Sl6-8ecb GB 6053506

Instructionbook SL 6-8 ECB
MODELRANGE
SL 6-8 ECB
CONDESIGN INFOCOM AB, SWEDEN
Publ. No. 6053.506 0546 1

Instruction book SL 6-8 ECB
YOUR SMV FORK-LIFT TRUCK
This user manual provides you with the TECHNICAL REMARKS Delivery inspection
information you need to know about
starting, driving, servicing and SMV is constantly developing both the Every SMV fork-lift truck is carefully
maintaining your SMV fork-lift truck. design and manufacture of its products. inspected before it leaves the factory to
Illustrations and technical details ensure that it is fully in order and is fully
Using and attending to the truck concerning the design, parts and equipped in accordance with the order.
properly will preserve its qualities for a performance of the fork-lift truck are Authorised SMV dealers are then
long and profitable working life, and will subject to alteration as a result of this required to re-inspect the truck before it
make full use of its applications. technological development. is delivered to the customer.
The expressions "front", "back", "right" SMV therefore assumes no In order to avoid later complaints and
and "left" indicate the position in which responsibility on the basis of those problems, the customer should also
the relevant component is installed in the specifications, illustrations and check that the truck is in full working
truck as seen from the driving descriptions found in the user manual. order and is fully equipped when it is
compartment. delivered, with a receipt of the
If you have any questions concerning acceptance/handover of the truck from
Follow all instructions in the manual on SMV fork-lift trucks and ordering spares, the dealer.
using the fork-lift truck and carry out contact your nearest authorised dealer.
maintenance and inspection as described Take care to supply the correct address Always perform Lubrication, Checking,
in the maintenance table on a regular for delivery. Maintenance and Daily Maintenance
basis and at the correct time, using the according to the Maintenance tables in
specified lubricant. If any repairs are needed, use only SMV this book as well as the Delivery Report
original spares. This is necessary in before operating the Fork-lift truck for
Maintenance must be carried out only by order for your SMV fork-lift truck to the first time.
qualified staff. retain its original technical standard.
The following technical manuals
Above all, we would like to emphasise When ordering spares, it is important to accompany every fork-lift truck:
the importance of following both the indicate the item number found in the
general traffic regulations and the spares list as well as the following 1 Spares catalogue for the fork-lift truck
guidelines in force for the use of fork-lift information: 1 User manual for the fork-lift truck
trucks and the prevention of accidents at 1 Machine card
work. Model:
Serial number/year of manufacture: When contacting your authorised
The regulations in force for normal and Delivery date: dealer, always indicate:
regular use of commercial trucks must be
strictly adhered to by management, When ordering spares for the following 1. Truck designation
commercial operators and service staff. units, you must indicate their individual 2. Truck serial number
manufacturing numbers: 3. Year of manufacture.
The user, not SMV, is responsible for any
dangers that may arise when the truck is Engine no.:
being used for applications not Mast no.:
approved by the manufacturer. The lift height of the mast:
Hydraulic pump no.:
SMV fork-lift trucks are designed for the Transmission no.:
transport and lifting of loads indicated Drive shaft no.:
on the load-bearing capacity plate.
No alterations and, above all, no When the fork-lift truck is delivered, the
additions or conversions may be made to details on the type plate should be
the fork-lift truck without the permission written in this user manual.
of the manufacturer.
The user instructions for additional parts

issued by the manufacturer apply to
those additional parts.
2 Publ. No. 6053.506 0546

SAFETY REGULATIONS
Safety regulations
* Follow national safety regulations * Lifting a person or persons is forbidden unless the
truck is equipped with an approved lift cage for this
* The truck must only be driven by those trained purpose
to do so and who have the permission of the
management * Never exceed the lifting capacity of the truck - see
type plate and load diagram
* Remember: The national and state laws on
driving licences and driving regulations always * The load should always be transported in a lowered
apply! position
* Before starting up, ensure that no person(s) or * Always report damage and wear and tear affecting
other obstacles are in the way of the truck or the safety/function and life of the truck
its equipment
* The hydraulics of the truck are equipped with a
* Do not block doors and/or emergency exits. highpressure hydraulic accumulator. Take great care
when working with the hydraulic system. Only
* The truck must not be used if it has faulty service staff with knowledge of the hydraulics may
brakes, steering, lifting or other important intervene here.
functions
* Use protective equipment - helmet, gloves, eye and
* Passengers are not allowed ear protection when working on the truck.
Publ. No. 6053.506 0546 3

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

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

symbol or the signal word.
4 Publ. No. 6053.506 0546

SAFETY REGULATIONS
BEFORE OPERATION ENVIRONMENTAL ASPECTS
Persons responsible, particularly truck- Driving, manoeuvring and steering 1.Driving the lift truck
drivers and service staff, must be should be practised until the driver is Exhaust emissions, noise, leakage (oil,
instructed on the regulations for normal fully acquainted with all these opera- fuel, fluids).
and safe use of commercial trucks which tions. influenced negatively by incorrect
accompany this manual. driving and handling of the lift truck.
Follow the guidelines and safety Only after that stage can training in 2. Remainings fromservicing
regulations applicable to: stacking manoeuvres begin. Oil, fuel, filters and filter deposit,
- use of commercial trucks The stability of the truck in the working cleaning fluids have to be disposed of
- roads and work places area can only be guaranteed if the or recovered according to local
- drivers (rights, obligations and regula- correct procedures are followed. legislation.
tions for implementation) Follow the driving instructions in the 3. Remainings from repairs
- any extra equipment instruction book carefully in order to Metall, batteries, electronics, rubber
- different types of vehicle avoid forbidden maneuvers or incorrect (tyres, hoses, seals), solutions,
- service (maintenance and inspection) driving. Incorrect driving may cause chemicals have to be disposed of or
- annual inspection for the prevention accidents. recovered according to local
of accidents. legislation.
Prevention of accidents
The driver (/owner) or other persons in NORMS
positions of responsibility must ensure In some countries, lift trucks must be
that the above guidelines and safety This lift truck is built regarding the
inspected once a year by trained staff in
regulations are adhered to. following norms according to
accordance with the prevention of
When a trained driver is about to operate accidents regulations. Authorised SMV
the truck, instruct him on: Noise 2000/14/EC PrEN 12053
dealers can supply information on these.
- special functions of the SMV truck ISO 3744:1998
- extra equipment DIN 45635
We reserve the right to modify our
- special operating applications. design and material specifications
Vibrations 2000/44/EC PrEN 13059:1997
without prior notice.
Emissions 97/23/EC
Publ. No. 6053.506 0546 5

OUTLINE PICTURE OF THE LIFT
TRUCK
DESCRIPTION
1. Steer axle 4. Engine casing 7. Lift cylinders

2. Counterweight 5. Driver’s cab 8. Carriage
3. Frame 6. Tilt cylinders 9. Spreader
10. Drive axle
6 Publ. No. 6053.506 0546

ID PLATES AND SERIAL NUMBERS
TRUCK
1. Mast number 4. Steer axle number 7. Chassies number

2. Load capacity plate 5. Engine number 8. Differential number
3. Spreader number 6. Transmission number 9. Drive axle number
Publ. No. 6053.506 0546 7

TECHNICAL DESCRIPTION
TECHNICAL DESCRIPTION
Specification SL 8 EC B means: The brakes are operated by an oil-cooled The driver’s cab meets or exceeds all
SL = Silver Lift wet disc-braking system. The applicable safety standars, and is
8 = 8 high stacking foot brakes are controlled by the foot rubbermounted to protect the driver
EC = empty container brake valve which activates the drive from vibrations.
B = series designation. axle. The parking brake is controlled
electrically and activates a hydraulic Entrance to the cab is on the left side
The engine is a water-cooled, turbo- cylinder on the drive shaft. via the steps on the truck. It is also
charged possible to exit the cab from the right
6-cylinder diesel engine. The double hydraulic pumps are side.
The engine drives a three or four speed mounted directly on the gearbox. The
transmission using a torque converter. system is divided into four circuits, All hydraulic controls for the lifting
The gear selector is electrical with two for manoeuvring, one for servo functions are grouped on the console
three or four gears for driving forward/ functions and one for steering. The to the right of the driver’s seat. The
backward. The torque converter is relief valves in the hydraulic circuits parking brake and the switch for
equipped with an oil cooler which lies are installed to prevent the system selecting additional electrical equip-
underneath the radiator. The gearbox from overloading. ment
has a disengaging valve controlled by instruments, gauges and warning
the brake pedal in the cab. This valve The steering is fully servo-assisted. lights together with the switches for
disengages the gearbox so that the If the engine should stall, it is still the direction indicators and windscreen
operator can control the brakes whilst possible to steer the truck without wipers are located on the front mounted
maintaining a high engine speed during servo assistance, although it is heavy instrument panel.
stacking manoeuvres. going.
Gear control lever on the steer shaft.
The drive axle is operated by the Two control valves, mounted on the The electrical system is 24 V and has
gearbox using the universal drive shaft. chassis, are controlled from the cab by two serial-connected 140 Ah heavy
This shaft is of the double-reducing servo-assisted control levers on the duty batteries.
heavy duty type with a conical gear as right of the driver. These regulates the
the primary shaft, a planetary shaft as functions for lifting, tilting, side-shifting,
the secondary shaft, unloaded trunnions spreading the forks, and any
and conical roller bearings. extra functions.
The steer axle is mounted in ”sphere- The mast consists of an outer and an
lastic” inner upright, a lifting carriage, two
bushes which allow sufficient lifting cylinders and two tilt cylinders.
wheel movements for stability on The inner upright section moves along
uneven ground. The parallel tie-rods the outer upright with support wheels
are between the steering cylinder and and support backing rollers. The mast
the wheel axles. is mounted on two axles in the chassis.
8 Publ. No. 6053.506 0546

CONTENTS
YOUR SMV LIFTTRUCK ............................................................. 2 DISASSEMBLING CARRIAGE AND MAST .......................... 51

SAFETY REGULATIONS .............................................................. 3 Disassembling the carriage ................................................................ 51
OUTLINE PICTURE OF THE LIFTTRUCK ............................. 6 Disassembling the mast ..................................................................... 51
ID-PLATES AND SERIAL NUMBER .......................................... 7 TIGHTENING BOLTED JOINTS ............................................... 52
TECHNICAL DESCRIPTION ....................................................... 8 Tightening torque, Tightening the wheel nuts ...................................... 52
CONTENTS ...................................................................................... 9 Drive shaft, Differental nuts, The engine mounting ............................ 53
DAILY MAINTENANCE .............................................................. 10 The gearbox, Drivaxle suspension, Counterweight ............................ 54
Daily maintenance and service befor operation ................................. 10 Steer axle ......................................................................................... 55
Check the washer level ..................................................................... 10 LUBRICATION POINTS ............................................................. 56
Coolant level ...................................................................................... 10 Lubrication chart .......................................................................... 56-60
Checking the engine oil level ............................................................... 11 LUBRICATIONS POINTS, SPREADER ................................... 58
Checking the oil level in the gearbox .................................................. 11 General rules which apply to lubrication ............................................ 58
Air filter indicator .............................................................................. 11 Wear pads for main beams and extending beams .............................. 58
Checking the hydraulic oil level .......................................................... 12 Extention cylinder support wear pads and tracks ............................... 58
Topping up the hydraulic oil ............................................................... 12 Upper side shift slider pads ................................................................ 59
Checking the fuel level ...................................................................... 12 End beams and twist locks ................................................................ 59
Filling with fuel .................................................................................. 13 Housing for double twist locks ........................................................... 59
Checking the condition and pressure of the tyres ............................... 13 Lower side shift sliderpads ................................................................ 60
Main sercuit switch ........................................................................... 13 End beam slider pads ......................................................................... 60
CONTROLS AND INSTRUMENTS IN THE CAB ................. 14 Cylinders ........................................................................................... 60
WARNINGLIGHTS AND INDICATORS ................................... 15 LUBRICATION ............................................................................. 61
BEFORE DRIVING ....................................................................... 16 Lubricating the mast ......................................................................... 61
Adjusting the driver’s seat ................................................................. 16 Lubricating the steer axle, Lubricating the drive shaft ....................... 62
Adjustment lever of steering wheel ................................................... 17 Lubricating the door hinges, compartment doors,
Starting the engine ............................................................................. 18 lubricating the engine bonnet .............................................................. 63
Funktion of gauges and indicators ...................................................... 18 CHANGING OIL AND FILTERS ................................................ 64
Stopping the engine ............................................................................ 19 Changing the engine oil, topping up the engine oil,
IQAN-panel (EMC) ..................................................................... 20-28 cleaning the engine oil filter ............................................................... 64
OPERATING .................................................................................. 29 Changing the oil in the gearbox ......................................................... 65
Driving forwards ............................................................................... 30 Changing the transmission breathing filter .......................................... 65
Stopping the truck, Driving backwards .............................................. 31 Changing the gerarbox oil filter .......................................................... 65
STEERING AND BRAKING ...................................................... 32 Checking and changing the oil in the drive axle .................................. 66
Steering, The disengaging switch, The parking brake switch ............. 32 Changing the hydraulic oil, filters and hydraulic tank breathing filter .. 67
EMERGENCY STOP AND VENTILATION ............................ 33 Bleeding of hydraulic pumps, Start of pumps ..................................... 68
Emergency stop, ventilation and cab filter .......................................... 33 Changing the fuel filters, bleeding of the fuel system
MANOEUVERING THE LIFTING EQUIPMENT ................... 34 cleaning of the sludge separator ........................................................ 69
Manoeuvering mast ........................................................................... 34 Cleaning/Changing the air filter, Safety cartridge ............................... 70
Manoeuvering joystick ....................................................................... 34 CHECKING AND OTHER MAINTENANCE ......................... 71
LIFTING LOADS WITH STANDARD SPREADER ................ 35 Checking the air intake system .......................................................... 71
Before lifting loads, Capacity plates, Emergency lowering ................ 35 Checking the battery .......................................................................... 71
Spreader lights, Picking up a container .............................................. 36 Changing the windscreen wipers ....................................................... 71
Transport with the container .............................................................. 38 Checking the cooling system, Replacing the coolant .......................... 72
Discharging a container ..................................................................... 39 Checking the exhaust system, Valve clearance .................................. 73
LIFTING LOADS, DOUBLE STACKING ................................. 40 Checking of fuel system .................................................................... 73
Spreader lights, Picking up two containers ......................................... 40 Checking the fuel system and tank .................................................... 74
Alignment of top container ................................................................ 40 Checking and adjustment of drive belts .............................................. 75
Transport with two containers ........................................................... 42 Checking the mast and carriage ........................................................ 76
Discharging two containers ............................................................... 43 Checking weld constructions ............................................................. 76
SERVICE AND MAINTENANCE ............................................... 44 Checking of the steer axle bearings ................................................... 76
General information ........................................................................... 44 Steer wheels suspension ................................................................... 77
Electric welding, Jump starts ............................................................. 45 Adjusting wheel bearings ................................................................... 77
Running in/servicing after the first 100 - 150 hours of operation ........ 45 Adjusting the spindle bearings ............................................................ 77
TRANSPORT AND TOWING CHECKING AND OTHER MAINTENANCE .......................... 78
Towing, Parking brake .................................................................. 45-46 MAINTENANCE TABLE ............................................................ 79
CLEANING .................................................................................... 47 MAINTENANCE DATA .............................................................. 80
Cleaning the truck. Cleaning the cooler ............................................ 47 FUEL AND OIL RECOMMENDATIONS ................................ 81
CHANGING A WHEEL ................................................................ 48 ELECTRICAL SYSTEM .............................................................. 84
Changing a wheel ............................................................................. 48 NOTES ........................................................................................... 110
Specifications for tyres ...................................................................... 48
Specifications for rims. Other type of tyres ....................................... 48
Dismantling the drive wheel ............................................................... 49
Mounting the drive wheels ................................................................. 49
Disassembling the steer wheel .......................................................... 50
Assambling the steer wheel ............................................................... 50
Publ. No. 6053.506 0546 9

DAILY MAINTENANCE
Daily maintenance and service before operation
Points to check:
- Washer level
- Water level of the radiator
- The level of the engine oil
- The gear box oil level
- The air filter indicator (the engine's air filter)
- Hydraulic oil level
- The fuel level
- Tire pressure and condition
- Main switch
- Brake operation
- Steering operation
Check the washer level
Washer tank is placed on the right side of the truck, below the
bonnet. Fill when necessary.
Coolant level
1
- Open the cap of the expansion tank (1). First a 1/4 of a turn
to ensure that the system is not under pressure.
- The level should be up to the center of the tank.
10 Publ. No. 6053.506 0546

DAILY MAINTENANCE
Checking the engine oil level

2
1
- Lift the engine casing.
- The dip stick (3) is on the left-hand side of the engine.
- Remove the dip stick (3) completely and dry it off with a
clean cloth.
- Dip the stick back in fully and remove again.
- The oil level should be between the minimum and maxi mum
level indicators.
- If necessary, remove the filler cap (2) and top up the oil.
- Fill with oil to the maximum level indicator on the dip stick.
Checking the oil level in the gearbox
- Start the engine and run until the oil has reached operating
temperature.
- Remove the dip stick (1) and dry it off with a clean cloth.
- Dip the stick back in fully and remove again.
- The oil level should be between the minimum and maximum
level indicators.
- If necessary, remove the filler cap (2) and top up the oil.
- Fill with oil to the maximum level indicator on the dip stick.
- Turn off the engine.
Air filter indicator
- Check the indicator (1).

- If the indicator shows RED, reset the indicator by pressing
the knob (2) under the unit.
- Start the engine. If the indicator still shows red, stop the
engine and clean or replace the air filter.
Publ. No. 6053.506 0546 11

DAILY MAINTENANCE
HYDRAULIC SYSTEM
Checking the hydraulic oil level
- Check that the oil level is between the MIN and MAX marks
on the indicator at the side of the hydraulic oil tank
(the lifting frame should be lowered).
Topping up the hydraulic oil
WARNING
Hot hydraulic oil may spray from the oil
refill.
Risk of serious injury.
Do not open the oil cap whilst the engine
is running.
- Unscrew the oil cap (1).

- Fill with hydraulic oil up to the upper mark on the indicator.
See above.
- Screw the cap back on.
Checking the fuel level
- Turn the ignition key to position 1.

- Wait until the fuel indicator on the dashboard (2) has stabili-
sed.
2 - If necessary, fill.
WARNING
To avoid air being sucked into the fuel
injection
system, the fuel tank should never be run
completely empty. If air enters the fuel
system,
the engine will stop and the system must be
deaired.
- Turn off, the ignition key.
12 Publ. No. 6053.506 0546

DAILY MAINTENANCE
Filling with fuel
- Open the tank cap located on the left-hand side of the truck
and fill with the recommended fuel.
- Screw on the cap.
- The capacity of the fuel tank. See page 80.
Checking the condition and pressure of the tires
- Check that the tyres have not been damaged or become too
worn.
- Remove any foreign objects from the tread.
- Check that the tyres have the correct pressure of 9 bar.
- Pump the tyres according to the relevant regulations.
Main circuit switch

- The main switch (1) is located on the right-hand side
2 of the truck.
- Turn the cut-out switch clockwise to turn it on.
- Turn the switch anti-clockwise to turn it off and
remove the key.
WARNING
Beware of short-circuiting the battery,
which may cause fire or explosion.
Risk of serious injury or death.
The main disconnect does not cut the power
to the alternator. Always disconnect the
ground (minus) cable at the battery when
working near or on the alternator.
Publ. No. 6053.506 0546 13

CONTROLS AND INSTRUMENTS IN THE CAB
14 2 3 4
5 6
8
13
12 9
11
10
DESCRIPTION
1. Steering wheel 5. Directional switch 10. Brake pedal

2. Wiper front screen 6. Front screen washer 11. Disengaging switch
3. High/low beam 7. Steering wheel adjustment 12. Air condition/Heating
4. Horn 8. Joystick 13. Instrument/switch panel
9. Accelerator 14. Direction and gear selector
14 Publ. No. 6053.506 0546

WARNING LIGHTS AND GAUGES
31
15
30
32
33
28
24
25
22
20
18 14
13
29 16 12
11
23 10
21
9
19
17
8
26
27
3
1 2
1. Parking brake 10. Rotating beacon 22. Indication, engine, pressure

2. Working lights, mast 11. Joystick steering (optional) 23. Indication, engine, temp.
3. Working lights, roof 12. Central lubrication (optional) 24. Indication, gearbox, pressure
4. Working lights, extra 13. Central lubrication (optional) 25. Indication, gearbox, temp.
5. Road lights 14. Joystick steering, indication (opt.) 26. Emergency stop
6. Screen washer, roof/rear 15. Preheating indication (optional) 27. Ignition switch
7. Intermittment wiper, rear 16. Indication, brake, pressure 28. Hour meter
8. Intermittment wiper, roof (optional) 17. Indication, brake, temp. 29. Fuel
9. Hazard 18. Indication, parking brake 30. Oilpressure, engine
19. Indication, battery 31. Oilpressure, gearbox
20. High beam 32. Temp. engine
21. Directionals 33. Temp. gearbox
Publ. No. 6053.506 0546 15

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

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

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

Lever to the right - full stroke.
Lever one step to left - stroke limited partially.
Lever to the left - stroke fully limited.
- Adjust the armrest with the hand wheel (8).
- To remove seat press pedal (9) Option
- Fasten the safety belt before driving.
WARNING
Never operate a machine without having
fastened the seat belt properly.
The safety belt should always be used when
driving.
WARNING
Never drive the truck unless the seat is
locked in position.
A seat that is not locked in position may
cause the driver to make uncontrolled
movements, which may cause the machine to
be handled incorrectly.
16 Publ. No. 6053.506 0546

BEFORE DRIVING
Adjustment of steering wheel
When positioning the steering wheel.

- Pull lever (1) upward to adjust the tilt.
- Pull lever (1) downward to adjust the height.
Publ. No. 6053.506 0546 17

BEFORE DRIVING
STARTING THE ENGINE
WARNING
Exhaust fumes are harmful. Never run
the engine in unventilated places.
Use fume extraction.
Before starting up the engine, the gear selector on the left-

hand side of the instrument panel must be in neutral.
On starting up
- Position yourself in the driver’s seat.
- Insert the ignition key into the ignition lock, position (0).
- Turn the key into position (1). The electrical system is now
turned on.
- The battery light (9) and oil pressure lights (6, 7 and 8)
illuminates.
- Turn the key into position (II). Release the key as soon as
the engine has ignited.
- If the engine does not start within 20 seconds, wait at
least 1 minute and try again.
NOTE
Maximum 3 starting attempts per minute.
Stop solenoid may get over heated as it is activated after
each attempt.
Function of gauges and indicators

WARNING
If any of the following warning lights
come on, or an indicator shows an
abnormal reading during operation, the
fault must be remedied immediately.
Do not use the machine, even if the brake
pressure light illuminates as brakes may
not work.
- The battery light (9) goes out after the engine has started. If
this light comes on whilst the engine is running, the
generator is not charging.
- The engine oil pressure light (8) goes out after the engine
has started. If this light comes on whilst the engine is run
ning, the pressure is too low. See also gauge (1) normal
value is 1-6 bar.
- The temperature of the engine cooling liquid (6). If this light
comes on, the temperature of the liquid is too high. (100° C)
See also temperature gauge (4) normal value is 90-95° C.
- The gearbox oil pressure light (7) goes out after the engine-
has started. If the light comes on whilst the engine is
running, the gearbox pressure is too low. See also gauge (2)
normal value is 16-20 bar.
- The gearbox temperature (5) lights up when the temperature
of the oil is too high. See also gauge (3) max value 120° C.
- The accumulator pressure lights up (10) when the brake
pressure is low.
18 Publ. No. 6053.506 0546

BEFORE DRIVING
Stopping the engine
Use the emergency stop only in an emergency situation.

4 See page 33.
3 - Release the accelerator (1).
- Apply the brakes in a controlled manner (2).
- Engage the parking brake (3).
- Put the driving direction control (4) into neutral.
CAUTION
Allow the engine to idle for a few
minutes if it has constantly been run
hard this is to avoid any turbo damages
or overheating.
The current must not be interrupted
before the engine has stopped.
2 2
- Turn the ignition key to position (0).

- Remove the key from the ignition switch when leaving the
truck.
- Turn the main circuit switch off if the truck is being left
unsupervised.
Publ. No. 6053.506 0546 19

BEFORE DRIVING
Description of the EMC drive monitor type IQAN
The drive monitor’s purpose is to efficiently control the fork lift’s hydraulic system and drive line by utilising both analog and
digital information from various sensors.
Prevent gear change from forward (F) to reverse (R) as long as the machine is not stationary. Increase engine RPM when hoisting.
Prevent full flow from the hydraulic pump at low engine RPM. Limit engine RPM in case of high engine or transmission tempera-
ture.
The following options are also offered - automatic transmission, and joystick steering with proportionaly limited steering
movement at higher speeds.
The monitor informs and warns the driver via a display, if any value happens to be abnormal eg. overload, abnormal pressure, or
temperature.
The monitor can also be used for fault finding.
The monitor computes the following information:

- Position of the regulator motor on the fuel injection pump
- Position of the accelerator pedal
- Pressure in hoist cylinders
- The engine, transmission and brake accumulator’s pressure
- Temperature of the engine and transmission
- Fuel level
- Position of gearshift lever and declutch gear function
- Parking brake switch
- RPM of engine and drive train
- Steering wheel’s angle and orbitrol pressure. Joystick steering option
The monitor controls the following functions:

- Fuel pump regulator motor (engine RPM)
- The transmission’s valves for F&R, 1st, 2nd, 3rd and 4th gears
- Parking brake valve
- Steering system when joystick type steering fitted, optional
- Automatic transmission, optional
The following information can be obtained by utilising the display’s various keys.
Description of the keys
Step keys (1) up, (2) forward, (3) down, and (4) back, pages
through the menues.
Menu/enter key (5), change menues/endorse fault information.
Alternative keys (6,7,8 and 9)
After starting turning on the ignition switch, this picture will be

shown for approx. 1 second and will then be followed by the
logo which will be visible for approx 2 to 3 seconds.
20 Publ. No. 6053.506 0546

BEFORE DRIVING
First page picture menu
The picture menu contains three pages where various digital

and analog values are shown.
- (2) forward.
- (4) backwards.
- (5) can be used to change between the picture
and text menues.
- (14) chosen gear, forward, reverse, neutral, 1, 2, 3,
and 4.
- (10) fuel level in litres.
- (11) engine’s oil pressure in Bar.
- (12) engine’s temperature in degrees centigrade.
- (13) engine RPM.
- (2) continue to page two of picture menu.
- (5) return to text menu.
Second page picture menu
- (13) pressure in hoist cylinder in Bar.

- (10) tilt angle in degrees (0 = horisontal).
- (12) temperature of transmission oil.
- (11) Brake temperature in degrees C.
- (4) return to first page of picture menu.
- (2) continue to third page of picture menu.
- (5) return to text menu.
Third page picture menu
- (11) Hour meter reading.

- (10) Batteri voltage.
- (12) Propeller shaft RPM
- (13) reference voltage, IQAN
- (2) to first page of picture menu.
- (5) to text page.
Publ. No. 6053.506 0546 21

BEFORE DRIVING
Text menu, first page
The text menu is optained by pressing key (5) and includes two
pages with sub menues.
- (8) tune menu.
- (6) load indicator.
- (2) text menu second page.
- (5) return to picture menu.
Submenu Load Indicator (option)
On the submenu the present load is indicated on the upper box.

The lower box indicates the total load. Several loads could here
be entered and added. To achieve the most accuracy of the
indicator, proceed as follows when checking or entering loads:
- Mast should be vertical,
- Load lifted a half-meter from ground.
- To avoid any misreading due to shocks, machine should be
stationary and value of “LOAD” should be stable.
- To avoid any misreading due to friction in mast rollers and
cylinders, load should slowly be lowered and stopped gently.
- (9) Log in load and add to memory.

- (8) Zero set of memory.
- (7) Print (If available)
- (6) Go to second sub menu.
- (5) Return to first page.
Second submenu
- (9) Calibration of the indicator

This should always be made if attachment or forks
are replaced. Proceed as above under “checking a load”.
- (8) Statistics could be printed
- (5) Return to first page.
22 Publ. No. 6053.506 0546

BEFORE DRIVING
Tune menu
This sub menu gives access to tune certain functions, for

example; Lift- and extension functions, start and maximum
current. Joystick steering and start and maximum current. It's
also possible to adjust ramp on these functions. Choose
function by operating joystick. Choosed function will be
shown at the upper left corner. Press keys (6), (7), (8) or (9)
depending what to be tuned.
Headline will be lit up.
Press key (1) or (3) to increase or decrease the value. (Larger
steps could be optained by using keys (2) or (4).
The adjusted value is entered by key (5).
Key (5) will also return to picture menu.
Text menu, second page
The second page is reached by pressing key (2) on the first text
menu page and contains the following sub menues:
- (9) information
- (8) display
- (7) service
- (6) trouble shooting
- (5) return to picture menu
Submenu information
This menu contains important machine data

SL 6-8 ECB
Publ. No. 6053.506 0546 23

BEFORE DRIVING
Submenu display
This menu gives the possibility of adjusting brilliance, contrast,

time and language.
- (6) language
- (7) time
- (8) contrast
- (9) brilliance
The present settings are shown and it is possible to adjust

them by using keys (1, 2, 3 and 4).
Submenu Service
This menu gives further sub menues.

- (9) E-gas is an automatic setup for electric
foot throttle. (Only Scania DSI 9).
- (8) adjustment of forward/reverse interlock.
- (7) adjustment of upgear.
- (6) adjustement of downgear.
(6) and (7) automatic gearshift option.
Submenu E-gas
E-GAS is an automatic adjustment of the accelerator system’s

adjustment motor in relation to engine RPM.
- (8) start the adjustment program. The program is

automatically run. The adjustment takes a few minutes
and the engine must be running.
- (7) switch off adjustment if program has not succeded.
- (6) stores the new adjustment.
24 Publ. No. 6053.506 0546

BEFORE DRIVING
Sub menu F/R interlock
Key (9) activates F/R interlock level. By pressing key (1)

increases and key (3) decreases the value and by that the
speed that allow change of direction.
This is adjustable only within limits from
0 km/h - 3 km/h.
- (5) return to sub menu Service.
Sub menu up gear.
- Press key (9) to activate the function for shifting from

1st to 2nd. Box will light up.
- Adjust by keys (1) and (3) to in/decrease the value and by
that change the speed when shift take place between
1st and 2nd
2nd to 3rd.
- Adjust by key (1) and (3) to in/decrease the value.
- Press key (7) to activate the function for shifting
from 3rd to 4th.
- Adjust by key (1) and (3) to in/decrease the value (4-shift
gearbox only).
Speeds can be set only within limits that are acceptable for the
drive train.
Sub menu down gear.

2nd to 1st.
- Box will light up.
- Adjust by keys (1) and (3) to in/decrease the value
and by that change the speed when shift take place
between 2nd and 1st
- Press key (8) to activate the function for shifting
from 3rd to 2nd.
- Adjust by key (1) and (3) to in/decrease the value.
4th to 3rd.
- Adjust by key (1) and (3) to in/decrease the value. (4-shift
gearbox only).
Speeds can be set only within limits that acceptable for the
drive train.
Publ. No. 6053.506 0546 25

BEFORE DRIVING
Sub menu Measure
This menu is obtained from the text menu’s second page gives
six different submenus.
Page one
- (6) Digital output
- (7) Digital input
- (8) Current out.
- (9) Voltage in,
Go to page two (not shown) by pressing key (4) or (2)
- (9) frequency 6 two pages.
- (8) internal
Sub menu voltage in
In this menu all voltage-input gates could be checked.

By activating a function, for example the joystick, the
value for the joystick will change accordingly.
- Press key (3) or (1) to change from “value” to
“pin no” See below
- Press key (2) or (4) to scroll to a second page of
voltage input.
- Key (5) return to picture menu.
Sub menu voltage in, pin numbers.
Same as above except that the pin number for the input gate is
shown instead of value.
These pin numbers correspond with the electric diagrams
- Key (5) return to picture
26 Publ. No. 6053.506 0546

BEFORE DRIVING
Sub menu Current output.
Output current for proportional valves “PV” could here be

checked.
- Press key (3) or (1) to change from “value” to
“pin no”
- Key (2) or (4) scroll to a second page
Sub menu Current output, pin numbers.
Pin numbers corresponding to electric diagram are shown.

- (5) Return to picture menu.
Sub menu Digital inputs.
Value of the digital inputs could be checked.

On = active, off = passive .
- Press key (1) or (3) to obtain pin numbers instead of
value.
- Press key (2) or (4) to obtain a second page.
- Press key (5) to return to picture menu.
Publ. No. 6053.506 0546 27

BEFORE DRIVING
Sub menu Digital in put, pin numbers.
Pin numbers corresponding to electric diagram are shown.

- (5) Return to picture menu.
Sub menu Digital outputs.
The value of the output signals could here be checked. On

= active , off = passive .
- Press key (1) or (3) to obtain pin numbers instead
of value.
- Press key (2) or (4) to obtain a second page.
Sub menu Digital Outputs / Pin numbers.
Pin numbers are shown that correspond to electric diagrams.

28 Publ. No. 6053.506 0546

OPERATING
Operating
WARNING
Driving on uneven terrain may cause
damage to the machine.
Driving on surfaces with not enough sup-
port may cause the machine to roll or sink.
Risk of serious injury and damage to vehicle.
The truck is not intended for off-road driving. The truck
is not equipped with wheel suspension and should
therefore only be driven on level ground intended for the
total weight and surface pressure of the truck.
WARNING
Risk of the brakes not stopping the machine.
Risk of the machine rolling.
Risk of serious injury and damage to
vehicle.
Driving on slopes steeper than 15% is not permitted as a
rule because of the minimum regulations for braking and
the stabilising capabilities of the truck. If the truck has
to be driven along steeper slopes, you should contact
your SMV dealer. The hill-climbing capacity of the truck
indicated in the data sheet is based on the pulling power
of the truck, and applies only to driving over obstacles
and minor irregularities in ground level.
WARNING
Always adjust your method of driving to the
condition of the road (undulations, etc.), to
hazards within the working area and the
load.
Risk of serious injury and damage to vehicle.
- Start the engine.
- Tilt the lifting frame backwards a little.
- Hold the steering wheel steady. Always use the whole of
your hand to hold the wheel.
WARNING
The working range of the machine is large
and visibility from the driver’s cab is
limited.
Risk of serious injury and damage to vehicle. Before you
start to move the truck, check that the road ahead is free
and that you have a clear view.
WARNING
Avoid driving on slopes or uneven ground
when transporting a container. Never cross
or turn on a slope.
Publ. No. 6053.506 0546 29

OPERATING
Driving forwards
2
1 NOTE
To avoid damage and overheating of drive line:
- Always start in first gear. Select gears only at low ideling
speed of the engine.
- Put into first gear using the gear stick (1).
- Push the driving direction control (2) forward.
- Release the parking brake (3).
- Depress the accelerator (4) slowly so that the truck starts
off gently.
NOTE
When starting up a hill, hold the machine still using the
brake pedal (5) until you have sufficient pulling power.
5 4
30 Publ. No. 6053.506 0546

OPERATING
Stopping the truck
- Take your foot off the accelerator (3).

2 - Press the brake pedal (4) and stop the truck in a gentle,
controlled manner.
3
WARNING
Sudden braking and acceleration may
cause the machine to roll or tip.
vehicle.
Avoid violent acceleration and braking.
CAUTION
Do not use the gearbox as a brake.
4
- When the truck has stopped completely, engage the parking
brake (3) before releasing the brake pedal (4).
- Put the driving direction control (2) into neutral.
Driving backwards
Changing the direction of driving
2 1 CAUTION
The truck must be completely stopped
3 before changing the direction of driving.
Serious damage may be inflicted on the
gear box and drive axel.
- Put into first gear using the gear stick (1).

- Pull the driving direction control (2) backwards.
- Release the parking brake (3).
- Depress the accelerator (4) slowly so that the truck starts

gently.
3
NOTE
When starting uphill, hold the machine still using the
brake pedal (5) until you have obtained sufficient pulling
power.
Always start in the lowest gear.
5 4
Publ. No. 6053.506 0546 31

STEERING AND BRAKING
Steering
Very little effort is needed to turn the steering wheel thanks

to the servo-assisted steering system.
To minimise unnecessary wear and tear to the tires, the

steering wheel should, if possible, be turned only when the
truck is moving.
The disengaging switch
- Release the accelerator (1).

- Activate the clutch using the disengaging switch (3).
- If the disengager is pressed at the same time as the brake ()
pedal, the brakes are applied.
- When braking using only the brake pedal (2), the disengaging
function is activated only after the brakes have been applied.
NOTE
Never release the disengaging switch while engine is
at high rpm.
3 2 1
2 The parking brake switch
- The parking brake switch (1) is to the left of the steering

wheel.
- The parking brake should not be used to bring the truck to a
1
halt unless in an emergency.
- When the parking brake is applied, the warning light (2) is
illuminated.
- If the driver is leaving the seat with parking brake not
activated, an audio signal is sounding.
32 Publ. No. 6053.506 0546

EMERGENCY STOP AND VENTILATION
Emergency stop
- When using the emergency stop (press button (1) down

1 wards), all functions are cut out, the parking brake is
activated and the engine stops.
WARNING
There is a risk of tipping over if the
emergency stop is used when the truck is
moving.
vehicle.
Ventilation
A 1 2
A = STANDARD.
- (1) heating
- (2) fan
B = ACC
- (1) temperature
1 2 C 1 2 - (2) fan
B
- (3) recirculation
C = AC
- (1) heating
- (2) fan
- (3) recirculation
- (4) cooling
3 3 4
Cab filter
2
1
A filter for cab air intake is located on the right hand
dashboard.
- Loosen screws (1).
- Disassamble cover (2).
- Pull up the filter cassette (3) gentle to avoid dust in the
1
climate unit and cabin.
Replace the filter insert, Part No. 2050000143.

3
Publ. No. 6053.506 0546 33

MANOUVERING THE LIFTING EQUIPMENT
Manoeuvring the mast
Manoeuvring the joystick
WARNING
The lifting of loads may present the risk of serious injury or damage to the vehicle.
The use of the machine beyond its designed purposes may cause capacity and stability to
be exceeded.
Use the mast and its attachments only for approved applications.
The driver must be trained to handle the machinery and its equipment.
Always manoeuvre the control gently and slowly.
The speed of the hydraulic function depends on position of the control.
The control automatically slips into it’s initial position when released.
All hydraulic controls sit on the console to the right of the

driver’s seat.
34 Publ. No. 6053.506 0546

LIFTING LOADS WITH STANDARD SPREADER
Before lifting loads
Capacity plates
Before lifting a load, read the lifting capacity plate inside

the cab.
The values indicated on the capacity plate are valid for

compact and regular loads, and if they are exceeded, there is
a risk to the stability of the truck and the tensile strength of
the lifting frame.
Maximum capacity depends on the height of the lift and the

distance to the centre of the load.
Emergency lowering
The truck is equipped with a hydraulic servo (option electro/

hydraulic servo). If the engine or the hydraulic system should
fail, it is impossible to lower the load by means of the hydrau-
lic controls.
The lifting circuit is equipped with a gatevalve (2) that makes

emergency lowering possible.
DANGER
1 Make sure carriage and mast can be
lowered without obstructions.
Make sure that there are no object or
personell underneath or near load or
atachments.
vehicle.
- Remove the cover plate (1).
- Open gatevalve (2) gently.
CAUTION
Once mast have been lowered it can not
2 be lifted again unless the engine is
running and the hydraulics is functioning
properly.
Publ. No. 6053.506 0546 35

Spreader lights
1 2 3
- Red light (1) indicates both twist locks open.
- Yellow light (2)indicates both twist locks are aligned to
corner castings.
- Green light (3) indicates both twist locks locked.
Picking up a container
- Red light (1) will indicate open.

1 - Approach the container to be lifted as carefully and
accurately as possible.
- Tilt the mast to vertical position.
5 4 NOTE
- Raise or lower the spreader to the correct height.

2 - Operate the spreader sideshift and align to the container.
3 - Approach the container to be lifted carefully and at the
center until both pillars contact the container.
- Pull up the parking brake button.
- Lower the spreader until the twistlocks (4) are seated in
the corner castings (5).
- Yellow light (2) will indicate alignment.
- Lock the twistlocks (4).
- Green light (3) will indicate locked twist locks.
36 Publ. No. 6053.506 0546

- As soon as the load is lifted the middle light (yellow) goes

out and the twistlock function is interrupted.
- Lift up only as much as needed to ensure clearance from the
container below. (”A”= approx. 20-40 cm.)
- Reverse the truck carefully to a position where the lifted
container is clear of the front face of the container below. ”B”
not more than 20 to 40 cm.
- Raise or lower the spreader into driving height.
DANGER
Load and attachment my drop down.
Do not allow anyone to stand or walk
under the elevated portion of the truck
whether it is empty or loaded.
Publ. No. 6053.506 0546 37

Transport with the container
- Do not drive with a container shifted to the side. Centralize

the load by side shifting.
- Lower the load as much as possible without obstructing the
visibility, i.e. not below ”C”.
- Always transport the container at this driving height.
- Work with a guide if visibility ist obstructed.
WARNING
or turn on a slope.
38 Publ. No. 6053.506 0546

Discharging a container
- Carefully drive the truck to the storage place.

- Lift the spreader to the correct height.
- Set the mast to the vertical position.
- Pull the parking brake.

- Slowly lower the spreader until the yellow light (2) is
illuminated.
2 - Tilt the mast slightly forward.
1 - Unlock the twistlocks.
- Red light (1) will indicate open twist locks.
- Lift the spreader up out of the corner castings.

- Release the parking brake.
- Reverse the truck.
- Lower the spreader to the driving position.
WARNING
Never park and leave the truck
unattended with the container or
attachment lifted, or the spreader
engaged in a container.
Publ. No. 6053.506 0546 39

LIFTING LOADS, DOUBLE STACKING
Spreader lights
1 2 3
The spreader is equipped with with two indicator light panels,
one on each side of the carrier. The top row indicates the the
condition of the upper twistlocks and the bottom row indicates
the condition of the lower twistlocks.
NOTE
Both panels indicate simultaneously the condition of both
twist locks.
- Red light (1) indicates both twist locks open.

- Yellow light (2)indicates that both twist locks are fully
inserted into the container castings of the container or
containers.
- Green light (3) indicates both pairs of twist locks locked.
Picking up two containers
- Red light (1) will indicate open.

- Approach the containers to be lifted as carefully and
accurately as possible.
1 - Tilt the mast to vertical position.
Alignment of top container
- Raise or lower the spreader to correct height.

- Align the upper twistlocks to the lower castings of the top
container by sideshifting.
- Insert and activate the upper twistlocks into lower castings
of the top container.
- Sideshift and drive carefully forward until both containers are
accurately positioned on top of each other. It is possible to
correct a container that is pushed forward approx. 100 mm
forward and approx 35 mm out of line sideways.
- Yellow light (2) in top row indicates alignment.
H1546ECB
40 Publ. No. 6053.506 0546

- Drive the truck carefully forward until the lower twistlocks

are correctly positioned inside the upper corner castings of
the bottom container.
- Yellow lights (2) in the bottom row indicate alignment.
2 - Lock the twistlocks.
- Green lights (3) in both top and bottom row will indiate
3
locked twist locks. Both containers are now locked to the
spreader.
- As soon as the load is lifted the middle light (yellow) goes

out and the twistlock function is interrupted.
- Lift up only as much as needed to ensure clearance from the
container below. (”A”= approx. 20-40 cm.)
- Reverse the truck carefully to a position where the lifted
containers are clear of the front face of the container below.
”B” not more than 20 to 40 cm.
- Raise or lower the spreader into driving height.
DANGER
Do not allow anyone to stand or walk
under the elevated portion of the truck
whether it is empty or loaded.
WARNING
Never park and leave the truck unattended
with the container or attachment lifted,
or the spreader engaged in a container.
Publ. No. 6053.506 0546 41

Transport with two containers
- Do not drive with the containers shifted to the side.

Centralize the load by side shifting.
- Lower the load as much as possible without obstructing the
visibility, i.e. not below ”C”.
- Always transport the container at this driving height.
- Work with a guide if visibility ist obstructed.
WARNING
or turn on a slope.
42 Publ. No. 6053.506 0546

Discharging containers
- Carefully drive the truck to the storage place.

- Lift or lower the spreader to the correct height.
- Set the mast to the vertical position.
- Slowly lower the spreader until the yellow light (2) is

illuminated.
- Tilt the mast slightly forward.
- Unlock the twistlocks.
- Red light (1) will indicate open twist locks.
1
2
- Reverse the truck slowly until the twistlocks are free from
the container castings.
- Lower the spreader to the driving position.
Publ. No. 6053.506 0546 43

SERVICE AND MAINTENANCE
General information
WARNING
The machine contains several chemical
substances, which may cause skin irrita-
tion and allergies.
Risk of personal injury when in prolonged contact with
skin!
When handling chemical substances such as oils, hydrau-
lic oils, fuel, grease etc. avoid direct contact with the
skin. Use protective gloves. Immediately wash skin that
comes in contact with chemical substances.
Preventive maintenance and maintenance must be carried

out regularly and in accordance with the regulations supplied
in the inspection table so that the truck will work as well as
possible.
Maintenance must only be carried out by trained staff or an

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

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

test on the truck.
CAUTION
If the machine is used in extremely warm,
cold or dusty environments or in other
unfavourable conditions, the service
should be carried out more frequently
compared to the inspection table (see pp
78-79).
Clean the area around each component before lubricating,

changing filters or repairing the hydraulic system. Use only
clean containers when topping up lubricants.
44 Publ. No. 6053.506 0546

TRANSPORT AND TOWING
Electric welding
When carrying out welding work close to and on the engine,
remove the battery leads (positive and negative). Connect the
welding ground lead to the component to be welded as close
as possible to the welding point, never to the engine or in
such a manner that the current can pass over a bearing.
When you have finished welding, connect the leads to the
alternator and control unit before connecting the batteries.
Jump-starts
Connect the first cable from the + contact of the auxiliary
battery to the + contact of the starter motor. Then connect the
second cable from the contact of the fully charged battery to
the chassis, e.g. the starter motor fixing bolt, or a nearby
sidemember. When the engine starts, remove the cables in the
reverse order.
Running in/servicing after the first 100 -150 hours

of operation
The machine may be driven at full speed right from the start.
However, prolonged maximum loading of the hydraulic
system and gearbox should be avoided during the
first 50 hours of operation.
After the first 100 - 150 hours, carry out first service.
Towing
CAUTION
As the truck is equiepped with a hydrau-
lic braking system, servo-assisted
steering and a hydraulic gearbox, the
enginge must be idling when being towed.
If it’s not possible, the hydraulic parking brake (1) must be
manually released, see next page.
WARNING
The truck will now have no brakes and
must only be towed by a vehicle which has
sufficient braking capacity to stop both
vehicles.
vehicle.
- Place large blocks by the wheels.

- Release the parking brake (1), see next page for details.
- The universal driveshaft (2) must be disconnected before
towing can begin.
- Tow the truck very carefully at no more than 3-5 km/h.
1 - The truck can still be steered, even if the steering is heavier
with the loss of servo-assisted steering.
2 - After being repaired, the brake function should be checked
and the parking brake adjusted.
- Reposition the universal drive shaft and tighten it.
Publ. No. 6053.506 0546 45

TRANSPORT AND TOWING
Adjustment of parking brake

10 9 DANGER
8 7 When the parking brake is released, the
vehicle does not have any park brake
function. You must block the wheels to
prevent the vehicle from moving. Serious
personal injury and damage to components
can result.
NOTE
It is important that the parking brake is activated (released)
during adjustment.
- Park the vehicle on a level surface.
- Start the machine to ensure correct brake system pressure.
1
2 - Release the parking brake by using the switch in the cabin.
4 The oil chamber (10) should now be pressurised. The piston

3 assembly, consisting of push rod (9), piston (4), adjusting
5 6 screw (5), and lock nut (6) should be totally extrudet,
compressing the spring washers (8).
To ensure that the brake pressure is maintained it may be
necessary to run the engine.
PARKING BRAKE
- Remove the cap (7).
The parking brake consist of brake calliper and a brake disc - Release lock nut (6) and turn the adjuster screw (5)
which is mounted on the drive axle. clockwise until both brake pads (2) are in contact with the
The brake calliper consists of housing (1), piston (4), spring brake disc (3).
washers (7) which press on the piston, brake pads (2) and - Turn the adjuster screw counterclockwise until the disc (3)
disc (3). is just moving freely.
The brake is normally applied. - Tighten lock nut (6) and recheck by moving the disc (3).
The brake calliper is opened by hydraulic pressure in the - Apply the parking brake.
oil chamber (9). Hydraulic pressure moves the piston and - Remove the blockage from the wheels.
compresses the springs. At least 100 bar is required to open - Test the function of the parking brake.
the brake. - Install the cap (7).
Pressure is coming from the accumulator system via a solenoid
valve, controlled by the parking switch. Parking brake emergency release
DANGER
... WARNING When the parking brake is released, the
The brake is a pure parking brake and vehicle does not have any park brake
should be used as such - to keep the machine function. You must block the wheels to
stationary. Due to the gear ratio through the prevent the vehicle from moving. Serious
drive axle, the brake is very powerful, personal injury and damage to components
however if the brake is used to stop the can result.
machine it will wear the pads rapidly.
Use the parking brake to stop the machine with only in If hydraulic pressure is not available, the parking brake can
emergency. After such a braking the brake should be be manually released using the following procedure.
checked, adjusted and if necessary pads replaced.
As being an emergency brake, the function of it has to be - Park the vehicle on a level surface. Block the wheels to
checked daily by the operator. To ensure the function and prevent the vehicle from moving.
to make the following adjusting procedures to go easy , it’s - Remove the cap (7).
necessary to keep the calliper well lubricated and all parts - Loosen the lock nut (6).
in good condition. In case of any doubts, dismantle, clean - Turn the adjusting screw counterclockwise until the brake is
and lubricate. released. Emergency release requires approximately 30 lb-ft
(40 Nm) torque on the adjusting screw (5).
- Tighten the lock nut (3). Install the cap.
- Before you return the vehicle to service, adjust the brake
using the procedure in this section.
46 Publ. No. 6053.506 0546

CLEANING
Cleaning the truck
The length of time between cleaning sessions depends on

the type of work carried out by the truck. If it is used in
extremely aggressive environments where it is exposed to
elements like salt water, fertilisers, chemicals, cement, etc.,
it should be thoroughly cleaned when the work is finished.
WARNING
Hot steam or aggressive degreasing
agents should be used with great care.
Protective clothing and eye protection
must be worn.
- Protect all electrical components and the air intake filter

from steam, water, etc., during cleaning.
- Clean particularly the areas around the oil top-up and
lubrication places before servicing.
- If a degreasing agent is used in cleaning, allow sufficient time
for it to penetrate and then rinse with a powerful jet of water.
- After cleaning the engine, it should be run warm so that it
dries and to check that no water that has penetrated has
caused any faults.
- All materials used in cleaning should be disposed in an
environmentally-friendly manner.
- Always lubricate the truck after steam cleaning.
See page 56-63.
Cleaning the cooler
CAUTION
The cooler must only be cleaned when the
engine has been turned off and cooled
down.
- The most suitable way of cleaning the cooler is with dry

compressed air.
- Blow against the direction of the fan.
- In extreme cases, solvents or a jet of steam can also be
used with great care.
- Allow the solvent time to penetrate. Rinse off with water
- Run the engine warm so that surplus water evaporates and
does not cause rusting.
NOTE
The cooler must not be cleaned with high-pressure water.
Publ. No. 6053.506 0546 47

CHANGING A WHEEL
PRESSURE RELEASE
WARNING
The hydraulic system contains high
pressure accumulators to maintain the
brake function during a possible engine
failure.
Always release the brake pressure before maintaining or
servicing the hydraulics of the truck.
Never loosen any hydraulic hoses without
ensuring that the brake pressure is released.
Changing a wheel
Changing a wheel is a two-man operation.
- An ancillary truck fitted with an attachment for the wheel
(1) facilitates the work.
2 - Position the truck on even ground.
- Lift the side of the truck and support the underside of the
chassis in accordance with recommendations.
Positioning of the jack

WARNING
The changing of tires involves heavy
lifting and the handling of tires with high
air pressure.
vehicle.
Observe the following regulations before lifting the
truck. Use only a jack that has sufficient lifting capacity.
See technical data sheet for axle pressure.
- To lift the truck drive axle, position the jack
underneath the drive axle (1) and block the steer axle
wheels.
- To lift the steer axle of the truck, position the jack
underneath the main plate of the steer axle (2) and
block the drive axle wheels.
- When working underneath the truck, support the
underside of the chassis with suitable material. Do
NOT simply rely on the jack.
Specifications of tyres
See machine card.
1
Specifications for rims
Use only rims that are approved by the truck manufacturer.
Other type of tyres

The truck is designed to use pneumatic tires. Solid/cushion
2 tires are used only in consultation with the truck
manufacturer.
48 Publ. No. 6053.506 0546

CHANGING A WHEEL
Dismantling the drive wheels
Outer drive wheel
DANGER
Tires with high air pressure.
Never stand square with the wheel when
releasing and pumping air.
Release the air from both tires. If you do not, the conical
ring and locking heads may release and shoot off when
the pressure changes.
Note that the valves may be damaged or that a valve may
become plugged with ice when the air is released.
If the air cannot be released through the valve it may be
necessary to drill a hole in the tread.
WARNING
When changing tires, use only tires which
are approved by the manufacturer.
- Remove all but two of the nuts (1).

- Use the ancillary truck to support the weight of the outer
wheel on its forks (2).
- Remove the two remaining nuts (1).
- Lean the outer wheel against the ancillary truck’s wheel
support and secure it.
- Reverse the ancillary truck carefully and unload the outer
wheel (3).
Inner drive wheel
- Remove the outer drive wheel.

- Use the forks of the ancillary truck to support the weight of
the inner wheel (5).
- Lean the inner wheel (5) against the wheel support (2) and
secure it.
- Carefully reverse the ancillary truck and unload the inner
wheel (5).
Mounting the drive wheels
The inner drive wheel
- Load the inner wheel (5) onto the ancillary truck and
fasten it to the support.
- Clean the application surfaces.
- Carefully drive the ancillary truck to the required position
and place the inner wheel (5) over the drive axle and the
hub.
- Remove the fastening device from the wheel support (2)
and the inner wheel (5) and straighten the wheel.
- Lower the forks of the ancillary truck until the inner wheel
is resting on the hub.
- Carefully reverse the ancillary truck.
Publ. No. 6053.506 0546 49

CHANGING A WHEEL
Outer drive wheel
- Load the outer wheel (3) onto the ancillary truck and
secure it to the wheel support. Carefully drive the ancillary
truck into position and place the outer wheel over the hub.
- Remove the fastening device from the wheel support (2)
and the outer wheel (3) and straighten the wheel.
- Secure the rim and hold it in place with two nuts placed
diagonally to each other.
- Fasten the remaining nuts and tighten the wheel nuts
crosswise 60 kpm.
- Pump the tyres to 9 bar.
Disassembling the steer wheel

DANGER
3 Tires with high air pressure.
Never stand square with the wheel
when emptying and pumping air.
Release the air from the tires. If you do not, the conical
ring and locking heads may release and shoot off when
the pressure changes.
Note that the valves may be damaged or that a valve may
become plugged with ice when the air is released. If the
air cannot be released through the valve it may be
necessary to drill a hole in the tread.
2 - Remove all but two of the wheel nuts (1).
- Use the ancillary truck forks to support the weight of the
steer wheel (2).
- Remove the remaining nuts.
- Lean the steer wheel against the wheel support (3)
and fasten it.
- Carefully reverse the ancillary truck and unload the
steer wheel.
Assembling the steer wheel
- Load the steer wheel (2) onto the ancillary truck and
fasten it onto the support.
- Clean the surfaces of the machine.
- Carefully drive the ancillary truck into position and place
the steer wheel (9) against the hub.
- Use the forks of the ancillary truck to support the weight
of the steer wheel.
- Fix and tighten two of the nuts (1) diagonal to each other.
- Remove the fork support.
- Assemble and tighten up the remaining nuts 60 kpm.
- Pump the tyres up to 9 bar.
2
50 Publ. No. 6053.506 0546

DISASSEMBLING CARRIAGE AND MAST
WARNING
The mast and aggregate are heavy units and
must be handled with the utmost care.
vehicle.
Do not carry out any work on the mast/carriage when
the mast or the carriage is in the raised position. The
mast and the carriage must be secured if work is being
carried out on the mast.
Disassembling the carriage
- Attach the spreader on to a laden container and lock the

twistlocks.
- Lower the inner upright until the lift chains are slack
- Pull out the pins of the lift chains.
- Secure the chains to prevent them from falling over the
chain wheel.
- Unfasten the hoses at the carriage and plug up their ends.
- Secure the hoses to prevent them from falling over the
hose wheels.
- Tilt the mast so that the load is removed from the carriage
wheels.
- Carefully raise the inner mast, watching out for chains and
hoses.
- When the lowest part of the inner upright has passed over
the carriage upper support wheels, reverse the truck and
lower the inner upright.
To assemble, follow the instructions in reverse order.
Disassembling the mast
- Secure the truck with chains around the lower cross

member
of the carriage and the lower yoke of the outer mast.
- Ensure that there is no pressure in the hoses by making all
control lever movements with the engine turned off.
- Unfasten and plug all hydraulic hoses.
- Fasten the lift chains/wires to the lifting eyes of the outer
mast.
- Tight the lift chains/wires.
- Tilt outwards or inwards to remove the load from the tilt
cylinders.
- Disassemble the front tilt shafts.
- Tilt the cylinders inwards.
- Raise the lift chains further to remove the load from the
upright’s anchor points.
- Pull out the upright suspension axles using puller screws.
- Put down the upright on a suitable base.
Publ. No. 6053.506 0546 51

TIGHTENING BOLTED JOINTS
Tightening torque
Information on friction ratio is needed in order to select the
exact tightening torque. The tables below specify the torque
for ”lightly greased” bolts.
WARNING
It is important that the torque of the
bolted joints is checked regularly. It is
especially important in connection with
the ”first servicing”.
It is particulary important to check all bolts after the first
service.
The following pages describe how bolted joints should be
tightened using a torque key.
Millimetre screws
Tensile strength class
THREAD 8.8 10,9 12,9

M kpm kpm kpm
6 1.11 1.56 1.87

8 2.66 3.75 4,50
10 5.25 7.38 8.86
12 9.12 12.8 15.4
14 14.5 20.4 24.4
16 22.2 31.3 37.5
18 31.0 43.6 52.3
20 43.4 61.0 73.2
22 58.4 82.2 98.6
24 75.0 105 127
27 108 152 183
30 148 208 250
33 199 280 336
36 257 362 434
Inch screws
Tensile strength class
Thread 8.8 10,9 12,9

UNC kpm kpm kpm
1/4” 1.24 1.76 2.07

5/16” 2.51 3.55 4.20
3/8” 4.42 6.10 7.38
7/16” 7.06 9.97 11.8
1/2” 10.7 15.1 17.8
9/16” 15.3 21.6 25.5
5/8” 21.1 29.8 35.3
3/4” 37.1 52.4 61.9
7/8” 59.4 83.9 99.1

1” 88.9 126 148
1 1/8” 126 178 210
1 1/4” 176 249 294
1 1/38” 232 328 387
1 1/2” 306 432 510
Tightening the wheel nuts

CAUTION
The wheel nuts must be checked on new
trucks, or if a wheel has been removed and
replaced, before the truck is put into
operation, and then on a daily basis for
two weeks. Tighten the nuts crosswise to
65 kpm.
52 Publ. No. 6053.506 0546

Drive shaft
To the gearbox (1) 3/8 UNF, 12.9 7.5 kpm

To the drive axle (2) 7/16 UNF, 12.9 12.0 kpm
1
2
Differential nuts
2
- (1) M12 UNF 10.9 13 kpm
- (2) M14 10.9 20.4
The engine mounting
1 Check the condition of the rubber suspensions.

If any wear and tear is discovered, replace the damaged
parts.
The engine mountings are accessible from the engine
compartment, one on each side of the rear part of the engine.
2
- (1) M20 8.8 43 kpm
- (2) M16 8.8 22 kpm
- (3) M16 8.8 22 kpm
- (4) M12 8.8 12.5 kpm

3
4
Publ. No. 6053.506 0546 53

The gearbox
Check the condition of the mountings and the rubber

suspension. Replace the worn parts if you discover any wear
3 and tear.
2
The mountings are accessible from the engine compartment,
one on each side of the gearbox.
- (1) M20 8.8 43 kpm

- (2) M16 8.8 22 kpm
1 - (3) M16 8.8 22 kpm
- (4) 3/4" UNC 8.8 37 kpm
Drive axle suspension

1
- (1) M30 8.8 148 kpm
Counterweights
- (1) M36 8.8 75 kpm

- (2) M24 8.8 75 kpm
1
2
54 Publ. No. 6053.506 0546

Steer axle
- (1) M30 x 2 20 kpm

- (2) M20 8.8 145 kpm
2
Publ. No. 6053.506 0546 55

LUBRICATION POINTS
3
5
4
6 7 14 8 9
10
12
13 15
11
56 Publ. No. 6053.506 0546

LUBRICATION POINTS
19 19
21 18 18 21
22
16
17
16
17
20 20
LUBRICATION/MAINTENANCE POINTS
Position Description Illustration number Page number

No
1. Cab filter H 1077 33

2. Mast H 1380 61
3. Universal drive shaft H 1372 62
4. Drain plug, transmission H 1373 66
5. Drain plug, engine H 1347 64
6. Steer axle H 1276 62
7. Oil cleaner H 1348 64
8. Air filter H 1054 70
9. Oil filter transmisson H 1216 65
10. Drive axle H 1356 + H 1373 66
11. Hydraulic filter H 102 s 67
12. Filler cap transmission H 083 66
13. Fuel filter H 1342 69
14. Filler cap engine H 1341 64
15. Washer tank H 1360 10
LUBRICATION/MAINTENANCE POINTS,SPREADER,SEE PAGE 58.
16. Wear pads H 1365 58

17. Extention cylinder support H 1535 58
18. Upper sideshift slider pads H1530 58
19. Twist locks H 1379+H1532 59
20. Lower sideshift slider pads H1531 59
21. End beam slider pads H1534 60
22. Cylinders H1533 60
Publ. No. 6053.506 0546 57

LUBRICATION POINTS, SPREADER
General rules which apply to lubrication
- Clean of old grease and clean nipples.

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

demanding conditions, particularly of the slide bearings.
Wear pads for main beams an extending beams

2
2 - No. of grease points - 14.
2 - Interval - every 500 hous or 3 months.
- 6 tracks on the inside of each main beam (1).
- 1 track on each extending beam (2).
Extention cylinder support wear pads and tracks
- No. of grease points - 4.

- Interval - every 1000 hours or 6 months.
- 2 tracks in each extention beam.
58 Publ. No. 6053.506 0546

Upper side shift slider pads
- No greasing necessary.
- Interval - every 250 hours or monthly - check for wear of the

nylon wear pads and replace before metal to metal contact
between the carriage and the spreader occurs.
Endbeams and twist locks
- No. of greasing points: 4.

- Interval - every 500 hours or 3 months
2 grease nipples (1) on each endbeam.
Housings for double twist locks
- Maintenance free
- Interval - every 250 hours or monthly - check for wear and

possible damage of the twistlock and the nose of the twist-
lock housing (2).
H1532ECB
Publ. No. 6053.506 0546 59

Lower side shift sliderpads
- No greasing necessary.

between the carriage and the spreader occurs.
H1531ECB
End beam slider pads
- No greasing necesssary.

between the end beam and the extension beam occurs.
Cylinders
1
- No. of greasing points: 6
- Interval – every 500 hours or 2 month – 2 grease nipples (1)

on each slew cylinder and side shift cylinder.
60 Publ. No. 6053.506 0546

LUBRICATION
Lubricating the mast
WARNING
The mast and aggregate are heavy units
and must be handled with the utmost
care. Risk of serious injury and damage
to vehicle. As the mast and carriage
have to be lifted during certain
lubrication moments, make sure that
the mast/carriage are secured.
- Lubricate the supension shafts of the mast (1) at the

nipples, one on each side, accessable through the inside of
the mast while the cariage is lifted up. Unload the shaft pins
by lifting the mast using either a jack or a wood block and
tilt forwards.
- Lubricate the tilt cylinder shafts (2) from the centre of the
shaft pins, two on each side. Unload the shafts by tilting the
mast backwards.
- Lubricate the carriage sidethrust rollers (4) from the inside of
the carriage, two on each side.
- Lubricate the carriage wheel rollers (5) from the inside, two
on each side.
- The corresponding rollers and wheels of the inner upright are
reached by lifting up the carriage.
- Lubricate the chain wheels (6) through the nipples (7).
CAUTION
Do not apply too much grease on the
support rollers. Exessive grease in mast
channels will make rollers and wheels
slide instead of rolling.
Lubricating points may vary with diffe-
rent types of masts.
Publ. No. 6053.506 0546 61

LUBRICATION
Lubricating the steer axle

2
- Clean off old grease and clean nipples.
- Lubricate the parallel tie-rods, four points (1) - two points on
each parallel tie-rod (slide bearings).
- Lubricate the spindle nuts (2), one upper and one lower on
each side.
1
2
Lubricating the drive shaft
- Clean the nipples before lubricating.

- Lubricate the nipples (1), 2 in all.
62 Publ. No. 6053.506 0546

LUBRICATION
Lubricating the door hinges
- Inspect and clean the hinges of the cabin doors.

- Lubricate the hinges (1) and open and close the doors in
order to check that all parts of the hinges have been
lubricated.
Lubricating the compartment doors
- Inspect and clean the hinges of the doors.

- Lubricate the hinges (1) and open and close the doors in
order to check that all parts of the hinges have been
lubricated.
Lubricate the engine bonnet
- Inspect and clean the hinges, 2 in all, of the bonnet.

- Lubricate the hinges (1), open and close the doors in order to
check that all parts of the hinges have been lubricated.
3
Publ. No. 6053.506 0546 63

CHANGING OIL AND FILTERS
Changing the engine oil and filters
NB!
It is of advantage if the oil is at operational temperature.
WARNING
Engine oil may be hot.
Use care in opening the cap to avoid
burns.
Replace the oil at least once a year.
- Open the engine cover.
- Place a suitable container underneath the drain plug (3).
- Unscrew the drain plug (3).
- Allow the oil to run out.
3 - Check that the seal is not damaged. Renew if necessary.
- Fit the drain plug (3).
- Tighten up the drain plug.
Checking the oil level and topping up the engine oil

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

- Unscrew the filters and discard using a filter spanner.
- Smear the new filter’s rubber sealing ring with a thin layer of
oil. Screw in by hand until the ring touches the filter holder.
Tighten the filter by a further half turn, but nomore.
- Start the engine and allow it to run for several minutes.
Check that there are no leakas by the filters.
- Stop the engine, wait about 5 minutes, then check the oil
level. If required, top up to the MAX mark on the dipstick.
NOTE
Never use tools to tighten the filter. Always use original
spares.
H1348
2
64 Publ. No. 6053.506 0546

Changing the oil in the gearbox

2
NOTE
It is of advantage if the oil is at operating temperature when
replaced.
- Clean around the drain plug and sump valve.

- Place a suitable container underneath the drain plug (1).
- Remove the drain plug and allow the oil to run out.
WARNING
3 The gearbox oil may be hot.
Be careful when changing the gearbox oil.
2
- Place a suitable container underneath the sump valve
plug (2).
1 - Remove the sump valve plug (2) and the sump filter (3).
- Clean the filter with diesel fuel oil.
- Dry the sump filter.
- Remont the sump filter (3), seal and the plug (2).
- Remont the drain plug (1).
Changing of transmission breathing filter

- Unscrew the breathing filter (1).
1
- Replace with new.
Changing the gearbox oil filter
- Carefully clean outside of oil filter.

- Place a container underneath the filter (1).
- Loosen the drain plug (2) and drain oil.
6 - Loosen the canister with the bolt (3).
5 - Remove the filter insert (4).
- Clean the canister.
4 - Install a new filter.
- Replace the O-ring (5). Lubricate lightly.
NOTE
Place the new O-ring on the filter bracket (6) not the
3 canister.
2 - Install the canister.

1 - Tighten the bolt (3) to 3.4 - 4.8 kpm.
- Start the engine and check for leaks.
Publ. No. 6053.506 0546 65

Topping up the gearbox oil

- Remove the oil cap (2).
- Fill the gearbox with oil to the maximum mark on the
1 dipstick (1).
- Run the engine at 500 - 600 rpm for one minute to fill the
torque converter and pipes.
2 - Check the level of the oil when the engine has been
runingfor one minute and then fill up with oil to the mini-
mum mark.
- Check the oil level again when the operating temperature
has reached 82 - 93° C. Fill to the maximum level mark.
- Refit the dipstick (1) and the oil cap (2).
NOTE
See Maintenance Data regarding the oil volume in the
gearbox.
- Do a test run and then check that there are no leaks.
- Recheck the oil level.
Checking the oil in the drive axle
NOTE
Both hubs and the diff casing to be checked.
- Park the truck on level ground.

- Place the truck so that the hub level mark (1) is horizontal.
- Carefully unscrew the filling/level plug (2) and check the
oil level.
- If oil runs out from the plug, screw it back in.
- If no oil runs out, fill up with oil until it begins to seep out
from the filling/level plug (2).
- Repeat the procedure for the other hub.
- Check the level in the banjo cap by unscrewing the
filling/level plug (3).
- If oil runs out of the plug, screw it back in.
1 - If no oil runs out, fill it with oil until it begins to seep out.
2
Changing the oil in the drive axle
NOTE
Both hubs and the diff casing to be replaced.
- Park the truck on level ground.

- Make a drainage hose using a thread which fits through the
5 draining hole (2).
- Fix the hose in the drain hole while the drain plug is
in its uppermost position.
- Carefully drive the truck forwards/backwards so that the
drain plug returns to its lowest position.
- Allow the oil to run out through the hose into a suitable
vessel.
- Repeat the procedure on the other side.
- Drain the diff casing through the drain plug (4).
- Since the oil is of high viscosity, it is suitable to drain
when the oil is warm or overnight.
- Refit all three drain plugs (2 and 4).
4 - Place the truck so that the hub level mark (1) is horizontal.
- Fill the drive axle trough the three filling holes (2 and 3).
- Check the breathing valve (5) and clean if necessary.
66 Publ. No. 6053.506 0546

Changing the hydraulic filter
5 The return filters are situated on the right-hand side of the

hydraulic tank by the filling cap.
The truck is equipped with one set of filters.
4 CAUTION
Follow these instructions. Otherwise you
may risk damaging the hydraulic system.
- Remove the upper running plate (2), if necessary.

- Clean carefully around the filter cover (1).
- Remove the filter cover.
- Loosen the four screws of the filter housing in the return
1 3 chamber.
2
- Lift up the filter housing as a complete unit (3, 4,5).
NOTE
Do not disassamble the filter housing in the tank.
- Place the filter housing on a bench and remove the

element by pressing and turning the bypass valve (5).
- Check that the valve is closed.
- If the tank is empty: Also check the bottom of the tank for
1 any impurities.
- Clean the filter housing.
- Fit new filters and close with the bypass valve (5). Press
and turn to the correct position.
- Fit the filter housing in the tank.
- Fill with oil if it has been drained.
- Fit the filter cap.
- Start the engine and check for leakage.
- Turn off the engine and check the level.
Changing of hydraulic tank breathing filter
- Unscrew the breathing filter (1).

- Replace with new.
Changing the hydraulic oil
The hydraulic oil is replaced at the same time as the filter. It

is recommended that the oil be replaced after 2 000 hours of
operation. This may vary, depending on the truck’s working
environment.
- Drain the oil out through the bottom plug (1), using a
suitable vessel. Oil volume, See page 80.
- Alternatively, the oil can be sucked up through the filter
housings if the filters have been removed.
- Inspect the bottom of the tank for any impurities.
- Assemble the filters and caps as above.
- Fill with hydraulic oil through the filler cap (2).
That way, the oil poured in is filtered through the filters. It is
advisable for the oil to be filled under some pressure.
Publ. No. 6053.506 0546 67

Air bleeding of hydraulic pumps

CAUTION
Extensive damage to the hydraulic system
may be caused by air in the system.
Never start the truck if the pumps are not
air-bled.
3
As the hydraulic pumps are located above the oil level in the
tank it is necessary to bleed the pumps when :
2 - The tank has been drained
1 - A pump has’s been replaced.
- Suction lines or bleeder screws have been opened.
Due to the level difference it is necessary to achieve an over
pressure in the tank during the bleeding.
Most appropriate is to do this with compressed air 0,5 to 1,0
bar in to the tank .
- Remove the breather filter (1)
- Fill into the hydraulic tank by a plastic plug (2) with an
air gun (3) .
- Place a suitable vessel under the pump in order to collect
4 any drain oil.
- Open the breather plug (4).
- Let air /oil pass until clean oil, free from air is coming.
- Tight plug
- Release the air pressure in tank.
NOTE
It is necessary to maintain the pressure in the tank until
the bleeder plug is tightened.
Do not open plugs or suction lines unless necessary. It will
always require a new bleeding procedure.
Start of pumps
After bleeding of pump it’s possible to start machine.
However its important that any remaining air in the pump is
returned to tank.
1 To ensure this there is one bypass valve that can be opened,
see picture to the left.
(1) = open (2) = closed
Before starting the engine:
- Open valve
- Connect a 0-250 bar gauge to “PM” on corresponding
valve group.
- Start the machine.
Pressure should now increase in “PM”.
2 - Let engine idle for approximately 1 min.
- Check the hydraulic flow by observing the speed of the
different functions.
- Adjust stand-by and max pressure.
68 Publ. No. 6053.506 0546

Changing the fuel filter

1
Change the fuel filter every 1000 service hours (more
frequently if working conditions require it) or when the
filters become clogged.
- Clean the filters’ exterior and surrounding areas.
- Unscrew the filters by hand and discard.
- Clean filter head.
- Screw in new filters by hand until sealing ring makes contact
with the cap. Screw in a further half-turn by hand.
- Bleed the fuel system. See below.
CAUTION
Never use a sealant or lubricant. Never
use tools to tighten the filter.
Always use original spares when
changing filters.
Bleeding of the fuel system
Low-pressure system:
2
- Open bleeding nipple (1) on brake filter cap.
- Use the hand pump (2) until the brake fluid at the bleeding
nipple is free from air bubbles.
High-pressure system:
The high-pressure system does not normally require
bleeding as any air reaching the injection pump is ejected
into the combustion chamber through the injectors.
However, if the fuel pipe has been dismantled, the fuel has
run out or the engine has not been used for some time, it
may be necessary to bleed the system to facilitate restarting
of the engine.
- Detach the injection pipes from the injectors.
- Depress the accelerator fully.
H1343
- Turn the ignition key and turn the engine over until
fuel is flowing from all the injection pipes.
- Reattach injection pipes and tighten.
Cleaning of sludge separator
- Remove and clean sludge separator (3).

- Remount the vessel and tighten the ring securely.
- Start the engine and check there is no leakage.
- Change the vessel sealing ring regularly or when leakage
occurs.
CAUTION
A leaking seal will disrupt fuel flow from
the tank to the metering pump as it will
enable air to enter the system.
3
H1344
Publ. No. 6053.506 0546 69

Cleaning/changing the air filter
WARNING
The air filter contains a significant
amount of dust particles.
Danger of respiratory distress!
2 3 4 A protective mask must always be worn
1 when servicing the air intake system. Do
not inhale the dust particles.
Consider the environment when carrying
out this work.
CAUTION
Do not clean the inside of the filter
casing with compressed air. All
maintenance on the air intake system
must be carried out while the engine is
turned off. This is a dry filter element and
must not be cleaned with water.
- Open all of the clips (1) and remove the cap (2).
- Empty out the dust which has collected in the cap and dry
the cap using a damp cloth.
- Remove the element carefully (3).
- Clean the inside of the filter casing (4) clean using a damp
cloth.
- Blow dry compressed air over the filter element to clean it,
a maximum of 5 bar, from the inside until no more dust
comes out.
NOTE
Discard the filter element:
- if it has been cleaned 5 times.
- if it is damaged.
- after 1 000 hours of use.
H118 - after 12 months of use.
Record each service carried out on the filter element.
Safety cartridge
- The safety cartridge (6) is normally replaced after around

1
3 000 hours of use, or if there has been any damage to the
main filter.
- Disassemble the filter lining as above.
- Fit in a new safety cartridge.
H119
70 Publ. No. 6053.506 0546

CHECKING AND OTHER MAINTENANCE
Checking the air intake system
It is of paramount importance for the air intake system to be

1 intact. Broken and leaking pipes can drastically shorten the
life of the engine.
Check the system regularly.
2
- Check the hoses (1) for fissures and damage. If necessary,
replace them.
- Ensure that all hose clips (2) are tightened and fit snugly.
- Check that the filter container is intact.
H098
Checking the battery
The batteries are located in the compartment on the right hand

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

- Remove corrosion from the battery connections and check
that the cable connections are tightened.
- Lubricate the battery terminals using acid-free grease.
WARNING
The battery contains corrosive acid.
Always use the necessary protective
equipment.
Batteries generate explosive hydrogen
when charged. Ensure that there is good
ventilation and avoid sparking.
Changing the windscreen wipers
3 - Remove the bolt (1).

- Remove the blade (2) from the arm (3).
- Insert the new blade (2) into the arm (3).
- Replace the bolt.
- Lower the wiper back onto the windscreen.
Publ. No. 6053.506 0546 71

Checking the cooling system
- Check all hoses by pressing them to find any fissures and

leaks. If in doubt, replace them.
- Check the radiator for damage, leaks or blockage.
For cleaning, see page 47.
- Check the function of the cab heater.
- Check the level of the coolant: see below, glycol content,
see page 83, and for any impurities.
- Replace the coolant if it is not clean and clear.
- Check the rubber pads in the radiator fittings (6) on the
bottom of the radiator and the upper bracing (7) - replace
if necessary.
- Check that the nuts (8) are tight.
Replacing the coolant

1 2
WARNING
The coolant may be pressurized and hot.
Risk of serious injury!
7 The system may be pressurised, even if it is
3 not the pressure type .
- Open the cap of the expansion tank (1) with care - first
turn it 1/4 of a turn to ensure that the system is not under
pressure when the cap has been removed.
- It can only be refilled through the expansion tank (2). The
6 4 cap of the cooler (3) is only used for filling when the
system has been completely drained.
8 - Drain the whole system through the tap (4) when replacing
the hoses and system components.
- Turn the cab heater control to maximum. Place a suitable
container underneath the drainage tap.
- Open the tap and drain the system fully.
- Turn off the tap.
- Fill the system through the radiator filler cap (3).
- Screw on the cap.
1 - Fill up through the expansion tank (1) to the maximum
level.
- Start the engine and let it idle.
- Observe the level during this period and top up if necessary.
- When the operating temperature is reached, the level
should have stabilised.
- The level should be up to the centre of the tank (5).
72 Publ. No. 6053.506 0546

Checking the exhaust system for leaks
WARNING
The exhaust system may be hot.
Risk of burns!
Wait until the exhaust system has cooled
before starting work.
- Check the overall condition of the exhaust system, replace

pipes or the silencer if they are leaking due to corrosion.
- Check all joints and screw joints.
- Check the exhaust manifold.
- Check the rubber silencer suspension. Replace if necessary.
- Start the engine.
- Check for any leaks in the exhaust system.
Valve clearance
NOTE
The valve clearance should be checked when the engine is
cold. Follow the instructions in the engine manufacturer’s
instruction book.
Checking of fuel system
The following symptoms suggest insufficient fuel flow.

- Engine runs unevenly
- Engine stops after prolonged idling
- Engine misfires
- Engine displays loss of power
- Engine vibrates markedly
First check there is sufficient fuel in the tank. If so, check the
following.
Publ. No. 6053.506 0546 73

Air in the system

- Detach the tank fuel return from its pipe and attach a hose.
Place the other end of the hose in a basin containing some
fuel.
- Run the engine at 800-1000 rpm. There may be individual
bubbles, but if the bubbles increase or foam forms, air has
been sucked into the system.
- Remedy by tightening all loose connections in the system.
Clogged filters or pipes

Low-pressure system:
- Attach a manometer to the filter inlet and another to the
outlet. Pressure drop through a perfectly clean filter should
not be greater than 0.05-0.08 bar at full revs. A pressure drop
of 0.35 bar signifies that the filter is clogged and must be
changed.
- If the pressure drop of 0.35 bar persists despite a new filter,
all low-pressure pipes must be blown clear with compressed
air.
High-pressure system:
Check the fuel pipes between the injection pump and the
injectors by:
- Starting the engine
- Detaching one fuel pipe at a time from the injectors. If no fuel
runs out, the pipe may be clogged, deformed or cracked.
Change the pipe.
Faults in the injectors

- Start the engine and run at low idling speed.
- Stop off one injector at a time by detaching the fuel
line. If the engine is unaffected, the injector should
be repaired or changed.
Contact SMV or other authorized service agent if the engine
fails to function satisfactorily when the above points have
been checked.
Checking the fuel tank
- Check the tank for any leaks.

2 - Drain the tank of any grime and water through the
drain plug (1).
- Place a suitable vessel underneath the drain plug.
- When clear fuel comes through, close the drain plug.
- Check the seal around the fuel cap (2).
74 Publ. No. 6053.506 0546

Checking and adjustment of drive belts

1
- Check regularly that the belts are properly tensioned.
When properly tensioned the belts should give by 10-12 mm
when depressed midway.
- Adjust the belts by loosening the compressor (1) and the
alternator (2). The tension wheel (3) is spring weighed.
Tension the belts and tighten the nuts of the compressor and
the alternator to 120 Nm.
- Replace belts if damaged, badly worn or smeared with oil.
A new belt requires about 24 hours operation to wear in.
3
NOTE
Always replace both items of a paired set at the same time.
2 When adjusting the dynamo belt, press it down into the
centre of the dynamo; otherwise it may sit crookedly and
H1346
be damaged.
Publ. No. 6053.506 0546 75

Checking the mast and carriage
Use a claw wrench or crowbar to check the space between:
- the carriage and the inner mast.

- the inner and outer masts.
If there is an obvious gap of over 5mm, seek advice from the

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

2
Check the wheel and spindle bearings regulary and always
when the tires are replaced. Inportant during the running in
period. As these bearings are exposed to high loads and
3 chocks it is of greatest importance that there is no play
whatsoever in these bearings. Any play will result soner or
later in bearing breakdown. Bearings are adjustable. See page
77. Play in link bearings is acceptable to 1-2 mm per each
bearing, this is however not adjustable.
Use a jack to lift up each side (see page 48) and check as
1 follows:
- Check the spindle bearings by lifting the wheel with a
prybar (1).
- Check the hub bearings by prying the wheel vertically (2).
- Check the link bearings by turning the wheels in the
steering direction (3).
76 Publ. No. 6053.506 0546

Steer wheels suspension

2
Steer axel P/N 200060.02
Adjusting wheel bearings

- Undo the cap (1).
- Check that the bearing grease is clean and free from particles.
If not, the reason for the gap may be a damaged bearing.
- Turn up the lock washer (2).
- Tighten the nut (3); the correct tightening torque is
25 - 30 kpm.
- Rotate the hub. This should only offer light resistance.
A noise or irregular rotation signifies a broken down
bearing. Replace the bearing.
3 - Check for no play.
- Lock the nut (3) using the lock washer (2).
H105 - Fit the cap (1).
Adjusting the spindle bearings

1
- Remove the steering link.
- Remove the cap (1).
- Check the grease.
- Turn down the lock washer (2).
- Unscrew the nut (3) a few turns.
- Check that the lower nut (4) is tightened; the correct torque
3 is about 100 kpm.
2
- NOTE: The nut (4) is not used to preload the bearing.
All bearing preload is adjusted with the upper nut (3).
- Tighten the upper nut (3) to about 25 - 30 kpm.
- Check that there is no gap and that the spindle can easily be
turned without noise or irregular resistance.
- Remount the caps (1).
1 3
1 5
Publ. No. 6053.506 0546 77

DAILY MAINTENANCE AND SERVICE BEFORE OPERATION
Points to check
- Water level of the radiator ............................................................................................................. Page 10

- The level of the engine oil ............................................................................................................. Page 11
- The air filter indicator (the engine’s air filter) ... .......................................................................... Page 11
- The gear box oil level .................................................................................................................... Page 11
- Hydraulic oil level ......................................................................................................................... Page 12
- The fuel level ........................................................................................................................... Page 12-13
- Tyre pressure and condition, wheel nuts ....................................................................................... Page 13
- Washer level ................................................................................................................................... Page 10
- Brake operation
- Steering operation
SERVICE AFTER THE FIRST 50-100 HOURS OF OPERATION

- Checking and tightening of all bolted joints ......................................................................... Pages 52-55
- Lubricating the truck according to lubrication table ............................................................. Pages 56-63
- Changing engine oil ....................................................................................................................... Page 64
- Cleaning the engine oil filter ......................................................................................................... Page 64
- Changing the fuel filter .................................................................................................................. Page 69
- Changing the transmission filter ................................................................................................... Page 65
- Checking (or cleaning) air filter and intake. ................................................................................. Page 70
- Checking the oil in the driveaxle. .................................................................................................. Page 42
- Checking the battery ...................................................................................................................... Page 71
- Checking the drive belts ................................................................................................................ Page 75
ADDITIONAL SERVICEPOINTS AFTER

THE FIRST 500 RUNNING HOURS
- Adjustment of valve clerance engine. See manufactures manual.

- Changing the hydraulic oil filter .................................................................................................... Page 67
78 Publ. No. 6053.506 0546

MAINTENANCE TABLE
INSPECTION AND MAINTENANCE TABLE
When Every Every Every Every

Service necessary 250 hour 500 hours 1 000 hours 2 000 hours
Cleaning the machine ................................................ p.47

Cleaning the cooler .................................................... p.47
Replacing windscreen wipers .................................... p.71
Filling up the washing fluid .......................................... p.10
Checking the electrical system ................................................................ 84-

Checking the oil level in the drive
axle and cleaning the breathing valve .................................................... p.66
Lubricating in accordance with ........................................................... p. 56-
Checking the condition of the battery
and the electrolyte level ......................................................................... p.71
Checking the tension and condition
of the V-belts ......................................................................................... p.75
Checking the mast in accordance with .................................................. p.76
Checking the cab filter .......................................................................... p.33

Checking warning boards
Changing the engine oil ..................................................................................................... p.64

Cleaning the engine oil filter ....................................... p.64 .............................................. p.64
Changing the transmission oil filter ..................................................................................... p.65
Checking the fittings of the engine
and transmission ................................................... p.53-54 ......................................... p.53-54
Checking the steer axle bearings ................................................................................. p.76-77
Cleaning the air intake filter ........................................ p.71 .............................................. p.71
Changing the return filter (hydraulic
system ............................................................................................................................................................. p.67
Changing the element in the air
filter (engine) .............................................................. p.70 ............................................................................. p.70
Checking the cooling
system for leakage ........................................................................................................................................... p.72
Checking the exhaust
system for leakage ........................................................................................................................................... p.73
Changing the fuel filter ................................................ p.69 ............................................................................. p.69
Changing the oil in the gearbox ........................................................................................................................ p.65
Tightening bolted joints .......................................... p.52-55 ........................................................................ p.52-55
Cleaning the fuel tank ................................................ p.74 ....................................................................................................... p.74

Changing the hydraulic oil and filter ............................................................................................................................................ p.67
Changing the oil in the drive axle ................................................................................................................................................ p.66
Checking the mast and carriage ................................................................................................................................................ p.76

Checking weld constructions ..................................................................................................................................................... p.76
Publ. No. 6053.506 0546 79

MAINTENANCE DATA
INSPECTION AND MAINTENANCE DATA MAINTENANCE
No. Unit Material/oil

/lubricant
1 Engine Engine oil Scania DI9 See manufacturer´s manual

VOLVO TWD 731 VE
2 Air filter Air pressure

max. 5 bar (cleaning)
3 Fuel tank Diesel 300 l
4 Cooling system Glycol/water

mixture 50 l
5 Hydraulic tank Hydraulic oil Tank 380 l

System 430 l
6 Drive axle Gearbox oil Each hub Diff.
7 Gearbox Gearbox oil 21 l
8 Battery Distilled water When necessary
9 Tyres Air 9.0 bar
10 Wheel nuts - Page 52
11 All lubrication points Grease When necessary
12 Valve clearance Volvo See manufacturer´s manual

(engine)
13 Fuel injectors Diesel See manufacturer´s manual
14 Belt tension
(fan/generator) - 10-12 mm
80 Publ. No. 6053.506 0546

FUEL AND OIL RECOMMENDATIONS
Quality of the engine oil
The engine oil must comply with one of below classifications Changing the oil due to a change in season may be avoided by
for oil: using what are known as multi-grade oils. Specified intervals
- ACEA E3, E4, or E5 for changing the oil also apply to multi-grade oils.
- TBN-value should at least be 12-13 (ASTM 2896)
NOTE
Check with your oil supplier that your oil meets these No oil additives of any sort should be added to those oils
demands. recommended! Using such additives could invalidate
the engine warranty.
The recommended oil change intervals are valid if the sulphur
content of the fuel is below 0.3%. Mixing different brands of oil should be avoided.
If the sulphur content is higher the 0.3%, the oil change
intervals must be divided in half (250 h). Since the temperature ranges for adjacent SAE classes
overlap, the oil does not need to be replaced when short-term
When the engine is in use, some of the oil which serves as a temperature replaces occur.
lubricant will be burned (used) prior to reaching the pistons.
The combustion products in combination with the high
temperatures lead to ”oil wear”, particularly for the chemical
additives.
Since this oil wear depends on operating conditions, the

quality of the oil (the productivity of the oil) and the fuel
used, the intervals between changing the oil may vary in
length.
The longest possible time before the engine lubricating oil is

replaced is one year, i.e. the oil should be replaced after a
maximum of one year’s operation.
Since the viscosity of the oil varies according to temperature,

the temperature in the place where the truck is being used is
vital to the choice of the engine oil viscosity range
(see diagram).
Publ. No. 6053.506 0546 81

OIL SPECIFICATION, GEARBOX
These recommendations are valid for Spicer Hurth hydraulic Oil viscosity
transmissions, Clark HR 32 000, HR 36 000 and T 40 000.
Transmission lubricant must be qualified by one of the Use mono-grade oils with highest viscosity according to the
following specifications in order of preference: diagram below, if possible.
- Caterpillar TO-4 At fluctuant temperature, multi-viscosity oils are approved if

- John Deere J20 C,D the viscosity does not span over more than a 10 point range,
- MIL-PRF-2104G for example 10W/20, 20W/30.
- Allison C-4
- Dexron IID equivalent NOTE
This recommendation is not valid for transmissions with
NOTE! electronic gearshift, i.e. TE 17, TE 27, TE 32.
Lubricants equivalent to •Dexron IID are not approved for use
in transmissions or converters with graphic friction material.
The following oils are not approved:

- •Dexron III
- Engine oil
- GL-5 oils
•Dexron is a General Motors registered trademark
82 Publ. No. 6053.506 0546

RECOMMENDED FUELS AND HYDRAULIC OILS
Diesel HYDRAULIC OIL Coolant

Use only fuel in accordance with DIN
51601 with a cetane rating not below 45. API CE/SF, Gl 4 Use only monoethylene glycol-based
CCMC D 4 coolants with an additive to prevent
The diesel sulphur content must not MIL-L-2104 D (from factory) corrosion.
exceed 0.5%. If the sulphur content lies Use hydraulic oil from a well-known oil
between 0.5 and 1.0% the service company for mobile applications. Do not mix with anti-freeze liquid
intervals in the maintenance table must Engine oil with a viscosity of SAE 10 containing ethanolamine.
be halved. may also be used. Viscosity: SHS 37 at
normal operating temperature.
If the values are higher, contact the Additive: 1,5 % LUBRIZOL should Drive axle oil
manufacturer of the fork-lift truck or the always
lubricant. be added. This is necessary for the wet API GL.5 SAE 80 W-140
disc brakes to work optimally.
NOTE N.B.
As the surrounding temperature falls, the Previous are recommendations. In case
flow characteristics of the diesel are Grease of any doubt - always contect the
reduced to a point where paraffin begins SMV-dealer.
to precipitate. If ”summer quality” diesel Multipurpose type E.P. according to
is used, this may cause trouble in NLGI Grade 2.
operation. For this reason, ”winter
quality” diesel should be used during
thecold part of the year, as it operates in
thecold better and functions reliably
at -15° C.
Using additives to improve the flow is

not recommended. They may reduce the
capacity to start from cold.
Liquid anti-freeze % volume mixture Mixture of

at the lowest liquid anti-freeze anti-freeze and
temperature °C water
-12 25 1:3
-18 30 1:2
-25 40 1:1,5
-37 50 1:1
-60 66 2:1
Publ. No. 6053.506 0546 83

ELECTRICAL SYSTEM
Fuses
Fuses are located below the left hand dash board. They are
numbered (1), upper left to (30), lower right. Italic = optional.
Fuses below the dash board
1 7 13 19 25 Fuses are located below the dash board. They are numbered
(1), upper left to (30), lower right.
6 12 18 24 30
1 2 3 Fuses and relays in the battery compartment.

1 Starter motor K31
2 Auto stop K32
3 Starter hold function K33
84 Publ. No. 6053.506 0546

ELECTRICAL SYSTEM
FUSES AND RELAYS SPECIFICATIONS
Fuses are located below the dashboard. Italic = optional.
Fuse No. Si ze Function

F1 7,5 amp. Stop solenoid, charging indicator and maneuver for working lights
F2 7,5 amp. Brake light, pos. light, cab. light and switch lights.
F3 15 amp. Airconditioner
F4 5 amp. Fuel solenoid, lubricating pump and parking brake
F5 15 amp. AC-condensor fan
F6 7,5 amp. Road lights, high beam
F7 7,5 amp. Road lights, low beam
F8 10 amp. IQAN-MG (analog)

F9 10 amp. IQAN-MG (digital)
F10 10 amp. IQAN-XP (analog)
F11 10 amp. IQAN-XP (digital)
F12 7,5 amp. Hazard and airconditioner
F13 7,5 amp. Main supply ignition switch, unloading valve and preheater
F14 10 amp. Roadlights
F15 15 amp. Entrance light
F16 10 amp. Wipers, washers and horn
F17 7,5 amp. Directionals and seat heater
F18 7,5 amp. Seat compressor
F19 7,5 amp. Working light attachment
F20 7,5 amp. Rotating beacon, rear view heater, map light and search light.
F21 7,5 amp. Back up lights
F22 10 amp. Radio, com.radio and converter 24/12V
F23 15 amp. 24V AUX.
F24 7,5 amp. IQAN-M (+RTC), timer engine preheater
F25 3 amp. Left positionlight
F26 3 amp. Right positionlight
F27 7,5 amp. Working light mast
F28 7,5 amp. Working light mast
F29 7,5 amp. Working light roof
F30 7,5 amp. Working light roof
Fuses F51-F58, F61-F 67 are located in the battery compartment.

F71 is located in the SCANIA-box wtih relay K31.
F51 10 amp. Main for fuse F12 and F24

F52 10 amp. Spare
F53 1 amp. Radio memory
F54 10 amp. Fuel heater
F55 10 amp. Fuel heater
F56 Spare
F57 Spare
F58 Spare
F61 30 amp. Main for fuse F1, F3, F4, and F5
F62 30 amp. Main for fuse F8, F9, F10 and F11
F66 30 amp. Main for fuse F20, F22 and F19
F67 30 amp. Main for fuse F19
F68
Publ. No. 6053.506 0546 85

ELECTRICAL SYSTEM
RELAY AND BRIDGE SPECIFICATIONS
Relays K1 - K14, K16 - K18 are located below the dashboard. Relays K31, K32, K33 are placed in the battery
compartment.
All relays are equipped with a light diode at the spool.
Relay No. Function
K1 Mainrelay ignition switch

K4 Working light mast
K5 Working light extra
K6 Working light attachment
K7 Back up lights
K8 Direction selector
K9 Stop solenoid
K10 Intermittment wiper rear
K11 Intermittment wiper roof
K12 Intermittment wiper front
K13 Directionals
K14 DEC II (Scania control unit)
K16 Interlock forward (no EMC)

K17 Interlock backward (no EMC)
K18 Neutral safety switch (no EMC)
K31 Start engine

K32 Auto stop
K33 Starter hold function
Bridge No. Cable No. Function
X100:1 08 000 Supply IQAN-MG, + BAT A

X100:2 08 000 Supply IQAN-MG, + BAT A
X100:3 08 011 +AREF, IQAN-MG
X100:4 08 012 -AREF, IQAN-MG
X100:5 10 013 +AREF, IQAN-XP
X100:6 10 014 -AREF, IQAN-XP
X100:7 09 714 Parking brake
X100:8 16 014 Horn
X100:9 21 001 Back up lights, back up alarm
X100:10 02 002 Brake light
X100:11 02 003 Instrument lights
X100:12 22 001 12V from converter
X100:13 23 000 24V aux.
X100:14 20 001 Rotating beacon
X100:15 13 004 Start unload
X100:16 16 000 Supply for wiper and washer
X100:17 -12V Ground radio (-12V)
X100:18
X100:19 17 002 Directional left
X100:20 17 003 Directional right
X100:21 13 003 Unloading valve
86 Publ. No. 6053.506 0546

ELECTRICAL SYSTEM
EXPLANATION OF THE SCHEMATICS
The format of the electrical schematics
The electrical schematics are designed for the purpose of simplifying the location of faults and servicing.
The various electrical schematics are divided into circuits, work lighting, heating and ventilation, etc.
This means that, when locating faults, it is only necessary to use the electrical schematics which cover that
particular circuit. Only in a few exceptional cases is it necessary to use more than one electrical schematic.
If this is necessary, there are coordinate axes around the schematic which can indicate the correct position.
The vertical axis has letters and the horizontal one the numbers which are linked to the number of the
electrical schematic.
The numbering of the leads
The numbering of a lead aims to simplify the location of faults and servicing.
The number of a lead is based on which fuse it comes from. The first digit (or the first two digits of a
four-digit number) indicates which fuse the lead comes from. If the last two numbers are 000, this means
that the lead comes directly from the relevant fuse. For example, cable no. 12000 means that this lead comes
directly from fuse 12. Every time the lead is interrupted via a part, the last two digits of the consecutive order
are changed, e.g. 12001, 12002, 12003, etc.
WARNING
Beware of short-circuiting the battery, which may cause fire or explosion.
The main disconnect does not cut the power to the alternator.
Always disconnect the ground (minus) cable at the battery when
working near or on the alternator.
Publ. No. 6053.506 0546 87

ELECTRICAL SYSTEM
CONTENTS
The following electrical schematic forms a complete schematic electrical system for the
SMV SL 4-8 ECB-trucks.
Function
Power supply .............................................................................................................................................................. Page 89
Start and stop .............................................................................................................................................................. Page 90
Screenwipers .............................................................................................................................................................. Page 91
Washers ...................................................................................................................................................................... Page 92
Heating, ventilation and air conditioning (AC/ACC) ................................................................................................. Page 93
Cab light, seat heating, buzzer and rotating beacon ................................................................................................... Page 94
Seatcompressor, Radio and 12/24 V outlet ............................................................................................................... Page 95
Speed and RPM-controls ........................................................................................................................................... Page 96
Transmission .............................................................................................................................................................. Page 97
Brakes ......................................................................................................................................................................... Page 98
Joystick steering ........................................................................................................................................................ Page 99
Lift mast ..................................................................................................................................................................... Page

100
Clamps ........................................................................................................................................................................ Page

101
Lubrication system ..................................................................................................................................................... Page

102
Engine control ............................................................................................................................................................ Page

103
Canbus, PC-aux and power supply ............................................................................................................................. Page

104
Brake light, flashers and hazards ................................................................................................................................ Page

105
Working lights ............................................................................................................................................................ Page

106
Road and position lights ............................................................................................................................................. Page

107
Instruments ................................................................................................................................................................. Page

108
Manual G-shift ........................................................................................................................................................... Page

109
88 Publ. No. 6053.506 0546

POWER SUPPLY
Publ. No. 6053.506 0546 89

START AND STOP
90 Publ. No. 6053.506 0546

SCREEN WIPERS
Publ. No. 6053.506 0546 91

WASHERS
92 Publ. No. 6053.506 0546

HEATING, VENTILATION AND AIR CONDITIONING
Publ. No. 6053.506 0546 93

CAB LIGHT, SEAT HEATING, BUZZER AND ROTATING BEACON
94 Publ. No. 6053.506 0546

SEAT COMPRESSOR, RADIO AND 12/24 V OUTLET
Publ. No. 6053.506 0546 95

SPEED AND RPM. CONTROLS
96 Publ. No. 6053.506 0546

EMERGENCY SWITCH
DEC II ENGINE SWITCH
Publ. No. 6053.506 0546

IGNITION LOCK
Instructionbook
RPM COUNTER DIESEL ENGINE
RPM COUNTER GEAR BOX

OUTPUT
x118 (DEC II ACC)
SEE MANUFACT.
SPEC
FOOT THROTTLE
Sheet 11a
SPEED AND RPM. CONTROLS, DEC II
97
SL 6-8 ECB
TRANSMISSION
98 Publ. No. 6053.506 0546

BRAKES
Publ. No. 6053.506 0546 99

JOYSTICK STEERING
100 Publ. No. 6053.506 0546

LIFT MAST
Publ. No. 6053.506 0546 101

LUBRICATION SYSTEM
102 Publ. No. 6053.506 0546

ENGINE CONTROL
Publ. No. 6053.506 0546 103

CANBUS, PC-AUX AND POWER SUPPLY
104 Publ. No. 6053.506 0546

BRAKE LIGHT, FLASHERS AND HAZARD
Publ. No. 6053.506 0546 105

WORKING LIGHTS
106 Publ. No. 6053.506 0546

ROAD AND POSITIONS LIGHTS
Publ. No. 6053.506 0546 107

INSTRUMENTS
108 Publ. No. 6053.506 0546

MANUAL G-SHIFT
BL25
Publ. No. 6053.506 0546 109

NOTES
110 Publ. No. 6053.506 0546

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Instructionbook SL 6-8 ECB

Publ. No. 6053.506 0546 1

The user instructions for additional parts

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WARNINGS AND IMPORTANT INFORMATION

Read the instruction book carefully before you

Always read the instructions that follow the safety alert

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1. Steer axle 4. Engine casing 7. Lift cylinders

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1. Mast number 4. Steer axle number 7. Chassies number

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YOUR SMV LIFTTRUCK ............................................................. 2 DISASSEMBLING CARRIAGE AND MAST .......................... 51

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Daily maintenance and service before operation

Check the washer level

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Checking the engine oil level

Checking the oil level in the gearbox

Air filter indicator

- Check the indicator (1).

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Checking the hydraulic oil level

Topping up the hydraulic oil

- Unscrew the oil cap (1).

Checking the fuel level

- Turn the ignition key to position 1.

- Turn off, the ignition key.

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Filling with fuel

Checking the condition and pressure of the tires

Main circuit switch

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1. Steering wheel 5. Directional switch 10. Brake pedal

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1. Parking brake 10. Rotating beacon 22. Indication, engine, pressure

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Adjusting the driver’s seat

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

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

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

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Adjustment of steering wheel

When positioning the steering wheel.

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STARTING THE ENGINE

Before starting up the engine, the gear selector on the left-

Function of gauges and indicators

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Stopping the engine

Use the emergency stop only in an emergency situation.

- Turn the ignition key to position (0).

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Description of the EMC drive monitor type IQAN

The monitor computes the following information:

The monitor controls the following functions:

Description of the keys

After starting turning on the ignition switch, this picture will be

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