Idcg02 02GB

Forklift trucks 18-33 tonnes
Publ. no IDCG02.02GB
Operator's manual in original OPERATOR’S MANUAL
DCG 180-330
1 Foreword ................................................................................................................................ 1
1.1 About the operator's manual.............................................................................................. 1
1.2 About the documentation kit .............................................................................................. 4
1.3 Inspection and maintenance .............................................................................................. 5
2 Safety ..................................................................................................................................... 6
2.1 Safety and emergency equipment ..................................................................................... 8
2.2 CE marking ........................................................................................................................ 9
2.3 ANSI/ITSDF marking ....................................................................................................... 10
2.4 Keep in mind ..................................................................................................................... 11
2.5 Fire................................................................................................................................... 18
3 Overview............................................................................................................................... 20
3.1 Description ....................................................................................................................... 20
3.2 Plates ............................................................................................................................... 26
4 Instruments and controls ...................................................................................................... 33
4.1 Warning and indicator lights............................................................................................. 39
4.2 Ignition key lock and start and stop button for the engine................................................ 42
4.3 Switches .......................................................................................................................... 44
4.4 Travel direction selector and parking brake ..................................................................... 57
4.5 Multi-function lever........................................................................................................... 59
4.6 Load handling .................................................................................................................. 60
4.7 Pedals .............................................................................................................................. 65
4.8 Steering wheel ................................................................................................................. 67
4.9 Driver's seat ..................................................................................................................... 71
4.10 Heating / Air conditioning ................................................................................................. 73
4.11 Control system ................................................................................................................. 75
5 Handling ............................................................................................................................... 92
5.1 Running-in ....................................................................................................................... 94
5.2 Daily inspection................................................................................................................ 95
5.3 Error codes ...................................................................................................................... 96
5.4 Operating ....................................................................................................................... 163
5.5 Load handling ................................................................................................................ 179
5.6 Customer settings via display ........................................................................................ 196
6 Inspection and maintenance............................................................................................... 205
6.1 Daily inspection.............................................................................................................. 206
6.2 Maintenance ................................................................................................................... 211
6.3 Service ........................................................................................................................... 245
7 Transporting the machine ................................................................................................... 247
7.1 Towing............................................................................................................................ 248
7.2 Lifting and transporting the machine.............................................................................. 250
7.3 Service position.............................................................................................................. 252
7.4 Attachment of lifting equipment...................................................................................... 253
7.5 Long-term storage.......................................................................................................... 277
8 Environment and standards................................................................................................ 278
9 Specifications ..................................................................................................................... 280
10 Terminology ........................................................................................................................ 292
11 Index.................................................................................................................................... 295
Operator’s manual DCG 180-330 IDCG02.02GB

IDCG02.02GB Operator’s manual DCG 180-330
1 Foreword 1
1 Foreword
1.1 About the operator's manual
General
Thank you for choosing Kalmar as your machine supplier. We hope
that we will meet your expectations.
This Operator's manual contains information that you must keep in

mind for safe handling and optimal use of your new Kalmar machine.
Operator's manual, purpose

The operator's manual describes how the machine should be operated
and maintained in a correct manner.
Cargotec will not accept any responsibility for machine modifications

without permission from Cargotec. Further, Cargotec will not accept
any responsibility if other lifting devices, tools or work methods are
used other than those described in this manual.
Storage
The operator's manual should always be kept in the machine.
About machine version

The information in this publication corresponds with the machine's
design and appearance on delivery from Cargotec. Deviations may
arise due to customer adaptations.
Cargotec reserves the right to make changes to specifications and

equipment without prior notice. Information provided in the manual
applies at the date of issue.
Copyright
Cargotec Sweden AB
Duplication of the content in this manual, in whole or in part, is strictly

prohibited without written permission from Cargotec Sweden AB.
All duplication by any means, such as copying, printing, etc., is

prohibited.
Manufacturer
This machine is manufactured by Cargotec Sweden AB, SE-340 10
Lidhult, Sweden.

2 1 Foreword – Reading instructions
1.1.1 Reading instructions

Warning information
This manual contains descriptions of warnings that apply to your safety.
Warnings provide information about potential dangers that, if the
warnings are not followed, could result in injury or product damage.
DANGER
Situation that could lead to severe personal injury or
death if regulation is not followed.
WARNING
Situation that could lead to personal injury if regulation
is not followed.
CAUTION
Situation that could lead to product damage if
regulation is not followed.
Important information
Important information is denoted with NOTE and is intended to
facilitate the work process, handling or to increase understanding of
the information.
NOTE
Important information not related to safety.
Read the operator's manual

The symbol to the left is used in certain cases on the machine and
refers to important information in the Operator's manual.
000262
Read the operator's manual
Read the Maintenance manual

The symbol to the left is used in certain cases on the machine and
001128
refers to important information in the Maintenance manual.
Read the Maintenance manual

1 Foreword – Reading instructions 3
Optional equipment
There is a range of optional equipment available for the machine.
000264
Each description of optional equipment in the manual is marked with
a symbol, and contains an explanatory text. The symbol is positioned
Indicates optional equipment visibly by the text and image in question.
See the machine card for complete specifications of the machine's

product alternatives and optional equipment.

4 1 Foreword – About the documentation kit
1.2 About the documentation kit

Documentation kit
The following documentation is supplied for the machine:
• Operator's manual (in cab with machine).
• Maintenance manual.
• Spare parts catalogue with machine card.
There is supplementary documentation that can be ordered for the

machine:
• Workshop manual.
• Supplier documentation for engine, transmission, and drive axle.
Ordering documentation
The documentation is ordered from the dealer for Cargotec.
Always indicate publication number when ordering. The publication

number is printed down to the left on the cover and at the bottom of
all pages in the manual.

1 Foreword – Inspection and maintenance 5
1.3 Inspection and maintenance

General
Maintenance must be managed properly in order for the machine to
operate satisfactorily and at the lowest cost. Intervals for inspection
and maintenance refer to operation under normal environmental and
working conditions.
Maintenance described in this operator's manual can be performed by

the operator, see Chapter 6 Inspection and maintenance. It describes
the daily inspections that comprise ongoing checks and actions that the
operator should carry out when starting a shift.
Maintenance
For other maintenance not included in this operator's manual (service
and repairs), contact an authorised workshop.

6 2 Safety
2 Safety
General
Safety rules are intended to reduce the risk of personal injuries as well
as damage to the load or other property.
Only personnel trained for this machine may handle, operate, perform
service or be in its vicinity during its use.
The safety information in this operator's manual is intended for your

information and safety. It cannot, and is not intended to, cover all
possible events during operation. Responsible operators with the
right training is the only way to ensure the safe and prolonged use
of the machine.
The machine was thoroughly tested and adjusted before it left the
factory. This does not preclude the possibility that it has been damaged
during delivery. The machine must undergo a thorough inspection in
order to ensure correct function before being put into service.
Important to read the operator's manual

Incorrect operation may lead to injury and product, and/or property
damage. For this reason, please read this operator's manual very
carefully before using the machine. The operator's manual contains
important information about your Kalmar machine, the machine's
handling, safety during work and about the machine's daily inspection.
000262
In addition, you will obtain a lot of valuable information that makes

it easier for you at work.
The operator's manual should always remain in the machine. If it is lost

a replacement must be acquired immediately.
NOTE
Never use a machine that does not have an operator's manual.
Ask your foreman or supervisor if there is anything in the text you do

not understand or if you feel information is missing in any area.

2 Safety – Safety 7
Intended use
• The machine must only be used for what it is designed and
manufactured for, i.e. to lift and transport goods (whose weight
and load centre/centre of gravity do not exceed the machine's
maximum permitted load capacity). If it is used in any other
way or in potentially dangerous environments (e.g. an explosive
environment, an area with asbestos dust) then special safety rules
must be followed and the machine must be equipped for such
operations.
• The machine should not be modified or changed without permission
from Cargotec. In the event of modifications approved by Cargotec
the signs on the machine and documentation affected must be
adapted to apply to the modification.
In the event of modification or conversion without Cargotec's
permission Cargotec's product liability ceases to apply. Modification
and conversion may only be made if the knowledge exists to
verify and test the modifications and conversions. Modifications
and conversions must be documented (date and action) and the
organisation responsible must be stated with name and address.
Signs and stickers must be updated in accordance with the
machine's new design.
• The machine may not be operated on public roads unless it has
been adapted according to national road safety regulations.
• It is always the machine owner's responsibility to ensure that the
machine has approved fire-fighting equipment in accordance with
the regulations in force.
Operator requirements
• The machine may only be operated by specially trained operators
who have the work supervisor's permission to operate the machine.
• Laws and regulations regarding driver's licenses, operator ID, etc.
must always be followed.
• The operator must be aware of and follow all local safety rules.
• The operator must follow the manufacturer's instructions.
• The operator should read and understand the machine's warning
and information plates as well as understand and be able to use
the machine's safety and warning equipment.
Prohibited operation
Machine operation is prohibited:
• If safety and warning equipment such as rear view mirrors,
headlights, etc., do not function correctly.
• In case of defective brakes, steering or lifting equipment.
• If there are unauthorised persons or vehicles within the machine's
work area.
• If the machine has been repaired, modified or adjusted without the
supervisor's/work management's permission.
• If the machine is equipped with tyres not approved by Cargotec.

8 2 Safety – Safety and emergency equipment
2.1 Safety and emergency equipment

General
A good work environment has safety and emergency equipment to
help make the operator's work safe, as well as safety equipment to
signal to the surrounding personnel.
The machine may be equipped with the following safety equipment:

1. Back-up alarm
2,8 11 8 7
2. Revolving beacon/flashing beacon
The revolving beacon on the cab is vertically adjustable.
9
3. Horn
12
4. Electrically powered loud air horn
5. Fire extinguisher
Fire extinguishers are normally located on the left-hand front
wing but can also be located on the right-hand front wing behind
the right or left-hand footsteps (or several of these locations
simultaneously).
If the machine is supplied with a fire extinguisher, it should be of
018133
the type ABE according to EN 3 pt. 1, 2, 4, and 5. With such a fire

1,8 6 10 5 3,4 1 8 extinguisher, it is possible to extinguish fires in both solid organic
materials and fluids. Adapted fire extinguishing equipment can be
ordered from Cargotec.
6. Seat belt
A 3-point seat belt is available as an option for the driver's seat
with a high back rest .
7. Buzzer in the cab to indicate an alarm or forgotten action, e.g. if
the operator leaves the driver's seat without applying the parking
brake.
8. Camera with monitor
Used to provide improved rearward vision when manoeuvring
and/or load handling with the machine. The monitor is usually
placed inside the cab by the front right door pillar.
9. Exterior mirrors :
Used to provide improved visibility while manoeuvring and load
handling.
9c 9a 9a shows blocked area in front of machine
9b shows blocked area to the side/behind the machine
9b
9c shows blocked area in behind machine
10. Control breaker for load handling
Cuts off all power supply and control signals to load handling.
11. Protective grating for roof window .
018134
12. Protective grating for windscreen .

2 Safety – CE marking 9
2.2 CE marking
CE marking
(Declaration of Conformity, only applies to machines marketed
within EU/EEA.)
This machine is CE marked. This means that upon delivery it fulfils the
applicable "Essential Health and Safety Requirements" specified in
the EU Machine Directive, 2006/42/EC, as well as other EU directives
relevant to this machine type.
As proof that the requirements are fulfilled, the machine is provided

with an EC Declaration of Conformity, issued by Cargotec for every
machine. The EC declaration also includes tools and options produced
by Cargotec. The documentation is a valuable document that must be
properly preserved and saved for at least 10 years. The documentation
must always follow with the machine when it is sold.
See example of EC Declaration after 11 Index.
Anyone making modifications that affect the safety of the machine

also assumes responsibility for them. If the machine is used for other
014507
purposes or with other tools than what is specified in these instructions,

safety must be ensured in each individual case. The machine owner
Machine plates for CE marking is responsible that the machine is used in accordance with the
instructions in the operator's manual. In some cases the application
area may require a new CE marking and issue of new EC declaration
of conformity.
For additional information, see standards under chapter 8 Environment

and standards.

10 2 Safety – ANSI/ITSDF marking
2.3 ANSI/ITSDF marking

ANSI/ITSDF marking
(Only applies to machines for the North American market.)
This machine is ANSI/ITSDF marked. This means that upon delivery it

fulfils the basic safety requirements of ANSI/ITSDF B56.1.
Anyone making modifications that affect the safety of the machine also
assumes responsibility for them.
If the machine is used for other purposes or with other tools than what
is specified in these instructions, safety must be ensured in each
individual case. The machine owner is responsible that the machine is
used in accordance with the instructions in the operator's manual.
For additional information, see standards under chapter 8 Environment

and standards.
014483
Machine plates for ANSI/ITSDF marking

2 Safety – Keep in mind 11
2.4 Keep in mind

Interrupted operation and/or parking
CAUTION
Always turn off the electric power when the machine is
left, e.g. when parking or at the end of the shift.
Risk of fire!
Turn off the electric power with the battery
disconnector.
For machines with SCR-system (emission control with AdBlue):
NOTE
Wait for two minutes before the system voltage is disconnected
with the battery disconnector so that the SCR system has time to
be drained of AdBlue, this is particularly important in cold weather.
NOTE
Always check that a gear is not engaged before turning the start
key or resetting the control breaker for load handling.
NOTE
Never leave the operator's station without first applying the parking
brake (ON position).
NOTE
Always remove the start key if the machine is to be left unattended.
During work shifts
DANGER
Forks or other attachments are work tools that handle
large loads.
Extreme hazard to personal health and risk of property
damage!
Make sure that no persons stand or walk under a
raised work attachment, regardless of whether it is
loaded or not.
DANGER
External equipment may only be used if it is approved
by Cargotec.
damage!
Only use equipment that is approved by Cargotec.

12 2 Safety – Keep in mind
DANGER
The parking brake should never be applied when the
machine is moving, unless an emergency requires it.
Very heavy braking. Risk of machine tipping, load
tipping over, being dropped or damage to property
or extreme danger!
Stop the machine before applying the parking brake.
DANGER
The machine's work area is large and visibility from
the operator's cab is restricted.
damage!
Keep in mind:
• Always check that no persons are in the way of the
machine or its equipment. Also check that the area
upwards is free. If there are unauthorised persons
or vehicles within the work area then the machine
must be stopped.
• The operator must always face in the travel
direction and should operate with special care
where persons or vehicles may appear.
• The operator must adapt the speed to the load and
ground conditions, visibility, and wind conditions,
etc.
• The operator must pay extra attention and operate
with special care near electric power lines,
viaducts, docksides, ramps, doorways, etc.
• Always operate carefully so that the attachment
does not collide with posts, power lines, etc.
• Use available visibility-enhancing equipment such
as rear view mirrors and camera ( ).

WARNING
Transporting loads is associated with major risks.
Risk of roll-over and tipping over! Chance of load
damage to property! Extreme danger!
Respect the lifting capacity of the machine and
exercise the greatest caution during load handling:
• The machine must only be operated on even
surfaces, intended for the machine's total weight
and ground pressure.
• All transporting of loads must take place in
transport position. Exercise caution when
operating, think about the width and height so that
the mast or forks/attachment do not collide with
poles, cables, etc.
• Do not transport the load in a higher position than
necessary since this may cause the machine to roll
or tip over.
• Always operate with the load facing uphill on an
uphill or downhill grade, never operate or turn
across a grade.
• Operate the machine in reverse if the transported
load obscures visibility to the front.
• No personnel may encroach or stand under a
raised load.
• The operator must avoid forceful acceleration
and heavy braking to prevent risk of tipping and
roll-over.
• The operator must always adjust the speed when
turning to prevent skidding and risk of roll-over or
tipping over.
In the event of tipping or roll-over, hold onto the
steering wheel and remain in the cab. Do NOT
attempt to jump out of the cab until any movement
of the machine has finished.
When handling special loads local regulations may
apply. Learn about them and follow them.
WARNING
The machine's load capacity is limited.
Risk of roll-over and tipping over!
It is forbidden to exceed the machine's load capacity.
See the rating plate and load diagrams.

WARNING
The strength of the roof window may be significantly
reduced in case of exposure to substances containing
aromatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the surface layer of the roof window and
clean only with washer fluid or mild detergent. Rinse
thoroughly with lukewarm water afterwards. Replace a
damaged roof window that shows cracks or scratches
immediately!
WARNING
Lifting loads in very windy conditions is associated
with great danger.
Risk of roll-over and tipping over! Extreme danger!
Avoid lifting loads in high wind speeds.
WARNING
The machine emits exhausts during operation.
Health hazards and fatal danger in poorly ventilated
facilities!
If possible, avoid operating the machine indoors
in poorly ventilated premises. Use exhaust venting
equipment!
WARNING
Work position on the machine is located up high.
Risk of falling and bodily injury!
Always use steps and handles when you go up or
down from the machine. Always turn to face the
machine. Do not jump!

WARNING
No lowering of load handling equipment when control
is activated.
Risk of crushing! Make sure that nobody is under the
load handling equipment.
If the load handling equipment is blocked so that it
cannot be lowered to its original position, contact the
Cargotec Service organisation!
WARNING
Cab doors must always be closed when operating.
Risk of personal injury and crushing in case of
roll-over and tipping!
Always close the doors during the work shift.
WARNING
Passengers may only be carried in the cab provided
that there is a seat available for passengers. Do not
carry passengers on the machine outside the cab or
on the load.
Risk of personal injury!
A passenger in the cab must use a permanently
mounted extra passenger seat and seatbelt.
WARNING
The machine's hydraulic system includes accumulators
with high pressure.
Always exercise extreme caution when working
with the hydraulic system and avoid unnecessarily
remaining close to hydraulic components or hoses.
The accumulators must be drained prior to work in the
hydraulic system (see Maintenance manual).

WARNING
Handle batteries and connectors with great care during
charging and boosting (jump starting). Do not mix
up the battery terminals! Follow the instructions for
starting with a booster battery!
Danger of short circuit! Warning - risk of hydrogen gas
forming! Danger of sparks and fire! Hydrogen gas is
very explosive!
Batteries must always be equipped with covers over
terminals and connections. Connect positive terminals
first. Then connect the negative terminals in order to
avoid sparks that could ignite the hydrogen gas.
CAUTION
The machine uses oils and lubricants.
Health hazard in the event of protracted skin contact!
Avoid skin contact with oils and lubricants. Use
protective gloves.
CAUTION
AdBlue can irritate with skin and eye contact and if
inhaled.
Health hazard!
Handle carefully and avoid skin contact, wear
protective gloves. In the event of any contact with
the skin and spillage on clothing, wash the skin with
large quantities of water and change contaminated
clothing and gloves. In the event of eye contact, rinse
thoroughly with water for several minutes and seek
medical advice if necessary. If inhaled, breathe fresh
air and seek medical advice if necessary.
WARNING
Fire extinguishers contain dry chemicals.
Risk of breathing difficulties when using in an enclosed
space!
Use the fire extinguisher from the outside and into the
area to be extinguished. After use, ventilate the space
thoroughly.

CAUTION
Cracks or scratches result in reduced strength of the
roof window.
Low strength!
Replace a damaged roof window immediately.
CAUTION
The parking brake can be used as an EMERGENCY
BRAKE.
Brake shoe linings wear out and lose their braking
performance! Risk of unwanted movement by the
parked machine!
After emergency braking with the parking brake the
brake shoe linings must be checked as soon as
possible and replaced if necessary. Braking action of
the parking brake may be lost as the brake shoe linings
may have been worn down.
If the parking brake has been released mechanically
then it must always be reset to restore the machine's
parking brake function.
WARNING
Optional equipment such as two-way radio, remote
control door opener, etc. may emit non-ionising
radiation. Such equipment transmits within the
frequency band 100 - 500 MHz.
Danger of interference to active medical devices (e.g.
pacemakers).
Do not use two-way radios, remote control door
opener, etc. when someone with an implanted active
medical device is in the cab.
NOTE
Cargotec will not assume any responsibility for installed optional
equipment, which is not installed by Cargotec or an installer
approved by Cargotec.

18 2 Safety – Fire
2.5 Fire
Action in the event of fire
DANGER
In the event of fire the operator's safety must not be
compromised.
If given the opportunity, take the following action at
the slightest sign of fire:
1. Stop the machine and turn the ignition key to stop
position.
2. Leave the cab.
3. Switch off the system voltage with the battery
disconnector.
4. Alert the rescue services.
5. Try to extinguish the fire.
If this is not possible, leave the machine and the
risk area.
DANGER
Smoke can be extremely toxic.
Smoke subdues, suffocates and can kill people!
Smoke can cause damage to lungs and respiratory
organs even in small quantities.
Avoid breathing fumes, do not stand in the smoke.
Use breathing apparatus for fire fighting and work
with burnt material.

2 Safety – Fire 19
Fire prevention measures
DANGER
Residue from fuel, oils, grease or other flammable
materials on the engine or in the engine compartment
is a fire hazard.
Fire hazard!
Remove residue of flammable materials in the engine
compartment as soon as they are detected. Be extra
careful on hot surfaces such as exhaust systems,
manifolds or turbochargers. If leakage of oil, fuel or
coolant is detected, the reason should be investigated
and the fault corrected before starting the engine.
Make it a habit to make a visual inspection of the engine and engine

compartment during the daily inspection. This helps to quickly detect
if anything abnormal has happened or is about to happen. Look
particularly closely for oil, fuel, AdBlue or coolant leakage, loose bolts,
worn or poorly tensioned drive belts, loose connections, damaged
hoses and electrical cables. The inspection only takes a few minutes
and can prevent serious faults and costly repairs.
CAUTION
High-pressure washing of sensitive components may
lead to short-circuiting and cause malfunction.
Product damage!
Do not use a high-pressure washer on the cab, radiator,
battery compartment, electric components, control
units, connectors, cable joints, cylinder seals, stub
axles, axle seals and chains.
Action after fire

When handling a machine damaged by fire, or exposed to excessive
heat, the following safety regulations must always be followed:
• Check that the fire has been fully extinguished. Re-extinguish if
necessary.
• Make sure that system voltage is switched off with the battery
disconnector.
• Make sure that the machine is in a secure location, service position.
• Check for that there are no leaks which could cause damage to
the surrounding environment.
• Never touch the burned components with bare hands in order to
avoid coming into contact with molten polymer material.
• Use breathing apparatus, thick gloves and protective safety
goggles.
• Contact Cargotec.

20 3 Overview
3 Overview
3.1 Description
General
The DCG 180-330 machine is a forklift truck of heavy capacity for all
types of load handling. It has a maximum lifting capacity of 18 to 33
tonnes. The machine has a one lifting mast. There are three lifting
mast options and these come in different lifting heights:
1. Duplex
2. Duplex Free Lift
3. Triplex Free Lift
This section provides a short presentation of the machine's parts, see

General, page 21.
3.1.1 Identification of the machine

Type designation of forklift truck
Each machine from Cargotec has a type designation. Type designation
DCG 250-12 (LB) (example) indicates the following:
• D - Diesel engine
• C - Counterweight forklift
• G – Generation
• 250 – Lift capacity, decitonne
• 12 – Distance to centre of gravity, in decimetres
• (LB) - Low-profile machine
Machine card
Cargotec machines are adaptable in different ways with product
alternatives and optional equipment. This is in order to satisfy as broad
a customer base as possible.
A machine card is supplied together with the spare parts catalogue.

The machine card contains complete specifications of the machine's
product alternatives and optional equipment.
The machine card must be updated when the machine is modified

and Cargotec must be informed.

3 Overview – Overview description 21
3.1.2 Overview description

General
This section provides a short presentation of the machine's parts, which
are pointed out in the overview figure below.
018135
1 2 3 4
1. Steering axle
2. Engine
3. Transmission
4. Drive axle
5. Load handling, lifting mast
6. Load handling, lifting carriage
7. Cab

22 3 Overview – Overview description
Engine
The engine is a straight 6-cylinder turbocharged low emission engine
with intercooler. The engine provides the power for propulsion and
hydraulics.
DCG 180–250 is equipped with one of the following engine alternatives:
• Cummins QSB6.7 Stage 3A/Tier 3 (164 kW)
• Cummins QSB6.7 Stage 4/Tier 4f (168 kW)
• Volvo TAD871VE Stage 4/Tier 4f (185 kW)
DCG 280–330 is equipped with one of the following engine alternatives:
• Cummins QSB6.7 Stage 3A/Tier 3 (194 kW)
• Cummins QSB6.7 Stage 4/Tier 4f (194 kW)
• Volvo TAD871VE Stage 4/Tier 4f (185 kW)
Transmission
The transmission is fully automatic with torque converter. Manual
shifting is possible with the switch on the steering wheel panel. The
transmission has 3 forward gears and 3 reverse gears. The hydraulic
pumps for working hydraulics are mounted on the transmission.
The machine is equipped with Dana TE17.
Drive axle
The drive axle (front axle) is equipped with a differential and hub
reductions of the planetary gear type.
Brakes
The machine has a brake circuit and is equipped with hydraulically
operated brakes. The brake units consist of fully enclosed oil-cooled
disc brakes with external cooling.
The parking brake is electro-hydraulically operated and brakes with a
disc brake. The disc brake acts on the drive axle's input shaft. The
parking brake is released by hydraulic pressure and is applied either
the travel direction selector by the steering wheel or automatically
(by spring force) in the event of a power failure or loss of hydraulic
pressure. Parking brake application is automatic if the ignition key
lock is switched off.
Steering
The machine is steered with the rear axle (steering axle). A
double-acting hydraulic cylinder acts on the wheel pair. The steering
is linear, that is, the steering angle is dependent on the number of
steering wheel turns.
Load handling
The mast and lifting carriage are used for load handling. The load is
manoeuvred in height and is tilted (angled) forward or backward.
The lifting carriage is normally equipped with side shift and fork
spreading.
The fork bracket is fitted on the lifting carriage and can be equipped
with e.g. forks, inverted forks, coil ram and top lift attachment fitted
either on the forks or on the inverted forks. The load is manoeuvred in
height, laterally and is tilted (angled) forward or backward. There are
two types of top lift attachment, fixed (20" or 40") or adjustable between
20" and 40". The top lift attachments have twistlocks for locking the
load. Securing the load and operating the attachment are handled
electrically and hydraulically.

Electrical system
The electrical system consists of electrical and electromagnetic
components such as battery, switches, cable harnesses, solenoid
valves, fuses and relays.
Control system
The machine has a computer-based control system for monitoring
and controlling the machine's functions as well as handling functions
in the machine, such as power electronics, drivetrain and hydraulic
system. The control system also facilitates maintenance and provides
the operator with information about errors or safety related events
arising in the machine. The operator can also see information on the
display about the current operating status of the engine, transmission
and control units.
Cab
The cab is available in two versions. Controls, instrumentation and
equipment are based on common modules whose functions are
customised.
• Cab
The enclosed cab is a closed operator position with doors built on
a supporting frame to withstand falling loads. It is equipped with a
fresh air system with filtered air intake and recirculation as well as
heater unit or air conditioning ( ).
• Open cab:
The Open cab is an open operator's station constructed of a
structural frame to withstand falling loads.
The roof window is made of high-strength material and withstands

heavy blows, e.g. from falling objects.
Hydraulic system
The hydraulic system includes the sub-functions of brakes and working
hydraulics.
The working hydraulics include hydraulics for steering, load handling

and cab functions. The working hydraulics are supplied by two variable
load sensing pumps.
The brake system has a fixed gear pump, high-pressure filter,

accumulators and cooler .
The hydraulic oil is cleaned with a return filter in the hydraulic tank.

24 3 Overview – Overview description
Other equipment
Standard equipment
1
2
14 15 16
3 17
4 18
13
12 5
6
11
018131
7
10 9 8
1. Interior lighting Mesh pocket in right-hand door side; storage

compartment. Not available on the overhead guard.
2. Interior rear view mirror
12. Storage compartment in right-hand arm rest
3. Combined wiper, windscreen and roof
13. Storage compartment for the operator's manual.
4. Steering wheel console with three individually
Located behind the door to the right in the rear wall.
adjustable shafts with electrically adjustable height
position 14. Opening window right and left-hand door
5. Storage compartment in front panel. 15. Work lights, cab roof rear edge, directed backwards, 2
lamps
Cup holder for storage compartment in the front
panel. The cup holder can be mounted in any storage 16. Roof window standard 6 mm.
compartment.
17. Mast work lights, 2 lights
6. Storage compartment for paper in the seat console
18. Tempered safety glass in the front windscreen
7. Work console with four individually adjustable shafts
Clear windows
with electrically adjustable height and length position
19. Non-slip plate on e.g. steps and lower edge of the
8. Storage compartment in front panel
door sill
9. Horn. Located inside the front cover.
(Not positioned in figure).
10. Door handle for cab instep
11. Bottle holder in left-hand door side. Not available on
the overhead guard.

Optional equipment
17 18 19 20 21
2 3 4
1 5 22
16 6
31 23
15 7 24
14 25
8
13 11,30 26
9
12
11
018132
8 10 9 26 29 28 27
1. Audio system 20. Extra working lights, cab roof, front edge, 2 lamps
2. Sun visor, rear window 21. External rear view mirrors
3. Sun visor, roof window 22. Extra mast work lights, 2 lamps
4. Location for two-way radio Protective grille for mast working lights
5. Seat for passenger with 2-point seat belt, to the left 23. Laminated front windscreen
of the driver's seat
Tinted windows
6. Sun visor, front windscreen
24. Extra work light between the tilt cylinders, 1 lamp
7. Writing table with light Steps between tilt cylinders
8. Socket 12/24 VDC, 4 sockets 25. Direction indicators with position lights
9. Extra cup holder for the storage compartment in the Grating for headlights
front panel
26. Mud flap, steering and drive wheels
Refrigerated storage compartment right-hand side front
27. Central lubrication, machine
panel (in combination with ECC)
28. Revolving operator's station
10. Electrically powered loud air horn . Located inside
the front cover. 29. Baseplate, cab
11. Camera with monitor Mounted between cab and frame.
Distance warning function for back-up camera 30. Grating for rear lights
12. Storage compartment behind the driver's seat console 31. Litter container
32. Tool kit
13. Air-suspension driver's seat with 3-point seat belt and
electrical heating
33. Aluminium non-slip plates for lamp protection and
Head rest
front wings
Arm rest left-hand side
14. Alcolock
34. Heater: (Not positioned in figure)
15. Extra internal rear view mirror
A 110 V or 230 V for connecting the engine heater
16. Mesh pocket headlining; storage compartment (only with or without compartment heater
with elevated roof)
B Electric or diesel-driven compartment heater. A
17. Extra work lights, cab roof rear edge, directed pause heater is available as an optional.
forwards 2 or 4 lamps
C Oil heater hydraulic tank, high voltage 230/380 V.
Extra working lights for container handling, 4 lamps
D Eberspächer. Refer to the manufacturer's
18. Adjustable search light instructions.
Controlled electrically by remote control.
19. Roof window extra strong 12 mm

26 3 Overview – Plates
3.2 Plates
Product plates
Below are the product signs that must be on the machine when
operating within the EU/EEA, there are more variations available for
other markets. When ordering spare parts and in case of enquiries per
telephone or correspondence, always state model designation and
serial number in accordance with the plates. The plates' part numbers
are stated on each respective plate. Plates that have been damaged,
illegible or painted over must be replaced immediately.
018136
1, 2, 5
1. Machine plate (example), A54516

T = Machine type
M = Machine model
S/N = Serial number for the machine / Year of manufacture
Q, D, H= Indicates classed load capacity (Q) according to EN1551
at centre of gravity distance (D) up to lifting height (H)
W= Machine's operating weight (without load)
P= Engine power
Q, C, D, H = Approved load at lifting height (H) at respective
013973
distance (so-called load centre) horizontally and vertically from

mast and forks (D and C).
Machine plate can only be ordered with complete engraving.
2. Additional plate for attachment, A54560
Specifications for the machine's approved lifting equipment.
NOTE
The plate's design depends on type of attachment.
013974
S/N = Serial number for machine

A = Identification number for attachment
H = Lifting height
D = Centre of gravity distance
Q = Lift capacity
C= Centre of gravity's height. Distance from the forks up to the
load's vertical centre of gravity
Plate can only be ordered with complete engraving.
• Additional plate for sidelift-attachment, A54560
013980

3 Overview – Plates 27
• Additional plate for attachment, top lift, A54560
013976
• Additional plate for attachment, top lift, inverted forks, A54560
013977
3. Additional plate for attachment, A33808

Specifications for the machine's approved lifting equipment. The
sign is in the cab for the operator's information. Corresponds with
signs item 1 and item 2.
NOTE
016642
The plate's design depends on type of attachment.
S/N = Serial number for machine

H = Lifting height
D = Centre of gravity distance
Q = Lift capacity
C= Centre of gravity's height. Distance from the forks up to the
load's vertical centre of gravity
The plate can only be ordered with data filled-in for the specific
machine.
4. Type plate for mounted attachment (example), A54854
S/N = Serial number for the attachment / Year of manufacture
H = Maximum hydraulic pressure to attachment
Q = Maximal load
013978
D = Approved centre of gravity distance from front edge

fork/attachment for maximum load
COG = Centre of gravity distance for attachment's own weight
(without load)
LLC = Lost load distance due to attachment
W = Attachment's own weight (without load)
5. Plate for certified sound level (example), A54572
LWA (external) = Total sound intensity at machine.
Legal requirements within EU/EEA.
011937

Warning and information plates

The following figures show the warning texts and information texts
that are located on the machine. The operator must be aware of the
warnings and should also follow the instructions and information given
on the plates.
Make sure warning and information symbols on the machine and its
components are always easy to see and are legible. Plates that have
been damaged, illegible or painted over must be replaced immediately.
5
1 1
3
1 10 10
1
9 6 2
018969
7 8 4 3 7 7
Frame, cab
Frame, cab
1. Lift point, 423049.0100
Attaching point for lift device when lifting of machines. There are
lifting points on:
• mast
000276
• rear
2. Warning! A26939.0100
Warning! Read the operator's manual for information.
000277

3. Warning! A54527.0200
Air conditioning. Filling of refrigerant requires special competence
and authorisation (follow national legislation and local rules).
1 = Refrigerant, type
2 = Amount, kg
3 = Pressure, bar
The plate is also on the condenser, compressor and at the air inlet
1 (front edge of cab) as plate A30770.0200.
2
3
014532
4. Warning! A30531.0200
Risk of crushing.
005225
5. Warning! A30533.0300
Risk of crushing.
015460
6. Plate for non-ionising radiation, A57336.0100 .

Must be fitted on machines equipped with two-way radio or other
form of customised optional equipment in the cab that may emit
non-ionising radiation. The sign can be ordered from Cargotec if
necessary.
012968
7. Transport lock A38769.0100.

Fastening point for machine transport lock.
016612
8. Cab tilting 307900.0700

012843

Safety
Safety
9. Warning! A32442.0100
Do not jump. Always stay in the machine when there is a risk of
roll-over and hold on to the steering wheel.
000284
10. Fire extinguisher, A43461.0100
Specifies where extinguishing is to be performed in the event of
a fire in the engine compartment. The nozzle for extinguishing is
pushed through the sign.
001833
A43461.0100
15
018970
16 13 14 16 16 12 11 14 13 16
Engine
Engine
11. Filling point, fuel, 450202.0100
D
000286
450202.0100
12. Filling point, AdBlue (filler cap)

016976
13. Warning! A30530.0200

Rotating fan.
008149
A30530.0200

14. Warning! A30532.0200

Hot surfaces.
000850
15. Warning! Filling point, coolant, A57775.0100
Use only ready-mixed recommended coolant.
013692
Power transmission, wheels
Power transmission, wheels

16. Inflation pressure, factory-fitted tyres
A32049.0100 1.0 MPa
000290
NOTE
Read chapter 6 Inspection and maintenance regarding safety when
handling wheels.
The conditions for inflation pressure change if factory-fitted tyres
are replaced with another tyre brand! Contact Cargotec. The
plate for tyre air pressure must be replaced with a plate with the
applicable tyre pressure!
20 20
018971
17 19 21 18 21
Hydraulic system
Hydraulic system
17. Filling point hydraulic oil, 450203.0100
000292

18. Warning! A36163.0100

Pressure. Always release the pressure from the accumulator
before working on the hydraulic system.
002497
19. Hydraulic pressure, A54518
Indication of the machine's set pressures. The figures are
engraved.
019038
Lifting mast and attachment
Lifting mast and attachment

20. Warning! A30771.0100
Do not walk under the load, attachment or forks. Do not stand
on the forks.
DANGER
Forks or other attachments are work tools that
handle large loads.
Extreme hazard to personal health and risk of
property damage!
Make sure that no persons stand or walk
under a raised work attachment, regardless of
000858
whether it is loaded or not.
Electrical system
21. Fuses, A61553.0400 (electronic box frame) and A60777.0100
(electronic box cab).
The machines fuses are shown here, see Fuses for electrical
system, general, page 236.

4 Instruments and controls 33
4 Instruments and controls

General
Do not operate the machine before you know the position and function
of instruments and controls, and completely understand how they are
used!
This chapter gives general information about instruments, switches,

controls and other equipment in the machine's cab.
NOTE
Thoroughly read the following chapter about instruments and
controls.

34 4 Instruments and controls – Instruments and controls
Cab overview
1 2 3 4 5
015213
13 12 11 10 9 8
1. Travel direction selector and parking brake
2. Multi-function lever
3. Steering wheel
4. Steering wheel panel
5. Display with function keys
6. Right-hand dashboard panel, front section
7. Right-hand dashboard panel, centre section
Right-hand dashboard panel with joystick, centre section
8. Right-hand dashboard panel, rear section
9. Arm rest and storage box
10. Driver's seat
11. Accelerator
12. Brake pedals
13. Joystick or mini steering wheel
Rear cab section, see Rear cab section, page 37.

4 Instruments and controls – Instruments and controls 35
Steering wheel panel

14. Ignition key lock
14
21 22 23 30 16 17 15. Engine start and stop button
16. Indicator light, parking brake
17. Indicator light, high beams
18
18. Indicator light for active error codes
24 19
19. Indicator light for direction indicators
25 20 20. Warning lamp, by-pass of safety system
21. Switch for combined windscreen wiper, windscreen/roof window,
26 continuous
Switch for windscreen wiper, windscreen, continuous
012692
27 28 29 32 31 33 15 22. Switch for combined windscreen wiper, windscreen/roof window,
intermittent wiping
Switch for windscreen wiper, windscreen, intermittent wiping
23. Switch for windscreen flusher
24. Switch for windscreen wiper, roof, intermittent wiping
25. Switch, windscreen wiper roof, continuous
26. Switch, windscreen wiper rear, continuous
27. Switch for windscreen wiper, rear, intermittent wiping
28. Light sensor
29. Switch for inching
30. Switch for manual shifting up
31. Switch for manual shifting down
32. Switch for automatic shifting
33. Travel direction indicator, Forward Neutral Reverse
Right-hand dashboard panel, front section
34 35 36 37 38 39 40 34. Control breaker

43
35. Switch for pause heater
36. Recirculation switch
37. Switch for defroster
38. Switch for reduced fan speed
41 42 44 45 46 39. Switch for automatic regulation of air conditioning

40. Switch for increased fan speed
41. Switch for increased temperature
42. Switch for reduced temperature
012693
43. Switch for cooling

47 48 49 50 51 52 44. Switch for air distribution, to the floor
45. Switch for air distribution, to the operator
46. Switch for air distribution, to the roof
47. Switch for by-pass of safety system
48. Switch for heated rear view mirror
Switch for heated rear windscreen
49. Control lever for electrically-operated mirrors
50. Switch for mirrors cab/machine
51. Switch preventing regeneration of the engine's after-treatment
system (applies to Cummins QSB6.7 Stage 4/Tier 4f)
52. Switch for audio off (radio)

Right-hand control panel, centre section
Right-hand control panel, centre section
53 e 53
d
c
b a
a b 62 54 55 56 57
f c
d
k
j
i
h
g
60
58 59
56 57 58 59 60 61
015321
62 55
54
e
Right-hand dashboard panel, centre section
a. Control for lifting/lowering f
b. Control for tilt
016423
c. Control for side shift
d. Control for spreading
e. Control for levelling Right-hand dashboard panel, centre section with joystick
f. Travel direction selector, Forward - Neutral - a. Control for side shift/spreading
Reverse
b. Travel direction selector, Forward - Neutral - Reverse
g. Switch to open the twistlocks
c. Spare
h. Switch for tilt control
d. Spare
i. Spare
e. Switch to open the twistlocks
j. Spare
f. Switch for alternative function "shift button"
k. Spare
53. Control for load handling

54. For machine with control levers (linear levers):
Switch for twistlocks, automatic/manual
55. Spare
56. Spare
57. Spare
58. For machine with control lever (joystick):
Switch for twistlocks, automatic/manual
59. Switch, hydraulic lateral sliding cab
60. Switch to rotate the operator's station
61. Spare
62. Switch for horn

4 Instruments and controls – Instruments and controls 37
Right-hand control panel, rear section
Right-hand control panel, rear section
63 64 65 66 67 68 69 70 71 63. Switch for work lights on cab

64. Switch for work lights on mast
65. Switch for extra work lights
66. Switch for extra work lights on cab
67. Switch for back-up light
68. Switch for length adjustment of the right-hand control panel
69. Switch for height adjustment of steering wheel
72 73 74 75
70. Switch for height adjustment of the right-hand control panel
71. Function keys and navigation wheel for control system
72. Switch for headlights
10:23
0
10
rpm x 100
20
30
73. Switch, interior lighting
74. Switch, revolving beacon
21°
1
385 9999
km/h
km/h
75. Switch for flashing hazard lights
016430
71
Right-hand dashboard panel, rear section and display
Rear cab section
Rear cab section

76. Compartment for the operator's manual
77
The operator's manual may also be located in a pocket on the
rear of the driver's seat.
77. Electronic box with fuses and relays
76
016431
Rear cab section

Roof panel
Roof panel
78 79 80 81 82 78. Light sensor

79. Not used
016432
80. Indicator light for locked twistlocks

81. Indicator light, contact
Roof panel 82. Indicator light for unlocked twistlocks

Roof panel
Roof panel
78 83 84 85 86 83. Indicator light for extra function

84. Indicator light for clamp 1
016669
85. Indicator light for tilt control
86. Indicator light for clamp 2
Roof panel
Control for load handling
For more controls for load handling and their functions, see Operator's
manual section 4.6 Load handling.

4 Instruments and controls – Warning and indicator lights 39
4.1 Warning and indicator lights

General
This section describes the warning lamps and indicator lights in the
cab. They indicate the status of subsystems/systems. An illuminated
warning lamp should be attended to immediately. An illuminated
indicator light informs of imminent action.
Warning lamps and indicator lights are grouped in the steering wheel
panel. The brightness of the lamps is adjusted according to the
ambient lighting conditions. All lamps light up briefly when the ignition
is switched on .
Numbers in brackets refer to the positions in Cab overview, page 34.
Indicator light, parking brake (16)

The light (red) is activated when the parking brake is applied.
If the indicator light flashes, the parking brake has been applied
000311
automatically (not by the operator) when the machine has stopped,

or released by the operator without the service brake pedal being
depressed.
The service brake pedal must be pressed down and the lever moved to
the released position to release the parking brake, provided that the
brake system is adequately pressurised.
To activate the parking brake it is sufficient to move the lever to the

position for applying the parking brake.
The service brake must be activated when the parking brake is

released otherwise the indicator light for the parking brake flashes
(position 16) and the event menu is displayed, see Event menu release
the parking brake, description, page 86.
Indicator light, high beams (17)

The light (blue) is activated when the high beams are on.
000309
Indicator light for active error codes (18)

The indicator light (orange) shows that the control system has one or
more active error codes.
000299
Indicator light, direction indicators (19)

The lamp (green) flashes when the direction indicators or hazard lights
are on.
000310

40 4 Instruments and controls – Warning and indicator lights
Warning lamp, by-pass of safety system (20)

The warning light (orange) shows the by-pass of safety functions.
NOTE
000300
By-pass takes place as long as the switch for by-pass of safety
system (position 47) is activated.
Travel direction indicator, Forward Neutral

Reverse (33)
Travel direction indicator for F (Forward), N (Neutral) or R (Reverse)
is activated to indicate the selected direction.
000403
Indicator light for locked twistlocks (80)

The indicator light (green) is activated when the twistlocks are locked
and with that the load.
000312
Indicator light, contact (81)

The indicator light (orange) is activated when the attachment has
contact with the load.
012697
Indicator light for unlocked twistlocks (82)

The indicator light (red) is illuminated when the twistlocks are unlocked
and release the load.
000314
Indicator light for extra function (83)
Indicator light (green) for extra function.

016670
Indicator light for clamp 1 (indicator light for extra

function (84))
Indicator light (red) is illuminated when the clamping pressure on clamp

1 is reached.
016671

4 Instruments and controls – Warning and indicator lights 41
Indicator light for tilt control (indicator light for

extra function (85))
The indicator light (yellow) shows the status of the tilt control (automatic
tilt system). Tilt control is activated/deactivated with the switch on the
016672
linear lever for the tilt function.
Tilt control status is shown in accordance with:

• The light flashes. The mast's vertical position is being adjusted.
• The light comes on with a constant light. The mast is in the vertical
position.
• The light has gone out. Tilt control is not active.
Indicator light for clamp 2 (indicator light for extra

function (86))
Indicator light (green) is illuminated when the clamping pressure on

clamp 2 is reached.
016671

42 4 Instruments and controls – Ignition key lock and start and stop button for the engine
4.2 Ignition key lock and start and

stop button for the engine
General
This section describes starting and stopping the engine.
Ignition key lock function
0 0 Ignition voltage and drivetrain are switched off, the key can
be removed.
Voltage to certain functions such as interior lighting, pause
I heater, alcolock and standby voltage control units.
14 I Ignition voltage switched on and drivetrain activated for
starting.
016968
14. Ignition
Start and stop button's function

The start button is used to engage the starter and is held down until
the engine starts. The ignition must be in the I position in order for
the start button to work. The engine can also be stopped by holding
the button down for one second.
NOTE
The machine is equipped with an electric restart interlock, which
prevents engagement of the starter motor when the engine is
rotating.
Conditions for the starter motor to engage are that the transmission
is in neutral position and that the engine is not already running.
012816
15
15. Start button

4 Instruments and controls – Ignition key lock and start and stop button for the engine 43
Alcolock function
The machine may be equipped with an alcolock. In order to start the

machine the operator must blow into the alcolock, which then measures
the alcohol content in the breath. A successful breath test permits
the machine to be started.
For information about handling statistics, maintenance, etc., see the

manufacturer's instructions.
016631
Alcolock

44 4 Instruments and controls – Switches
4.3 Switches
General
This section describes the switches in the cab. Each switch controls
a function.
The switches on the panels have white pilot lights that change to
a green or red function light when the function is activated. The
brightness of the switches is adjusted according to the ambient lighting
conditions. All function lights in the switches light up briefly when the
ignition is switched on. Only the functions that are available on the
machine will display a white pilot light followed by a function light.
A white light in a switch indicates a function that can be activated.

The switch changes colour when a function is activated. When the
colour has changed to green, this indicates that the function has been
switched on.
Switch for combined windscreen wiper,

windscreen/roof window, continuous (21)
Switch (green) for combined windscreen wiper on the front
windscreen/roof window. Continuous wiping. Wiping stops when the
operator leaves the seat. Reactivated when the operator sits in the
012705
driver's seat.
Wiping windscreen/roof window activated/deactivated with the press

of a button.
The switch is connected in parallel with the Switch, windscreen wiper

roof, continuous (position 25).
NOTE
Do not use the wipers on dry or dirty windscreens without first
activating the windscreen washers. The roof window is especially
sensitive to scratching and can be damaged by dry wiping.
Switch for windscreen wiper, windscreen,

continuous (21)
Switch (green) for the windscreen wiper on the front windscreen.

Continuous wiping. Wiping stops when the operator leaves the seat.
Reactivated when the operator sits in the driver's seat.
012705
Wiping windscreen is activated/deactivated with the press of a button.
NOTE

4 Instruments and controls – Switches 45
Switch for combined windscreen wiper,

windscreen/roof window, intermittent (22)
Switch (green) for combined windscreen wiper on the front
windscreen/roof window. Intermittent wiping. Wiping stops when the
operator leaves the seat. Reactivated when the operator sits in the
012706
driver's seat.
Intermittent wiping windscreen/roof window activated/deactivated with

the press of a button.
The event menu appears when intermittent wiper mode is activated,

see Event menu intermittent wiper, description, page 88.
Two time intervals can be selected:

• Short interval - one press of the button.
• Long interval - a further press of the button.
• Switch off - a further press of the button.
The switch is connected in parallel with the Switch, windscreen wiper

roof, intermittent (position 24).
NOTE
Switch for windscreen wiper, windscreen,

intermittent (22)
Switch (green) for the windscreen wiper on the front windscreen.

Intermittent wiping. Wiping stops when the operator leaves the seat.
Reactivated when the operator sits in the driver's seat.
012706
Intermittent wiping windscreen is activated/deactivated with the press

of a button.


NOTE

Switch for windscreen flusher (23)

Switch (green) for washing the screens. Washing occurs in the screens
where the wiper is activated.
012707
Pressing the button when no wipers are activated activates the front
wipers or the combined wipers on the front windscreen/roof window
and washing on each screen.
If the machine is equipped with a turnable operator's station then the

wiper on the rear window is activated when the driver's seat is in the
reversed position .
Wiping temporarily changes over to continuous wiping with window

flushing.
Windscreen washing is active as long as the button is pressed down.
Event menu appears with a low washer fluid level, see Event menu low
washer fluid level, description, page 85.
NOTE
Switch, windscreen wiper roof, interval (24)
Switch (green) for windscreen wiper on roof window. Intermittent

wiping. Wiping stops when the operator leaves the seat. Reactivated
when the operator sits in the driver's seat.
012715
Intermittent wiping is activated/deactivated with the press of a button.


The switch is connected in parallel with the Switch for combined

windscreen wipers front windscreen/roof window, intermittent (22).
NOTE

Switch, windscreen wiper roof, continuous (25)
Switch (green) for windscreen wiper on roof window. Continuous

012714
Wiping is activated/deactivated with the press of a button.
The switch is connected in parallel with the Switch for combined
windscreen wipers front windscreen/roof window, continuous (21).
NOTE
Switch, windscreen wiper rear, continuous (26)

Switch (green) for windscreen wiper on rear window. Continuous
012713
Wiping is activated/deactivated with the press of a button.
NOTE
Switch, windscreen wiper rear, interval (27)

Switch (green) for windscreen wiper on rear window. Intermittent
012712
Intermittent wiping is activated/deactivated with the press of a button.

NOTE
Switch for inching (29)

Switch (green) for activating inching.
Inching is activated/deactivated with the press of a button.
012711
Switch for manual shifting up (30)

Switch (green) to shift up one gear. Shifting up takes place from
the current gear. If automatic shifting is selected, it is automatically
switched off if the switch for manual shifting up or down is activated.
012708
At the same time the switch colour for manual shifting up and down
goes from white to green.
The current gear is shown in the operating menu.

Switch for manual shifting down (31)

Switch (green) to choose to shift down one gear. Shifting down takes
place from the current gear. If automatic shifting is selected, it is
automatically switched off if the switch for manual shifting up or down
012709
is activated. At the same time the switch colour for manual shifting up
and down goes from white to green.
Downshift is activated with the press of a button. Manual shifting is

activated.
The current gear is shown in the operating menu.
Switch for automatic shifting (32)

Switch (green) for selecting automatic shifting.
Automatic shifting is activated by pressing a button. Feature automatic

012710
shifting is disabled if the switch for manual shifting up or shifting down

is activated.
Switch for pause heater (35)
Switch (green) for pause heater. The cab fan emits heat from the
012716
engine's cooling system during short-term parking of the machine.
Instructions for use:

a. Park the machine. Let the engine idle.
b. Set desired temperature (position 41, 42).
c. Press in the switch for pause heater (position 35).
d. Switch off the ignition with the ignition key lock.
The pause heater is now activated and strives to maintain preset
temperature for the cab.
If the cab temperature drops down to the set temperature, or pause
heater has been running for the preset time, the pause heater
stops running when the engine's cooling system can no longer
deliver the heat needed.
NOTE
The higher the preset cab temperature, the shorter the operating
time for the pause heater.
Recirculation switch (36)

Recirculation switch (green) If this function is activated, air circulates
inside the compartment without fresh air being taken from outside and
is used to prevent bad air, or unpleasant odours from entering the cab.
012717
Recirculation is activated/deactivated with the press of a button.
Switch for defroster (37)

The switch (green) for the defroster can be used to quickly demist the
windscreens. When the defroster is activated the function controls fan,
temperature and damper position.
012718
The defroster is activated/deactivated by pressing a button or with any

of the other switches for the system. The defroster function switches
off automatically.

Switch for reduced fan speed (38)

Switch (green) to lower fan speed in the cab. When the fan speed
is controlled with the switch the automatic fan control is disengaged.
The automatic function is reactivated with the switch for automatic
regulation of air conditioning (position 39).
012719
Reduced fan speed is activated with the press of a button.
The fan speed is displayed in the operating menu.
The event menu appears when the fan speed drops, see Event menu
raise/lower fan speed, description, page 87.
Switch for automatic regulation of air conditioning

(39)
Switch (green) for automatic fan speed control, temperature control
and air distribution in the cab. With AUTO mode enabled, the control
system attempts to maintain the temperature set on the display. Fan
012720
speed, temperature control and air distribution in the cab take place
automatically.
Automatic regulation is reactivated with the press of a button if manual

control is selected with the buttons for air distribution or fan speed.
Temperature setting and fan speed are shown in the operating menu.
Switch for increased fan speed (40)

Switch (green) to increase the fan speed in the cab. When the
fan speed is controlled with the switch the automatic fan control is
disengaged. The automatic function is reactivated with the switch for
automatic regulation of air conditioning (position 39).
012721
Increased fan speed is activated with the press of a button.
The fan speed is displayed in the operating menu.
The event menu appears when the fan speed increases, see Event
menu raise/lower fan speed, description, page 87.
Switch for increased temperature (41)

Switch (red) to increase the cab temperature. Setting takes place in
steps of 0.5 °C.
012723
Temperature increase is activated with the press of a button.
The temperature range is 16 °C to 28 °C. Setting of max. temperature

switches off automatic climate control (control of fan, heat and air
distribution) and sets the heat valve in the max. position.
If necessary, cab air is cooled or heated to the set temperature.
Desired cab temperature is displayed in the operating menu.
The event menu appears when the cab temperature is increased,

Event menu raise/lower cab temperature, description, page 87.

Switch for reduced temperature (42)

Switch (blue) to decrease the cab temperature. Setting takes place in
steps of 0.5 °C.
012722
Temperature decrease is activated with the press of a button.
The temperature range is 16 °C to 28 °C. Setting of min. temperature

switches off automatic climate control (control of fan, heat and air
distribution) and sets the heat valve in the min. position.
If necessary, cab air is cooled or heated to the set temperature.
Desired cab temperature is displayed in the operating menu.
The event menu appears when the cab temperature is decreased,

Event menu raise/lower cab temperature, description, page 87.
Switch for cooling (43)
Cooling function switch (green).

012727
Cooling is activated/deactivated with the press of a button.
The system's cooling function does not start if the fan is switched off or
if the doors are open. The fan stops after a short period if the doors are
opened. If the doors are not closed after a further short period then the
cooling compressor will also be switched off.
Switch for air distribution, to the floor (44)

Switch (green) for air distribution, to the floor. When the air distribution
is controlled with the switch the automatic air distribution is disengaged.
012724
Air distribution toward the floor is activated/deactivated by pressing a

button. The air distribution can be combined toward the floor, operator
and roof.
Switch for air distribution to the operator (45)

Switch (green) for air distribution to the operator. When the air
distribution is controlled with the switch the automatic air distribution is
disengaged. The automatic function is reactivated with the switch for
012725
automatic regulation of air conditioning (position 39).
Air distribution to the operator is activated/deactivated with a press

of the button. The air distribution can be combined toward the floor,
operator and roof.
Switch for air distribution to the roof (46)

Switch (green) for air distribution to the roof. When the air distribution is
controlled with the switch the automatic air distribution is disengaged.
012726
Air distribution toward the roof is activated/deactivated by pressing a

button. The air distribution can be combined toward the floor, operator
and roof.

Switch for by-pass of safety system (47)

Bypassing the machine's safety features. Rocker switch.
The operator may, if the situation so requires, disconnect all safety
012733
features on the machine.
0 1
Position 0 provides normal function.
Position 1 provides the option to:

• to lock or open twistlocks without contact.
• length adjust the attachment with locked twistlocks.
• lift, without indication of locked or open twistlocks.
• Selection of travel direction without the sensor in the driver’s seat
indicating that someone is sitting in the seat, speed is limited to
10 km/h.
(The machine adopts neutral position when no one is sitting in
the driver’s seat.)
• Release of the parking brake in the event of a fault in the parking
brake or without the sensor in the driver’s seat indicating that
someone is sitting in the seat.
• Use of load handling functions at reduced speed without the sensor
in the driver’s seat indicating that someone is sitting in the seat.
• rotate the operator's station without all conditions being met.
• use load handling functions when the turnable operator's station
is not in the permitted position.
• drive the machine with the speed limitation 5 km/h when the
turnable operator's station e.g. is not in the permitted position.
Warning lamp for by-pass (position 20), shows when the by-pass of
safety features is activated.
WARNING
Safety features are blocked.
No safety system is engaged!
Only use bypass in emergency situations!
WARNING
By-pass of load handling functions must not be used
during normal load handling.
damage.
Only use the bypass in emergency situations.

Switch for electrically heated rear view mirrors

(48)
Switch (green) for electrically heated rear view mirrors. Rocker switch.
012792
0 1 Position 0 – Function for electrically heated rear view mirrors
deactivated.
Position 1 - The function electrically-heated rear view mirrors is

activated for a preset time.
If both the machine and cab are equipped with electrically heated
mirrors all of these are activated with the same switches.
If the cab is equipped with electrically heated mirrors and screens the
functions are activated with the same switches.
The event menu appears when the electrically heated mirrors

are activated and deactivated, see Event menu heating rear view
mirrors/rear windscreen, description, page 87.
Switch for electrically heated rear windscreen (48)
Switch (green) for electrically heated rear windscreen. Rocker switch.

012792
0 1 Position 0 – The function for rear windscreen heating is deactivated.
Position 1 - The function electrically-heated rear windscreen is

activated for a preset time.
If the cab is equipped with electrically heated mirrors and screens the
functions are activated with the same switches.
The event menu appears when the electrically heated rear windscreen
is activated and deactivated, see Event menu heating rear view
mirrors/rear windscreen, description, page 87.
Control lever for electrically-operated mirrors (49)
RO R
MIR R Control lever for setting the machine's mirrors.
L
Select left (L) or right (R) mirrors using the control lever.
Set the mirror with the help of the control lever.
Set the control lever in the centre position again to avoid unwanted
adjustment of the rear view mirrors.
015219
Switch for mirrors cab/machine (50)
Switch (green) to select if the mirrors on the cab or the machine should
be controlled by the control lever for electrically-operated mirrors.
013656
Position 0 – Control of mirrors on the cab.

0 1
Position 1 – Control of mirrors on the machine.

Switch for preventing regeneration of the engine's

after-treatment system (51)
Applies to Cummins QSB6.7 Stage 4/Tier 4f.
The switch (green) prevents regeneration of the engine's after-treatment
system.
015210
Position 0 – The regeneration function for the engine's after-treatment
0 1 system is activated with automatic control via the engine control unit.
Position 1 – The regeneration function for the engine's after-treatment
system is deactivated. If regeneration is in progress, the engine control
unit will stop the process, and it is started once all conditions are again
fulfilled and the switch is in position 0.
The event menu is shown when regeneration of the engine's
after-treatment system is deactivated, see Deactivated regeneration of
the engine's after-treatment system, description, page 86.
NOTE
The function must only be used temporarily if the situation
so requires. Prolonged driving without regeneration of the
after-treatment system may result in the system needing to be
sent away for overhaul at an authorised service centre leading to
downtime, this is in accordance with the engine manufacturer's
instructions.
Switch for audio off (radio) (52)
Switch (green) for audio off in the cab, e.g. dampening of the radio
012731
volume.
0 1
Position 0 – Function audio off is deactivated.
Position 1 – Function audio off is activated.
Switch for twistlocks, automatic/manual locking

(54)
See Switch for twistlocks, automatic/manual locking (58), page 53.
Switch for twistlocks, automatic/manual locking

(58)
Switch (green) for locking the twistlocks. The switch is spring-loaded in
position 2.
Position 1 - Twistlocks are locked automatically when there is contact
015587
1 0 2 with the load. The parking brake must be OFF, see position 1 and
indicator light for parking brake, position 16.
Position 0 - Locking of twistlocks not activated.
Position 2 - Twistlocks are locked manually. Button spring-returns.
See Instructions for top lift attachment, page 184.
Switch for hydraulic lateral sliding cab (59)
Switch (green) for cab movement.

012793
1 0 2 Position 0 - Rest position.

Position 1 – Cab to right.
Position 2 – Cab to left.

Switch to rotate the operator's station (60)
Switch (green) to rotate the operator's station Rocker switch.

Position 0 - Rest position.
012788
1 0 2 Position 1 - Rotate to the right (forward).
Position 2 – Rotate to the left (backward).
Switch for horn (62)
012790
Switch for horn. Rocker switch.
Switch for horn in right-hand dashboard panel

016330
Switch for horn in joystick
Switch for work lights on cab (63)
Switch (green) for work lights on cab.

012760
Work lights on the cab are activated/deactivated with the press of a

button.
Switch for work lights on mast (64)

Switch (green) for work lights on mast.
Work lights on the mast are activated/deactivated with the press of a
012762
button.
Switch for extra work lights (65)
Switch (green) for extra work lights on the fender or between the masts.
012763
Extra work lights are activated/deactivated with the press of a button.
Switch for extra work lights on cab (66)
Switch (green) for extra work lights on cab.

012764
Extra work lights on the cab are activated/deactivated with the press
of a button.
Switch for back-up light (67)

Switch (green) for back-up light.
Back-up light is activated/deactivated by pressing the button when
012765
travel direction reverse is selected. The function of the back-up lights

is reset after ignition off/on to be switched on when travel direction
reverse is selected.

Switch for length adjustment of the right-hand

control panel (68)
Switch (white) for length adjustment of the right-hand control panel.
Length adjustment is activated with the press of a button.
012766
Switch for height adjustment of steering wheel
(69)
Switch (white) for height adjustment of steering wheel.
Height adjustment is activated with the press of a button.

012768
Switch for height adjustment of the right-hand

control panel (70)
Switch (white) for height adjustment of the right-hand control panel.
Height adjustment is activated with the press of a button.

012767
Function keys and navigation wheel for control

system (71)
Function keys and navigation wheel for control system, see 4.11
Control system, page 75.
017965
Switch for headlights (72)

Switch (green) for headlights. Also activates the tail lights.
The headlights are activated/deactivated with the press of a button.

012771

Switch, interior lighting (73)

Switch (green) for interior lighting in cab.
The lighting is activated/deactivated with the press of a button.
012772
Switch for revolving beacon (74)
Switch (green) for revolving beacon used to attract attention in
012773
connection with hazards.
The revolving beacon is activated/deactivated with the press of a

button.
Switch for flashing hazard lights (75)

Switch (red) for flashing hazard lights used to attract attention in
connection with parking hazard.
012774
The warning beacon is activated/deactivated with the press of a button.

4 Instruments and controls – Travel direction selector and parking brake 57
4.4 Travel direction selector and

parking brake
General
This section describes the travel direction selector (position 1) that is
used to choose the direction and for the parking brake.
1
015215
1. Travel direction selector on steering column
Selecting direction of travel

Travel direction is selected with the travel direction selector on:
F P • steering column
• control lever, see Linear levers (up to 5 levers), page 62
• mini-wheel, see Mini-wheel, page 68
• joystick control, see Joystick control, page 69
N The lever is spring-loaded and the selected direction of travel is shown
on the steering wheel panel.
The current gear is shown on the display.
Selecting direction of travel:

• F - Forward. Move the lever forward for forward drive.
015430
R • N - Neutral. Neutral. Move the lever up or down for neutral.

• R - Reverse. Move the lever backward for reverse drive. (Acoustic
Travel direction selector on steering column warning signal )
Manual up and down shifting is performed using the switches for

manual shifting up (position 30) and manual shifting down (position 31).
Selection of automatic shifting is done with the switch for automatic
shifting (position 32).

58 4 Instruments and controls – Travel direction selector and parking brake
Parking brake
Activation of the parking brake is performed with the travel direction
F P selector. Lift the control upward toward the steering wheel and then
move it forward to the parking braking position. The parking brake
indicator light shows when the parking brake is activated, see Indicator
light, parking brake (16), page 39.
Deactivate the parking brake by pressing down the service brake pedal
N and then move the travel direction selector from the parking position
to neutral/gear position. The event menu appears when you try to
release the parking brake without the service brake being pressed
down or when the brake pressure is too low, see Event menu release
the parking brake, description, page 86.
015430
R DANGER
or extreme danger!

4 Instruments and controls – Multi-function lever 59
4.5 Multi-function lever

General
This section describes the functions of the multi-function lever (position
2 2).
015221
Light control
With headlights on: The multi-function lever is used to switch between
high and low beam. Move the control upward to switch between full
and low beam.
015433
With headlights off: The multi-function lever is used as a headlamp

flasher. Move the control upward for high beam flash, return is
automatic.
On machines with high and low beam, the multi-function lever is

used for changing between high and low beam. Move the control
upward to switch between full and low beam.
Horn
Move the lever inwards towards the steering wheel for horn.
015431
Direction indicators
Move the lever backward or forward to indicate left and right travel
indication respectively.
015432

60 4 Instruments and controls – Load handling
4.6 Load handling

General
This section describes the functions of the control for load handling
(position 53). The control governs functions for handling the forks
and other attachments. Some hydraulic functions are controlled by
switches, see 4.3 Switches, page 44.
It is possible to vary the speed of the different hydraulic functions, i.e.

lift, tilt, etc., by varying the extent of the lever deflection. It is also
possible to vary the speed of the hydraulic functions with the engine
speed (rpm).
WARNING
In an emergency! In the event of undesired
activation/movement of a function.
Risk of personal injury and/or property damage!
IMMEDIATELY TURN OFF all working hydraulics by
pressing the CONTROL BREAKER for hydraulics.
NOTE
The operator must sit in the driver's seat in order for the load
handling functions to work.
NOTE
Position of a control is need-adapted and may thus differ from this
section. See the plates on the machine.

4 Instruments and controls – Load handling 61
Right-hand control panel
A B The control panel to the right of the operator is adjustable in several

ways for optimum ergonomics.
1. Panel position is longitudinal.
Adjust the control panel to the desired position, see Switch for
length adjustment of the right-hand control panel (68), page 55.
2. Panel position is vertical.
Adjust the control panel to the desired position, see Switch for
height adjustment of the right-hand control panel (70), page 55.
016983
3. The angle of the rear section.
Pull the control (position A) upwards and adjust the panel manually
A. Control for adjusting the rear section to the desired position.
B. Control for adjusting the centre section 4. The angle of the centre section.
Pull the control (position B) upwards and adjust the panel manually
to the desired position.
5. The angle of the control lever's grip .
Contact service for adjustment of the control lever's angle.

62 4 Instruments and controls – Control for load handling
4.6.1 Control for load handling

Linear levers (up to 5 levers)
Fingertip-operated linear levers.
a. Lifting/lowering
LIFT - pull the lever backwards.
LOWER - push the lever forwards.
Lowering the speed can only be varied with lever deflection - the
engine speed has no effect.
b. Tilt
REVERSE - pull the lever backwards.
FORWARD - push the lever forwards.
Function for tilt control is deactivated in the event of lever
movement.
c. Side shift
34 a b c d e LEFT - push the lever forwards.
RIGHT - pull the lever backwards.
The forks cannot be side-shifted if fork spreading is at maximum.
d. Spreading (positioning)
OUTWARDS - push the lever forwards.
INWARDS - pull the lever backwards.
Positioning locks when one of the forks reaches the end position.
Side shift to the centre and spread again.
f k
j Fork spreading left fork
i
h FORK TO LEFT – push the lever forwards.
g FORK TO RIGHT - pull the lever backwards.
Spreading sidelift attachment
INCREASE SPREADING – move the lever forward.
DECREASE SPREADING – pull the lever backward.
For attachments that clamp in the load (e.g. paper handling
attachment)
OPEN ATTACHMENT - depress the switch fitted on the lever and
move the lever forward.
CLOSE ATTACHMENT - pull the lever backwards.
The function may be located on another lever.
018607
e. Levelling
FORK UP - pull the lever backwards.
FORK DOWN - push the lever forwards.
Levelling acts on the right or left fork.
Central levelling
CENTRAL LEVELLING ANTICLOCKWISE – push the lever
forward.
CENTRAL LEVELLING CLOCKWISE – pull the lever backward.
Fork spreading right fork
FORK TO LEFT - pull the lever backwards.
FORK TO RIGHT – push the lever forwards.

4 Instruments and controls – Control for load handling 63
f. Selecting direction of travel . The switch is spring-loaded, the

current gear is shown in the display and the selected direction of
travel is shown on the steering wheel panel.
Travel direction FORWARD – move the switch forward.
Travel direction NEUTRAL – move the switch up and down.
Travel direction REVERSE – move the switch backward.
g. Switch to open the twistlocks
Lower the attachment so that contact is obtained, and depress
the button to open twistlocks.
h. Switch for tilt control
Switch activates/deactivates tilt control.
i. Spare
j. Spare
k. Spare
34. Control breaker for hydraulics
Control lever
34
53
015960
34. Control breaker for hydraulics

53. Control lever

64 4 Instruments and controls – Control for load handling
62
53
e
a
f
016705
53 Lift, lower / Tilt in, tilt out [Levelling ] SPREADING OUT - move the upper thumb control
forward.
LIFT - pull the whole control lever backward.
SPREADING IN - move the upper thumb control
LOWER - move the whole control lever forward. backward.
Lowering the speed can only be varied with lever b. Selecting direction of travel .
deflection - the engine speed has no effect.
The control is spring-loaded, the current gear is shown in
TILT OUT - move the whole control lever to the right. the display and the selected direction of travel is shown
on the steering wheel panel.
TILT IN - move the whole control lever to the left.
Travel direction FORWARD - move the lower thumb
FORKS UPWARD - press in the shift-button control forward.
(position f) and move the whole control lever to the Travel direction NEUTRAL – move the lower thumb
right. control up or down.
FORKS DOWNWARD - press in the shift-button Travel direction REVERSE - move the lower thumb control
(position f) and move the whole control lever to the backward.
left.
c. Spare
CENTRAL LEVELLING ANTICLOCKWISE - press d. Spare
in the shift-button (position f) and move the whole
control lever to the left. e. Opening the twistlocks .
CENTRAL LEVELLING CLOCKWISE - press Lower the attachment so that contact is obtained, and
in the shift-button (position f) and move the whole depress the button to open twistlocks.
control lever to the right. f. Switch for alternative function "shift key" . The switch
changes the function of the other controls on the control
a. Side shift / Spreading lever.
SIDE SHIFT LEFT - move the upper thumb control 62. Switch for horn .
downward.
SIDE SHIFT RIGHT - move the upper thumb control
upward.

4 Instruments and controls – Pedals 65
4.7 Pedals
General
This section describes the machine's foot-operated functions.
NOTE
The default pedal height setting can be changed by adjusting the
angle of their console. The adjustment must be performed by a
service technician.
11
015214
12
The pedal system can be equipped with dual accelerator pedals where
the left brake pedal is replaced by an accelerator pedal for controlling
11. Accelerator the machine's drive backward while the right pedal regulates the
machine's drive forward.
12. Brake pedal
Accelerator (11)
The accelerator pedal (position 11) is electronic and controls the engine
speed via the CAN bus and the machine's control system.

66 4 Instruments and controls – Pedals
Brake pedals (12)

The brake pedals (position 12) are hydraulic and connected to the
machine's hydraulic system. The brake pedals are used for service
brake.
The accumulator stores energy so that there is brake pressure even if

the engine stops. The event menu appears if the accumulator pressure
drops too low, see Event menu low accumulator pressure, description,
page 80.
The brake function is available in different versions:

• Brake without inching
The service brake is combined with declutching and at a specific
brake pressure and a minimum engine speed the drive is
declutched completely. The brake pressure level and engine speed
are adjustable within specific maximum and minimum values and
adjustability is dependent on machine model, contact Cargotec
service if values need to be adjusted.
If the brake pedal is pressed down without declutching occurring,
the engine helps to slow down the machine provided that the
throttle is released.
• Brake with inching .
Switch (position 29) for inching.
012711

Inching is not activated.
The brakes are activated by the brake pedal. Declutching occurs
when the pedal is pressed down and a specific brake pressure and
minimum engine speed are reached. The pressure and speed are
dependent on machine model. The function can be adjusted and
declutching can be disabled via the display and settings.
Inching enabled.
Inching and braking are controlled with the brake pedal. When you
depress the pedal the drive starts to slip, i.e. inching. The system
is disengaged if overloaded. Ideally inching can be used when you
want a higher engine speed available during load handling.
If the brake pedal is pressed down more than half of the pedal
range the drive is completely declutched. This can vary depending
on the drivetrain.

4 Instruments and controls – Steering wheel 67
4.8 Steering wheel

General
This section describes controls for steering. The following alternatives
are available for steering the machine:
• adjustable steering wheel (position 3)
• joystick (position 13)
• mini steering wheel (position 13)
Steering wheel
Clockwise rotation of the steering wheel steers the machine to the
right, and vice versa.
The steering wheel's (position 3) inclination and height can be set to

the desired operating position.
1. Steering wheel angle in the longitudinal direction.
To adjust: Move the control on the steering column upward, angle
the steering wheel in the longitudinal direction and lock the control
when the steering wheel is in the desired position.
015216
2. Steering wheel angle in the lateral direction.

To adjust: To adjust: move the steering wheel's right-hand side
upward, angle the steering wheel sideways and lock the control
when the steering wheel is in the desired position.
3. Steering wheel's height.
To adjust: set the desired height with the Switch for height
adjustment of the steering wheel, see Switch for height adjustment
of steering wheel (69), page 55.
015217

68 4 Instruments and controls – Steering wheel
Mini-wheel
3 Mini-steering wheel control is an electro-hydraulic system, mounted in

the left arm rest, to steer the machine with an ergonomically designed
2 rotating plate. Clockwise rotation of the steering wheel steers the
machine to the right, and vice versa. The wheels always follow the
1 position of the mini-wheel. If the steering wheel is released, both the
4
mini-wheel and the wheels remain in the set position.
5 The standard steering wheel is equipped with sensors that detect any
steering wheel movement in an emergency situation. If the operator
starts to steer using the standard steering wheel, the mini steering
wheel is disengaged.
1. Direction indicators.
2. Mini-wheel.
The steering wheel's position on the arm rest is adjustable.
3. Switch for engaging the mini steering wheel.
Conditions: The speed must be below 3 km/h. If the speed
exceeds 3 km/h mini-wheel cannot be engaged.
6 NOTE
A sensor in the armrest mount on the driver's seat detects the
armrest angle. If the arm rest is angled upward, the mini steering
wheel function is deactivated at a certain angle and must be
activated again with the switch for engaging the mini steering wheel.
4. Travel direction selector F/N/R. The switch is spring-loaded, the

Travel direction NEUTRAL – move the switch up and down.
015422

5. With headlights switched off: The switch is used for the headlamp
flasher.
If the switch is held depressed for more than 2 seconds then the
windscreen and roof wipers are activated and make one sweep.
Machines with high and low beam and headlights switched on: The
switch is used to change between high and low beam.
6. Arm rest. Can be folded up to easily enter and leave the driver's
seat.

4 Instruments and controls – Steering wheel 69
Joystick control
1 2 3
4 Joystick control functions as the mini steering wheel, with the difference
that the mini steering wheel is replaced by a lever that is moved
left/right in order to steer the machine.
The standard steering wheel is equipped with sensors that detect any
steering wheel movement in an emergency situation. If the operator
starts to steer using the standard steering wheel, joystick steering is
5 disengaged.
1. Joystick.
2. Direction indicators.
3. Travel direction selector F/N/R. The switch is spring-loaded, the
016849
Travel direction NEUTRAL - move the switch right or left.
4. With headlights switched off: The switch is used for the headlamp
flasher.
If the switch is held depressed for more than 2 seconds then the
windscreen and roof wipers are activated and make one sweep.
Machines with high and low beam and headlights switched on: The
switch is used to change between high and low beam.
5. Switch for engaging the mini steering wheel.
Conditions: The speed must be below 3 km/h. If the speed
exceeds 3 km/h mini-wheel cannot be engaged.
NOTE
A sensor in the armrest mount on the driver's seat detects the
armrest angle. If the arm rest is angled upward, the mini steering
wheel function is deactivated at a certain angle and must be
activated again with the switch for engaging the mini steering wheel.

70 4 Instruments and controls – Steering wheel
Adjustment of the mini steering wheel/joystick

control
1. Adjusting the mini steering wheel longitudinally.
Adjust the mini steering wheel (position 1) to the desired position.
1
2. Adjusting the arm rest longitudinally.
To adjust: Loosen the knob (position 2) and adjust the arm rest to
the desired position. Lock the arm rest with the knob when the arm
rest is in the desired position.
015423
3. Height of the mini steering wheel/joystick control.

To adjust: Loosen the knob (position 3) and adjust the arm rest
to the desired position. Tighten the knob when the arm rest is in
the desired position.
4. Longitudinal angle of the mini steering wheel/joystick control.
To adjust: Loosen the Allen screw (position 4) and angle the
bracket for mini steering wheel/joystick control to the desired
position. Tighten the Allen screw when the bracket is in the desired
015424
position.
4
3
5. Sideways position of the mini steering wheel/joystick control.

To adjust: Loosen the Allen screw (position 5) and turn the arm
rest and bracket for the mini steering wheel/joystick control to the
desired position. Tighten the Allen screws when the armrest and
bracket are in the desired position.
015425

4 Instruments and controls – Driver's seat 71
4.9 Driver's seat

General
This section describes the driver's seat (position 10) in the cab.
Driver's seat
Standard seat
Standard seat
The driver's seat is equipped with several controls for adjustment as
11 follows (adjustment is easier when nobody is sitting in the seat):
1. Seat belt, 2-point.
Seat belt, 3-point .
2. Seat tilt.
3. Horizontal suspension (forward/backward) .
4. Seat length.
10 5. Height of seat.
Mechanical elevation of seat height:
1
9 Turn the knob clockwise or anticlockwise until desired height is
obtained.
Air suspension elevation of seat height: .
2
Lift the control up to increase seat height or alternatively press
8 the control down to reduce seat height. The suspension adapts
automatically to the bodyweight of the operator.
3 An indicator shows green when the correct height is reached. The
7 indicator turns red when the seat's suspension is set outside the
comfort mode.
4 6. Longitudinal adjustment.
Release the seat using the lever and move the seat forwards or
5 6 backwards.
7. Back rest angle.
Release the lock with the lever, set the desired tilt angle and
release the lever to lock in the desired position.
8. Adjusting arm rest, left .
9. Lower back (lumbar) support.
Turn knob until desired firmness in lumbar support is obtained.
10. Seat heating .
017255
11. Adjusting the head rest .

Driver's seat with adjustment possibilities

72 4 Instruments and controls – Driver's seat
Optional seat Grammer
Optional seat Grammer
The driver's seat is equipped with several setting controls, they have
the following functions:
1. Seat heating.
1
2. Upper lumbar support.
Press + or - until the required firmness in the lumbar support is
2 reached.
3. Lower lumbar support.
Press + or - until the required firmness in the lumbar support is
3 reached.
4. Back rest angle.
10 Release the lock with the lever, set the desired tilt angle and
4
9 5. Horizontal suspension (forward/backward).
Control forward = locked.
8
Control backward = suspension.
7 To lock the suspension, move the control forward and then press
the seat backward until a click is heard when the suspension locks.
018507
6 5 6. Longitudinal adjustment.
Release the seat with the lever, set the desired distance and
7. Height and angle of the seat
Angle setting: Set the vertical dampening (position 8) to the softest
position, sit on the seat, pull the control upward and release
directly. The suspension adapts automatically to the bodyweight.
Height control: Move the control upward to increase the seat
height or downward to lower the seat height.
8. Vertical dampening (up/down).
Control to the left = soft.
Control straight up = medium.
Control to the right = hard.
9. Seat length.
Release the length with the control, set the desired length and
release the control to lock in the desired position.
10. Seat tilt.
Release the tilt with the control, set the desired tilt and release the
control to lock in the desired position.
11. Seat belt, 2-point (not shown in the figure).
Seat belt, 3-point (not shown in the figure).

4 Instruments and controls – Heating / Air conditioning 73
4.10 Heating / Air conditioning

General information on air conditioning
This section describes function of:
38 39 40 43
• The heating system, EHC. EHC automatically regulates the fresh
air flow and air distribution in the cab and constantly strives toward
regulating the temperature to a selected temperature level. It
37 cannot cool the fresh air, but warms it if necessary to achieve the
selected temperature.
36 • Air conditioning, ECC. The ECC automatically regulates air flow
and air distribution in the cab and it constantly strives to regulate
35 the temperature to a selected comfort level by heating or cooling
the air in the cab to the selected temperature.
The heating/air conditioning system receives heat from the engine's

cooling system and provides heat when the engine is warm. Cooling
012820
41 42 44 45 46 performance is generated by the cooling compressor (for ECC).
Panel for heating and air conditioning (position 6) The system is controlled by fan, heat and air distribution as well as
function for recirculation and defroster:
• Automatic control of the fan speed, temperature control and air
distribution in the cab is activated by switch (position 39). With
AUTO mode enabled, the control system attempts to maintain
the temperature selected on the display. Both fan speed and
temperature control are automatic.
• Heat (and cooling performance for ECC) is controlled
with temperature switches (position 41, 42). Cooling is
activated/deactivated with the switch for cooling (position 43).
When adjusting the temperature the event menu appears on the
display, Event menu raise/lower cab temperature, description,
page 87.
• If necessary, the airflow can be adjusted manually with the switch
for the fan (position 38, 40). When adjusting the fan speed the
event menu appears on the display, Event menu raise/lower fan
speed, description, page 87.
• If necessary, the air distribution can be adjusted manually with the
switch for the air distribution (position 44, 45, 46). The fresh air
intake is equipped with a fine filter. Filter replacement is indicated
on the display by a filter monitor.
NOTE
Filter replacement is first indicated in the event of high fan capacity
use.
• If necessary, the recirculation of cab air can be activated/deactivated

with the switch for recirculation (position 36).
• Defroster for fast demisting of windows is activated/deactivated
with the switch for defroster (position 37). As there is no cooling
function on machines with EHC the dehumidification function may
be less effective.
• The pause heater is activated/deactivated with the pause heater
switch (position 35) .

74 4 Instruments and controls – Heating / Air conditioning
NOTE
Operator's door and windows shall be closed for satisfactory
function of the system.
For ECC: A short while after one of the doors is opened, the fan is
switched off. After an additional period the air conditioning system's
cooling compressor shuts off (cooling function and air- drying
015218
stops). Close the door and the cooling compressor and fan are
activated again. The function can be turned off via the machine's
settings in the service menus.
Fresh air inlet for cab The current settings for the heating/air conditioning system are shown
in the display.
For information on the switches, see 4.3 Switches, page 44.
For information on the display, see 4.11 Control system, page 75.

4 Instruments and controls – Control system 75
4.11 Control system

General
This section describes the control system (position 71) and the
information that can be obtained from the operating menus (position 5).
a
The machine is equipped with an electronic system for control and
monitoring of the machine's different functions.
The system gives the operator information in the form of:

• Error code information
10:23
0
10 20 Three levels of error code information can be shown. In the event
22
rpm x 100
of a new error code, error code information is shown over the
entire display. See 5.3 Error codes, page 96.
21° 18
99999
km/ h • Operating information
Pwr/ No r/ ECO Operating information includes, for example, machine speed,
engine rpm, fuel level, etc.
D U
• Event-controlled information
Event-controlled information is, e.g. contact and overload.
Information is presented on the display (position a). The function keys

(position c-e) are used to navigate the display menus and confirm
selections. Figures are stated with example data.
b c d e
The information in the display can be selected to show values with
c e metric (SI) or imperial (US) units, see Setting the unit, page 198.
018137
d
a. Display
b. Pop-up for button function
c. Enter/YES/Save
d. Navigate through menus/adjust values with the
wheel or buttons , , or
e. Exit/NO

76 4 Instruments and controls – Control system
Description
The loop for the operating menus is described in this section.
1
0:00pm 2
10 20
0 30
7 rpm x 1 0 0
2
0:00pm 0: 0 0 p m 2
0
21° 1899999
km / h 32.8 l/h 1756
9.5
r pm
km/ h
Pwr/ No r/ ECO 20.2 km/ h
26.1 l/h
16.7 t 74.8 km
0 D U
120:36 h 1 23 14432
0
6 3
0:00pm 0:00pm
- 1. 9 t 89° C 3. 3 b a r
74. 9 t
522. 9 t
5 4
0: 00pm 0: 00 pm
7 0° C
2 3 . 4V
5 0° C
018138
Example of operating menus 4. Transmission and hydraulics operating menu

1. Operating menu 5. Operating menu electrical system
2. Operating menu trip computer work shift 6. Operating menu extra functions, e.g. scales
3. Engine operating menu 7. Operating menu customer settings

4 Instruments and controls – Operating menus 77
4.11.1 Operating menus

Description
10:23 2 g After starting the machine the operating menu is displayed with engine
a
speed, speed, time, fuel level and information on the current setting for
b 0
10 20
22
h the heating or air conditioning system.
rpm x 100
c a. Time.
i
d
21° 18
99 9 9 9
km / h
k
j
b. Field for the four event menus with the highest priority and which
have status indicators. When there are only up to two event menus
with status indicators, status for heating or air conditioning is
shown in the lower part of the field.
e Pwr/ No r/ ECO
c. Fuel economy. The green field indicates economical driving while
1 6. 7 t l
017924
f D U the red field indicates uneconomical driving that consumes a lot
of fuel.
d. Speed in km/h.
e. Eco Drive Mode setting. Eco Drive Mode, page 165. Selected
mode has white text, the row is only shown on machines with Eco
Drive Mode.
f. Fuel level.
g. Current gear.
h. Engine speed.
i. Utilised load capacity, the bar shows load 0-100%.
j. Operating time in hours (h).
k. AdBlue level (only applies to specific engine alternatives).
l. Scales, current weight in tonnes or lbs (pounds).
4.11.1.1 Operating menu trip computer work shift

Operating menu trip computer work shift, description
2
Trip computer for work shift shows current work shift machine statistics
10:23
since last reset to zero.
a 1756 rpm
d a. Instantaneous fuel consumption in litres per hour.
32.8 l/h
9.5 km/h e b. Average fuel consumption, in litres per hour.
b 20.2 km/h f c. Estimated operating hours to empty tank in hours and minutes.
26.1 l/h
74.8 km g d. Current engine speed in revolutions per minute.
e. Current speed in km/h.
c h
120:36 h 1 23 14432 f. Average speed in km/h.
016367
g. Driving distance in kilometres.

h. Number of lifts.
Trip computer work shift is reset automatically if the machine has been
switched off for longer than two hours or manually with .
4.11.1.2 Engine operating menu

Engine operating menu, description
10:23
a. Shows current engine coolant temperature in °C or °F.
b. Shows current engine oil pressure in bar or psi.
a b
89° C 3.3 bar
014519

78 4 Instruments and controls – Operating menus
4.11.1.3 Transmission and hydraulics operating menu
Transmission and hydraulics operating menu,

description
10:23
a. Shows the current transmission oil temperature in °C or °F.
b. Shows the current hydraulic system oil temperature in °C or °F.
a
89° C
b
65° C
014520
4.11.1.4 Operating menu electrical system
Operating menu electrical system, description
10:23
a. Shows the current battery voltage in volts.
28.0V
014521
4.11.1.5 Operating menu scales
Operating menu scale, description
0:00pm
a. Displays the tare in tonnes or lbs (pounds).
b. Current weight in tonnes or lbs (pounds) (net weight).
-1. 9 t a c. Total weight in tonnes or lbs (pounds) (gross weight).
74. 9 t b To operate the scales, see Scales, page 191.
522 . 9 t c
016370

4 Instruments and controls – Event menus 79
4.11.1.6 Operating menu customer settings
Operating menu system, description

a. Number of active error codes with error code level stop.
10:23 h
b. Number of active error codes with error code level warning.
a c. Number of active error codes with error code level information.
0
d. Menu for customer settings such as date and time, SI/US units,
b i Eco Drive Mode .
0 e. Menu for statistics, history and operating hours.

f. Menu for services and settings.
c
0
g. Menu for machine check.
h. Menu for active error codes.
016374
g i. Menu for inactive error codes.
d e f
For a more detailed description of the different submenus, see 5.6
Customer settings via display, page 196.
4.11.2 Event menus

General
Event menu categories
10:23 The control system attracts the operator's attention to important

information by showing the event menus on the control system display.
a The event menus are divided into the categories: STOP, WARNING,
INFO and NOTICE. Each menu is displayed with an icon with a border
b around it. The severity of the menu is indicated by the colour of the
border around the function symbol.
Some event menus give an audio signal to attract the operator's

attention.
014952
Table Event menu categories

Example figure STOP Red border.
a. The colour of the border indicates the category
of the event menu. WARNING Yellow border.
b. Symbol for the current function. INFO Grey border.

NOTICE No border.
Event menus with the level STOP, WARNING and INFO menus can
be acknowledged with otherwise they automatically disappear
when the state that generated the event ends. Event menus with
the level NOTICE automatically disappear. Menus that have been
acknowledged can be displayed with the current symbols in the status
field to the left. The event menus are ranked according to a priority
order in which those with the highest priority are displayed in the status
field. Not all event menus have status indicators and no icon will appear
in the status field for these. If there are more than four active event
menus, those with the highest priority are displayed, yet all menus
with status indicators are placed in a queue and are displayed when
there is space in the status field. If there is space in the status field,
information for the heating or air conditioning system will be shown in
the lower part of the field.
How each event menu affects the machine's different functions is

described under each event menu.

80 4 Instruments and controls – Event menus
4.11.2.1 Event menu brake temperature
Event menu brake temperature, description

The figure is shown if:
• the temperature of the brakes is too high.
The machine's speed is limited for safety reasons when the
temperature is too high.
If the figure is shown, let the machine idle until the brake temperature
has reached the normal level. The display then disappears. The
display can be removed with the function key .
014984
4.11.2.2 Event menu low accumulator pressure
Event menu low accumulator pressure, description

• The hydraulic oil pressure in the brake system is too low. The red
border is not displayed for a specific time during startup when the
pressure is being built up. The current pressure is shown in the
menu.
The event menu disappears when the hydraulic oil pressure has
reached the right level. The display can be removed with the function
015440
key .
4.11.2.3 The event menu parking brake not activated

and no operator in the driver's seat
The event menu parking brake not activated and no

operator in the driver's seat, description
• The parking brake is not activated and the operator is not sitting
in the driver's seat.
The event menu disappears when the operator sits in the driver's seat,
or when the parking brake is activated. The display can be removed
with the function key .
015441

4.11.2.4 Event menu AdBlue end

Event menu AdBlue end, description
Only applies to machines with Volvo TAD871VE and Cummins QSB6.7
Stage 4/Tier 4f

• There is a fault in the supply of AdBlue.
• The engine indicates low AdBlue level.
Emission is control not working and engine power is limited.
016679
If the figure is shown, top up the AdBlue. The display then disappears.
The display can be removed with the function key .
NOTE
Fuel and AdBlue must be filled at the same time.
4.11.2.5 Event menu engine coolant temperature

Event menu engine coolant temperature, description
• The coolant temperature is high.
If the figure is shown, let the machine idle until the coolant temperature
has reached the normal level. The display then disappears. The
014987
4.11.2.6 Event menu oil temperature transmission

Event menu oil temperature transmission, description
• Transmission oil temperature is high.
If the figure is shown, let the machine stand and idle until the
transmission oil has reached the normal temperature. The display then
disappears. The display can be removed with the function key .
014988
4.11.2.7 Event menu oil temperature hydraulics

Event menu oil temperature hydraulics, description
• The hydraulic system's oil temperature is high.
If the figure is shown, let the machine stand and idle until the hydraulic
oil has reached the normal temperature. The display then disappears.
015479

4.11.2.8 Event menu height warning
Event menu height warning, description
The figure is shown when:

• set lifting height is reached.
016677
4.11.2.9 Event menu height limitation
Event menu height limitation, description

• set lifting height is reached. Lift movement is stopped.
If the figure is shown, lower the mast. The display then disappears.
016678
4.11.2.10 Event menu overload lift
Event menu overload lift, description

• the lifting equipment is overloaded. The overload system stops
lift and tilt.
The event menu disappears when the overload ceases. In the event
of overload the load can always be lowered and tilted out to withdraw
016682
from the overload situation. The display can be removed with the
function key .
4.11.2.11 Event menu overload tilt
Event menu overload tilt, description

lift and tilt.
016683
function key .

4.11.2.12 Event menu overload lift and tilt
Event menu overload lift and tilt, description

lift and tilt.
016684
function key .
4.11.2.13 Event menu seat belt
Event menu seat belt, description

• The belt is not fastened and the speed exceeds 3 km/h
If the figure is shown, fasten the seat belt. The display then disappears.
016369
4.11.2.14 Event menu low accumulator pressure
Event menu low accumulator pressure, description

• Try to release the parking brake when the accumulator pressure
is low.
If the figure is shown, wait until the pressure is built up in the

accumulators and release the parking brake. The display then
016341
4.11.2.15 Event menu parking brake
Event menu parking brake, description

• The parking brake is activated and you try to engage a gear.
• The parking brake is activated and you try to activate the automatic
functions that require the parking brake to be released.
Release the parking brake and the display disappears. The display can
be removed with the function key .
014990

4.11.2.16 Event menu low AdBlue level

Event menu low AdBlue level, description
Stage 4/Tier 4f

• The level in the AdBlue tank is low.
014991
NOTE
4.11.2.17 Event menu AdBlue

Event menu AdBlue, description
Stage 4/Tier 4f

• There is a fault in the supply of AdBlue.
• The engine indicates low AdBlue level.
NOTE
016680
4.11.2.18 Event menu low fuel level

Event menu low fuel level, description
• The level in the fuel tank is low.
If the figure is shown, top up the fuel. The display then disappears. The
For machines with Volvo TAD871VE and Cummins QSB6.7 Stage

4/Tier 4f:
014992
NOTE
4.11.2.19 Event menu battery capacity

Event menu battery capacity, description
• The battery capacity is becoming low.
If the figure is shown, check battery voltage and charge or replace the
batteries. The display then disappears. The display can be removed
with the function key .
014993

4.11.2.20 Event menu no operator in seat

Event menu no operator in seat, description
The figure is shown with:
• Attempt to engage a gear without anyone sitting in the driver's
seat. The transmission then goes to neutral and the gear must be
engaged again once the operator sits in the seat again.
• The working hydraulics are activated without anyone sitting in the
driver's seat.
• Attempt to rotate the operator's station without someone sitting in
the driver's seat .
014994
If the figure is shown, sit down in the driver's seat and select the gear
again, try to rotate the operator's station once more or activate the
working hydraulics. The display then disappears. The display can be
removed with the function key .
4.11.2.21 Event menu open door

Event menu open door, description
• A function is limited because the door(s) is/are not closed.
In the event that the display is shown, close the door(s). The display
then disappears. The display can be removed with the function key .
015206
4.11.2.22 Event menu low washer fluid level

Event menu low washer fluid level, description
• The level in the washer fluid reservoir is low.
If the figure is shown, top up the washer fluid. The display then
015205
4.11.2.23 Event menu air filter air conditioning system

Event menu air filter air conditioning system,
description
• The air filter in the air-conditioning system is clogged.
If the figure is shown, replace the air filter. The display then disappears.
015442

4.11.2.24 Event menu release the parking brake
Event menu release the parking brake, description

• Attempt to release the parking brake is made without the service
brake pedal being pressed down.
• Attempts to rotate the operator's station are performed without the
service brake pedal being depressed sufficiently or the parking
brake is not activated .
In case the figure is shown:
014995
• Depress the service brake pedal and release the parking brake.
• Depress the service brake pedal or activate the parking brake and
try to rotate the operator's station once again.
The display then disappears. The display can be removed with the
function key .
4.11.2.25 Deactivated regeneration of the engine's

after-treatment system, description
Deactivated regeneration of the engine's

after-treatment system, description
Only applies to Cummins QSB6.7 Stage 4/Tier 4f.

• the after-treatment system's regeneration is prevented.
This is done by activating the Switch preventing regeneration of
the engine's after-treatment system, see Switch for preventing
regeneration of the engine's after-treatment system (51), page 53.
In the event that the figure is shown, regeneration is prevented.

014996
4.11.2.26 Event menu preheating
Event menu preheating, description

• Preheating is activated.
The event menu disappears when preheating is complete. The display

can be removed with the function key .
014997

4.11.2.27 Event menu raise/lower cab temperature

Event menu raise/lower cab temperature, description
• The cab temperature is raised or lowered. Desired temperature is
displayed in the menu.
The event menu disappears a short time after the most recent
temperature change with the cab temperature switches. The display
18.6°
017813
4.11.2.28 Event menu raise/lower fan speed
Event menu raise/lower fan speed, description
• The fan speed is raised or lowered.
The event menu disappears a short time after the last fan change
with the switches for fan speed. The display can be removed with the
function key .
014999
4.11.2.29 Event menu start interlock

Event menu start interlock, description
• The start interlock (Immobiliser) function prevents the operator
from staring the engine, e.g. with the alcolock.
• The starter motor has run too long. The engine's control unit stops
the starting attempt. A new attempt to start the engine can be
made when the starter has rested for a while. Applies to Cummins
QSB6.7.
• Engine or hydraulic oil heater is engaged.
015200
The event menu disappears when the conditions for starting the
machine are met. The display can be removed with the function key .
4.11.2.30 Event menu heating rear view mirrors/rear

windscreen
Event menu heating rear view mirrors/rear windscreen,
description

• Heating in rear window is activated.
• Heating rear view mirrors/rear windscreen activated.
The event menu disappears a short time after activation. The display
015201


• Heating in rear window is deactivated.
• Heating rear view mirrors/rear windscreen deactivated.
The event menu disappears a short time after the function is

deactivated. The display can be removed with the function key .
015202
4.11.2.31 Event menu service
Event menu service, description

• Time to next service is approaching. The remaining time to service
123 in hours is shown in the menu.
Ensure that the machine is serviced according to the prescribed

intervals. The display can be removed with the function key .
017812
4.11.2.32 Event menu control breaker
Event menu control breaker, description

• The control breaker is pressed in when specific functions are
activated.
• The control breaker is activated.
Reset the control breaker by turning it clockwise. The display can be

015444
4.11.2.33 Event menu intermittent wiper
Event menu intermittent wiper, description

• Slow intermittent wipers are activated.

015445


• Fast intermittent wipers are activated.
015446
4.11.2.34 Event menu speed limitation
Event menu speed limitation, description

• Functions in the machine are prevented because the speed is too
high.
If the figure is shown, reduce speed. The display then disappears.

016346
4.11.2.35 Event menu battery charging
Event menu battery charging, description

• The engine's alternator does not charge the battery for a few
seconds.
If the figure is shown, increase the engine speed in order to increase

alternator output. The display disappears after 2 seconds when the
alternator is charging the battery. If the display does not disappear,
release the load safely, park the machine and contact service.
016352
4.11.2.36 Event menu low coolant level engine
Event menu low coolant level engine, description

• The coolant level in the engine's expansion tank becomes too low.
If the figure is shown, release the load safely, park the machine and
check the coolant level, see Cooling system, general, page 224.

016368

4.11.2.37 Event menu rotate the operator's station
Event menu rotate the operator's station, description

• The travel direction selector is activated when the operator's
station is in zone C.
• Load handling functions are activated when the operator's station
is in zone C, D or E.
• The operator's station rotates without the operator activating the
016608
switch to rotate the operator's station.
• The switch to rotate the operator's station is activated but the
turning torque is too high.
If the figure is shown, do not activate the travel direction selector or load
handling functions in zones where they stop the function. The display
then disappears. The display can be removed with the function key .
180°
E
D
B
A
0°
016607
4.11.2.38 Event menu mini-wheel/joystick control,

description
Event menu mini-wheel/joystick control, description
The figure shows when the switch to rotate the operator's station is
activated at the same time as mini-wheel/joystick control.
If the figure is shown, do not use the mini-wheel/joystick control when

rotating the operator's station. The display then disappears. The
016609

4.11.2.39 Event menu arm rest
Event menu arm rest, description

The figure shows when the switch to rotate the operator's station is
activated and the right-hand arm rest is not in the permitted range.
The figure also shows whether the left-hand arm rest by the
mini-wheel/joystick control is in the lowered position .
If the figure is shown, adjust the right-hand arm rest to the permitted
position and lower the arm rest by the mini-wheel/joystick control
and try to rotate the operator's station once again. The display then
016610
4.11.2.40 Event menu, clamped load
Event menu, clamped load, description

• Open attachment is activated without the switch on the lever being
activated.
If the figure is shown, activate the switch and select open attachment
with the lever. The display then disappears. The display can be
016681

92 5 Handling
5 Handling
General
The machine is intended to be used in the way that is described in
the operator's manual. If the machine is used in any other way or in
potentially dangerous environments, e.g. an explosive environment,
then special safety rules must be followed and the machine must be
equipped for such an environment.
NOTE
It is the operator who is responsible for ensuring that the machine
comes in for service according to prescribed service intervals.
Procedures are described in the maintenance manual.
The information in the chapter for handling the machine does not
relieve the operator of the responsibility of following laws or other
national regulations for road safety and work safety.
Awareness, alertness, good judgement and respect for governing

safety regulations are prerequisites for avoiding accident risks.
Environmental impact
It is important that the machine is used in a way that results in minimal
environmental impact with regards to fuel consumption, exhausts, and
noise emissions. Therefore, keep the following in mind:
• Plan the work and optimise machine use.
• Avoid operating with full throttle when transporting.
• Do not rev the engine unnecessarily when load handling.
• Optimise operation with regard to acceleration and braking.
• Minimise the time the machine runs at idling speed. Do not allow
the machine to idle when there is a break in the work.

5 Handling – Handling 93
Emergency equipment
The following emergency equipment is available on the machine:
• Emergency exit from cab, right-hand door.
In an emergency:
1. Open the emergency exit right-hand door with handle on inside.
34 • Control breaker for load handling.

In an emergency:
1. Press down the control breaker (position 34) immediately.
All load handling functions stop and the transmission is set into
neutral.
2. Restore control breaker (turn clockwise).
• Fire extinguisher
Fire extinguishers are located on the left-hand front wing but can
also be located on the right-hand front wing behind the right or
left-hand footsteps (or several of these locations simultaneously).
012702
In case of engine fire, press in the fire extinguisher's nozzle

through the perforation on the plate for fire extinguisher on the
sides of the engine hood.
WARNING
By-pass of load handling functions must not be used
during normal load handling.
damage.
Only use the bypass in emergency situations.

94 5 Handling – Running-in
5.1 Running-in
General
The machine should be operated with great care during the running-in
period. The intention is to considerably increase the service life of
the machine.
Recommended running-in period is 10 hours of operating time. This

results in fewer malfunctions.
Engine
The oil and filter must be changed according to intervals described in
the maintenance manual.
Transmission
The oil and filter must be changed according to intervals described in
the maintenance manual.
Tyres and rims

For a new machine it is extremely important that the wheel nuts
are check-tightened during the first week of operation until they are
properly set in. This should be done at intervals of 4-5 operating
hours (up to approx. 40-50 operating hours). Then the wheel nuts are
check-tightened according to intervals described in the maintenance
manual.

5 Handling – Daily inspection 95
5.2 Daily inspection

General
Daily inspection of the machine is extremely important in order to
ensure that it is safe both for the operator and its surroundings.
Every operator should perform checks before a new work shift. In this
way, operators can avoid running defective machines with malfunctions
that have been generated or caused during an earlier work shift.
WARNING
Never use a machine without first performing the daily
inspection.
Risk of personal injury and property damage!
For work instructions, see 6.1 Daily inspection, page
206. Report to the foreman/supervisor if defects are
found on the machine during daily inspection!
For work instructions, see 6.1 Daily inspection, page 206.

96 5 Handling – Error codes
5.3 Error codes

Error codes, general
Error codes indicate that there is a defect on the machine. Errors are
10:23 d indicated by an Indicator light for active errors (position 18) on the
CUSTOMER SETTI NGS
a steering wheel panel. The number of active errors is totalled on the
display (position a-c). Some error codes are displayed via pop-up
0
e menus to attract the operator's attention. The error codes should be
b used by operators and service technicians to identify faults and to
0 implement suitable action.
c In case of an error code indication, it's very important to identify the

error code and to perform an action to correct the problem.
015223
0
All error code information for active and inactive error codes is collected
a. Number of active error codes with error code on the operating menu Customer settings and the sub-menus Active
level stop. Errors (position d) and Error history (position e).
b. Number of active error codes with error code Select Active Errors or Error history with or and press to
level warning. activate the desired menu.
c. Number of active error codes with error code
level information.
d. Menu for active error codes, Active errors.
e. Menu for inactive error codes, Error history.
Error code information via pop-up menu
Error code information via pop-up menu
10:23 Error codes are automatically shown via pop-up menus on the display.
Some information about the error code can be read out directly by
the symbols in the pop-up menu. The menus Active errors and Error
history show detailed information about the error codes.
Press to show specific detailed information via the Active errors

menu.
Press to confirm the error and the display returns to show the menu
that was active before the pop-up men was activated. If there are more
015224
active errors, the next pop-up menu is shown.

Σ5
Example figure
Error code information Active errors
Error code information Active errors
10:23
Detailed information about the error codes are presented under Active
ACTI VE ERRORS 1/ 1 0 errors where, among others, the error code level, action with error code
and the device that generated the error code are presented.
0 111/ 5480 - 5
For information about how the error code should be interpreted, see
Field d: Error code number, page 103.
0 Scroll through active error codes with and . Leave the error code
list by pressing the function key .
015225
Example figure Active errors

5 Handling – Error codes 97
Error code information in Error history
Error code information in Error history
10:23
Detailed information about the last 50 inactive error codes is presented
ERROR HI STORY 1/ 1 2 under Error history where, amongst other things, the error code level,
the unit that generated the error code and the date and time are
1 111/ 5 1 7 0- / 3 presented.
0
2 01 1- 0 9- 19 1 0: 23
For information about how the error code should be interpreted, see
2 111/ 5 1 6 0- / 3 Field d: Error code number, page 103.
0 2 01 1- 0 9- 19 1 0: 23
3 Scroll through inactive error codes with and . Leave the error code
0/ 0- / 0
0 00 0- 0 0- 00 0 0: 00 list by pressing the function key .
014945
0
Example figure Error history
Action in the event of error code
CAUTION
STOP indicates a malfunction in the machine which
may affect the safety of the operator and others in the
vicinity or may cause a breakdown. Read the error
code. Switch off the engine and perform action in
accordance with the error code table.
WARNING and INFORMATION alarms indicate
malfunctions of such character that work does not
have to be stopped. The capacity of the machine may
be reduced and specific functions may stop working.
- Perform the measures according to the error code
table immediately.
10:23 1 Errors are indicated through the pop-up menus, and by an indicator
light for active errors (position 18) being lit.
Stop the machine and let the engine run at idle speed.
2 Identify error code level, see Field a: Error code level, page 100.
NOTE
If several error codes come from the engine or transmission, the
error code level is shown for the most serious error code.
015224
Σ5 3 Note all error codes. For explanation, see Display figure for error
code information, page 100.
4 Perform the action depending on the action symbol shown in the
Example figure
middle field, see Field b: Operator action, page 100.
5 Check: Start the engine and check under Active errors that the
error code has disappeared.

98 5 Handling – Error code indication
5.3.1 Error code indication

General
10:23 Error codes are indicated with an activated indicator light for active
error codes (position 18) and a pop-up menu. The error codes are
divided into three error code levels depending on their severity.
The error code levels are shown as follows:

a b c d • STOP is indicated by:
1. Lit indicator light for active fault codes (position 18).
2. STOP symbol in the pop-up menu.
3. Red border around the pop-up menu.
Σ5 • WARNING indicated by:
2. Warning triangle in the pop-up menu.
3. Yellow border around the pop-up menu.
• INFORMATION indicated by.
2. Information symbol in the pop-up menu.
3. Grey border around the pop-up menu.
015226
a Symbol for the error code level

STOP, WARNING or INFORMATION
b Symbol for action
c Symbol for component
d Border indicates error code level
Red = STOP
Yellow = WARNING
Grey = INFORMATION

5 Handling – Error code information on display 99
5.3.2 Error code information on display

Error code display
Error code information is shown with display figures in two ways:
10:23 • Automatically in display.

The error code is confirmed by . When the error code is
confirmed the display returns to the previous selected menu. If the
error code is active then it is stored in the error code list under the
operating menu Active errors.
If the error code remains active, the figure returns in the display
within 3-5 minutes. Level STOP error codes are shown five times,
WARNING three times and INFORMATION once or not at all.
014954
Σ5
Example of automatic figure in display
10:23
• In error code list Active errors.
ACTI VE ERRORS 1/ 1 0 Active error codes are stored in the error code list. Navigate to
the operating menu Customer settings with or , select Active
0 11 1/ 5 480- 5 errors and confirm with . Navigate the error code list with the
function keys and . Leave the error code list by pressing the
function key .
0
NOTE
If error code isn't included in the error code list, it may be due to
015225
0
the following:
– condition for error detection no longer exists, e.g., control
Example of the error code list Active errors
lever is released or engine is off.
– loose connection/poor contact.

100 5 Handling – Error code information on display
Display figure for error code information
10:23 The menus are divided into fields where the information is displayed.
• Field a: Error code level. Shown with a symbol.
• Field b: Operator action. Shown with a symbol.
• Field c: Component that generated the error code. Shown with
a b c a symbol.
• Field d: Error code.
• Field e: Number of errors. For Error history the number of errors
is limited to the last 50 errors.
015228
• Field f: Number of errors on each error code level.
h
• Field g: Date and time.
Pop-up menu for error codes • Field h: Number of unconfirmed pop-up menus.
10:23
Field a: Error code level
ACTI VE ERRORS e
f The control and monitoring system gives error code information in three
0 d levels which are indicated with a symbol in the display unit.
Symbol Action
0 a b c STOP
Indicates a serious malfunction that may jeopardise
the operator's safety or cause machine failure. The
015229
0
error code must be attended to immediately.
WARNING
Active error codes shown in Active errors
Indicates malfunction in machine that should be
10:23 taken care of as soon as possible.
ERROR HI STORY e
f
1
d INFORMATION
0 a g c
Information to the operator that something should
2 be rectified, e.g. broken bulb. Rectify the cause
11 1/ 5 1 6 0- / 3
0 at a suitable opportunity. Instructions for action
2 01 1 - 0 9 - 19 1 0: 23
are normally found in chapter 6 Inspection and
3 0/ 0- / 0 maintenance.
0 00 0 - 0 0 - 00 0 0: 00
015230
0
Field b: Operator action
The control system provides information about what action the operator
Inactive error codes are shown in Error history
should carry out. The information is indicated with a symbol on the
display unit.
Symbol Action
Carry out action according to the daily inspection,
see Instructions, page 206.
Error requires action by trained personnel.

One of the functions of the machine is not working
fully.
Critical error.
Errors that may jeopardise the machine or safety,
such as low oil pressure or overload. Stop the
machine and safeguard the error.
Read the operator's manual.

Field c: Affected function

For an explanation of the display fields, see Display figure for error
Symbol Function Symbol Function Symbol Function

Engine Fuel level AdBlue level
Temperature electric Temperature electric Particulate filters

motor hydraulics motor drive
Exhaust temperature Air filter Engine coolant level
Coolant temperature Engine oil level Preheating engine

engine
Transmission Oil temperature torque Lock-up, torque converter

converter
Differential locks Transmission oil level Oil pressure, transmission
Transmission oil Power transmission Tyre pressure

temperature
Regulator (inverter) Brakes Brake pressure
Parking brake Oil temperature brake Steering

system
Suspension Load handling Control levers
Lift/lower Lift/lower Extension
Side shift Side shift Spreading (positioning)
Spreading (positioning) Rotation Tilt
Tilt lock Tilt Levelling

Symbol Function Symbol Function Symbol Function

Levelling lock Levelling Contact twistlocks
Locked twistlocks Unlocked twistlocks Contact top lift attachment
Contact side-lift Bottom lift attachment Support jacks

attachment
Control system Boom angle Boom length
Scales Overload system Overload system
Height limit Frame, body, cab and Hour meter (operating

accessories hours)
Seat Revolving driver's seat Air conditioning
ECH, ECC Fresh air filter Pause heater
Temperature water heater Recirculation Washer fluid
Wipers Revolving or flashing Lighting

beacon
Horn Heating rear Cab sliding length

windscreen/rear view
mirrors
Vertically adjustable cab Tiltable cab Central lubrication
Hydraulic oil filter Hydraulic oil temperature Battery charging
CAN bus CAN bus drivetrain

Field d: Error code number
Field d: Error code number

The control system gives error codes from the machine's sub-systems:
1 2 3 Device number (AAA)
10:23
The first part of the error code specifies the device that generated the
ACTI VE ERRORS error. The following devices can generate error codes:
AAA/ BCCCC- DD E
Device number Unit
0
1–99 Devices in the RedCAN system
100 Engine
0
111 Transmission ZF
210 Exhaust system
015233
Component type (B)

Example figure error codes A letter before the digits in the component number specifies the type of
1. Device number (AAA) component concerned. The following component types can be read:
2. Component number (SPN) (BCCCC-DD)
Component letter Component type
3. Type of error (FMI) (E)
A Unit
B Sensor
D Control unit
E White light
F Fuse
G Battery or alternator
H Signal unit for audio or light
K Relay
M Electric motor
P Meter
R Resistor, potentiometer
S Switch, contact
X Connector
Y Solenoid valve
Component (CCCC)
The digits are a unique number (SPN) to locate the faulty component.

Component placement (DD)

In cases where multiple components have the same component
number two letters or a serial number 1-9 are added to make the error
code unique. The letters usually denote a location on the machine.
The following locations are used:
Letters Location
LE Left
RI Right
UP Upper
LO Lower
FR Front
LF Left front
RF Right front
RE Rear
LR Left rear
RR Right rear
Type of error (EE)

The FMI code denotes the type of error.
Table Specifications FMI
FMI Description SAE-text

0 Value too high. Data valid, but higher than normal operating range.
1 Value too low. Data valid, but lower than normal operating range.
2 Incorrect data. Intermittent or incorrect data.
3 Electrical problem. Abnormally high voltage or short-circuit to higher voltage.
4 Electrical problem. Abnormally low voltage or short-circuit to lower voltage.
5 Electrical problem. Abnormally low current or open circuit.
6 Electrical problem. Abnormally high current or short-circuit to ground.
7 Mechanical problem. Incorrect response from mechanical system.
8 Mechanical problem or electrical Abnormal frequency.
problem.
9 Communication error. Abnormal update rate.
10 Mechanical problem or electrical Abnormally wide variations.
problem.
11 Unknown malfunction. Non-identifiable malfunction.
12 Component error. Incorrect unit or component.
13 Incorrect calibration. Values outside calibration values.
14 Unknown malfunction. Special instructions.
15 Value too high. Data valid but higher than normal operating range: The least serious
level.
16 Value too high. Data valid but higher than normal operating range: Moderately
serious level.
17 Value too low. Data valid but under normal operating range: The least serious level.
18 Value too low. Data valid but under normal operating range: Moderately serious
level.
19 Communication error. Received network data incorrect.

FMI Description SAE-text

20 Data too high. Data valid but higher than normal value.
21 Data too low. Data valid but lower than normal value.
22-30 Reserved for SAE-allocation.
31 FMI not available or the condition Not available or the condition exists.
indicated by SPN exists.
32 Electrical problem. Abnormally high resistance or short-circuit to higher voltage.
33 Electrical problem. Abnormally low resistance or short-circuit to lower voltage.
34 Time exceeded. Time exceeded.
35 Communication error. CAN bus error.
36 Communication error. Driver error.
37 Communication error. Over flow.
38 Communication error. Error passive stat.
39 Communication error. Baud rate.
40 Communication error. Control unit disappears (stop sending messages) after start up.
41 Communication error. Control unit missing on start up.
42 Communication error. CAN-bus segment after the control unit is faulty. Normal side.
43 Communication error. CAN-bus segment after the control unit is faulty. RedCAN side.
44 Communication error. Control unit incorrectly positioned RedCAN circuit.
45 Communication error. Checksum error in the control unit.
Field e: Number of error codes

Specifies the number of menu pages with active fault codes in Active
errors and the number of menu pages with inactive error codes Error
history.
Field f: Number of errors on each error code level

Specifies the number of active error codes on each error code level.
Field g: Date and time

Specifies the date and time when the error code was confirmed.
Field h: Number of unconfirmed pop-up menus

Specifies the number of unconfirmed pop-up menus.

106 5 Handling – Error code tables
5.3.3 Error code tables

General
Error codes are sorted in numerical order. The tables contain the
following information:
• Type - Denotes the type of component, see Component type (B),
page 103.
• SPN - Denotes the component concerned, see Component
(CCCC), page 103.
• FMI - Denotes the type of error, see Type of error (EE), page 104.
• Node - Denotes which unit has generated the error, see Device
number (AAA), page 103.
• Location - denotes the component's location in the machine,
Component placement (DD), page 104.
• Description - Indicates description of the error code as well as any
limitation that can occur in the machine in case of the error code
in question.
• Action - Indicates STOP/WARNING/INFORMATION for action
according to error code level, with or without detailed information.
If the error code number isn't included in the error code table, contact
service.
Error codes machine
Error codes machine
Type SPN FMI Node Loca- Description Action

tion
S 1310 7 11 Travel direction selector, logical error. STOP!
B 2190 2 1 Sensor, cab filter. INFO
B 2460 2 1 Low pressure, air conditioning. WARNING!
K 3150 6 1 Relay, ignition, grounded circuit. STOP!
K 3312 6 1 Driving forward relay, signal status. INFORMATION
K 3312 6 2 Driving forward relay, signal status. INFORMATION
K 3320 6 1 Driving reverse relay, signal status. INFORMATION
K 3320 6 2 Driving reverse relay, signal status. INFORMATION
K 3600 6 2 Relay, starter motor. WARNING!
E 4000 5 2 LE Low beam, left. Check the lamp. INFORMATION
E 4000 5 3 LR Low beam left rear, at turnable operator's INFORMATION
station. Check the lamp.
E 4000 6 2 LE Low beam, left. INFORMATION
E 4000 6 3 LR Low beam left rear, at turnable operator's INFORMATION
station.
E 4000 5 2 RI Low beam, right. Check the lamp. INFORMATION
E 4000 5 3 RR Low beam right rear, at turnable operator's INFORMATION
E 4000 6 2 RI Low beam, right. INFORMATION
E 4000 6 3 RR Low beam right rear, at turnable operator's INFORMATION
station.
E 4020 5 2 LE High beam, left. Check the lamp. INFORMATION

5 Handling – Error code tables 107
Error codes machine

tion
E 4020 5 3 LR High beam left rear, at turnable operator's INFORMATION
E 4020 6 2 LE High beam, left. INFORMATION
E 4020 6 3 LR High beam left rear, at turnable operator's INFORMATION
station.
E 4020 5 2 RI High beam, right. Check the lamp. INFORMATION
E 4020 5 3 RR High beam right rear, at turnable INFORMATION
operator's station. Check the lamp.
E 4020 6 2 RI High beam, right. INFORMATION
E 4020 6 3 RR High beam right rear, at turnable INFORMATION
operator's station.
E 4041 5 2 1 Working lighting load centre. Check the INFORMATION
lamp.
Extra work lights, frame left. Check the
lamp.
E 4041 6 2 1 Working lighting load centre. INFORMATION
Extra work lights, frame left.
E 4041 5 2 2 Work lights option. Check the lamp. INFORMATION
Extra work lights, frame right. Check the
lamp.
E 4041 6 2 2 Work lights option. INFORMATION
Extra work lights, frame right.
E 4042 5 1 LE Extra work lights, cab left. Check the INFORMATION
lamp.
E 4042 6 1 LE Extra work lights, cab left. INFORMATION
E 4042 5 1 RI Extra work lights, cab right. Check the INFORMATION
lamp.
E 4042 6 1 RI Extra work lights, cab right. INFORMATION
E 4042 6 1 1 Extra work lights left. INFORMATION
E 4042 6 1 2 Extra work lights right. INFORMATION
E 4043 5 2 LE Work lights, mast left. Check the lamp. INFORMATION
E 4043 6 2 LE Work lights, mast left. INFORMATION
E 4043 5 2 RI Work lights, mast right. Check the lamp. INFORMATION
E 4043 6 2 RI Work lights, mast right. INFORMATION
E 4050 5 1 LE Work lights, backward left. Check the WARNING!
lamp.
E 4050 6 1 LE Work lights, backward left. WARNING!
E 4050 5 1 RI Work lights, backward right. Check the WARNING!
lamp.
E 4050 6 1 RI Work lights, backward right. WARNING!
H 4110 6 2 Brake light. INFORMATION
H 4110 6 3 Brake lights front, at turnable operator's INFORMATION
station.

Error codes machine

tion
H 4120 6 2 1 Tail lights. INFORMATION
H 4120 6 3 1 Tail lights front, at turnable operator's INFORMATION
station.
H 4160 6 2 Position light. INFORMATION
H 4220 6 2 LE Direction indicators left. INFORMATION
H 4220 6 2 RI Direction indicators right. INFORMATION
H 4281 6 2 Revolving beacon, counterweight. WARNING!
H 4282 6 1 Revolving beacon, cab. WARNING!
E 4340 6 1 Interior lighting. WARNING!
H 5630 6 1 2 Indicator light clamping pressure OK, WARNING!
grounded circuit.
H 5640 6 1 2 Indicator light tilt control, grounded circuit. WARNING!
H 5991 6 1 0 Indicator light, buckled seat belt. WARNING!
H 5992 6 1 Indicator light, Mini steering wheel/joystick WARNING!
control.
Y 6004 6, 5 2 Solenoid valve lower. WARNING!
Y 6004 6, 5 2 2 Solenoid valve lower 2. WARNING!
Y 6005 6, 5 2 Solenoid valve lift. WARNING!
Y 6005 6, 5 2 2 Solenoid valve lift 2. WARNING!
Y 6010 6, 5 2 Solenoid valve tilt out. WARNING!
Y 6011 6, 5 2 Solenoid valve tilt in. WARNING!
Y 6018 6, 5 2 Solenoid valve spreading out. WARNING!
Y 6018 6, 5 2 LE Solenoid valve spreading out left fork. WARNING!
Y 6018 6, 5 2 RI Solenoid valve spreading out right fork. WARNING!
Y 6019 6, 5 2 Solenoid valve spreading in. WARNING!
Y 6019 6, 5 2 LE Solenoid valve spreading in left fork. WARNING!
Y 6019 6, 5 2 RI Solenoid valve spreading in right fork. WARNING!
Y 6020 6, 5 2 Solenoid valve side shift left. WARNING!
Y 6021 6, 5 2 Solenoid valve side shift right. WARNING!
Y 6022 6, 5 2 Solenoid valve extra hydraulic function WARNING!
out.
Y 6023 6, 5 2 Solenoid valve extra hydraulic function in. WARNING!
Y 6035 6, 5 2 Solenoid valve levelling right WARNING!
up/anticlockwise.
Y 6036 6, 5 2 Solenoid valve levelling left up/clockwise. WARNING!
Y 6080 6, 5 2 Solenoid valve activation cab movement. WARNING!
Y 6085 6, 5 2 Solenoid valve share hydraulic function 1. WARNING!
Y 6087 6, 5 2 Solenoid valve share hydraulic function 2. WARNING!
Y 6088 6, 5 2 Solenoid valve accumulator shut off. WARNING!
Y 6095 6, 5 2 Solenoid valve split function mast. WARNING!

Error codes machine

tion
Y 6120 6, 5 1 1 Damper motor, recirculation. INFORMATION
Y 6120 6, 5 1 2 Damper motor, recirculation. INFORMATION
Y 6150 6 2 1 Voltage feed to electric control module for STOP!
joystick control/mini steering wheel.
Y 6150 6 2 2 Electric control module for joystick STOP!
control/mini steering wheel.
Y 6150 2 2 3 Electric control module for joystick STOP!
control/mini steering wheel.
Y 6150 31 2 Control unit control valve feedback seat STOP!
position and Control unit mini-wheel or
joystick control (Y6150) are missing.
Y 6360 6, 5 3 FR Directional control valve steering, forward. STOP!
At revolving driver's seat.
Y 6360 6, 5 3 RE Directional control valve steering, STOP!
backward. At revolving driver's seat.
Y 6420 2, 5, 2 Solenoid valve parking brake. STOP!
6
Y 6450 6, 5 2 Electromagnetic clutch cooling INFORMATION
compressor.
K 6501 6 1 LE Windscreen wiper left, relay. INFORMATION
K 6501 6 1 RI Windscreen wiper right, relay. INFORMATION
M 6501 7 1 LE Windscreen wiper left, position signal. INFORMATION
M 6501 7 1 RI Windscreen wiper right, position signal. INFORMATION
M 6502 7 1 Wiper rear window, position signal. INFORMATION
M 6502 6, 5 1 Rear windscreen wipers. INFORMATION
M 6503 7 1 Combined wipers, windscreen and roof INFORMATION
window, position signal.
Alternative wiper roof window, position
signal.
M 6503 6, 5 1 Combined wipers, windscreen and roof INFORMATION
window.
Alternative wiper roof window.
M 6511 6 1 Motor washing, front windscreen. INFORMATION
M 6512 6, 5 1 Motor washing, rear windscreen. INFORMATION
M 6513 6, 5 1 Motor washing, combined wipers front INFORMATION
windscreen and roof window.
Alternative motor washing, roof window.
M 6570 6, 5 1 Cabin fan. INFORMATION
M 6670 6, 5 1 Circulation pump pause heater. INFORMATION
M 6680 6, 5 2 Cooling fan, hydraulic oil cooler. WARNING!
Y 6720 3, 4 1 Damper motor air distribution, position INFORMATION
signal.
Y 6720 6, 5 1 1 Damper motor air distribution. INFORMATION
Y 6720 6, 5 1 2 Damper motor air distribution. INFORMATION

Error codes machine

tion
Y 6730 3, 4 1 Heating valve, position signal. INFORMATION
Y 6730 6, 5 1 1 Heating valve. INFORMATION
Y 6730 6, 5 1 2 Heating valve. INFORMATION
M 6750 6, 5 3 Motor, revolving driver's seat. WARNING!
M 6750 6, 5 3 Motor, revolving driver's seat. WARNING!
Y 6760 6, 5 1 Solenoid valve, swivel driver's seat. WARNING!
Y 6760 6, 5 3 RI Solenoid valve, brake revolving driver's WARNING!
seat.
Y 6760 6, 5 3 LE Solenoid valve, brake revolving driver's WARNING!
seat.
B 6900 3, 4 11 1 Accelerator pedal, signal A. WARNING!
B 6900 3, 4 11 2 Accelerator pedal, signal B. WARNING!
M 6930 6, 5 2 1 Pump central lubrication frame. INFORMATION
B 6941 3, 4, 11 Engine right dashboard panel INFORMATION
7 forward/backward position signal.
M 6941 6 11 1, 2 Engine right dashboard panel INFORMATION
forward/backward.
B 6942 3, 4, 11 Engine right dashboard panel up/down INFORMATION
7 position signal.
M 6942 6 11 1, 2 Engine right dashboard panel up/down. INFORMATION
B 6943 3, 4, 11 Engine steering wheel panel up/down INFORMATION
7 position signal.
M 6943 6 11 1, 2 Engine steering wheel panel up/down. INFORMATION
P 7080 14 1, 2, 3, Operating hours do not correspond WARNING!
11, 12 to reference Control unit frame KFU
(D7971).
B 7226 3, 4 2 Sensor, lift pressure. WARNING!
B 7228 3, 4 2 Height sensor, lift. WARNING!
B 7229 3, 4 2 Sensor, tilt angle. WARNING!
B 7235 3, 4 2 LE Sensor, power cell left. WARNING!
B 7235 3, 4 2 RI Sensor, power cell right. WARNING!
B 7236 3, 4 2 Sensor, power cell tilt. WARNING!
B 7238 3, 4 2 Sensor, pressure tilt cylinder. WARNING!
B 7242 7 2 Central lubrication frame. INFORMATION
B 7244 3, 4 2 Electric dipstick transmission sensor. WARNING!
B 7245 3, 4 2 LE Sensor, feedback steering, channel 1. WARNING!
B 7245 3, 4 2 RI Sensor, feedback steering, channel 2. WARNING!
B 7252 3, 4 11 Ambient light intensity sensor. WARNING!
B 7570 3, 4 2 Sensor fuel level. INFORMATION
B 7681 3, 4 2 Brake pressure sensor. WARNING!
B 7682 3, 4, 2 Sensor parking brake WARNING!
15

Error codes machine

tion
B 7683 3, 4 2 Accumulator pressure sensor. WARNING!
B 7701 2 3 Revolving driver's seat, incorrect or no STOP!
feedback.
B 7740 32, 1 Ambient temperature sensor. INFORMATION
33
B 7751 32, 1 Inner temperature sensor. INFORMATION
33
B 7752 32, 1 Fan temperature sensor. INFORMATION
33
B 7753 32, 1 Temperature display sensor. INFORMATION
33
B 7760 32, 2 Hydraulic oil temperature sensor. WARNING!
33
B 7770 2 3 Turnable operator's station, position STOP!
operator's station.
B 7770 2 3 Turnable operator's station, no change of WARNING!
angle when turning is requested.
B 7770 3, 4 3 Turnable operator's station, position STOP!
operator's station.
A 7870 2 2 Sensor fault, overload system. STOP!
D 7901 31 12 Control unit missing. STOP!
D 7930 31 2 1 Control unit missing. STOP!
D 7940 31 2 1 Control unit missing. STOP!
A 7991 31 1 Control unit missing. WARNING
E 8020 6, 5 2 Electrically-heated rear view mirror. INFORMATION
R 8070 3, 4 11 1 Control lever lift/lower. WARNING!
R 8070 3, 4 11 1 Joystick lifting/lowering. WARNING!
R 8070 3, 4 11 2 Control lever tilt out/in. WARNING!
R 8070 3, 4 11 2 Joystick tilt out/in. WARNING!
R 8070 3, 4 11 3 Control lever side shift. WARNING!
R 8070 3, 4 11 3 Joystick side shift. WARNING!
R 8070 3, 4 11 4 Control lever spreading/spreading WARNING!
left/extension left.
R 8070 3, 4 11 4 Joystick spreading left. WARNING!
R 8070 3, 4 11 5 Control lever 5th function. WARNING!
R 8070 3, 4 11 6 Levelling, spreading right-hand side. WARNING!
M 8100 6, 5 1 Condenser roof. INFORMATION
R 8250 3, 4 1 Potentiometer joystick control. STOP!

Error codes machine

tion
R 8250 3, 4 1 1 Potentiometer mini-steering wheel, STOP!
channel 1.
R 8250 3, 4 1 2 Potentiometer mini-steering wheel, STOP!
channel 2.
H 8500 6 1 Horn. WARNING!
K 8881 6 1 Relay rear windscreen heating. INFORMATION
A 9630 6, 5 2 Fire extinguishing system.
H 9650 6 2 1 Reverse alarm. WARNING!
H 9650 6 3 2 Reverse alarm front, at revolving driver's WARNING!
seat
10002 14 1 Configuration number does not STOP!
correspond for Control unit KCU (D7901).
correspond for Control unit KFU (D7971).
correspond for Control unit KFU-2
(D7972).
correspond for Control unit KPU (D7902).
correspond for Control unit KID (D7950).
10003 14 1 Program version does not correspond for WARNING!
Control unit KCU (D7901).
Control unit KFU (D7971).
Control unit KFU-2 (D7972).
Control unit KPU (D7902).
Control unit KID (D7950).
10004 14 1 No Setup file for Control unit KCU STOP!
(D7901).
10004 14 2 No Setup file for Control unit KFU STOP!
(D7971).
10004 14 3 No Setup file for Control unit KFU-2 STOP!
(D7972).
10004 14 11 No Setup file for Control unit KPU STOP!
(D7902).
10004 14 12 No Setup file for Control unit KID (D7950). STOP!
10005 14 1 1 No drivetrain parameter file, Control unit STOP!
KCU (D7901).
KCU KFU (D7971).
10005 14 2 2 No load sensor parameter file, Control STOP!
unit KCU KFU (D7971).

Error codes machine

tion
10005 14 2 3 No fuel tank parameter file, Control unit STOP!
KCU KFU (D7971).
10005 14 2 4 No central lubrication parameter file, STOP!
10005 14 2 5 No front tyre parameter file, Control unit STOP!
KFU (D7971).
10005 14 2 6 No overload system (OLS) parameter file, STOP!
10005 14 2 7 No parameter file Eco Drive Mode (EDM), STOP!
KFU-2 (D7972).
10005 14 11 7 No control lever parameter file, Control STOP!
unit KPU (D7902).
KID (D7950).
10101 3 1 Battery voltage Control unit KCU (D7901). WARNING!
10101 4 1 Battery voltage Control unit KCU (D7901). STOP!
Check the fuses.
10102 3 1 Ignition voltage Control unit KCU (D7901). WARNING!
10102 4 1 Ignition voltage Control unit KCU (D7901). STOP!
Check the fuses.
10102 3 2 Ignition voltage Control unit KFU (D7971). WARNING!
10102 4 2 Ignition voltage Control unit KFU (D7971). STOP!
Check the fuses.
10102 6 2 2 Ignition voltage Control unit engine WARNING!
(D7940).
10102 3 3 Ignition voltage Control unit KFU-2 WARNING!
(D7972).
10102 4 3 Ignition voltage Control unit KFU-2 STOP!
(D7972). Check the fuses.
10102 3 11 Ignition voltage Control unit KPU (D7902). WARNING!
10102 4 11 Ignition voltage Control unit KPU (D7902). STOP!
Check the fuses.
10102 3 12 Ignition voltage Control unit KID (D7950). WARNING!
10102 4 12 Ignition voltage Control unit KID (D7950). STOP!
Check the fuses.
10103 6 1 Redundant voltage feed Control unit KCU STOP!
(D7901).
10103 3, 4 2 Redundant voltage feed Control unit KFU STOP!
(D7971).
10103 3, 4 3 Redundant voltage feed Control unit STOP!
KFU-2 (D7972).
10103 4 11 Redundant voltage feed Control unit KPU STOP!
(D7902).

Error codes machine

tion
10103 3, 4 12 Redundant voltage feed Control unit KID STOP!
(D7950).
10104 3, 4 1 5V reference voltage Control unit KCU WARNING!
(D7901).
10104 3, 4 2 5V reference voltage Control unit KFU WARNING!
(D7971).
10104 3, 4 3 5V reference voltage Control unit KFU-2 WARNING!
(D7972).
10104 3, 4 11 5V reference voltage Control unit KPU WARNING!
(D7902).
10104 3, 4 11 1 5V voltage feed to steering wheel panel. WARNING!
10104 6 11 2 Background lighting, steering wheel WARNING!
panel.
10104 6 11 3 Function lighting, steering wheel panel. WARNING!
10104 3, 4 12 5V reference voltage Control unit KID WARNING!
(D7950).
10105 2, 6 2 1, 2 Reference ground Control unit KFU WARNING!
(D7971).
10105 2, 6 3 1, 2 Reference ground Control unit KFU-2 WARNING!
(D7972).
10106 6 1 24V voltage feed left-hand arm rest (mini STOP!
steering wheel/joystick control).
10106 6 2 1 24V voltage feed sensor frame. WARNING!
10106 6 2 2 24V voltage feed sensor mast. WARNING!
10106 6 11 1 24V voltage feed switch cab. WARNING!
10106 6 11 2 24V voltage feed switch cab. WARNING!
10106 6 11 3 24V voltage feed components cab. WARNING!
10106 6 11 4 24V voltage feed control breaker. WARNING!
10107 6 11 1 Guide lights dashboard panel. WARNING!
10201 40 12 CAN bus, control unit disappeared after STOP!
start-up, Control unit KID (D7950).
10201 41 12 CAN bus, control unit not found at STOP!
start-up, Control unit KID (D7950).
10201 42 12 CAN bus, segment error normal side, WARNING!
10201 43 12 CAN bus, segment error RedCAN side, WARNING!
10201 44 12 CAN bus, control unit misplaced, Control STOP!
unit KID (D7950).
10202 35 2 CAN bus drivetrain open circuit. STOP!
10202 36 2 CAN bus drivetrain communication error. STOP!
10204 35 1 CAN bus option cab, open circuit. STOP!

Error codes machine

tion
10204 36 1 CAN bus option cab, communication STOP!
error.
error.
error.
10301 2 1 Non-volatile memory Control unit KCU STOP!
(D7901).
10301 2 2 Non-volatile memory Control unit KFU STOP!
(D7971).
10301 2 3 Non-volatile memory Control unit KFU-2 STOP!
(D7972).
10301 2 11 Non-volatile memory Control unit KPU STOP!
(D7902).
10301 2 12 Non-volatile memory Control unit KID STOP!
(D7950).
10302 2 1 Application log Control unit KCU (D7901). STOP!
10302 2 2 Application log Control unit KFU (D7971). STOP!
10302 2 3 Application log Control unit KFU-2 STOP!
(D7972).
10302 2 11 Application log Control unit KPU (D7902). STOP!
10302 2 12 Application log Control unit KID (D7950). STOP!
10303 0 1 High temperature circuit board, Control STOP!
unit KCU (D7901).
unit KFU (D7971).
unit KFU-2 (D7972).
unit KPU (D7902).
unit KID (D7950).
10304 2 1 Processing time for software in Control STOP!
unit KCU (D7901).
unit KFU (D7971).
unit KFU-2 (D7972).
unit KPU (D7902).
unit KID (D7950).
10305 6 1 High power consumption Control unit WARNING!
KCU (D7901).
KFU (D7971).

Error codes machine

tion
KFU-2 (D7972).
KPU (D7902).
10305 6 12 High power consumption Control unit KID WARNING!
(D7950).
10306 3 2 1, 2, 3 Control breaker voltage Control unit KFU WARNING!
(D7971).
10306 4 2 1, 2, 3 Control breaker voltage Control unit KFU STOP!
(D7971).
10306 3 3 1, 2, 3 Control breaker voltage Control unit WARNING!
KFU-2 (D7972).
10306 4 3 1, 2, 3 Control breaker voltage Control unit STOP!
KFU-2 (D7972).
10307 2 1 Memory error Control unit KCU (D7901). STOP!
10307 2 2 Memory error Control unit KFU (D7971). STOP!
10307 2 3 Memory error Control unit KFU-2 (D7972). STOP!
10307 2 11 Memory error Control unit KPU (D7902). STOP!
10307 2 12 Memory error Control unit KID (D7950). STOP!

Error codes engine

• The display indicates an error code as it appears in the machine,
according to SAE J1939 in SPN/FMI.
• Supplier-code indicates the error code in accordance with the
engine manufacturer's specification.
Error codes Volvo TAD871VE
Display Supplier
(SPN/FMI) code Description Action
28/2 - + switches. WARNING
29/2 - Accelerator. WARNING
51/3 P02E612 Sensor throttle position. Engine speed limited to idling WARNING
speed.
speed.
speed.
speed.
speed. Engine difficult to start or does not start at all.
91/0 P012085 Accelerator. Speed limitation. WARNING
91/9 P012082 Accelerator. WARNING
91/19 P012083 Accelerator. Speed limitation. WARNING
94/0 P008B97 High fuel pressure. WARNING
94/3 P253912 Fuel pressure sensor. WARNING
94/18 P008A00 Low fuel pressure. Reduced output and torque. WARNING
97/0 P226985 Water in fuel. WARNING: Drain fuel prefilter,
see 6.2.2 Fuel system.
97/4 P226411 Sensor, water-in-fuel. WARNING
97/12 P226401 Sensor, water-in-fuel. WARNING
98/1 P250F00 Low oil level engine. WARNING: Check the oil level in
the engine. See 6.2.6 Engine oil.
98/4 P250A11 Sensor oil level engine. WARNING: Check the oil level in
98/5 P250A13 Sensor oil level engine. WARNING: Check the oil level in

Display Supplier
98/18 P108600 Low oil level engine. WARNING: Check the oil level in
100/1 P052400 Oil pressure too low. Reduced engine power or engine WARNING: Check the oil level in
is turned off. the engine. See 6.2.6 Engine oil.
100/3 P052012 Oil pressure sensor. STOP
100/5 P052013 Oil pressure sensor. STOP
100/18 P109300 Low oil pressure in engine. Reduced engine power or WARNING: Check the oil level in
engine is turned off. the engine. See 6.2.6 Engine oil.
102/0 P111800 Boost pressure too high. Reduced engine power. STOP
102/3 P010512 Sensor, boost pressure. Reduced engine power. STOP
102/5 P010513 Sensor, boost pressure. Reduced engine power. STOP
102/16 P111600 High charge-air pressure. STOP
105/0 P111A00 Boost temperature too high. Reduced engine power. STOP
105/4 P011011 Sensor, boost temperature. STOP
105/5 P011013 Sensor, boost temperature. STOP
105/16 P111900 High boost temperature. STOP
107/0 P10F800 Low pressure between air filter and turbo. WARNING
107/3 P100712 Sensor air pressure intake. WARNING
107/12 P100701 Pressure sensor air filter. WARNING
108/5 P222613 Sensor air pressure. WARNING
110/0 P021700 Coolant temperature too high. Reduced engine power. STOP: Check the coolant level.
See 6.2.5 Cooling system.
110/4 P011511 Sensor, coolant temperature. Engine hard to start. STOP
110/5 P011513 Sensor, coolant temperature. Engine hard to start. STOP
110/16 P111E00 High coolant temperature. STOP: Check the coolant level.
111/1 P256000 Low coolant level. STOP: Check the coolant level.
111/3 P255612 Sensor, coolant level. STOP
111/18 P111D00 Low coolant level. STOP: Check the coolant level.
131/3 P047012 Pressure sensor exhaust gases. Engine brake, low WARNING
performance.
131/5 P047013 Pressure sensor exhaust gases. Engine brake, low WARNING
performance.
131/12 P047001 Pressure sensor exhaust gases. WARNING
157/0 P008800 Fuel pressure, too high. Reduced engine power. WARNING
157/1 P008700 Fuel pressure, too low. The engine can be switched off. WARNING

Display Supplier
157/4 P019011 Pressure sensor fuel. Reduced engine power. WARNING
157/14 P00C600 Pressure sensor fuel. The engine turns over but does WARNING
not start.
157/16 P114700 Fuel pressure, high. Reduced engine power. WARNING
158/2 PID158/1 Voltage feed Control unit engine (D7940). The engine WARNING
may be difficult to start.
158/2 P05611F Voltage feed Control unit engine (D7940). Uneven torque. WARNING
158/3 - Voltage feed Control unit engine (D7940). WARNING
158/4 - Voltage feed Control unit engine (D7940). WARNING
172/4 P00D911 Ambient temperature sensor. Engine difficult to start at WARNING
low temperatures.
172/5 P00D913 Ambient temperature sensor. Engine difficult to start at WARNING
low temperatures.
173/0 P242800 Exhaust temperature too high. Reduced engine power. WARNING
173/16 P112E00 High exhaust temperature. WARNING
175/0 P029800 Oil temperature too high. Reduced engine power. STOP
175/4 P019511 Sensor, oil temperature. Speed limitation. STOP
175/5 P019513 Sensor, oil temperature. STOP
175/16 P112500 High oil temperature. STOP
190/0 P021900 Engine speed too high. Engine speed is limited. WARNING
190/16 P119D00 Engine speed too high. WARNING
411/3 P040912 Pressure sensor exhaust gas recirculation (EGR). WARNING
412/0 P112100 EGR temperature too high. Reduced engine power. WARNING
412/4 P040A11 Temperature sensor exhaust gas recirculation (EGR). WARNING
412/16 P112200 EGR temperature higher than normal. Reduced engine WARNING
power.
626/2 - Start button WARNING
626/3 P100212 Relay, preheating. Engine difficult to start at low WARNING
temperatures.
temperatures.
temperatures.
628/2 P060741 Memory error in Control unit engine (D7940). Engine does WARNING
not start.

Display Supplier
628/2 - Memory error in Control unit engine (D7940). Engine does WARNING
not start.
not start.
not start.
not start.
not start.
636/7 P001676 Camshaft speed sensor. The engine takes longer to start WARNING
than normal or does not start at all.
636/8 P034038 Speed sensor camshaft. The engine takes longer to start WARNING
than normal.
636/9 P034031 Speed sensor camshaft. The engine takes longer to start WARNING
than normal.
637/2 P03351F Crankshaft speed sensor. The engine takes longer to start WARNING
than normal. Reduced torque.
637/8 P033538 Crankshaft speed sensor. The engine takes longer to start WARNING
637/9 P033531 Crankshaft speed sensor. The engine takes longer to start WARNING
639/2 U001088 Control unit engine (D7940), communication error CAN WARNING
bus drivetrain (J1939).
Engine shut-off: the engine cannot be started.
Engine running: the engine can only be stopped by using
the emergency stop.
639/2 - Control unit engine (D7940), communication error CAN WARNING
the emergency stop.
639/9 - Control unit engine (D7940), communication error CAN WARNING
the emergency stop.
641/0 P004577 Variable turbo geometry too high value. Reduced engine WARNING
power.
641/2 P256214 Actuator variable turbo geometry. Reduced engine power. WARNING
641/3 P006E17 Actuator variable turbo geometry. Reduced engine power. WARNING
641/9 U010C00 Actuator variable turbo geometry. Reduced engine power. WARNING
641/17 P112B00 Variable turbo geometry temperature higher than normal. WARNING
Reduced engine power.

Display Supplier
647/3 P048012 Electromagnetic clutch cooling fan. Cooling fan drive WARNING
locked at 100%.
647/4 P048011 Electromagnetic clutch cooling fan. Cooling fan drive not WARNING
working, risk of overheating.
647/5 P048013 Electromagnetic clutch cooling fan. Cooling fan drive WARNING
locked at 100%.
651/3 P020112 Injector cylinder 1. The engine has reduced power output. WARNING
677/3 P061512 Start relay on the starter motor. Engine does not start. WARNING
679/3 P009012 Fuel pressure regulator (MPROP). Reduced engine WARNING
power.
power.
power.
679/7 P228D72 Fuel pressure regulator (MPROP). Reduced engine WARNING
power.
729/5 P054013 Preheating element. Engine difficult to start at low WARNING
temperatures.
temperatures.
729/7 P05407F Relay, preheating. Engine difficult to start at low WARNING
temperatures.

Display Supplier
729/12 P054001 Preheating element. Engine difficult to start at low WARNING
temperatures.
970/3 P100112 Stop-button on engine. The engine is switched off and WARNING
cannot be started.
cannot be started.
cannot be started.
970/11 P100190 Stop-button on engine. Engine cannot be started. WARNING
970/14 P100192 Stop-button on engine. Engine cannot be started. WARNING
1188/3 P024312 Actuator intercooler pressure control. WARNING
1239/14 P009400 Fuel leakage, minor. WARNING
1347/7 P06279C Fuel pressure pump. Reduced engine power. WARNING
1485/7 P068573 Voltage feed Control unit engine (D7940). WARNING
1639/3 P052612 Sensor fan speed. The cooling fan does not disengage. WARNING
1668/2 U008088 Engine control unit (D7940) communication error. WARNING
1761/3 P203A12 Level sensor AdBlue tank. WARNING
P203A86
1761/17 P114500 AdBlue level, below normal level. WARNING
1761/18 P203F00 AdBlue-level, low. Reduced engine power. WARNING
2000/9 U010000 Control unit engine (D7940) communication error CAN WARNING
2017/9 U014100 Control unit engine (D7940) communication error CAN WARNING
2036/9 U117100 Communication error with machine. WARNING
2659/10 P04007C EGR system. WARNING
2659/18 P04009C EGR system, low flow. WARNING
2791/2 P048613 EGR position sensor. Reduced engine power. WARNING
2791/3 P041A12 EGR unit. Reduced engine power. WARNING
2791/4 P041A11 EGR unit. Reduced engine power. WARNING
2791/5 P040313 EGR unit. Reduced engine power. WARNING
2791/9 U010A00 Communication error between EGR unit and Control unit WARNING
engine (D7940). Reduced engine power.
2791/11 P040392 EGR valve. Reduced engine power. WARNING
2791/12 P040341 EGR valve. Reduced engine power. WARNING

Display Supplier
2791/17 P114E00 EGR valve, temperature higher than normal. Reduced WARNING
engine power.
3031/0 P24FF00 AdBlue-temperature too high. WARNING
3031/4 P205A11 Temperature sensor AdBlue tank. WARNING
3031/5 P205A13 Temperature sensor AdBlue tank. WARNING
3031/12 P205A86 Temperature sensor AdBlue tank. Reduced engine power. WARNING
P205A01
3216/2 P220064 NOx sensor inlet catalytic converter WARNING
3216/5 P225D00 NOx sensor inlet catalytic converter WARNING
3216/9 U029D00 NOx sensor inlet catalytic converter Reduced engine WARNING
power.
3216/11 P220093 NOx sensor inlet catalytic converter Reduced engine WARNING
power.
3216/12 P22FB92 NOx sensor inlet catalytic converter WARNING
3216/14 P22001C NOx sensor inlet catalytic converter WARNING
3226/2 P220E64 NOx sensor outlet catalytic converter. WARNING
3226/3 P229E12 NOx sensor outlet catalytic converter. Reduced engine WARNING
power.
3226/5 P229E13 NOx sensor outlet catalytic converter. Reduced engine WARNING
power.
3226/7 P225F00 NOx sensor outlet catalytic converter. Reduced engine WARNING
power.
3226/9 U029E00 NOx sensor outlet catalytic converter. Reduced engine WARNING
power.
3226/12 P22FE00 NOx sensor outlet catalytic converter. WARNING
3226/13 P220E93 NOx sensor outlet catalytic converter. WARNING
3226/14 P220E1C NOx sensor outlet catalytic converter. WARNING
3241/4 P054411 Sensor exhaust temperature 1. WARNING
3241/12 P054401 Sensor exhaust temperature 1 WARNING
3361/12 P204F93 Metering valve AdBlue. Reduced engine power. WARNING
3361/12 P208A86 AdBlue pump. Reduced engine power. WARNING
3363/3 P20B112 Heating valve AdBlue tank. Risk that AdBlue freezes in WARNING
the tank.
the tank.
the tank.
3364/17 P207F9A Incorrect AdBlue quality. WARNING

Display Supplier
3464/3 P02E012 Actuator motor throttle. WARNING
3464/7 P02E09C Actuator motor throttle. WARNING
3464/10 P02E07C Actuator motor throttle. WARNING
3464/12 P02E09B Actuator motor throttle. WARNING
3468/2 P018564 Fuel temperature manifold. WARNING
3468/4 P018511 Fuel temperature sensor. WARNING
3468/16 P016800 Fuel temperature too high. Reduced engine power. WARNING
3509/3 P06B017 Voltage feed sensor A. WARNING
3509/4 P06B016 Voltage feed sensor A. WARNING
3510/3 P06B317 Voltage feed sensor B. WARNING
3510/4 P06B316 Voltage feed sensor B. WARNING
3511/3 P06E617 Voltage feed sensor C. WARNING
3511/4 P06E616 Voltage feed sensor C. WARNING
3519/4 P025A11 Sensor temperature AdBlue tank. WARNING
3519/5 P205A13 Sensor temperature AdBlue tank. WARNING
3597/3 P065712 AdBlue pump unit voltage feed A. No AdBlue additive. WARNING
3597/4 P065711 AdBlue pump unit voltage feed A. No AdBlue additive. WARNING
3598/3 P266912 AdBlue pump unit voltage feed B. Risk that AdBlue WARNING
freezes.
3598/4 P266911 AdBlue pump unit voltage feed B. Risk that AdBlue WARNING
freezes.
4334/4 P204A11 Pressure sensor AdBlue. Reduced engine power. WARNING
4334/5 P204A13 Pressure sensor AdBlue. Reduced engine power. WARNING
4354/3 P20B912 Hose heater A AdBlue. Risk that AdBlue freezes in the WARNING
hose.
hose.
hose.
4355/3 P20BD12 Hose heater B AdBlue. Risk that AdBlue freezes in the WARNING
hose.
hose.
hose.
4356/3 P20C112 Hose heater C AdBlue. Risk that AdBlue freezes in the WARNING
hose.

Display Supplier
hose.
hose.
hose.
4374/0 P202D7A AdBlue system, pressure leakage. WARNING
4374/1 P208A92 AdBlue pump unit, motor speed too low. No AdBlue WARNING
additive.
4375/0 P10AD12 Motor AdBlue pump unit. WARNING
4375/3 P208A12 Motor AdBlue pump unit. WARNING
4375/14 P21CAA1 Motor AdBlue pump unit. WARNING
4376/3 P20A012 Directional control valve AdBlue pump unit. AdBlue is not WARNING
pumped back to the tank when the engine is switched off.
4752/7 P245700 EGR cooler, temperature deviation. WARNING
5016/4 P26E711 AdBlue pump unit voltage feed D. WARNING
5392/31 P20E892 AdBlue pressure. Reduced engine power. WARNING
5394/3 P204712 AdBlue injection unit. No AdBlue additive. WARNING
5394/12 P204786 AdBlue injection unit. WARNING
5435/14 P204F94 AdBlue system. WARNING
5485/14 P10CE97 AdBlue pump unit, no return flow. WARNING
5765/10 P041A2A EGR temperature sensor. Reduced engine power. WARNING
520244/3 P009B12 Fuel pressure relief valve. Reduced engine power. WARNING
520244/12 P018F00 Fuel pressure relief valve. Reduced engine power. WARNING
520245/0 P016E00 Fuel pressure, too high. Reduced engine power. WARNING

Display Supplier
520245/1 P016F00 Fuel pressure, too low. Reduced engine power. WARNING
520245/16 P228F00 Fuel pressure above normal level. Reduced engine power. WARNING
520245/18 P228E00 Fuel pressure below normal level. WARNING
520335/5 U300001 Control unit engine (D7940). Engine does not start. WARNING
520416/9 U11F00 Communication error Control unit after-treatment system WARNING
(UDS). No AdBlue additive.
520688/0 P11A600 Exhaust temperature too high. WARNING
520688/3 P11A412 Sensor exhaust temperature. WARNING
520688/16 P11A500 Exhaust temperature higher than normal. WARNING

Table Error codes Cummins QSB6.7 Stage 3A/Tier 3
Error codes Cummins QSB6.7 Stage 3A/Tier 3
Display Supplier
91 / 3 131 Accelerator pedal or lever position sensor circuit. Major WARNING!
decrease in engine power. Only emergency operation
power.
91 / 4 132 Accelerator pedal or lever position sensor circuit. Major WARNING!
decrease in engine power. Only emergency operation
power.
91 / 9 3326 SAE J1939 multiplexing, system error accelerator pedal WARNING!
sensor. Engine speed limited to idling speed.
94 / 3 546 Sensor, injection pressure. WARNING!
94 / 4 547 Sensor, injection pressure. WARNING!
94 / 15 2261 Fuel pressure. Least serious level. Decrease in engine WARNING!
power.
94 / 17 2262 Fuel pressure. Least serious level. Engine difficult to start. WARNING!
Decrease in engine power.
94 / 18 559 Fuel pump feed pressure. Moderately serious level. The WARNING!
2215 engine control unit has detected fuel pressure in the fuel
rail, which is higher than the requested pressure. Engine
power decreases
97 / 3 428 Sensor circuit for water in fuel indicator. No performance WARNING!
1845 loss. No water in fuel warning available.
97 / 4 429 Sensor circuit for water in fuel indicator. No performance WARNING!

1846 loss. No water in fuel warning available.
97 / 15 418 Water in fuel indicator. The least serious level. Water has WARNING!
been detected in the fuel filter. Possible white smoke,
power reduction or difficult to start.
97 / 16 1852 Water in fuel indicator. Moderately serious level. Possible WARNING!
white smoke, power reduction or difficult to start.
100 / 1 415 Engine oil duct pressure. The most serious level. STOP! Very serious
Progressive power reduction that increases with time after
the warning. If the Engine protection shutdown function is
activated, the engine is switched off 30 seconds after the
red STOP light starts to flash.
100 / 2 435 Oil pressure switch sensor circuit. No performance loss. WARNING!
100 / 3 135 Oil pressure sensor circuit. No performance loss. WARNING!
100 / 4 141 Oil pressure sensor circuit. No performance loss. WARNING!
100 / 18 143 Engine oil duct pressure. Moderately serious level. No WARNING!
performance loss.
101 / 0 556 Crankcase pressure. The engine is switched off. WARNING!
101 / 2 1942 Crankcase pressure. WARNING!
101 / 16 555 Crankcase pressure. No performance loss. WARNING!
1974
102 / 2 2973 Intake manifold pressure sensor circuit. Engine power WARNING!
decreases.

Display Supplier
decreases.
decreases.
105 / 0 155 Temperature intake manifold 1. The most serious level. STOP! Very serious
105 / 3 153 Intake manifold air temperature sensor circuit. Possible WARNING!
white smoke. The fan remains switched on if controlled
by the engine control unit. No engine protection for the
intake manifold air temperature.
105 / 4 154 Intake manifold air temperature sensor circuit. Possible WARNING!
intake manifold air temperature.
105 / 10 783 Temperature inlet manifold. The engine is switched off. WARNING!
105 / 16 488 Circuit, temperature sensor inlet manifold. WARNING!
108 / 2 295 Barometric pressure. WARNING!
108 / 3 221 Barometric pressure sensor circuit. Engine power WARNING!
decreases.
108 / 4 222 Barometric pressure sensor circuit. Engine power WARNING!
decreases.
109 / 1 228 Sensor coolant pressure. Most serious level.
109/3 231 Sensor coolant pressure. No limitation. WARNING!
109/4 232 Sensor coolant pressure. No limitation. WARNING!
110 / 0 151 Engine coolant temperature. The most serious level. STOP! Very serious
110 / 3 144 Engine coolant temperature sensor circuit 1. Possible WARNING!
engine coolant temperature.
110 / 4 145 Engine coolant temperature sensor circuit 1. Possible WARNING!
engine coolant temperature.
110 / 14 1847 Engine coolant temperature high. The engine is switched WARNING!
off.
110 / 16 146 Engine coolant temperature. Moderately serious level. WARNING!
the warning.
111 / 1 235 Coolant level. The most serious level. Progressive power STOP! Very serious
reduction that increases with time after the warning. If
the Engine protection shutdown function is activated, the
engine is switched off for 30 seconds after the red STOP
light starts to flash.
111 / 2 422 Coolant level. The engine is switched off. WARNING!

Display Supplier
111 / 3 195 Coolant level sensor circuit. No performance loss. WARNING!
111 / 4 196 Coolant level sensor circuit. No performance loss. WARNING!
111 / 18 197 Coolant level. The most serious level. Progressive power WARNING!
reduction that increases with time after the warning. If
the Engine protection shutdown function is activated, the
engine is switched off for 30 seconds after the red STOP
light starts to flash.
157 / 0 449 Injector measurement, pressure channel number 1. WARNING!
1911 Moderately serious level. No noise or possible noise
from the engine associated with higher injection pressure
(particularly while idling or with a high load). Engine power
decreases.
157 / 1 2249 Injector measurement, pressure channel number 1. The WARNING!
most serious level. No noise or possible noise from
the engine associated with higher injection pressure
decreases.
157 / 2 554 Injector measurement, pressure channel number 1. The WARNING!
engine control unit estimates the fuel pressure and the
power output is reduced.
157 / 3 451 Injector measurement, channel number 1, pressure WARNING!
sensor circuit. Power and/or speed reduction.
157 / 4 452 Injector measurement, channel number 1, pressure WARNING!
sensor circuit. Power and/or speed reduction.
157 / 16 553 Injector measurement, channel number 1, pressure. WARNING!
Moderately serious level. No noise or possible noise
from the engine associated with higher injection pressure
decreases.
166 / 2 951 Imbalance between cylinders. WARNING!
168 / 16 442 Voltage battery 1. Moderately serious level. WARNING!
168 / 18 441 Voltage battery 1. Moderately serious level. WARNING!
173 / 0 2737 Exhaust temperature sensor. WARNING!
173 / 16 248 Exhaust temperature sensor. WARNING!
175/0 214 High engine oil temperature. Power and/or speed WARNING!
reduction.
175/3 212 Sensor, oil temperature. No limitation. WARNING!
175/4 213 Sensor, oil temperature. No limitation. WARNING!
175 / 16 421 High engine oil temperature. The engine is switched off. WARNING!
190 / 0 234 Engine crankshaft speed/position. The most serious level. STOP! Very serious
190 / 2 689 Engine's crankshaft speed/position. Engine may run WARNING!
2321 rough. May be difficult to start. The engine is run with
backup speed sensor. Engine power is reduced.
190 / 16 1992 Engine crankshaft speed/position. Moderately serious WARNING!
level. Engine speed signal indicates engine speed above
engine protection limit. Fuel injection disabled until engine
speed fails below the overspeed limit.
441 / 3 293 Auxiliary temperature sensor input signal 1. No WARNING!
performance loss.

Display Supplier
441 / 4 294 Auxiliary temperature sensor input signal 1. No WARNING!
performance loss.
441 / 14 292 Ambient temperature 1. Possible reduced engine power. WARNING!
611 / 4 238 Voltage feed no. 3, sensor. WARNING!
611 / 16 2292 Measuring device fuel inlet. Moderately serious level. WARNING!
Engine may be difficult to start. Engine power is reduced.
611 / 18 2293 Fuel injection unit. Moderately serious level. The engine WARNING!
has lower power output.
611 / 31 757 Control unit engine (D7940). Engine may be difficult to WARNING!
start.
612 / 2 115 The engine's magnetic crankshaft speed/position sensor WARNING!
425 has lost both signals. The fuel to the injectors is shut-off
and the engine cannot be started.
627 / 2 1117 No power supply with the ignition on. Possibly no WARNING!
noticeable performance decreases or the engine stalls
or is difficult to start.
627 / 12 351 Voltage feed to injectors. D7940 measured that injector WARNING!
boost voltage is low. Possible smoke, low power output,
engine misfiring, and/or engine will not start.
629 / 12 111 Engine control unit internal error. Engine might not start. WARNING!
1597
630 / 12 3697 Engine control unit memory error. Engine may not be WARNING!
able to start.
633 / 31 2311 Circuit error in fuel actuator no. 1. Possible low power WARNING!
output.
639 / 2 426 SAE J1939. Link error between Control unit engine WARNING!
(D7940) and other units in SAE J1939.
639 / 9 285 Timeout error for SAE J1939 multiplexer PNG. WARNING!
639 / 13 286 Configuration error for SAE J1939 multiplexer. WARNING!
644 / 2 286 Input signal from external speed request. WARNING!
651 / 5 322 Circuit for injector solenoid coil drive cylinder 1. The WARNING!
engine may misfire or run rough.
651 / 7 1139 Injector solenoid coil drive cylinder 1. The engine is WARNING!
switched off.
652 / 5 331 Injector solenoid cylinder #2 circuit. The engine may WARNING!
misfire or run rough.
engine is switched off.
switched off.
switched off.

Display Supplier
switched off.
switched off.
697 / 3 2557 External PWM drive circuit 1. WARNING!
697 / 4 2558 External PWM drive circuit 1. WARNING!
723 / 2 778 Engine reserve crankshaft speed/position sensor no. 2. WARNING!
2322 Possible low power output.
723 / 2 1376 Engine speed sensor error (camshaft). Possibly difficult to WARNING!
start. Engine power decreases.
723 / 7 731 Engine speed/position sensor camshaft and crankshaft. WARNING!
Engine runs at low power output.
974 / 3 133 Circuit for remote accelerator pedal or lever position WARNING!
sensor 1.
974 / 4 134 Circuit for remote accelerator pedal or lever position WARNING!
sensor 1.
1075 / 3 2265 Electric lift pump for the engine's fuel feed circuit. The WARNING!
engine may be difficult to start.
1075 / 4 2266 Electric lift pump for the engine's fuel feed circuit. The WARNING!
engine may be difficult to start.
1079 / 3 386 Voltage feed no. 1, sensor. Engine power decreases. WARNING!
1080 / 3 227 Voltage feed no. 2, sensor circuit. Engine power WARNING!
decreases.
decreases.
1172 / 3 691 Intake temperature sensor circuit for compressor WARNING!
turbocharger no. 1. Engine power is reduced.
1172 / 4 1172 Intake temperature sensor circuit for compressor WARNING!
turbocharger no. 1. Engine power is reduced.
1347 / 3 272 Circuit for fuel high pressure solenoid valve. Engine runs WARNING!
poorly and with reduced power
1347 / 4 271 Circuit for fuel high pressure solenoid valve. Engine runs WARNING!
poorly at idle and has low power output
1347 / 7 281 Fuel pumping element no. 1. Engine not running or has WARNING!
low power output.
1388 / 14 187 Circuit for auxiliary pressure sensor. Possible reduced WARNING!
engine power.
decreases.
3511 / 3 239 Voltage feed no. 3, sensor circuit. Possibly difficult to start WARNING!
the engine and rough running.

Display Supplier
decreases.
decreases.
3938 / 3 1978 Speed/load. WARNING!
3938 / 4 1979 Speed/load. WARNING!
4182 / 3 1411 Frequency potentiometer. WARNING!
4182 / 4 3695 Frequency potentiometer. WARNING!
4183 / 3 1412 Potentiometer (Droop Adjust Potentiometer). WARNING!
4183 / 4 3696 Potentiometer (Droop Adjust Potentiometer). WARNING!
5571 / 0 3741 Common rail relief valve. Most serious level. Engine WARNING!
coughing / stops / does not start / difficult to start.
5571 / 7 3727 Common rail relief valve. Reduced performance. WARNING!

Table Error codes Cummins QSB6.7 Stage 4/Tier 4f
Error codes Cummins QSB6.7 Stage 4/Tier 4f
Display Supplier Description Action

SPN/FMI code
27 / 4 2272 EGR valve position. WARNING!
Engine power decreases.
51 / 3 6497 Position sensor accelerator pedal. WARNING!
81 / 16 2754 Particulate trap inlet pressure. WARNING!
84 / 2 241 Engine speed sensor circuit. WARNING!
Engine speed is limited.
91 / 0 148 Position sensor accelerator pedal WARNING!
91 / 1 147 Position sensor accelerator pedal WARNING!
1358 Engine power decreases.
sensor.
Engine speed limited to idling speed.
sensor - CAN-bus data error.
94 / 3 546 Fuel pressure sensor. WARNING!
95 / 16 2372 Differential pressure, fuel filter. WARNING!
97 / 3 428 Water-in-fuel sensor circuit. WARNING!
No water in fuel warning available.
97 / 4 429 Water-in-fuel sensor circuit. WARNING!
No water in fuel warning available.
97 / 15 418 Water-in-fuel indicator high. Least serious level. WARNING!
Possible power reduction or difficult to start.
97 / 16 1852 Water-in-fuel indicator high. Moderately serious level. WARNING!
Possible power reduction or difficult to start.
100 / 1 415 Engine oil pressure low. STOP! Check the oil level in
Engine power decreases. engine, fill when necessary.


SPN/FMI code
100 / 2 435 Engine oil pressure sensor. WARNING!
100 / 18 143 Engine oil pressure low. WARNING! Check the oil level in
Engine power decreases. engine, fill when necessary.

101 / 15 1974 Crankcase pressure. Least serious level. WARNING!
102 / 2 2973 Inlet manifold pressure sensor circuit. WARNING!
102 / 3 122 Inlet manifold pressure sensor. WARNING!
102 / 4 123 Inlet manifold pressure sensor. WARNING!
102 / 16 124 Inlet manifold pressure sensor. Pressure below permitted WARNING!
limit value. Moderately serious level.
103 / 15 2288 Turbo #1 high speed. WARNING!
103 / 16 595 Turbo #1 high speed. Moderately serious level. WARNING!
103 / 18 687 Turbo #1 low speed. Moderately serious level. WARNING!
105 / 0 155 Circuit, temperature sensor inlet manifold. STOP! Very serious.
105 / 3 153 Inlet manifold temperature sensor. WARNING!
105 / 4 154 Inlet manifold temperature sensor. WARNING!
105 / 15 2964 Inlet manifold temperature high. Moderately serious level. WARNING!
105 / 16 488 Inlet manifold temperature high. Moderately serious level. WARNING!
107 / 15 5576 Engine air filter pressure. Least serious level. WARNING!
107 / 16 3341 Engine air filter pressure. Moderately serious level. WARNING!
108 / 3 221 Sensor air pressure. WARNING!
108 / 4 222 Sensor air pressure. WARNING!


SPN/FMI code
110 / 0 151 Engine coolant temperature. The most serious level. The STOP! Very serious. Check
engine's coolant temperature signal indicates that the coolant level.
coolant temperature is higher than the critical limit for
engine protection.
110 / 2 334 Sensor engine coolant. The coolant temperature sensor WARNING!
reads an incorrect value during starting.
110 / 3 144 Sensor engine coolant. WARNING!
110 / 4 145 Sensor engine coolant. WARNING!
110 / 16 146 Engine coolant temperature. Moderately serious level. WARNING! Check the coolant
The engine's coolant temperature signal indicates that the level.
coolant temperature is higher than the warning limit for
engine protection.
110 / 31 2646 Coolant temperature engine. The EGR valve has closed WARNING!
in order to reduce the coolant temperature.
111 / 1 235 Engine coolant level. Moderately serious level. Low WARNING!
coolant level detected. Check the coolant level, fill if
Engine power decreases. necessary.
111 / 3 195 Engine coolant level. WARNING!
6522
6523
111 / 9 3613 Coolant level sensor loss of communication. WARNING!
111 / 17 2448 Engine coolant level. Least serious level. WARNING!
Check the coolant level, fill if
necessary.
111 / 18 197 Engine coolant level. Moderately serious level. WARNING!
Engine power decreases. Check the coolant level, fill if
necessary.
157 / 0 449 Fuel pressure high. WARNING!
157 / 3 451 Injection pressure measurement bank 1. WARNING!
Power and/or speed reduction.
157 / 4 452 Injection pressure measurement bank 1. WARNING!
Power and/or speed reduction.
157 / 16 553 Fuel pressure high. WARNING!
157 / 18 559 Fuel pressure low. Moderately serious level. WARNING!
Engine coughing / stops / does not start / difficult to start.


SPN/FMI code
168 / 16 442 High Battery #1 voltage. Moderately serious level. WARNING!
6256
168 / 17 3724 Low Battery #1 voltage. Least serious level. WARNING!
Reduced performance.
168 / 18 441 Low Battery #1 voltage. Moderately serious level. WARNING!
The engine may stop or be difficult to start.
171 / 3 249 Sensor for ambient air temperature. WARNING!
175 / 3 6524 Sensor for engine oil temperature. WARNING!
175 / 4 6525 Sensor for engine oil temperature. WARNING!
190 / 0 234 Engine over-revving. STOP!
190 / 2 689 Main speed sensor error. WARNING!
190 / 2 Rotation speed/position sensor. WARNING!
190 / 16 2468 Engine crankshaft speed/position - Data above normal STOP!
level. Speed above critical level. Moderately serious level!
The engine is switched off.
191 / 9 3328 Transmission speed sensor output. WARNING!
237 / 13 4517 Vehicle identification number has not been programmed. WARNING!
411 / 2 1866 EGR-valve delta pressure. WARNING!
412 / 3 2375 EGR temperature sensor. WARNING!
412 / 4 2376 EGR temperature sensor. WARNING!
412 / 15 2961 EGR temperature. The least serious level. WARNING!
412 / 16 2962 EGR temperature. Moderately serious level. WARNING!
441 / 3 293 Extra temperature sensor # 1 circuit. WARNING!


SPN/FMI code
441 / 14 292 Extra temperature sensor # 1 - Special instructions. STOP!
Temperature limit exceeded.
558 / 13 432 Accelerator pedal idling validation circuit. WARNING!
Engine only running at idling speed.
558 / 19 3527 Accelerator pedal idling validation circuit. WARNING!
563 / 9 3488 Anti-lock braking system (ABS). WARNING!
563 / 31 4215 Anti-lock braking system (ABS) Active. Error message WARNING!
from ABS control unit.
Cruise control not working.
611 / 2 523 Speed sensor. WARNING!
612 / 2 115 Engine speed and position sensor circuit has lost the input WARNING!
from the magnetic sensor.
The engine stops and cannot be started.
625 / 9 291 Data link error (OEM / Vehicle Data Link) - Abnormal STOP!
degree of change.
Engine may not be able to start.
629 / 12 111 Engine control unit internal error. WARNING!
343 Engine may not be able to start.
630 / 12 3697 Engine control unit memory error. STOP!
Engine may not be able to start.
633 / 31 2311 Circuit, fuel injection valve. WARNING!
639 / 9 285 SAE J1939 multiplexing PGN time limit exceeded. WARNING!
639 / 13 286 SAE J1939 multiplexing, configuration error. WARNING!
640 / 14 599 Fuel injection valve. STOP!
641 / 7 2387 Variable Turbo Geometry valve circuit. WARNING!
641 / 9 2636 Variable Turbo Geometry valve circuit. WARNING!
641 / 11 2198 Variable Turbo Geometry valve. WARNING!
641 / 13 1898 VGT (Variable Geometry Turbo). WARNING!
2449 Reduced performance.


SPN/FMI code
641 / 15 1962 VGT (Variable Geometry Turbo). WARNING!
647 / 3 2377 Fan, control circuit. WARNING!
The fan may remain on continuously or be totally
inoperable.
647 / 4 245 Fan, control circuit. WARNING!
The fan may remain on continuously or be totally
inoperable.
651 / 5 322 Injector solenoid cylinder #1. WARNING!
The engine may misfire or run rough.
677 / 3 584 Circuit, start relay. WARNING!
Either the engine does not start or, in addition, the engine
has no start interlock.
677 / 4 585 Circuit, start relay. WARNING!
The engine has no start interlock.
697 / 3 2557 Extra PWM Driver 1. WARNING!
697 / 4 2558 Extra PWM Driver 1. WARNING!
701 / 14 4734 Extra input/output #1. No data messages between Control STOP!
unit, engine (D7940) and machine.
702 / 3 527 Extra input/output #2. WARNING!


SPN/FMI code
703 / 3 529 Extra input/output #3. WARNING!
723 / 2 778 Engine speed sensor #2. WARNING!
2322
723 / 7 731 Engine speed sensor/position sensor #2 mechanically WARNING!
misaligned between the camshaft and crankshaft.
729 / 3 2555 Air preheating element. WARNING!
6556 The intake air heaters can be ON or OFF the whole time.
729 / 4 2556 Air preheating element. WARNING!
6557 The intake air heaters can be ON or OFF the whole time.
748 / 9 3641 Transmission output retarder. WARNING!
862 / 3 6336 Crankcase ventilation heater. WARNING!
862 / 4 6337 Crankcase ventilation heater. WARNING!
974 / 3 133 Remote accelerator pedal or lever to position sensor 1. WARNING!
Remote accelerator pedal not working.
974 / 4 134 Remote accelerator pedal or lever to position sensor 1. WARNING!
Remote accelerator pedal not working.
974 / 19 288 SAE J1939 multiplexing, value error, remote accelerator STOP!
sensor.
Engine running only at idling speed.
1072 / 3 6418 Engine brake (compression) actuator 1. WARNING!
6421
6422
1075 / 3 6258 Electric lift pump for the engine's fuel feed. WARNING!
1075 / 4 6259 Electric lift pump for the engine's fuel feed. WARNING!
1081 / 9 3555 Engine - Wait for start lamp. WARNING!
1172 / 3 691 Turbocharger pressure temperature sensor. WARNING!
1172 / 4 692 Turbocharger pressure temperature sensor. WARNING!
1176 / 2 743 Turbo #1 Compressor Inlet pressure. WARNING!
1194 / 13 3298 Anti-theft encryption cores. WARNING!
1209 / 2 2554 Exhaust pressure sensor. WARNING!


SPN/FMI code
1231 / 2 3329 J1939 network 2. WARNING!
1267 / 3 338 Circuit idle shutdown vehicle accessory relay. WARNING!
1267 / 4 339 Circuit idle shutdown vehicle accessory relay. WARNING!
1323 / 31 1654 Engine misfiring cylinder 1. WARNING!
1347 / 3 272 Fuel valve high pressure. WARNING!
1377 / 2 497 Switch circuit. WARNING!
1378 / 31 649 Interval for changing engine oil reached. WARNING!
1387 / 3 1539 Extra pressure sensor circuit #1. WARNING!
1387 / 4 1621 Extra pressure sensor #1. WARNING!
1569 / 31 3714 Engine protection - Torque reduction - Critical error codes WARNING!
related to engine operation.
1623 / 9 3186 Tachograph output axle speed. WARNING!
1632 / 14 2998 Torque limitation. WARNING!
1639 / 0 4789 Fan speed. WARNING!
6467 Most serious level!


SPN/FMI code
1639 / 1 4791 Fan speed. WARNING!
6468 Most serious level!
1639 / 2 Fan speed. WARNING!
1675 / 31 3737 Starter motor overheat protection. The starter motor has STOP!
been switched off to avoid damage.
The start function is prevented until the starter motor has
cooled down.
1761 / 1 1673 AdBlue tank, level. Data below normal level. Most serious STOP!
level!
1761 / 3 1669 AdBlue tank, level sensor circuit. WARNING!
1761 / 4 1668 AdBlue tank, level sensor circuit. WARNING!
1761 / 10 4769 AdBlue tank level. WARNING!
1761 / 11 4739 AdBlue tank, level sensor. Unknown malfunction. WARNING!
1761 / 13 4732 AdBlue tank, level sensor. WARNING!
1761 / 17 3497 AdBlue tank level. Least serious level! WARNING!
1761 / 18 3498 AdBlue tank level. Moderately serious level! WARNING!
2630 / 3 2571 Outlet temperature intercooler. WARNING!
2630 / 4 2572 Outlet temperature intercooler. WARNING!
2789 / 15 2346 Temperature inlet turbine turbo. WARNING!
Decrease in engine power.
2791 / 5 2349 EGR-valve control unit. WARNING!
2791 / 15 1961 EGR-valve control unit, temperature. WARNING!


SPN/FMI code
3031 / 2 1679 AdBlue tank temperature. Temperature not in phase with WARNING!
surrounding environment.
3031 / 3 1678 AdBlue tank, temperature sensor. WARNING!
3031 / 9 4572 AdBlue tank temperature. WARNING!
3031 / 11 4737 AdBlue tank temperature. WARNING!
3216 / 2 3228 NOx sensor inlet. WARNING!
6458
6459
3218 / 2 3682 NOx sensor power supply. WARNING!
3226 / 2 1694 After-treatment outlet NOx sensor. The value from the WARNING!
NOx sensor is too high or too low.
3226 / 4 1887 NOx sensor outlet. WARNING!
6463
6464
3228 / 2 3681 NOx sensor power supply. WARNING!
3246 / 3 3319 After-treatment 1 exhaust filter outlet temperature. WARNING!
3361 / 2 2976 AdBlue temperature in metering unit. WARNING!


SPN/FMI code
3362 / 31 1682 AdBlue metering unit inlet pipe. WARNING!
3363 / 3 1683 AdBlue tank heater. WARNING!
3363 / 16 1713 AdBlue tank heater. Moderate serious level. WARNING!
3363 / 18 1712 AdBlue tank heater. Moderate serious level. Cannot thaw WARNING!
the fluid.
3364 / 2 3878 AdBlue pressure sensor. WARNING!
3364 / 3 1686 AdBlue quality sensor. WARNING!
3364 / 4 1685 After-treatment AdBlue quality sensor. WARNING!
3364 / 7 3876 After-treatment AdBlue pressure sensor. WARNING!
3364 / 9 3868 After-treatment AdBlue quality. WARNING!
3364 / 13 3364 AdBlue quality. WARNING!
3364 / 18 3867 AdBlue quality. Moderately serious level. WARNING!


SPN/FMI code
3464 / 3 6493 Electronic accelerator pedal. WARNING!
3510 / 3 227 Voltage feed no. 2, sensor circuit. WARNING!
Possibly difficult to start the engine and rough running.
Possibly difficult to start the engine and rough running.
3515 / 5 4743 Sensor AdBlue temperature 2. WARNING!
3515 / 6 4744 Sensor AdBlue temperature 2. WARNING!
3515 / 11 4745 AdBlue temperature 2. WARNING!
3521 / 11 4768 AdBlue properties. Unknown fluid in tank. WARNING!
3597 / 2 1117 Voltage feed 1. Low voltage to actuator on VGT (Variable WARNING!
Geometry Turbo).


SPN/FMI code
3597 / 12 351 Voltage feed injector. WARNING!
3597 / 18 1938 Voltage feed 1. Low voltage to actuator on VGT (Variable WARNING!
Geometry Turbo).
3610 / 2 6553 Particulate filter after-treatment system outlet pressure. WARNING!
3610 / 3 6552 Particulate filter after-treatment system pressure sensor WARNING!
outlet.
3610 / 4 6551 Particulate filter after-treatment system pressure sensor WARNING!
outlet.
3667 / 3 3139 Engine air shutdown circuit. WARNING!
3695 / 2 4213 Switch for regeneration, but in OFF position. Regeneration WARNING!
6568 required.
Possible frequent need for regeneration.
3936 / 7 6265 Particulate filter after-treatment system. WARNING!
4094 / 31 3543 NOx limits exceeded. Poor AdBlue quality. WARNING!
4096 / 31 3547 AdBlue tank empty. WARNING!
4185 / 31 1427 Relay for shutdown in the event of over-revving. WARNING!
4186 / 31 1428 Relay for shutdown in the event of low oil pressure. WARNING!
4187 / 31 1429 Relay for shutdown in the event of high engine WARNING!
temperature.
4188 / 31 1431 Relay for indication of low oil pressure. WARNING!
4223 / 31 1432 Relay for indication of high engine temperature. WARNING!
4334 / 16 3575 AdBlue pressure sensor. Moderate serious level. WARNING!
4334 / 18 3574 AdBlue pressure sensor. Moderate serious level! WARNING!
4337 / 10 4249 AdBlue metering temperature. WARNING!
4340 / 3 3237 AdBlue line heater 1. WARNING!


SPN/FMI code
4360 / 0 3229 SCR temperature inlet. Exceeded maximum engine WARNING!
protection temperature limit. Most serious level!
4360 / 2 3144 SCR temperature inlet. WARNING!
4360 / 15 3164 SCR temperature inlet. Least serious level! WARNING!
4360 / 16 3231 SCR temperature inlet. Exceeded maximum temperature WARNING!
limit. Moderate serious level!
4363 / 0 3165 SCR temperature outlet. Most serious level! STOP!
4363 / 2 3148 SCR temperature outlet. WARNING!
4363 / 16 3235 SCR temperature outlet. Most serious level! STOP!
4364 / 18 3582 SCR conversion of catalyst output. Moderate serious level. WARNING!
4376 / 3 3577 AdBlue return valve. WARNING!


SPN/FMI code
4765 / 2 3315 Catalyst (DOC) temperature inlet. WARNING!
4765 / 16 3251 Catalyst (DOC) temperature inlet. STOP!
4766 / 0 5387 Catalyst (DOC) temperature outlet. Most serious level. STOP!
4766 / 2 5386 Catalyst (DOC) temperature outlet. WARNING!
4766 / 15 5389 Catalyst (DOC) temperature outlet. Least serious level. WARNING!
4766 / 16 5388 Catalyst (DOC) temperature outlet. Moderate serious WARNING!
level.
4792 / 7 3751 SCR catalyst. WARNING!
4792 / 14 4585 SCR catalyst. Wrong system has been installed. STOP!
4794 / 31 3151 SCR catalyst, system missing. WARNING!
4796 / 31 1664 Catalyst (DOC) missing. WARNING!
5018 / 11 2637 Catalyst (DOC) WARNING!
5018 / 14 5617 Catalyst (DOC). WARNING!
5024 / 10 3649 NOx sensor outlet. Abnormal rate of change. WARNING!
5031 / 10 3583 NOx sensor outlet. Abnormal rate of change. WARNING!
5245 / 31 4863 Critical SCR-related error codes active. WARNING!


SPN/FMI code
5246 / 0 3712 Critical SCR-related error codes active. Most serious level! STOP!
5298 / 18 1691 Catalyst (DOC). Moderate serious level. WARNING!
Possible frequent need for regeneration of the
after-treatment system.
5394 / 2 3755 Metering valve AdBlue. WARNING!
5484 / 3 3633 Engine fan clutch 2. WARNING!
6456
5484 / 4 3634 Engine fan clutch 2. WARNING!
6457
5491 / 3 3562 AdBlue relay line heater. WARNING!
5491 / 4 3563 AdBlue line heater relay. WARNING!
5491 / 7 6537 AdBlue line heater relay. WARNING!
5571 / 0 3741 Common rail relief valve. Most serious level. WARNING!
5571 / 3 4262 Common rail relief valve. WARNING!
5571 / 15 5585 Common rail relief valve. Least serious level. WARNING!
5603 / 9 3843 Cruise control inactivate command. WARNING!
5603 / 31 3845 Cruise control inactivate command. WARNING!
5605 / 31 3844 Cruise control pause command. WARNING!
5742 / 3 4161 Temperature sensor particle filter after-treatment system. WARNING!


SPN/FMI code
5743 / 3 4164 SCR temperature sensor. WARNING!
5743 / 16 4166 SCR temperature sensor. Moderate serious level. WARNING!
5745 / 3 4168 AdBlue heater metering unit. WARNING!
5745 / 4 4169 AdBlue heater metering unit. WARNING!
5745 / 18 4171 AdBlue heater metering unit. Moderately serious level. WARNING!
5746 / 3 4155 AdBlue relay heater metering unit. WARNING!
5746 / 4 4156 AdBlue relay heater metering unit. WARNING!
5798 / 10 4251 AdBlue heater metering unit, temperature. WARNING!
6303 / 3 4865 Coolant level sensor. WARNING!
6303 / 4 4866 Coolant level sensor. WARNING!
6655 / 3 4951 ECU power lamp WARNING!
6511
6655 / 4 4952 ECU power lamp WARNING!
6512
6713 / 9 5177 VGT (Variable Geometry Turbo), software. WARNING!
6713 / 13 4956 VGT (Variable Geometry Turbo), not calibrated. STOP!
6713 / 31 4957 VGT (Variable Geometry Turbo), software without WARNING!
calibration.
6802 / 31 5278 AdBlue metering system frozen. WARNING!
6881 / 9 5653 Switch for preventing regeneration of the engine's WARNING!
6881 / 13 5654 Switch for preventing regeneration of the engine's WARNING!
6882 / 3 5393 Catalyst (DOC) temperature module. WARNING!


SPN/FMI code
6918 / 31 5632 Regeneration SCR system is prevented due to WARNING!
disconnected switch.
6928 / 31 5631 Regeneration SCR system prevented due to time limit. WARNING!
SCR system cannot perform cleaning.
520784 / 3 5183 Fan blade position sensor. WARNING!
6471
6472
6473
520808 / 31 5291 Engine emergency switch activated. WARNING!
520809 / 31 5292 Time exceeded since last test of engine air shutdown. WARNING!
520968 / 9 5939 Limited operation. WARNING!
520968 / 19 5941 Limited operation. WARNING!
524286 / 31 5617 After-treatment system. WARNING!

Error codes transmission

Error codes from the transmission generally have error code level
"WARNING", but error codes from the transmission can specify another
error code level in accordance with the action column in the table below.
• The display (D7930) indicates an error code as it appears in the
machine. The error codes are shown in the display on Control unit,
transmission (D7930) located in electronic box frame.
• Display SPN/FMI indicates error code acc. to SAE J1939.
• Supplier-code indicates the error code in accordance with the
engine manufacturer's specification.
Dana Spicer Off-Highway TE17000FF

Display Display Supplier
(D7930) SPN/FMI code Description Action
00.50 520349/1 7F09D Memory error in control unit transmission. Transmission STOP
2 in locked neutral position (Shutdown).
20.60 520293/1 7F065 Logical error Pressure sensor gear 1/3 (B7651). STOP
Transmission in locked neutral position (Shutdown).
20.61 520293/0 7F065 Logical error Pressure sensor gear 1/3 (B7651). STOP
Transmission in locked neutral position (Shutdown).
21.00 520297/1 7F069 Oil pressure sensor. Transmission in locked neutral STOP
position (Shutdown).
21.01 520297/0 7F069 Oil pressure sensor. Transmission in locked neutral STOP
22.00 520298/1 7F06A Oil pressure sensor. Transmission in locked neutral STOP
22.01 520298/0 7F06A Oil pressure sensor. Transmission in locked neutral STOP
23.00 520299/1 7F06B Oil pressure sensor. Transmission in locked neutral STOP
23.01 520299/0 7F06B Oil pressure sensor. Transmission in locked neutral STOP
24.00 520300/1 7F06C Oil pressure sensor. Transmission in locked neutral STOP
24.01 520300/0 7F06C Oil pressure sensor. Transmission in locked neutral STOP
30.04 520336/1 7F090 Low battery voltage. STOP
30.05 520336/0 7F090 High battery voltage. WARNING
31.00 520339/1 7F093 Reference voltage to sensor is too low. WARNING
31.01 520339/0 7F093 Reference voltage to sensor is too high. WARNING
34.00 520379/3 7F0BB Sensor fault in a speed sensor. Transmission in neutral WARNING
1 position.
34.01 520380/1 7F0BC Measured turbine rpm at start-up is too low. WARNING
Transmission in neutral position.


34.02 520381/0 7F0BD Measured drum rpm at start-up is too high. Transmission WARNING
in locked neutral position (Shutdown).
34.03 520382/1 7F0BE Internal rotation speeds indicate that there is no system WARNING
pressure when there should be. Transmission in locked
neutral position (Shutdown).
34.04 520382/0 7F0BE Internal rotation speeds indicate that there is system WARNING
pressure when there should not be. Transmission in
locked neutral position (Shutdown).
38.00 520371/0 7F0B3 Disengaged 4WD/2WD-selector has jammed in INFORMATION
engaged position or the feedback signal is incorrect.
38.01 520371/1 7F0B3 Engaged 4WD/2WD-selector has jammed in disengaged INFORMATION
position or the return signal is incorrect.
38.07 520371/7 7F0B3 4WD/2WD selector is in changeover mode (tooth INFORMATION
against tooth).
39.00 520372/0 7F0B4 Disengaged Low/High-selector has jammed in engaged INFORMATION
position or the feedback signal is incorrect.
39.01 520372/1 7F0B4 Engaged Low/High-selector has jammed in disengaged INFORMATION
position or the return signal is incorrect.
40.06 520286/2 7F05E Wrong direction from the gear selector. Transmission in WARNING
neutral position.
40.08 520257/3 7F041 The seat direction changed during operations. INFORMATION: Stop
1 Transmission in neutral position. the machine and select
neutral. Check seat
direction or show the
driver how the seat is
turned as per the correct
procedure.
41.06 520287/2 7F05F Incorrect gear selection from the gear selector. Control WARNING
unit does not allow change of gear range, however,
operation of machine is possible.
42.04 520320/1 7F080 Actual gear ratio too low. One or several clutches STOP or WARNING
slipping. Transmission in locked neutral position
(Shutdown).
42.05 520320/0 7F080 Actual gear ratio too high. One or several clutches STOP or WARNING
slipping. Transmission in locked neutral position
(Shutdown).
43.03 520291/4 7F063 Sensor temperature torque converter. WARNING
43.07 520291/1 7F063 Torque converter's temperature exceeds 100 °C. WARNING: Note the
6 error and try to reduce
temperature in torque
converter by operating
calmly.


43.08 520291/0 7F063 Torque converter's temperature exceeds 120 °C. WARNING: Stop the
The control unit protects the transmission and does not machine, select neutral
allow the temperature in the torque converter to exceed and apply full throttle
the maximum limit. Transmission in locked neutral (limited to 50 %) to cool
position (Shutdown). The engine is limited to 50 % of the transmission oil so
the maximum speed. that temperature drops
below 100 °C (error code
43/03 disappears).
When temperature in
torque converter is below
100 °C, resume work with
machine.
44.10 520390/9 7F0C6 Position accelerator pedal no message from engine's WARNING
control unit.
45.06 520264/2 7F048 Invalid combination for redundant digital speed inputs. INFORMATION
The speed is limited
46.05 520246/1 7F036 Max. torque at inching has been exceeded. WARNING: Stop the
5 machine, select neutral.
Reselect the gear.
47.01 520315/0 7F07B Transmission has exceeded the limit value for upper INFORMATION: Release
rpm. the accelerator pedal and
slow down the machine.
50.00 520208/4 7F010 Pressure sensor gear 1/3. Transmission in locked STOP
50.01 520208/3 7F010 Pressure sensor gear 1/3. Transmission in locked STOP
50.04 520208/1 7F010 Pressure sensor gear 1/3. WARNING
7
50.05 520208/1 7F010 Pressure sensor gear 1/3. WARNING
5
51.00 520209/4 7F011 Sensor transmission oil temperature. WARNING
51.01 520209/3 7F011 Sensor transmission oil temperature. WARNING
51.04 520209/1 7F011 Sensor transmission oil temperature, value error. INFORMATION
7
51.05 520209/1 7F011 Sensor transmission oil temperature, value error. INFORMATION
5
52.00 520210/4 7F012 Temperature monitor torque converter. INFORMATION
52.01 520210/3 7F012 Temperature monitor torque converter. INFORMATION
52.04 520210/1 7F012 Temperature monitor torque converter, value error. INFORMATION
7
52.05 520210/1 7F012 Temperature monitor torque converter, value error. INFORMATION
5
53.00 520211/4 7F013 Analogue input signal. INFORMATION
53.04 520211/17 7F013 Analogue input signal, value error. INFORMATION
54.00 520212/4 7F014 Reference voltage sensor 5 V. WARNING
54.01 520212/3 7F014 Reference voltage sensor 5 V. WARNING


7
5
56.00 520214/4 7F016 Pressure sensor gear 2. Transmission in locked neutral INFORMATION
56.01 520214/3 7F016 Pressure sensor gear 2. Transmission in locked neutral INFORMATION
56.04 520214/1 7F016 Pressure sensor gear 2, value error. INFORMATION
7
56.05 520214/1 7F016 Pressure sensor gear 2, value error. INFORMATION
5
7
5
7
5
60.00 520218/6 7F01A Sensor rpm drum. STOP or WARNING
If several rpm signals or the engine rpm signal are
incorrect, control unit transmission activates Limp-home.
60.01 520218/5 7F01A Sensor rpm drum. STOP or WARNING
60.03 520218/1 7F01A Sensor rpm drum, value error. STOP or WARNING
0
61.00 520219/6 7F01B Sensor rpm output shaft. STOP or WARNING
61.01 520219/5 7F01B Sensor rpm output shaft. STOP or WARNING
61.03 520219/1 7F01B Sensor rpm output shaft, value outside limit values. STOP or WARNING
0
61.04 520219/1 7F01B Sensor rpm output shaft, value error. STOP or WARNING


61.05 520219/0 7F01B Sensor rpm output shaft, value error. STOP or WARNING
62.00 520220/6 7F01C Sensor engine rpm. STOP or WARNING
62.01 520220/5 7F01C Sensor engine rpm. STOP or WARNING
62.03 520220/1 7F01C Engine speed information not available. Transmission STOP or WARNING
0 locked to gear 1 and 2 (Limp-home).
62.04 520220/1 7F01C Sensor engine rpm, value error. STOP or WARNING
62.05 520220/0 7F01C Sensor engine rpm, value error. STOP or WARNING
62.06 520314/1 7F07A Faulty engine speed information when the turbine speed STOP or WARNING
is calculated. Transmission locked to gear 1 and 2
(Limp-home).
63.00 520221/6 7F01D Sensor rpm turbine. STOP or WARNING
63.01 520221/5 7F01D Sensor rpm turbine. STOP or WARNING
63.03 520221/1 7F01D Sensor rpm turbine value error. STOP or WARNING
0
70.00 520224/4 7F020 Servo valve gear forward/reverse. Transmission locked STOP: Stop the machine
to gear 1 and 2 (Limp-home). and shift to neutral. Select
reverse gear.
reverse gear.
70.02 520224/6 7F020 Servo valve gear forward/reverse. Transmission in STOP
70.03 520224/8 7F020 Servo valve gear forward/reverse. Transmission in STOP
reverse gear.
71.00 520225/4 7F021 Servo valve gear 1/3. Transmission locked to gear 1 STOP: Stop the machine
and 2 (Limp-home). and shift to neutral. Select
reverse gear.
reverse gear.
71.02 520225/6 7F021 Servo valve gear 1/3. Transmission in locked neutral STOP
reverse gear.


reverse gear.
72.00 520226/4 7F022 Servo valve gear 2. Transmission locked to gear 1 and STOP: Stop the machine
2 (Limp-home). and shift to neutral. Select
reverse gear.
reverse gear.
72.02 520226/6 7F022 Servo valve gear 2. Transmission in locked neutral STOP
reverse gear.
reverse gear.
73.00 520227/4 7F023 Analogue output signal. Transmission locked to gear 1 STOP: Stop the machine
reverse gear.
reverse gear.
73.02 520227/6 7F023 Analogue output signal. Transmission in locked neutral STOP
reverse gear.
reverse gear.
74.00 520228/4 7F024 Analogue output signal. STOP
77.02 520239/3 7F02F All gear packages disengaged. Transmission in locked STOP
1 neutral position (Shutdown).
80.00 520231/4 7F027 Solenoid valve driving forward. Transmission locked to STOP: Stop the machine
gear 1 and 2 (Limp-home). and shift to neutral. Select
reverse gear.


reverse gear.
reverse gear.
81.00 520232/4 7F028 Solenoid valve driving reverse. Transmission locked to STOP: Stop the machine
reverse gear.
reverse gear.
reverse gear.
82.00 520233/4 7F029 Solenoid valve gear selection 1/3. Transmission locked STOP: Stop the machine
reverse gear.
reverse gear.
reverse gear.
83.00 520234/3 7F02A Digital output signal. Transmission locked to gear 1 and STOP: Stop the machine
reverse gear.
83.01 520234/4 7F02A Digital output signal. Transmission locked to gear 1 and STOP: Stop the machine
reverse gear.
85.01 520236/3 7F02C Towing detected. STOP
1
C4.99 520388/9 7F0C4 Abnormal update rate. WARNING
90.90 520352/3 7F0A0 Software error, Transmission control unit. Transmission STOP
1 locked in neutral position (Shutdown).
90.xx - 520192/0 7F000 Transmission fault Transmission in locked neutral STOP or INFORMATION
99.xx position (Shutdown).
90.xx 520432/xx 7F0F0 Communication error CAN bus drivetrain. One error STOP
code per message. Transmission in locked neutral
91.xx 520433/xx 7F0F1 Communication error CAN bus drivetrain. One error STOP
code per message. Transmission in locked neutral
92.00 520434/0 7F0F2 Software error, Transmission control unit. -
92.01 520434/1 7F0F2 Shifting has no direction. Transmission locked in neutral STOP
92.02 520434/2 7F0F2 Doubled direction. Transmission locked in neutral STOP
92.03 520434/3 7F0F2 Doubled shifting. Transmission locked in neutral STOP


92.04 520434/4 7F0F2 Doubled pulse pattern. Transmission locked in neutral STOP
92.06 520434/6 7F0F2 Signal error. Transmission locked in neutral position STOP
(Shutdown).
92.07 520434/7 7F0F2 Gear control position. Transmission locked in neutral STOP
(Shutdown).
(Shutdown).
0 (Shutdown).
(Shutdown).
2 (Shutdown).
3 (Shutdown).
92.14 520434/1 7F0F2 Signal error speed sensor 1-2. Transmission locked in STOP
92.15 520434/1 7F0F2 Signal error speed sensor 3. Transmission locked in STOP
92.16 520434/1 7F0F2 Signal error speed sensor. Transmission locked in STOP
92.17 520434/1 7F0F2 Faulty supply voltage. Transmission locked in neutral STOP
7 position (Shutdown).
92.18 520434/1 7F0F2 Signal error sensor. Transmission locked in neutral STOP
92.19 520434/1 7F0F2 Signal error pressure sensor. Transmission locked in STOP
92.20 520434/2 7F0F2 Incorrect configuration. Transmission locked in neutral STOP
92.30 520434/3 7F0F2 Incorrect configuration. Transmission locked in neutral STOP
93.00 520435/0 7F0F3 Memory error, Transmission control unit. Transmission STOP: Switch off the
locked in neutral position (Shutdown). machine and the main
electrical power.
electrical power.
electrical power.
electrical power.
electrical power.


electrical power.
electrical power.
93.10 520435/1 7F0F3 Memory error, Transmission control unit. STOP: Switch off the
0 machine and the main
electrical power.
93.11 520435/11 7F0F3 Memory error, Transmission control unit. STOP: Switch off the
machine and the main
electrical power.
electrical power.
electrical power.
electrical power.
electrical power.
electrical power.
electrical power.
electrical power.
electrical power.
0 locked in neutral position (Shutdown). machine and the main
electrical power.
95.71 520347/3 7F09B Control unit cannot interpret input data. Transmission STOP
1 locked in neutral position (Shutdown).
95.72 520436/2 7F09B Memory error, Transmission control unit. Transmission STOP: Switch off the
electrical power.
95.73 520436/2 7F09B Memory error, Transmission control unit. Transmission STOP: Switch off the
electrical power.
99.90 520438/0 7F0F6 Hardware fault. Transmission locked in neutral position STOP: Switch off the
(Shutdown). machine and the main
electrical power.


99.91 520438/1 7F0F6 CPU overload. Transmission in locked neutral position STOP: Switch off the
electrical power.
electrical power.
electrical power.
99.95 520394/3 7F0CA Communication error, Transmission control unit. STOP
1
99.99 520438/9 7F0F6 Calibration error hardware. Transmission locked in STOP
E0.01 520417/1 7F0E1 Machine's speed is too high to enable downshift. INFORMATION
5
E1.01 520418/1 7F0E2 Machine speed is too high to enable change of travel INFORMATION
5 direction.
E2.01 520419/1 7F0E3 Engine rpm is too high to enable change of travel INFORMATION
5 direction or select same travel direction again.
E3.00 520420/1 7F0E4 Machine's speed limitation is activated. INFORMATION
4
E3.01 520420/1 7F0E4 Machine's speed limitation is activated regardless of if INFORMATION
5 speed is above the limit value.
E3.02 520420/1 7F0E4 Machine's speed is higher than the upper limit value. INFORMATION
6
E4.00 520421/1 7F0E5 Abnormal speed reduction. The transmission INFORMATION
7 disconnects automatic gearing for a time.
E4.01 520421/1 7F0E5 Abnormal acceleration. The transmission disconnects INFORMATION
5 automatic gearing for a time.
E5.01 520416/1 7F0E0 Time for calibration reached. Calibrate the
3 transmission.
E6.00 520422/3 7F0E6 The operator is not sitting in the operator's seat and the INFORMATION
1 gear selector is not in neutral and/or the parking brake
is not activated.
E7.01 520423/1 7F0E7 Turbine speed exceed the limit value. Transmission INFORMATION
5 control unit forces engine to idle.
E8.01 520424/1 7F0E8 Conditions to switch between 2WD and 4WD not INFORMATION
5 satisfied. The machine must be stationary.
E9.01 520425/1 7F0E9 Conditions to switch between High and Low not INFORMATION
5 satisfied. The machine must be stationary.
E.1.01-0 520442 - 7F0FA - Calibration error. INFORMATION
5 520445 7F0FD
E.1.06 520442 - 7F0FA - Calibration error. INFORMATION
520445/6 7F0FD
9 520445 7F0FD
E.1.10 520442 - 5 7F0FA - Calibration error. INFORMATION
20445/10 7F0FD


520445 7F0FD
20445/14 7F0FD
520445 7F0FD
20445/16 7F0FD
4 520445 7F0FD
20445/25 7F0FD
20445/26 7F0FD
520445 7F0FD
20445/28 7F0FD
20445/29 7F0FD
5 520445 7F0FD
520445/6 7F0FD
9 520445 7F0FD
20445/10 7F0FD
520445 7F0FD
20445/14 7F0FD
520445 7F0FD
20445/16 7F0FD
4 520445 7F0FD
20445/25 7F0FD
20445/26 7F0FD
520445 7F0FD
20445/28 7F0FD
E.229 520442 - 5 7F0FA - Calibration error. INFORMATION
20445/29 7F0FD


5 520445 7F0FD
520445/6 7F0FD
9 520445 7F0FD
20445/10 7F0FD
520445 7F0FD
20445/14 7F0FD
520445 7F0FD
20445/16 7F0FD
4 520445 7F0FD
20445/25 7F0FD
20445/26 7F0FD
520445 7F0FD
20445/28 7F0FD
52044/29 7F0FD
xx.49 - - Undefined failure. STOP
Control unit transmission can generate two states with reduced

functionality to protect the transmission in the event of serious
malfunctions:
• "Limp-home"
In this condition only gear 1-2 in each direction can be used. When
the error occurs the transmission shifts to neutral position. To
continue, set the travel direction selector to neutral position and
select the travel direction again.
• "Shutdown"
In this mode the transmission is permanently in neutral to protect
the transmission.

5 Handling – Operating 163
5.4 Operating
5.4.1 While operating
General
DANGER
The machine's work area is large and visibility from
the operator's cab is restricted.
damage!
Keep in mind:
• Always check that no persons are in the way of the
machine or its equipment. Also check that the area
upwards is free. If there are unauthorised persons
or vehicles within the work area then the machine
must be stopped.
• The operator must always face in the travel
direction and should operate with special care
where persons or vehicles may appear.
• The operator must adapt the speed to the load and
ground conditions, visibility, and wind conditions,
etc.
• The operator must pay extra attention and operate
with special care near electric power lines,
viaducts, docksides, ramps, doorways, etc.
• Always operate carefully so that the attachment
does not collide with posts, power lines, etc.
• Use available visibility-enhancing equipment such
as rear view mirrors and camera ( ).
WARNING
inspection.
WARNING
Never operate the machine without wearing the
seatbelt.
Extreme danger!
Always use the seatbelt when operating the machine,
even when you expect a short shift. The seatbelt must
not be modified.

164 5 Handling – While operating
WARNING
The operator must exercise additional caution when
the reverse alarm is switched off.
Extreme danger!
Always check that no persons are in the way of the
machine or its equipment.
WARNING
Don't let the engine idle for a long time.
Risk of engine damage!
Turn off the engine during breaks in operation and
load handling.
Instructions
Make a habit of checking the following at regular intervals while
operating:
• that all gauges are within normal range, optimum operating value is
when the indicator needle is in the centre of the normal operating
range (straight up).
• that fuel indicator on the display shows that there is fuel in the tank.
NOTE
The fuel level should never go down to empty tank.
• that the AdBlue indicator on the display shows that there is AdBlue
in the tank.
Applies to machines with Volvo TAD871VE and Cummins QSB6.7
Stage 4/Tier 4f.
• that all warning lights are off.
• that horn, lighting, brake lights and direction indicators function
correctly.
• that all hydraulic functions function correctly.
• that no error codes have been generated (shown on operator's
display with error code indication and symbol). See 5.3 Error
codes, page 96.
When necessary, the control system can set speed limitations for the
machine. This happens in the event of the following:
• high hydraulic oil temperature.
• pressed down control breaker.
• operator's station not in position straight ahead or straight back,
see Use the revolving operator's station, page 177.

5 Handling – While operating 165
Eco Drive Mode

Eco Drive Mode consists of functions for reducing fuel consumption
and thereby environmental impact.
Eco Drive Mode contains three operating modes for how the machine's
fuel-saving functions should operate.
Depending on options, the operating mode can be set via customer

settings, see Setting of Eco Drive Mode, page 199.
Power
• No limitations activated.
Normal
• Operator guidance, stage 1.
• Performance loss, stage 1.
• Engine limited to idling speed in neutral position and passive
machine.
• The engine is switched off automatically after a certain time.
ECO
• Operator guidance, stage 2.
• Performance loss, stage 2.
• Engine limited to idling speed in neutral position and passive
machine.
• The engine is switched off automatically after a certain time.

166 5 Handling – Starting engine
5.4.2 Starting engine

General
WARNING
If it's difficult to start the engine, do not use start spray.
Risk of explosion!
In case of start problems, contact service.
Instructions
1. If the machine is equipped with an electric auxiliary heater,
disconnect the electrical cable from the machine .
2. Set the travel direction selector in neutral position or in the position
for activated parking brake.
The travel direction selector must be in neutral position or in the
position for activated parking brake, otherwise it is not possible
to start the engine.
3. Turn the ignition key lock to operating position, position I.
Current is now supplied to all electrical functions.
4. If the machine is equipped with an alcolock, blow in the alcolock .
The alcolock calculates the amount of alcohol in the breath.
In the event of a successful breath test, proceed as follows:
5. Press the start button and hold depressed until the starter motor
starts, release the start button when the engine starts.
When needed, the engine's control unit activates preheating during
a time period. The event menu for preheating indicates whether
preheating is activated, see Event menu preheating, description,
page 86.
Engine alternative Cummins QSB6.7 has automatic preheating
without an indicator for the operator.
NOTE
The starter motor can be activated 20-30 seconds then the circuit
cuts 1.5 to 2 minutes so the starter motor has time to cool. This
is to protect the starter motor.
5.4.3 Warming up
General
CAUTION
Never rev a cold engine at high engine speeds.
Run the engine at 1400-1500 rpm until it starts to get
warm.

5 Handling – Warming up 167
WARNING
Don't let the engine idle for a long time.
Turn off the engine during breaks in operation and
load handling.
Instructions
Engine
In cold temperatures the machine may not be used for tough work until
the engine and hydraulics are at operating temperature.
If the machine often needs to be cold started below -10 °C then an

engine heater and hydraulic oil heater should be installed.
Start the engine and let it idle for about 10 min, never rev a cold engine
as this can cause engine damage. Now warm run the engine at about
1400-1500 rpm until it starts to get warm. It is very important that the
engine is warmed up and the oil circulates well before the turbocharger
starts to operate at high revs.
Start working with the machine when the coolant has reached normal
operating temperature, approx. 85 °C, see Engine operating menu,
description, page 77.
Transmission
A cold transmission will not shift at temperatures below -12 °C. The
transmission must be warmed up. Follow the instructions for warming
up the engine.
Hydraulic system
Never operate a hydraulic function in the cold until the hydraulic oil is
warm, since there is a risk of damage and leakage in the hydraulic
system.
When the engine has reached its working temperature, warm run the
hydraulic oil by running the mast slowly up and down. Full actuation of
the hydraulic function may not be performed until the tank temperature
is +1 °C.
After this, all other hydraulic functions should be run slowly so that
warm oil circulates through the whole system, and this should be
repeated at least ten times.
NOTE
Hydraulic functions and the steering may feel sticky when the oil
is cold.

168 5 Handling – Gearshifting
5.4.4 Gearshifting
General
The machine is equipped with an automatic transmission. The system
shifts to a lower/higher gear under certain conditions, such as torque,
30
engine speed, travel speed, etc.
A cold transmission will not shift at temperatures below -12 °C. The
transmission must be warmed up, see warming up 5.4.3 Warming
up, page 166.
General about the automatic transmission:

• The transmission is locked in neutral position when the operator is
not sitting in the seat, see Transmission assumes neutral position,
page 170.
• Has a built-in control system, providing optimised operation.
013489
32 31 33 • Shows current gear on the control system display.

• The reversing lock prevents the travel direction being changed too
30. Switch for upshift quickly, i.e. prevents possible damage to the transmission. The
reversing lock is automatic and is dependent on engine speed
31. Switch for downshift
and travel speed.
32. Switch for automatic shifting • Shifting is variable (modulated) and gives smoother operation.
33. Travel direction indicator, Forward Neutral Normally start-up takes place in first gear. Use of first gear is
Reverse governed by engine speed, amongst other things.
Instructions
1 Deactivate the parking brake by first depressing the service brake
pedal and then move the travel direction selector from the parking
brake position to neutral/gear position.
2 Let the engine run at idle speed. Select travel direction.
a) Travel direction selector
Move the lever (position a):
• forward (F) for travel direction forward.
• reverse (R) for travel direction reverse.
• downwards or upwards (N) for neutral.
a
015234
015235
Travel direction selector on control lever lift/lower

5 Handling – Gearshifting 169
b) Travel direction selector on control for load handling

Move the switch (position b):
b • forward (F) for travel direction forward.
016970
Travel direction selector on control lever (joystick)
c) Travel direction selector on mini steering wheel or joystick

Move the switch (position c):
• forward (F) for travel direction forward.
c
3 Select automatic or manual shifting:
015435
Automatic shifting
1 Activate automatic shifting with the switch for automatic shifting A
(position 32). The system automatically shifts between all gears.
2 Automatic shifting is disengaged if the switch for upshift or
downshift (position 30, 31) is activated.
Manual shifting
1 Machine gearshifting takes place manually with the switch for
upshift or downshift (position 30, 31). The current gear is shown
on the display.
NOTE
In certain circumstances, the transmission may be forced to
reduce speed due to a problem. The control unit may then set the
transmission in "limp home" mode.
CAUTION
Changing the travel direction must be done with care.
The machine has a reversing lock as standard but
transmission service life is increased if change of
travel direction takes place at a lower travel speed and
engine speed.
Risk of machine damage! Axles may fail!
Change of travel direction must take place within the
limitations set by the reversing lock.

170 5 Handling – Steering
Transmission assumes neutral position

A control breaker senses when the operator leaves the operator's
station. The signal from the control breaker means that the transmission
automatically assumes neutral position. It is not possible to select any
travel direction.
NOTE
If the buzzer sounds when the operator sits in the seat and releases
the parking brake then the control breaker in the seat may be
malfunctioning. It is not possible to select any travel direction. The
function of the switch in the driver's seat must be checked.
The event menu appears if the driver's seat is left without the parking
brake being activated, see The event menu parking brake not activated
and no operator in the driver's seat, description, page 80.
5.4.5 Steering
General
The machine is equipped with servo steering. The steering wheel
movements are transferred hydraulically to the steering wheels on
the ground.
WARNING
The machine may not roll on a downhill grade if the
engine is off.
Hydraulic pressure for steering is missing and steering
capacity is lost! Danger!
Keep the engine running for hydraulic pressure.
5.4.6 Service brake

General
The brake pedal (position 12) used as service brake.
Use the brakes in a smooth but firm way. Brake pressure remains for
a time after the engine has been switched off, accumulated during
operation. If the accumulator pressure drops below a certain level then
the event menu shows low accumulator pressure. When the event
menu is shown the capacity of the service brake is limited. The buzzer
sounds and speed is limited. Finally, the parking brake is applied
automatically by a forceful spring in the brake cylinder. Check the
11 accumulators' sealing integrity if the pressure does not build up and is
not maintained, see chapter 6 Inspection and maintenance.
015214
12
11. Accelerator
12. Brake pedal

5 Handling – Parking brake 171
Service brake without inching

The service brake is combined with the declutching pedal. The drive is
declutched completely at a certain brake pressure.
If the brake pedal is applied without declutching taking place then the
engine can assist with braking the machine if the accelerator pedal
is released.
Service brake with inching
Switch for inching (position 29)
Switch for inching (position 29)

Inching is not activated.

012711 The brake is activated with the brake pedal and declutch takes place
when the pedal is depressed more than half of the pedal range.
Inching enabled.
Inching and braking are controlled with the brake pedal. When you
depress the pedal the drive starts to slip, i.e. inching. If the brake
pedal is pressed down more than half of the pedal range the drive
is completely declutched.
5.4.7 Parking brake

General
DANGER
or extreme danger!
WARNING
Never leave the operator's station without first applying
the parking brake.
Risk of machine starting to roll! Danger!
Apply the parking brake before leaving the operator's
station.
The parking brake is operated with the travel direction selector (position
1) on the steering wheel panel. Activate the parking brake by lifting
the control upward toward the steering wheel and then forward to
the parking brake position. The indicator light for the parking brake
(position 16) is lit red when the parking brake is applied and the event
menu appears, see Event menu parking brake, description, page 83.
To be able to deactivate the parking brake there must be an

accumulated brake pressure or the engine is started in order to reach
the brake pressure required when depressing the brake pedal.

172 5 Handling – Parking brake
Instructions
The parking brake is applied when:
• When the travel direction selector is moved to the position for the
parking brake (parking brake indicator light is lit red) and the event
menu for parking brake applied is shown, see Event menu parking
brake, description, page 83.
• The ignition is switched off (ignition key lock to 0 position).
When the machine is started again the parking brake is applied
without the travel direction selector being in the position for
activated parking brake. The indicator light for the parking brake
flashes to indicate that the parking brake must be activated and
deactivated with the travel direction selector to release the parking
brake. The light flashes even if the service brake is not activated at
the same time as you try to release the parking brake, even the
event menu is shown, see Event menu release the parking brake,
1 description, page 86.
015215
Check the sealing integrity of the accumulators if pressure is not

built up and maintained, see 6 Inspection and maintenance, page
1. Travel direction selector and parking brake 205.
An audible signal is activated if the operator gets up from the driver's

seat without first applying the parking brake and the event menu is
shown, The event menu parking brake not activated and no operator in
the driver's seat, description, page 80.
If the accumulator pressure drops below a certain level an error code is

shown in the display. The capacity of the service brake is restricted with
a low accumulator pressure error code. If the accumulator pressure
drops further, the parking brake is applied automatically by a strong
spring in the brake cylinder.
If the machine needs to be moved, see 7 Transporting the machine,

page 247.
Emergency brake
The parking brake can be used as emergency brake in emergency
situations.
CAUTION
The parking brake can be used as an EMERGENCY
BRAKE.
Brake shoe linings wear out and lose their braking
performance! Risk of unwanted movement by the
parked machine!
After emergency braking with the parking brake the
brake shoe linings must be checked as soon as
possible and replaced if necessary. Braking action of
the parking brake may be lost as the brake shoe linings
may have been worn down.
If the parking brake has been released mechanically
then it must always be reset to restore the machine's
parking brake function.

5 Handling – Heating / Air conditioning 173
DANGER
or extreme danger!
5.4.8 Heating / Air conditioning

General
The heating (EHC) /air conditioning system (ECC) receives heat
38 39 40 43 from the engine's cooling system and provides heat when the engine
is warm. For ECC the cooling function is generated by the cooling
compressor.
37
If necessary, the air conditioning can be controlled manually with the
36 switches for the fan, heating and air distribution. In addition to this there
are functions for recirculation and defroster.
35 With ECC: In the event of an open door, the air conditioning's cooling
compressor is switched off (cooling function and air drying stop). Close
the door and the cooling function is activated again.
012820
41 42 44 45 46
NOTE
Panel for heating and air conditioning system Open windows disrupt air conditioning function and capacity.
NOTE
Paper and similar located on the inner front panel can significantly
reduce air conditioning function and performance.
Setting the heating/air conditioning system

1 Activate automatic regulation of the air conditioning (position 39)
to achieve optimal function of the system.
Fan speed, temperature control and air distribution in the cab take
place automatically.
2 Set desired temperature (position 41, 42).
Set the temperature within temperature range 16 °C to 28 °C. See
temperature in display.
Setting of min. and max. respectively, shuts off automatic climate
control (control of fan, temperature and air distribution) and sets
the heat valve in min. (LO) and max. (HI) position respectively.
Cooling is activated/deactivated with the switch for cooling
(position 43) .
3 Align the panel nozzles as follows:
• in cold weather, aim the panel nozzles against the windows,
• in hot weather, aim the panel nozzles upwards.
4 Manual setting the fan's capacity is made with the switch for the
fan (position 38, 40). Return to automatic control with the switch
(position 39).
Manual control is possible in five steps from Off to Max. Fan speed
is indicated by a bar in the operating menu.

174 5 Handling – Heating / Air conditioning
NOTE
When the fan is switched off all functions for heating/air
conditioning are stopped.
NOTE
When setting the fan capacity manually, automatic control of the
fan is stopped.
5 Manual setting of air distribution is performed using the switch for

air distribution (position 44, 45, 46).
NOTE
When setting the air distribution manually, automatic control of
the air distribution is stopped.
6 Normally, recirculation (position 36) and defroster (position 37)

do not have to be used.
NOTE
With EHC it is inappropriate to operate with recirculation unless it
is to avoid temporary exhaust gases or odours from outside.
Mist on windows
WARNING
Misting on the windscreens can lead to limited visibility
from the cab.
damage!
Make sure the windscreens are free of mist before
using the machine.
1 Set a warm temperature (position 41). Ideally use the defroster

function.
2 Set a fan speed to a faster position (position 40).
3 Direct air distribution (position 46) and panel nozzles to the
windscreen for good visibility through the windows.
4 Check that recirculation (position 36) is not engaged. Recirculation
may impair effective demisting.
5 Activate defroster (position 37).
The defroster controls the function fan, temperature and damper
015236
position to optimally heat and more quickly dry the air at the
windscreen for faster demisting. The function is active for 6
A minutes.
A NOTE
A. Panel nozzles The defroster function is active for 6 minutes. Check that
temperature control returns to the set value when the defroster
is switched off.
6 If there is a lot of mist, direct the panel nozzles to the windscreen

for optimal demisting.
With ECC: The cooling function will be active and help to
dehumidify the air .

5 Handling – Heating / Air conditioning 175
Setting the diesel heater

Direct start of heater
A B C The diesel heater is controlled by a separate timer with display, fitted

in the cab. Running time and up to three activation times can be set
D
using the timer.
D
Mo When the heater is not running or the machine's lighting is switched
Tu
We
Th
off, the timer reverts to standby mode after 10 seconds, if no button is
Fr
Sa
Su
depressed. Press the off/on button to wake the display.
O E
K
Direct start of heater
017917
G F 1. Wake the timer by pressing the off/on button (position G).
2. Press the front / rear (position D) until the heater symbol flashes in
A. Application bar the menu bar (position B).
B. Menu bar 3. Press OK (position E), the message field (position C) shows
C. Message field running time, and the heater symbol is shown in the status bar
(position F).
D. Front / rear
E. OK Setting the timer (1 - 3)
F. Status bar 1. Wake the timer by pressing the off/on button (position G).
G. Off / On 2. Press front / rear (position D) until the P-symbol flashes in the
menu bar (position B). Confirm the selection with OK (position E).
3. Set memory (1 - 3) with front / rear (position D), confirm with OK
(position E). The memory is indicated by a flashing number in the
application bar (position A).
4. Set day of the week with front / rear (position D), confirm with
OK (position E). The day of the week is indicated by the flashing
abbreviation in the application bar (position A).
5. Set start time (hour) with front / rear (position D), confirm with OK
(position E). The setting is indicated by the flashing hour in the
message field (position C).
6. Set start time (minutes) with front/rear (position D), confirm with
OK (position E). The setting is indicated by the flashing minutes in
the message field (position C).
7. Set the function with front / rear (position D), confirm with OK
(position E). The function is indicated by a flashing symbol in the
status bar (position F).
Normally, the heater is preset and only needs to be confirmed with
OK.
8. Set the desired running time with front / rear (position D), confirm
with OK (position E). The running time is indicated by the flashing
time in the message field (position C).
Normally, the running time is set and only needs to be confirmed
with OK.
Setting the clock
1. Wake the timer by pressing the off/on button (position G).
2. Press front / rear (position D) until the clock symbol flashes in the
message field (position B). Confirm the selection with OK (position
E).
3. Set day of the week with front / rear (position D), confirm with
OK (position E). The day of the week is indicated by the flashing
abbreviation in the application bar (position A).
4. Set hour with front / rear (position D), confirm with OK (position E).
The setting is indicated by the flashing hour in the message field
(position C).
5. Set minutes with front / rear (position D), confirm with OK (position
E). The setting is indicated by the flashing minutes in the message
field (position C).
6. Set running time with front / rear (position D), confirm with OK
(position E). The setting is indicated by the flashing time in the
message field (position C).

176 5 Handling – Stopping the engine - parking
Switching off timer start

1. Wake the timer by pressing the off/on button (position G).
2. Press front / rear (position D) until the P-symbol flashes in the
menu bar (position B). Confirm the selection with OK (position E).
3. Set memory (1 - 3) with front / rear (position D), confirm with OK
(position E). The memory is indicated by a flashing number in the
application bar (position A).
4. Press front / rear (position D) until OFF is shown in the message
field (position C). Confirm the selection with OK (position E).
Switching off the heater when it is active
1. Press the front / rear (position D) until the heater symbol flashes in
the menu bar (position B).
2. Press OK (position E).
5.4.9 Stopping the engine - parking

General
NOTE
Never disconnect the system voltage with the battery disconnector
when the engine is running! The voltage regulator may be
damaged.
WARNING
Always turn off the electric power when the machine is
left, e.g. when parking or at the end of the shift.
Risk of fire!
Turn off the electric power with the battery
disconnector.
Instructions
1. Stop the machine and set the travel direction selector in the
position for parking brake.
2. Tilt the mast slightly forward so that the underside of the forks can
rest on the ground. Lower the forks to the ground.
3. Let the engine run 1 minute at idle speed before stopping the
engine so that the engine cools down slightly and the turbo
bearings are lubricated.
4. Stop the engine by turning the ignition key lock to position 0.
If the start button (position 15) is pressed for more than one second
when the engine is already running then just the engine is stopped.
If the machine is going to be parked for a long time, e.g. after a
work shift is over, then the battery disconnector should be turned
to the OFF (0) position.
For machines with Volvo TAD871VE and Cummins QSB6.7 Stage
4/Tier 4f:
NOTE
Wait for two minutes before the system voltage is disconnected
with the battery disconnector so that the SCR system has time to
be drained of AdBlue, this is particularly important in cold weather.
Certain machines are equipped with automatic engine stop:

• In case the operator leaves the machine for some time without
stopping the engine, normally 5 minutes.

5 Handling – Turnable operator's station 177
5.4.10 Turnable operator's station

General
Turning the operator's station is primarily used to facilitate operations.
Use the revolving operator's station

The operator's station can, by using the rotate operator's station switch,
be rotated and locked in any position from 0-180 degrees.
Conditions to rotate the operator's station are:

• Control breaker must be inactivated.
• The operator must sit in the driver's seat.
180°
E • The machine speed must be lower than 5 km/h except when the
D operator's station is in zone C where the speed must be below
0.5 km/h.
C • The brake pressure must be above a certain pressure or the
parking brake activated.
B
• Right-hand arm rest in permitted position.
A • For mini-wheel/joystick control, the left-hand arm rest must be
0° lowered .
• Mini-wheel/joystick control disabled when rotating the operator's
station in zone C .
If any of the conditions are not fulfilled, event menus to guide you
through what needs to be changed are displayed, see Event menu
rotate the operator's station, description, page 90.
016607
NOTE
Remember that the angle/position of the back rest may limit the
options for turning the operator's station.
Shift between forward/reverse occurs at the transition from zone C to

either zone B or D. This means that the steering angle is changed
automatically. The function of the travel direction selector is also
adapted to the position of the operator's station.
Lighting such as headlights, brake lights, back-up lights and tail lights
are on both ends of the machine and are automatically switched on
correctly in relation to the direction the operator's station is facing.
Windscreen/window washing is also adapted according to the position

of the operator's station.

178 5 Handling – Turnable operator's station
Restrictions in machine functions

The machine's functions have different restrictions depending on which
zone the operator's station is located.
Table Restrictions in machine functions
Zone Restrictions
180°
E A No restrictions.
D
B Speed limitation can occur.
C Drive stopped.
C
Load handling functions inactivated.
B D Speed limitation when reversing (direction of forks) and

A driving forward. Speed limitations may be different when
0° driving forward and reversing.
E No speed limitation.
016607

5 Handling – Load handling 179
5.5 Load handling

General
During all lifting work, make sure that the max. lift capacity is not
exceeded, see machine plate or load diagram.
The forklift's capacity is indicated by three parameters:
018139
• position of load's centre of gravity
• lifting height
300 mm
• weight of the load
The capacity varies between models and versions, see the machine
and type plates, section 3.2 Plates.
Transport position
NOTE
The operator must sit in the driver's seat in order for the load
handling functions to work.
018152
Transport position
It is important to estimate the position of the centre of gravity. If the

machine appears to be side-heavy, the load should be lowered and
adjusted with side shift so that the load's centre of gravity is moved to a
position along the machine's centre line.
The function load handling refers to, e.g., to lift, lower, rotate, angle or
hold loads. Load handling also includes lifting devices for handling
different types of load, e.g. sidelift attachment.
018140
Load handling subfunctions.
Lift and lower • Lift/lower

• Tilt
• Side shift
• Spreading (positioning)
• Fork levelling
• Rotation, only for top lift
018141
Tilt
018142
Side shift

180 5 Handling – Load handling
018143
Spreading (positioning)
018144
Levelling
018157
Rotation

5 Handling – Load handling 181
Overload system
The machine can be equipped with an overload warning system.

Warning systems must ALWAYS be functional! The system is used for
stationary load handling, so that the machine's strength and forward
stability are not jeopardised.
When the machine approaches the stability limit, the following takes
place:
• buzzer in the cab sounds (indication to operator)
See 2.1 Safety and emergency equipment, page 8.
• warning figure is shown on the display (indication to operator)
See:
Event menu overload lift, description, page 82
Event menu overload tilt, description, page 82
Event menu overload lift and tilt, description, page 83
• load handling movement is stopped.
In this mode, the mast, and with that the load, can only be lowered
and then tilted out so that the buzzer stops and the display figure
is cleared.
The overload system is not intended for controlling lateral stability or

stability during operation. In addition, it does not take sloping ground
conditions into consideration.
For advice on the handling of the machine, see section 2.4 Keep in
mind, page 11.

182 5 Handling – Lifting load
5.5.1 Lifting load

General
There are different types of lifting tool for load handling, most common
are:
• forks
• inverted forks
• sidelift attachment for container handling
• top lift attachment mounted on forks
• top lift attachment mounted on inverted forks
• coil ram
There are three types of top lift attachment

• fixed 20'
• fixed 40'
• adjustable 20' - 40'
For a top lift attachment, the attachment must be aligned with all
four corners against the container both when locking and releasing
the twistlocks. When releasing, the container must also stand
securely with all four corners on the ground surface. The top
lift attachment is equipped with indicator lights that indicate its
different positions. The indicator lights are positioned to the right
on the top lift attachment.
This manual describes lifting using forks, and lifting using the top lift
attachment fitted on inverted forks.
DANGER
• Never handle unstable or loosely loaded goods.
Take great care when handling long, high or wide
goods to prevent the load from sliding off, being
damaged or tipping the machine.
• Remember not to exceed the maximum load
capacity, see the type plate. If necessary, estimate
the centre of gravity and determine the maximum
load capacity with the help of load diagram located
in the cab.
• Never tilt the mast forward with a load on it.
raised load.
Risk of load tipping over, being dropped or damage to
property or extreme danger!
Make sure that the load is positioned securely before
lifting.

5 Handling – Lifting load 183
DANGER
Make sure that the lifting equipment is marked with the
capacity data. There must always be a type plate from
Cargotec or other manufacturers with the capacity
data for all attachments.
damage!
Make sure that nothing other than approved lifting
equipment or attachments are used.
WARNING
Do not use a machine where the indicator lights are
out of order.
Danger of reduced safety during load handling!
If the indicator lights don't work, stop work with the
machine and repair.

184 5 Handling – Lifting load
Instructions for forks

1 Move forward towards the load, as close as possible.
• Aim to have the machine's centre line towards the load's
centre of gravity.
• The approach angle to the load should be as straight as
possible.
• Tilt the mast forwards slightly.
018145
• Lower the forks as low as possible and adjust the fork
spreading and insert them under the load.
• Tilt the mast backwards so that the forks are horizontal.
NOTE
When handling drums, strive to keep the forks as close together
as possible.
2 Keep the machine at a standstill with the service brake.

Alternatively, apply the parking brake if required and/or shift to
neutral. If necessary, use wheel chocks on the drive wheels.
DANGER
The operator must exercise extra caution during
load handling near electric power lines, by viaducts,
docksides, ramps, doorways, etc.
Extreme danger!
Use the parking brake and stop blocks!
3 Lift the load and tilt the mast backwards.

If the machine seems side heavy - lower the load and change the
lifting point using side shift so that the load's centre of gravity is
along the machine's centre line.
WARNING
018146
Forks (with or without load) are easily manoeuvrable

work tools with great strength.
damage!
Make sure that no person stands under a raised
attachment, whether it is loaded or not. Take great
care when driving.
Instructions for top lift attachment

1 Run towards the stack of containers, as close as possible. Strive
to line up the machine's centre line with the centre of the container.
2 Keep the machine at a standstill with the service brake.
Alternatively, apply the parking brake if required and/or shift to
neutral.

5 Handling – Lifting load 185
3 For adjustable attachment, adjust with spreading to relevant

container length.
Right light, C - Twistlocks unlocked, red light illuminates, indicates
that load is not secured.
4 Position the attachment slightly above the container. Adjust with
rotation, side shift and tilting.
5 Lower the attachment on the container.
The display shows the event menu for contact and indicates when
one to three twistlocks have contact.
018147
6 Middle light, B – Contact, orange light activated, indicates when
all four corner boxes have correct contact against the container,
event menu contact is switched off.
7 Lock twistlocks with the switch for twistlocks, see Switch for
twistlocks, automatic/manual locking (58), page 53.
If automatic locking of twistlocks is used, locking is automatic when
the attachment is in contact with the load.
Locking alternative is selected with the switch for automatic or
manual locking, see Switch for twistlocks, automatic/manual
locking (58), page 53.
018148
NOTE
For automatic locking of twistlocks, the parking brake must be
released.
8 Right light, C - Twistlocks unlocked, off.

Left light, A - Twistlocks locked, illuminates with green light and
indicates that load is secured and ready for lifting.
The lift function is disengaged when both right light, C - Twistlocks
unlocked, and left light, A - Twistlocks locked, are off. Left light, A -
Twistlocks locked, is activated with green light when the locking
process has been completed.
CAUTION
018149
Do not start to lift if light C "Twistlocks unlocked" is

on, or if any of the lights A "Twistlocks locked" or B
"Contact" are off.
The load is not secured!
Try to lock twistlocks once again.
9 Ready for lifting.

When the container is lifted, the light for contact (position B)
should go out. Use side shift to centre the load so that its lateral
point-of-gravity is along the machine's centre line.
018150

186 5 Handling – Transporting load
5.5.2 Transporting load

General
WARNING
Transporting loads is associated with major risks.
Risk of roll-over and tipping over! Chance of load
damage to property! Extreme danger!
• The machine must only be operated on even
surfaces, intended for the machine's total weight
and ground pressure.
• All transporting of loads must take place in
transport position. Exercise caution when
operating, think about the width and height so that
the mast or forks/attachment do not collide with
poles, cables, etc.
• Do not transport the load in a higher position than
necessary since this may cause the machine to roll
or tip over.
• Always operate with the load facing uphill on an
uphill or downhill grade, never operate or turn
across a grade.
• Operate the machine in reverse if the transported
load obscures visibility to the front.
raised load.
• The operator must avoid forceful acceleration
and heavy braking to prevent risk of tipping and
roll-over.
• The operator must always adjust the speed when
turning to prevent skidding and risk of roll-over or
tipping over.
In the event of tipping or roll-over, hold onto the
steering wheel and remain in the cab. Do NOT
attempt to jump out of the cab until any movement
of the machine has finished.
When handling special loads local regulations may
apply. Learn about them and follow them.

5 Handling – Transporting load 187

1 Lift the load slightly. Back away from the loading site.
2 Adjust the mast and load height to transport position.
Correct transport position is with the load as far down and in as
possible without obstructing visibility, see Transport position, page
187. The load's centre of gravity must be centred laterally.
018146
Instructions for top lift
1 Lift the load slightly. Back away from the stack.
When the load is lifted, the middle light, B - Contact, (orange), is
off. The function for twistlocks is then disengaged.
2 Adjust load height and tilt angle to transport position. See
Transport position, page 187.
018150
Transport position

When the machine is to be operated with or without a load, adopt
the transport position to minimise the risk of roll-over and imbalance
while operating.
018139
If the load blocks visibility ahead then the machine must be reversed.
NOTE
300 mm
When handling special loads local regulations may apply. Learn

what they are and follow them.
Transport position
The machine shall be run in transport position even without load to

maximise operator visibility.
When in transport position without a load, the mast must be vertical

and the forks raised slightly above the ground, approx. 300 mm. (See
figure to the left). The forks should, if possible, be spread so that both
300 mm
fork tips are visible, this means the machine's total length including
forks is visible.
018151
Transport position without load

188 5 Handling – Transporting load

When in transport position, the mast is tilted back and the load lifted for
good forward visibility, see the figure to the left. The load's centre of
gravity must be centred laterally.
The machine shall be run in transport position even without load to

maximise operator visibility.
When in transport position without a load, the mast must be vertical and
the attachment raised for good forward visibility, see figure to the left.
018152
Transport position with load
Operating on grades
It is important to operate with extreme care on grades since there's
an increased risk of tipping and rolling over. Remember the angle of
the ramp.
• Operating with a load.
Adjust load height and tilt angle to transport position, see Transport
position, page 187.
Always drive with the lifting attachment upwards in the grade,
regardless of travel direction, i.e. the truck must be reversed down
a grade.
• Operating without a load.
Lower the lifting attachment and tilt back the mast as far as
possible.
018154
Always drive with the lifting attachment upwards in the grade,

regardless of travel direction, i.e. the truck must be reversed down
Operating with a load on grades a grade.
Working near overhead high voltage power lines

Operate with extreme care in all work near overhead high voltage
power lines, keeping in mind the height of the lifting mast and load.
DANGER
If the machine comes into contact with overhead high
voltage power lines. Remain seated and call for help!
Extreme danger!
Remain in the cab. Wait for assistance.

5 Handling – Unloading 189
5.5.3 Unloading
General
There are different types of lifting attachments for load handling,
e.g. forks, coil rams and sidelift attachment or top lift attachment for
container handling.

1 Move forward and stop in front of the unloading location.
• If necessary, lift the load sufficiently for unloading, but no
higher.
• The approach angle to the unloading location should be as
straight as possible.
• Tilt the mast to vertical position.
018155 2 Move forward slowly until the load is in position above the
unloading surface.
3 Apply the parking brake if desired, or hold the machine stationary
with the service brake. Alternatively, shift to neutral.
4 Lower the load slowly and make sure that it is standing firmly on the
unloading surface, e.g. level ground or the stack of another load.
5 Reverse away slowly from the unloading location and raise/lower
the forks to transport position.
NOTE
For attachments that clamp, e.g. attachment for rolls of paper,
the switch and lever must be activated simultaneously in order for
the attachment to open.

190 5 Handling – Unloading
Instructions for top lift attachment

1 Run towards the stack of containers, as close as possible.
2 Lift the load over the stack.
Strive to centre the load over the container stack.
3 Apply the parking brake if desired, or hold the machine stationary
with the service brake. Alternatively, shift to neutral.
4 Position the load over the stack. Adjust with rotation, side shift
and tilting.
018156
5 Lower the load.
When contact is obtained, the middle light, B - Contact, is activated.
6 Open twistlocks. Left light, A - Twistlocks locked, goes out (green)
when release of twistlocks is initiated. Right light, C - Twistlocks
unlocked, illuminates (red) when the twistlocks are completely
open.
When releasing twistlocks with activated automatic locking of
twistlocks you must:
a. Activate the switch to open locked twistlocks until the red light
is on.
018149
b. Lift until the yellow light goes out before releasing the switch
to open the twistlock.
Never lift when twistlocks are in the process of being released.
NOTE
Automatically locked twistlocks are also opened manually.

5 Handling – Functions for load handling 191
5.5.4 Functions for load handling

Scales
Load weight is approximated with the operating menu for scales.
NOTE
The scales must be calibrated regularly with a known weight for
accurate weighing. The weight should be large for the greatest
accuracy.
NOTE
For calibration, contact service personnel.
1 Set the mast vertically.

2 Position the load at the same centre of gravity distance as for
calibration.
3 Perform the lifting movement and then lower the load slowly about
30 cm.
0:00pm
4 Select the operating menu for the scales with or and confirm
with . A border around the row for the current weight (position
b) indicates that the function is activated.
5 The different rows have different functions:
-1. 9 t a
Select row with or . Confirm the selection with .
74. 9 t b Undo the selection with .
a. Shows tare weight in tonnes or pounds (lbs).
522 . 9 t c The value shown in row (a) can be reset to zero (tared) using
016370
the function keys.

Select taring with or .
a. Shows tare weight in tonnes. Switch between taring (current tare weight is displayed) or to
b. Actual weight in tonnes (net weight). no tare (0 shown). Confirm with .
c. Total weight in tonnes (gross weight). b. Current weight in tonnes or pounds (lbs), (net weight).
The value in row (b) can be added to row (c).
Select row (b) with or .
Add the value in row (b) to row (c) with .
c. Total weight in tonnes or pounds (lbs) (gross weight).
The value in the row (c) can be reset.
Select row (c) with or .
The value on row (c) can be reset with .
Leave the menu with .

192 5 Handling – Functions for load handling
Tilt control
Tilt control always strives to hold the mast and the load vertically. The
system is load compensating and also takes into account the machine's
displacement when the load is picked up/put down. Compensation
for loading takes place after the lifting/lowering function has been
completed.
The function for tilt control is activated with the switch (position A).
1 Perform load handling, e.g. lifting/lowering the load.
2 Activate the function for tilt control with the switch (position A).
Indicator light (orange) in the roof panel gives the status:
• The light flashes: The mast's vertical position is being
adjusted.
• The light comes on with a constant light: The mast is in the
vertical position.
• The light has gone out: Tilt control is not active.
3 Continue with load handling.
Tilt control works continuously until the function is deactivated
A
016674
Tilt control is deactivated:

• If the tilt control switch (position A) is depressed.
• If the tilt function is activated with the linear lever for tilt or the
control lever.
• If the operator moves from the driver's seat. Tilt control stops
after 2 seconds.
• If the hydraulic control breaker is depressed.
• In the event the lift or tilt function is overloaded.
Height warning
A Height warning warns when the set lifting height is reached. Height
warning is adjustable according to customer requirements.
When the mast reaches a certain preset height (position A), the
machine warns and the event menu is shown.
The figure in the display is always shown when the lifting height
exceeds the set lifting height.
018159

Height limitation
Height limitation restricts how high the mast can be operated. Height
limitation is adjustable according to the customer needs.
When the mast reaches a certain preset height (position A), the
A machine stops the lift movement and the height limitation event menu
is shown. Lower the mast for continued load handling.
If it is necessary to lift above the height limitation, the function can

be bypassed. Activate the switch for bypassing the safety system
(position 47) and use the lift function. After a few seconds the switch
for bypassing the safety system (position 47) can be deactivated,
lifting/lowering can then be performed without bypassing.
Event menu in the display is always shown when the lift height exceeds
018160 the height limitation, see Event menu height limitation, description,
page 82.

194 5 Handling – Functions for load handling
Sidelift attachment
General
Max General
Points to consider when handling sidelift attachments with empty
container:
WARNING
Do not use a machine where the indicator lights are
out of order.
Danger of reduced safety during load handling!
If the indicator lights don't work, stop work with the
machine and repair.
• Before work begins, check the function of sidelift attachment's

indicator lights.
It is forbidden to use the attachment if the lights give incorrect
018161
indication or do not work.

Using the attachment without functioning indicator lights is a great
Transport position with side lift attachment
safety hazard.
• The brakes shall always be operated smoothly and with great care
according to the existing conditions.
• When operating without a load the sidelift attachment must be
lowered to the lowest position.
• When operating with a load the machine must be in transport
position, see the figure.
• It is forbidden to drive the machine with a load in a higher position
than that shown in the figure. The sidelift attachment, with or
without load, may only be lifted higher than that shown in the figure
when stacking.
• After stacking, the sidelift attachment must always return to the
transport position (with load) or the lowest position (without load)
before the machine can be operated again.
• During all operation the mast must be at maximum tilt backwards,
see the figure.
• If forward visibility is obscured by the load, the operator must
always reverse.
WARNING
Sidelift attachments (with or without load) are easily
manoeuvrable work tools with great strength.
damage!
Make sure that no person stands under a raised
attachment, whether it is loaded or not. Take great
care when driving.

Hoisting technique
1 Set spreading to the container length in question (position d).
A B C Right light, C - Twistlocks unlocked, red light illuminates, indicates
that load is not secured.
2 Drive slowly toward the container, adjust with side shift (position c).
3 Tilt the mast forward slightly (position b), lower the sidelift
attachment (position a) to the container and fit the two twistlocks
into the locking holes in the container so that both sides of the
attachment are resting on the container. Check that the indicator
light B comes on.
4 Locked twistlocks (position 54).
If automatic locking of twistlocks is used, locking is automatic when
53 the attachment is in contact with the load.
e
d
c NOTE
b
a For automatic locking of twistlocks, the parking brake must be
released.
5 Right light C — Twistlocks unlocked, off.

Left light A — Twistlocks locked, illuminates with green light and
indicates that load is secured and ready for lifting.
g CAUTION
015237
54
Do not start to lift if light C "Twistlocks unlocked" is
on, or if any of the lights A "Twistlocks locked" or B
Light panel on attachment. "Contact" are off.
A. Indicator light for locked twistlocks The load is not secured!
B. Indicator light, contact Try to lock twistlocks once again.
C. Indicator light for unlocked twistlocks
6 Tilt the mast backward and lift. Check that indicator light B for
53. Control for load handling
contact goes out when the container is lifted.
a. Control lever for lift and lower
7 Transport the container in transport mode. Reverse if the container
b. Control lever for tilt blocks the view.
c. Control lever for side shift 8 Releasing the container: Set the container down on the surface.
Check that the indicator light B comes on. Release the twistlocks.
d. Control lever for spreading
Check that the indicator light C comes on.
e. Control lever for levelling
g. Switch to open the twistlocks NOTE
54. Switch for twistlock, automatic/manual locking. For load handling with the control lever, see the plates on the
machine.

196 5 Handling – Customer settings via display
5.6 Customer settings via display

5.6.1 Menu for date and time
Description
Setting the time
1 Select menu for customer settings with or and confirm with
10:23
.
0
016375
10:23 2 Select SET TIME/DATE with or and confirm with .

CUSTOMER SETTI NGS
a. Setting the date and time
b. Setting units
0
SET TI ME/ DATE a c. Setting of Eco Drive Mode
SET SI / US UNI TS b
0
SET ECO DRI VE MODE c
017373
10:23 3 Select SET TIME with or and confirm with .

CUSTOMER SETTI NGS
0
SET TI ME 1 0: 2 3
SET DATE 2 01 1 - 0 9- 16
0
SET TI ME STYLE
014935
10:23 4 Adjust the hours with and , confirm with . Continue in this
SET TI ME way with the minutes and seconds. Leave the menu with .
07:15 : 45
0
014941

5 Handling – Menu for date and time 197
Setting the date

10:23
.
016375
0

CUSTOMER SETTI NGS
b. Setting units
0
0
017373
10:23 3 Select SET DATE with or and confirm with .

CUSTOMER SETTI NGS
0
SET TI ME 1 0: 2 3
SET DATE 2 01 1 - 09- 16

0
SET TI ME STYLE
015322
10:23 4 Adjust the year with and , confirm with . Continue in this
SET DATE way with the month and day. Leave the menu with .
2011- 0 9- 19
0
014942
Setting the time format

10:23
.
0
016375

198 5 Handling – Menu for date and time

CUSTOMER SETTI NGS
b. Setting units
0
0
017373
0
10:23 3 Select SET TIME STYLE with or and confirm with .

CUSTOMER SETTI NGS
0
SET TI ME 1 0: 2 3
SET DATE 2 01 1 - 0 9- 16
0
SET TI ME STYLE
015323
10:23 4 Select the time format 24h or 12h am/pm with or . Leave
SET TI ME STYLE the menu with .
0
2 4h
1 2h a m/ p m
0
014943
Setting the unit

10:23
.
0
016375
10:23 2 Select SET SI/US UNITS with or and confirm with .

CUSTOMER SETTI NGS
b. Setting units
0
0
017373

5 Handling – Menu for date and time 199
10:23 3 Select SI UNITS or US UNITS with or . Leave the menu

CUSTOMER SETTI NGS with .
0
SI UNI TS
US UNI TS
0
014936
0
Setting of Eco Drive Mode
The menu is only available if the machine is set for Eco Drive Mode
to be selectable by the operator.
10:23
.
0
016375
10:23 2 Select SET ECO DRIVE MODE with or and confirm with .
CUSTOMER SETTI NGS
b. Setting units
0
0
017373
10:23 3 Select POWER, NORMAL or ECO with or . Leave the menu

CUSTOMER SETTI NGS with .
For a more detailed description, see Eco Drive Mode, page 165.
0
POWER
NORMAL
0
ECO
017376

200 5 Handling – Menu for active error codes
5.6.2 Menu for active error codes

Description
1 Select the menu for ACTIVE ERRORS with or and confirm
10:23
with .
016376
0
a b c 2 The menu shows the active error codes.

Scroll through the error codes with or . Leave the menu
10:23 with .
ACTI VE ERRORS 1/ 1 0 d
a. Device that generated the error code.
k 0 11 1/ 548 0- 5 e b. Component error code concerns (SPN code).

c. Type of error (FMI code).
d. Number of active error codes. The first digit shows the error
j 0
being displayed, the second digit the number of active error
codes.
i 0 e. Information can be found in the operator's manual.

f. Symbol for the device that generated the error code.
014944
h g f g. Symbol for operator action.

h. Symbol for the error code level.
i. Number of error codes with the level INFORMATION.
j. Number of error codes with the level WARNING.
k. Number of error codes with the level STOP.
For more information, see Error codes, general, page 96.

5 Handling – Menu for inactive error codes 201
5.6.3 Menu for inactive error codes

Description
1 Select the menu for INACTIVE ERRORS with or and confirm
10:23
with .
016377
0
10:23
2 The menu shows the inactive error codes.
ERROR HI STORY 1/ 1 2 Scroll through the error codes with or . Leave the menu
with .
1 111/ 5 1 7 0- / 3
0
2 01 1- 0 9- 19 1 0: 23 For more information, see Error codes, general, page 96.
2 111/ 5 1 6 0- / 3
0 2 01 1- 0 9- 19 1 0: 23
3 0/ 0- / 0
0 00 0- 0 0- 00 0 0: 00
014945
5.6.4 Menu for statistics and history

Description
10:23 1 Select the menu for running times with or and confirm with .
0
016353
2 The menu shows the cumulative operating time for the machine's
10:23 1/ XX
components. This counter cannot be reset.
OPERATI NG HOURS
a. Operating time engine in hours.
121 2332 h
a b. Operating hours for transmission, with gear activated, in hours.
798 4 h c. Operating hours for hydraulic functions activated, in hours.
b
d. Proportion of engine operating hours at idling speed, in
374 3 h c percent.
48 % d Select the next statistics and history menu with or go back with
016354
. Leave the menu with .

202 5 Handling – Menu for statistics and history
3 The menu shows resettable operating time, since the last reset
10:23 2 / XX
for the machine's components.
OPERATI NG HOURS
a. Operating time engine in hours.
123 3 2 h b. Operating hours for transmission, with gear activated, in hours.
a
c. Operating hours for hydraulic functions activated, in hours.
798 4 h b
d. Proportion of engine operating hours at idling speed, in
374 3 h c percent.
48 % d Select which row should be reset by pressing momentarily.
Select row with or . Reset the row with .
016355
Reset all rows by pressing for more than 2 seconds.
Select the next statistics and history menu with or go back with
4 The menu shows driving distances.
10:23 3/XX
DISTANCE a. Cumulative driving distance in km or miles. This counter
cannot be reset.
123 3 2 km a b. Driving distance odometer 1 since last reset to zero in km or
miles.
798 4.1 km b c. Driving distance odometer 2 since last reset to zero in km or
374 3.5 miles.
km c
Select which row should be reset by pressing momentarily.
016356

5 The menu shows accumulated fuel statistics. This counter cannot
10:23 4/ XX
be reset.
FUEL
a. Total fuel consumption in litres or gallons.
163 4 5 l a b. Average fuel consumption in litres/hour or gallons/hour.
25. 1 c. Average fuel consumption in litres/100 km or gallons/100
l/h b miles.
15. 4 1/100km c d. Average fuel consumption in litres/lift or gallons/lift.
3.2 3 l/pcs d Select the next statistics and history menu with or go back with
016357
6 The menu shows resettable fuel statistics since the last reset.
10:23 5/ XX
FUEL a. Fuel usage in litres or gallons.
b. Average fuel consumption in litres/hour or gallons/hour.
134 2 l a c. Average fuel consumption in litres/100 km or gallons/100
25. 1 miles.
l/h b
d. Average fuel consumption in litres/lift or gallons/lift.
15. 8 1/100km c
4.1 4 l/pcs d Select row with or . Reset the row with .
016358

7 The menu shows accumulated load statistics. This counter cannot
10:23 6/ XX
be reset.
LOAD
a. Total number of lifts.
1 23 234 7 6 pcs a b. Average lift rate in number of lifts/hour.
1 23 7.3 pcs/h b Select the next statistics and history menu with or go back with
016359

5 Handling – Menu for services and settings 203
8 The menu shows resettable load statistics.

10:23 7/ XX
LOAD a. Number of lifts counter 1.
b. Number of lifts counter 2.
1 23
1 243 2 pcs a c. Average lift rate in number of lifts/hour.
1 23
2 33 pcs b Select which row should be reset by pressing momentarily.
1 23 5.2 pcs/h c
016360
9 The menu shows resettable load statistics.

10:23 10/ XX
LOAD a. Cumulative lifting load of 1000s of tonnes. This counter
cannot be reset.
234 76 1000t a b. Total lifting load since last reset to zero in tonnes.
234 76 t b c. Average load per lift since last reset to zero in tonnes/lift or
pounds/lift.
24. 3 t/pcs c
017819

10:23 11/XX
10 The menu shows resettable load and fuel statistics.
LOAD a. Average lifting load since last reset to zero in tonnes/hour or
pounds/hour.
15. 4 t/h a b. Average fuel consumption since last reset to zero in litres/hour
or gallons/hour.
25. 1 l/h b
c. Average fuel consumption since last reset to zero in litres/100
5.1 l/100t c tonnes or gallons/100 tonnes.
017820

5.6.5 Menu for services and settings

Description
10:23
Used for diagnostics, calibration and settings on the machine by
CUSTOMER SETTI NGS authorised personnel. Access code required.
0
014981

204 5 Handling – Menu for machine check
5.6.6 Menu for machine check

Menu for machine check, description
10:23 1 Select the menu for MACHINE CHECK with or and confirm
with .
016361
10:23
2 The menu shows lamp checking. This function switches on all the
MACHI NE CHECK lights on the machine in order to facilitate daily inspection.
Switch on all the lights on the machine with . The tick in the box
indicates that the lights are switched on.
NOTE
Run the engine at idle in order to prevent discharge of the
batteries.
016362
Select the next menu with or go back with . Leave the menu
with .
10:23 3
MACHI NE CHECK The menu shows central lubrication. This menu activates the
central lubrication for extra lubrication or function check of the
central lubrication.
Activate the central lubrication's main units with . The tick in the
box indicates that a lubrication cycle is activated.
Select the next menu with or go back with . Leave the menu
with .
016365

6 Inspection and maintenance 205
6 Inspection and
maintenance
General
This chapter describes:
• DAILY INSPECTION - performed by the operator.
Daily inspection describes the running inspection that significantly
contributes to making the machine a safe and reliable workplace.
• MAINTENANCE - performed by the operator.
Maintenance describes some simple maintenance actions.
• SERVICE - performed by trained service technician.
Service is performed according to a service schedule and by
service technicians. Service is described in the maintenance
manual.
It is the operator who is responsible for ensuring that the machine
comes in for service according to prescribed service intervals.
Procedures are described in the maintenance manual.
• ERROR CODE INFORMATION - read off by the operator.
Error code information is read off by the operator from the control
system's display in the cab. Depending on the type of error code, it
is handled by the operator or a service technician.
NOTE
All time information refers to operating time, that is, the time shown
by the hour meter on the panel.
CAUTION
Only spare parts approved by Cargotec may be used.
This is to maintain the machine's safety as well as to
meet warranty and service agreements!
Only use spare parts and fluids approved by Cargotec
in order to fulfil warranty terms.

206 6 Inspection and maintenance – Daily inspection
6.1 Daily inspection

General
Daily inspection of the machine is extremely important in order to
ensure that it is safe both for the operator and its surroundings.
Every operator should perform checks before a new work shift. In this
way, operators can avoid running defective machines with malfunctions
that have been generated or caused during an earlier work shift.
WARNING
inspection.
Instructions
Perform the following checks:
1. Visual inspection of the machine's exterior and engine
compartment. Pay attention to odours from fuel or electronic
equipment. Walk around the machine and check the following:
• Leakage from engine, fuel and AdBlue systems, transmission,
drive axle, steering cylinder, hydraulic hoses and hydraulic
cylinders.
DANGER
Residue from fuel, oils, grease or other flammable
materials on the engine or in the engine compartment
is a fire hazard.
Fire hazard!
Remove residue of flammable materials in the engine
compartment as soon as they are detected. Be extra
careful on hot surfaces such as exhaust systems,
manifolds or turbochargers. If leakage of oil, fuel or
coolant is detected, the reason should be investigated
and the fault corrected before starting the engine.
• Loose wheel nuts

Following a wheel replacement, check-tightening of the bolted
joints is very important (after approx. 4-5 operating hours)
• Damage to rims
• Uneven tyre wear - remove any objects that may penetrate the
tyres, e.g. glass, metal filings, etc.
• Any blisters or damage to the tyres - contact service
immediately to replace tyres that are blistered or damaged.
• Tyre pressure
• Damage or cracks in vital components and their mountings
such as lifting chains, fork mountings, mast and tilt cylinders

6 Inspection and maintenance – Daily inspection 207
DANGER
Cracks in materials or welds in load bearing structures
can reduce the machine's strength.
damage!
If there are cracks in materials or welds in
load-carrying structures/structural elements, the
machine shall be taken out of use immediately
and taken for repair. Contact Cargotec for repair
instructions.
• If the machine is equipped with sidelift attachment or top lift

attachment, check that sensors for twistlocks and contact are
clean and free from grease
• Cab with regards to damage and dirty windows, rear view
mirrors.
Also check that the cab is locked to the chassis.
• If the machine is equipped with hydraulic oil cooler, check that
it is in working order.
2. In cold weather:
• Check that wiper blades have not frozen to the windscreen.
WARNING
Attempting to manually move the wiper armswill
damage the wiper motor's gear or shaft.
Damage to the wiper motor's gear or shafts.
Never try to manually move the wiper arms.
• Remove snow and ice from air inlets and radiator grill.
• Antifreeze in washer fluid.
• Disconnect the electric auxiliary heater for the cab and engine
. The auxiliary heater for the engine does not heat the
AdBlue tank and AdBlue hoses.
3. Check fluid levels for the following fluids in accordance with the
description, see . Top up, if necessary, with the correct fluid:
• Hydraulic oil.
• Oil for brake system .
• Batteries' electrolyte level.
• Coolant.
• Washer fluid - windows.
• Engine oil, see Engine oil, general, page 225
• Transmission oil.
4. Check the engine
• Check the engine's air filter indicator, also check and drain
the water separator under the fuel prefilter if required (Volvo
engine) and the fuel filter (Cummins engine). For a description,
see Air filter engine, general, page 223 and Fuel system,
general, page 216.

5. Start the machine according to instructions and check:

• Instruments - warning lamps, indicators, any error codes.
• Fuel level - the gauge must not show empty tank.
• AdBlue– level - the gauge must not show empty tank.
Only applies to certain engine alternatives.
Operating the machine without AdBlue leads to restricted
engine power output. In serious cases, a service technician
may need to reset the engine in order to regain full
performance.
• Lighting, direction indicators, signal, brake lights, warning lights
and reflectors, check function and any other considerations.
All the lights on the machine can be switched on simultaneously
with the menu for machine check, see Menu for machine
check, description, page 204.
• Windscreen wipers.
• Check that mirrors are intact, clean and well-adjusted for
visibility all around the machine.
• Cooling function in the ECC .
6. Operate the machine slowly/carefully and check the following
functions:
• Brakes - check-brake at least three times.
• Steering - in both directions.
• Transmission - all gears - forward and reverse.
• Noise from engine, transmission or drive axle.
7. Run all functions with hydraulic cylinders (lift, tilt, side shift and
spreading) to their end positions for lubrication of the cylinder
barrels and piston rods.

6 Inspection and maintenance – Daily inspection 209
8. If the machine is equipped with sidelift attachment or top lift

attachment, check the lift attachment and that:
• Indicator lights for twistlocks and contact are working.
2 • The contact pins for the twistlocks can be moved up and down
easily. Note that a contact pin that binds in the upper position
can indicate contact despite the frame not being positioned
against the container.
• Check the function of the twistlocks. This is done by lifting an
empty container until the light "Contact" goes out. It should not
now be possible to open the twistlocks.
5
007007
1. Sensor twistlock
2. Sensor contact
3. Lock guide
4. Lift pin
5. Contact pin
WARNING
Make sure that the engine is off when working with
twistlocks.
Twistlocks can be locked automatically if all sensors
for contact are activated manually at the same time.

9. For central lubrication :

Make sure grease has not seeped out from the safety valve
(position A). This is a sign that the central lubrication is not working
properly.
10. Check the machine's operating hours - notify the
foreman/supervisor if the machine is close to a service interval.
11. Notify the foreman/supervisor immediately if any defects are
detected on the machine.
WARNING
Do not use the machine if the system for locking
containers does not work.
A Safety valve
damage!
B Filler nipple
Use of the machine must be discontinued, and it has to
be taken to a service workshop for needed actions.
12. Check if any error codes are active.

See 5.3 Error codes, page 96.
13. Make sure that AdBlue is drained from the hoses when the
machine is turned off. The AdBlue– pump can still be heard for
short time after the engine has been switched off.
The system voltage must not be cut with the battery disconnector
before the pump has stopped.
Only applies to certain engine alternatives.

6 Inspection and maintenance – Maintenance 211
6.2 Maintenance
General
The following maintenance actions are described in this chapter:
– Cleanliness, general, page 214
– Fuel system, general, page 216
– Windscreen washer, general, page 221
– Wiper blades, general, page 222
– Air filter engine, general, page 223
– Cooling system, general, page 224
– Engine oil, general, page 225
– Transmission oil, general, page 227
– Hydraulic system, general, page 228
– Oil, brake system, general, page 229
– Tyres and rims, general, page 230
– Accumulator, general, page 232
– Central lubrication, general, page 233
– Battery and battery disconnector, general, page 234
– Fuses for electrical system, general, page 236
– Lighting, general, page 244
Safety during maintenance

Observe the following when maintenance work is to be performed:
• Always switch off the engine during service work. The only
exception is when service work requires engine power.
• Use stop blocks at the wheels.
• No work may be carried out on the machine without the right
knowledge and skills to do the work correctly. Maintenance
performed incorrectly may be dangerous.
• Always use a hard hat, protective glasses, gloves, work shoes and
other protective items as required by the work situation.
• Read all plates and instructions on the machine and in the
operator's manual before performing any maintenance. Each one
contains important information about handling and maintenance.
• Avoid spills when draining/filling oils, fuel and AdBlue. Use
reservoirs/tanks, pump, hose, etc. for safe handling. Oils, fuel
and AdBlue cause environmental damage. They should be taken
care of by an authorised company. AdBlue is also corrosive
and damages electrical wiring, etc. and must be rinsed away
immediately if spilt.
• Always drain the pressure from the accumulators before working
on the hydraulic system.

212 6 Inspection and maintenance – Maintenance
Tilting the cab
WARNING
Never work under a cab that is not tilted over its
balance position or secured by other means.
Risk of crushing injury.
Always tilt the cab as far as possible. At the maximum
A,B,D C tilt angle (on a horizontal surface), the centre of gravity
of the cab means that it cannot tip back.
C The cab must always be tilted over its balance position. If the lateral
space is insufficient, the cab must always be secured against accidental
lowering by means of a stay.
A B Preparations:
• Park the machine on a horizontal surface.
• Set the gear and travel direction selector to neutral.
• Tilt the mast forward and lower the forks.
• Apply the parking brake.
• Check that there are no loose items in the cab.
• Close the doors.
Tilting
1. Turn both lock handles (position C) so that they are located in their
outer position to loosen the cab from the frame.
2. Turn the pump valve (position B) clockwise.
3. Fit the pump rod in its bracket (position A).
4. Pump until the cab has reached the end position.
NOTE
018185
D
Stop pumping/raising when the cab is at the end position, otherwise
A. Pump rod bracket the pump valve will be difficult to turn.
B. Pump valve
Lowering
C. Lock handle (figure shows the open position)
1. Turn the pump valve (position B) anticlockwise.
D. Control buttons
2. Fit the pump rod in its bracket (position A).
3. Pump all the way until the cab makes contact with the frame.
inner position in order to lock the cab to the frame.

6 Inspection and maintenance – Maintenance 213
Electric tilting
outer position to loosen the cab from the frame.
2. Turn the pump valve (position B) clockwise.
3. Use the control buttons (position D) to raise the cab to the end
position. Depress both buttons simultaneously.
NOTE
Stop pumping/raising when the cab is at the end position, otherwise
the pump valve will be difficult to turn.
Electric lowering
1. Turn the pump valve (position B) anticlockwise.

2. Use the control buttons (position D) to lower the cab until it makes
contact with the frame. Depress both buttons simultaneously.
inner position in order to lock the cab to the frame.

214 6 Inspection and maintenance – Cleanliness
6.2.1 Cleanliness
Cleanliness, general
Dirt has a negative impact on performance. Experience shows that
clean machines have fewer malfunctions.
The machine should be washed regularly for optimal functionality.

Keep the following in mind when washing:
• Run the hydraulic cylinders to the inner positions.
• Use mild cleaning agents.
Use a degreaser if necessary. Scrub if necessary.
• Use a high-pressure washer, wide water jet.
CAUTION
High-pressure washing of sensitive
components may lead to short-circuiting and
cause malfunction.
Product damage!
Do not use a high-pressure washer on the
cab, radiator, battery compartment, electric
components, control units, connectors, cable
joints, cylinder seals, stub axles, axle seals and
chains.
NOTE
After washing with de-greaser, the hydraulic cylinders should be run
in and out a few times to obtain satisfactory lubrication once again.
WARNING
hydrocarbons.
Low strength! Danger!
Check the surface layer of the roof window and
clean only with washer fluid or mild detergent. Rinse
thoroughly with lukewarm water afterwards. Replace a
damaged roof window that shows cracks or scratches
immediately!

6 Inspection and maintenance – Cleanliness 215
CAUTION
Cleaning agents contain different solvents.
Health-hazardous and highly flammable.
Ensure good ventilation when cleaning the machine.
Avoid skin contact, use protective gloves. If you
get dizzy when using cleaning agents, get fresh air
immediately and contact a doctor. If the cleaning agent
has found its way into your eyes, rinse immediately
with lots of water and contact a doctor immediately.
CAUTION
Cracks or scratches result in reduced strength of the
roof window.
Low strength!
Replace a damaged roof window immediately.
CAUTION
Objects may shoot off when using compressed air for
cleaning.
Risk of injury.
Use protective goggles and protective gloves. Exercise
caution to avoid injury to yourself or those nearby.
For optimum functionality the machine should also be kept clean inside
the cab.
• Plastic material: Vacuum clean, brush/wipe with lightly moistened
rag. Use mild cleaning agent and always wipe down with a lightly
moistened rag and clean water.
• Textile material: Vacuum clean, brush/clean with e.g. furniture or
carpet cleaning agent in accordance with the instructions on the
packaging.

216 6 Inspection and maintenance – Fuel system
6.2.2 Fuel system

Fuel system, general
Fuel filling is located on the left-hand side of the machine.
NOTE
In order to prevent fuel and AdBlue being filled in the wrong tank,
the filler cap for fuel is black and for AdBlue it is blue.
NOTE
Make sure that the area around the tank cap is clean when
refuelling.
B A
The filler pipe for the AdBlue tank is equipped with an integrated
strainer. The inner diameter of the filler pipe makes it impossible to
fill with an automatic nozzle for diesel. The filler pipe also has an
integrated magnet which can be used for opening the special automatic
018186
nozzle for filling AdBlue.
A. Fuel filler orifice

B. Filling AdBlue. WARNING
Fuel is highly flammable and health hazardous.
Fire hazard! Health hazard!
Handle with great care and avoid all possible ignition
sources, for example, cigarettes, sparks. Avoid skin
contact, use protective gloves. In the event of skin
contact and spills on clothes, wash the skin and
change clothes.
CAUTION
The quality of the diesel affects the service life of the
engine.
Make sure that correct diesel quality is used.
Incorrect diesel quality will lead to after-treatment
system failure resulting in high repair costs.

6 Inspection and maintenance – Fuel system 217
IMPORTANT
If AdBlue is accidentally poured into the fuel tank this
can lead to the following:
• The engine will not run at full power or not at all.
• Injectors can be damaged.
• Corrosion may arise in the exhaust system between
the turbo and the after-treatment system.
• Expensive repairs.
If fuel is accidentally poured into the AdBlue tank this
can lead to the following:
• The after-treatment system can be seriously
damaged.
• The engine no longer satisfies emission
requirements.
• Expensive repairs.
Fuel
• Always refuel with diesel. For tank volume and fuel quality, see 9
Specifications, page 280.
• Never use additives in the diesel.
• In wintertime, try to fill up immediately after finished operation.
This prevents condensation in the fuel tank. Do not use
anti-condensation agents, for example, alcohol, in the fuel.
• Do not refuel when the engine is running.
• Make sure that the fuel nozzle is connected securely in the filler
pipe (to prevent spills and generation of static electricity).
• Clean around the filler pipe after refuelling and handle used rags,
wiped up fuel, etc. in an environmentally sound manner.

CAUTION
AdBlue can irritate with skin and eye contact and if
inhaled.
Health hazard!
Handle carefully and avoid skin contact, wear
protective gloves. In the event of any contact with
the skin and spillage on clothing, wash the skin with
large quantities of water and change contaminated
clothing and gloves. In the event of eye contact, rinse
thoroughly with water for several minutes and seek
medical advice if necessary. If inhaled, breathe fresh
air and seek medical advice if necessary.
CAUTION
AdBlue spilt on hot components evaporates quickly.
Irritating to the eyes and respiratory system.
Turn your face away. Vaporised AdBlue can act
corrosive to eyes and mucous membranes in the
throat. In the event of eye contact, rinse thoroughly
with water for several minutes and seek medical advice
if necessary. If inhaled, breathe fresh air and seek
medical advice if necessary.
IMPORTANT
Avoid spilling AdBlue on the ground and in
watercourses.
Spillage on the ground must be absorbed with sand or
other absorbent, non-combustible materials.
IMPORTANT
Never fill another AdBlue other than that specified in 9
Specifications.
Risk of damage to the after-treatment system!
Never start the engine if anything other than pure
AdBlue has been filled in the AdBlue tank.

6 Inspection and maintenance – Fuel system 219
IMPORTANT
Avoid spilling AdBlue on the machine.
AdBlue is highly corrosive and harmful primarily to
wiring and electrical components.
Clean AdBlue from electrical wiring and components
immediately. If a connector has been exposed to
AdBlue solution then it must be replaced immediately
so that the AdBlue solution does not creep further into
the wiring. AdBlue creeps at a speed of 0.6 m/h in the
wiring. Cleaning with water and compressed air is not
sufficient due to AdBlue oxidising the metal itself.
AdBlue
• Always fill with pure AdBlue. For tank volume and AdBlue quality,
see 9 Specifications, page 280.
• Never use additives in the AdBlue.
• In wintertime, try to fill up immediately after finished operation. This
prevents condensation in the AdBlue tank.
• Do not refuel when the engine is running.
Switch off the engine and wait 2 minutes before refilling AdBlue.
When the engine is switched off AdBlue is pumped back into the
tank. If the engine is not switched off before refilling then there
is a risk of overfilling and leakage, with damage to the machine
and the environment as a result when the engine is switched off
the next time.
• Make sure the nozzle for AdBlue is correctly fitted to the filler pipe.
We recommend that filling equipment with automatic shut-off is
always used in order to avoid spills.
• Clean around the filler pipe after refuelling and handle used rags,
wiped up fuel, etc. in an environmentally sound manner.

Fuel prefilter (Volvo engine) and fuel filter (Cummins

engine), instructions
NOTE
The water separator should be drained of water when necessary
or at least every 50 operating hours.
DANGER
The fuel is highly flammable.
Fire hazard! Extreme danger!
Make sure that open flames, sparks, or red-hot/glowing
objects have been extinguished before starting work
on or near the fuel system. Do not smoke near the
machine during work on the fuel system.
1 Turn off the engine and the main system voltage with the battery
disconnector.
2 Position a receptacle under the filter.
019491
018187
Cummins QSB6.7 Volvo TAD817VE

3 Drain the water from the filter.
Use manual force to open the drain valve. Turn until the valve
opens and draining starts, drain until clear fuel is visible. Close the
valve and tighten the cock with manual force.
CAUTION
When closing, do not turn too hard. Overtightening
may damage the threads.

6 Inspection and maintenance – Windscreen washer 221
WARNING
Fuel on hands.
Rash and irritation.
Avoid skin contact with the fuel, use gloves.
4 Remove the collection container. Handle the fuel as

environmentally hazardous and fire hazardous waste.
6.2.3 Windscreen washer

Windscreen washer, general
CAUTION
hydrocarbons.
The strength of the roof window may be affected!
Only use clean water with an antifreeze agent, e.g.
antifreeze fluid.
The washer fluid reservoir (position A) is located to the left of the cab's
front edge.
Low washer fluid level is indicated with the event menu, see Event
menu low washer fluid level, description, page 85.
018162
A. Washer fluid reservoir
Instructions
1 Check the level in the reservoir. Top up with washer fluid as
required. For volume, see 9 Specifications, page 280.
2 Add anti-freeze. Select a suitable concentration (dilution
water/anti-freeze fluid) according to the prevailing outdoor
temperatures.

222 6 Inspection and maintenance – Wiper blades
6.2.4 Wiper blades

Wiper blades, general
Instructions
A B
WARNING
Attempting to manually move the wiper armswill
damage the wiper motor's gear or shaft.
Damage to the wiper motor's gear or shafts.
Never try to manually move the wiper arms.
C
NOTE
016943
Check the condition of the wiper blades; replace damaged wiper blades
in order to reduce the risk of damage to the windows.
Wiper blades, combined windscreen and roof wipers
Instructions
A • Roof wiper: Carefully lift the wiper blade's locking arm and detach
the washer hose from the blade's nozzle. Replace the wiper blade,
lock in the wiper blade and refit the washer hose.
B
NOTE
C
If the wiper arm is lifted too much then it may be damaged and
wiper blade contact may be affected.
• Rear wiper: Lift the wiper arm, press in the wiper blade's locking
catch (position B) and replace the wiper blade. Check that the
C
wiper blade is locked in the correct position.
• Windscreen wipers: Undo the wiper blade's attaching bolt (position
C). Carefully lift the wiper arm to replace the wiper blade. Fit the
018386
attaching bolt (position C).
Wiper blades, separate windscreen and roof wipers NOTE

If the wiper arm is lifted too much then it may be damaged and
wiper blade contact may be affected.

6 Inspection and maintenance – Air filter, engine 223
6.2.5 Air filter, engine

Air filter engine, general
Instructions
NOTE
Poorly filtered induction air can very quickly result in serious engine
damage.
The filter is changed by the service technician during scheduled

inspection and service. When the machine is used in very dusty air, the
filter may be clogged after a relatively short time.
In the induction system, between the engine and air filter (A), there's an
A
indicator (B) which shows red when the air filter is clogged.
The air filter has a dust reservoir (position C) which is normally emptied
during operation by vibration in the induction system. It can also be
emptied manually by shaking it.
Instructions
• Check the indicator regularly and contact service as soon as the
indicator shows a red signal.
• The indicator can be reset to zero.
C
018188
B
A. Position for air filter reservoir
B. Indicator for change
C. Dust reservoir

224 6 Inspection and maintenance – Cooling system
6.2.6 Cooling system

Cooling system, general
Coolant is filled in the system's expansion tank (position B). The coolant
level with a cold engine must be visible in the sight glass (position C)
on the expansion tank.
Low coolant level is indicated via the event menu, see Event menu low
coolant level engine, description, page 89.
NOTE
A low coolant level may cause engine damage or may cause the
engine to stop.
A High coolant temperature is indicated via the event menu, see Event
B
menu engine coolant temperature, description, page 81.
C Instructions
D
WARNING
The cooling system is pressurised when the coolant is
018189
hot. Steam or hot coolant may spray out.

Risk of scalding and burn injuries and incorrect
coolant level.
A. Position of the coolant container (expansion
tank) Never open the filler cap when the coolant temperature
is higher than the ambient temperature. Always wait
B. Filling point
until the coolant has fully cooled down before checking
C. Sight glass the level. Incorrect coolant level may cause engine
D. Sensor, coolant level damage.
WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
Handle with care. Avoid skin contact. Wear protective
glasses and protective gloves. In the event of skin
contact, wash the skin.
CAUTION
Use approved coolant.
Risk of engine damage and invalidated warranty if
unapproved coolant is used.
Only use coolant approved by the engine supplier
when changing and topping up the coolant.
• Allow the coolant to cool to the ambient temperature, use the

operating menus to check the coolant level.
• Check the coolant level in the expansion tank. Fill with coolant
approved by the engine supplier as required. For volume, see 9
Specifications, page 280.

6 Inspection and maintenance – Engine oil 225
6.2.7 Engine oil

Engine oil, general
WARNING
protective gloves.
A B
The engine's oil filler pipe (position B) and oil dipstick (position C) are
located under the hood.
C To check the oil level, the vehicle must be on level ground and in
service position.
• Check the oil level.
Check the oil level when the engine is warm. Switch off the engine
and wait approx. 5 minutes (wait at least 15 minutes for Cummins
QSB6.7 Stage 4/Tier 4f) before checking the oil level.
018190
Wipe off the oil dipstick before checking.

The oil dipstick has two markings, MAX and MIN, the oil level
should be between these markings.
Cummins QSB6.7 Stage 4/Tier 4f
A. Placement filling and oil dipstick engine oil NOTE
B. Oil filling
The oil dipstick is long on certain machines. Wear gloves.
C. Oil dipstick
• Top up as required with new engine oil (position B). For volume
and quality, see 9 Specifications, page 280.
Fill - wait a moment - check the oil dipstick.
NOTE
Work carefully when filling engine oil to prevent other fluids or
particles from contaminating the oil. Other fluids or particles in the
engine oil means a risk of engine damage.

226 6 Inspection and maintenance – Engine oil
A B A C B
019492
019493
Cummins QSB6.7 Stage 3A/Tier 3 Volvo TAD871VE Stage 4/Tier 4f
A. Placement filling and oil dipstick engine oil A. Placement filling and oil dipstick engine oil
B. Oil filling B. Oil filling
C. Oil dipstick C. Oil dipstick

6 Inspection and maintenance – Transmission oil 227
6.2.8 Transmission oil

Transmission oil, general
Instructions
WARNING
protective gloves.
B A
The transmission's oil filler pipe and dipstick are located under the hood
on the left-hand side of the machine.
Instructions
• Check the oil level.
Check the oil level with the engine idling and the transmission in
neutral position and at operating temperature (60-70 °C).
There are two holes in the oil dipstick that show MIN and MAX. The
bottom hole is MIN and the top one is MAX. The oil level should
be between the two holes when the transmission is warm and at
idling speed in neutral position.
• Wipe off the oil dipstick before checking.
MIN MAX
NOTE
018191
The oil dipstick is long. Wear gloves.
• Top up as required with new transmission oil (position B). For

A. Position for filling point and level checking volume and quality, see 9 Specifications, page 280).
B. Oil dipstick and filling point transmission oil It is recommended to fill the oil when the transmission is at
operating temperature. Top up – wait awhile – check on the
dipstick.
NOTE
Work carefully when filling transmission oil to prevent other fluids or
transmission oil means a risk of transmission damage.

228 6 Inspection and maintenance – Hydraulic system
6.2.9 Hydraulic system

Hydraulic system, general
Instructions
WARNING
protective gloves.
C E A
The hydraulic oil tank is located on the machine's right-hand side.
D Instructions
• Check the oil level (position B) when the oil reaches the working
temperature. All hydraulic pistons should be in retracted position
(pushed in).
The level should be in the middle of the sight glass.
• Top up as required with new oil (position D). For volume and
quality, see 9 Specifications, page 280.
• Check that the oil cooler isn't clogged.
Clean as needed.
B NOTE
Work carefully when filling engine oil to prevent other fluids or
engine oil involve a risk of damage to the brake system or working
hydraulics.
018197
A. Position for hydraulic oil tank

B. Sight glass
C. Breather filter
D. Filler hole in cover plate for oil filter
E. Oil cooler

6 Inspection and maintenance – Oil, brake system 229
6.2.10 Oil, brake system

Oil, brake system, general
Instructions
WARNING
B D A C E Avoid skin contact with oils and lubricants. Use
protective gloves.
The tank for the brake system is located on the machine's right-hand
side.
Instructions
• Check the oil level (position E).
The level should be in the middle of the sight glass.
• Top up as required with new oil (position C). For volume and
quality, see 9 Specifications, page 280).
• Check that the oil cooler (position B) is not clogged. Clean as
needed.
NOTE
Work carefully when filling brake oil to prevent other fluids or
018196

brake oil means a risk of damage to the brake system.
A. Oil tank for brake system
B. Oil cooler
C. Filling point
D. Breather filter
E. Sight glass oil tank

230 6 Inspection and maintenance – Tyres and rims
6.2.11 Tyres and rims

Tyres and rims, general
DANGER
Changing tyres is high-risk work.
Extreme danger!
Let service personnel change tyres, they have the
competence and authority to handle tyres!
DANGER
Penetrating objects such as crushed glass, pieces of
wood, metal shavings, etc. and mechanical defects,
such as uneven brake wear, can cause tyre damage.
Risk of tyre explosion! Extreme danger!
Check the tyres at regular intervals for external
damage and tyre pressure.
WARNING
Check-tighten the wheel nuts on a new wheel after 4-5
operating hours.
damage!
Tighten bolted joints crosswise. Contact a service
technician as required.
CAUTION
Spare and replacement tyres must be of brand names
approved by Cargotec.
Risk of overloaded tyres!
Use tyres approved by Cargotec.
IMPORTANT
Wheels, tyres and rims are dimensioned and selected
for each machine type so that maximum wheel loads
and travel speeds are not exceeded. For this reason it
is not permitted to change tyre dimension, tyre make,
tyre type, rim type, or rim make without approval from
Cargotec.

6 Inspection and maintenance – Tyres and rims 231
Changing wheel:
Changing wheels, see Maintenance manual.
DANGER
When changing tyres, deflate first.
Deflate tyres by loosening and removing the valve.
DANGER
Rim damage makes wheel handling extremely
dangerous!
Let service personnel change tyres, they have the
competence and authority to handle tyres!
Inflating tyres
Care of compressor for inflating tyres:
• An air filter with water separator should be installed in the line from
the compressor used for inflating tyres. The water filter minimises
the risk of corrosion on wheel rims.
• Drain the water separator regularly.
DANGER
Never stand in front of a tyre when inflating! Do
not exceed prescribed air pressure, which must be
checked at ambient temperature. When changing
tyre or rim version, another tyre pressure may apply,
contact Cargotec. The plate for tyre air pressure
must be replaced with a plate with the applicable tyre
pressure!
Extreme danger!
Always follow instructions for inflating tyres to avoid
018163
serious accidents.

232 6 Inspection and maintenance – Checking the accumulator
Instructions
Instructions
1 2 3
1. Before inflating, make sure that the rim's lock ring is in the correct
position.
NOTE
If the tyre has been completely deflated, the rim must be dismantled
and checked for damage. Let service personnel change tyres, they
002202
have the competence and authority to handle tyres!
2. Connect the compressor with a locking air-chuck to the nipple on

1. Lock ring
the tyre.
2. Rim edge
3. Stand at an angle behind the tyre and remain there until inflating
3. Tapered rim has been completed. This is to avoid being hit by rim parts in the
event of an explosion.
4. Inflate the tyre to the prescribed pressure, see chapter 9
Specifications. When changing tyre or rim version, another tyre
pressure may apply, contact Cargotec.
6.2.12 Checking the accumulator

Accumulator, general
The function of the accumulator (position A) is to maintain even brake
pressure and to maintain brake pressure, and thus braking action, a
short time after eventual loss of hydraulic pressure.
The accumulator is precharged with nitrogen gas.
Instructions
Check the sealing integrity in accordance with the following points if
the event menu for low accumulator pressure, see Event menu low
accumulator pressure, description, page 80, appears in the control
A system display:
1. Start the engine and let it run until the accumulator is filled.
2. Stop the engine.
018164
3. Press down the brake pedal with long pumping brake strokes, with
a slight delay between each braking action. Count the number of
A. Accumulator brake applications until the accumulator is empty, i.e. when the
resistance disappears when the pedal is pressed down.
It must be possible to brake six times before the accumulator is
drained.
4. Start the engine, let the accumulator charge and repeat the test
a couple of times.
If you cannot make at least six brake applications before the
accumulator is drained, there is something wrong with the accumulator
circuit. Contact service as soon as possible for troubleshooting and
suitable action.
WARNING
The machine's hydraulic system includes accumulators
with high pressure.
Always exercise extreme caution when working
with the hydraulic system and avoid unnecessarily
remaining close to hydraulic components or hoses.
The accumulators must be drained prior to work in the
hydraulic system (see Maintenance manual).

6 Inspection and maintenance – Central lubrication 233
6.2.13 Central lubrication

Central lubrication, general
Central lubrication (which replaces the majority of manual lubrication)

consists of a pump unit located in the right-hand cab step that lubricates
selected lubrication points. The lubricant quantity can be adjusted
according to requirements, contact Cargotec Service.
NOTE
Cleanliness when performing work on the central lubrication system
is extremely important. Dirt and debris can cause disturbances
in the system. Naphtha or light petroleum can be used to clean
the system. Do not use e.g. Tri or other organic solvents such as
alcohol, methanol, acetone or the like.
Instructions
• Maintenance for central lubrication is the filling of lubricant and
A. Safety valve checking that all connected lubrication points receive sufficient
lubricant.
B. Filler nipple
• Fill the reservoir up to the "Max" mark through the filler nipple
(position B).
Lubricating grease must be clean from contaminants and must not
change consistency as it ages.
• If the reservoir has become completely empty and is then filled, the
pump may need to be operated for longer in order to provide all the
lubrication points with a sufficient amount of lubricant.
Operate the pump manually with the menu for machine check, see
Menu for machine check, description, page 204.

234 6 Inspection and maintenance – Battery and battery disconnector
6.2.14 Battery and battery disconnector

Battery and battery disconnector, general
WARNING
Short-circuiting of battery.
Risk of explosion! Fire hazard! Risk of personal injury!
The battery's terminals must not be connected to each
other or to common grounding point (frame).
B
CAUTION
Always turn off the system voltage at the end of your
shift, when working on the electrical system and when
welding on the machine.
Danger!
Turn off the system voltage with the battery
disconnector. After the engine is turned off, wait a
A while before switching off the system voltage. The
018212
diesel engine's control system performs actions,

depending on the model, up to two minutes after the
A. Battery disconnector engine is turned off.
B. Battery cover
The electrical system works with a system voltage of 24 Volt (DC). The
power source consists of two series-connected 12 Volt (DC) batteries
which are charged by an AC alternator with rectifier. The negative
terminal is connected to the body.
The plus terminal is connected to a battery disconnector (position A).
The batteries are located inside of a cover (position B) behind the steps
on the machine's left-hand side.

6 Inspection and maintenance – Battery and battery disconnector 235
Checking electrolyte level in battery
WARNING
Battery electrolyte contains corrosive sulphuric acid.
Risk of corrosive injuries! Health hazard!
Use protective glasses and protective gloves when
working with the batteries. Immediately remove any
electrolyte on bare skin. Wash with soap and plenty of
water. If the electrolyte has found its way into your
eyes, rinse immediately with lots of water and contact
a doctor immediately.
Checking the electrolyte level is recommended. Fill as required with

deionised water.
1. Switch off the machine's system voltage with the battery
disconnector (position A) and then open the cover (position B).
2. Check the level. Fill as required with deionised water.
Electrolyte's fluid surface should be 10 mm over cells.
Batteries contain substances hazardous to the environment and

personal health. Therefore, discarded batteries must be handled in
accordance with local/national regulations in force.
Starting with booster battery
WARNING
Handle batteries and connectors with great care during
charging and boosting (jump starting). Do not mix
up the battery terminals! Follow the instructions for
starting with a booster battery!
Danger of short circuit! Warning - risk of hydrogen gas
forming! Danger of sparks and fire! Hydrogen gas is
very explosive!
Batteries must always be equipped with covers over
terminals and connections. Connect positive terminals
first. Then connect the negative terminals in order to
avoid sparks that could ignite the hydrogen gas.
1 Switch off the system voltage with the battery disconnector

(position A).
2 Open the battery cover on the machine's left-hand side.
3 Check that the engine on the machine with booster batteries is
switched off.
4 Check that the booster batteries are connected in series so that
they supply 24 VDC. Do not disconnect the normal cables to the
machine's batteries.
5 Connect in the following order:
a. The red booster cable (+) to the discharged batteries' positive
terminal.
b. The red booster cable (+) to the booster batteries' positive
terminal.
c. The black booster cable (-) to the booster batteries' negative
terminal.

236 6 Inspection and maintenance – Fuses for electrical system
d. The black booster cable (-) to a point some distance from the
discharged batteries, e.g. by the negative cable's connection to
the frame or directly to the engine block.
6 Start the machine containing the booster batteries.
7 Make the system voltage with the battery disconnector.
8 Try to start the engine and then run the engine at increased idling
speed for approx. 10 minutes to charge the batteries.
Do not move the connections during the start attempt - risk of
sparks. Do not lean over any of the batteries.
9 Disconnect the cables in the reverse order as to when connecting
them. One cable at a time! Batteries must always be equipped
with covers over terminals and connections.
6.2.15 Fuses for electrical system

Fuses for electrical system, general
D The machine's electrical system is fuse-protected in three levels:

A
• Main fuses
• Distribution fuses
• Fuses
The machine's electrical system is also divided into two electrical

power circuits:
• Battery voltage, i.e. the voltage output in the machine when the
battery disconnector is in position I.
• Ignition voltage, i.e. the voltage output in the machine when the
ignition key lock is in position I provided the battery disconnector
is in position I.
CAUTION
Never use fuses with too high ampere rating.
Risk of cable damage or cable fire!
Follow instructions on the fuse plate for fuse type and
ampere rating.
C B
018205
Fuses on frame
A. Main fuses, F9952-1
B. Distribution fuses, F9952-2, F9954-1
C. Fuses in electronic box frame, F9958
D. Fuses in electronic box cab, F9968

6 Inspection and maintenance – Fuses for electrical system 237
019477
Fuse plate for the cab electronic box
018225
Fuse plate for the frame electronic box
See also:
• Main fuses, page 238.
• Distribution fuses, page 239.
• Fuses, page 240.

Main fuses
Main fuses
The machine's main fuses are located inside the battery cover for the
batteries on the left-hand side of the machine.
Table Main fuses F9951
Fuse number / Size Functions

1 / 100 A Fuses everything that is disconnected
with the main switch.
2 / 50 A Fuses everything that is not
disconnected with the main switch.
018213
1 2
Main fuse in the battery compartment on the frame
Instructions
When checking and changing main fuses:
1 Turn off the system voltage with the battery disconnector.
The engine must be switched off.
See Battery and battery disconnector, general, page 234.
2 Open the battery cover.
3 Remove the plastic cover.
4 Check and change main fuses when necessary.
Fuse plate on the inside of the cover provides information about
each fuse.

Distribution fuses
Distribution fuses
The machine's distribution fuses are located in the electronic box on
the left-hand side of the machine.
Table Distribution fuses, battery voltage F9952-2
Fuse number /
Size Functions
1 / 50A Frame
2 / 50A Cab
F9952-2
1 Table Distribution fuses, ignition voltage F9954-1
2 Fuse number /
F9954-1 Size Functions
1 1 / 50A Frame
2
2 / 50A Cab
3
3 / 50A Control unit KFU (D7971) and Control unit
KFU (D7972)
4/- -
018214
Distribution fuses in electronic box frame
Instructions
When checking and changing distribution fuses:
2 Remove the cover for the electronic box on the frame.
3 Remove the plate with fuses fitted in front of the distribution fuses.
4 Remove the plastic cover.
5 Check and change distribution fuses when necessary.
each fuse.

Fuses
Fuses
The machine's fuses are located in the electronic box in the cab (F9968)
and in the electronic box on the left-hand side of the machine (F9958).
Table Fuses battery voltage frame F9958-RD
Fuse number /
Size Functions
RD1 / 15A/30A Control unit engine (D7940) for Volvo
TAD871VE (15A).
Control unit engine (D7940) for Cummins
QSB6.7 Stage 4/Tier 4f (30A).
RD2 / 30A Control unit engine (D7940) for TAD871VE.
Control unit engine (D7940) for Cummins
QSB6.7.
RD3 / 15A After-treatment system AdBlue pump,
RD4 / 15A After-treatment system heating AdBlue,
RD5 / - -
RD6 / 5A Control unit, transmission (D7930).

RD7 / - Tyre pressure monitoring
RD8 / 30A Electric cab tilting
Table Fuses ignition voltage frame F9958-BK
RD1 BK1 GN1

Fuse number /
Size Functions
RD2 BK2 GN2
BK1 / 10A Power supply after-treatment system
RD3 BK3 GN3
Cummins QSB6.7 Stage 4/Tier 4f (10A).
RD4 BK4 GN4
BK2 / - -
RD5 BK5 GN5
BK3 / 5A Start interlock
RD6 BK6 GN6
BK4 / - -
RD7 BK7 GN7
RD8 BK8 GN8 BK5 / 20A Expansion module KEM (Kalmar

Expansion Module)
BK6 / 5A Control unit (D7930) for transmission
-
018215
BK7 / -
BK8 / 15A Horn
Fuses in electronic box frame, F9958 Loud horn

Table Fuses options frame F9958-GN
Fuse number /
Size Functions
GN1 / - -
GN2 / - -
GN3 / - -
GN4 / - -
GN5 / 10A Battery voltage before the battery

disconnector for the cab
GN6 / 20A Diesel heater
GN7 / - -
GN8 / 5A Engine compartment lighting

Fuses battery voltage cab F9968 RD
Table Fuses battery voltage cab F9968 RD
Fuse number /
Size Functions
RD1 / 5A Start up, alcolock, start interlock
RD2 / 15A Control unit KCU (D7901)
RD3 / - -
RD4 / 5A Radio
RD5 / 10A Service, RMI
RD6 / 10A Customer-specific equipment
RD7 / - -
RD8 / 10A Loud horn
Table Fuses ignition voltage cab F9968 BK
Fuse number /
Size Functions
BK1 / 10A Control unit KPU (D7902)
BK2 / 10A Service, RMI , distance warning system
back-up camera
BK3 / 10 A Monitor, back-up camera
RD1 BK1 GN1

BK4 / 5A Radio
RD2 BK2 GN2 BK5 / 25A Seat heating, seat belt, ventilation control
driver's seat
RD3 BK3 GN3
RD4 BK4 GN4

BK6 / 10A 24 V socket cab, electrically operated
mirrors , customer-specific equipment
RD5 BK5 GN5
RD6 BK6 GN6

BK7 / 15A Work lights
RD7 BK7 GN7 BK8 / 10A Searchlight

RD8 BK8 GN8
Table Fuses options cab F9968 GN
Fuse number /
018216
Size Functions
GN1 / 25A Heated rear window
Fuses in electronic box cab, F9968 GN2 / 10A Double windscreen wipers front
GN3 / 10A Voltage converter 12/24 VDC
GN4 / - -
GN5 / 5A Revolving operator's station

GN6 / - Motor, left-hand arm rest
GN7 / - -
Compressor, air suspension driver's seat

GN8 / 10A , ventilation feed driver's seat

Instructions
When checking and changing fuses:
2 Remove the cover for the electronic box.
3 Check and change fuses when needed.
each fuse.
Fuse engine option Cummins QSB6.7

The engine fuse for preheating is located on the right-hand side of
the machine.
Table Fuse engine option Cummins QSB6.7 Stage 4/Tier 4f
Fuse number /
Size Functions
1 / 150A Preheating
1
018217
Instructions
When checking and changing fuses:
2 Check and change fuses when needed.

244 6 Inspection and maintenance – Lighting
6.2.16 Lighting
Lighting, general
It is important to use the right type of bulb for each respective lighting
point, see section 9 Specifications.
Light bulbs can be changed for the following:

• Interior lighting
• Position light
• Headlights, (with high/low beam)
• Back-up light, white
• Work light, glow lights
• Revolving beacon
Direction indicators front replaced complete.
Taillights, brake lights and direction indicators rear are in a single fitting
and are replaced complete.

6 Inspection and maintenance – Service 245
6.3 Service
General
It's very important that inspections and service are performed at the
recommended intervals.
Service is performed by Cargotec, or by service technicians authorised

by Cargotec.
CAUTION
Service interval must be followed.
This is to maintain the machine's safety as well as to
meet warranty and service agreements!
Use spare parts and fluids approved by Cargotec in
order to fulfil warranty terms.
Service intervals and actions are described in the maintenance manual.
CAUTION
Undo the connectors from the control units.
Risk of damage to the control units!
When welding on the machine, all control units shall
be disconnected to prevent damage.

246 6 Inspection and maintenance – Service
WARNING
For safety reasons, the following spare parts may only
be replaced with genuine spare parts:
• Brake valve
• Drive axle
• Valve for mini-wheel/joystick steering
• Steering valve (Orbitrol)
• Control valve steering incl. priority valve
• Steering axle
• Steering cylinder
• Steering spindle
• Hub
• Rim
• Mast, carriage
• Lift cylinder incl. load control valve
• Separate load control valve
• Lifting chains
• Chain tightener and shaft
• Forks, fork carrier
• Tilt cylinder
• Twistlock
• Attachment assembly
• Lifting ears
• Control breaker (for hydraulic function)
• Cab
• Hydraulic cylinder, cab tilt
• Frame
• Accumulator
• Tilt valve
• Main valve load handling
• Accumulator charging valve
• All control units

7 Transporting the machine 247
7 Transporting the machine

Safety
DANGER
The machine must be firmly secured for transport! The
machine is heavy and can cause extensive damage in
the event of a fall and similar.
damage!
Follow the instructions in order to secure the machine
during transport.
WARNING
Operator doors must always be closed during
transport.
Danger!
Always close operator doors during transport.

248 7 Transporting the machine – Towing
7.1 Towing
General
DANGER
The machine cannot be operated or braked if the
hydraulic pressure is lost, e.g., if the engine is off.
Rolling machine! Extreme danger!
If possible, tow with maintained hydraulic pressure.
If it's not possible to have the engine running when
towing, a tow bar must be used! Only tow for short
distances!
CAUTION
Do not try to start the machine by towing.
Causes serious damage to engine and power
transmission!
Start the engine according to instructions in the
operator's manual.
Before taking actions and after finished towing, the parking brake
must be applied and the wheels blocked to prevent the machine from
starting to roll.
Extreme care must be observed during towing work to avoid personal

injuries.
When towing, keep in mind:

• The towing vehicle should be heavier than the vehicle in tow.
• If possible when towing, the engine should be running in order for
brakes and steering to function.
When the engine is switched off, there is no hydraulic pressure for
the steering function and thus the machine's steering function is
severely limited. In addition, transmission lubrication is insufficient.
• The brakes function as long as there is pressure in the
accumulator/accumulators, then the service brake stops
functioning and the parking brake is applied automatically. If it is
necessary to move/tow the machine after that, the parking brake
must be released mechanically, see section 7.1.1 Mechanical
release of parking brake.
• Only tow for very short distances.
• If it is necessary to tow the machine, the propeller shaft must be
released from both transmission and drive axle.

7 Transporting the machine – Mechanical release of parking brake 249
7.1.1 Mechanical release of parking brake

Description
The parking brake is applied automatically by a forceful spring in the
brake cylinder if the pressure in the hydraulic accumulator(s) should
drop below a certain level.
If the machine has to be moved (towed) without sufficient pressure

in the hydraulic accumulator(s), the parking brake must be released
mechanically (manually).
DANGER
Before starting to work with the parking brake, make
sure that the machine cannot move when the braking
action is released.
Rolling machine! Extreme danger!
Block the wheels to avoid unwanted rolling of the
machine.
CAUTION
The parking brake has high spring force. If the brakes
are opened incorrectly, parts may detach and fly off
with great force.
Follow the instructions.
The parking brake is a disc brake on the drive axle's input shaft.
1 Remove protective cover from caliper (position A).
2 Note the nut's position on the bolt and remove the split pin that
A B C
secures the nut.
3 Screw in the nut, this compresses the brake spring. Screw until
the brake pads release from the brake disc.
4 Restore the parking brake function by screwing out the nut to the
same position acc. to item 2. Install new split pin.
5 Refit protective cover on the caliper.
NOTE
The parking brake may have to be adjusted again.
See Maintenance manual.
000835
NOTE
A. Protective cover If the parking brake has been released mechanically, the parking
brake must always be restored in order to give the machine
B. Brake disc for parking brake parking brake function.
C. Connection propeller shaft

250 7 Transporting the machine – Lifting and transporting the machine
7.2 Lifting and transporting the

machine
General
When lifting and transporting the machine, follow the governing safety
regulations.
DANGER
High demands are made of the lifting and transport
equipment, e.g. lifting chains, hooks, etc.
Extreme danger!
Check the equipment and its capacity, lifting slings on
the machine as well as lashing points on the transport
vehicle and machine.
DANGER
Overload of load equipment.
Extreme danger!
Lifting equipment must be dimensioned for the load.
Never walk under hanging loads.
The following actions are recommended when the machine is to be

transported:
• Turn off the system voltage with the battery disconnector.
• Apply parking brake.
• Remove any fragile equipment, e.g. rear view mirrors.
• Secure the machine for transport on e.g. a truck with chains. See
the sign for the machine's weight.
Front: Attach the chains in the eyes on frame left and right-hand
side (by leading edge wheel housing) or around the drive axle.
NOTE
Cross the chains when securing for optimal stability.
Rear: Secure chains in towing eye (by vertical counterweight), alt.

around the steering axle.
• If transport is to take place on a public road:
Make sure that laws and regulations are followed with regards to
height, weight, width, and axle load limitations.

7 Transporting the machine – Lifting machine 251
7.2.1 Lifting machine

Instructions
The machine must be lifted as follows:
1 Fit two lifting slings in the two lifting eyes of the counterweight.
2 Fit two lifting slings in the two lifting eyes of the lifting mast.
Mast with low lifting height does not have lifting eyes. Lifting straps
must be guided round the cut-out for the lift cylinder or in some
other way so that the straps are secured to the mast.
3 The lifting device must be adapted so that the lifting point runs
through the machine's centre of gravity.
018175
7.2.2 Transporting the machine

General
For machines with high lifting height, the mast must be removed to
follow the regulations in force.
Lashing down for transport

The machine must be transported on a trailer that is wide enough to
support the drive axle's inner wheel.
1. Reverse the machine up on the trailer.
2. Run the lifting carriage down completely and tilt the mast forwards
as far as possible.
3. Apply the parking brake and switch off the engine.
4. Turn off the system voltage with the battery disconnector.
5. Anchor the machine's front section with chains fitted with hooks
and a tensioning unit. Attach the chains securely at the anchor
points on the chassis marked with the sign for transport locking
and at the designated anchor points on the trailer.
018176
6. Anchor the machine's rear section with chains fitted with hooks
and a tensioning unit. Attach the chains at the anchor points on the
wheel housings marked with the sign for transport locking and at
the designated anchor points on the trailer.
7. Fold in the rear view mirrors and remove protruding parts, such as
the revolving beacon, to prevent damage during transport.

252 7 Transporting the machine – Service position
7.3 Service position

General
Service position is used for service, maintenance and other situations
when the machine needs to be secured.
Service position entails:

• The machine is parked, i.e. parking brake applied.
• Lifting carriage lowered and mast tilted forward.
• Engine off.
• System voltage switched off (with battery disconnector).
• If necessary: Lift up the machine on axle stands or back up the
018177 machine on ramps. Axle stands and ramps must be dimensioned
for the machine's weight.

7 Transporting the machine – Attachment of lifting equipment 253
7.4 Attachment of lifting equipment

General
This section describes how the attachment of lifting equipment should
be performed. It covers both mechanical and hydraulic attachment.
Hydraulic system, depressurising

1 Machine in service position see 7.3 Service position, page 252.
2 Depressurise the hydraulic system by opening the drain valve on
the accumulator charging valve.
NOTE
Keep the accumulator drain valve open for as long as work is in
progress.
NOTE
After the work has been finished, close the drain valve and
tighten the lock ring.
018937

254 7 Transporting the machine – Assembly of mechanics to mast and carriage
7.4.1 Assembly of mechanics to mast and carriage

General
Ensure that the lifting equipment is firmly attached before operating
the machine.
The hydraulic hoses must be depressurised before assembly.

Depressurise the hydraulic system by opening the accumulator drain
valve. See Hydraulic system, depressurising, page 253.
WARNING
The lifting equipment is classified as a tool.
damage!
Make sure that nobody is under the lifting equipment
during the assembly work.
DANGER
Lifting equipment classified as an attachment (e.g.
coil ram and paper clamp) must be marked with a type
plate. Machine capacity with the current attachment
must be shown on the capacity plate.
Machine capacity with standard lifting equipment
(mast, carriage and forks) is stated on the machine
plate.
damage!
Make sure that nothing other than approved lifting
equipment is used.

7 Transporting the machine – Assembly of mechanics to mast and carriage 255
Mast
NOTE
Read the safety instructions for the oil before starting work, see
section B Safety.
CAUTION
Do not overfill!
Leakage and environmental damage!
Check the hydraulic oil level with all hydraulic
cylinders fully retracted.
1 Turn off engine.

2 Turn the start key to position 0 and switch off the main electric
power.
3 Connect lifting equipment to the lifting eyes on the mast in a
secure manner so that the mast does not tilt when lifted. Lift the
mast from the ground.
4 The shafts and bearing surfaces must be checked before the mast
is refitted for deep grooves/scratches, fibres must not protrude
above the bearing surface. If there are signs of damage, then the
shaft, bearings and seals must be replaced.
007791
5 Lift the mast so that it is hanging vertically, lift the mast into position.
NOTE
The mast is secured into the frame of the truck with robust shafts
that run in maintenance-free bearings.
It is of the utmost importance that the bearing surfaces are
completely clean during mast installation.
The shafts and bearing surfaces mentioned above must NEVER
be lubricated with oil or grease.
6 Align the mast and position the shafts in their mast mountings.
Then fasten the shafts, fit circlips.
007786

7 Use suitable lifting equipment and align one tilt cylinder in position
against the bracket in the mast.
8 Start the engine and activate the tilt function, extend the tilt
cylinder's piston rod until it aligns against the bracket in the mast.
9 Turn off engine.
10 Connect the tilt cylinder to the mast, align the tilt cylinder in position
and fit spacers. Fit circlips.
11 Repeat points 7 to 10 for the other tilt cylinder.
12 Remove the lifting equipment from the mast.
13 Grease connectors with contact grease and connect them together.

7 Transporting the machine – Assembly of mechanics to mast and carriage 257
14 Remove the plugs and connect the mast's hydraulic hoses in

accordance with the marking.
1
2
3
4
018977
1. Connections for fork spreading

2. Connections for side shift
15 Remove the plugs and connect the hydraulic hoses to the lifting
cylinders in accordance with the marking.
16 Switch on the main electric power and start the engine.
17 Check the sealing integrity of the hydraulic connections.
18 Install the lifting carriage, see Lifting carriage, page 258.
19 Check the mast's functions.
018978

Lifting carriage
NOTE
Read the safety instructions for the oil before starting work, see
section B Safety.
1 Start the machine and set the mast vertically.

2 Lift the mast high enough so that there is space for the lifting
carriage.
3 Connect the lifting equipment to the lifting carriage in a secure
manner and drive the machine towards the mast, or position the
lifting carriage in the mast with the lifting equipment.
4 Lower the mast.
6 Depressurise the hydraulic system, see Hydraulic system,
depressurising, page 253.
018981
7 Fasten the lifting chain tensioners in the lifting carriage.

018979

7 Transporting the machine – Assembly of hydraulics to mast and carriage 259
8 Tension the chain with the chain tensioner. Check that the chains
are tensioned equally.
9 Adjust the lifting carriage's lower position so that the carriage
sides cannot run against the bottom plate of the outer mast. Then
measure the ground clearance of the lifting carriage. The distance
must be equal on the right and left-hand sides, with a tolerance of
5 mm. Adjust further with the chain tensioner if necessary.
018980
10 Connect the hydraulic hoses to the lifting carriage in accordance

with the marking.
NOTE
Replace the O-rings. Check that the O-rings are in the correct
position.
11 Detach the lifting equipment.

12 Switch on the main electric power and start the engine.
13 Activate the load handling functions. Check the sealing integrity of
the hydraulic connections.
14 Check the oil level in the hydraulic system with all cylinders in
007718
retracted position. Top up if necessary.
7.4.2 Assembly of hydraulics to mast and carriage

General
The hydraulic hoses must be depressurised before connection.
Depressurise the hydraulic system by opening the accumulator drain
valve. See Hydraulic system, depressurising, page 253.
Carriage
Connect the hydraulic hoses in accordance with the marking and the
following information about the mast.

260 7 Transporting the machine – Assembly of hydraulics to mast and carriage
Mast FKLD
18–25 tonnes
18–25 tonnes
1. Side shift right
2. Side shift left
3. Spreading in
4. Spreading out
5. Extra function in
6. Extra function out
1 7. Electrical cable
2
3
4 8. Central lubrication
5
6
7 018973
8
28–33 tonnes
28–33 tonnes
1. Side shift right
2. Side shift left
3. Spreading in
4. Spreading out
1 6. Extra function out
2
3 7. Electrical cable, central lubrication
4
5
6
018974
Mast FFKD
18–25 tonnes
18–25 tonnes
1. Electrical cable, central lubrication
2. Spreading out
3. Spreading in
4. Side shift left
1 3 5 7 5. Side shift right

6. Extra function out
018975
2 4 6
28–33 tonnes
28–33 tonnes
1. Electrical cable, central lubrication
2. Spreading out
3. Spreading in
4. Side shift left
1 3 5 7 5. Side shift right

6. Extra function out, cable for indicator
018976
8. Cable for indicator

2 4 6 8

7 Transporting the machine – Forks 261
7.4.3 Forks
Forks, general
The forks are very heavy. Make sure that they are handled in a safe
manner.
CAUTION
The forks may tip over during fitting and removal.
Product damage! Personal injury!
Handle the fitting and removal of forks in a safe and
cautious manner.
WARNING
Exercise caution when changing forks.
Risk of crushing!
Fitting the roller forks

2 Raise the lifting carriage slightly so that it is at just the right height
for fitting the fork.
4 Check that the fork to be fitted is firmly anchored with tensioning
straps or similar in e.g. a loading pallet before being fitted to the
lifting carriage. This is in order to prevent the fork from tipping over.
Move the lifting equipment in from the side of the carriage.
CAUTION
cautious manner.
5 Connect the axle mounting to the fork using the four screws.
B
017279
A. Screw
B. Axle mounting

262 7 Transporting the machine – Forks
Removing the roller forks

2 Raise the lifting carriage slightly and position a hand truck with
a loading pallet under the fork being removed. Lower the lifting
carriage so that the fork is in contact with the loading pallet. Anchor
the fork with tensioning straps or similar so that it does not tip over
when it is detached from the lifting carriage.
4 Fasten the side shift cylinder with tensioning straps or similar.
5 Undo the screws that secure the side shift cylinder to the fork.
6 Remove the fork from the carriage by pulling it sideways.
CAUTION
A
B cautious manner.
017279
A. Screw
B. Axle mounting

Fitting the roller fork with levelling function

2 Raise the lifting carriage slightly so that it is at just the right height
for fitting the fork.
Move the lifting equipment in from the side of the carriage.
CAUTION
cautious manner.
017284
WARNING
The cylinders for the levelling forks can be retracted or
extended for assembly and removal.
Risk of crushing!
Handle the fitting and removal of levelling forks in a
safe and cautious manner.
5 Connect the axle mounting to the fork using the four screws.
B
017279
A. Screw
B. Axle mounting

Removing the roller fork with levelling function

a loading pallet under the fork being removed. Lower the fork
completely so that the cylinder is fully retracted and then lower the
lifting carriage so that the fork is in contact with the loading pallet.
Anchor the fork with tensioning straps or similar so that it does not
tip over when it is detached from the lifting carriage.
5 Undo the screws that secure the side shift cylinder to the fork.
B
017279
A. Screw
B. Axle mounting
6 Remove the fork from the carriage by pulling it sideways.
CAUTION
cautious manner.
017284
WARNING
The cylinders for the levelling forks can be retracted or
extended for assembly and removal.
Risk of crushing!
Handle the fitting and removal of levelling forks in a
safe and cautious manner.

Fitting a fork for the fork carrier system (hook type)

CAUTION
cautious manner.
2 Tilt the mast forwards and drive the machine towards the forks.
1 3 Correct with fork spreading and side shift so that the fork bracket
fits against the fork's upper attachment hook.
4
3 Lift slightly and tilt backwards, check that the fork bracket fully
5 grips into the upper attachment hook.
4 4 Lift until the fork is in full contact with the fork bracket.
5 Fit the shaft and secure with bolt and pins.
2
015643
Lifting fork for the fork carrier system (hook type)

1. Fork bracket
2. Lifting fork
3. Bolt
4. Pin
5. Shaft

Removing a fork for the fork carrier system (hook

type)
CAUTION
cautious manner.
2 Pull the pin out from the bolt.

1 3
3 Pull the bolt out from the shaft that secures the forks.
4 4 Pull or tap out the shaft so that the fork loosens from the fork
bracket.
5
5 Lower/tilt forward and move away from the fork.
4
2
015643
Lifting fork for the fork carrier system (hook type)

1. Fork bracket
2. Lifting fork
3. Bolt
4. Pin
5. Shaft

Fitting a fork for the fork carrier system (pin type)

CAUTION
cautious manner.
Correct with fork spreading and side shift so that the fork carriers
fit against the forks' bracket.
3 Fit the shaft and secure with bolt and pins.
002049
Lifting fork for the fork carrier system (pin type)

1. Bolt
2. Pin
3. Ring pin
4. Shaft
5. Lifting fork
6. Fork bracket

Removing a fork for the fork carrier system (pin type)

CAUTION
cautious manner.
2 Pull the pin out from the bolt.

3 Pull the bolt out from the shaft that secures the forks.
4 Pull or tap out the shaft so that the fork loosens from the fork
bracket.
5 Tilt the mast backwards and back the machine away from the forks.
002049
Lifting fork for the fork carrier system (pin type)

1. Bolt
2. Pin
3. Ring pin
4. Shaft
5. Lifting fork
6. Fork bracket

Fitting inverted forks/coil ram for the fork carrier

system
1 Operate side shift and fork spreading so that the fork bracket
reaches the right position for forks/coil ram.
2
3
002050
1. Upper attachment hook

2. Lock pin
3. Moving locking catch
4. Lower attachment hook
2 Fold out the moving locking catches down onto the forks/coil ram.
3 Tilt the mast forwards and move the machine forwards towards the
forks/coil ram. Correct with fork spreading and side shift so that
1 the fork bracket aligns against the upper attachment hooks for
the forks/coil ram.
4 Lift slightly and tilt backwards, check that the fork bracket fully
grips into the upper attachment hooks.
5 Lift until the forks/coil ram are in full contact with the fork bracket.
Check that the lower attachment hooks are gripping the lifting
carriage's lower beam.
6 Fold in the moving locking catches and lock with the pins.
2
3
002051
Coil ram.
2. Lock pin

Removing inverted forks/coil ram for the fork carrier

system
1 Position the forks/coil ram in a safe stowage location, e.g. in a
stand.
2
3
002050

2. Lock pin
2 Fold out the moving locking catches down onto the forks/coil ram.
3 Tilt the mast forwards so that the lower attachment hooks release.
1 4 Lower slightly so that the upper attachment hooks release and
reverse away from the forks/coil ram.
2
3
002051
Coil ram.
2. Lock pin

Attachment of kissing forks

1 Operate side shift and fork spreading so that the fork carriers reach
the right position for the forks.
Correct with fork spreading and side shift so that the fork carriers
fit against the forks' attachment hook.
3 Lift slightly and tilt backwards, check that the fork carrier bracket
fully grips into the attachment hooks.
4 Lift until the forks are in full contact with the fork carriers.
5 Install the pins and insert the bolts.
6 Lock using the pins.
4
3
2
012550
Kissing forks.
1. Attachment hook
2. Shaft
3. Bolt
4. Pin

Removal of kissing forks

1 Lower the forks so that they are resting against the surface below,
e.g. in a stand, or anchor them in a loading pallet
2 Pull out the pins from the bolt.
3 Pull out the bolts and pins.
4 Tilt the mast forward and lower slightly so that the attachment
hooks release, and reverse away from the forks.
4
3
2
012550
Kissing forks.
1. Attachment hook
2. Shaft
3. Bolt
4. Pin

Attachment of fork carrier

2 Raise the lifting carriage so that it is at just the right height for
attaching the fork carrier.
4 Check that the fork carrier to be fitted is firmly anchored with
tensioning straps or similar in e.g. a loading pallet before being
attached to the lifting carriage. This is in order to prevent it from
tipping over.
Move the fork carrier in from the side of the carriage.
CAUTION
The fork carrier may tip over during fitting and removal.
Handle the fitting and removal of fork carriers in a safe
and cautious manner.
5 Connect the axle mounting to the fork carrier using the four screws.
B
017279
A. Screw
B. Axle mounting

Removal of fork carrier

2 Raise the lifting carriage slightly and position a hand truck with a
loading pallet under the fork carrier being removed. Anchor the
fork carrier with tensioning straps or similar so that it does not tip
over when it is detached from the lifting carriage.
4 Check that the fork carrier to be fitted is firmly anchored with
tensioning straps or similar in e.g. a loading pallet before being
attached to the lifting carriage. This is in order to prevent it from
tipping over.
CAUTION
Handle the fitting and removal of fork carriers in a safe

6 Undo the screws that secure the side shift cylinder to the fork
carrier.
7 Remove the fork carrier from the carriage by pulling it sideways.
A
CAUTION
B Handle the fitting and removal of fork carriers in a safe
017279
A. Screw
B. Axle mounting

7 Transporting the machine – Attachment 275
7.4.4 Attachment
Removal of fork-mounted top lift
WARNING
Exercise caution when changing e.g. attachments or
exchangeable forks.
Risk of crushing!
WARNING
Always make sure that forks, inverted forks or coil ram
are always stored in a safe place.

2 Set the length setting at 20'' (adjustable top lift).
3 Set the top lift in a safe stowage location, on an empty container,
for example.
4 Set the rotation in centre position (or extension to min.) so that the
hydraulic pressure is equalised and it becomes easier to detach
the quick couplings. This also prevents unnecessary oil spillage.
6 Connect the hydraulic hoses and electrical cable from the top lift to
the quick couplings on the lifting carriage. Check that hoses and
cables are routed so that they cannot be damaged.
7 Unlock the braces behind the forks, set the mast vertical and
reverse away from the top lift.
Attachment of fork-mounted top lift
WARNING
Exercise caution when changing e.g. attachments or
exchangeable forks.
Risk of crushing!
WARNING
Always make sure that forks, inverted forks or coil ram
are always stored in a safe place.
1 Set fork spreading so that the forks fit the fork pockets.
2 Insert the forks into the fork pockets.
4 Lock the forks to the top lift with the braces behind the forks.
5 Connect the hydraulic hoses and electrical cable from the top lift to
the quick couplings on the lifting carriage. Check that hoses and
cables are routed so that they cannot be damaged.
6 Check the different functions of the top lift.

276 7 Transporting the machine – Attachment
Connecting the top lift attachment

1 Operate the side shift and fork spreading so that the forks reach
the correct position for the fork pockets.
2 Insert the forks into the fork pockets.
1 3 Machine in service position see 7.3 Service position, page 252.
2
4 Secure the forks to the top lift attachment with the braces behind
the forks. Lock using bolts and pins.
5 Connect the hydraulic hoses and electrical cable from the top lift
002061
attachment to the quick couplings on the lifting carriage. Check that
hoses and cables have been routed so that they are not damaged.
Top lift attachment, locking braces. 6 Check the different functions of the top lift attachment.
1. Bolt
2. Pin
Uncoupling the top lift attachment

1 For adjustable attachment, set the length setting at 20'.
2 Position the top lift attachment in a safe stowage location. For
example, on a container or in a stand.
3 Set the rotation in centre position so that the hydraulic pressure is
equalised and it becomes easier to detach the quick couplings. In
1 this way, oil spillage is avoided.
5 Detach the quick couplings.
6 Unlock the braces behind the forks, set the mast vertical and
reverse away from the top lift attachment.
2
002060
Top lift attachment, connection of quick couplings.

1. Electrical cable
2. Hydraulic hoses

7 Transporting the machine – Long-term storage 277
7.5 Long-term storage

General
For long-term storage of the machine, contact Cargotec.

278 8 Environment and standards
8 Environment and
standards
General
The ever-increasing industrialisation of our world is having a significant
impact on our global environment. Nature, animals and people are
subjected daily to risks in connection with various forms of chemical
handling.
There are still no fully environmentally safe chemicals, such as oils and
coolants, available on the market. Therefore, all who handle, perform
service on or repair machines must use the tools, assisting devices and
methods necessary to protect the environment in an environmentally
sound manner.
By following the simple rules below, you will contribute to protecting

our environment.
Recycling
Conscientious recycling of the machine is the starting point for the life
cycle to come full circle, and for being able to recycle and make use of
material in new products. According to calculations by Cargotec, the
machine is more than 90% recyclable by weight.
Environmentally hazardous waste

Components such as batteries, oils, and various chemicals and other
items that may constitute environmentally hazardous waste must be
handled and taken care of in an environmentally safe and sound
manner.
Discarded batteries contain substances hazardous to personal health

and the environment. Therefore, handle batteries in an environmentally
safe manner and according to national regulations.
Oils and fluids

Oils freely discharged cause environmental damage and can also be a
fire hazard. Therefore, when emptying and draining oils or fuel, take
appropriate action to prevent unnecessary spills.
Waste oils and fluids should always be taken care of by an authorised

disposal company.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal the leaks.
Air conditioning
The refrigerant in the air conditioning for the cab adds to the
"greenhouse effect" if released into the open air. Special training is
required for all service work on the air conditioning. Many countries
also require certification by a governing authority for such work. When
scrapping an air conditioning unit, the refrigerant shall be taken care
of by a certified company.
Working in a contaminated area

The machine must be equipped for work in contaminated areas
(environmentally polluted or health-hazardous area) before work is
started. Also, there are special local rules in force for such handling
and when servicing such a machine.

8 Environment and standards – Environment and standards 279
Declarations
The machine does not contain asbestos.
The machines contains lead in batteries and in electric cabling. In

certain models, there are lead castings as counterweight.
If the machine is equipped with air conditioning then refrigerant of type

R134a is used.
Standards
CE marking
Machines for the EU/EEA market are CE marked. This means that
upon delivery the machine fulfils the applicable "Essential Health
and Safety Requirements" specified in the EU Machine Directive,
2006/42/EC, as well as other EU directives relevant to this machine
type. For more information, see section 2.2 CE marking.
ANSI/ITSDF marking
Versions of this machine for North America are ANSI/ITSDF marked.
This means that, when delivered, the machine fulfils the basic safety
requirements specified in ANSI/ITSDF B56.1. For more information,
see section 2.3 ANSI/ITSDF marking.
EMC, electromagnetic interference

The EU's EMC directive regarding "Electromagnetic compatibility",
2004/108/EC, gives a general description of the standards that may be
required of a machine from a safety aspect, where the limit values have
been established in international standards. A machine or device that
meets these standards should be CE marked.
Cargotec machines are specially tested with regards to electromagnetic

interference in accordance with harmonised standard EN12895.
The machine's CE marking and declaration of conformity also cover
the EMC directive. If other electronic equipment is installed on the
machine, it must be CE marked and tested on the machine with regards
to electromagnetic interference. It must also be approved by Cargotec.
Vibration standard
Vibration emitted by the machine is measured according to harmonised
standard EN 13059, where the level of vibration varies depending on
with which type of tyres and driver's seat the machine is equipped. See
section 9 Specifications.

280 9 Specifications
9 Specifications
Data
The machine's weights and dimensions vary depending on how the
machine is equipped. Detailed information regarding this is given in the
product specification and data sheet for the machine in question.
DCG 180-250 DCG 280-330

0 Complete machine Volvo Cummins Cummins Volvo Cummins Cummins
TAD871VE QSB6.7 QSB6.7 TAD871VE QSB6.7 QSB6.7
Stage Stage Stage Stage Stage Stage
4/Tier 4f 3A/Tier 3 4/Tier 4f 4/Tier 4f 3A/Tier 3 4/Tier 4f
Guaranteed sound power level in LWA 110 LWA 109 LWA 109 LWA 110 LWA 110 LWA 110
accordance with 2000/14/EC and dB(A) dB(A) dB(A) dB(A) dB(A) dB(A)
2005/88/EC including measurement
uncertainty 1.5 dB.
DCG 180-250 DCG 280-330

1 Engine Volvo Cummins Cummins Volvo Cummins Cummins
TAD871VE QSB6.7 QSB6.7 TAD871VE QSB6.7 QSB6.7
Stage Stage Stage Stage Stage Stage
4/Tier 4f 3A/Tier 3 4/Tier 4f 4/Tier 4f 3A/Tier 3 4/Tier 4f
Output in accordance with ISO 3046 185 kW 164 kW at 168 kW at 185 kW 194 kW at 194 kW at
(marked output) between 2200 rpm 2200 rpm between 2200 rpm 2200 rpm
1500 – 22 1500 – 22
00 rpm 00 rpm
Torque ISO 3046 1160 Nm at 949 Nm at 949 Nm at 1160 Nm at 987 Nm at 990 Nm at
1100 – 15 1500 rpm 1500 rpm 1100 – 15 1500 rpm 1500 rpm
00 rpm 00 rpm
Max. rotation speed 2200 rpm
Number of cylinders 6
Alternator, output 3080 W 1680 W 1680 W 3080 W 1680 W 1680 W
System voltage, voltage – capacity 24 V (2x12 V / 145 Ah)
2 Transmission DANA TE17

No. of gears, forward - reverse 3 - 3
3.3 Power transmission, drive

DCG 180-250 DCG 280-330
axle
Drive axle, type Kessler D91 AxleTech PRC3806W4H
4 Brakes
Footbrake system – wheel affected Wet Disc Brake – drive wheel
Parking brake system – wheel affected Spring brake - drive wheel
5 Steering
Steering system Hydraulic servo

9 Specifications – Specifications 281
6 Wheels DCG 180-250 DCG 280-330

Dimension, front and rear 14.00x24 16.00x25
Tyre pressure, also see pressure plate 1.0 MPa 1.0 MPa
Tyre type, front and rear Inflated with air. Spare and replacement tyres must be of brand
names approved by Cargotec.
9 Cab Cab Protection bar

Equivalent sound pressure level LpAZ 72 dB(A) LpAZ 73 dB(A)
in cab according to EN12053 with
measurement uncertainty σR=2.5 dB.
Measurement value with standard
engine.
Whole-body vibrations according 0.4 - 0.7 m/s2
to EN13059 with measurement
uncertainty k=0.3 x measured value.
Lamp Output (W) Socket

Direction indicator, front - LEDs are replaced complete
Tail lights, brake lights & direction indicators rear - LEDs are replaced complete
Position lamps - LEDs are replaced complete
Headlights, (with high and low beam) 75/70 P43t-38 (H4)
Back-up light 70 PK22s (H3)
Back-up light LED - LEDs are replaced complete
Work lights glow lights 70 PK22s (H3)
Work lights, LED - LEDs are replaced complete
Revolving beacon LED - LEDs are replaced complete

Flashing beacon 15 Xenon tube. Insert replaced
complete.
Adjustable search light 70 PK22s (H1)
Interior lighting - Replaced complete

282 9 Specifications – Specifications
Volumes
For oil types see Oils and lubricants, recommendation, page 285.
DCG 180 DCG 200 DCG 220 DCG 250 DCG 280 DCG 300 DCG 330
1.2 Engine, fuel system -12LB -12LB -12LB -12LB -12LB -12LB -12LB
Fuel tank, volume 300 l 300 l 300 l 375 l 450 l 450 l 450 l
Fuel quality Recommendation for Stage 3A/Tier 3 engines
Diesel according to:
EN590,
ASTM D 975 No 1-D,
ASTM D 975 No 2-D.
CAUTION
Use only the fuel of approved quality.
Risk of engine damage, warranty invalidated.
Only fuel of a quality that is approved by the engine supplier
may be used.
WARNING
If fuel with a sulphur content higher than 0.3% is used then
the engine oil and oil filter must be changed at more frequent
intervals.
Change the engine oil and oil filter in accordance with the
prescribed intervals.
Requirements for Stage 4/Tier 4f engines

Diesel according to:
EN590,
ASTM D 975 No 1-D,
ASTM D 975 No 2-D.
CAUTION
Use only the fuel of approved quality.
Risk of engine damage, warranty invalidated.
Only fuel of a quality that is approved by the engine supplier
may be used.
AdBlue tank, volume 35 l

AdBlue quality AdBlue, according to ISO standard 22241.

1.7 Engine, cooling system Volvo TAD871VE Cummins QSB6.7 Cummins QSB6.7
Stage 4/Tier 4f Stage 3A/Tier 3 Stage 4/Tier 4f
Coolant volume 35 l 33 l 33 l
Coolant filling point Volvo Penta Coolant ES Compleat, Premix ES Compleat, Premix
VCS, ready-mixed
CAUTION
Risk of engine damage and invalidated warranty if unapproved
coolant is used.
Only use coolant approved by the engine supplier when
changing and topping up the coolant.
1.8 Engine, lubrication system Volvo TAD871VE Cummins QSB6.7 Cummins QSB6.7
Stage 4/Tier 4f Stage 3A/Tier 3 Stage 4/Tier 4f
Oil type, quality See Oils and lubricants, recommendation, page 285.
Oil volume incl. filter 27 l 23 l 23 l
2.6 Transmission, lubrication DANA TE17

system
Oil type See Oils and lubricants, recommendation, page 285
Oil volume 39 l
DCG 180-250 DCG 280-330

3.3 Power transmission, drive Kessler D91 AxleTech PRC3806W4H
axle
Oil quality See Oils and lubricants, recommendation, page 285.
Oil volume, differential 29.9 l 34 l
Oil volume, hub reduction 2x3.8 l 2x12.5 l
4.8 Brake system, separate oil

tank
Oil quality See Oils and lubricants, recommendation, page 285
Oil tank brake system, volume 90 l
7 Load handling
Oil quality See Oils and lubricants, recommendation, page 285
Oil volume, planetary gear, hydraulic 1.6 l
motor

9 Frame, body, cab and

accessories
Refrigerant air conditioning R134a
Volume refrigerant 2000 g (unless otherwise indicated on the air conditioning sign)
Lubricant air conditioning ZXL100PG
Lubricant quantity air conditioning 0.3 l (depending on compressor)

Volume, washer fluid Max. 6 l
10 Common hydraulics
Oil quality See Oils and lubricants, recommendation, page 285.
Oil additive Lubrizol 3%
Volume hydraulic oil tank 360 l
Volume hydraulic oil tank, machine 270 l
with separate oil tank for brake
system

Oils and lubricants, recommendation

The service intervals specified by Cargotec in the maintenance manual
only apply if oils are selected in accordance with the table below. The
table indicates recommended viscosity for different oil types, and
grades, depending on the outdoor temperature.
Any deviation from this table must be approved in writing by Cargotec,

and may mean changed service intervals.
°C -30 -20 -10 0 +10 +20 +30 +40 +50

Oil type, quality °F -22 -4 +14 +32 +50 +68 +86 +104 +122
1.8 Engine, lubrication system
Cummins QSB6.7 Stage 3A/Tier SAE 15W40 (engine oil)
3:
SAE 10W30 (engine oil)
API: CH-4/SJ, CI-4/SK
ACEA: E5, E7 SAE 5W30 (engine oil)
Cummins: CES-20071,
CES-20072, CES-20076,
CES-20077, CES-20078
1.8 Engine, lubrication system
Cummins QSB6.7 Stage 4/Tier SAE 5W/40 or 15W/40 (engine oil)
4f:
SAE 10W/30 (engine oil)
API: CJ-4
ACEA: E9-08 SAE 5W/30 (engine oil)
Cummins: CES 20081
Volvo: VDS-4
2.6 Transmission, lubrication

system SAE 10W, 10W/30, 10W/40
API: CD/CE/CF-4/CF/CG-4/ SAE 15W/30, 15W/40
CH-4/CI-4/SF/SG/SH/SJ/SL
ACEA: Categories A, B, E SAE 20W/20, 20W/40
SAE 30
3.3 Power transmission, drive

axle SAE 80W140
Kessler SAE 80W90
Hypoid oil, API GL-5 and
MIL-L-2105B SAE 90
SAE 85W140
AxleTech
Hypoid oil, API GL-5 SAE 80W140
SAE 75W90
1 Only applies to synthetic or semi-synthetic engine oil.

°C -30 -20 -10 0 +10 +20 +30 +40 +50

Oil type, quality °F -22 -4 +14 +32 +50 +68 +86 +104 +122
4 Brakes (UTTO oil 2)
GM Allison C-4 SAE 5W30 (transmission oil)
John Deere J20 C, D
Caterpillar TO-4
10 Common hydraulics
Hydraulic oil AV 32
SS 155434 AV 46
Hydraulic oil HVLP 46

DIN 51524 HLP 68
Hydraulic oil ISO - LHV 46

ISO 6743/4 ISO - LHM 68
NOTE
Oil filters must be changed in connection with oil change.
2 The oil in the brake system has to meet one of the quality
requirements.
ACEA = Association des Constructeurs Européenne d'Automobiles
API = American Petroleum Institute
CES = Cummins Engine Standard
VDS = Volvo Drain Specification
Engine oil
NOTE
Oil filters must be changed in connection with oil change.
Stage 3A/Tier 3 engines
WARNING
Change intervals for engine oil and oil filter depend on
the sulphur content in the fuel.
Change the engine oil and oil filter in accordance with
the prescribed intervals.

Lubricating grease
Use a universal grease type EP in accordance with NLGI Grade 2 (EP2)
for all lubrication points except for lifting equipment and slide plates.
For central lubrication, only universal grease type EP in accordance

with NLGI Grade 2 (EP2) without molybdenum disulphide may be used.
For lifting equipment use a universal grease type EP in accordance

with NLGI Grade 2 (EP2) with 3-5% molybdenum disulphide mixture.
For slide plates use a lubricant approved by Cargotec. Obtained from

Cargotec Spare Parts Department. 0.65 kg cartridge for grease gun
part. no. 923110.0360 and 5 kg tin part. no. 923595.0003.
NOTE
Select lubricant class according to the prevailing climate.
Contact grease
Use contact grease part no. 923836.0552. Applies for sealed
connectors.
Sealant silicone
Use silicone part. no. 923107.0308.
Adhesive system for window panes

Only use PU polymer recommended by Cargotec.
Coolant
Use ready-mixed recommended coolant. Choose the mixture of
coolant that is adapted for the right temperature.
CAUTION
Risk of engine damage and invalidated warranty if
unapproved coolant is used.
Only use coolant approved by the engine supplier
when changing and topping up the coolant.

Unit explanations
Unit Abbreviation
Newton metre Nm
Kgf/m kpm
Kilo pascal kPa
Mega pascal MPa
Kilowatt kW
Kilojoule kJ
British thermal unit Btu
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Metre m
Kilometre km

Conversion SI-units
Recalculation Recalculation
SI-unit factor Non-SI factor SI
Torque
Nm x 10.2 = kg·cm x 0.8664 = lb·in
Nm x 0.74 = lbf·ft x 1.36 = Nm
Nm x 0.102 = kg·m x 7.22 = lb·ft
Pressure (Pa = N/m2)
kPa x 4.0 = in.H2O x 0.249 = kPa
kPa x 0.30 = in.Hg x 3.38 = kPa
kPa x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
kp/cm 2 x 14.22 = psi x 0.070 = kp/cm2
N/mm 2 x 145.04 = psi x 0.069 = bar
MPa x 145 = psi x 0.00689 = MPa
Power (W = J/s)
kW x 1.36 = hp (cv) x 0.736 = kW
kW x 1.34 = bhp x 0.746 = kW
kW x 0.948 = Btu/s x 1.055 = kW
W x 0.74 = ft·lb/s x 1.36 = W
Energy (J = Nm)
kJ x 0.948 = Btu x 1.055 = kJ
J x 0.239 = calorie x 4.19 = J
Speed and acceleration
m/s2 x 3.28 = ft/s2 x 0.305 = m/s2
m/s x 3.28 = ft/s x 0.305 = m/s
km/h x 0.62 = mph x 1.61 = km/h
Horsepower/torque
Bhp x 5252 rpm= TQ (lb·ft) TQ x rpm 5252 = bhp
Temperature
°C = (°F – 32)/1.8 °F = (°C x 1.8) + 32
Flow factor
l/min (dm3 /min) x 0.264 = US gal/min x 3.785 = litre/min

Conversion table length

Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm – 1 mm = 0.001 m
Conversion table area

Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 - 1000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
ft2 - 0.092903 - 0.000929 1 0.1111 144.000

yd2 - 0.83613 - 0.008361 9 1 1296.00
in2 6.4516 0.000645 - - 0.006943 0.000771 1
1 ha = 100 a – 1 mile2 = 259 ha = 2.59 km2
Conversion table volume

Unit cm3 = cc m3 l in3 ft3 yd3
cm3 = ml 1 0.000001 0.001 0.061024 0.000035 0.000001
m3 1000000 1 1000 61024 35.315 1.30796
dm3 (l) 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft3 28316.8 0.028317 28.317 1728 1 0.03704
yd3 764529.8 0.76453 764.53 46656 27 1
1 gal (US) = 3785.41 cm3 = 231 in3 = 0.83267 gal (UK)
Conversion table weight

Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 1000000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 tonne (metric) = 1.1023 ton (US) = 0.9842 ton (UK)

Conversion table pressure

Unit kp/cm2 bar Pa = N/m2 kPa lbf/in2 lbf/ft2
kp/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa = N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kg/cm2 = 735.56 Dry (mmHg) = 0.96784 atm

292 10 Terminology
10 Terminology
Explanations
Term Description
Accumulator Reservoir that stores (accumulates) pressure for, i.e. hydraulic functions.
AdBlue AdBlue (DEF) contains deionised water mixed with 32.5% urea.
Attachment Part of the machine that grips the load when lifting.
Anti-corrosion agent Prevents oxidation, in simple terms, rustproofing.
Working hydraulics All load handling functions, e.g. lifting/lowering, tilt, side shift, positioning and levelling.
Wheelbase Distance between drive axle and steering axle.
Bar Unit to express pressure.
Battery disconnector Cuts off power supply from battery.
CAN Controller Area Network - Network for communication between the control units.
CAN bus The network between the control units in the machine.
CECS Common Electrical and Control System. An electronic control system that monitors and
regulates certain systems in the machine that require CECS, such as certain engine
and transmission alternatives.
Central lubrication An automatic system for lubrication of a preset number of lubrication points.
Daily inspection Actions that should be performed daily to ensure the machine's functionality.
Decitonne Tenth of a tonne, measure of machine's lift capacity.
DEF Diesel Exhaust Fluid, see AdBlue.
Displacement The oil volume that the pump can supply per pump revolution.
Display "Window" showing digital information, i.e. on steering wheel panel in the cab.
DOC Diesel Oxidation Catalyst. DOC is a catalytic converter that removes carbon monoxide
(CO) and hydrocarbons (HC) from the exhaust gas, and even a certain amount of
particles, soot, etc.
Operating time Number of hours machine has been in operation, shown on hour meter in cab.
Drive axle Driving axle that receives the torque from the drivetrain.
Drivetrain Parts in the machine involved in power transmission; engine, torque converter,
transmission, propeller shaft and drive axle with differential and hub reduction.
ECC Electric Climate Control. Air conditioning with thermostat-controlled cooling,
dehumidification and heating.
EHC Electric Heat Control. Heating system with thermostat-controlled heating.
Electrolyte level Fluid level in battery cells.
Electric servo Load handling's hydraulic components receive control signals from electro-mechanical
controls.
Expansion tank Tank for coolant.
Fixed displacement Non-adjustable volume (capacity) in a pump.
FMI Fault Message Identifier. The part of the error code indicating the type of error.
Forks Lifting device that lifts the load.
Fork bracket Bracket for forks, fitted on the lifting carriage.
Main fuse Located by battery. Breaks the current to all systems in the whole machine.
Hydraulic oil Oil for hydraulic system. See specifications in operator's manual.
Hydraulic oil pump Pump in hydraulic system.

10 Terminology – Terminology 293
Term Description
Hydraulic servo Load handling's hydraulic components receive control signals from mechanical controls.
Hydraulic system System that uses oil pressure to transfer power to different functions.
Cab Enclosed type of cab.
Hanging load Lifted load.
Indicator Manual "sensor", for example, shows that a filter is clogged and needs to be changed.
Inverted forks Forks turned upside down, for lifting and fitting top lift.
KCU Kalmar Cab Unit - Control Unit KCU (D7901) is fitted in the cab and is the control unit
that controls the start-up and shutdown of the machine's electrical system.
KFU Kalmar Frame Unit – Control unit KFU (D7971) is fitted in the electronic box on the
left-hand side. The control unit operates components in the frame and on the mast.
KID Kalmar Information Display - Control unit KID (D7950), the display in the cab.
KPU Kalmar Panel Unit - Control unit KPU (D7902) is fitted in the right-hand switch panel in
the cab and operates switches and controls in the cab.
KST Kalmar Service Tool - Computer program for service, calibration, setting and
programming of the machine's control units.
Piston rod Rod that is pushed into the piston's cylinder barrel and is acted upon by the hydraulic
pressure.
Refrigerant Fluid/gas in air conditioning. Must only be handled by authorised trained personnel.
LC Load centre.
Lift capacity Indicates machine's maximum lift capacity.
Lifting point Attaching point for lift device when lifting an object.
Lifting carriage Lifts the load, located on the mast.
Low-emission engine Engine with low emissions of hazardous substances. Manufactured in accordance
with regulations.
Solenoid valve An electro-magnetically controlled valve. See also proportional valve.
Control valve Valves that can be used to control something, for example, to release pressure and thus
lower a mast or a fork.
Machine model Machine type. Specified, for example: DCG 90-180. See also type designation.
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Torque converter Hydraulic, variable clutch.
Counterweight Weights adapted to the machine's lift capacity to constitute an opposing load when lifting.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases torque
from the drivetrain.
Pilot oil pressure A low control pressure to, for example, a valve.
Planetary gear Type of transmission with gears in constant engagement.
Product alternative One of several alternatives is selected for a machine, e.g. engine alternative.
Progressive steering Quick steering wheel movements give greater steering angles.
Proportional valve An electro-magnetically controlled valve. If a voltage is applied, the valve is activated
in proportion to the voltage amplitude. In simple terms, infinitely variable valve, as
opposed to on/off valve. For example, found on transmission's valve housing.
Frame member Structural members in the frame.
Recirculation Circulation in a closed system.

294 10 Terminology – Terminology
Term Description
SCR Selective Catalytic Reduction. Exhaust technology which means that AdBlue is added
to the exhaust gases to reduce nitrogen oxides (NOx). The urea in AdBlue breaks
down into ammonia, which in the SCR catalytic converter, reacts with nitrogen oxide
(NOx) as harmless nitrogen and water vapour is formed. Available for Volvo Stage
4/Tier 4f engines.
Serial number Unique machine designation. On the machine plate.
Service position How machine should be safely positioned before service may be started.
Servo A small movement by the user results in a large angle, i.e. servo steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side shift Parallel sideways movement of forks.
Levelling Forks are tilted, e.g. if load stands on uneven ground.
SPN Suspect Parameter Number. Is a unique number for machine components. Used in
circuit diagrams and error codes.
Spreading (positioning) Spreading of the forks, e.g. change to relative distance between the forks.
Mast Carrier of attachment and load.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, which is emptied
automatically during operation.
Steering axle Wheel axle with steering.
Protection bar Protective cage with protective heavy-duty frame construction. Open.
Buzzer Acoustic alarm to catch the operator's attention.
Option Extra equipment for machine.
Tilt The mast is tilted forward or backward.
Top lift Attachment. See attachment.
Transmission oil Oil for transmission and torque converter. See specifications in operator's manual.
Securing machine for transport Actions before transporting machine.
Twistlocks Two or four locking pins, one in each corner of the attachment, pushed down in
corresponding holes in container and twisted to lock the container when lifting.
Type designation Indicates machine type and capacity. See also machine model.
Maintenance Periodic maintenance actions so that machine functions safely and for a long service life.
Variable pump Pump with adjustable flow rate.
Variable displacement Adjustable volume (capacity) of a pump.
Valve slide Moveable part in valve. Determines oil's path.
Wet brakes Brake discs in oil bath.
Recyclable Used equipment must be handled according to national laws and regulations.

11 Index – Index 295
Index Event menu overload lift . . . . . . . .

Event menu overload lift and tilt. . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
82
83
Event menu overload tilt . . . . . . . . . . . . . . . 82
Event menu parking brake . . . . . . . . . . . . . . 83
A Event menu preheating . . . . . . . . . . . . . . . 86
Event menu raise/lower cab temperature . . . . . . . 87
About the documentation kit . . . . . . . . . . . . . . 4 Event menu raise/lower fan speed . . . . . . . . . . 87
About the operator's manual . . . . . . . . . . . . . . 1 Event menu release the parking brake . . . . . . . . . 86
Air filter, engine . . . . . . . . . . . . . . . . . . . 223 Event menu rotate the operator's station . . . . . . . . 90
ANSI/ITSDF marking . . . . . . . . . . . . . . . . 10 Event menu seat belt . . . . . . . . . . . . . . . . 83
Assembly of hydraulics to mast and carriage . . . . . . 259 Event menu service . . . . . . . . . . . . . . . . . 88
Assembly of mechanics to mast and carriage . . . . . . 254 Event menu speed limitation . . . . . . . . . . . . . 89
Attachment . . . . . . . . . . . . . . . . . . . . 275 Event menu start interlock . . . . . . . . . . . . . . 87
Attachment of lifting equipment . . . . . . . . . . . . 253 Event menu, clamped load . . . . . . . . . . . . . . 91
Event menus . . . . . . . . . . . . . . . . . . . . 79
B
Battery and battery disconnector . . . . . . . . . . . 234 F
Fire . . . . . . . . . . . . . . . . . . . . . . . . 18
Foreword . . . . . . . . . . . . . . . . . . . . . . 1
C Forks . . . . . . . . . . . . . . . . . . . . . . . 261
CE marking . . . . . . . . . . . . . . . . . . . . . 9 Fuel system . . . . . . . . . . . . . . . . . . . . 216
Central lubrication . . . . . . . . . . . . . . . . . 233 Functions for load handling . . . . . . . . . . . . . 191
Checking the accumulator . . . . . . . . . . . . . . 232 Fuses for electrical system . . . . . . . . . . . . . . 236
Cleanliness . . . . . . . . . . . . . . . . . . . . 214
Control for load handling . . . . . . . . . . . . . . . 62
Control system . . . . . . . . . . . . . . . . . . . 75 G
Cooling system . . . . . . . . . . . . . . . . . . . 224
Gearshifting . . . . . . . . . . . . . . . . . . . . 168
Customer settings via display . . . . . . . . . . . . 196
D H
Daily inspection . . . . . . . . . . . . . . . . 95, 206 Handling. . . . . . . . . . . . . . . . . . . . . . 92
Deactivated regeneration of the engine's after- Heating / Air conditioning . . . . . . . . . . . . 73, 173
treatment system, description . . . . . . . . . . . . 86 Hydraulic system . . . . . . . . . . . . . . . . . . 228
Description . . . . . . . . . . . . . . . . . . . . 20
Driver's seat . . . . . . . . . . . . . . . . . . . . 71
I
Identification of the machine . . . . . . . . . . . . . 20
E Ignition key lock and start and stop button for the
Engine oil . . . . . . . . . . . . . . . . . . . . . 225 engine . . . . . . . . . . . . . . . . . . . . . . 42
Engine operating menu . . . . . . . . . . . . . . . 77 Inspection and maintenance . . . . . . . . . . . 5, 205
Environment and standards . . . . . . . . . . . . . 278 Instruments and controls. . . . . . . . . . . . . . . 33
Error code indication . . . . . . . . . . . . . . . . 98
Error code information on display . . . . . . . . . . . 99
Error code tables . . . . . . . . . . . . . . . . . . 106 K
Error codes . . . . . . . . . . . . . . . . . . . . 96 Keep in mind . . . . . . . . . . . . . . . . . . . . 11
Event menu AdBlue . . . . . . . . . . . . . . . . . 84
Event menu AdBlue end . . . . . . . . . . . . . . . 81
Event menu air filter air conditioning system . . . . . . 85
Event menu arm rest . . . . . . . . . . . . . . . . 91 L
Event menu battery capacity . . . . . . . . . . . . . 84 Lifting and transporting the machine . . . . . . . . . . 250
Event menu battery charging . . . . . . . . . . . . . 89 Lifting load . . . . . . . . . . . . . . . . . . . . . 182
Event menu brake temperature . . . . . . . . . . . . 80 Lifting machine . . . . . . . . . . . . . . . . . . . 251
Event menu control breaker . . . . . . . . . . . . . 88 Lighting . . . . . . . . . . . . . . . . . . . . . . 244
Event menu engine coolant temperature . . . . . . . . 81 Load handling . . . . . . . . . . . . . . . . . 60, 179
Event menu heating rear view mirrors/rear windscreen . . 87 Long-term storage . . . . . . . . . . . . . . . . . 277
Event menu height limitation . . . . . . . . . . . . . 82
Event menu height warning . . . . . . . . . . . . . 82
Event menu intermittent wiper . . . . . . . . . . . . 88
Event menu low accumulator pressure . . . . . . 80, 83
M
Event menu low AdBlue level. . . . . . . . . . . . . 84 Maintenance . . . . . . . . . . . . . . . . . . . . 211
Event menu low coolant level engine . . . . . . . . . 89 Mechanical release of parking brake . . . . . . . . . 249
Event menu low fuel level . . . . . . . . . . . . . . 84 Menu for active error codes . . . . . . . . . . . . . 200
Event menu low washer fluid level . . . . . . . . . . 85 Menu for date and time . . . . . . . . . . . . . . . 196
Event menu mini-wheel/joystick control, description . . . 90 Menu for inactive error codes. . . . . . . . . . . . . 201
Event menu no operator in seat. . . . . . . . . . . . 85 Menu for machine check . . . . . . . . . . . . . . . 204
Event menu oil temperature hydraulics . . . . . . . . 81 Menu for services and settings . . . . . . . . . . . . 203
Event menu oil temperature transmission . . . . . . . 81 Menu for statistics and history . . . . . . . . . . . . 201
Event menu open door . . . . . . . . . . . . . . . 85 Multi-function lever . . . . . . . . . . . . . . . . . 59

296 11 Index – Index
O Steering . . . . . . . . . . . . . . . . . . . . . . 170
Oil, brake system . . . . . . . . . . . . . . . . . . 229 Steering wheel . . . . . . . . . . . . . . . . . . . 67
Operating . . . . . . . . . . . . . . . . . . . . . 163 Stopping the engine - parking . . . . . . . . . . . . 176
Operating menu customer settings . . . . . . . . . . 79 Switches . . . . . . . . . . . . . . . . . . . . . 44
Operating menu electrical system . . . . . . . . . . . 78
Operating menu scales . . . . . . . . . . . . . . . 78
Operating menu trip computer work shift . . . . . . . . 77 T
Operating menus . . . . . . . . . . . . . . . . . . 77
Terminology . . . . . . . . . . . . . . . . . . . . 292
Overview . . . . . . . . . . . . . . . . . . . . . 20
The event menu parking brake not activated and no
Overview description . . . . . . . . . . . . . . . . 21
operator in the driver's seat . . . . . . . . . . . . . 80
Towing . . . . . . . . . . . . . . . . . . . . . . 248
Transmission and hydraulics operating menu . . . . . . 78
P Transmission oil . . . . . . . . . . . . . . . . . . 227
Parking brake . . . . . . . . . . . . . . . . . . . 171 Transporting load . . . . . . . . . . . . . . . . . . 186
Pedals . . . . . . . . . . . . . . . . . . . . . . 65 Transporting the machine . . . . . . . . . . . 247, 251
Plates . . . . . . . . . . . . . . . . . . . . . . . 26 Travel direction selector and parking brake . . . . . . . 57
Turnable operator's station . . . . . . . . . . . . . . 177
Tyres and rims . . . . . . . . . . . . . . . . . . . 230
R
Reading instructions . . . . . . . . . . . . . . . . . 2
Running-in . . . . . . . . . . . . . . . . . . . . . 94 U
Unloading . . . . . . . . . . . . . . . . . . . . . 189
S
Safety . . . . . . . . . . . . . . . . . . . . . . . . 6 W
Safety and emergency equipment. . . . . . . . . . . . 8
Service . . . . . . . . . . . . . . . . . . . . . . 245 Warming up . . . . . . . . . . . . . . . . . . . . 166
Service brake . . . . . . . . . . . . . . . . . . . 170 Warning and indicator lights . . . . . . . . . . . . . 39
Service position . . . . . . . . . . . . . . . . . . 252 While operating. . . . . . . . . . . . . . . . . . . 163
Specifications . . . . . . . . . . . . . . . . . . . 280 Windscreen washer . . . . . . . . . . . . . . . . . 221
Starting engine . . . . . . . . . . . . . . . . . . . 166 Wiper blades . . . . . . . . . . . . . . . . . . . . 222

Declaration of Conformity
We, Cargotec Sweden AB, SE-340 10 Lidhult, (Registration No. 556014-5418) herewith
declare that the machine,
Type Forklift Truck
Model DCG 220-12LB
Serial No A207XXXXX
Year of construction 2015
Engine Cummins QSB6,7 (168kW)
is manufactured in conformity with the requirements in

- The Machinery Directive 2006/42/EC
- The Electro Magnetic Compatibility Directive 2004/108/EC

- the harmonised standard EN-ISO 3691-1 Industrial trucks - Safety requirements and verification
- Part 1: Self-propelled industrial trucks.
- the harmonised standard EN 16307-1 Industrial trucks - Safety requirements and verification -
Part 1: Supplementary requirements for self-propelled industrial trucks.
- the Outdoor Noise Directive 2000/14/EC, with use of annex VI, procedure 1 as amended by the
Directive 2005/88/EC, internal control of production with assessment of technical documentation
and periodical checking, under supervision of the Notified Body 0404:
0404 SMP - Svensk Maskinprovning

Fyrisborgsgatan 3
SE-754 50 Uppsala
Noise related value 168 / 2200 kW/rpm

Measured sound power level LWA 107 dB
Guaranteed sound power level LWA 109 dB
Name
Position Head Of Counterbalanced Products
InfoString: 2A / KAT / O / G / GB / 20130610 / 093512
Authorized to compile the technical file
Place, Date of Issue Signature

last page
Cargotec Sweden AB
Cargotec improves the efficiency of cargo flows by offering solutions for Torggatan 3
the loading and unloading of goods on land and at sea – wherever cargo SE-340 10, Lidhult, Sweden
is on the move. Cargotec’s main daughter brands for cargo handling
Hiab, Kalmar and MacGregor are global market leaders in their fields. tel. +46 372 260 00
Cargotec’s global network offers extensive services that ensure the fax +46 372 263 90
continuous, reliable and sustainable performance of equipment. www.cargotec.com

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Forklift trucks 18-33 tonnes

Operator’s manual DCG 180-330 IDCG02.02GB

This Operator's manual contains information that you must keep in

Operator's manual, purpose

Cargotec will not accept any responsibility for machine modifications

About machine version

Cargotec reserves the right to make changes to specifications and

Duplication of the content in this manual, in whole or in part, is strictly

All duplication by any means, such as copying, printing, etc., is

Operator’s manual DCG 180-330 IDCG02.02GB

1.1.1 Reading instructions

Read the operator's manual

Read the operator's manual

Read the Maintenance manual

refers to important information in the Maintenance manual.

Read the Maintenance manual

IDCG02.02GB Operator’s manual DCG 180-330

See the machine card for complete specifications of the machine's

Operator’s manual DCG 180-330 IDCG02.02GB

1.2 About the documentation kit

There is supplementary documentation that can be ordered for the

Always indicate publication number when ordering. The publication

IDCG02.02GB Operator’s manual DCG 180-330

1.3 Inspection and maintenance

Maintenance described in this operator's manual can be performed by

Operator’s manual DCG 180-330 IDCG02.02GB

The safety information in this operator's manual is intended for your

Important to read the operator's manual

In addition, you will obtain a lot of valuable information that makes

The operator's manual should always remain in the machine. If it is lost

Ask your foreman or supervisor if there is anything in the text you do

IDCG02.02GB Operator’s manual DCG 180-330

Operator’s manual DCG 180-330 IDCG02.02GB

2.1 Safety and emergency equipment

The machine may be equipped with the following safety equipment:

the type ABE according to EN 3 pt. 1, 2, 4, and 5. With such a fire

12. Protective grating for windscreen .

IDCG02.02GB Operator’s manual DCG 180-330

As proof that the requirements are fulfilled, the machine is provided

See example of EC Declaration after 11 Index.

Anyone making modifications that affect the safety of the machine

purposes or with other tools than what is specified in these instructions,

For additional information, see standards under chapter 8 Environment

Operator’s manual DCG 180-330 IDCG02.02GB

2.3 ANSI/ITSDF marking

This machine is ANSI/ITSDF marked. This means that upon delivery it

For additional information, see standards under chapter 8 Environment

Machine plates for ANSI/ITSDF marking

IDCG02.02GB Operator’s manual DCG 180-330

2.4 Keep in mind

For machines with SCR-system (emission control with AdBlue):

During work shifts

Operator’s manual DCG 180-330 IDCG02.02GB

IDCG02.02GB Operator’s manual DCG 180-330

Operator’s manual DCG 180-330 IDCG02.02GB

IDCG02.02GB Operator’s manual DCG 180-330

Operator’s manual DCG 180-330 IDCG02.02GB

IDCG02.02GB Operator’s manual DCG 180-330

Operator’s manual DCG 180-330 IDCG02.02GB