung,
ohne direkte Sonneneinstrahlung,
gelagert werden.
Wenn ein Kolbenspeicher länger als zwei
Jahre gelagert ist, dann alle Dichtung vor
Inbetriebnahme auswechseln.
Wenn ein Kolbenspeicher länger als drei
Monate mit einem Vorspanndruck von
über 5 bar gelagert ist, dann den Druck
auf 5 bar verringern.
Vorgespannte Kolbenspeicher an einem
sicheren Ort, geschützt gegen Kollision
und Feuer, die zu Explosion führen
können, lagern.
3. Installation
Achtung!
Am Kolbenspeicher darf nicht
geschweißt, genietet, gelötet oder
mechanische Arbeiten vorgenommen
werden. Es besteht Explosionsgefahr.
Achtung!
Bei dem gasseitigen Anschließen des
Druckspeichers an die Anlage sorgfältig
vorgehen. Der Kolbenspeicher könnte
vorgespannt sein.
In den einzelnen Ländern können
unterschiedliche Vorschriften für Betrieb
und Installation von Kolbenspeichern
gelten. Vor der Installation und dem
Betrieb die zutreffenden nationalen
Vorschriften für das Land ermitteln, in
dem der Kolbenspeicher eingesetzt wird.
Der Kolbenspeicher kann in jeder Lage
eingebaut werden. Um die Gefahr von
Verschleiß zu verringern, wird der
Einbau in senkrechter Lage mit dem
Flüssigkeitsanschluss nach unten
empfohlen.
Streng verboten:
 Am Kolbenspeicher Bauteile weder
Anschweißen, Annieten noch Anlöten!
 Alle Arbeiten, die die mechanischen
Eigenschaften des Kolbenspeichers
beeinträchtigen!
 Am Kolbenspeicher Änderungen ohne
die Genehmigung von PMC Cylinders
vornehmen!
Darauf achten, dass die Flüssigkeit für
die Anlage geeignet ist!
Der maximale, zulässige Druck des
Kolbenspeichers muss gleich oder höher
als der des Hydraulikkreises sein.
Umgebungsbedingungen prüfen und die
Anlage in erforderlicher Weise schützen.
Oberhalb des Gasventils muss ein freier
Raum von 200 mm vorhanden sein,
damit die Füll- und Regelausrüstung
angebaut werden kann.
Alle Markierungen müssen sichtbar
bleiben.
Wenn eine Anzeigeeinheit für die
Kolbenpostion verwendet wird, dann
muss diese in geeigneter Weise
geschützt und senkrecht mit dem
Flüssigkeitsanschluss nach unten
eingebaut werden.
PMC Cylinders bietet Zubehör in Form
von Schellen und Halterungen für die
sichere Halterung des Kolbenspeichers
beim Einbau an. (Siehe das zugehörige
Datenblatt.)
Bei kleinen Kolbenspeichern bis zu
ungefähr 10 kg wird die Befestigung mit
zwei Schellen empfohlen. Bei größeren
Geräten hängt die Anzahl der Schellen
von Größe und Gewicht des
Kolbenspeichers ab. Zur
Gewichtsentlastung wird zu einem Halter
geraten.
Nur für Hydraulikanlagen geeignete
Anschlüsse verwenden und diese mit
dem vorgegebenen Anzugsmoment DE
montieren.
3.1 Sicherheitsausrüstung
Sicherheitsausrüstungen auf den Seiten
für Gas und Flüssigkeit zur Begrenzung
des Drucks im Kolbenspeicher einbauen.
Auf der Gasseite eine Sollbruchscheibe
oder ein federvorgespanntes
Druckbegrenzungsventil verwenden.
Beide Baugruppen reagieren beim
Erreichen des eingestellten Drucks,
35
unabhängig von der Ursache des hohen
Drucks.
Auf der Flüssigkeitsseite eine
Sicherheitsbaugruppe mit einem
Sicherheits- / Druckbegrenzungsventil
installieren.
3.2 Vorspannen
Achtung!
Der Kolbenspeicher darf nur mit
Stickstoff (N₂). gefüllt werden.
Explosionsgefahr beim Füllen mit
Sauerstoff oder Luft.
Der Vorspanndruck des Gases muss für
den Kolbenspeicher passend sein.
Die Stickstoffqualität ist für die Leistung
und die Lebensdauer des
Stickstoffspeichers entscheidend.
Qualität für industrielle Anwendungen ist
ausreichend. Stickstoff mit einer
Mindestreinheit von 99,95% (Klasse 4.0
oder höher) verwenden.
3.3 Gasventil
Öffnet und schließt, wenn der Anschluss
der Fülleinrichtung auf- oder
abgeschraubt wird. Der Hohlstift in der
Düse der Fülleinrichtung öffnet das
Ventil. Ansonsten ist das Ventil
geschlossen.
N.B.
Wenn das Gasventil eine
Sechskantmutter besitzt, diese mit
einem Anzugsmoment von 6-7 Nm
festziehen.
6-7 Nm
36
Die Fülleinrichtung zum Füllen und
Ablassen des Stickstoffs benutzen.
4. Inbetriebnahme
Wenn der Kolbenspeicher vor der
Inbetriebnahme entlüftet werden muss,
dann ist das am ölseitigen Anschluss
vorzunehmen.
Vor der Benutzung des Kolbenspeichers
ist der notwendige Druck zu erzeugen.
Der Druck wird an Hand der
Betriebsdaten des Kolbenspeichers
errechnet.
Der ermittelte Betriebsdruck und die -
temperatur hängen von den
Materialqualitäten des Kolbenspeichers
ab. Sie sind auf dem Typenschild des
Erzeugnisses angegeben.
Den Kolbenspeicher so montieren, dass
auch im Fall von Schwingungen oder
eines möglichen Bruchs der
Anschlussrohre usw. die Sicherheit
gewährleistet ist.
Vor der Druckbeaufschlagung prüfen:
 Der Kolbenspeicher ist richtig
installiert.
 Die Bauteile wie Gasventile,
Sollbruchscheiben und
Leitungsverbindungen sind
entsprechend an- und die
Baugruppen vorschriftsmäßig
festgezogen.
 Keine Undichtigkeiten nach der
Druckbeaufschlagung Bei
Undichtigkeiten die betroffenen
Verbindungen nachziehen Können
die Undichtigkeiten nicht behoben
werden, PMC Cylinders konsultieren.
 Anbaugeräte dürfen keine
Verformung am Kolbenspeicher
verursachen.
5. Wartung
5.1 Allgemeine Wartung
Für eine lange, einwandfreie
Nutzungsdauer sind die folgenden
Wartungsarbeiten regelmäßig
auszuführen.
Prüfen:
 Den Vorspanndruck des Stickstoffs in
der ersten Betriebswoche regelmäßig
und danach in geeigneten Abständen
(siehe Punkt 5.2.) kontrollieren . Nur
ausreichend sauberes Gas einfüllen.
 Verbindungen auf Festigkeit und
Dichtheit prüfen.
 Funktionsfähigkeit der Sicherheits-
und Sperreinrichtungen testen.
 Halterungen inspizieren.
 Den Kolbenspeicher mit einer Lupe in
regelmäßigen Intervallen auf
Beschädigung durch Korrosion oder
andere Verformung untersuchen.
Äußere Korrosion ist nicht zulässig
und muss sofort behandelt werden.
Kleine äußere Korrosionsstellen mit
Farbe beseitigen.
 Die Markierung am Kolbenspeicher
muss sichtbar bleiben. Bei
verschlissenem Kolbenspeicher den
Hersteller kontaktieren.
5.2 Prüfungsintervalle
Wir empfehlen die folgenden Intervalle
für die Vorspannprüfung:
 Direkt nach Installation
 Eine Woche nach Installation
 Sechs Wochen nach Installation
Danach, im Normalbetrieb, einmal alle
sechs Monate, bei hohen
Betriebstemperaturen einmal im Monat.
5.3 Leckage
Leckage kann dann auftreten, wenn die
Flüssigkeit auf der Gasseite austritt oder
Gas auf der Flüssigkeitsseite entweicht.
Zu niedriger Gasdruck kann ein
Anzeichen für äußere oder innere
Undichtigkeiten auf der Gasseite sein.
Innere Leckage
Zu hoher Gasdruck kann ein Anzeichen
dafür sein, dass Flüssigkeit auf die
Gasseite entweicht. Zu niedriger
Gasdruck kann ein Anzeichen dafür sein,
dass Gas auf die Flüssigkeitsseite
entweicht.
Innere Leckage kann folgenden
Ursachen haben:
 Die Kolbendichtung ist verschlissen
oder beschädigt.
 Die innere Oberfläche des Zylinders
ist beschädigt.
DE
Verschlissene und beschädigte
Dichtungen sind durch Originale zu
ersetzen. Beschädigte Zylinder hingegen
sind vom Fachpersonal zu untersuchen,
ob der Schaden repariert werden kann
oder der Zylinder auszutauschen ist
(siehe Punkt 7, Service).
37
Externe Leckage
Zu niedriger Gasdruck kann ein
Anzeichen für äußere Undichtigkeiten
sein. Flüssigkeit kann von der
Flüssigkeitsseite und Gas von der
Gasseite entweichen.
Externe Leckage kann folgenden
Ursachen haben:
 Die Schutzkappendichtung ist
verschlissen oder beschädigt.
 Die Dichtfläche im Gewinde der
Dichtung ist beschädigt.
 Die Dichtung des Zylinders ist
beschädigt.
 Das Ventil ist nicht fest genug
angezogen oder wurde beschädigt.
Verschlissene und beschädigte
Dichtungen können durch Originale
ersetzt werden. Ein beschädigtes
Verschlusskappen- oder
Kolbenspeicherrohr hingegen sind von
Fachpersonal zu untersuchen, ob der
Schaden repariert werden kann oder die
Teile auszutauschen sind. Ein
beschädigtes Ventil ist zu erneuern.
Sichere Demontage, siehe Punkt 7.
Service
7. Service
Achtung!
Der Anwender ist in vollem Umfang für
die Einhaltung der zutreffenden
Vorschriften verantwortlich. Nur
entsprechend geschultes Personal
darf Wartungsarbeiten am
Kolbenspeicher durchführen.
Achtung!
Besondere Vorsicht ist beim Montieren
sowie Demontieren der Anlage auf der
Gasseite des Kolbenspeichers walten
zu lassen. Den Kolbenspeicher immer
drucklos machen!
Achtung!
Das Öl speichert Wärme über einen
gewissen Zeitraum nach dem
Abschalten.
Gas niemals über die Gasseite durch
Öffnen des Gasventils oder einer
anderen Verbindung ausströmen lassen.
Das Gasventil oder andere Bauteile
können umherfliegen.

Schnelles Ablassen des Gases birgt

6. Lebensdauer
Erstickungsgefahr. Für ausreichende
Belüftung sorgen.
Die Lebensdauer des Kolbenspeicher ist
begrenzt. Die Lebensdauer hängt von
Wenn Informationen zur Demontage
der Druckamplitude und Anzahl der
oder Reparatur erforderlich sind, bitte
Druckzyklen ab.
PMC Cylinders konsultieren.
Nur originale Bauteile von PMC
In der Konformitätsdokumentation ist die
Cylinders verwenden.
Anzahl von Lastspielen angegeben.
Diese Angaben sind zur Bestimmung der
Servicearbeiten, Prüfungen und
Lebensdauer des Kolbenspeichers
Reparaturen können im Werk von PMC
notwendig. Die Lebensdauer wird von
Cylinders in Vaggeryd ausgeführt
den Betriebsbedingungen der
werden.
Hydraulikanlage beeinflusst.

38
1. Introduction
Les accumulateurs à piston de PMC
Cylinders, de la série PAC et PAS,
portent le marquage CE. Leur utilisation
dans l'UE a été approuvée et ils ont été
vérifiés selon les procédures décrites
dans les modules B (prod. type) et D, en
conformité avec la directive UE
2014/68/EU relative aux équipements
sous pression.
Lire attentivement le Mode d'emploi
avant utilisation. Prendre en particulier
bien note des textes d'avertissement
avant d'utiliser l'accumulateur à piston.
Une mauvaise utilisation peut être à
l'origine de blessures et d'accidents
graves, voire mortels.
N.B.
Il incombe à l'utilisateur de vérifier le
respect des réglementations en vigueur.
À noter également que seul le personnel
dûment formé est autorisé à intervenir, à
installer et à entretenir l'accumulateur à
piston.
Il convient de respecter les
réglementations relatives à la mise en
service et à l'utilisation de l'accumulateur
à piston en vigueur sur le site
d'installation.
Le Manuel peut être téléchargé sur le
site www.pmccylinders.se.
Conserver le Manuel dans un endroit
facilement accessible, pour pouvoir s'y
référer au besoin.
2. Livraison
Avertissement
Ne pas utiliser les accumulateurs à
piston qui ont été endommagés
pendant le transport.
Les accumulateurs à piston remplis de
gaz doivent être transportés avec le plus
grand soin possible, dans le respect de
toutes les réglementations en vigueur
concernant le transport de produits
remplis de gaz.
Utiliser uniquement des équipements de
levage agréés pour le transport et la
manutention.
L'accumulateur à piston peut être livré
sous deux formes différentes:
 Préchargé d'azote gazeux (N₂) à une
pression de maximum 2 bars pour
éviter la corrosion et empêcher le
piston de bouger pendant le transport.
Dans ce cas, l'accumulateur à piston
n'est pas considéré comme préchargé
et la valeur ne figure pas sur
l'étiquette de l'accumulateur à piston.
 Préchargé d'azote (N₂) à une pression
spécifiée par le client. Cette pression
est mentionnée sur l'étiquette de
l'accumulateur à piston.
FR
39
2.1 Marquage
Le marquage est une information gravée
sur l'accumulateur à piston, et figurant
sur les étiquettes.
Il appartient à l'utilisateur de vérifier que
tous les marquages de l'accumulateur à
piston sont intacts et parfaitement
lisibles. Il est strictement interdit de
modifier ou de supprimer un marquage.
En outre, les marquages endommagés
doivent être remplacés. Contacter le
fournisseur à cet effet.
L'autocollant fixé sur l'accumulateur à
piston spécifie généralement la pression
préchargée, mais il n'est pas
nécessairement rempli, étant donné qu'il
peut être préchargé par le fabricant
après la livraison.
2.2 Contrôle à la réception
 Toujours vérifier qu'un produit livré
correspond bien au produit
commandé.
 Vérifier que l'emballage n'est pas
endommagé, s'il y a un risque que
l'accumulateur à piston ait été
endommagé.
 Vérifier que la surface n'est pas
endommagée.
 Vérifier que l'accumulateur à piston et
les accessoires ne présentent pas
d'autres signes de détérioration.
 Vérifier que la déclaration de
conformité correspond au marquage
présent sur l'accumulateur à piston.
40
2.3 Manutention
Avertissement
Toujours utiliser des équipements de
protection adaptés pour manipuler les
accumulateurs à piston.
Prendre garde à ne pas endommager
l'accumulateur à piston (surface,
accessoires, etc.) de quelle façon que ce
soit.
Pour monter de gros accumulateurs à
piston, utiliser des équipements de
levage et des sangles de levage de
capacité adaptée. Veiller à bien
équilibrer l'accumulateur à piston.
Les capuchons d'extrémité des gros
accumulateurs à piston comportent des
trous filetés destinés aux œillets de
levage, à utiliser pour le montage.
2.4 Stockage
L'accumulateur à piston a été
spécialement préservé pour la livraison
(graissé, obturé et rempli d'azote). Il peut
être stocké deux ans maximum, dans un
endroit sec et frais, à l'abri des rayons
directs du soleil.
Si l'accumulateur à piston est entreposé
pendant plus de deux ans, tous les joints
devront être remplacés avant la mise en
service.
Si l'accumulateur à piston est entreposé
pendant plus de trois mois et préchargé
à >5 bars, il faudra réduire la pression à
un maximum de 5 bars.
Les accumulateurs à piston préchargés
doivent être entreposés dans un endroit
sûr, à l'abri des collisions et des
incendies, pour éviter tout risque
d'explosion.
3. Installation
Avertissement
Afin d'éviter tout risque d'explosion, il
est interdit de procéder à des
opérations de soudage, de rivetage, de
brasage ou à des travaux mécaniques
sur l'accumulateur à piston.
Avertissement
Faire preuve d'une extrême vigilance
pour installer le côté gaz de
l'accumulateur à piston. L'accumulateur
à piston est peut-être préchargé !
Selon les pays, différentes
réglementations peuvent s'appliquer
concernant l'utilisation et l'installation de
l'accumulateur à piston. Avant d'installer
et d'utiliser l'accumulateur à piston,
vérifier les réglementations nationales en
vigueur dans le pays d'utilisation.
L'accumulateur à piston peut être installé
dans n'importe quelle position. Pour
réduire le risque d'usure et de
déchirement, il est recommandé
d'installer l'accumulateur à la verticale,
orifice du fluide orienté vers le bas.
Il est strictement interdit de:
 Souder, riveter ou braser des
composants sur l'accumulateur à
piston.
 Prendre des mesures susceptibles
d'altérer les propriétés mécaniques de
l'accumulateur.
 Modifier l'accumulateur sans
l'autorisation de PMC Cylinders.
Vérifier que le fluide est adapté à
l'équipement.
Vérifier que la pression maximale
admissible de l'accumulateur à piston est
égale ou supérieure à celle du circuit
hydraulique.
Vérifier les conditions environnementales
et protéger l'équipement selon les
besoins.
Vérifier que l'espace au-dessus du
robinet de gaz est d'environ 200 mm
pour permettre la précharge et le
montage de l'équipement de contrôle.
Tous les marquages doivent rester bien
visibles.
En cas d'utilisation de l'indicateur de
position du piston, toujours le fixer
correctement et le monter à la verticale,
orifice du fluide orienté vers le bas.
PMC Cylinders propose une gamme
d'accessoires, notamment des attaches
et des supports, pour fixer l'accumulateur
à piston pendant l'installation. (Voir la
fiche de données séparée.)
Dans le cas de petits accumulateurs à
piston – jusqu'à environ 10 kg – il est
recommandé de les fixer à l'aide de deux
attaches. Pour les unités plus lourdes, le
nombre d'attaches dépendra de la taille
et du type d'accumulateur à piston; il est
également recommandé d'utiliser un
support pour alléger le poids.
Utiliser des raccords adaptés
spécialement conçus pour les systèmes
hydrauliques et veiller à les serrer au
couple correct.
3.1 Équipements de sécurité FR
Il est recommandé d'installer un
équipement de sécurité côté fluide et
côté gaz, afin de limiter la pression dans
l'accumulateur à piston.
Il est également recommandé d'installer
un disque de rupture ou une soupape de
surpression à ressort côté gaz. Ces
41
deux appareils s'ouvrent à une pression
préréglée, quelle que soit la cause de la
pression élevée.
Il est recommandé d'utiliser un bloc de
sécurité avec une soupape de
sécurité/de réduction de pression côté
fluide.
3.2 Précharge
Avertissement
L'accumulateur à piston ne doit être
rempli qu'avec de l'azote gazeux (N₂).
Risque d'explosion en cas d'utilisation
d'oxygène ou d'air.
Vérifier que la pression de précharge du
gaz est bien adaptée à l'unité.
La qualité de l'azote gazeux est
importante pour la performance et la
longévité de l'unité. Une qualité
industrielle suffit. Utiliser de l'azote
gazeux d'une qualité de pureté minimale
de 99,95 % (classe 4.0 ou supérieure).
3.3 Robinet de gaz
S'ouvre et se ferme au montage ou
démontage du raccord fileté de
l'équipement de précharge. L'axe creux
de la buse de l'équipement de précharge
ouvre le robinet. Le reste du temps, le
robinet reste fermé.
N.B.
Si le robinet de gaz est doté d'un écrou
de manœuvre hexagonal, le serrer au
couple de 6-7 Nm pour le fermer.
6-7 Nm
42
Utiliser l'équipement de précharge pour
le vidage ou le remplissage d'azote
gazeux.
4. Démarrage
Si l'air doit être évacué de l'accumulateur
à piston avant utilisation, procéder à
cette opération au raccord côté huile.
Avant d'utiliser l'accumulateur, le
pressuriser correctement, en calculant la
pression conformément aux données
opérationnelles de l'appareil.
La pression de service et la température
de service autorisées dépendent des
matériaux utilisés dans l'accumulateur et
sont spécifiées sur le marquage du
produit.
L'accumulateur doit être monté de
manière à garantir la sécurité en cas de
vibrations ou d'éventuelles ruptures des
tuyaux de raccordement, etc.
Avant de procéder à la pressurisation,
vérifier que:
 l'accumulateur à piston a été installé
correctement;
 les équipements, comme les robinets
de gaz, les disques de rupture les
raccords de tuyaux ont été serrés au
couple correct et que tous les
composants sont vissés
correctement;
 il n'y a pas de fuite après la
pressurisation. En cas de fuite,
resserrer le raccord concerné. Si la
fuite persiste, contacter PMC
Cylinders.
 les fixations n'exercent pas de
contraintes sur l'accumulateur.
5. Maintenance
5.1 Maintenance générale
Afin de garantir le bon fonctionnement à
long terme, procéder régulièrement aux
opérations de maintenance suivantes.
Vérifier:
 la pression de précharge de l'azote
gazeux régulièrement au cours des
deux premières semaines d'utilisation,
puis à des intervalles appropriés (voir
point 5.2). Lors du remplissage de
l'azote gazeux, vérifier qu'il est
suffisamment propre;
 que les raccords sont serrés
correctement et étanches;
 la performance des blocs de sécurité
et d'arrêt;
 les supports de montage;
 l'accumulateur, en procédant
régulièrement à une inspection
visuelle pour détecter d'éventuelles
détériorations provoquées par la
corrosion, ou autre déformation. La
corrosion externe est inadmissible et
doit être traitée immédiatement. Les
problèmes de corrosion externe
mineure peuvent être réparés avec de
la peinture;
 que le marquage fixé sur
l'accumulateur reste lisible. Si
l'accumulateur est usé, contacter le
fournisseur.
5.2 Fréquence des contrôles
Les périodicités suivantes de contrôle de
la pression préchargée sont
recommandées:
 directement après l'installation
 une semaine après l'installation
 six semaines après l'installation
Ensuite, dans des conditions de
fonctionnement normales, une fois tous
les six mois et, dans le cas de
fonctionnement à des températures de
service élevées, une fois par mois.
5.3 Fuites
Des fuites peuvent survenir si le fluide se
déverse côté gaz ou si le gaz fuit côté
fluide. Une pression du gaz trop basse
peut être signe d'une fuite de gaz
externe ou interne.
Fuite interne
Une pression du gaz trop élevée peut
être signe d'une fuite de fluide côté gaz.
Une pression du gaz trop basse peut
être signe d'une fuite de gaz côté fluide.
Une fuite interne peut être provoquée
par:
 l'usure ou la détérioration du joint de
piston
 la détérioration de la surface interne
du cylindre
Les joints usés et endommagés doivent
être remplacés par des joints d'origine,
tandis que les cylindres détériorés
FR
doivent être inspectés par le personnel
compétent dûment autorisé, capable de
juger s'il est possible de réparer le dégât
ou s'il faut remplacer le cylindre (voir
point 7. Entretien).
43
Fuite externe
Une pression du gaz trop basse peut
être signe d'une fuite externe. Le fluide
peut fuir depuis le côté fluide ou le gaz
peut s'échapper depuis le côté gaz.
Une fuite externe peut être provoquée
par:
 l'usure ou la détérioration du joint du
capuchon d'extrémité.
 la détérioration de la surface
d'étanchéité du filet du joint.
 la détérioration du cylindre au joint.
 le serrage insuffisant ou la
détérioration du robinet.
7. Entretien
Avertissement
Il incombe à l'utilisateur de vérifier le
respect des réglementations en
vigueur. À noter également que seul le
personnel dûment formé est autorisé à
entretenir l'accumulateur à piston.
Avertissement
Faire preuve d'une extrême vigilance
pour démonter et remonter le côté gaz
de l'accumulateur à piston.
L'accumulateur à piston doit être
dépressurisé!

Les joints usés et endommagés doivent Avertissement

être remplacés par des joints d'origine,
tandis que le capuchon d'extrémité ou le L'huile peut rester chaude encore un
tuyau de l'accumulateur détériorés certain temps après l'arrêt.
doivent être inspectés par le personnel
compétent dûment autorisé, capable de
juger s'il est possible de réparer le dégât
ou s'il faut remplacer les pièces Ne jamais vidanger le côté gaz en
défectueuses. Si le robinet de gaz est ouvrant le robinet de gaz ou d'autres
endommagé, le remplacer. Pour le raccords. Le robinet de gaz ou d'autres
démontage en toute sécurité, voir point composants pourraient être expulsés.
7. Entretien.
Le relâchement rapide du gaz peut
comporter un risque de suffocation.
6. Longueur de vie
Vérifier que le local est bien aéré.
L'accumulateur à piston a une durée de
Pour toutes informations concernant le
vie limitée. La longueur de vie dépend de
démontage et les réparations, contacter
l'amplitude de la pression et du nombre
PMC Cylinders.
de cycles de pression.
Utiliser exclusivement des composants
d'origine PMC Cylinders.
Le nombre autorisé d'interrupteurs de
charge est spécifié dans la
Les entretiens, les contrôles et les
documentation de conformité. Ces
réparations peuvent être effectués à
données sont nécessaires pour
l'usine de PMC Cylinders, à Vaggeryd.
déterminer la longueur de vie de
l'accumulateur. La durée de vie dépend
des conditions de fonctionnement dans
le système hydraulique.

44
1. Wstęp
Produkowane przez PMC Cylinders
akumulatory tłokowe należące do serii PAC i
PAS posiadają oznakowanie CE i są
zatwierdzone do użytku w obrębie Unii
Europejskiej. Są one poddawane kontroli
zgodnie z procedurami opisanymi w
modułach B (prod. type) i D, według
dyrektywy 2014/68/EU Unii Europejskiej
dotyczącej urządzeń ciśnieniowych.
Przed użyciem należy dokładnie
przeczytać instrukcję obsługi. Przed
przystąpieniem do użytkowania akumulatora
tłokowego należy zwrócić szczególną uwagę
na ostrzeżenia. Nieprawidłowe użytkowanie
może doprowadzić do wypadków grożących
obrażeniami ciała lub nawet śmiercią.
UWAGA
Użytkownik ponosi całkowitą
odpowiedzialność za zapewnienie
przestrzegania stosownych przepisów.
Montaż, obsługę i konserwację akumulatora
tłokowego może wykonywać wyłącznie
odpowiednio przeszkolony personel.
Konieczne jest przestrzeganie przepisów
dotyczących rozruchu eksploatacyjnego i
użytkowania akumulatora tłokowego,
obowiązujących w miejscu jego
zainstalowania.
Instrukcję obsługi można pobrać ze strony
internetowej www.pmccylinders.se.
Instrukcję obsługi należy przechowywać w
miejscu zapewniającym łatwy dostęp w razie
potrzeby.
2. Dostawa
Ostrzeżenie
Nie wolno używać akumulatorów, które
uległy uszkodzeniu podczas transportu.
Cały transport wypełnionych gazem
akumulatorów tłokowych musi odbywać się
przy zachowaniu możliwie jak największej
ostrożności, a ponadto muszą być
przestrzeganie wszystkie stosowne przepisy
transportowe dotyczące produktów
wypełnionych gazem.
Do transportu i przeładunku może być
używany wyłącznie zatwierdzony sprzęt do
podnoszenia.
Akumulator tłokowy jest dostarczany w
jednym z dwóch stanów:
 Wstępnie napełniony azotem (N₂) o
ciśnieniu maks. 2 bary w celu
przeciwdziałania korozji oraz
uniemożliwienia ruchu tłoka podczas
transportu. Ten stan nie jest traktowany
jako stan wstępnego naładowania i nie
jest on wyszczególniony na etykiecie
akumulatora tłokowego.
 Wstępnie naładowany azotem (N₂) o
ciśnieniu określonym przez klienta. To
ciśnienie jest podane na etykiecie
umieszczonej na akumulatorze tłokowym.
PL
45
2.1 Oznaczenia
Oznaczenia zawierają informacje wybite na
akumulatorze tłokowym i umieszczone na
etykietach.
Użytkownik jest odpowiedzialny za
sprawdzanie, czy wszystkie oznaczenia
umieszczone na akumulatorze tłokowym
pozostają w nienaruszonym stanie i są
całkowicie czytelne. Surowo zabrania się
zmiany lub usuwania oznaczeń, zaś
uszkodzone oznaczenia należy zawsze
wymieniać. Skontaktować się z dostawcą.
Na umieszczonej na akumulatorze tłokowym
nalepce podane jest zwykle ciśnienie
wstępnego ładowania. Ciśnienie to nie jest
podawane, jeśli akumulator będzie wstępnie
ładowany po dostawie przez producenta.
2.2 Kontrola odbiorcza
 Zawsze należy sprawdzić, czy dostawa
jest zgodna z zamówieniem.
 W przypadku możliwości wystąpienia
uszkodzenia akumulatora tłokowego
należy sprawdzić, czy uszkodzeniu uległo
opakowanie.
 Sprawdzić, czy nie występują
uszkodzenia powierzchni akumulatora.
 Sprawdzić, czy nie występują żadne inne
uszkodzenia akumulatora tłokowego i
jego akcesoriów.
 Sprawdzić, czy deklaracja zgodności
pokrywa się z oznaczeniami na
akumulatorze tłokowym.
46
2.3 Prace przeładunkowe
Ostrzeżenie
Podczas przeładunku ciężkich
akumulatorów tłokowych należy zawsze
używać odpowiedniego sprzętu
ochronnego.
Uważać, aby w żaden sposób nie uszkodzić
akumulatora tłokowego (jego powierzchni,
akcesoriów itp.).
Do montażu dużych akumulatorów
tłokowych należy używać odpowiedniego
sprzętu do podnoszenia oraz zawiesi
pasowych. Zwracać uwagę na prawidłowe
zrównoważenie akumulatora tłokowego.
W pokrywach końcowych dużych
akumulatorów tłokowych znajdują się
gwintowane otwory, umożliwiające
wkręcenie śrub z łbem do podnoszenia.
2.4 Przechowywanie
Akumulator tłokowy jest dostarczany w
stanie zakonserwowanym (nasmarowany,
zatkany i napełniony azotem). W tym stanie
może być przechowywany przez okres do
dwóch lat w suchym, chłodnym miejscu,
nienarażonym na bezpośrednie działanie
promieni słonecznych.
Jeśli akumulator tłokowy był przechowywany
przez okres przekraczający dwa lata, przed
rozpoczęciem jego użytkowania należy
wymienić wszystkie uszczelnienia.
Jeśli akumulator tłokowy był przechowywany
przez ponad trzy miesiące w stanie
wstępnego naładowania przy ciśnieniu >5
barów, ciśnienie musi zostać zmniejszone do
wartości nieprzekraczającej 5 barów.
Wstępnie naładowane akumulatory tłokowe
muszą być przechowywane w bezpiecznym
miejscu, zabezpieczone przed uderzeniami i
ogniem, co mogłoby spowodować ich
wybuch.
3. Montaż
Ostrzeżenie
Aby uniknąć niebezpieczeństwa wybuchu,
nie wolno wykonywać spawania, nitowania,
lutowania ani żadnych prac mechanicznych
dotyczących akumulatora tłokowego.
Ostrzeżenie
Szczególną ostrożność należy zachować
podczas instalowania sprzętu po gazowej
stronie akumulatora tłokowego. Akumulator
tłokowy może być wstępnie naładowany.
W różnych krajach mogą obowiązywać
różne przepisy dotyczące montażu i
użytkowania akumulatorów tłokowych. Przed
montażem i rozpoczęciem użytkowania
należy ustalić, jakie przepisy obowiązują w
kraju, w którym akumulator tłokowy będzie
użytkowany.
Akumulator tłokowy może być zamontowany
w dowolnej pozycji. W celu ograniczenia
narażenia na zużycie eksploatacyjne zaleca
się montaż w pozycji pionowej, przyłączem
cieczowym do dołu.
Surowo zabrania się:
 Spawania, nitowania lub lutowania
jakichkolwiek elementów na akumulatorze
tłokowym.
 Podejmowania jakichkolwiek działań,
które mogą mieć wypływ na mechaniczne
właściwości akumulatora.
 Dokonywania modyfikacji akumulatora
bez zgody firmy PMC Cylinders.
Należy się upewnić, że używana ciecz jest
odpowiednia do danego rodzaju sprzętu.
Należy się upewnić, że najwyższe
dopuszczalne ciśnienie robocze akumulatora
tłokowego jest równe lub wyższe niż
ciśnienie w obwodzie hydraulicznym.
Sprawdzić warunki środowiskowe i zapewnić
odpowiednią ochronę sprzętu.
Zapewnić wynoszącą ok. 200 mm przestrzeń
nad zaworem gazowym, aby umożliwić
montaż sprzętu do wstępnego ładowania i
kontroli.
Wszystkie oznaczenia muszą pozostać
widoczne.
W przypadku używania wskaźnika położenia
tłoka należy go zawsze prawidłowo
zamocować i zainstalować pionowo,
przyłączem cieczy do dołu.
PMC Cylinders posiada w swojej ofercie
asortyment akcesoriów w postaci zacisków i
wsporników do mocowania akumulatora
tłokowego podczas montażu. (Patrz odrębny
arkusz danych.)
W przypadku małych akumulatorów
tłokowych, o masie do ok. 10 kg, zaleca się
mocowanie przy użyciu dwóch zacisków. W
przypadku cięższych jednostek liczba
zacisków zależy od wielkości i typu
akumulatora tłokowego, ponadto zaleca się
użycie wspornika mocującego w celu
odciążenia zacisków.
Należy używać odpowiednich przyłączy
przeznaczonych do instalacji hydraulicznych,
a także pamiętać o stosowaniu właściwego
momentu dokręcania.
3.1 Sprzęt bezpieczeństwa
W celu ograniczenia ciśnienia w
akumulatorze tłokowym zalecamy
zamontowanie odpowiedniego wyposażenia
zabezpieczającego po stronie cieczowej i
gazowej.
Zalecamy zamontowanie przepony
bezpieczeństwa lub sprężynowego zaworu
bezpieczeństwa po stronie gazowej. Oba te
zabezpieczenia otwierają się przy wstępnie
ustawionym ciśnieniu, niezależnie od
przyczyny wystąpienia wysokiego ciśnienia.
Zalecamy zastosowanie bloku
PL
bezpieczeństwa z zaworem
zabezpieczającym/redukcyjnym po stronie
cieczowej.
47
3.2 Ładowanie wstępne
Ostrzeżenie
Akumulator tłokowy musi być ładowany
wyłącznie azotem (N₂). Użycie tlenu lub
powietrza grozi wybuchem.
Sprawdzić, czy ciśnienie gazu podczas
wstępnego ładowania jest właściwe dla
używanego akumulatora.
Duże znaczenie dla prawidłowego działania i
trwałości eksploatacyjnej urządzenia ma
jakość użytego azotu. Wystarczająca jest
jakość przemysłowa. Należy stosować azot
o minimalnym stopniu czystości
wynoszącym 99,95% (klasy 4.0 lub wyższej).
3.3 Zawór gazowy
Otwiera się i zamyka w przypadku
podłączenia lub odłączenia gwintowanego
przyłącza sprzętu do wstępnego ładowania.
Umieszczony w dyszy sprzętu do wstępnego
ładowania rurkowy trzpień otwiera zawór. W
innych sytuacjach zawór pozostaje
zamknięty.
UWAGA
Jeśli zawór gazowy wyposażony jest w
sześciokątną nakrętkę regulacyjną, należy
ją dokręcić momentem 6-7 Nm w celu
zamknięcia zaworu.
6-7 Nm
Sprzęt do wstępnego ładowania służy do
opróżniania lub napełniania akumulatora
azotem.
48
4. Rozruch
Jeśli konieczne jest usunięcie powietrza z
akumulatora tłokowego przed rozpoczęciem
jego użytkowania, należy to zrobić po stronie
przyłącza olejowego.
Przed rozpoczęciem użytkowania
akumulatora należy wytworzyć w nim
ciśnienie o wartości obliczonej zgodnie z
parametrami roboczymi urządzenia.
Dopuszczalne ciśnienie robocze i
temperatura robocza zależą od materiałów
użytych do budowy akumulatora i są
określone w oznaczeniu umieszczonym na
produkcie.
Akumulator musi zostać zmontowany w
sposób gwarantujący bezpieczeństwo w
przypadku wystąpienia drgań lub
ewentualnych pęknięć w rurach
przyłączeniowych itp.
Przed wytworzeniem ciśnienia należy
sprawdzić:
 czy akumulator tłokowy został
prawidłowo zainstalowany;
 czy wyposażenie, takie jak zawory
gazowe, przepony bezpieczeństwa i
przyłącza rurowe, zostało prawidłowo
dokręcone oraz czy wszystkie elementy
zostały prawidłowo nagwintowane;
 czy po wytworzeniu ciśnienia nie
występują nieszczelności. W przypadku
wystąpienia nieszczelności należy
dokręcić odpowiednie przyłącze. Jeśli
produkt jest w dalszym ciągu
nieszczelny, należy skontaktować się z
firmą PMC Cylinders.
 czy przyłączone akcesoria nie powodują
występowania naprężeń w akumulatorze.
5. Przeglądy
5.1 Przeglądy ogólne
W celu zapewnienia długiego,
bezproblemowego użytkowania należy
regularnie przeprowadzać wymienione
poniżej przeglądy.
Sprawdzać:
 ciśnienie użytego do wstępnego
naładowania azotu regularnie podczas
pierwszych tygodni użytkowania,
następnie zaś w odpowiednich odstępach
czasu (patrz punkt 5.2). Azot używany do
napełniania musi mieć dostateczną klasę
czystości;
 czy dokręcone przyłącza są szczelne;
 prawidłowość działania bloków
zabezpieczających i odcinających;
 wsporniki montażowe;
 wzrokowo akumulator w regularnych
odstępach czasu pod kątem
występowania uszkodzeń
spowodowanych korozją lub wszelkich
innych odkształceń. Zewnętrzne ogniska
korozji są niedopuszczalne i należy je
niezwłocznie usuwać. Niewielkie
zewnętrzne ogniska korozji usuwa się
przez pomalowanie;
 czy oznaczenia na akumulatorze są
czytelne. Jeśli akumulator jest zużyty,
należy skontaktować się z dostawcą.
5.2 Częstotliwość przeglądów
Zalecamy sprawdzanie ciśnienia wstępnego
naładowania w następujących odstępach
czasu:
 bezpośrednio po zamontowaniu
 tydzień po zamontowaniu
 sześć tygodni po zamontowaniu
Następnie, w przypadku normalnych
warunków roboczych, co sześć miesięcy,
zaś w przypadku wysokich temperatur
roboczych - co miesiąc.
5.3 Nieszczelność
Nieszczelność może wystąpić, jeśli ciecz
wycieka na stronę gazową lub gaz wycieka
na stronę cieczową. Zbyt niskie ciśnienie
gazu może wskazywać na występowanie
zewnętrznego lub wewnętrznego wycieku
gazu.
Wyciek wewnętrzny
Zbyt wysokie ciśnienie gazu może
wskazywać na występowanie wycieku cieczy
na stronę gazową. Zbyt niskie ciśnienie gazu
może wskazywać na występowanie wycieku
gazu na stronę cieczową.
Wyciek wewnętrzny może być
spowodowany:
 zużyciem lub uszkodzeniem
uszczelnienia tłoka
 uszkodzeniem wewnętrznej powierzchni
cylindra
Zużyte lub uszkodzone uszczelnienia należy
wymienić na oryginalne uszczelnienia, zaś
uszkodzone cylindry muszą zostać
skontrolowane przez wykwalifikowany,
upoważniony personel w celu ustalenia, czy
uszkodzenie może zostać naprawione, czy
też cylinder musi zostać wymieniony (patrz
punkt 7. Serwis).
PL
49
Wyciek zewnętrzny
Zbyt niskie ciśnienie gazu może wskazywać
na występowanie zewnętrznego wycieku.
Ciecz może wyciekać ze strony cieczowej
lub gaz ze strony gazowej.
Wyciek zewnętrzny może być
spowodowany:
 zużyciem lub uszkodzeniem
uszczelnienia pokrywy końcowej,
 uszkodzeniem powierzchni
uszczelniającej w połączeniu
gwintowanym,
 uszkodzeniem cylindra w obrębie
uszczelnienia,
 niedostatecznym dokręceniem lub
uszkodzeniem zaworu.
Zużyte lub uszkodzone uszczelnienia należy
wymienić na oryginalne uszczelnienia, zaś
uszkodzona pokrywa końcowa lub rura
akumulatora muszą zostać skontrolowane
przez wykwalifikowany, upoważniony
personel w celu ustalenia, czy uszkodzenie
może zostać naprawione, czy też konieczne
jest dokonanie wymiany. Jeśli zawór jest
uszkodzony, należy wymienić zawór
gazowy. Informacje dotyczące bezpiecznego
demontażu zaworu podano w punkcie 7.
Serwis.
6. Trwałość eksploatacyjna
Trwałość eksploatacyjna akumulatora
tłokowego jest ograniczona. Trwałość
eksploatacyjna zależy od amplitudy ciśnień
oraz liczby cykli ciśnieniowych.
Dopuszczalną liczbę przełączeń pod
obciążeniem podano w dokumentacji
zgodności. Powyższe dane są wymagane do
podjęcia decyzji dotyczącej trwałości
eksploatacyjnej akumulatora. Trwałość
eksploatacyjna zależy od warunków pracy w
instalacji hydraulicznej.
50
7. Serwis
Ostrzeżenie
Użytkownik ponosi całkowitą
odpowiedzialność za zapewnienie
przestrzegania stosownych przepisów.
Prace serwisowe dotyczące akumulatora
tłokowego może wykonywać wyłącznie
odpowiednio przeszkolony personel.
Ostrzeżenie
Szczególną ostrożność należy zachować
podczas demontażu i montażu sprzętu po
gazowej stronie akumulatora tłokowego.
Akumulator tłokowy musi zostać
rozhermetyzowany.
Ostrzeżenie
Olej może utrzymywać wysoką
temperaturę przez pewien czas po
wyłączeniu urządzenia.
W żadnym wypadku nie wolno opróżniać
gazowej strony akumulatora przez
otworzenie zaworu gazowego lub innych
przyłączy. Zawór gazowy lub inne elementy
mogą wystrzelić.
Nagłe uwolnienie gazu może pociągać za
sobą ryzyko uduszenia. Należy zapewnić
dobrą wentylację.
W celu uzyskania informacji na temat
demontażu i napraw należy skontaktować
się z firmą PMC Cylinders.
Używać wyłącznie oryginalnych
podzespołów firmy PMC Cylinders.
Usługi serwisowe, kontrolne i naprawcze
mogą zostać wykonane w fabryce firmy
PMC Cylinders w Vaggeryd.
51
PMC CYLINDERS AB
Box 20
SE-567 21 Vaggeryd
SWEDEN

 +46 (0) 393 365 00

www.pmccylinders.se

52
INSTRUCTION MANUAL

Pedals
One pedal
The pedal is a combined declutch and brake pedal. If you press down the pedal with normal pressure, it operates as
a regular brake. If you increase the force, the pedal hits a contact and the transmission declutches.

Two pedals
» Left pedal - Declutch and brake pedal
» Right pedal - Brake pedal

Use the right pedal to brake. This does not affect the left pedal.

The two pedals are used to engage the brakes and declutch the transmission at the same time, e.g. to increase the
engine rpm. The declutch contact is placed on an anchor plate (directly under the left pedal). The anchor plate is
connected to the right pedal. When the left pedal is pressed down, it hits the declutch anchor plate and the
transmission declutches. Simultaneously, the right pedal is automatically engaged (the forklift slows down) because
it is connected to the left pedal.

The pedals are placed with a small level difference. This makes it easier for the driver to feel which pedal he operates.
If both pedals are pressed down by mistake, the transmission will be declutched and the engine brake will not be used.

Figure 3

Braking
When the brakes are engaged they generate heat energy. To avoid undue stress on the brakes, transmission and axles,
do not engage the brakes for too long.

Edition 1 KM-21:GB
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Hydraulic system
Hydraulsystem 7
INSTRUCTION MANUAL

Breather - hydraulic system

Exchange
You must change the hydraulic system’s breather every 1000 hour of operation or every 5th month. Check also
the hydraulic system’s breather every time you check the oil level in the hydraulic tank. Some machines have
two breathers.

» Clean the underside of the old breathers, so that no dirt particles falls into the tank.

» Remove the breathers and reject them.

» Insert new breathers.

Breather

Filler base

Level indicator

Figure 4

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INSTRUCTION MANUAL

Hydraulic filter
The hydraulic filters must during normal conditions be changed every 1000 hours of operation. Besides that, the
filter base is equipped with an indicator. If the poiner shows red during operation, the filter must be changed
immediately. If the lift truck is equipped with compressed air brakes there are three filters. If the lift truck has
hydraulic brakes there are five filters.

Change of filters
The lift truck must stand horizontally, have the hydraulic cylinders redrawn or the aggregate lowered to the ground,
the parking brake switched on and the main circuit breaker off.

WARNING!
Hot oil in contact with the skin could cause burns.

» Place a vessel under the filter house into which the oil can flow.

» Remove the plug under the filter house and let the oil pour into it.

» Remove the filterhouse.

» Remove the filter chuck from the filter house and discard it.

» Clean the filter base and change O-ring.

» Dry and clean the filter house in parafin or diesel oil.

» Place a new filter chuck in the filter house.

» Mount the filterhouse.

» Check that the seal isn't worn and screw the plug back underneath the filter house.

» Start the engine and let it run at an idle speed.

» Check that there isn’t any leakage.

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INSTRUCTION MANUAL

Accumulator pressure

Domed nut

Measuring point

Figure 150

Control of pressure
The accumulator pressure should be 30-35 bar (435-510 psi). It must absolutely not be below 30 bar (435 psi).

» Connect a pressure gauge to the measuring point. See figure 150.

» Adjust the engines rpm to 1500 and push the control to tilt to its end position.

» Take a reading from pressure gauge and adjust the pressure if needed.

Adjustment
If you need to adjust the pressure it’s often too low.

» Stop the engine.

» Unfasten the domed nut.See figure 150.

» Place a M6-washer in the domed nut. The pressure on the spring increases and the pressure will increase.

» Fasten the domed nut and the washer.

» Start the engine and check that the accumulator pressure is correctly adjusted.

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INSTRUCTION MANUAL

Hydraulic pressure
Measuring outlet

Locking nut
Adjusting screw

Figure 591

Control 2-sections/3-sections

Check
Check in table 222 what pressure your truck should have.

» The hydraulic oil should have reached normal working temperature.

» Connect a pressure gauge to the measuring outlet. See figure 591.

» The engine revs should be 1500 rpm when checking and adjusting the hydraulic pressure.

» 32120-52120
Move the control lever for tilting to an end position. Hold the lever in the deflected position so that the
hydraulic control is overloaded.

TMF 12/9-28/21
Move the control lever for grapple close to the end position. Hold the lever in the deflected position so that
the hydraulic control is overloaded.

» Read off the pressure gauge and adjust the pressure if necessary.

Adjusting
» Undo the locking nut with a 1 1/8" (29 mm) combination spanner. See figure 591.

» Turn the adjusting screw with a 1/4" Allen key, until the correct pressure is set.
Right turn – higher pressure
Left turn – lower pressure

» Tighten the locking nut. It is important to hold the adjusting screw in the set position while the locking nut
is being tightened.

» Check that the correct hydraulic pressure has been set.

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INSTRUCTION MANUAL

Nut which sits on the adjusting screw

Locking nut

Measuring outlet

Figure 590

Control 4-sections/5-sections

Check
Check in table 222 what pressure your truck should have.

» The hydraulic oil should have reached normal working temperature.

» Connect a pressure gauge to the measuring outlet. See figure 590.

» The engine revs should be 1500 rpm when checking and adjusting the hydraulic pressure.

» 32120-52120
Move the control lever for sideways displacement to an end position. Hold the lever in the deflected
position so that the hydraulic control is overloaded.

TMF 12/9-28/21
Lift up the roller buffer to its end position. Hold the button in the deflected position so that the hydraulic
control is overloaded.

» Read off the pressure gauge and adjust the pressure if necessary.

Adjusting
» Remove the long nut with a 3/4" (19 mm) combination spanner and remove the sealing washer.
See figure 590.

» Undo the locking nut.

» Turn the adjusting screw with a 7/32" Allen key, until the correct pressure is set.
Right turn – higher pressure
Left turn – lower pressure

» Tighten the locking nut. It is important to hold the adjusting screw in the set position while the locking nut is
being tightened.

» Check that the correct hydraulic pressure has been set.

» Reinstall the sealing washer and the long nut.

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INSTRUCTION MANUAL

Pressure setting
The engine revs should be 1500 rpm when adjusting the hydraulic pressure.
Carry out a test lift to check the correct setting of hydraulic pressure on the hydraulic controls.

Control 2-sect. Control 3-sect.

Part no.: 907781 Part no.: 907919
Type: V3A4013DS7VS Type: V3A4013DSD6VS

Control 4-sect. Control 5-sect.

Part no.: 907226 Part no.: 907147
Type: V4109SDDD86VS Type: V4109SDDDD117VS

Hydr.pressure (bar) Hydr.pressure (bar) Hydr.pressure (bar) Hydr.pressure (bar) Hydr.pressure (bar)
Machine model 2-sect./3-sect. 4-sect./5-sect. 4-sect./5-sect. 4-sect./5-sect. 4-sect./5-sect.
Allison Dana Caterpillar ZF

32120 Duplex, fork 164 150 164 - 164

32120 Simplex, fork 164 150 164 - 164

32120 Free lift, fork 172 150 172 - 172

32120 Duplex, grapple 150 150 150 - 150

35120-50 Duplex, fork 176 150 176 - 176

37120 Duplex, fork 160 150 160 - 160

42120 Duplex, fork 164 150 164 - 164

42120 Duplex, int. fork, 35 t under spreader 835 165 150 165 - 165

42120 Duplex, int. fork, 32 t under spreader 835 175 150 175 - 175

42120 Duplex, gantry, spreader 838 165 150 165 - 165

42120 Duplex, free lift, fork 170 150 170 - 170

45120 Duplex, fork 195 150 195 - 195

45120 Duplex, int. fork, 35 t under spreader 835 175 150 175 - 175

45120 Duplex, gantry, 35 t under spreader 838 179 150 179 - 179

45120 Duplex, free lift, gantry, spreader 838 175 150 175 - 175

45120 Triplex, free lift, 37 t under spreader 835 185 150 185 - 185

50120 Duplex, fork 202 150 202 - 202

50120 Duplex, gantry, spreader 838 180 150 180 - 180

50120 Duplex, free lift, fork 180 150 180 - 180

52120 Duplex, gantry, spreader 838 190 150 190 - 190

S1150 225 - 225 - 225

TMF 12/9 wheel base 50 or 52 160 160 - - 150

TMF 15/11 wheel base 52 or 54 175 160 - - 160

TMF 25/18 wheel base 57 190 160 - 190 -

TMF 25/18 wheel base 60 200 160 - 200 -

TMF 28/21 wheel base 60 200 160 - 200 -

Table 222

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INSTRUCTION MANUAL

Hydraulic oil tank

Check the hydraulic oil level and air filter every 10 operating hours or every day.
The tank is on the right-hand side of the truck. There is an oil level gauge on the back of the tank for checking the
oil level. There are two air filters and an oil filler pipe on top of the tank. See fig. 987.

Air filters

Refill plug

Oil level gauge

Figure 987

Checking the hydraulic oil level

Check the oil level when the oil is cold. The oil level should be at least half way up the gauge but should never
exceed the MAX mark.

Air filters
The filters should be changed every 1000 operating hours or every 5 months.

» Clean the undersides of the old filters so that no particles of dirt fall down into the tank.

» Remove the filters and take them to a collection facility for safe disposal.

» Fit new filters.

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INSTRUCTION MANUAL

Oil
The oil in the tank should be changed every 4000 operating hours or every second year. See Maintenance Procedures
under Group 14 in the Instruction Manual, for the right grade of oil.

WARNING!
If hot oil comes into contact with
skin it can cause serious burns.

» Place a collecting vessel beneath the drain plug.

» Unscrew the drain plug and drain the tank.

» Check that the gasket is in good condition and screw the drain plug back into place.

» Fill the tank to the right level.

» Start the engine and let it idle for a while.

» Check the level and add more oil if necessary.

Tank volumes
Wheel base (mm) Volume (litres)
5000 900
5400 995
5700 995
6000 995
6500 995

Edition 2 KM-465:GB
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INSTRUCTION MANUAL

Servo controls
Levers
Various forklift functions can be operated using the levers on the right side of the steering wheel.
By varying the lever movement, the speed of the various hydraulic functions can be varied. The speed also varies
with the engine speed, except for the lowering speed.

Functions
Lever functions if the forklift is equipped with sideshift, fork positioning and fork levelling.

» Lift/Lower (1)
Lift Move the lever backwards 1 2 3 4 5
Lower Move the lever forwards

» Tilt (2)
Backwards Move the lever backwards
Forwards Move the lever forwards

» Sideshift (3)
Right Move the lever backwards
Left Move the lever forwards

» Fork positioning (4)
Inwards Move the lever backwards
Outwards Move the lever forwards

» Fork levelling (5)

Lift Move the lever backwards
Lower Move the lever forwards Figure 7

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INSTRUCTION MANUAL

Lever functions if the forklift is equipped with fast lift, sideshift and fork positioning.

» Lift/Lower (1)
Lift Move the lever backwards 1 2 3 4 5
Lower Move the lever forwards

» Fast lift (2)

Move the lever backwards while simultaneously
moving the Lift/Lower lever.
Note! To lower, use the Lift/Lower lever.

» Tilt (3)
Backwards Move the lever backwards
Forwards Move the lever forwards

» Sideshift (4)
Right Move the lever backwards
Left Move the lever forwards

» Fork positioning (5)
Inwards Move the lever backwards Figure 7
Outwards Move the lever forwards

Lever functions if the forklift is equipped with fast lift and sideshift.

» Lift/Lower (1)
Lift Move the lever backwards 1 2 3 4
Lower Move the lever forwards

» Fast lift (2)

Move the lever backwards while simultaneously
moving the Lift/Lower lever.
Note! To lower, use the Lift/Lower lever.

» Tilt (3)
Backwards Move the lever backwards
Forwards Move the lever forwards

» Sideshift (4)
Right Move the lever backwards
Left Move the lever forwards

Figure 31

Edition 1 KM-313:GB
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INSTRUCTION MANUAL

Hydraulic pump
The hydraulic pump is placed under the engine. As the oil level in the hydraulic tank is higher than the hydraulic
pump, you must empty the tank before you change the pump.

The hydraulic pump is too heavy to carry by yourself. You must therefore use a jack or similar, that holds the pump
when it becomes loose.

When you change the hydraulic pump we recommend you to also change hydraulic filters. If the old pump has had
a breakdown, the filters must be changed to eleminate the risk of foreign metal paricles.

IMPORTANT!
Cleanliness is to be observed when handling hydraulic components.
Very small particles can effect the system seriously.

Change of hydraulic pump

» Empty the hydraulic tank.

» Unfasten the pressure and suction tubes. See figure 147 and 148.

» Place a jack or similar under the pump.

» Unscrew the bolts that hold the hydraulic pump.

» Pull out the pump from the splines.

» Change o-ring.

» Push the new pump on the splines and fasten it with the bolts.

» Make sure that there is a space between the hydraulic pump and the gear box. If there isn’t a gap you
must dismount the pump and material must be cut away on the pump and eventually on the gear box.

» Fill the hydraulic tank. Check so that there is enough oil in the tank. If there isn’t enough oil in the
hydraulic tank and you start the engine, the new hydraulic pump is guaranteed to fail.

» Start the machine and check that there is no oil leakage.

Edition 1 KM-131:GB
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INSTRUCTION MANUAL

Fastening bolt (even on the

other side of the pump)

Suction tubes
Figure 147

Fastening bolt (even on the

other side of the pump)

Pressure tube to
the priority valve

Pressure
tube to the
hydraulic
control
Figure 148

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INSTRUCTION MANUAL

Steering pressure
Hose and adapter that Hose and adapter that Adapter with pressure
have to be removed have to be removed when limiter – applies to
when adjusting adjusting – applies to newer VLH valve
older VLH valve models models
VLE valve

VLH valve

Measuring
outlet

Figure 737 Figure 736

Check
Check the control pressure on the priority flow regulator valve. The recommended pressure varies depending on
the truck model:
860-1875/1890 140-150 bar
18120-34120 165-170 bar
32120-52120 168 bar
S1150 209 bar
TMF 12/9-28/21 168 bar

» For VLE valve: Connect the pressure gauge to the measuring outlet. See figure 737.
Note! Variations may occur!

» For VLH valve: Connect the pressure gauge to the measuring outlet. The position of the measuring outlet
varies depending on the truck model:
1060-34120 Right-hand side of frame. Follow CF from the valve. See figure 736.
S1150 Left-hand side of frame. Follow CF from the valve. See figure 736.
TMF 25/18- 28/21 Right-hand side behind the access door under the cab. Follow CF from the valve.
See figure 736.
Note! If the machine has lever control/mini-wheel, the measuring outlet will be on the PVG valve!

» Set the engine revs at approx. 1000 rpm and turn the wheel to an end position.

» Read the pressure gauge.

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INSTRUCTION MANUAL

Adjusting VLE valves and older VLH valve models

» Stop the engine.

» For VLE valves: Unscrew the left hose and the adapter marked ”T” on the priority flow regulator valve.
See figure 737.

» For older VLH valve models: Unscrew the hose and the adapter marked ”T” on the priority flow regulator
valve. See figure 736.

» Use an Allen key to adjust the pressure with the Allen screw.
Clockwise – Increases pressure
Anti-clockwise – Reduces pressure

» Reinstall the adapter and the hose.

» Start the engine again and use the pressure gauge to check the control pressure.

» Stop the engine and adjust the control pressure if necessary.

Adjusting newer VLH valve models

» For newer VLH valve models: Unscrew the adapter with pressure limiter. There are screwdriver slots in the
front end of the pressure limiter. Use a suitable screwdriver to adjust the pressure. See figure 736.
Clockwise – Increases pressure
Anti-clockwise – Reduces pressure
Note! A 1/2 turn is approximately 40 bar.

» Reinstall the adapter with the pressure limiter.

» Start the engine again and use the pressure gauge to check the control pressure.

» Stop the engine and adjust the control pressure if necessary.

Edition 3 KM-143:GB
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Air conditioning
Klimatanläggning 8
INSTRUCTION MANUAL

Climate control
General
The climate control system automatically regulates the temperature in the cab to the selected temperature setting.

The climate control system draws in air from outside or recirculates the air inside the cab. The fine filter is located
behind the driver’s seat, the wide-meshed filter is located in the air intake at the top of the cab. The driver regulates
where the air should come from using a setting control (in the interval 20/80% - 80/20%).

The climate control system is available with air conditioning and engine-off heating. These are optional features
and have to be ordered separately.

The climate control system heats up the air using the engine’s coolant and if the truck is fitted with air conditioning
it cools the air with R134a refrigerant.

The air flows into the cab through vents under the driver’s seat and/or on the dashboard. The arrows indicate the
air streams. The driver regulates the air streams with a variable setting control on the left-hand side of the climate
control panel.

A BC D

Figure 829

E F

A Switch
Choose the operating setting with the switch. See Operating settings.

B Fan control
Turn the control clockwise to increase fan speed. Turn it anti-clockwise to reduce fan speed.
Fan speed has variable settings.

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INSTRUCTION MANUAL

C Temperature control
Turn the control clockwise to increase the flow of heat. Turn it anti-clockwise to reduce the flow of heat.
The temperature has variable settings.

D Defroster/cab
Turn the control clockwise to set the flow of air to defrost. Turn it anti-clockwise to set the flow of air to the
cab area.

E Air exhaust control

Select defrost position + nozzles under panel or exhaust under seat.

F Air intake control

Air from outside 80%/20%
Recirculation 80%/20%
Use recirculation as briefly as possible, as recirculation causes condensation.

Uses of the operating settings

Fan forced heating

» Used to heat the cab quickly. Switch to normal operation/automatic when the required temperature has been
reached.

Normal operation/Automatic
» The system keeps the set temperature in the cab. Without air conditioning (optional) the temperature in the
cab can never drop below the outdoor temperature.

Normal operation/Automatic + Engine-off heating (Optional)

» The system keeps the set temperature in the cab. Without air conditioning (optional) the temperature in the
cab can never drop below the outdoor temperature. As soon as the ignition is turned off, the off-engine
heating starts and operates as long as the cooling water from the engine is hotter than 39°C.

Note! Fan forced heating and off-engine heating are not affected by the temperature control setting. The fan
operates at the set value when off-engine heating is used. Air conditioning turns off automatically when the outdoor
temperature is approx. -5°C.

Operating settings
Fan forced heating
» Switch as per figure 528.
» Fan control at max.
Figure 528
» Return to normal operation/automatic when the required
temperature has been reached.

Normal operation/Automatic
» Switch as per figure 529.
Figure 529 » Fan control at required speed
» Fan control at required temperature.

Normal operation/Automatic + Engine-off heating (Optional)

» Switch as per figure 530.
» Fan control at required speed.
Figure 530
» Fan control at required temperature.

Note! The fan and temperature have variable settings. See figure 829.

Edition 1 KM-414:GB
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INSTRUCTION MANUAL

Care/Maintenance
The system must be inspected and maintained regularly for it to work satisfactorily for many years.

Daily
» Check the condensing unit. If necessary, carefully clean the flanges with compressed air from inside the condenser.
Note! If the compressed air is too powerful, it may damage the condenser ribs.

Weekly
» Shake dirt off the filters. Do not use water or compressed air.

Monthly
» Check the belt tension, fastening and alignment of the compressor.
» Check that the cooling unit’s drain outflow is not blocked so that condensed water does not remain in the unit.
» Inspect the system’s hoses and protect them from wear and overheating next to hot engine parts.
» The condenser air’s inlet and outlet areas must not be obstructed.
» Check that the condenser is securely mounted to prevent damage from vibration.
» The cooling unit’s recirculation intake in the cab must not be obstructed.
» Make a note of the compressor’s and condenser’s run time. If it is unusually long or short, contact
service personnel. In normal operation (outdoor temperature 0 - 25°C and 25% fan speed) the run/pause
time ratio is approx. 2:1.

NOTE!
» Refrigerant systems may only be serviced by
accredited or licensed companies.
» Hose connections must not be disconnected.
» The cooling system is pressurised. Incorrect
operation may cause human injury.

Troubleshooting
Even if you do not have qualifications in cooling technology, you can still perform the following basic trouble-
shooting procedures.

1. The system’s cooling output gradually decreases during the day.

A. The cooling thermostat is probably set too high, causing ice to form on the cooling unit.

2. The system’s cooling output is poor.

A. Insufficient flow of air through the cooling unit reduces output and can be due to blocked air vents,
clogged air intake or leakage in the air distribution system.
B. The condenser unit is blocked or the condenser cooling is poor (fan motor not working).

3. No cooling output.
A. Check the unit’s fuses and relays. Check for loose cables to the compressor and condenser fan motor.
B. Check that the thermostat is in good condition.
C. The cooling system’s low pressure pressostat has been triggered due to a lack of refrigerant in the
system. This may be due to a ruptured pipe or heavy leakage. This must be rectified by authorised
personnel.

Edition 1 KM-414:GB
Page 3 (4)
8
INSTRUCTION MANUAL

Cab air filter

Fine filter
» Filter class: EU 7.
» Cleaning: Shake dirt off. Do not use water or compressed air.
» Replacement filter: We recommend changing the filter after approx. 1000 operating hours. The replacement
interval depends entirely on the exterior environment.

Wide-meshed filter
» Filter class: 20 PPI
» Cleaning: Wash in soapy water.

Edition 1 KM-414:GB
Page 4 (4)
8
Electrical equipment
Elsystem 9
 DOCUMENT NO:

114404:GB
CREATED EDITION DATE PAGE
FUSE LIST NB 1 060322 1/ (1)

1:1 15A IQAN XP/XS/XT2-unit

1:2 15A IQAN XP/LL/LM-unit
1:3 5A IQAN XP-unit, Activating switch IQAN EH-steering.
1:4 10A ZF EST-37 shifting system. ZF display
1:5 10A ZF EST-37 shifting system, AEB. Parking signal IQAN
1:6 15A Volvo EMS/CIU control system. Emergency stop switches engine
1:7 10A Control lamps, Gauges, EH-steering.
1:8 15A Electric coolant pumps hydraulic/transmission, Heated driver seat.
2:1 10A Control system brakes.
2:2 15A Wiper motor front, Washer motor, Signal heated rear view mirror. Horn
2:3 15A Wiper motor rear, Wiper motor roof.
2:4 15A Main/dipped beam, Flasher, Search light.
2:5 10A Seat locking device, Signal radio/cd, Central lubrication system.
2:6 15A Additional equipment, Weight system, Lift acc, Diff lock, Sanders.
2:7 15A Climate system.
2:8 10A Ignition key, Buzzer seat, Radio/cd, Clock.
3:1 10A ZF EST-37 shifting system.
3:2 10A Volvo EMS/CIU control system, Vodia.
3:3 10A Signal ignition relay, 5 minutes engine stop.
3:4 15A Start relay.
3:5 15A Parkering brake, Buzzer seat. Shut of wiper front by parking brake.
3:6 10A Heated rear view mirror, Brake light.
3:7 15A Parking light, Rear light, Rotating beacone, Signal main/dipped light. Signal working light.
3:8 15A Horn, Hazard.
4:1 15A Climate system.
4:2 10A Interior light, Spotlights.
4:3 20A Working lights roof.
4:4 15A Reversing lights.
4:5 20A Working lights mast.
4:6 15A Working lights torped/additional equipment.
4:7 15A Compressor driver seat.
4:8 20A AC condenser climate system.
 DOCUMENT NO.:

107878:GB
CREATED ISSUE DATE PAGE
RELAY LIST NB 23 010716 1/ (9)

R1 903433 Shiftronic, 1st gear

R2 903433 Disengagement, forward

R3 903433 Disengagement, reverse

R4 903433 Button gear shifting, holding relay

R5 903433 Button gear shifting, activation

R6 903433 Automatic gear shifting, 2nd 3rd

R8 903433 Operator’s seat buzzer

R9 903433 Automatic raising of log pusher when reversing

R11 903433 Parking lights

R13 903433 Full/dipped beam headlights

R14 903433 Reversing light

R14A 903433 Extra reversing light

R15 903433 Extra work lights, mast, spreader and/or cowl

R16 903433 Extra mast work lights

R17 903433 Standard mast work lights

R18 903433 External cab roof lights

R18B 903433 External cab roof lights

R19 902123 Flashing direction indicator (right, left)

R20 903433 Extra button, roof wiper (arm rest)

R29 903433 Low-pressure lamp, hydraulic brakes

R30 903433 Charging relay, hydraulic brakes

R31 903433 Horn

R32 907388 Start

R33 903433 Stop, condenser

R34 900128 Flashing relay, director indicator

R35 V1622515 Low coolant level

R36 900128 Low-pressure lamp, hydraulic brakes

R38 903433 Fan reversal, door switches

R39 903433 Holding relay, hydrostatic fan reversal and gearbox disengagement

R47 903433 Start prevention device (ZF 3WG 310)

R48 903433 Disengagement (ZF 3WG 310)

R49 903433 Neutral activation (ZF 3WG 310)

R50 903433 Holding relay activation (ZF 3WG 310)

 DOCUMENT NO.:

107878:GB
CREATED ISSUE DATE PAGE
RELAY LIST NB 23 010716 2/ (9)

R51 903433 Shifting 2nd 3rd (ZF 3WG 310)

R52 903433 Shifting 1st (ZF 3WG 310)

R53 903433 Reversing light (ZF 3WG 310)

R55 904283 Main relay, ignition

R56 902275 Front intermittent wiper

R57 902275 Roof intermittent wiper

R58 902275 Rear intermittent wiper

R60 903433 Stop

R61 903433 D+ generator

R62 903433 Compressor, operator’s seat

R63 900128 Flashing relay, log pusher down

R64 903433 Work light switch-off when applying handbrake

R65 903433 Work light switch-off when applying handbrake

R66 903433 Polarity reversal relay, operator’s seat stopped

R67 905608 Time pulse relay, automatic telescoping mode

R68 905608 Time pulse relay, automatic lifting mode

R69 903433 Automatic telescoping mode

R70 903433 Automatic telescoping mode

R71 903433 Automatic telescoping mode

R72 903433 Automatic lifting mode

R73 903433 Automatic lifting mode

R74 903433 Shift relay, forward gear clutch unit (Caterpillar)

R75 903433 Shift relay, reverse gear clutch unit (Caterpillar)

R76 903433 Button gear shifting (Caterpillar)

R77 903433 Button gear shifting (Caterpillar)

R78 903433 Start prevention device (Caterpillar)

R79 903433 Neutral (Caterpillar)

R91 903433 AC/engine-off heating

R96 903433 AC

R101 903433 Travel lights

R102 903433 Telescope work lights

R103 903433 Telescope work lights

R104 903433 Rear work light on lifting arm bracket

 DOCUMENT NO.:

107878:GB
CREATED ISSUE DATE PAGE
RELAY LIST NB 23 010716 3/ (9)

R105 903433 Rear work light in centre of lifting arm bracket

R106 903433 Rear work light at front of lifting arm bracket

R107 903433 Rotating warning light on lifting arm bracket

R108 903433 Heated rear view mirrors

R111 903433 Cab fan

R112 903433 AC switch-off when door open

R113 903433 Automatic lifting mode

R114 903433 Transmission disengagement (inching)

R115 903433 Condenser relay, AC power supply

R116 903433 Hi/low relay, AC condenser

R117 903433 3rd gear locking when telescope extended

R201 903433 Lift limiter

R202 903433 Telescope extension limiter

R203 903433 Telescope retraction limiter

R204 903433 Radio

R205 903433 Lifting lock (Elme spreader)

R206 903433 Lowering lock (Elme spreader)

R207 903433 EHC shifting relay (function 4)

R208 903433 EHC shifting relay (function 4)

R209 903433 Button gear shifting, 4 gears

R210 903433 Button gear shifting, 4 gears

R211 903433 Emergency reversing of machine (Korsnäs)

R212 903433 Lowering lock on levelling fork

R213 903433 Pump controller PCB

R214 903433 EHC lifting lock (Elme spreader)

R215 903433 Lowering lock

R216 903433 Neutral

R217 903433 Work-light switch-off (5 min. stop)

R218 903433 Roof wiper

R219 911265 Time relay, 5 min. stop

R220 902238 Variable intermittent wiper

R221 903433 Stop (Cummins 6BTA 5.9C)

R222 904283 Ignition (IQAN)

 DOCUMENT NO.:

107878:GB
CREATED ISSUE DATE PAGE
RELAY LIST NB 23 010716 4/ (9)

R223 903433 Engine oil pressure switch (IQAN)

R224 903433 Engine water temperature switch (IQAN)

R225 903433 Holding relay (IQAN)

R226 903433 Operator’s seat switch (IQAN)

R227 903433 Stop (Scania)

R228 900128 Load warning

R229 903433 Hazard warning lights for front/rear gear

R230 900128 Hazard warning lights for front/rear gear

R231 903433 Hazard warning lights for front/rear gear

R232 903433 Quick lift

R233 903433 Electronic accelerator KGK

R234 903433 Floating log pusher

R235 904283 Pump, cab tilting

R236 903433 Emergency steering pump, start lock

R237 903433 Emergency steering pump, pump

R238 903433 Grapple attachment

R239 903433 Start lock

R240 903433 Relay, 4th gear

R241 903433 Fork carriage electro-hydraulics EH62

R242 904283 Fork carriage electro-hydraulics EH59

R243 903433 Fork carriage electro-hydraulics EH58

R244 903433 Fork carriage electro-hydraulics EH60

R245 903433 Fork carriage electro-hydraulics EH61

R246 903433 Wiper switch-off when applying parking brake

R247 903433 Parking brake, fire extinguishing

R248 903433 Rear light, trailer socket

R249 903433 Stop light, trailer socket

R250 903433 Left direction indicator, trailer socket

R251 903433 Right direction indicator, trailer socket

R252 903433 Stop relay TAD620VE / TAD722VE

 DOCUMENT NO.:

107878:GB
CREATED ISSUE DATE PAGE
RELAY LIST NB 23 010716 5/ (9)

R253 906224 Time relay, log pusher delay

R254 903433 Relief valve, pump controller

R255 903433 Extra function

R256 903433 Extra function

R257 903433 Cooling water pump, transmission

R258 903433 Current feed from ignition, IQAN system

R259 903433 Current feed from battery, IQAN system

R260 903433 Switching of forward gear signal

R261 903433 Switching of reverse gear signal

R262 903433 Switching of reverse warning signal

R263 903433 Switching of right direction indicator

R264 903433 Switching of left direction indicator

R265 903433 Switching of brake light

R266 903433 Switching of rear light/parking light

R267 903433 Switching of dipped beam headlights

R268 903433 Switching of full beam headlights

R269 903433 Switching of reverse light

R270 903433 Disengagement relay, IQAN system

R271 903433 Safety system (ultrasonic)

R272 903433 Safety system (lifting lock)

R273 903433 ZF gear shift system (parking)

R274 906224 Step lights (delay)

R275 903433 Step lights (delay)

R276 903433 Hydraulically controlled parking brake

R277 903433 Hydraulically controlled parking brake

R278 903433 Hydraulically controlled parking brake,

R279 903433 Hydraulically controlled parking brake

R280 903433 Hydraulically controlled parking brake

R281 903433 IQAN system, unloading relay

 DOCUMENT NO.:

107878:GB
CREATED ISSUE DATE PAGE
RELAY LIST NB 23 010716 6/ (9)

R282 903433 AC compressor

R283 903433 Cooling water pump, hydraulics

R284 903433 Safety system (warning light)

R285 903433 Cooling water level

R286 903731 Cummins generator (12 V)

R287 903433 Cummins generator

R288 903433 Hazard (holding relay)

R289 903433 Step lights

R290 903433 Cab roof edge lights

R291 903433 Seat belt warning

R292 903433 D5/Display control

R293 904283 D5/Over-voltage relay

R294 903433 Button gear shifting 2 × F/N/R (ZF/CAT)

R295 903433 Button gear shifting 2 × F/N/R (ZF/CAT)

R296 903433 Lift accumulator blocking

R297 903433 Electric line circuit breaker

R298 903433 1st gear locking (safety system, load magnet)

R299 903433 1st gear locking (safety system, load magnet)

R300 903433 Direction indicator audible signal relay

R301 903433 Lifting lock (safety system, load magnet)

R302 903433 Safety system (load magnet)

R303 904058 AC controller unit

R304 903433 Start prevention device, Econen

R305 914125 Main switch/contactor

R306 903433 Differential lock warning

R307 903433 Alco-lock, operator change

R308 903433 Alco-lock, preheating

R309 903433 Speed warning

R310 916143 Electric line circuit breaker

 DOCUMENT NO.:

107878:GB
CREATED ISSUE DATE PAGE
RELAY LIST NB 23 010716 7/ (9)

R311 916143 Wiper motor, front window (53)

R312 916143 Wiper motor, front window (53b)

R313 916143 Transmission disengagement (CCO)

R314 916143 Wiper motor, rear window (53)

R315 916143 Wiper motor, roof window (53)

R316 916143 Alco-lock (preheating)

R317 916143 Alco-lock (operator change)

R318 916143 Radio/CD player

R319 916143 Water valve (polarity reversal)

R320 916143 Seat buzzer

R321 916143 Step lights

R322 916143 Seat heater

R323 904283 Compressor, operator’s seat

R324 903433 Extra engine air cooler

R325 903433 Preheating unit, ECC

R326 903433 Preheating unit, ECC

R327 916217 Main relay, ignition

R328 916215 Start

R329 903433 Water valve (politary reversal)

R330 903433 Step lights (delay)

R331 903433 Engine ventilation cover, open

R332 903433 Engine ventilation cover, close

R333 916671 Time relay X min, engine stalling

R334 903433 Eberspäscher shutdown, Fire extinguishing.

R335 903433 Telematic modem

R336 903433 Eberspäscher shutdown, Fire extinguishing.

R337 903433 Warning lights, optional.

R338 903433 Load signal, external equipment

R339 917255 Pressure request to Spreader

 DOCUMENT NO.:

107878:GB
CREATED ISSUE DATE PAGE
RELAY LIST NB 23 010716 8/ (9)

R340 917255 LH+ positioning request, Spreader

R341 917255 LH– positioning request, Spreader

R342 917255 RH+ positioning request, Spreader

R343 917255 RH– positioning request, Spreader

R344 916215 Electric circuit breaker

R345 916215 Wiper motor, front windscreen (53)

R346 916215 Wiper motor, rear windscreen (53)

R347 916215 Entry lights

R348 916215 Transmission disengagement (CCO)

R349 916215 Reversing light

R350 916215 Work lights, overturning buffer

R351 916215 Work lights, cab roof front edge

R352 916215 Horn

R353 916215 Travel light arch

R354 916215 Front work light arch

R355 916215 Side work light arch

R356 916215 Rear work light arch

R357 916215 Power heated rear view mirrors

R358 916215 Rotating warning light

R359 916215 Telescope work lights

R360 916215 Telescope work lights

R361 916215 Preheating unit, ECC

R362 916215 Preheating unit, ECC

R363 916215 Engine start

R364 916215 Operator’s seat heating

R365 903433 Compressor, operator’s seat

R366 903433 Compressor, horn

R367 916215 Telematic modem

R368 916215 Front windscreen washer motor

 DOCUMENT NO.:

107878:GB
CREATED ISSUE DATE PAGE
RELAY LIST NB 23 010716 9/ (9)

R369 916215 Central lubrication

R370 903433 Central lubrication

R371 917255 SEL1 camera system

R372 917255 SEL2 camera system

R373 917255 POC camera system

R374 903433 Safety system (load magnet)

R375 916143 Power on ind (Cummins)

R376 916143 SCR hose heater (Cummins)

R377 916143 SCR hose heater (Cummins)

R378 916143 SCR hose heater (Cummins)

R379 916143 SCR dosing unit (Cummins)

R380 916143 SCR supply (Cummins)

R381 916143 -
 DOCUMENT NO.:

107877:GB
CREATED EDITION DATE PAGE
EH LIST NB 13 010330 1/ (2)

EH1 Gearbox solenoids EH2 Pressure switch, brake pressure charging

EH3 Charging valve EH4 Low-pressure switch/sensor, brakes

EH5 Parking brake sensor, standard EH5A See EH5

EH5B See EH5 EH5C Parking brake sensor, hydraulic control

EH5D Parking brake sensor, warning system override EH6 Parking brake solenoid

EH7 Magnetic valve, lever operation EH8 Solenoid, lift blocking

EH9 Pressure switch, lift blocking EH10 Cut-off valve, hydrostatic fan reversal

EH11 Magnetic valve, hydrostatic fan reversal EH12 Solenoid, roller buffer down

EH13 Solenoid, roller buffer up EH14 Solenoid, clockwise rotation

EH15 Solenoid, counter-clockwise rotation EH16 Solenoid, tilt out (grapple, mast)

EH17 Solenoid, tilt in (grapple, mast) EH18 Solenoid, telescope extension

EH19 Solenoid, telescope retraction EH20 Solenoid, lifting

EH21 Solenoid, lowering EH22 Solenoid, open grapple

EH23 Solenoid, close grapple EH24 Brake light switch

EH25 Solenoid, scale EH26 Solenoid, 2-speed lifting (fast lifting)

EH27 Brake light switch solenoid, lifting system EH28 Lowering blocking valve, spreader
accumulator

EH29 Lifting lock valve, spreader EH30 Sensor, lowering blocking

EH31 Solenoid, side shift left EH32 Solenoid, side shift right

EH33 Solenoid, fork spreading out (open clamping arm) EH34 Solenoid, fork spreading in (close clamping arm)

EH35 Solenoid, extra EH36 Solenoid, levelling down

EH37 Solenoid, levelling up EH38 Solenoid, spreader lock piston

EH39 Solenoid, charging valve EH40 Pressure switch, pre-charging pressure (hydraulic
brakes)

EH41 Relief valve, 2-speed lifting (fast lifting) EH42 Solenoid, differential gear

EH43 Solenoid, sander EH44 Selector valve

EH45 Solenoid, servo pressure accumulator EH46 Tilt blocking valve

EH47 Lifting sensor, tilt blocking EH48 Pressure switch, load warning

EH49 Relief valve, see hydraulic diagram 108235 EH50 Load pressure switch (pump control)

EH51 Servo pressure switch EH52 See hydraulic diagram 110451

EH53 Electrohydraulic steering left EH54 Electrohydraulic steering right

EH55 Solenoid, log pusher out/side-flip out EH56 Solenoid, log pusher in/side-flip in

EH57 Pressure switch, emergency steering pump EH58 Solenoid, optional spreader (lock)
 DOCUMENT NO.:

107877:GB
CREATED EDITION DATE PAGE
EH LIST NB 13 010330 2/ (2)

EH59 Solenoid, optional spreader (unlock) EH60 Solenoid, right fork spreading

EH61 Solenoid, left fork spreading EH62 Equalizing solenoid

EH63 Pressure switch/sensor, inching EH64 Pressure switch, load pressure

EH65 Pressure switch, Orbitrol EH66 Solenoid, left clamp open

EH67 Solenoid, left clamp close EH68 Solenoid, right clamp open

EH69 Solenoid, right clamp close EH70 Solenoid, retardation braking

EH71 Temperature sensor, hydraulic oil tank EH72 Temperature sensor, transmission converter

EH73 Temperature sensor, hydraulic oil servo EH74 Pressure switch, transmission

EH75 Pressure switch, tilt EH76 Pressure switch, lifting servo

EH77 Brake oil temperature sensor EH78 Pressure switch, braking deceleration

EH79 Pressure switch, hydrostatic fan EH80 Drain valve, fan reversal

EH81 Solenoid, cab tilt up EH82 Solenoid, cab tilt down

EH83 Solenoid, roller buffer hitch EH84 Pressure switch, large controller

EH85 Pressure switch, small controller EH86 Cab tilt up

EH87 Cab tilt down EH88 Solenoid, lifting (small)

EH89 Hydrostatic fan EH90 Solenoid, servo pressure accumulator (extra)

EH 91 Solenoid, release of the parking brake EH 92

 DOCUMENT NO.:

107876:GB
CREATED ISSUE DATE PAGE
DESIGNATION LIST NB 12 010717 1/ (5)

1 Ignition lock 2 Preheating switch

3 Reversing warning indicator 4 Coolant indicator lamp, engine

5 Oil pressure indicator lamp, engine 6 Charging indicator lamp, generator

7 Hour counter 8 Oil pressure meter, engine

9 Temperature meter, engine 10 Coolant level and temperature indicator lamp, engine

11 Oil pressure meter, gearbox 12 Temperature meter, gearbox

13 Fuel tank meter 14 AC compressor

15 Fuse box (main fuse) 16 Starter motor

17 Battery 18 Main switch

19 Preheating 20 Magnetic valve, stopping

21 Coolant sensor, engine 22 Temperature sensor, engine (lamp)

23 Oil pressure sensor, engine (lamp) 24 Oil pressure sensor, engine

25 Temperature sensor, engine 26 Weighing system switch

27 Oil pressure sensor, gearbox 28 Temperature sensor, gearbox

29 Fuel level sensor 30 2-speed lifting switch

31 Parking/low beam headlight switch 32 High beam headlight switch

33 Mast, spreader and front chassis light switch 34 Brake light switch

35 Direction indicator lever 36 Hazard warning light switch

37 Director indicator lamp 38 Rotating warning light switch

39 Front rear/left direction indicators 40 Headlights, full beam, low beam and parking lights

41 Generator 42 Standard mast lights

43 Optional mast lights 44 Optional mast lights

45 Rear lights: brake lights, direction indicators, rear lights 46 Rotating warning light

47 Cab illumination switch 48 Left/right reverse lights

49 Gearshift lever 50 Front chassis work lights

51 Disengagement switch 52 Lift system accumulator switch

54 Drive line sensor 55 Gearbox solenoids

56 LED indicator, brake pressure charging 57 Oil pressure indicator lamp, brakes

58 Parking brake switch 59 Operator’s seat switch

60 Locking device, swivelling operator’s seat 61 Locking switch, swivelling operator’s seat

62 Full/low beam indicator 63 Parking brake sensor

64 Spreader lights 65 Operator’s seat buzzer

66 Front wiper switch 67 Roof window wiper switch

 DOCUMENT NO.:

107876:GB
CREATED ISSUE DATE PAGE
DESIGNATION LIST NB 12 010717 2/ (5)

68 Rear wiper switch 69 Washer switch

70 Horn switch 71 Front wiper motor

72 Roof wiper motor 73 Rear wiper motor

74 Washer motor 75 Compressor, operator’s seat

76 Horn 77 Heater, operator’s seat

78 Heater, AC unit 79 Engine sensor

80 Sensor, operator’s seat buzzer, air brakes 81 Disengagement sensor, air brakes

82 Clock 83 Central lubrication

84 Central lubrication switch 85 Reading lamp

86 Search lamp 87 Engine compartment illumination

88 Gearbox compartment illumination 89 Gearshift lever

90 Optional hour counter 91 1st, 2nd, 3rd gear selector button

92 Relay 93 RPM sensor, gearbox

94 Pump controller board 95 Pump controller box

96 ZF transmission buzzer 97 Manual/automatic selector button

98 Pump controller box 99 Safety board buzzer

100 Inductive sensor 101 Radio/CD player

102 Switch, power heated rear view mirrors 103 Gearshift selector button switch, activation

104 Gearshift selector button, forward/reverse 105 Button steering switch, activation

106 Button steering 107 Mini steering wheel

108 Gearbox solenoids 109 Emergency shutdown switch

110 Electric circuit breaker 111 Hitch switch (roller buffer)

112 Position sensor, steering axle 113 Pressure sensor, Orbitrol system

114 Brake air pressure meter 115 Parking brake indicator lamp

116 2nd/3rd gear selector switch 117 Activation button, EH steering

118 Speedometer 119 Counter

120 Armrest valve 121 Revtronic

122 Roof light switch 123 Roof lights

124 Tilt microswitch 125 Indicator lamp, roller buffer down

126 Indicator lamp, extended mast 127 Lifting indicator lamp

128 Microswitch, roller buffer down lamp 129 Microswitch, extended mast lamp

130 Microswitch, lifting lamp 131 12 V outlet in panel

132 Tilt check lamp 133 Emergency shutdown, IQAN

 DOCUMENT NO.:

107876:GB
CREATED ISSUE DATE PAGE
DESIGNATION LIST NB 12 010717 3/ (5)

134 Engine compartment switch, hydrostatic fan 135 Display, IQAN

136 Switch, hydrostatic fan reversal 137 Position sensor, lifting

138 XP unit, IQAN 139 Switch, front wiper with extra stroke

140 XS unit, IQAN 141 Roller buffer up/down switch

142 Position sensor, telescoping mast 143 Voltmeter

144 Tilt switch 145 Fan in condenser

146 Pressure switch, 2-speed fan (condenser) 147 Thermostat, 2-speed fan (condenser)

148 Etherstart button (Cummins M11) 149 Etherstart solenoid (Cummins M11)

150 Joystick, IQAN LST 151 Temperature sensor IQAN

152 XT2 unit, IQAN 153 Engine compartment illumination switch

154 Gearbox compartment illumination switch 155 Electric accelerator servo

156 Switch, rear wiper switch and washer 157 Brake air pressure sensor

158 Brake oil temperature meter 159 Brake oil temperature sensor

160 Minitronic 161 Printed circuit board

162 Starter relay 163 Switch, front lights, front lifting arm bracket, roller buffer

164 Switch, extended mast lights 165 Switch, lights, rear lifting arm bracket, side lifting arm
bracket

166 Rear lights 167 Optional rear lights

168 Extended mast lights 169 Optional extended mast lights

170 Front lights 171 Optional front lights

172 Roller buffer lights 173 Terminal box on lifting arm bracket

174 Terminal box on extended mast 175 Armrest switch

176 Emergency shutdown, EHC 177 Left armrest: tilt, grapple, steering

178 Right armrest: rotation, lifting, telescopic function 179 Terminal box, EHC

180 Terminal box, EHC 181 3-channel IPS box

182 3-channel IPS box 183 4-channel IPS box

184 Linear lever (4x) 185 Linear lever (5x)

186 1-channel IPS box 187 Mode switch button

188 Fork levelling button 189 EHC lever

190 EHC lever with on/off buttons 191 EHC lever with joystick

192 Sideshift button 193 Emergency shutdown switch

194 Fuel valve, shutdown (Cummins) 195 Electric fuel control regulator (Cummins)

196 Regulator, operating controls (Cummins) 197 Magnet sensor, electric accelerator (Cummins)
 DOCUMENT NO.:

107876:GB
CREATED ISSUE DATE PAGE
DESIGNATION LIST NB 12 010717 4/ (5)

198 Electric accelerator pedal (Cummins) 199 Fuse box

200 Switch, seat heater 201 EHC lever (ICM, 3 modes)

202 EHC lever (ICM, 2 modes) 203 EHC paddle (ICT4, 2 modes)

204 Key switch 205 Spreader check lamp

206 Spreader switch 207 Electric accelerator pedal

208 Lifting microswitch 209 Alarm, IQAN

210 XS unit, IQAN (option) 211 Test button, electric accelerator

212 AC switch 213 Switch, automatic raising of roller buffer when reversing

214 Switch, general cab illumination 215 Switch, cab spotlight

216 Temperature potentiometer 217 Fan speed potentiometer

218 Cab temperature potentiometer 219 AC controller unit

220 Variable fan controller unit 221 Thermostat on fan housing

222 Thermostat, engine-off heating 223 Water pump, engine-off heating

224 AC compressor 225 AC condenser

226 Radio converter 227 Water valve

228 Cab reading lamp 229 General cab illumination

230 Switch, lifting arm bracket lights 231 Switch, automatic telescoping mode

232 Switch, automatic lifting mode 233 Switch, step lights

234 Rear window washer motor 235 Step lights

236 Emergency travel switch 237 Switch, AC switch-off at open door

238 Position lights 239 Rotating warning light on from lifting arm bracket

240 Heated rear view mirrors 241 Switch, engine compartment illumination (inside cab)

242 Air filter sensor 243 Air filter indicator lamp

244 Gearbox pressure sensor 245 Engine temperature

246 Fuel valve cut-off 247 Engine buzzer

248 Tachometer 249 Fuse holder (terminal box)

250 Fuse holder panel 251 Fuse holder, engine

252 Lever control 253 Switch, differential gearbox

254 Sander switch 255 Switch, gearshift program

256 Shiftronic 257 Switch, high/low

258 Switch, 1st gear in armrest 259 Switch, 1st gear by gearshift lever

260 Switch, 2nd/3rd/4th gear in armrest 261 Potentiometer, map reading lamp

262 Map reading lamp 263 Display

 DOCUMENT NO.:

107876:GB
CREATED ISSUE DATE PAGE
DESIGNATION LIST NB 12 010717 5/ (5)

264 Pushbutton (floating twistlocks) 265 Diagnostic lamp, electric accelerator

266 Manual accelerator button, electric accelerator 267 Controller unit, electric accelerator (KGK)

268 Pushbutton, electric cab pump 269 Pump, electric cab tilting

270 Steering switch, IQAN 271 Microswitch, swivelling operator’s seat

272 Solenoid, Orbitrol turning 273 GSM modem

274 Lifting block 275 Rheostat, intermittent wiper

276 Optional function 277 Optional function

278 Optional function 279 Retardation potentiometer

280 Temperature switch, hydraulic oil 281 Temperature switch, gearbox oil

282 Electric water pump 283 Water pump check lamp

284 Diagnostics button, engine 285 Gearbox check lamp

286 Engine controller unit 287 Inching potentiometer

288 Gearbox controller unit 289 RPM sensor, transmission

290 Filter monitor, gearbox 291 Valve ass’y, gearbox

292 Engine speed regulator 293 Pressure sensor, engine

294 RPM sensor, engine 295 Temperature sensor, engine

296 Termination resistor 297 Bypass cable

298 Check lamp, water in fuel 299 Sensor, water in fuel

300 Inclination sensor 301 Button, start in 1st gear

302 JH lever 303 Lever handle, STG3

304 Microswitch, lift position 305

 DOCUMENT NO:

113857:GB
CREATED EDITION DATE PAGE
PLUG-LIST NB 1 050906 1/ (12)

P1 1 Voltage feed from main fuses P4 1 Stop light right rear light

2 Voltage feed from main fuses 2 Direction indicator right

3 Voltage feed from main fuses 3 Rear light right rear light

4 Voltage feed from main fuses 4 Ground right rear light

5 Ground feed from engine 5 Rear light right

6 Ground feed from engine 6 Ground right/left rear lights

7 Ground feed from engine 7 Vacant

8 Vacant 8 Vacant

9 Vacant 9 Vacant

P2 1 Work light torpedo / spreader P5 1 Stop light left rear light

2 Parking light right front light 2 Direction indicator left rear light

3 Feeding spreader 3 Rear light left rear light

4 Feeding spreader 4 Ground left rear light

5 Dim light right front light 5 Rear light left

6 Head light right front light 6 Reversing buzzer / rotating warning light

7 Ground right front light 7 Reversing buzzer / rotating warning light

8 Direction indicators right front light 8 Vacant

9 Reserve right front light 9 Vacant

P3 1 Vacant P6 1 Sensor fuel level

2 Parking light left front light 2 Sensor fuel level

3 Work light mast standard 3 Sensor brake oil temperature

4 Work light mast extra 4 Pressure switch brake oil

5 Dim light left front light 5 Pressure switch brake oil

6 Head right left front light 6 Thermostat hydraulic oil (pump)

7 Ground left front light 7 Pressure switch parking brake / valve parking break

8 Direction indicator left front light 8 Pressure switch parking brake

9 Reserve left front light 9 Thermostat hydraulic oil (pump)

 DOCUMENT NO:

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PLUG-LIST NB 1 050906 2/ (12)

P7 1 Valve parking brake P10 1 AC condenser

2 Signal horn 2 AC condenser

3 Signal horn 3 AC condenser

4 Compressor seat 4 Water valve

5 Compressor seat 5 Water valve /interval heating pump

6 Emergency switch engine external 6 Interval heating pump

7 Emergency switch engine external 7 Thermostat interval heating pump

8 AC compressor 8 Thermostat interval heating pump

9 Waterpump coolant, hydraulic 9 Vacant

P8 1 PVG-valve P11 1 Volvo CAN EMS

2 PVG-valve 2 Volvo CAN EMS

3 PVG-valve 3 Volvo CAN EMS

4 Central lubrication pump 4 Volvo CAN EMS

5 Central lubrication pump 5 Volvo CAN EMS

6 Central lubrication pump 6 Volvo CAN EMS

7 Central lubrication pump 7 Volvo CAN EMS

8 Central lubrication pump 8 Volvo CAN EMS

9 Central lubrication pump 9 Vacant

P9 1 Valve weighing equipment P12 1 Vacant

2 Valve weighing equipment 2 Vacant

3 Valve lifting accumulator 3 Vacant

4 Valve lifting accumulator 4 Vacant

5 Valve differential blocking 5 Vacant

6 Valve differential blocking 6 Vacant

7 Valve sanders 7 Vacant

8 Valve sanders 8 Vacant

9 Vacant 9 Vacant
 DOCUMENT NO:

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PLUG-LIST NB 1 050906 3/ (12)

P13 1 Voltage feed before main switch P16 1 Filter switch transmission EST37

2 Electric main switch 2 Filter switch transmission EST37

3 Water pump coolant, transmission 3 Temp. sensor valve package transmission EST37

4 Water pump coolant, transmission 4 Temp. sensor valve package transmission EST37

5 Volvo EMS2 5 Extra equipment transmission EST37

6 Volvo EMS2 6 Extra equipment transmission EST37

7 Generator D+ 7 Temperature sensor transmission

8 Generator W 8 Temperature sensor transmission

9 Option 9 Pressure sensor transmission

P14 1 Vacant P17 1 Shifting valve package transmission EST37

2 Vacant 2 Shifting valve package transmission EST37

3 Vacant 3 Shifting valve package transmission EST37

4 Vacant 4 Shifting valve package transmission EST37

5 Vacant 5 Shifting valve package transmission EST37

6 Washer motor 6 Shifting valve package transmission EST37

7 AC compressor 7 Shifting valve package transmission EST37

8 Vacant 8 Temperature sensor transmission (pump)

9 Vacant 9 Temperature sensor transmission (pump)

P15 1 Engine speed transmission EST37 P18 1 EHC valve E+/1

2 Engine speed transmission EST37 2 EHC valve D+/1

3 Turbine speed transmission EST37 3 EHC valve C+/1

4 Turbine speed transmission EST37 4 EHC valve B+/1

5 Internal speed transmission EST37 5 EHC valve A+/1

6 Internal speed transmission EST37 6 EHC valve A+, A-/2

7 Outgoing speed transmission EST37 7 EHC valve B+, B-/2

8 Outgoing speed transmission EST37 8 EHC valve C+, C-/2

9 Outgoing speed transmission EST37 9 EHC valve D+, D-/2

 DOCUMENT NO:

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PLUG-LIST NB 1 050906 4/ (12)

P19 1 EHC valve E+, E-/2 P22 1 Option

2 EHC valve A-/1 2 Option

3 EHC valve B-/1 3 Option

4 EHC valve C-/1 4 Option

5 EHC valve D-/1 5 Option

6 EHC valve E-/1 6 Option

7 EHC valve F+, F-/2 7 Option

8 EHC valve F+/1 8 Option

9 EHC valve F-/1 9 Option

P20 1 Feeding steering wheel sensor (Vref+) P23 1 Option

2 Feeding steering wheel sensor (Vref-) 2 Option

3 Signal A steering wheel sensor 3 Option

4 Signal B steering wheel sensor 4 Option

5 Feeding pressure sensor orbitrol (Vref+) 5 Option

6 Feeding pressure sensor orbitrol (Vref-) 6 Option

7 Signal pressure sensor orbitrol 7 Option

8 Vacant voltage input 8 Option

9 Vacant voltage input 9 Option

P21 1 Feeding load pressure sensor (Vref+) P24 1 Vacant

2 Feeding load pressure sensor (Vref-) 2 Vacant

3 Signal load pressure sensor 3 Vacant

4 Vacant 4 Vacant

5 Vacant 5 Vacant

6 Vacant 6 Vacant

7 Vacant 7 Vacant

8 Vacant 8 Vacant

9 Vacant 9 Vacant
 DOCUMENT NO:

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PLUG-LIST NB 1 050906 5/ (12)

P25 1 Gear handle P28 1 Feeding ignition switch U30

2 Gear handle 2 Ignition switch U15

3 Gear handle 3 Ignition switch U50

4 Gear handle 4 Breaker emergency stop EH-system

5 Gear handle 5 Breaker emergency stop EH-system

6 Gear handle 6 Feeding fuse box panel U15

7 Diagnostic lamp engine 7 Feeding fuse box panel U30

8 Gear handle 8 Feeding converter radio/cd

9 Declutch contact, pedal 9 Feeding from converter 12V

P26 1 E-gas pedal P29 1 Feeding gauges

2 E-gas pedal 2 Tachometer

3 E-gas pedal 3 Fuel gauge

4 E-gas pedal 4 Gauge brake oil temperature

5 Display ZF 5 Gauge cooling water temperature

6 Display ZF 6 Gauge oil temperature transmission

7 Program switch transmission 7 Gauge oil pressure transmission

8 Program switch transmission 8 Gauge oil pressure engine

9 E-gas pedal 9 Feeding indicators

P27 1 Indicator oil pressure engine P30 1 Indicator parking brake

2 Indicator cooling water temperature engine 2 Indicator brake oil pressure

3 Indicator cooling water level engine 3 Breaker parking brake 5min stop

4 Indicator cooling pump, transmission 4 Breaker parking brake seat buzzer

5 Diagnostics switch engine 5 Breaker parking brake U30

6 Diagnostic switch engine 6 Breaker parking brake U15

7 Indicator generator / hour meter 7 Breaker parking brake U15

8 Indicator direction indicators 8 Breaker wiper motor front

9 Indicator direction indicators 9 Breaker wiper motor front

 DOCUMENT NO:

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PLUG-LIST NB 1 050906 6/ (12)

P31 1 Breaker wiper motor front P34 1 Breaker horn

2 Wiper motor front 2 Breaker working light roof

3 Wiper motor front 3 Breaker working light mast

4 Breaker heated rear view mirror 4 Breaker working light mast

5 Breaker washer motor 5 Breaker interior light

6 Heated rear view mirror 6 Breaker interior light

7 Heated rear view mirror 7 Mute signal from radio extra

8 Breaker wiper motor rear 8 Indicator alarm transmission

9 Breaker wiper motor roof 9 Breaker parking brake, transmission

P32 1 Breaker wiper motor rear P35 1 Breaker heat seat

2 Breaker wiper motor rear 2 Breaker heat seat

3 Breaker wiper motor roof, extra 3 Indicator preheating, engine

4 Breaker wiper motor roof, extra 4 Temperature control climate system

5 Feeding breaker warning light/ights 5 Temperature control climate system

6 Breaker rotating beacone 6 Temperature control climate system

7 Breaker lights 7 Breaker climate system

8 Breaker lights 8 Breaker climate system

9 Breaker main lights 9 Breaker climate system

P33 1 Breaker hazard P36 1 Breaker central lubrication

2 Breaker hazard 2 Breaker central lubrication

3 Breaker hazard 3 Breaker central lubrication

4 Breaker hazard 4 Breaker central lubrication extra

5 Breaker hazard 5 Feeding breaker extra equipment

6 Breaker hazard 6 Breaker weighing system

7 Breaker direction indicator 7 Breaker lift accumulator blocking

8 Breaker direction indicator 8 Breaker differential blocker

9 Breaker direction indicator 9 Breaker sanders

 DOCUMENT NO:

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PLUG-LIST NB 1 050906 7/ (12)

P37 1 Breaker climate system P40 1 EST-37A, ED8

2 Fan knob climate system 2 EST-37A, ED9

3 Fan knob climate system 3 EST-37A, ED12

4 Fan knob climate system 4 Declutching

5 Fan knob climate system 5 Feeding interloch switch, transmission

6 Inching potentiometer extra 6 Breaker EH-steering

7 Inching potentiometer extra 7 Breaker EH-steering

8 Inching potentiometer extra 8 EST-37A, ED11

9 Inching potentiometer extra 9 Buzzer seat

P38 1 IQAN display P41 1 Wiper motor rear

2 IQAN display 2 Wiper motor rear

3 IQAN display 3 Wiper motor rear

4 IQAN display 4 Wiper motor roof

5 Feeding indicators from CIU 5 Wiper motor roof extra

6 IQAN display, shield 6 Wiper motor roof extra

7 Extra to panel 7 Interior light

8 Extra to panel 8 Interior light

9 Extra to panel 9 Spot light

P39 1 Brake light contact P42 1 Radio/cd

2 Brake light contact 2 Radio/cd

3 Extra from panel 3 Radio/cd

4 Extra from panel 4 Radio/cd

5 Extra from panel 5 Search light

6 Indicator coolant pump, hydraulic 6 Search light

7 Breaker working light 7 Rotating beacone

8 Indicator water in fuel 8 Extra to ceiling

9 Breaker interior light 9 Extra to ceiling

 DOCUMENT NO:

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PLUG-LIST NB 1 050906 8/ (12)

P43 1 Extra from ceiling P46 1 Vacant

2 Extra from ceiling 2 Vacant

3 Working light roof left 3 Vacant

4 Working light roof right 4 Vacant

5 Reversing light roof left 5 Vacant

6 Reversing light roof right 6 Vacant

7 Electric main switch, extra 7 Vacant

8 Electric main switch, extra 8 Vacant

9 Vacant 9 Vacant

P44 1 Climate system P47 1 Vacant

2 Climate system 2 Vacant

3 Climate system 3 Vacant

4 Climate system 4 Vacant

5 Climate system 5 Vacant

6 Thermostat climate system 6 Vacant

7 Thermostat climate system 7 Vacant

8 Air sensor climate system 8 Vacant

9 Air sensor climate system 9 Vacant

P45 1 Vacant P48 1 Vacant

2 Vacant 2 Vacant

3 Vacant 3 Vacant

4 Vacant 4 Vacant

5 Vacant 5 Vacant

6 Vacant 6 Vacant

7 Vacant 7 Vacant

8 Vacant 8 Vacant

9 Vacant 9 Vacant
 DOCUMENT NO:

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C49 1 Breaker forward and reverse gear 28 Vacant

2 Breaker forward and reverse gear 29 Vacant

3 Breaker forward and reverse gear 30 Vacant

4 Button activating touch shifting 31 Vacant

5 Button activating touch shifting 32 Vacant

6 Breaker in seat 33 Vacant

7 Breaker in seat 34 Vacant

8 Switch extra wipe front wiper drier 35 Vacant

9 Switch extra wipe front wiper drier 36 Vacant

10 Compressor in seat 37 Vacant

11 Compressor in seat

12 Turnable driver seat C50 1 Switch front wiper motor

13 Turnable driver seat 2 Switch front wiper motor

14 EH-steering PVG 3 IQAN joystick LL/LM

15 EH-steering PVG 4 IQAN joystick LL/LM

16 EH-steering PVG 5 IQAN joystick LL/LM

17 EH-steering PVG 6 IQAN joystick LL/LM

18 EH-steering PVG 7 IQAN joystick LST/LSL

19 Heat driver seat 8 IQAN joystick LST/LSL

20 Heat driver seat 9 IQAN joystick LST/LSL

21 EH-steering IQAN 10 IQAN joystick LST/LSL

22 EH-steering IQAN 11 IQAN joystick LST/LSL

23 EH-steering IQAN 12 IQAN joystick LST/LSL

24 EH-steering IQAN 13 IQAN joystick LST/LSL

25 Activating EH-steering IQAN 14 Switch rear wiper motor

26 Activating EH-steering IQAN 15 Switch roof wiper motor

27 EH-steering IQAN extra 16 Vacant

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PLUG-LIST NB 1 050906 10/ (12)

C51 1 IQAN XP, Fin A 28 IQAN XP, Vin A

2 IQAN XP, Fin B 29 IQAN XP, Vin B

3 IQAN XP, Cret E+ 30 IQAN XP, Vin C

4 IQAN XP, Cret D+ 31 IQAN XP, Vin D

5 IQAN XP, Cret C+ 32 IQAN XP, Vin E

6 IQAN XP, Cret B+ 33 IQAN XP, CAN H (can 1)

7 IQAN XP, Cret A+ 34 IQAN XP, CAN L (can 1)

8 IQAN XP, Cout A 35 IQAN XP, CAN H (can 2)

9 IQAN XP, Cout B 36 IQAN XP, CAN L (can 2)

10 IQAN XP, Cout C 37 IQAN XP, Vin G

11 IQAN XP, Cout D

12 IQAN XP, Cout E C52 1 IQAN XS, Din A

13 IQAN XP, Cret A- 2 IQAN XS, Din B

14 IQAN XP, Cret B- 3 IQAN XS, Din C

15 IQAN XP, Cret C- 4 IQAN XS, Vin D

16 IQAN XP, Cret D- 5 IQAN XS, Vin E

17 IQAN XP, Cret E- 6 IQAN XS, Vin A

18 IQAN XP, Cret F- 7 IQAN XS, Vin B

19 IQAN XP, Cret F+ 8 IQAN XS, +Vref

20 IQAN XP, +BatA 9 IQAN XS, Vin C

21 IQAN XP, Cout F 10 IQAN XS, -Vref

22 IQAN XP, +BatB 11 IQAN XS, Vin F

23 IQAN XP, +BatC 12 IQAN XS, Vin G

24 IQAN XP, +Vref 13 IQAN XS, -Bat

25 IQAN XP, -Bat 14 IQAN XS, +Bat

26 IQAN XP, Vin F 15 IQAN XS, Din D

27 IQAN XP, -Vref 16 IQAN XS, Din E

 DOCUMENT NO:

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PLUG-LIST NB 1 050906 11/ (12)

C52 17 IQAN XS, Din F C53 1 ZF AEB, (+)

18 IQAN XS, Din G 2 ZF AEB, (SDDK)

19 IQAN XS, Dout A 3 ZF AEB, (-)

20 IQAN XS, Dout B 4 ZF AEB, (EUPR)

21 IQAN XS, CAN L (can 1) 5 Vacant

22 IQAN XS, CAN H (can 1) 6 Vacant

23 IQAN XS, CAN H (can 2)

24 IQAN XS, CAN L (can 2) C54 1 Volvo Vodia, (+)

25 Vacant 2 Volvo Vodia, (CAN J1708A)

26 Vacant 3 Volvo Vodia, (-)

27 Vacant 4 Vacant

28 Vacant 5 Volvo Vodia, (CAN J1708B)

29 Vacant 6 Vacant

30 Vacant

31 Vacant C55 1 Heat driver seat

32 Vacant 2 Turning driver seat

33 Vacant 3 Turning driver seat

34 Vacant 4 Heat driver seat

35 Vacant 5 Breaker driver seat

36 Vacant 6 Breaker driver seat

37 Vacant 7 Compressor driver seat

8 Compressor driver seat

9 Vacant
 DOCUMENT NO:

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PLUG-LIST NB 1 050906 12/ (12)

C56 1 IQAN XT2, CAN L (can 1) 28 Vacant

2 IQAN XT2, CAN H (can 1) 29 Vacant

3 IQAN XT2, CAN L (can 2) 30 Vacant

4 IQAN XT2, CAN h (can 2) 31 Vacant

5 IQAN XT2, +Bat 32 Vacant

6 IQAN XT2, -Bat 33 Vacant

7 Vacant 34 Vacant

8 Vacant 35 Vacant

9 IQAN XT2, Vin A / Egas 36 Vacant

10 IQAN XT2, Fin A / Vin H 37 Vacant

11 IQAN XT2, Dout A

12 Vacant

13 Vacant

14 Vacant

15 Vacant

16 Vacant

17 Vacant

18 Vacant

19 Vacant

20 Vacant

21 Vacant

22 Vacant

23 Vacant

24 Vacant

25 Vacant

26 Vacant

27 Vacant
INSTRUCTION MANUAL

Dashboard
A B F G I

Figure 1147

C H J

A. Switch
Vehicle lights
0 - Turned off
1 - Rear lights, parking lights
2 - Rear lights, dipped headlights

Figure 15

Ceiling lights (Optional)

Figure 17

Work lights

Figure 17

Rotating warning lights (Optional)

Figure 26

Mini steering/button steering (Optional)

Figure 410

Gear programme
Manual - Automatic
alternatively
Start in first gear - start in second gear

Figure 633

Issue 1 KM-473:GB
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INSTRUCTION MANUAL

Interior light/reading light

0 - Turned off
1 - Interior light
2 - Reading light

Figure 504

Heated seat (Optional)

Figure 503

Power heated mirrors (Optional)

Figure 414

Air conditioning
See Climate Control, group 8 in the Instruction Manual.

Figure 413

Hazard warning lights (Optional)

Figure 27

Scale (Optional)

Figure 415

Wiper front/rear
0 - Turned off
1 - Interval wiping
2 - Constant wiping

Figure 13

Rheostat wiper front (Optional)

Figure 706

Wiper roof

Figure 13

Washing

Figure 702

Issue 1 KM-473:GB
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INSTRUCTION MANUAL

B. Indicator

Elapsed time indicator (hours)

The indicator shows the number of hours the engine has been running. Read
the indicator to determine when the truck needs to go in for regular service.

Figure 708

Fuel gauge
Never allow the truck to run out of fuel and stop. If this happens, air may
enter the system, which will then need venting in order to start the truck
again.

The volume of the fuel tank depends on the truck’s wheelbase. See Group 10,
Fuel Tank.
Figure 711

Oil pressure gauge, Gearbox (bar)

When driving, the pressure should be 16-18 bar (1600-1800 kPa)

Figure 713

Oil pressure gauge, engine (bar)

The gauge shows the engine’s lubricating oil pressure and, when driving,
should show 1.9 bar (190 kPa) at 2600 rpm.

Figure 714

Temperature gauge, brake cooling oil (°C)

Max. 100°C in the tank.

Figure 715

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INSTRUCTION MANUAL

Temperature gauge gearbox (°C)

Max. constant temperature should be 100°C. During shorter periods (max. 5
minutes), it is OK if temperatures reach 120°C.

Figure 709

Temperature gauge engine (°C)

QSM11
Opening temperature: 82°C/180°F
Fully open at: 93°C/200°F

Figure 712

Speedometer

Figure 710

Issue 1 KM-473:GB
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INSTRUCTION MANUAL

C. Indicator lights
Low hydraulic oil pressure - brakes
The light indicates that the pressure in the brake system is low. The light starts
to flash if the oil pressure drops below 110 bar (11.0 MPa) and stops at 120
bar (12.0 MPa).
If the light starts to flash while the truck is being driven, the truck should
Figure 582
be stopped immediately, the fault should be investigated and rectified at a
workshop.
You can apply the brake about 10 times before the parking brake is activated
(85-90 bar).
Operational control of the light when the ignition is turned on.

Parking
The light comes on and the gearbox is disengaged when the parking brake
is applied. If the brake pressure drops due to a fault in the brake system,
the light comes on when the pressure has dropped below 85-95 bar (8.5-9.5
MPa), depending on the model. If the light comes on when the truck is being
Figure 287
driven, the truck should be stopped immediately and the fault should be
identified and rectified. If the pressure drops below 75-85 bar (7.5-8.5 MPa),
the parking brake is applied.

Cooling water temperature

If the light comes on, the temperature is too high (110°C). Stop the truck
and make sure the cause is identified and rectified. The engine cuts out
automatically at 113°C.

Figure 18

Oil pressure
If the light comes on when the truck is being driven, the pressure has dropped
below 0.7 bar (70 kPa). Stop the truck immediately and make sure that the
cause is identified and rectified. The engine cuts out automatically if the
pressure drops below 50 kPa.
Figure 22

Cooling water level

If the light comes on when the truck is being driven, the coolant level has
dropped below MIN in the expansion vessel. Stop the truck and make sure
the cause is identified and rectified.

Figure 580

Generator
If the light comes on when the truck is being driven, the generator is not
charging. Stop the truck and make sure the cause is identified and rectified.

Figure 10

ZF alarm
Flashing together with a hexadecimal code in the ZF display. Read the fault
code to identify the cause. Rectify the fault.
Read more about this in the ZF manual for fault codes (FC392324).

Figure 703

Issue 1 KM-473:GB
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INSTRUCTION MANUAL

Fuel filter
Indicates water in the fuel. Check and rectify the fault.

Figure 705

Water pump
The light comes on when the external cooling water pump is activated when
the transmission or brakes indicate a cooling requirement.

Figure 704

Direction indicators
The light flashes when the direction indicator switch is switched on to
indicate a right or left turn.

Figure 9

Headlights
The light comes on when the headlights are activated.

Figure 16

Issue 1 KM-473:GB
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INSTRUCTION MANUAL

D. Parking brake
The brake system must have reached operating pressure before the parking brake releases. When there is no pressure
in the system, the parking brake is applied automatically. If you leave the truck without applying the parking brake,
a buzzer will sound.

E. Central lubrication (Optional)

The light is on during the lubrication pulses. The Quicklub button allows the operator to generate an additional
pulse. The ignition must be turned on.

F. Fan control
Variable setting control for the climate control fan speed. For more information, see Climate Control, group 8 in the
Instruction Manual.

G. Temperature control
Variable setting control for the climate control temperature. For more information, see Climate Control, group 8 in
the Instruction Manual.

H. Diagnostic function
The maintenance lamp, warning lamp or stop lamp will light up (depending on fault priority) when a fault is
detected during operation.

Maintenance lamp
The maintenance lamp will flash during ECM power up when it is time to change oil. It will also light up during
engine operation if there are some lower priority faults.

Warning/Diagnosis lamp
The warning lamp notifies the operator of important messages that require immediate attention. The warning lamp
also denotes diagnostic fault codes.

Stop/ Diagnosis lamp

The stop lamp notifies the operator of critical messages that require a prompt and decisive response. The stop lamp
also denotes diagnostic fault codes.

Flash out fault codes

Press the diagnostic switch and read the fault code. Fault codes consist of five groups of flashing codes and a brief
interval. The first and fifth flash are not included in the code.
For example: *(1 flash) **(2 flashes) ****(4 flashes) ****(4 flashes) *(1 flash) = Fault code 244.
If more than one fault code is active, use the increase/decrease switch to see the next code.
Refer to the flashing code table in the manual to locate and identify the fault.

Overide function
Override ECM automatic shutdown by pressing and holding down the protection override switch. This should only
be used in emergencies, due to the risk of engine failure.

I. ZF display
Read more about ZF transmission in the ZF Instruction Manual (5872 194 002) and about fault codes in the
ZF manual (FC392324).

J. Ignition key
0 - Everything turned off.
1 - Ignition on.
2 - Start position.

Issue 1 KM-473:GB
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INSTRUCTION MANUAL

Direction indicator lever

Lever forwards - Direction indicators left
Lever backwards - Direction indicators right
Lever upwards - Headlights
Figure 583 Lever downwards - Dipped headlights

Sound the horn by pressing the indicator lever in towards the steering wheel
stem.

Fuse holder
There is a constant 24V power supply to the fuse holder from the battery and
a 24V power supply from the ignition lock to the electrical optional equip-
ment. See Wiring Diagram, group 9 in the Instruction Manual.

Fuse holder

Figure 584

ZF gearshift
Read more about the gearshift and its functions under Gears, group 9 and in
the ZF Instruction Manual (5872 194 002).

Figure 717

Issue 1 KM-473:GB
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INSTRUCTION MANUAL

Adjusting the tachometer

On diesel engines connected at clamp W to an AC generator, setting is performed via the code switch and the potentiometer.
The number of impulses is set approximately with the code switch (impulses per engine revolution at the alternating
current generator’s clamp W), and revolutions are fine-tuned with the potentiometer, see figure 586.
The revolution display is compared using a reference tachometer (optical handheld tachometer or inductive tachometer).

» When setting using the handheld tachometer, two people need to be present, one to operate the instrument and
one to measure the reference revolutions. If the number of impulses is known, the code switch is set according
to the code table (approximate setting), see table 356.
The settings for the code switch for Volvo engines should be: OFF, ON, ON.
After this, fine adjustment is performed with the potentiometer.

» Fine adjustment of the revolutions display is possible only between 30% and 100% of the maximum
measurement range. Adjust the potentiometer with an insulated screwdriver so that the instrument’s display
agrees with that of the handheld tachometer.
Note! Always check that maximum revolutions on the tachometer tally with the engine’s maximum
revolutions. As a result of this, a slightly incorrect display for idling revolutions is possible.

If the number of impulses is known, set the code switch to “OFF, OFF, OFF”. Then perform fine adjustment with
the potentiometer. If it is not possible to adapt to the reference revolutions, try another setting of the code switch
and new fine adjustment with the potentiometer.

WARNING!
When measuring engine revolutions with a handheld tachometer,
there is a risk of burning or crushing injuries. Extra care should
therefore be taken. Never wear loose-fitting clothing.

Diesel engine clamp W

Switch Pulses/revolution
1 2 3
off off off 8-12
off off on 12-17
off on off 18-25
off on on 18-25
Table 356

Potentiometer
Code switch

Figure 586

Edition 1 KM-291:GB
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INSTRUCTION MANUAL

Fuses
Fuse replacement
The fuses are placed under the extra seat in the cabin. To locate the fuse number, refer to the Fuse List, Group 9 in
the Instruction Manual. Remove the broken fuse and replace it with a new one with the same amperage.

Figure 615

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INSTRUCTION MANUAL

Main fuses
Change of fuses
The forklift has got two main fuses, one with a value of 50 A and one with a value of 25A. They are placed on the
engine in the left part of the engine room (left service cover).

» Unfasten the plastic lid and pull it outwards.

» Unfasten the screws that hold the fuses and change the fuses.

» Fasten the plastic lid.

Fuse box

Main fuse 50A

Screws
that hold
the fuse Main fuse 25A

Screws
that hold
the fuse

Figure 181

Screw
that holds
the lid Lid

Edition 1 KM-298:GB
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INSTRUCTION MANUAL

Function control
When starting the truck and during operation, check the following points.

» Air pressure gauge (trucks equipped with compressed-air brakes). The pressure is correct if it is within
6.6-7.6 bar (95.7-110.2 psi, 660-760 kPa).

» Coolant temperature. The correct temperature is approximately 80°C (176°F).

» Temperature gauge, brake cooling oil (trucks equipped with hydraulic brakes). The temperature should not
exceed 100°C (212°F) during normal operation.

» Other gauges should be within the green segment or show normal values.

» Check that the horn, lights, working lights, brake lights and direction indicators work.

» Check that all hydraulic functions work properly.

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INSTRUCTION MANUAL

Windscreen washer
Fill the windscreen washer’s fluid tank. During the winter season, use frost-resistant washer fluid containing
methylated spirit or similar.

The jets can be adjusted. Insert a needle in the hole of the ball and adjust it to the required direction.

If the jets get clogged, unscrew the jets and clean them with compressed air.

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INSTRUCTION MANUAL

The battery
General
This is a 24-volt electrical system. The voltage is supplied from two 12 volt batteries connected in series. An
alternating current generator with built-in charging regulator manages the charging of the batteries.

The batteries are normally placed in a battery compartment on the left-hand side of the truck, behind the fuel tank.
On some truck models, however, the batteries and the main switch are located on the truck’s right-hand side.

The batteries contain substances that are harmful to both health and the environment. Used batteries must be handed
in to an environmental station or handled in accordance with any local regulations.

Main switch
One battery’s negative terminal is connected to the truck’s chassis. The other battery’s positive terminal is
connected to a main switch that is located by the battery compartment.
The main switch must not be disconnected and connected when the engine is running, as this can damage the
generator, the charging regulator and the engine’s electronic control modules.

Machines with D5 system have, in addition to the manual main switch, also an electric main switch which is
controlled by the D5 system.

For machines with finishing system / Adblue

To prevent hoses from rupturing if the AdBlue® / DEF solution freezes, the system is emptied after operation by a
shutdown procedure performed each time the engine is switched off.
Since the procedure takes approx. 90 seconds (depending on hose length) it is very important that the main switch
should not be switched off before the shutdown procedure is completed.

Edition 2 KM-442:GB
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INSTRUCTION MANUAL

WARNING!

Sulphuric acid
The battery’s electrolyte contains diluted sulphuric acid which can cause
extremely serious corrosive injuries. When working with the battery
protective gloves, a face mask or tightly fitting protective goggles must
be worn. Safety equipment for rinsing eyes or access to water must be
available at or near the workplace.
Rinse immediately with copious amounts of water if acid gets into the
eyes, onto the skin or clothes.
If the acid has splashed into the eyes, the eyes must be washed
immediately and should be rinsed continuously during transport to the
doctor. In the event of acid splashing in the eyes, medical attention must
always be sought.

Oxyhydrogen gas - explosion risk

Hydrogen forms when lead/sulphuric acid batteries are charged, and
when this comes into contact with the oxygen in the air, oxyhydrogen gas
is formed. This is a highly flammable and explosive gas.
Sparks caused by incorrect operation, short-circuits or static electricity, as
well as naked flames or smoking in the vicinity of the battery, are
sufficient for the battery to explode and cause extremely serious injuries.
Great care should therefore be taken to avoid sparks during installation,
removal, jump starts or charging the battery. Always wear personal
protective equipment and use insulated tools.

Replacing and installing batteries

» To ensure optimal economic operation of a battery, we recommend that both batteries are replaced at the
same time. Never mix different battery makes. Break the current with the main switch. Remove the old
batteries by first disconnecting the negative cable (the earth cable) and then the other battery cables.
This reduces the risk of short-circuits and sparks.

» Undo the battery holders and lift out the batteries. Clean the battery compartment.

» Check that the new batteries have the correct polarity and capacity. Incorrect polarity can cause damage
to the truck’s electrical system and electrical equipment.

» Install the new batteries in their holders. Tighten the batteries so that they are secure, but no harder, as
this can damage the batteries.

» When connecting the batteries, connect the positive cable first. Then connect the bridging cable between
the batteries and finally the negative cable (the earth cable).

» The cable terminals must be securely tightened. A poor contact can cause voltage drop and reduced
starting power. Lubricate them with terminal grease, universal grease or some form of rustproofing agent.

Edition 2 KM-442:GB
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INSTRUCTION MANUAL

Care and maintenance of the battery

Factors such as driving styles, number of starts, climate, etc. affect the service life, capacity and performance of
the batteries. To maintain satisfactory battery performance, the following should be observed:

» Never over-exert the batteries, as this reduces the service life. If the engine does not start immediately,
allow the batteries to recover for a few seconds before attempting to start the engine again.

» Check the condition of the generator belts regularly and make sure they are correctly tensioned. This is to
ensure that the generator provides full capacity. See Operating Manual, Group 14, Maintenance scheme.

» Regularly check the batteries’ condition, electrolyte level and electrolyte density (see Charging the
battery). See Operating Manual, Group 14, Maintenance scheme.

» Note! If the electrolyte level needs to be adjusted frequently, this can be due to a battery defect or
incorrect (too high) regulator voltage. If the electrolyte level is too low in a cell, this can result in an
internal battery explosion. If a fault in the generator or charging regulator is suspected, contact the
service personnel.

» Check that the battery cells’ ventilation plugs are properly tightened.

» Keep the batteries dry and clean. Dirt can cause and conduct leakage currents, which in turn can reduce
the output and damage the batteries. Also keep the battery compartment dry and clean.

» Keep the battery terminals and cable terminals free of corrosion (oxides). If the terminals are affected
by corrosion, start by disconnecting the cable terminals. Brush away the coating on both the battery
terminals and the cable terminals using a steel brush.
Reinstall the cable terminals and lubricate them with terminal grease, universal grease or some form of
rustproofing agent.

» Check that the batteries are properly installed in their holders.

NOTE!

General
Never turn off the main switch or disconnect the batteries
while the engine is running as this could damage the engines
electronic components.

Jump starting
Only batteries may be used for jump starting. A battery
jumper can create high voltages that can damage the engine
and the electronic components.

Battery charging
The batteries must be disconnected when connecting an
external charger.

Electrical welding
When welding, the engine and main switch must be turned
off and all electronic control modules must be disconnected
(see Operating Manual). Starter batteries and generators
must also be disconnected. The welding clamp should be as
close to the welding point as possible, never in the engine or
gearbox.

Edition 2 KM-442:GB
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INSTRUCTION MANUAL

Jump starting
The system voltage must not exceed 30 V under any circumstances. This means that only batteries may be used
for jump starting to prevent overvoltage which can damage the electronic components.

Vehicle workshops often have a battery booster that is easy to transport. Ensure that the cables are connected
correctly, and never allow the cables to come into contact with each other when they are carrying current.

Always begin by connecting the red cable between the uncharged battery’s positive terminal and the positive
terminal of the battery that is supplying the current.

First connect one end of the black cable to the negative terminal on the battery that is supplying the current. Then
connect the other end to the negative terminal on the uncharged battery.

When the engine is started, disconnect the cables in reverse order. Disconnect the negative cable first to avoid
short-circuits and sparks.

Charging the battery

It is imperative that the batteries are disconnected from the electrical system when connecting an external charger.

First disconnect the battery’s negative terminal, then the battery’s positive terminal. After the battery has been
charged, connect the cables in reverse order.

Rapid charging or normal/extended charging can be used to charge the battery. Normal/extended charging is
recommended if the battery is in poor condition or has not been used for a long time. If rapid charging is carried
out correctly, it will not damage the battery. However, the temperature in the battery must not exceed 45°C. If this
temperature is reached, charging must be stopped or the charge current must be reduced to normal charging.
However, rapid charging should not be performed too frequently, and is not recommended for older batteries.

Note! Always follow the manufacturer’s instructions on the battery charger and the battery.

Check the density of the electrolyte by drawing some electrolyte into an acid tester (hydrometer) and reading the
results on the scale.
The density of the electrolyte (weight by volume) in a fully-charged battery should be 1.28 g/cm³ - 1.30 g/cm³,
measured at approximately +25°C. The battery should be charged if the density is lower than 1.22g/cm³.
Check all the cells. If the density differs by more than four division marks between the cell with the highest and
the cell with the lowest value on the acid tester, the battery is exhausted and must be replaced. If the battery is
discharged, the electrolyte will freeze at approximately -10°C which will ruin the battery. A fully-charged battery,
on the other hand, does not freeze until approximately -70°C.

When the batteries have been charged, the electrolyte level should be checked and, if necessary, accumulator
water should be added.

» Check that the battery cells’ ventilation plugs are properly tightened.

» Check that the electrolyte level is correct in all the cells. Use a torch to help check the level. Each cell has
its own level marking. If there is no level marking, the level should be approximately 10 mm above the
element.

» If necessary, fill with accumulator water up to the level marking. Never use ordinary tap water. Only use
distilled or de-ionised water. Never fill above the level marking.

» Ensure there is adequate ventilation when charging indoors.

» Note! Always connect the battery charger to the battery before switching on the battery charger or
connecting the mains connector.

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INSTRUCTION MANUAL

» The battery is fully charged when the battery charger has switched off or when the charger’s ammeter has
fallen to 0 A (depending on the make and model of the battery charger). Alternatively, check the density
of the electrolyte in each cell once more.

» Note! Always switch off the battery charger or disconnect the mains connector before the charging
clamps are removed from the battery.

Electrical welding
When welding, the engine and main switch must be turned off and all electronic control modules must be
disconnected.
Starter batteries and generators must also be disconnected. The welding clamp should be as close to the welding
point as possible, never in the engine or gearbox.

Edition 2 KM-442:GB
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INSTRUCTION MANUAL

Gears (ZF)
General
Fully-automatic torque-controlled transmission with full modulation, 4 forward and 3 reverse gears . The actual
gearshift is located to the left of the steering wheel stem.

To start the truck, the gearshift has to be in neutral.

Before changing driving direction, the machine has to be standing still to prevent strain on the distribution gear
and power transmission, and at as low engine revs as possible (should not exceed 1500 rpm).
When the gearshift is put into reverse, the work lights come on to the rear.

Gearshift positions
F – Forward
N – Neutral
R – Reverse

Turn the gearshift handle for the highest gear you need
Position 1 – transmission locked in gear 1.
Position 2 – automatic shifting up and down
between gears 1 and 2.
Position 3 – automatic shifting up and down
between gears 1, 2 and 3.
Position 4 – automatic shifting up and down
between gears 1, 2, 3 and 4. Fully automatic.
Figure 717

Lock
Lock to prevent the machine from being started accidentally
Position N – gearshift locked in neutral
Position D – driving position

Driving forwards
» Allow engine to idle

» Choose position 4 on the gearshift, move the gearshift forwards to position F.

» Release the parking brake.

» Slowly depress the accelerator pedal for a smooth start.

Edition 1 KM-352:GB
Page 1 (3)
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INSTRUCTION MANUAL

Dashboard

ZF-display
Parking brake

Interlock transmission
Figure 716

ZF alarm

Parking brake When the parking brake is activated, the transmission automatically shifts to neutral
Interlock transmission See Dashboard under group 9
ZF alarm See Dashboard under group 9
ZF display

Showing direction of travel (right-hand side)

F – Forward
N – Neutral
R – Reverse

Showing gear position (middle)

1st shows
1F
2nd shows
2F
3rd shows
3F
4th shows
4F
Waiting for controller Neutral
Indication on the display: NN (middle and right-hand side). In this position, the electronics wait for the transmission
to shift to neutral. The transmission automatically puts itself into neutral to wait for the set values to be reached.

Edition 1 KM-352:GB
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INSTRUCTION MANUAL

Flashing line
Downshift position active.

Failure message
If the system senses a fault, a spanner flashes on the right-hand side of the display. If Neutral has been preset on the
control unit, a two-digit fault code is shown on the two alphanumerical indication positions (middle and right-hand
side). If more than one fault is sensed, the different fault codes are each shown cyclically on the display (about
1 second between each code).

NB! The failure message only appears when the control unit is in neutral.

Warning message
When the limit for warning messages is exceeded, for temperature in the sump, after the converter and engine revs,
the message on the display changes to the relevant fault code that corresponds with the warning.

NB! If several warnings are activated simultaneously, only the warning that has highest priority will be shown.

Fault code Warning Priority

WT Temperature after converter 1
WS Temperature in the sump 2
WE Engine revs 3

PN is shown
Direction of travel F or R is selected at the same time that the parking brake is activated. Transmission is in neutral
until the parking brake is released.

NOTE!
After the parking brake is released, the machine will start to drive along.

Flashing F or R
Direction of travel F or R is selected at the same time that the engine revs are too high.
NB! Gear engages when the engine revs fall to the right level.

EE is shown
EE appears on the display (middle and right-hand side).
This means the display has timed out, i.e. it is not receiving any data from EST-37.

Main reasons
» EST is in TOTAL RESETTING POSITION
» EST-37 has no supply. Data cable incorrectly connected, etc.

Fault codes – definition

The fault codes consist of two hexadecimal numbers. The first number indicates which group, the second signal
which kind of fault.

Edition 1 KM-352:GB
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INSTRUCTION MANUAL

Multifunction lever

Figure 774

Functions
Lever up headlamp flasher
Lever down headlamps high beam
Lever forward left indicator
Lever back right indicator
Press ring inwards windscreen, roof window and rear window washer
Button pressed horn

Symbols
Intermittent wiping

Off

Continuous wiping

Rapid continuous wiping

Starting position lights

Headlamp flasher

Headlamps low beam

Headlamps high beam

Edition 1 KM-376:GB
Page 1 (1)
9
Engine
Motor 10
INSTRUCTION MANUAL

Fuel tank
Draining
Contaminants and water can collect at the bottom of the tank. Drain the tank when it is almost empty by removing
the drain plug and allowing a few litres of diesel to drain out into a vessel.

Screw the plug back in and tighten it properly. Check that there is no leakage.

Tank volumes
Wheel base (mm) Volume (litres)
5000 900
5400 995
5700 995
6000 995
6500 995

When the fuel gauge is in the red, there are at least five litres left in the tank.

Figure 986

Edition 2 KM-464:GB
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INSTRUCTION MANUAL

Air cleaner
Air filter

Plastic cover

Dust collector

Figure 8

Fastener
Safety cartridge

Emptying of dust collector

The air cleaner has a dust collector. It needs to be emptied every 40th hour of operation or when needed.

WARNING!
Stop engine when servicing filter.

» Loosen the two fasteners.

» Remove the dust collecter’s plastic cover. Empty and clean the collector.

» Replace the dust collector with the arrow pointing upwards.

» Tighten the dust collector with the fasteners and check that the plastic cover closes tightly. Check also that
the arrow is pointing upwards.

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INSTRUCTION MANUAL

Change of air filter

The air filter is normally changed every 400 hour of operation. If the environment is dusty you need to change the
filter more often, to avoid a loss of power in the engine.

There is also a an indicator with a window. When you can see a red sign in the window it is time to change the air
filter.

» Remove the dust collector.

» Loosen the plastic cover and remove the dust.

» Remove the air filter.

» Clean the inside of the filter house.

» Insert a new and clean filter and put back the dust collector.

NOTE!
The arrow must point upwards.

» Set the indicator.

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INSTRUCTION MANUAL

Operational control of the

electric accelerator pedal
Procedure
» Use a digital voltmeter to measure the electric accelerator pedal’s voltage.

» The electric accelerator pedal should be connected and the ignition must be turned on when measuring.

» Connect the multimeter between pin 4 and pin 5 to measure the supply voltage to the electric accelerator pedal.
This reading should be 5VDC.

» Connect the multimeter between pin 2 and pin 4 to measure the signal voltage from the electric accelerator
pedal. For values, see below.

Pedal Min. value (pedal released) Max. value (pedal depressed)

911419 0,40-0,44V 3,00-3,20V
911420 0,50-0,55V 3,60-3,70V
912455 0,40-0,45V 3,65-3,75V
910437 0,40-0,44V 4,00-4,10V

Engine Item no.

Cummins QSB6,7 / QSC8,3 s.no -4745 912445
Cummins QSB6,7 / QSC8,3 s.no 4764- 911419
Cummins QSM11 910437
Cummins QSM11 (D5) 911419
Cummins QSX15 (D5) 911419
Scania DI9 56A DEC2 911419
Scania DI12 50A DEC2 911419
Scania DI12 56A EMS/S6 911419
Scania DC12 58A S6/PDE 911419
Volvo TAD650VE 911419
Volvo TAD750VE 911419
Volvo TAD620VE 911420
Volvo TAD722VE 911420
Volvo TWD1240VE 911420
Volvo TAD1251VE (D5) 911419
Volvo TAD1252VE (IQAN) 911420
Volvo TAD1252VE (D5) 911419

Edition 6 KM-355:GB
Page 1 (1)
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Cooling system
Kylsystem 11
INSTRUCTION MANUAL

Coolant
Check the coolant level every day or every 10 operating hours. Fill the cooling system’s expansion tank with coolant.
Use 50% ethylene glycol and 50% water to prevent the coolant from freezing. Mix the coolant before filling the
system. This mix can be used year round.

An electric sensor in the expansion tank detects if the coolant level is too low. If it is too low, a warning lamp on
the dashboard comes on.

Check
Check the coolant level when the engine is cold.

» Look in the sight glasses to check that the expansion tank is 2/3 full. If the expansion tank does not have a
sight glass, check the level by looking in the refill hole.
Fill expansion tanks made of plastic (Ill. 735) to the upper level mark.

» Top up with premixed coolant when necessary.

NOTE!
Do not overfill the system.

Changing coolant
Coolant should be changed and the system should be rinsed out once a year. Use hot water to rinse the system.

Coolant volume
See Coolant Volume, Group 14.

Cap Pressure cap Cap

– do not open!

Figure 735

Figure 141

Edition 6 KM-164:GB
Page 1 (1)
11
Transmission
Transmission 12
INSTRUCTION MANUAL

Instructions for AEB test

AEB tool item no. 909684 for transmission ZF
The AEB tool (1) is connected to the diagnostic socket (2) on the transmission’s TCU (3) and all necessary
information is shown on the display (4) in the dashboard.

Explanations
AEB = Automatic calibration of the transmission’s filling parameters
TCU = The transmission’s electronic control unit

Function (in brief)

AEB has the task of compensating tolerances (disc clearance and pressure levels) and can affect the filling
procedure in the clutch unit. For each clutch unit, filling parameters are analysed in a test cycle.
In the test cycle, parameters are analysed for:
» Length of time for rapid filling
» Pressure level for filling compensation.

An AEB test cycle takes approximately 3-4 minutes and must be carried out:
» When both transmission and electronics have been installed and the application is to be operated for the
first time.
» When one of the following has been replaced: Complete transmission, the electro-hydraulic valve assembly
or TCU.
» At each service and always at every oil and filter change in the transmission.
» When the quality of the gear changing deteriorates.

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INSTRUCTION MANUAL

It is important to observe the following conditions before testing:

» The gear selector lever must be in neutral (N).
» The parking brake must be activated.
» The transmission must have a normal working temperature of 60-90°C.

Action Information in display Comment

1 Warm up the transmission. Normal information
2 Stop the engine and switch off the ignition. No information
3 Connect the AEB tool in the diagnostic socket. No information
4 Place the gear selector lever in neutral (N). No information
Activate the parking brake.
5 Start the engine. PL TCU must recognise PL for at least
2 sec. before you can press the button.
6 Set the idling revs at 800 rpm. PL (if everything is ok)
7 Press the button on the AEB tool. ST (if everything is ok) The button must not be released until
TCU has started AEB or acknowledged
with an error code.
8 Hold down the button until AEB has started. K1... (AEB status) AEB has started, starts with K1, K2, ...,
KR, ... (the button must be released).
9 Wait until AEB has been concluded. OK
10 Stop the engine and switch off the ignition. No information
Disconnect the AEB tool.

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INSTRUCTION MANUAL

Symbol Explanation Comment

PL The AEB tool is connected to the diagnostic socket.
ST The button on the AEB tool is pressed.
K1..K4, KV, KR Calibrates the clutch unit K1..K4, KV, KR.
and Kx* Wait for start, initiation of clutch unit Kx*.
and Kx* Analysis of rapid filling time in clutch unit Kx*.
and Kx* Compensation pressure analysis in clutch unit Kx*.
OK Calibration of all clutch units completed.
STOP AEB interrupted (activation stopped).
STOP and Kx* AEB interrupted, clutch unit Kx* cannot be calibrated.
Tool symbol and Kx* Clutch unit Kx* could not be calibrated, AEB concluded.
E The engine revs are too low, increase the engine revs.
E The engine revs are too high, decrease the engine revs.
T The transmission's temperature is too low, warm up
the transmission.
T The transmission's temperature is too high, cool down
the transmission.
FT The transmission's temperature is not within the defined
temperature range during calibration.
FB The operating cycle is abnormal or the transmission's
temperature sensor is defective or the storage of
calibrated values in EEPROM has failed.
FO The output speed is not 0.
FN The gear selector lever is not in neutral.
FP The parking brake is not activated.
STOP The AEB tool is used incorrectly or is defective.
The transmission stops in neutral,
disconnect the AEB tool, restart
(ignition off/on).
The transmission stops in neutral and
TCU must be restarted (ignition off/on).
The transmission stops in neutral and
TCU must be restarted (ignition off/on).
The transmission stops in neutral and
TCU must be restarted (ignition off/on)
Normal working temperature 60-90°C.
Normal working temperature 60-90°C.
The transmission stops in neutral and
TCU must be restarted (ignition off/on).
The transmission stops in neutral and
TCU must be restarted (ignition off/on).
The transmission stops in neutral and
TCU must be restarted (ignition off/on).
The transmission stops in neutral and
TCU must be restarted (ignition off/on).
The transmission stops in neutral and
TCU must be restarted (ignition off/on).
The transmission stops in neutral and
TCU must be restarted (ignition off/on).

x* = Clutch unit in question

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INSTRUCTION MANUAL

Universal drive shaft

Figure 220

Control
A control should be performed regularly. The maintenance interval that is mentioned below is only a
recommendation. Consideration to the current working conditions must be taken and also to practical experience.

All unusual sounds must be located and measured immediately.

Play control should be performed continuously. You should check if there is any radial play in the spline joint or in
the knot joint bearings.

Lubrication
There are usually three lubrication points, on each knot joint for lubrication of the bearings and on the spline casing
for lubrication of the spline slide facing.

The universal drive shaft has nylon covered splines and the spline casings don't need any relubrication. We
recommend you to make an inspection once a year though. You should contact Svetruck AB if the universal drive
shaft is going to be used where the temperature conditions are extreme.

Before lubricating, the lubrication points must be properly cleaned. The bearings should be controlled. If they have
been subjected to very high temperatures, show signs of overheataing, if the bearing seals are damaged or if other
damages are found , the whole knot joint should be replaced.

The knot joint's lubrication nipples should be lubricated until grease flows through the seals at both the knot joints.
We recommend you to use BP Energrease LS EP2.

Lubrication of
knot joint

Figure 219

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INSTRUCTION MANUAL

Flange connection/Screw joint

» The flange screws are fastened crosswise round the periphery to correct moment with a dynamometric
wrench.

» The screws should only be lubricated lightly. Lubrication containing Molybdenum sulphide (MoS2),
mustn't be used.

Forklift/Universal drive shaft Fastening moment (Nm) Fastening moment (lbf ft.)

860-16120 (K36) 50 37

18120-TMF 25/18 (K46) 50 37

Edition 1 KM-124:GB
Page 2 (2)
12
Drive axle
Drivaxel 13
Service-Manual
Svetruck
101.1385.3; 101.1388.3; 101.1389.3; 101.1503.3

Edition 04/2007
Kessler + Co GmbH & Co. KG Tel +49 (0) 73 66/81-32
Huettlinger Straße 18-20 Fax +49 (0) 73 66/81-69
73453 Abtsgmuend service@kessleraxles.com
Germany www.kessleraxles.com
INSTRUCTION MANUAL

Addition Kessler service manual

Brake model depending on machine model.
Machine model Drive axle type Brake type Air gap (pressurized) (mm) Wear dimension (mm)
860-1890 D81 5340 2,4±0,9 2,0
ECS D81 6340 2,8±0,6 2,4
18120-25120 D911 4460 2,5+0,7/-0,1 1,6
28120-34120 D912 6460 3,0+0,5/-0,1 2,4
32120-TMF 15/11 D1020-1021-1022 8460 3,3+0,5/-0,1 3,2
62100 D106 10460 4,0+0,5/-0,1 4,0
TMF 25/18-32/22 D106 10460 4,0+0,5/-0,1 4,0

Edition 1 KM-477:GB
Page 1 (1)
13
Miscellaneous equipment
Övrig utrustning 14
INSTRUCTION MANUAL

Maintenance chart
Service points - Measures
Change the oil and the filters on the engine the first time after 50 hours of operation. After that the maintenance
chart shall be followed.

The following service intervals are valid when the conditions are normal. If you want more information about the
procedure, check under respectively group.

At every new service interval shall all the previous points be performed.

At approximately 500 hours of operation a warranty service is carried out. It means a complete control of your
Svetruck. The warranty service is made by an authorized dealer, by an authorized workshop or by Svetruck's own
service personnel.

Your Svetruck may be differently equipped from what the maintenance chart says. Overlook that service point in
that case.

13

13

8 20 7
18 19
9

1 11
10

3 6 12 17 2 14 15 6

16 4

Figure 730

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Page 1 (4)
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INSTRUCTION MANUAL

Daily inspection
(position according to figure 730)

Service point Measure Group

Engine » Check that there is no oil or fuel leakages. 10
Position 1 » Check the oil level before you start the machine or earliest three
minutes after stopping the machine. The oil level shall be between
the two marks MAX and MIN on the oil stick.

Transmission » Check that there are no oil leakage. 12
Position 2 » Check the oil level.

Drive axle » Check that there are no oil leakage. 13

Position 3

Hydraulic system/ » Check that there is no oil leakage and that the hoses and the lines 7
Cooling oil hydraulic are not worn or damaged.
brakes » Check the oil level. When you do the control all the hydraulic
Position 4 cylinders shall be retired. The oil level shall be between the two
marks on the indicator.
» Check that the oil filter and the breather are not clogged up.

Radiator » Check that there is no coolant leakage and that the hoses aren't 11
Position 5 worn.
» Check that there is no impurities in the core tube.
» Check the coolant level after you have stopped the engine. The
coolant level shall be between the two marks MAX and MIN.

Central lubrication » Check the grease level in the container. 14

container » Check the safety valve of the pump. If the pump is running and
lubricant is leaking from the valve, there is a blockage in the
lubricating system.
» Check that the indicator pin on the main distributor is moving.

Air cleaner » Empty and clean the dust collector when needed. 10

Instrument panel » Check that all instruments, gauges and indicator lamps works and 9
that they aren't damaged. Be specially attentively with the
indicator lamps of the brake system.

Tyres » Check that the tyres don't have any cuts or other damages. 5
Position 6 » Check that the tyres have correct air pressure.
» Check that the wheel nuts are tightened.

Seat compressor » Drain the compressor. 2

Lights » Check that the glass and lamps aren't broken and that they work
properly.

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INSTRUCTION MANUAL

Maintenance every 50 hours of operation or every week

(position according to figure 730)

Service point Measure Group

Mast suspension » Unload the mast when you lubricate. 3
Position 7

Steer axle » Lift the lift truck when you lubricate. 5

Position 8

Support rollers on fork » Lubricate. 4

Position 9

Tilt cylinder » Lubricate. 3

Position 10

Central lubrication » Funktion control. 14

Maintenance every 400 hours of operation or every other month

(position according to figure 730)

Service point Measure Group

Engine » Change oil and filters. 10
Position 1

Transmission » Change filters. 12

Position 2

Drive axle hydraulic » Lubricate 1 nipple. 13

brakes
Kirkstall D300, D304

Fan belts » Check and adjust. 11

Position 11

Universal drive shaft » Lubricate 2 nipples. 12

Position 12

Mast wheel and » Lubricate. 3 and 4
support rollers
Position 13

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INSTRUCTION MANUAL

Maintenance every 1000 hours of operation or every 5 months

(position according to figure 730)

Service point Measure Group

Transmission » Change oil and filters. 12
Position 2

Drive axle » Change oil and clean around the breather. 13

Position 3

Fuel system » Change filters och drain the tank. 10

Position 1 and 14

State of charge » Check the generator belts and the batteries. 9 and 10
Position 11 and 15

Hydraulic system » Change filter lining, breathing filter and return filter. 7
Position 16

Brake system » Change 2 hydraulic filters. 6

Position 17

Chain roller » Lubricate. 3

Position 18

Parking brake - » Check the brake linings and change if needed. 13

drive axle Adjust the brake pads if needed.
Position 19

Valve clearance » Check and adjust if needed. 10

Position 1

Maintenance every 2000 hours of operation or every 10 months

(position according to figure 730)

Service point Measure Group

Hydraulic brakes » Check charging pressure and brake pressure. 6
Position 17

Turbo compressor » Check charging pressure. 10

Position 1

Hydraulic system » Change oil. 7

Position 16

Steering axle » Check steering knuckle and wheel hub. 5

Position 8

Fuel injector » Check opening pressure, density and spray pattern. 10

Position 1

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Oil volume
Oil volume engine
Engine type Volume with filter change (litres)
Cummins 6BTA 5,9C 16
Cummins QSB6,7 19,7
Cummins QSB6,7 3B 19,7
Cummins 6CTA 8,3C 20
Cummins QSC8,3 22,7
Cummins M11C 36
Cummins QSM11 37
Cummins N14C 38
Cummins QSX15 45,4
Scania Di9 48A 27
Scania Di9 50A 27
Scania Di9 56A 27
Scania Di12 50A 33
Scania Di12 56A 33
Scania DC12 58A 33
Scania DC13 076A 45
Volvo TAD57xVE 16
Volvo TD61A 24
Volvo TD610V 24
Volvo TAD620VE 16
Volvo TD630VE 24
Volvo TWD630VE 24
Volvo TD640VE 24
Volvo TAD650VE 15,5
Volvo TD71A 29
Volvo TAD722VE 23
Volvo TD730VE 29
Volvo TWD730VE 29
Volvo TWD731VE 29
Volvo TAD750VE 21,5
Volvo TAD87xVE 27
Volvo TD100G 25
Volvo TD1030VE 36
Volvo TWD1031VE 36
Volvo TD121G 38
Volvo TWD1230VE 38
Volvo TWD1231VE 38
Volvo TWD1240VE 35
Volvo TAD1251VE, TAD1252VE 35
Volvo TAD137xVE 46-52
Volvo TID162APB 44
Volvo TD164KAE 44

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Oil volume transmission

Transmission type Volume with filter change (litres)
Allison 5633 42
Allison 7033 48
Caterpillar X177-7160 70
Dana 28000 24
Dana 32000 24
Dana 40000 42
ZF 3WG 190 24
ZF 4WG 190 24
ZF 3WG 200 24
ZF 4WG 210 24
ZF 3WG 310 30
ZF 4WG 310 30

Oil volume driveshaft

Driveshaft type Differential (l) Hub reduction (l/hub) Total volume (l)
Kessler D81 Wide = 2500 17,5 2 21,5
Kessler D81 Wide = 3500 25 2 29
Kessler D81 Wide = 4000 47 2,8 52,6
Kessler D91 18120-25120 27 2,8 32,6
Kessler D91 28120-34120 35 5 45
Kessler D102 37120-52120 76 12 100
Kessler D106 62100 72 11 94
Kessler D106 TMF 25/18-28/21 72 11 94
Kirkstall D90 23 2 27
Kirkstall D100-20 34 6 46
Kirkstall D100-25 36 6 48
Kirkstall D300 narrow 48 4,5 57
Kirkstall D300 wide 56 4,5 65
Kirkstall D304 narrow 48 4,5 57
Kirkstall D304 wide 56 4,5 65
Kirkstall RP32STWB34 narrow 45 9 63
Kirkstall RP32STWB34 wide 47 9 65
Meritor PRLC 1794 22,7 3,8 30,3
Meritor PRC 3805 22,7 9,5 41,7
Meritor PRC 7534 narrow 41 12 65
Meritor PRC 7534 wide 48 12 72

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Coolant volume
Total volume in the entire cooling system. Note! These figures are approximate.
Engine type Volume with plastic tank (litres) Volume with metal tank (litres)
Cummins 6BTA 5,9C 33 42
Cummins QSB6,7 - 24 860-1890 Air-Water/ Air-Air
Cummins QSB6,7 - 28 ECS
Cummins QSB6,7 3B - N/A Engine 11,5 liters
Cummins 6CTA 8,3C 33 42
Cummins QSC8,3 - 32 Air-Water
Cummins QSC8,3 - 31,5 Air-Air
Cummins M11C - 44
Cummins QSM11 32 (32-52) 40 (TMF) 45
Cummins N14C - 44
Cummins QSX15 56 -
Scania DI9 - 46
Scania DI12 - 44
Scania DC12 45 (32-52) 54 (TMF) 50
Scania DC13 38 (32-52) 46 (TMF) -
Volvo TAD57xVE - 27 Engine 13 liters
Volvo TD61A 33 -
Volvo TD610V 33 -
Volvo TAD620VE 25 -
Volvo TD630VE 33 -
Volvo TWD630VE 33 -
Volvo TD640VE - 36
Volvo TAD650VE - 25 Air-Water
Volvo TAD650VE - 21 Air-Air
Volvo TD71A 33 42
Volvo TAD722VE 29 -
Volvo TD730VE 33 42
Volvo TWD730VE 34 43
Volvo TWD731VE 34 43
Volvo TAD750VE - 30 Air-Water
Volvo TAD750VE - 23 860-1890 Air-Air
Volvo TAD750VE - 29 18120-34120 Air-Air
Volvo TAD87xVE - 31 Engine 17 liters
Volvo TD100G - 27
Volvo TD1030VE - 30
Volvo TWD1031VE - 30
Volvo TD121G - 80
Volvo TWD1230VE - 48
Volvo TWD1231VE - 48
Volvo TWD1240VE 44 -
Volvo TAD1251VE 50 -
Volvo TAD1252VE 50 -
Volvo TAD1372VE 50 -
Volvo TID162APB - 85
Volvo TD164KAE - 90

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Lubricating oils and lubricating

grease
It is very important to use the lubrication recommended by the manufacturer. See the manufacturer’s instruction
manual for more information about the grade and viscosity of lubricants.
It is important to use the correct viscosity oil at constant outdoor air temperature. Using the wrong viscosity can
cause serious damage to the drivetrain and drivetrain components. Check with your oil supplier.

The next page contains an extract from a number of manufacturers’ recommendations for grades of lubricants.
Always refer to the instruction manual of each manufacturer for specific information.

Transmission
The transmission is filled with engine oil when delivered from Svetruck.

NOTE!
Do not use ATF oil in the transmission!

Oils with SAE 15W-40 viscosity grade are not recommended for use as transmission oil. SAE 15W-40 may be used,
in exceptional cases, for machines in countries with a hot climate.

General temperature ranges for different viscosities. See the manufacturer’s instruction manual for more detailed
information if the temperature range is different for the engine and transmission.

SAE 10W -20°C to +30°C (-4°F to 86°F)

SAE 10W-30, 10W-40 -20°C to +40°C (-4°F to 86°F)
SAE 15W-40 -15°C to +40°C (5°F to 104°F)
SAE 20W-20 -10°C to +40°C (14°F to 104°F)
SAE 30 ± 0°C to +35°C (23°F to 95°F)

It is important to choose an oil for the temperature range. See the manufacturer’s instruction manual.

Oils with SAE 15W-40 viscosity grade are not recommended for use as transmission oil. These may be used, in
exceptional cases, for machines in countries with a hot climate.

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ACEA: A2, B2, E2

Transmission ZF
API: CG-4, CF-4, SJ
ACEA: A2, B2, E2
Transmission Dana 28000-32000
API: CG-4, CF-4, SJ
ACEA: A2, B2, E2
Transmission Dana 40000
API: C-4
Transmission Caterpillar API: C-4
Transmission Allison API: C-4
ACEA: E3, E5, E7
Engine Volvo TAD620 / 650 / 750VE
API: CI-4, CG4, CH-4
ACEA: E4 ***
Engine Volvo TAD722VE ***
API: CH-4, CI-4 ***
ACEA: E9 Low SAPS
Engine Volvo TAD872VE API: CJ-4
VDS4
ACEA: E3, E7, E5
Engine Volvo TWD1240VE
API: CG-4, CH-4, Ci-4
Engine Volvo TAD1251VE, TAD1252VE *****
Engine Volvo TAD1372VE VDS3, VDS4
ACEA: E3, E2
Engine Volvo
API: CD, CE, CF, CF-4, CG-4
Minimum: ACEA: E3, E4 or E5
Engine Scania Di9, Di12, DC12
API: CE, CFAPI: CF-4
ACEA: E5, E7
Engine Scania DC13
API: CI-4, CI-4+
Engine Cummins ACEA: E2
ACEA: E9 Low SAPS
Engine Cummins QSB6,7 3B
API: CJ-4
Driveshaft API: GL-5 *
DIN 51 524/3 HVLP
Hydraulic system
ISO-L-HV
DIN 51825 KP2K-20
Lubricating grease, Central lubrication
ISO-L-XBCEB2
Cooling oil hydraulic brakes API: GL-4 **, ****

ACEA Association des Constructeurs Européenne d' Automobiles.

API American Petroleum Institute.

VDS Volvo Drain Specification.

* Note! Applies only to Meritor axles. Only use pure mineral oil. For machines used in hot climate countries, we
recommend using oil that corresponds to the API standard: GL-5/MT-1.

Machines 860-16120
** Up to and including truck number 0103180, and also 0103182, 0113187, 0113189, 0113190 and 0113191.
If the brakes make a strange noise after warming up, fill with Lubrizol with approximately 0.5% of the oil volume.
Do not fill with more Lubrizol than necessary.

Machines 860-16120
From and including truck number 0103181, except for 0103182, 0113187, 0113189, 0113190 and 0113191.
The brakes may make a strange noise to begin with. This should disappear after driving for a while.
If the noise does not disappear, contact the service department.

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** Machines ECS
If the brakes make a strange noise after warming up, fill with Lubrizol with approximately 0.5% of the oil volume.
Do not fill with more Lubrizol than necessary.

Machines 18120-TMF 28/21

If the brakes make a strange noise after warming up, fill with Lubrizol with approximately 0.5% of the oil volume.
Do not fill with more Lubrizol than necessary.

*** Note! Only use full synthetic oil for TAD722VE.

**** Cooling oil as per API: use GL-4 if the vehicle has a separate cooling oil tank. If the machine does not have a
separate cooling oil tank, use hydraulic oil as per DIN 51 524/3 HVLP and ISO-L-HV.

***** For engines TAD1251VE and TAD1252VE, see Group 10 - Engine oil (KM-498).

Edition 2 KM-546:GB
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Warranty
Warranty certificate
When you buy a forklift from Svetruck AB you get a warranty certificate. The certificate is a valuable document
which guarantees the listed Svetruck product a 12 months warranty and a warranty inspection.

The warranty inspection means a free complete examination of the forklift after approximately 500 hours of operation.
The inspection is performed by Svetruck AB, an authorised Svetruck AB dealer or an authorised Svetruck workshop.

Note the operating time gauge to determine the exact number of operating hours.

Warranty
Svetruck AB gives a warranty for your Svetruck for a period of twelve months or a maximum of 2000 hours for
materials as well as reasonable labour charges for the first six months or 1000 hours of operation.

NOTE!
The warranty is only valid if the
warranty inspection is performed.

Svetruck AB extends no warranty for engines with auxiliary units, gearbox or other units which are warrented by
their respective manufactrurers. Any claims in respect of such units should be forwarded to Svetruck AB and will
be dealt with thereafter in accordance with the separate warrenty stipulations of each manufacturer.

Read more about the warranty on the warranty certificate.

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Towing
The truck should only be towed in emergencies where there is a danger to life or property, e.g. if the truck’s position
constitutes a fire hazard, environmental hazard, crushing risk, sliding risk or similar.
Towing should not be carried out over distances longer than that demanded by the situation.

WARNING!
The truck must not be driven or used without functioning
steering, brakes and parking brakes!
Take extreme care when towing if the truck does not have
functioning steering, brakes and parking brakes.

Braking system
The truck’s brakes and parking brakes work with the aid of hydraulic pressure
in a separate hydraulic system.
If the engine cannot be started, this will result in there being no hydraulic
pressure to the brakes, and it will not be possible to release the parking
brake either.
If the hydraulic pressure drops during the journey, a warning lamp will be lit
first and the parking brake will then be applied automatically. After this it will
not be possible to move the truck.
See instruction manual group 9, dashboard.

Steering system
The truck’s steering system works with the aid of hydraulic pressure (power
steering) If the engine cannot be started, this means that the steering
capacity is non-existent.

Jump starting
Towing the truck in order to attempt to start the engine is absolutely prohibited.
This can result in serious damage to the engine and the transmission.
If the batteries are discharged, the truck must be started using booster batteries and starter cables.
See instruction manual group 9, battery.

Operational stoppage
Towing or moving with the aid of another truck (to lift up the steering axle) should be avoided if the operational
stoppage can been rectified and the truck can be restored to a driveable condition. Such operational stoppages include
fuel stoppages, hydraulic oil leakage, coolant leakage, puncture or similar problems.
You should initially attempt to establish and rectify the fault on site.

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Measures prior to towing

The forks should be lowered and any load on the forks should be removed.

If the engine can be started, the engine revs should be around 1,000 rpm, the gear selector lever should be in neutral
and in the highest gear. The longest permitted towing distance is 10 km. The maximum permitted speed is 10 km/h.

If the engine cannot be started, the propeller shaft must without exception be disconnected.

If there is no hydraulic pressure to release the parking brake, it must be released mechanically.
Before the parking brake is released, the trucks wheels must be blocked so that the truck cannot start rolling out of control.

The parking brake is released mechanically by means of the adjusting screw for piston and brake pads being
unscrewed by hand. The adjusting screw has various designs depending on the type of drive shaft and brake calliper.
Note that the adjusting screw can be very difficult to undo.
See instruction manual group 6, parking brake.

After towing, the parking brake’s function must be restored by service or workshop personnel.

Equipment for towing

When towing trucks that do not have brakes and/or steering, a drawbar that is approved for towing must be used
without exception.
Chains, steel rope straps, strap slings, round slings, tension straps, rope or similar may not be used.
Alternatively, another truck with sufficient lifting capacity can be used to lift up the steering axle and the steer
wheels. Use suitable securing devices to secure the rear of the truck to the towing truck’s fork carriage so that it
cannot slide off the forks. If there are any lifting eyelets or securing eyelets, these must be used. The truck must be
towed backwards.

When towing trucks that have functioning brakes and steering, a chain with lockable hooks, steel rope straps or
towing straps may be used, provided they are approved for towing and can manage the load.

Recovery
If the truck needs to be recovered after driving into a ditch or if the truck has overturned, professional recovery
assistance must be called in.

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Technical description
Model 32120-48 37120-54 42120-54 42120-57 45120-57 50120-60 52120-60
Lifting capacity
1 Q Load t 32 37 42 42 45 50 52
Load centre
2 c mm 1200 1200 1200 1200 1200 1200 1200
Lifting height teleskopic mast
3 h3 Standard * mm 4000 4000 4000 4000 4000 4000 4000
Tilt
4 Forward α / backwards β * ° 10/10 5/10 5/10 5/10 5/10 5/10 5/10
Fork length
5 L1** mm 2500 2500 2500 2500 2500 2500 2500
Fork arm width/thickness
6 b x s ** mm 300x110 300x135 300x135 300x135 300x135 300x135 300x140
Distance between forks
7 b1 max-min mm 2910-920 2980-930 2980-930 2980-930 2980-930 2980-930 2980-930
Overall dimensions
8 L2 Length incl. forkshaft mm 6880 7740 7740 8040 8040 8340 8340
9 B Width mm 3450 3865 3865 4250 4250 4250 4250
10 h1 Closed height mm 4390 4670 4670 4670 4670 4670 4670
11 h4 Extended height mm 6390 6670 6670 6670 6670 6670 6670
12 h2 Height over cabin mm 3715 4000 4000 4000 4000 4000 4000
Turning radius
13 Wa mm 6600 7750 7750 8100 8100 8400 8400
Load arm
14 x from center of driveaxle mm 2355 2565 2565 2565 2565 2565 2565
90°-stacking aisle
15 Ast 4 with forklength acc. to pos 8 mm 10455 11815 11815 12165 12165 12465 12465
Driving and lifting performance
16 Driving speed fwds/rev km/h 26/26 27/27 27/27 27/27 27/27 27/27 27/27
17 Lifting speed with/without load m/sec 0.23/0.24 0.30/0.32 0.30/0.32 0.30/0.32 0.30/0.32 0.30/0.32 0.30/0.32
18 Lowering speed with/without load m/sec 0.30/0.20 0.30/0.30 0.30/0.30 0.30/0.30 0.30/0.30 0.30/0.30 0.30/0.30
Draw bar pull
19 In carriage loaded kN 223 282 282 282 282 282 282
Climbing performance
20 With/without load % 30/30 30/30 27/30 27/30 26/30 24/30 23/30
Total weight
21 Standard equipped *** kg 41400 53900 57000 55600 57400 58900 60100
Axle load
22 Driveaxle with/without load kg 68200/20500 85100/30500 92500/30500 91400/30500 95700/30500 101800/30500 104700/30500
23 Steer axle with/without load kg 5200/20900 5800/23400 6500/26500 6200/25100 6700/26900 7100/28400 7400/29600
Tyres
24 Dimension drivewheels 16.00x25” 18.00x25” 18.00x25” 18.00x25” 18.00x25” 18.00x25” 18.00x25”
25 Dimension steerwheels 16.00x25” 18.00x25” 18.00x25” 18.00x25” 18.00x25” 18.00x25” 18.00x25”
Wheelbase
26 y mm 4800 5400 5400 5700 5700 6000 6000
Track
27 Driveaxle/steeraxle mm 2475/2380 2600/2500 2600/2500 3100/2500 3100/2500 3100/2500 3100/2500
Ground clearance
28 m2 under liftmast mm 300 300 300 300 300 300 300
29 m1 mid forklift mm 465 480 480 480 480 480 480
Brakes
30 Mainbrake Wet disc brakes Wet disc brakes Wet disc brakes Wet disc brakes Wet disc brakes Wet disc brakes Wet disc brakes
31 Parkingbrake Spring brake Spring brake Spring brake Spring brake Spring brake Spring brake Spring brake
Engine
32 Manufacturer **** Cummins Cummins Cummins Cummins Cummins Cummins Cummins
Alternator
33 AC W 2240 2240 2240 2240 2240 2240 2240
Battery
34 Voltage/capacity V/Ah 24/110 24/170 24/170 24/170 24/170 24/170 24/170
Transmission
35 Type Converter Converter Converter Converter Converter Converter Converter
36 Type of gearshift Automatic Automatic Automatic Automatic Automatic Automatic Automatic
37 Number of gears fwds/rev. 4/3 4/3 4/3 4/3 4/3 4/3 4/3
38 Model ZF Ergopower ZF Ergopower ZF Ergopower ZF Ergopower ZF Ergopower ZF Ergopower ZF Ergopower
39 Operating pressure kPa 16500 16000 16500 16500 17500 18000 18000
Fueltank
40 Volume Litre 640 1000 1000 1000 1000 1000 1000

* Only Svetruck 32120-48

** Upon request.
*** Dependent on specification.
**** Alternatives Volvo or Scania on request.

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Edition 1 KM-621:GB
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CERTIFICATE
Registers and abbreviations
Register och förkortningar 15
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Table of contents
Accumulator pressure 7 Lexan windows 2
Air cleaner 10 Lift cylinder 3
Air filter - hydraulic system 7 Lifting 3
Air pressure system 6 Link arm 5
Automatic engine stop 9 Lubrication oils 14

Battery 9 Main fuses 9

Brake pressure 6 Maintenance chart 14
Mast 3
Central lubrication 14
Certificates 14 Overflow valve 7
Chain rollers 3
Chains 3 Pedals 6
Climate system 8 Piston accumulator 6
Cold start 10 Piston accumulator 7
Container spreader 4
Container spreader 14 Relay numbering 9
Coolant 11 Reversible driver’s seat 2
Cooling oil tank - hydraulic brakes 6 Rollers (carriage) 4
Rollers (mast) 3
Declaration of conformity CE 14 Running in 10
Drive axle oil 13
Driver’s seat 2 Servo controls 7
Start of engine 10
Engine heater 10 Steering 2
Engine oil 10 Steering axle 5
Steering cylinder 5
Foreword - Steering knuckle 5
Fork carriage 4 Steering pressure 7
Fork carriage cylinders 4 Steering pump 7
Forks 4 Steering wheel 2
Fuel filter 10 Stop of engine 10
Fuel system 10 Support roller (carriage) 4
Fuel tank 10 Support roller (mast) 3
Function control 9
Fuses 9 Technical data 14
Tilt cylinders 3
Gear change 9 Towing 14
Generator belt 10 Transmission 12
Turbo compressor 10
Hydraulic filter 7 Tyres 5
Hydraulic oil 7
Hydraulic pressure 7 Universal drive shaft 12
Hydraulic pump 7
Warranty 14
Instrument panel 9 Weighing equipment 7
Wheel bearings 5
King pin kit 5 Wheel nuts 5
Windscreen washer 9
Windscreen wiper 9

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Notes

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