Operators DCG

Forklift trucks 9-18 tonnes
Publ. no IDCG01.04GB
Operator's Manual in original OPERATOR'S MANUAL
DCG 90-180
DCG 70-32E3 - 70-35E4
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 ............................................................................................................................... 27
4 Instruments and controls ...................................................................................................... 35
4.1 Warning and indicator lights............................................................................................. 41
4.2 Ignition key lock and start and stop button for the engine................................................ 44
4.3 Switches .......................................................................................................................... 46
4.4 Travel direction selector and parking brake ..................................................................... 58
4.5 Multi-function lever........................................................................................................... 60
4.6 Load handling .................................................................................................................. 61
4.7 Pedals .............................................................................................................................. 65
4.8 Steering wheel ................................................................................................................. 67
4.9 Driver's seat ..................................................................................................................... 70
4.10 Heating / Air conditioning ................................................................................................. 71
4.11 Control system ................................................................................................................. 73
5 Handling ............................................................................................................................... 98
5.1 Running-in ..................................................................................................................... 100
5.2 Daily inspection.............................................................................................................. 101
5.3 Error codes .................................................................................................................... 102
5.4 Operating ....................................................................................................................... 148
5.5 Load handling ................................................................................................................ 161
6 Inspection and maintenance............................................................................................... 175
6.1 Daily inspection.............................................................................................................. 176
6.2 Maintenance .................................................................................................................. 180
6.3 Service ........................................................................................................................... 214
7 Transporting the machine ................................................................................................... 216
7.1 Towing............................................................................................................................ 217
7.2 Lifting and transporting the machine.............................................................................. 221
7.3 Service position.............................................................................................................. 224
7.4 Long-term storage.......................................................................................................... 225
8 Environment and standards................................................................................................ 226
9 Specifications ..................................................................................................................... 229
10 Terminology ........................................................................................................................ 239
11 Index.................................................................................................................................... 243
Operator's Manual DCG 90-180 IDCG01.04GB

IDCG01.04GB Operator's Manual DCG 90-180
1 Foreword 1
1 Foreword
1.1 About the operator's manual
General
Thank you for choosing Cargotec 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 with 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.

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.
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 must 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.

2 Safety – Safety 7
• 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 working environment has safety and emergency equipment to
make the operator's work easier and safer.
The machine may be equipped with the following safety equipment:
2 2 11 8 7 9 1. Back-up alarm
2. Revolving beacon/flashing beacon
The revolving beacon on the cab is vertically adjustable.
12 3. Horn
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
the type ABE according to EN 3 pt. 1, 2, 4, and 5. With such a
fire extinguisher, it is possible to put out fires in both solid organic
materials and fluids. Adapted fire extinguishing equipment can be
ordered from Cargotec.
012648
1, 8 6 10 3 5 4 1 8 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 operator'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
9a handling.
9a shows blocked area in front of machine
9b shows blocked area to the side/behind the machine
10. Control breaker for load handling
Cuts off all power supply and control signals to load handling.
11. Protective grating for roof window .
12. Protective grating for windscreen .
012649
9b

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):
NOTE
Wait for two minutes before the system voltage is disconnected with
the battery disconnector so that the SCR system has time to fully
drain, 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 does 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 contains a
high-pressure accumulator.
Always exercise extreme caution when working
with the hydraulic system and avoid unnecessarily
remaining close to hydraulic components or hoses.
The accumulator must be drained prior to work on 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
Do not use two-way radios, remote control door opener, etc. when
someone with an implanted active medical device (e.g. pacemaker)
is in the cab.
Equipment should not be used during operation or load handling as
this takes away from the operator's concentration.
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 before starting the engine and after operation, when the
engine has been stopped. This helps to quickly detect if anything
abnormal has happened or is about to happen. Look particularly closely
for oil, fuel or coolant leakage, loose bolts, worn or badly 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 90-180 machine is a forklift truck of medium capacity for all
types of load handling. It has a maximum lifting capacity of 9 to 18
tonnes. The machine has a one lift mast. There are three lift mast
options and these come in different lifting heights:
1. Duplex
2. Duplex Free Lift
3. Triplex Free Lift
The DCG 70-32E3-70-35E4 machine is a machine with mast for

handling empty containers. It has a maximum lifting capacity of 7
tonnes. There are two alternative lifting masts (different lifting heights):
1. Duplex 70-32E3
2. Duplex 70-35E4
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 120-12 (example) indicates the following:
• D - Diesel engine
• C - Counterweight forklift
• G – Generation
• 120 - Lift capacity, decitonne
• 12 - Distance to centre of gravity, in decimetres
Type designation DCG 70-32E3 (example) indicates the following:

• D - Diesel engine
• C - Counterweight forklift
• G – Generation
• 70 - Lift capacity, decitonne
• 32 - Wheelbase
• E - Empty container
• 3 - Lifting height, no. of containers when stacking
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.
012651
1 2 3 4
1. Steering axle
2. Engine
3. Transmission
4. Drive axle
5. Load handling, lifting mast
6. Load handling, trolley
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.
The machine is equipped with one of the following engine alternatives:

• Cummins QSB6.7 Stage 3A/Tier 3 (129 kW)
• Cummins QSB6.7 Stage 3B/Tier 4i (129 kW) (emission control
technology catalytic converter DOC)
• Cummins QSB6.7 Stage 3B/Tier 4i (164 kW) (emission control
technology DPF)
• Volvo TAD761VE Stage 3B/Tier 4i (160 kW) (emission control
technology DOC and AdBlue/SCR)
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.
Machines with Cummins QSB6.7 Stage 3A/Tier 3 (129 kW) or Cummins

QSB6.7 Stage 3B/Tier 4i (129 kW) is equipped with ZF 3WG161.
Machines with Volvo TAD761VE Stage 3B/Tier 4i (160 kW) or Cummins

QSB6.7 Stage 3B/Tier 4i (164 kW) is equipped with ZF 3WG171.
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 trolley are used for load handling. The load is
manoeuvred in height and is tilted (angled) forward or backward.
The trolley is available in different versions, normally one of the

following alternatives:
• Fixed carriage with manually moveable forks.
• Side shift carriage.
• Fork spreading carriage with side shift.
• Fork spreading carriage with side shift and central levelling.

The forks are manually adjustable with hook brackets for the trolley or
loose hanging in the pin type design or hook type for the shank or roller
type for carriage assembly. The carriage can be fitted with a coil ram or
attachment for empty containers.
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 generated error or safety related
events 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 can be
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 and
heating and 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: brakes, steering,
load handling, cab and fan control cooling fan motor. The hydraulic
system is powered by two variable load sensing pumps and a fixed
gear pump for charging the accumulator and powering of the hydraulic
motor for the drivetrain's cooling fan. The hydraulic oil is cleaned with
high pressure filters after the hydraulic pumps.

Other equipment
16,26,27,31 40 33 10 41 6,12 28 1,2,3 8,11
14 25,29
13 30
53 18
50
42
52
44
51
7 3,21,32
16,24 4, 5
22
16
016659
22 35 48 47 38 43 46 45 15,16 39 49 23
1. Rear view mirror
2. Extra internal rear view mirror
3. External rear view mirrors
4. Horn
Located inside the left-hand front cover.
5. Electrically powered loud air horn
Located inside the left-hand front cover.
6. Roof window standard 6 mm.
Roof window extra strong 12 mm
7. Seat for passenger, positioned to the left of the driver's seat
8. Tempered safety glass in the front windscreen
Laminated front windscreen
9. Clear windows
Tinted windows
(Not positioned in figure).
10. Opening window right and left-hand door
11. Sun visor, front windscreen
Infinitely extendable to selected position.
12. Sun visor, roof window
13. Sun visor, rear window
14. Audio system
Instructions are included.
15. Writing table with light
To manage paper in the cab. Lighting is placed in the roof.
16. Camera with monitor
Used to provide improved rearward vision when manoeuvring
and load handling with the machine. Camera is located on the
counterweight or cab and/or lifting equipment. Monitor is placed
in the cab.

17. Socket 12/24V DC (Not positioned in figure)

The socket is fused and marked. Four sockets are located on the
lower part of the A-pillar.
18. External handle for cab instep
19. Non-slip plate on e.g. steps and lower edge of the door sill
20. Aluminium non-slip plates for lamp protection and front wings
21. Steps between tilt cylinders
22. Mud flap, steering and drive wheels
23. Grating for headlights
24. Grating for rear lights
25. Protective grille for mast working lights
26. Working lights, cab roof rear edge, directed backwards, 2 lamps
27. Extra working lights, cab roof rear edge, directed forward, 2 or
4 lamps
28. Extra working lights, cab roof, front edge, 2 lamps
29. Mast working lights, 2 lights
30. Extra mast working lights, 2 lamps
31. Extra working lights for container handling, 4 lamps
On the cab roof, rear edge.
32. Extra working light between the tilt cylinders, 1 lamp
33. Adjustable search light
Controlled electrically by remote control.
34. Tool kit
35. Litter container
36. Heater: (Not positioned in figure)
A: 110 V or 230 V for connecting the engine heater with or without
compartment heater
B: Electric- or diesel driven compartment heater. A pause heater is
available as an optional.
C: Oil heater hydraulic tank, high voltage 230/380 V
D: Eberspächer. Refer to the manufacturer's instructions.
37. Aux. emission
Volvo TAD761VE can be equipped with particulate filters.
38. Revolving operator's station
39. Baseplate, cab
Mounted between cab and frame.
40. Mesh pocket headlining; storage compartment (only with elevated
roof)
41. Interior lighting
42. Steering wheel console with three individually adjustable shafts
with electrically adjustable height position
43. Work console with four individually adjustable shafts with
electrically adjustable height and length position
44. Cup holder for storage compartment in the front panel. The cup
holder can be mounted in any storage compartment.
Extra cup holder for the storage compartment in the front panel.
45. Storage compartment for paper in the seat console
46. Storage compartment in seat console
47. Mesh pocket in right-hand door side; storage compartment. Not
available on the overhead guard.

48. Bottle holder in left-hand door side. Not available on the overhead
guard.
49. Storage compartment in front panel
Refrigerated storage compartment right-hand side front panel (in
combination with ECC)
50. Storage compartment in right-hand arm rest
51. Storage compartment behind the driver's seat console .
52. Storage compartment for the operator's manual. Located behind
the door to the right in the rear wall.
53. Alcolock. Refer to the manufacturer's instructions .

3 Overview – Plates 27
3.2 Plates
Product plates
Below are the product signs that must be on the machine when
operating within the EU/EES, 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.
016649
5 4 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 lift 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 about 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

28 3 Overview – Plates
3. Additional plate for attachment, A33808

Specifications about the machine's approved lifting equipment.
The plate is in the cab for the operator's information. Corresponds
with plates 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 the front edge of the

fork/attachment edge 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.
1 1
1
1 3 9 1 5
016650
7 2 4 7 2 9 7 8 6 2
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
1 The plate is also on the condenser, compressor and at the air inlet
(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 .

Fitted on machine's equipped with additional equipment such as
communication radio, RMI, telephone, etc.
012968
7. Transport lock A38769.0100.

Fastening point for machine transport lock.
016612

Safety
Safety
8. 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
9. Fire extinguisher, A43461.0100
Specifies where extinguishing is to be performed with a fire in
the engine compartment. The nozzle for extinguishing is pushed
through the sign.
001833
A43461.0100
016651
15 12 15 15 10 14 13 11 15
Engine
Engine
10. Filling point, fuel, 450202.0100
D
000286
450202.0100
11. Warning! A47240.0200

Hot surfaces.
Rotating parts.
015461
Risk of crushing.

12. Warning! A47240.0300

Hot surfaces.
Rotating parts.
Risk of crushing.
015462
13. Warning! Filling point, coolant, A57775.0100

Use only ready-mixed recommended coolant.
013692
Power transmission, wheels
Power transmission, wheels

14. Filling point, transmission oil
455949.0100
000852
455949.0100
15. Inflation pressure, factory-fitted tyres

A32049.0700 0.9 MPa
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!

17
18 16 19
016652
Hydraulic system
Hydraulic system
16. Filling point hydraulic oil, 450203.0100
000292
17. Warning! A36163.0100

Pressure. Always release the pressure from the accumulator
before working on the hydraulic system.
002497
18. Hydraulic pressure, A54518

Indication of the machine's set pressures. The figures are
engraved.
015319

Lifting mast and attachment
Lifting mast and attachment

19. 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.

4 Instruments and controls 35
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.

36 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
(High and low beam switches, direction indicators, horn switch)
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 39.

4 Instruments and controls – Instruments and controls 37
Steering wheel panel
Steering wheel panel

14
21 22 23 30 16 17 14. Ignition key lock
15. Engine start and stop button
16. Indicator light, parking brake
18
17. Indicator light, high beams
24 19
18. Indicator light for active errors
25 20 19. Indicator light for direction indicators
20. Warning lamp, by-pass of safety system
26 21. Switch for combined windscreen wiper, windscreen/roof window,
continuous
012692
27 28 29 32 31 33 15 Switch for windscreen wiper, windscreen, continuous
Steering wheel panel 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
Right-hand dashboard panel, front section
34 35 36 37 38 39 40 34. Control breaker for hydraulic, drive and steering mini-steering

43 wheel
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
47 48 49 50 51 52 43. Switch for cooling

Right-hand dashboard panel, front section 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 exhaust filter
(applies to Cummins QSB6.7 Stage 3B/Tier 4i)
52. Switch for radio mute

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 lift/lower 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. Locking twistlocks
Switch for differential lock
55. Switch for spreading 20'-40'
56. Switch for automatic spreading 20'-40'
57. Switch for stop at 30' or 35'
58. Spare
59. Spare
60. Switch to rotate the operator's station
61. Spare
62. Switch for horn

4 Instruments and controls – Instruments and controls 39
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 working lights on mast
65. Switch for extra working lights
66. Switch for extra working lights on cab
67. Switch for back-up light
68. Switch for length adjustment of the right-hand control panel
72 73 74 75 69. Switch for height adjustment of steering wheel

70. Switch for height adjustment of the right-hand control panel
71. Switch 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°
13 85 km/h
km/h
9999
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
77. Electronic box with fuses and relays
76
016431
Rear cab section

Roof panel
Roof panel
Applies to DCG 70-32E3–70-35E4.
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 41
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 36.
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 84.
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

42 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
000312
and with that the load.
Indicator light, contact (81)

The indicator light (orange) is activated when the attachment has

012697
contact with the load.
Indicator light for unlocked twistlocks (82)

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

016670
Indicator light for clamp 1 (84)
Indicator light (red) is illuminated when the clamping pressure on clamp

1 is reached.
016671

4 Instruments and controls – Warning and indicator lights 43
Indicator light for tilt control (85)
The indicator light (orange) shows the status of the tilt control
(automatic tilt system). Tilt control is activated/deactivated with the
016672
switch on the 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 (86)
Indicator light (red) is illuminated when the clamping pressure on clamp

2 is reached.
016671

44 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 Ignition voltage and drivetrain are switched off, the key can
0 be removed.
I Voltage to certain functions such as interior lighting, pause
heater, alcolock and standby voltage control units.
I Ignition voltage switched on and drivetrain activated for
starting.
012815
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 45
Alcolock function
The machine may be equipped with an alcolock. In order to start the

machine the driver 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 statistics, etc., see the manufacturer's

instructions.
016631
Alcolock

46 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 those functions relevant to the machine
will then display a white pilot light or 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 after the
operator leaves the driver's seat. Reactivated when the operator sits
012705
in the 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 after the operator leaves the driver's
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 47
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 after the
operator leaves the driver's seat. Reactivated when the operator sits
012706
in the 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 87.
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 after the operator leaves the driver's
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 revolving operator's station then the

wipers on the rear windscreen are activated when the driver's seat is in
the standby 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 84.
NOTE
Switch, windscreen wiper roof, interval (24)
Switch (green) for windscreen wiper on roof window. Intermittent

wiping. Wiping stops after the operator leaves the driver's 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)

The switch (green) for recirculation. 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
012717
entering the cab.
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.
Reduced fan speed is activated with the press of a button.
The fan speed is displayed in the operating menu.
012719
The event menu appears when the fan speed drops, see Event menu
raise/lower fan speed, description, page 85.
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 regulation and air distribution in the cab take place
automatically.
Automatic fan speed is activated with the press of a button.
Switch for increased fan speed (40)

Switch (green) to increase the fan speed in the cab.
Increased fan speed is activated with the press of a button.

012721
The event menu appears when the fan speed increases, see Event
menu raise/lower fan speed, description, page 85.
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 85.
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 85.

Switch for cooling (43)
Cooling function switch (green).
012727
Cooling is activated/deactivated with the press of a button.
The air conditioning's cooling function will not start if the fan is off or if
the doors are open. If the doors are opened, the fan will shut off after
a while. If the doors are not closed within a short period, even the
cooling compressor will switch off.
Switch for air distribution, to the floor (44)

Switch (green) for air distribution, to the floor.
Air distribution toward the floor is activated/deactivated by pressing a

012724
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.
Air distribution toward the roof is activated/deactivated by pressing a

012725
and roof.
Switch for air distribution to the roof (46)

Switch (green) for air distribution to the roof.
Air distribution toward the roof is activated/deactivated by pressing a

012726
and roof.
Switch for by-pass of safety system (47)

Bypassing the machine's safety features. Rocker switch.
The driver 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 possibility to:

• to lock or open twistlocks without contact.
• length adjust the attachment with locked twistlocks.
• lift, without indication of locked or open twistlocks.
• to engage gear without the sensor in the driver's seat indicating
that someone is sitting in the seat.
• use load handling functions at a reduced speed without seating
in the seat.
• rotate the operator's position without all conditions being met.
• use load handling functions when the revolving operator's station
is not in the permitted position.
• drive the machine with the speed limitation 5 km/h when the
revolving 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.
012789
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 86.
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 86.

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.
The switch prevents regeneration of the engine's

exhaust filter (51)
Applies to Cummins QSB6.7 Stage 3B/Tier 4i.
The switch (green) prevents regeneration of the engine's exhaust filter.
Position 0 - The regeneration function for the engine's exhaust filter is

015210
activated with automatic control via the engine control unit.

0 1
Position 1 - The regeneration function of the engine's exhaust filter is
deactivated. If regeneration is in progress, the engine control unit will
stop the process and it begins once all conditions are met again and
the switch is in position 0.
The event menu appears when the regeneration of the engine's

exhaust filter is off, see Shut off regeneration of the engine exhaust
filter, description, page 85.
NOTE
The function may only be used temporarily if the situation requires.
Prolonged driving without regeneration of the exhaust filter can
result in the filter needing to be sent away for renovation by an
authorised service centre leading to downtime, this according to 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
0 1 volume.
Position 0 – Function audio off is deactivated.
Position 1 – Function audio off is activated.

Switch for differential lock (54)
Switch (green) for differential lock. Rocker switch.

Position 0 – Differential lock off.
012791
0 1 Position 1 – Differential lock on.
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 work lights on cab (63)
Switch (green) for working lights on cab.

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

button.
Switch for working lights on mast (64)

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

012764
Extra working 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.

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 73.
Switch for headlights (72)

Switch (green) for headlights. Also activates the rear 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.

58 4 Instruments and controls – Travel direction selector and parking brake
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
Selecting direction of travel

Travel direction is selected with the travel direction selector. The
F P 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's
diagnostic menus.
Selecting direction of travel:

• F - Forward. Move the lever forward for forward drive.
N • N - Neutral. Neutral. Move the lever up or down for neutral.
• R - Reverse. Move the lever backward for reverse drive. (Acoustic
warning signal )
Manual up and down shifting is performed using the switches for

manual shifting up (position 30) and manual shifting down (position 31).
015430
R Selection of automatic shifting is done with the switch for automatic

shifting (position 32).

4 Instruments and controls – Travel direction selector and parking brake 59
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 41.
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 84.
015430
R DANGER
or extreme danger!

60 4 Instruments and controls – Multi-function lever
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.
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

4 Instruments and controls – Load handling 61
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 46.
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 driver 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.
Adjust the right-hand control panel to the desired position, see Switch
for length adjustment of the right-hand control panel (68), page 56
and Switch for height adjustment of the right-hand control panel (70),
page 56.

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. Lift / lower
LIFT - pull the lever backwards.
LOWER - push the lever forwards.
Lowering 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. To activate
c. Side shift
LEFT - push the lever forwards.
RIGHT - pull the lever backwards.
The forks cannot be side-shifted if fork spreading is at maximum.
34 a b c d e d. Spreading (positioning)
OUTWARDS - push the lever forwards.
INWARDS - pull the lever backwards.
Positioning locks when one of the fork reaches the end position.
Side shift to the centre and spread again.
Spreading sidelift attachment
INCREASE SPREADING – move the lever forward.
DECREASE SPREADING – pull the lever backward.
k For attachments that clamp in the load (e.g. paper handling
j
i attachment)
h
OPEN ATTACHMENT - press the switch fitted on the lever and
g move the lever forward.
CLOSE ATTACHMENT - pull the lever backwards.
The function may be located on another lever.
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.
Locking/releasing twistlocks for sidelift attachments .
RELEASE TWISTLOCKS – push the lever forward.
016673
LOCK TWISTLOCKS – pull the lever backward.

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

current gear is shown in the display and the selected direction of
travel is shown on the steering 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
015160
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 ] SIDE SHIFT RIGHT - move the upper thumb control
upward.
LIFT - pull the whole control lever backward. SPREADING OUT - move the upper thumb control
LOWER - move the whole control lever forward. forward.
Lowering speed can only be varied with lever SPREADING IN - move the upper thumb control
deflection - the engine speed has no effect. backward.
b Selection of travel direction .
TILT OUT - move the whole control lever to the right.
The control is spring-loaded, the current gear is
TILT IN - move the whole control lever to the left. shown in the display and the selected direction of
travel is shown on the steering wheel panel.
FORKS UPWARD - press in the shift-button
(position f) and move the whole control lever to the Travel direction FORWARD - move the lower thumb
right. control forward.
Travel direction NEUTRAL – move the lower thumb
FORKS DOWNWARD - press in the shift-button control up or down.
(position f) and move the whole control lever to the
Travel direction REVERSE - move the lower thumb
left.
control backward.
CENTRAL LEVELLING ANTICLOCKWISE - press c Spare
in the shift-button (position f) and move the whole d Spare
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
a Side shift / Spreading switch changes the function of the other controls on
the control lever.
SIDE SHIFT LEFT - move the upper thumb control
downward. 62. Switch for horn .

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 78.
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 minimum and maximum values and
adjustability is dependent on the 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 56.
NOTE
015217
It is possible to set the distance up to the steering wheel and

steering panel. Contact Cargotec Service if the distance needs
to be adjusted.

68 4 Instruments and controls – Steering wheel
Mini steering 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-steering wheel. If the steering wheel is released,
4
both the mini-steering 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 driver starts
to steer using the standard steering wheel, the mini steering wheel
is disengaged.
1. Direction indicators.
2. Mini steering 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-steering 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

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.
015422
Travel direction REVERSE – move the switch backward.

5. With headlights on: The switch is used to change between high
and low beam.
With headlights switched off: The switch is used for headlamp
flasher with high beam.
6. Arm rest. Can be folded up to easily enter and leave the driver's
seat.
Joystick control
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 driver
starts to steer using the standard steering wheel, joystick steering is
disengaged.

4 Instruments and controls – Steering wheel 69
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

70 4 Instruments and controls – Driver's seat
4.9 Driver's seat

General
This section describes the driver's seat (position 10) in the cab.
Driver's seat
The driver's seat is equipped with several controls for adjustment as
follows (adjustment is easier when nobody is sitting in the seat):
1. Seat belt, 2-point.
Seat belt, 3-point .
2. Distance to pedals.
Release the seat using the lever and move the seat forwards or
backwards.
3. Seat tilt.
4. Horizontal suspension .
5. Seat length.
6. Height of seat.
Mechanical elevation of seat height:
Turn the knob clockwise or anticlockwise until desired height is
obtained.
Air suspension elevation of seat height: .
Lift the control up to increase seat height or alternatively press the
control down to reduce seat height. The suspension automatically
responds to the weight of the operator.
An indicator shows green when the correct height is reached. The
indicator turns red when the seat's suspension is set outside the
comfort mode.
Driver's seat with adjustment possibilities 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 .
11. Adjusting the head rest .

4 Instruments and controls – Heating / Air conditioning 71
4.10 Heating / Air conditioning

General
This section describes the function of:
38 39 40 43
• The heating, 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 fresh air, but warms it if necessary to achieve the
selected temperature.
36 • Air conditioning system, ECC. ECC automatically regulates air
flow and air distribution in the cab and it constantly aims towards
35 regulating 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
012820
cooling system and provides heat when the engine is warm. Cooling
41 42 44 45 46 performance is generated by the cooling compressor (for ECC).
Panel for heating and air conditioning 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 85.
• 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 85.
• 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) .

72 4 Instruments and controls – Heating / Air conditioning
NOTE
Operator's door and windows shall be closed for satisfactory
function of the system.
With ECC: A short while after one of the doors is opened, the fan
shuts 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 46.
For information on the display, see 4.11 Control system, page 73.

4 Instruments and controls – Control system 73
4.11 Control system

General
This section describes the control system and the information that can
a be obtained from the operating menus.
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:

10:23
10:23
1
10 2200
2 • Error code information
00 rpm x 100
rpm x 100
3 30 0
0 rpm x 1000 3
Three levels of error code information can be shown. In the event
of a new error code, error code information is shown over the entire
21°
1
385 9999
km/h
km/h
•
display. See the section 5.3 Error codes.
Operating information
Operating information includes, for example, machine speed,
engine rpm, fuel level, etc.
• 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
b c d e selections. Figures are stated with example data.
c e
012823
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

74 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
0:0 0pm 0 : 00 pm 2
0
21° 18 99999
km / h 32.8 l/h 1756
9.5
r pm
km/ h
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 0:0 0pm
- 1. 9 t 89 ° C 3. 3b a r
7 4. 9 t
5 2 2. 9 t
5 4
0: 00pm 0: 00 pm
7 0° C
2 3. 4 V
5 0° C
016615
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 75
4.11.1 Operating menus

Description
After starting the machine the operating menu is displayed with engine
a 10:23 2 e speed, speed, time, fuel level and information on the current setting for
10 20
b 0
rpm x 100
30
f the heating or air conditioning system.
c a. Time.
g
21° 18 99999
km/h
h
i
b. Field for the four event menus with the highest priority and which
have status indicators. If at most there are two event menus, the
status of heating or air conditioning system is shown in the lower
part of the field.
16.7 t
j c. Fuel economy. The green field indicates economical driving while
d
014524
D U the red field indicates uneconomical driving that consumes a lot
of fuel.
d. Fuel level.
e. Current gear.
f. Engine speed.
g. Scale, the bar shows the load 0-100 %. The current weight in
tonnes or lbs (pounds) is shown under the bar.
h. Speed in km/h.
i. Operating time in hours (h).
j. AdBlue level (only applies to specific engine options).
4.11.1.1 Operating menu trip computer work shift
Operating menu trip computer work shift, description
2
Trip computer work shift shows current machine statistics since the
10:23
last reset.
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.
c e. Current speed in km/h.

120:36 h 1 23 14432 h
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

76 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.
23.4V
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 169.
522 . 9 t c
016370

4 Instruments and controls – Event menus 77
4.11.1.6 Operating menu customer settings
Operating menu customer settings, 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 setting customer-specific settings for date and time, and
b i SI/US units.
0 e. Menu for statistics and operating time history .

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 4.11.3
Menus for customer settings, page 90.
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
Tabell Event menu categories

Example figure STOP Red border.
a The colour of the border indicates the
category of the event menu. WARN- Yellow border.
ING
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.

78 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.
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 driver in the driver's seat
The event menu parking brake not activated and no

driver in the driver's seat, description
• The parking brake is not activated and the driver is not sitting in
the driver's seat.
The event menu disappears when the driver 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 High exhaust temperature in the engine

exhaust filter
High exhaust temperature in the engine exhaust filter,
description
Only applies to Cummins QSB6.7 Stage 3B/Tier 4i.
• The exhaust gas temperature in the engine exhaust filter is high.
• Manual regeneration of the exhaust filter is carried out.
The display can be removed with the function key .
014985
4.11.2.5 High soot level in the engine exhaust filter

High soot level in the engine exhaust filter, description
• The soot level in the exhaust filter is high.
There are a number of levels indicating the severity of the soot level.
The levels are:
1. Event menu appears with a fixed light. This is the first warning level
when the filter becomes clogged, there are then two possibilities:
a Operate as usual and allow regeneration of the filter. Check
014986
that the regeneration function is not shut off with the switch,
see The switch prevents regeneration of the engine's exhaust
filter (51), page 54. The engine runs with an increased load.
When regeneration has been carried out the event menu goes
out.
b Perform manual regeneration, contact Service.
2. The border around the event menu flashes. Perform a manual
regeneration when possible, contact Service.
3. The border around the event menu flashes and error code
SPN1921 is shown. Perform manual regeneration as soon as
possible, contact Service.
4. Error code SPN1922 is shown. The filter must be removed and
regenerated at the workshop, contact Service.
After regeneration the display disappears. The display can be removed
with the function key .
4.11.2.6 Event menu AdBlue

Event menu AdBlue, description
Only applies to Volvo TAD761VE.
• Engine does not receive AdBlue.
• The level in the AdBlue tank is low.
If the figure is shown, top up the AdBlue. The display then disappears.
016679

4.11.2.7 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
4.11.2.8 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
4.11.2.9 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
4.11.2.10 Event menu height warning
Event menu height warning, description
The figure is shown when:

• set lifting height is reached.

016677

4.11.2.11 Event menu height limitation
Event menu height limitation, description

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

• lift equipment. The overload system stops the lift and tilt.
Th event menu disappears when the overload ceases. In the event

of overload the load can always be lowered and tilted out to avoid
the overload situation. The display can be removed with the function
016682
key .
4.11.2.13 Event menu overload tilt
Event menu overload tilt, description


016683
key .
4.11.2.14 Event menu overload lift and tilt
Event menu overload lift and tilt, description


016684
key .

4.11.2.15 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
4.11.2.16 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
4.11.2.17 Event menu parking brake
Event menu parking brake, description

• The parking brake is activated and you try to engage a gear and
when you try to activate certain automatic functions when the
parking brake is activated.
Release the parking brake and the display disappears. The display can
be removed with the function key .
014990
4.11.2.18 Event menu low AdBlue level
Event menu low AdBlue level, description

014991

4.11.2.19 Event menu AdBlue

Event menu AdBlue, description
Only applies to Volvo TAD761VE.

• Engine does not receive AdBlue.
016680 4.11.2.20 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
014992
4.11.2.21 Event menu no driver in the seat

Event menu no driver in the 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 driver sits in the seat again.
• The working hydraulics are activated without anyone sitting in the
driver's seat.
• Attempt to revolve the operator's station without anyone 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 .
4.11.2.22 Event menu open door

Event menu open door, description
• Doors are not closed during hydraulic cab sliding. The cab cannot
be operated until the doors are 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

4.11.2.23 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
4.11.2.24 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
4.11.2.25 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 is performed without the
service brake pedal being pressed down sufficiently or the parking
brake is not activated .
In case the figure is shown:

014995
• Press down the service brake pedal and release the parking brake.
• Press down the service brake pedal or activate the parking brake
and try again to turn the operator's station.
The display then disappears. The display can be removed with the
function key .

4.11.2.26 Shut off regeneration of the engine exhaust

filter
Shut off regeneration of the engine exhaust filter,
description

• Regeneration of the exhaust gas filter is prevented
This is done by activating the Switch prevent regeneration of the
engine's exhaust filter, see The switch prevents regeneration of the
engine's exhaust filter (51), page 54.
In the event that the figure is shown, regeneration is prevented. High

soot level in the engine exhaust filter, description, page 79 is shown
014995
if the exhaust filter needs to be regenerated.
4.11.2.27 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
4.11.2.28 Event menu raise/lower cab temperature

Event menu raise/lower cab temperature, description
• The cab temperature is raised or lowered. The 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
014998
4.11.2.29 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 most recent fan
speed change with the cab temperature switches. The display can be
014999

4.11.2.30 Event menu start interlock
Event menu start interlock, description

• The start interlock (Immobilizer) 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
Stage 3B/Tier 4i.
• Engine or hydraulic oil heater is engaged.
015200
The event menu disappears when the conditions to start the engine are
met. The display can be removed with the function key .
4.11.2.31 Event menu heating rear view mirrors/rear

windscreen
Event menu heating rear view mirrors/rear windscreen,

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

• 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
4.11.2.32 Event menu service
Event menu service, description

• Time to next service is approaching.
Ensure that the machine is serviced according to the prescribed

intervals. The display can be removed with the function key .
015443

4.11.2.33 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
4.11.2.34 Event menu intermittent wiper
Event menu intermittent wiper, description

• Slow intermittent wipers are activated.

015445

• Fast intermittent wipers are activated.

015446
4.11.2.35 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

4.11.2.36 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. Display 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
4.11.2.37 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 192.

016368
4.11.2.38 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 the zone C.
• Load handling functions are activated when the operator's station
is in the zone C, D or E.
016608
• The operator's station rotates without the driver activating the

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
180°
E
D
B
A
0°
016607
4.11.2.39 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 times as mini steering wheel/joystick control.
If the figure is shown, do not use the mini steering wheel/joystick control
when rotating the operator's station. The display then disappears. The
016609
4.11.2.40 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 area.
The figure also shows whether the left-hand arm rest by the mini
steering 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 with the mini steering wheel/joystick control the arm
rest down and try again to rotate the operator's position. The display
016610

90 4 Instruments and controls – Menus for customer settings
4.11.2.41 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 the
attachment with the lever. The display then disappears. The display
016681
4.11.3 Menus for customer settings
4.11.3.1 Menu for date and time
Description
Setting the time
10:23
1 Select the date and time menu with or and confirm with .
0
016375
10:23 2 Select SET TIME/DATE with or and confirm with .

CUSTOMER SETTI NGS
0
SET TI ME/ DATE a
SET SI / US UNI TS b
0
014934
a Setting the date and time.

b Setting units.
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

4 Instruments and controls – Menus for customer settings 91
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 : 4 5
0
014941
0
Setting the date
10:23
0
016375
10:23 2 Select SET TIME/DATE with or and confirm with .

CUSTOMER SETTI NGS
0
SET TI ME/ DATE a
0
014934

b Setting units.
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 - 0 9 - 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- 09 - 19
0
014942
0
Setting the time format
10:23
0
016375
10:23 2 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 3 Select the time format 24h or 12h am/pm with or . Leave
SET TI ME STYLE the menu with .
0
24 h
12 h a m/ pm
0
014943
Setting the unit
10:23
1 Select the menu for SI/US with or and confirm with .
0
016375

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

CUSTOMER SETTI NGS
0
SET TI ME/ DATE a
0
015324
0

b Setting units.
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
4.11.3.2 Menu for active error codes

Description
10:23
1 Select the menu for ACTIVE ERRORS with or and confirm
with .
0
016376
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/ 10 d
a. Device that generated the error code.
k 0 1 11 / 5480- 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.
e. Information can be found in the operator's manual.
i 0
f. Symbol for the device that generated the error code.
014944
h g f g. Symbol for the driver 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 102.

4.11.3.3 Menu for inactive error codes
Description
10:23
1 Select the menu for INACTIVE ERRORS with or and confirm
with .
016377
0
10:23
2 The menu shows the inactive error codes.
ERROR HI STORY 1/ 12 Scroll through the error codes with or . Leave the menu
with .
1 11 1 / 5 170 - / 3
0
20 11 - 09 - 19 1 0: 2 3 For more information, see Error codes, general, page 102.
2 11 1 / 5 160 - / 3
0 20 11 - 09 - 19 1 0: 2 3
3 0/ 0- / 0
00 00 - 00 - 00 0 0: 0 0
014945
4.11.3.4 Menu for statistics and operating time history
Description
10:23 1 Select the menu for running times with or and confirm with .
0
016353
10:23
2 The menu shows the cumulative operating time for the machine's
OPERATI NG HOURS components. This counter cannot be reset.
a. Operating hours engine (hours).
121 2332 h
a b. Operating hours transmission, with gear activated (hours).
798 4 h c. Operating hours hydraulic functions activated (hours).
b
d. Proportion of engine operating time that was idling (percent).
374 3 h c
Select the next statistics and history menu with or go back with
48 % d . Leave the menu with .
016354

10:23
3 The menu shows resettable operating time, since the last reset
OPERATI NG HOURS for the machine's components.
a. Operating hours engine (hours).
123 3 2 h a b. Operating hours transmission, with gear activated (hours).
798 4 h b c. Operating hours hydraulic functions activated (hours).
d. Proportion of engine operating time that was idling (percent).
374 3 h c
Select the row to be reset to zero with a short press on . Select
48 % d row with or . Reset the row with .
016355
Reset all rows by pressing for more than 2 seconds.
. Leave the menu with .
10:23
4 The menu shows driving distances.
DI STANCE a. Accumulated driving distance in km. This counter cannot be
reset.
123 3 2 km a b. Driving distance odometer 1 since last reset to zero in km.
798 4.1 km b c. Driving distance odometer 2 since last reset to zero in km.
Select the row to be reset to zero with a short press on . Select
374 3.5 km c row with or . Reset the row with .
016356
10:23
5 The menu shows accumulated fuel statistics. This counter cannot
FUEL 1 2h a m/ pm be reset.
a. Total fuel consumption in litres.
163 4 5 l a b. Average fuel consumption in litres/hour.
25. 1 l/h b c. Average fuel consumption in litres/100 km.
c d. Average fuel consumption in litres/lift.

15. 4 1/100km
3.2 3 l/pcs d
016357
10:23
6 The menu shows resettable fuel statistics since the last reset.
FUEL a. Fuel usage in litres.
b. Average fuel consumption in litres/hour.
134 2 l a c. Average fuel consumption in litres/100 km.
25. 1 l/h b d. Average fuel consumption in litres/lift.
15. 8 1/100km c Select the row to be reset to zero with a short press on . Select
d row with or . Reset the row with .
4.1 4 l/pcs
016358
10:23
7 The menu shows accumulated load statistics. This counter cannot
LOAD be reset.
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

10:23
8 The menu shows resettable load statistics.
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 the row to be reset to zero with a short press on . Select
1 23 5.2 pcs/h c row with or . Reset the row with .
016360
4.11.3.5 Menu for services and settings
Description
10:23
Used for diagnostics and settings on the machine by authorised
CUSTOMER SETTI NGS personnel. Access code required.
0
014981
4.11.3.6 Menu for machine check
Menu for machine check, description
10:23 1 Select the menu for MACHINE CHECK with or and confirm
with .
0
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 The menu shows cooling fan reversing.
MACHI NE CHECK Change the cooling fan's blow direction . The tick in the box
indicates the fan's blow direction is reversed.
with .
016363
10:23
4 The menu shows regeneration exhaust filters.
MACHI NE CHECK Activate regeneration of the engine exhaust filter . The tick in
the box indicates that regeneration is activated.
with .
016364
10:23 5
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.
with .
016365

98 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 99
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.

100 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 filer must be changed according to intervals described in
the maintenance manual.
Transmission
The oil and filer 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 101
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 section 6.1 Daily inspection.
Report to the foreman/supervisor if defects are found
on the machine during daily inspection!

102 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/ 10 errors where, among others, the error code level, action with error code
and the device that generated the error code are presented.
0 1 1 1/ 5 48 0- 5
Scroll through active error codes with and . Leave the error code
list by pressing the function key .
0
015225
Example figure Active errors

5 Handling – Error codes 103
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/ 12 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 / 5 170 - / 3 presented.
0
20 11 - 09 - 19 1 0: 2 3
Scroll through inactive error codes with and . Leave the error code
2 111 / 5 160 - / 3 list by pressing the function key .
0 20 11 - 09 - 19 1 0: 2 3
3 0/ 0- / 0
00 00 - 00 - 00 0 0: 0 0
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 machine's capacity may be
limited and certain functions may stop working. -
Perform actions according to error code table as soon
as possible.
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 106.
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 106.
4 Perform the action depending on the action symbol shown in the
Example figure
middle field, see Field b: Operator action, page 106.
5 Check: Start the engine and check under Active errors that the
error code has disappeared.

104 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
5.3.2 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

5 Handling – Error code information on display 105
10:23
• In error code list Active errors.
ACTI VE ERRORS 1/ 10 Active error codes are stored in the error code list. Navigate to
the operating menu Customer settings with or , select Active
0 1 1 1/ 5 48 0- 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:
Example of the error code list Active errors – condition for error detection no longer exists, e.g., control
lever is released or engine is off.
– loose connection/poor contact.

106 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 INFORMATION
0 a d c
g Information to operator about something that should
2 be taken care of, e.g., broken bulb. Take care of the
11 1 / 5 160 - / 3
0 cause at a suitable time. Action instruction is often
20 11 - 09 - 19 1 0: 2 3
found in chapter 6 Inspection and maintenance.
3 0/ 0- / 0
00 00 - 00 - 00 0 0: 0 0 Field b: Operator action
015230
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 176.
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.
Symbol Function Symbol Function Symbol Function

Engine Fuel level AdBlue level
Particulate filters Exhaust temperature Air filter for air intake

combustion air
Engine coolant level Engine oil level Preheater
Transmission Oil temperature torque Lock-up, torque converter

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

temperature
Brakes Servo brake system Parking brake system
Oil temperature brake Steering Suspension

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

Symbol Function Symbol Function Symbol Function

Unlocked twistlocks Container attachment Contact side-lift
attachment
Contact top-lift attachment Support jacks Control system
Boom angle Extension Scales
Overload/OLS Height limit Overload/OLS
Frame, body, cab and Hour meter (operating Seat

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

beacon
Horn Heating rear Vertically adjustable cab

windscreen/rear view
mirrors
Tiltable cab Cab sliding length Central lubrication
Hydraulic oil filter Hydraulic oil temperature Battery capacity
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
0
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 Torque converter
G Battery or alternator
H Horn
K Relay
M Electric motor
R Resistor
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
Front 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.
Tabell 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.
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. Baudrate.
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.

FMI Description SAE-text

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.

112 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 109.
• SPN - Denotes the component concerned, see Component
(CCCC), page 109.
• FMI - Denotes the type of error, see Type of error (EE), page 110.
• Node - Denotes which unit has generated the error, see Device
number (AAA), page 109.
• Placement - denotes the component's placement in the machine,
Component placement (DD), page 109.
• 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

Type SPN FMI Node Location Description Action
P 708 14 1, 11, Operating hours do not correspond with the WARNING!
12 reference KFU.
B 2070 3 2 Contact differential lock, feedback-signal. WARNING!
B 2460 2 1 Air conditioning pressure sensor OK (2-26 WARNING!
bar), clutch active.
K 3150 6 1 Ignition relay. 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 Start relay engine. WARNING!
E 4041 6, 5 2 1 Working lighting load centre. INFORMATION
E 4041 6, 5 2 2 Working lighting option. INFORMATION
E 4042 6 1 1 Extra working lighting left. INFORMATION
E 4042 6 1 1 Extra working lighting right. INFORMATION
E 4043 6, 5 2 LE Working lighting mast left. INFORMATION
E 4043 6, 5 2 RI Working lighting mast right. INFORMATION
E 4050 6, 5 1 LE Working lighting backward left. INFORMATION
E 4050 6, 5 1 RI Working lighting backward right. INFORMATION
H 4110 6 2 Brake light. INFORMATION
H 4120 6 2 1 Tail lights. 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 on counterweight. INFORMATION
H 4282 6, 5 1 Revolving beacon. WARNING!

5 Handling – Error code tables 113

E 4340 6 1 Interior lighting. INFORMATION
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 Fasten seat belt, indicator light. INFORMATION
H 5992 6 1 Mini steering wheel/joystick control, indicator WARNING!
light (on/off).
Y 6004 6, 5 2 Solenoid valve lower. WARNING!
Y 6005 6, 5 2 Solenoid valve lift. WARNING!
Y 6010 6, 5 2 Solenoid valve tilt out. WARNING!
Y 6011 6, 5 2 Solenoid valve tilt in. WARNING!
Y 6014 6, 5 2 Solenoid valve differential lock. 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 out. WARNING!
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 6091 6, 5 2 Solenoid valve fan speed engine cooling fan. WARNING!
Y 6092 6, 5 2 Solenoid valve fan speed direction, engine INFORMATION
cooling fan.
Y 6095 6, 5 2 Solenoid valve split function mast. WARNING!
Y 6120 6 1 2 Actuator motor, recirculation air conditioning. INFORMATION
Y 6120 6 2 2 Actuator motor, recirculation air conditioning. INFORMATION
Y 6150 6, 5 2 1 Voltage feed to electronic control module for STOP!
joystick control/mini steering wheel.
Y 6150 6 2 2 Electronic control module for joystick STOP!
control/mini steering wheel.
Y 6150 6 2 3 Electronic control module for joystick STOP!
control/mini steering wheel.
Y 6420 6, 5 2 Solenoid valve parking brake. STOP!
Y 6450 6, 5 2 Electromagnetic clutch cooling compressor. INFORMATION
K 6501 6 1 LE Left windscreen wipers, relay. INFORMATION
K 6501 6 1 RI Right windscreen wipers, relay. INFORMATION


M 6501 7 1 LE Left windscreen wipers, feedback signal. INFORMATION
M 6501 7 1 RI Right windscreen wipers, feedback signal. INFORMATION
M 6502 7 1 Wipers rear windscreen, feedback-signal. INFORMATION
M 6502 6, 5 1 Rear windscreen wipers. INFORMATION
M 6503 7 1 Combined wipers front windscreen and roof INFORMATION
window, feedback-signal.
Roof window wipers, feedback-signal. INFORMATION
M 6503 6, 5 1 Combined wipers front windscreen and roof INFORMATION
window.
Roof window wipers. INFORMATION
M 6511 6 1 Engine washer fluid, front windscreen. INFORMATION
M 6512 6, 5 1 Engine washer fluid, rear windscreen. INFORMATION
M 6513 6, 5 1 Engine washer fluid, combined wipers front INFORMATION
windscreen and roof window.
Engine washer fluid, roof window. INFORMATION
M 6570 6, 5 1 Heating fan. INFORMATION
M 6670 6, 5 1 Circulation pump pause heater. INFORMATION
M 6680 6, 5 2 Engine cooling fan hydraulic oil cooler. WARNING!
Y 6720 3, 4 1 Air distribution valve. INFORMATION
Y 6720 6, 5 1 1 Air distribution valve. INFORMATION
Y 6720 6, 5 1 2 Air distribution valve. INFORMATION
Y 6730 3, 4 1 Heating valve. INFORMATION
Y 6730 6, 5 1 1 Heating valve. INFORMATION
Y 6730 6, 5 1 2 Heating valve. INFORMATION
Y 6760 6, 5 1 Solenoid valve, swivel driver's seat. WARNING!
B 6900 3, 4 11 Accelerator pedal position A. WARNING!
B 6900 3, 4 11 Accelerator pedal position B. WARNING!
M 6930 6, 5 2 1 Central lubrication pump. INFORMATION
B 6941 3, 4, 7 11 Engine right-hand dashboard panel INFORMATION
forward/backward feedback-signal.
M 6941 6 11 1, 2 Engine right dashboard panel INFORMATION
forward/backward.
B 6942 3, 4, 7 11 Engine right dashboard panel up/down INFORMATION
feedback-signal.
M 6942 6 11 1, 2 Engine right dashboard panel up/down. INFORMATION
B 6943 3, 4, 7 11 Engine steering wheel panel up/down INFORMATION
feedback-signal.
M 6943 6 11 1, 2 Engine steering wheel panel up/down. INFORMATION
B 7226 3, 4 2 Lift pressure sensor. WARNING!
B 7228 3, 4 2 Lift height sensor. WARNING!
B 7229 3, 4 2 Tilt angle sensor. WARNING!
B 7235 3, 4 2 LE Left power cell sensor. WARNING!
B 7235 3, 4 2 RI Right power cell sensor. WARNING!
B 7236 3, 4 2 Tilt power cell sensor. WARNING!
B 7238 3, 4 2 Tilt cylinder pressure sensor. WARNING!


B 7244 3, 4 2 Electric dipstick transmission sensor. WARNING!
B 7245 3, 4 2 LE Feedback steering sensor, channel 1. WARNING!
B 7245 3, 4 2 RI Feedback steering sensor, 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 7683 3, 4 2 Accumulator pressure sensor. WARNING!
B 7740 32, 33 1 Ambient temperature sensor. INFORMATION
B 7751 32, 33 1 Inner temperature sensor. INFORMATION
B 7752 32, 33 1 Fan temperature sensor. INFORMATION
B 7753 32, 33 1 Temperature display sensor. INFORMATION
B 7760 32, 33 2 Hydraulic oil temperature sensor. WARNING!
D 7901 31 1 Control unit missing. STOP!
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 lift/lower. 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 Side shift control lever. WARNING!
R 8070 3, 4 11 3 Side shift joystick. WARNING!
R 8070 3, 4 11 4 Control lever spreading/spreading WARNING!
left/extension left.
R 8070 3, 4 11 4 Spreading left joystick. WARNING!
R 8070 3, 4 11 5 Control lever 5th function. WARNING!
R 8070 3, 4 11 6 Levelling, spreading right side. WARNING!
M 8100 6, 5 1 Condenser roof. INFORMATION
R 8250 3, 4 1 Potentiometer joystick control channel 1. STOP!
R 8250 3, 4 1 1 Potentiometer mini-steering wheel channel 1. STOP!
R 8250 3, 4 1 2 Potentiometer mini-steering wheel channel 2. STOP!
H 8500 6 1 Horn. WARNING!
K 8881 6 1 Relay rear windscreen heating. INFORMATION
H 9650 6 2 1 Back-up alarm. WARNING!
10002 14 1 Configuration number does not correspond STOP!
for D7901.
for D7971.
for D7902.


for D7950.
10003 14 1 Software version does not correspond for WARNING!
D7901.
D7971.
D7902.
D7950.
10004 14 1 Setup file missing for D7901. STOP!
10005 14 1 1 Drivetrain parameter file missing, D7901. STOP!
10005 14 2 2 Load detector parameter file missing, D7971. STOP!
10005 14 2 3 Fuel tank parameter file missing, D7971. STOP!
10005 14 2 4 Central lubrication frame parameter file STOP!
missing, D7971.
10005 14 2 5 Front tyre parameter file missing, D7971. STOP!
10005 14 2 6 OLS parameter file missing, D7971. STOP!
10005 14 11 7 Joystick parameter file missing, D7902. STOP!
10101 4 1 Battery voltage D7901. STOP!
10101 3 1 Battery voltage D7901. WARNING!
10102 6 2 2 ECM ignition voltage. WARNING!
10102 4 2 Ignition voltage D7971. STOP!
10102 3 2 Ignition voltage D7971. WARNING!
10103 6 1 CPU feed D7901. STOP!
10103 3, 4 2 CPU feed D7971. STOP!
10103 4 11 CPU feed D7902. STOP!
10103 3, 4 12 CPU feed D7950. STOP!
10104 3, 4 1 Reference voltage D7901. WARNING!


10104 3, 4 11 1 5V supply to the steering wheel panel. WARNING!
10105 3, 4 2 1 Reference ground 1 error D7971. STOP!
10105 2, 6 2 2 Reference ground 2 error D7971. STOP!
10106 6 1 Supply left armrest (with mini steering STOP!
wheel/joystick control).
10106 6 2 1 Supply sensor frame. WARNING!
10106 6 2 2 Supply sensor mast. WARNING!
10106 6 11 1 24V supply component. WARNING!
10106 6 11 24V supply component. WARNING!
10107 6 11 1 Searchlight dashboard panel. WARNING!
10201 42 1 RedCAN, CAN segment error normal side, WARNING!
D7901.
D7971.
D7902.
D7950.
10201 43 1 RedCAN, CAN segment error RedCAN side, WARNING!
D7901.
D7971.
D7902.
D7950.
10201 40 1 RedCAN, node disappeared after start up, STOP!
D7901.
D7971.
D7902.
D7950.
10201 41 1 RedCAN, node not found at start up, D7901. STOP!
10201 44 12 RedCAN, node misplaced, D7950. STOP!
10202 35 2 Drivetrain CAN bus. STOP!


10204 35 1 Cab option CAN bus. STOP!
10301 2 1 Non-volatile memory D7901. STOP!
10303 0 2 PCB temperature D7971. STOP!
10304 2 1 Processing time for software in control unit STOP!
D7901.
D7971.
D7902.
D7950.
10305 6 1 Power consumption in ECU D7901. WARNING!
10306 3 2 1 Safety voltage (group 1) D7971. WARNING!
10306 3 2 2 Safety voltage (group 2) D7971. WARNING!
10306 4 2 1 Safety voltage (group 1) D7971. STOP!
10307 2 1 Checksum, flash memory D7901. STOP!
10307 2 2 Checksum, flash memory D7971. STOP!
10308 2 1 Checksum, RAM memory D7901. STOP!
10308 2 2 Checksum, RAM memory D7971. STOP!
10309 2 1 Checksum, Boot loader memory D7901. STOP!
10309 2 2 Checksum, Boot loader memory D7971. STOP!

Error codes engine

• The display indicates an error code as it appears in the machine,
according to SAE J1939 in SPN/FMI.
• J1587 indicates error code acc. to SAE J1587 (Volvo).
Tabell Error codes Cummins QSB6.7 Stage 3A/Tier 3
Error codes Cummins QSB6.7 Stage 3A/Tier 3
Display
SPN/FMI Description Action
22 / 3 Crankcase pressure. WARNING!
52 / 0 Engine coolant temperature 2. The most serious level. Progressive output WARNING!
reduction that increases with time after the warning.
52 / 3 Sensor 2 engine coolant. Maybe white smoke. The fan remains switched on WARNING!
if controlled by the engine control unit. No engine protection for the engine
coolant temperature
52 / 4 Sensor 2 engine coolant. Maybe white smoke. The fan remains switched on WARNING!
if controlled by the engine control unit. No engine protection for the engine
coolant temperature.
52 / 16 Engine coolant temperature 2. Moderate serious level. Progressive output WARNING!
84 / 2 Machine speed sensor circuit. Engine speed limited to maximum engine speed WARNING!
without VSS parameter value. Cruise control, downshift protection, and speed
control do not work.
84 / 10 Machine speed sensor circuit. Engine speed limited to maximum engine speed WARNING!
without VSS parameter value. Cruise control, downshift protection, and speed
control do not work.
91 / 0 Accelerator pedal or lever position sensor circuit. Major decrease in engine WARNING!
power. Only emergency operation power.
91 / 2 Position sensor accelerator pedal. WARNING!
91 / 19 System error for SAE J1939 multiplexing accelerator pedal or level sensor. WARNING!
Engine only idles or does not accelerate to full speed.
94 / 1 Fuel pump feed pressure. Moderately serious level. Maybe difficult to start, low WARNING!
power output, maybe smoke from the engine. The engine might not start.
94 / 2 Injector metering duct 1 pressure. The engine control unit estimates the fuel WARNING!
pressure and the power output is reduced.
94 / 3 Sensor, injection pressure. WARNING!
94 / 4 Sensor, injection pressure. WARNING!
94 / 15 Fuel pressure. Least serious level. WARNING!
94 / 17 Fuel pressure. Least serious level. WARNING!
94 / 18 Fuel pump feed pressure. Moderately serious level. The engine control unit WARNING!
has detected fuel pressure in the fuel rail, which is higher than the requested
pressure. Engine power decreases
95 / 16 Fuel filter, differential pressure. Moderately serious level. Maybe power WARNING!
reduction.

Display
97 / 3 Sensor circuit for water in fuel indicator. No performance loss. No water in WARNING!
fuel warning available.
97 / 4 Sensor circuit for water in fuel indicator. No performance loss. No water in WARNING!
fuel warning available.
97 / 15 Water in fuel indicator. The least serious level. Water has been detected in the WARNING!
fuel filter. Maybe white smoke, power reduction, or difficult to start.
97 / 16 Water in fuel indicator. Moderately serious level. WARNING!
100 / 1 Engine oil duct pressure. The most serious level. Progressive output reduction STOP! Very serious
that increases with time after the warning. If the Engine protection shutdown
function is enabled, the engine is turned off 30 seconds after the red STOP
light flashes.
100 / 2 Oil pressure switch sensor circuit. No performance loss. WARNING!
100 / 3 Oil pressure sensor circuit. No performance loss. WARNING!
100 / 4 Oil pressure sensor circuit. No performance loss. WARNING!
100 / 18 Engine oil duct pressure. Moderately serious level. No performance loss. WARNING!
102 / 2 Intake manifold pressure sensor circuit. Engine power decreases. WARNING!
102 / 16 Pressure Intake manifold 1. Moderate serious level. Decrease in engine power. WARNING!
103 / 10 Turbocharger speed. Estimated turbocharger speed for possible low power WARNING!
output is used.
103 / 16 Turbocharger number 1 speed high: Warning level. Engine power decreases. WARNING!
Engine control unit uses an estimated turbocharger speed.
103 / 18 Turbocharger number 1 speed low: Warning level. Engine power decreases. WARNING!
Engine control unit uses an estimated turbocharger speed.
105 / 0 Temperature intake manifold 1. The most serious level. Progressive output STOP! Very serious
reduction that increases with time after the warning. If the Engine protection
shutdown function is enabled, the engine is turned off 30 seconds after the
red STOP light flashes.
105 / 3 Intake manifold air temperature sensor circuit. Maybe white smoke. The WARNING!
fan remains switched on if controlled by the engine control unit. No engine
protection for the intake manifold air temperature.
105 / 4 Intake manifold air temperature sensor circuit. Maybe white smoke. The WARNING!
fan remains switched on if controlled by the engine control unit. No engine
protection for the intake manifold air temperature.
105 / 16 Circuit, temperature sensor inlet manifold. WARNING!
108 / 2 Barometric pressure. Engine power decreases. WARNING!
108 / 3 Barometric pressure sensor circuit. Engine power decreases. WARNING!
108 / 4 Barometric pressure sensor circuit. Engine power decreases. WARNING!
109/3 Sensor coolant pressure. No limitation. WARNING!
109/4 Sensor coolant pressure. No limitation. WARNING!
109/18 High coolant pressure. Power and/or speed reduction. WARNING!
110 / 0 Engine coolant temperature. The most serious level. Progressive output STOP! Very serious
reduction that increases with time after the warning. If the Engine protection
shutdown function is enabled, the engine is turned off 30 seconds after the
red STOP light flashes.

Display
110 / 2 Engine coolant temperature. Engine control unit estimates the engine coolant WARNING!
temperature
110 / 3 Engine coolant temperature sensor circuit 1. Maybe white smoke. The fan WARNING!
remains switched on if controlled by the engine control unit. No engine protection
for the engine coolant temperature.
110 / 4 Engine coolant temperature sensor circuit 1. Maybe white smoke. The fan WARNING!
remains switched on if controlled by the engine control unit. No engine protection
for the engine coolant temperature.
110 / 15 High engine coolant temperature. The least serious level. Progressive output WARNING!
110 / 16 Engine coolant temperature. Moderately serious level. Progressive output WARNING!
111 / 1 Coolant level. The most serious level. Progressive output reduction that STOP! Very serious
increases with time after the warning. If the Engine Protection Shutdown
function is enabled, the engine is turned off for 30 seconds after the red STOP
light flashes.
111 / 2 Coolant level. WARNING!
111 / 3 Coolant level sensor circuit. No performance loss. WARNING!
111 / 4 Coolant level sensor circuit. No performance loss. WARNING!
111 / 17 Coolant level. The least serious level. WARNING!
111 / 18 Coolant level. The most serious level. Progressive output reduction that WARNING!
increases with time after the warning. If the Engine Protection Shutdown
function is enabled, the engine is turned off for 30 seconds after the red STOP
light flashes.
157 / 0 Injector measurement, pressure channel number 1. Moderately serious level. WARNING!
No or maybe noise from the engine associated with high injection pressure
(particularly while idling or with a high load). Engine power decreases.
157 / 1 Injector measurement, pressure channel number 1. The most serious level. WARNING!
157 / 2 Injector metering duct number 1 pressure. The engine control unit estimates WARNING!
the fuel pressure and the power output is reduced.
157 / 3 Injector measurement channel number 1, pressure sensor circuit. Power and/or WARNING!
speed reduction.
157 / 4 Injector measurement channel number 1, pressure sensor circuit. Power and/or WARNING!
speed reduction.
157 / 16 Injector measurement channel number 1, pressure. Moderately serious level. WARNING!
157 / 18 Fuel pump low feed pressure. Moderately serious level. Maybe difficult to start, WARNING!
low power output or smoke from the engine. The engine might not start.
166 / 2 Imbalance between cylinders. WARNING!
167 / 1 Charging system low voltage. The most serious level. STOP! Very serious
167 / 16 Charging system high voltage. Moderately serious level. WARNING!
167 / 18 Charging system low voltage. Moderately serious level. WARNING!
168 / 16 Voltage battery 1. Moderately severe level. WARNING!
168 / 18 Voltage battery 1. Moderately severe level. WARNING!
171 / 3 Outdoor temperature sensor, circuit error. WARNING!

Display
171 / 4 Outdoor temperature sensor, circuit error. WARNING!
174 / 3 Sensor, fuel temperature. WARNING!
174 / 4 Sensor, fuel temperature. WARNING!
174 / 16 High fuel temperature. WARNING!
175/0 High engine oil temperature. Power and/or speed reduction. WARNING!
175/2 Sensor, oil temperature.
175/3 Sensor, oil temperature. No limitation.
175/4 Sensor, oil temperature. No limitation.
190 / 0 Engine crankshaft speed/position. The most severe level. STOP! Very serious
190 / 2 Engine's crankshaft speed/position. Engine may run unevenly. May be difficult to WARNING!
start. The engine is powered by backup speed sensor. Engine power is reduced.
251 / 2 Power supply to real-time clock interrupted. No performance loss WARNING!
412 / 3 EGR temperature sensor. WARNING!
412 / 4 EGR temperature sensor. WARNING!
441 / 3 Auxiliary temperature sensor input signal 1. No performance loss. WARNING!
441 / 4 Auxiliary temperature sensor input signal 1. No performance loss. WARNING!
441 / 14 Ambient temperature 1. Possible reduced engine power.
558 / 2 Accelerator pedal or lever idling validation circuit. Engine only running at idling WARNING!
speed.
speed.
speed.
611 / 16 Measuring device fuel inlet. Moderately serious level. WARNING!
611 / 18 Measuring device fuel inlet. Moderately serious level. WARNING!
612 / 2 The engine's magnetic crankshaft speed/position sensor has lost both signals. WARNING!
The fuel to the injectors is shut-off and the engine cannot be started.
623 / 4 Red stop lamp. WARNING!
627 / 2 No power supply with the ignition on. Maybe no noticeable performance WARNING!
reduction or engine stops or is difficult to start.
627 / 2 Voltage feed to injectors. Maybe smoke, low power output, engine misfire, WARNING!
and/or engine will not start.
629 / 12 Engine control unit internal error. Engine might not start. WARNING!
629 / 12 Engine control unit critical internal hardware error. Defective control unit or WARNING!
component.
630 / 2 Engine control unit data lost. Serious data loss from the engine control unit. WARNING!
Maybe no noticeable performance decreases or the engine stalls or is difficult
to start.
630 / 13 Electronic calibration code, incompatibility. WARNING!
630 / 31 occurs in the engine control unit calibration program memory (RAM). Serious WARNING!
data loss from the engine control unit. Maybe no noticeable performance
decreases or the engine stalls or is difficult to start.
633 / 31 Circuit error in fuel actuator no. 1. Possible low power output. WARNING!

Display
639 / 9 Timeout error for SAE J1939 multiplexer PNG. WARNING!
639 / 13 Configuration error for SAE J1939 multiplexer. WARNING!
640 / 14 Input external engine protection. WARNING!
644 / 2 Input signal from external speed request. WARNING!
647 / 3 Fan control circuit. The fan may run the whole time or does not run at all. WARNING!
647 / 4 Fan control circuit. The fan may run the whole time or does not run at all. WARNING!
651 / 5 Circuit for injector solenoid coil drive cylinder 1. The engine may misfire or WARNING!
run rough.
651 / 7 Injector solenoid coil drive cylinder 1. The engine is switched off. WARNING!
652 / 5 Injector solenoid cylinder #2 circuit. The engine may misfire or run unevenly. WARNING!
652 / 7 Circuit for injector solenoid coil drive cylinder 2. The engine is switched off. WARNING!
run rough.
run rough.
run rough.
run rough.
677 / 3 Start relay circuit. WARNING!
697 / 3 External PWM drive circuit 1. WARNING!
697 / 4 External PWM drive circuit 1. WARNING!
702 / 3 Circuit, extra input/output 2. WARNING!
703 / 3 Circuit, extra input/output 3. WARNING!
703 / 11 Auxiliary equipment sensor input signal no. 3 (OEM switch). Maybe reduced WARNING!
engine power.
703 / 14 Sensor reserve equipment input #3 (OEM). WARNING!
723 / 2 Engine reserve crankshaft speed/position sensor no. 2. Possible low power WARNING!
output.
723 / 2 Engine speed sensor error (camshaft). Maybe difficult to start. Engine power WARNING!
decreases.
723 / 7 Engine speed/position sensor camshaft and crankshaft. Engine runs at low WARNING!
power output.
729 / 3 Circuit for intake air heater no. 1. WARNING!

Display
974 / 3 Circuit for remote accelerator pedal or lever position sensor 1. WARNING!
974 / 4 Circuit for remote accelerator pedal or lever position sensor 1. WARNING!
974 / 19 Data error for SAE J1939 multiplexing remote accelerator pedal or lever. WARNING!
1043 / 3 Voltage feed circuit for accelerator pedal or lever position sensor. The engine WARNING!
only runs at idle.
1043 / 4 Voltage feed circuit for engine speed/position sensor (crankshaft). Maybe WARNING!
difficult to start and runs unevenly.
1072 / 3 Engine brake actuator circuit no. 1. WARNING!
1075 / 3 Electric lift pump for the engine fuel feed circuit. The engine may be difficult WARNING!
to start.
1075 / 4 Electric lift pump for the engine fuel feed circuit. The engine may be difficult WARNING!
to start.
1112 / 3 Engine brake output 3. WARNING!
1112 / 4 Engine brake output 3. WARNING!
1136 / 3 Temperature sensor control unit engine. WARNING!
1136 / 4 Temperature sensor control unit engine.
1172 / 3 Intake temperature sensor circuit for compressor turbocharger no. 1. Engine WARNING!
power is reduced.
1172 / 4 Intake temperature sensor circuit for compressor turbocharger no. 1. Engine WARNING!
power is reduced.
1209 / 3 Sensor, exhaust pressure. WARNING!
1209 / 4 Sensor, exhaust pressure. WARNING!
1267 / 3 Accessory relay output. WARNING!
1267 / 4 Accessory relay output. WARNING!
1347 / 3 Circuit for fuel high pressure solenoid valve. Engine runs poorly and with WARNING!
reduced power
1347 / 4 Circuit for fuel high pressure solenoid valve. Engine runs poorly at idle and WARNING!
has low power output.
1347 / 7 Fuel pumping element no. 1. Engine not running or has low power output. WARNING!
1378 / 31 Change the oil and oil filter. WARNING! Service.
1388 / 3 Circuit for auxiliary pressure sensor, input signal 1. WARNING!
1388 / 4 Circuit for auxiliary pressure sensor, input signal 1. WARNING!
1388 / 14 Circuit for auxiliary pressure sensor. Possible reduced engine power. WARNING!
1484 / 31 J1939 error. WARNING!
1563 / 2 Control unit, identification input status. WARNING!
1661 / 4 Engine auto start lamp. WARNING!
1800 / 16 Battery temperature. Moderately serious level. WARNING!
2623 / 3 Position sensor accelerator pedal, circuit error. Major decrease in engine power. WARNING!
Only emergency operation possible.

Display
2623 / 4 Position sensor accelerator pedal, circuit error. Engine speed limited to idling WARNING!
speed.
2789 / 15 Boost pressure temperature input calculated. WARNING!
2790 / 15 Turbo, compressor outlet temperature. Least serious level. WARNING!
2802 / 31 Control unit D7940, no data.
2981 / 3 Sensor 2 coolant pressure.
2981 / 4 Sensor 2 coolant pressure.
2981 / 18 High coolant pressure 2. Power output and/or engine speed reduction.
3509 / 3 Voltage feed no. 1, sensor circuit. Engine power decreases.
3511 / 3 Voltage feed no. 3, sensor circuit. Maybe difficult to start the engine and rough
running.
3511 / 4 Voltage feed no. 3, sensor circuit. Maybe difficult to start the engine and rough
running.
3512 / 3 Voltage feed no. 4, sensor circuit.
3512 / 4 Voltage feed no. 4, sensor circuit.
520199 / 3 Cruise control (resistive).
520199 / 4 Cruise control (resistive).
Tabell Error codes Cummins QSB6.7 Stage 3B/Tier 4i
Error codes Cummins QSB6.7 Stage 3B/Tier 4i
Display
27 / 4 EGR-valve position, circuit error. WARNING!
81 / 16 Particulate trap inlet pressure. WARNING!
84 / 2 Engine speed sensor circuit. WARNING!
84 / 9 Engine speed sensor circuit. WARNING!
84 / 19 Engine speed sensor circuit.
91 / 3 Position sensor accelerator pedal, circuit error. WARNING!
91 / 9 SAE J1939 multiplexing. WARNING!
91 / 19 SAE J1939 multiplexing, system error accelerator sensor. WARNING!
93 / 2 Extra validation sensor operation curve limitation. WARNING!

Display
95 / 16 Fuel filter, differential pressure. Moderately serious level. WARNING!
97 / 3 Water-in-fuel sensor circuit. WARNING!
97 / 4 Water-in-fuel sensor circuit. WARNING!
97 / 15 Water-in-fuel indicator high. Least serious level. WARNING!
100 / 1 Engine oil pressure low. STOP! Check the oil
level in engine, fill when
necessary.
100 / 2 Engine oil pressure sensor. WARNING!
100 / 3 Engine oil pressure sensor, circuit error. WARNING!
100 / 4 Engine oil pressure sensor, circuit error. WARNING!
100 / 18 Engine oil pressure low. WARNING! Check the oil
level in engine, fill when
necessary.
101 / 3 Crankcase pressure, circuit error. WARNING!
101 / 4 Crankcase pressure, circuit error. WARNING!
101 / 16 Crankcase pressure. Moderately serious level. WARNING!
102 / 2 Inlet manifold pressure sensor circuit. WARNING!
102 / 3 Inlet manifold pressure sensor. WARNING!
102 / 4 Inlet manifold pressure sensor. WARNING!
103 / 15 Turbo #1 high speed. Least serious level. WARNING!
103 / 16 Turbo #1 high speed. Moderately serious level. WARNING!
103 / 18 Turbo #1 low speed. Moderately serious level. WARNING!
105 / 0 Inlet manifold temperature sensor circuit. STOP! Very serious
105 / 3 Inlet manifold temperature sensor. WARNING!
105 / 4 Inlet manifold temperature sensor. WARNING!
105 / 16 Inlet manifold temperature high. Moderately serious level. WARNING!
108 / 2 Sensor air pressure. Engine power decreases. WARNING!
110 / 0 Engine coolant temperature high. Most serious level. STOP! Very serious.
Check coolant level.
110 / 2 Sensor engine coolant. WARNING!
110 / 3 Sensor engine coolant, circuit error. WARNING!
110 / 4 Sensor engine coolant, circuit error. WARNING!
110 / 16 Engine coolant temperature. Moderately serious level. WARNING! Check the
coolant level.
110 / 31 Engine coolant temperature. WARNING!

Display
111 / 1 Engine coolant level. Moderately serious level WARNING!
Check the coolant level,
fill if necessary.
111 / 2 Engine coolant level. STOP! Very serious
111 / 3 Engine coolant level. WARNING!
111 / 4 Engine coolant level. WARNING!
111 / 17 Engine coolant level. The least serious level. WARNING!
fill if necessary.
111 / 18 Engine coolant level. Moderately serious level. WARNING!
fill if necessary.
157 / 0 Fuel pressure high. Most serious level. Engine power decreases. WARNING!
157 / 3 Injection pressure measurement bank 1, circuit error. Power and/or speed WARNING!
reduction.
157 / 4 Injection pressure measurement bank 1, circuit error. Power and/or speed WARNING!
reduction.
157 / 16 Injection pressure measurement bank 1, high pressure. Engine power WARNING!
decreases.
157 / 18 Injection pressure measurement bank 1, low pressure. WARNING!
168 / 16 High Battery #1 voltage. Moderately serious level. WARNING!
168 / 18 Low Battery #1 voltage. Moderately serious level. WARNING!
190 / 0 Engine over-revving. STOP!
190 / 2 Main speed sensor error. WARNING!
190 / 2 Speed/position sensor. WARNING!
191 / 9 Transmission speed sensor output. WARNING!
191 / 16 Transmission speed sensor output. Moderately serious level. WARNING!
191 / 18 Transmission speed sensor output. Moderately serious level. WARNING!
191 / 19 Transmission speed sensor output. WARNING!
411 / 2 EGR-valve delta pressure. WARNING!
411 / 3 EGR-valve delta pressure, circuit error. WARNING!
411 / 4 EGR-valve delta pressure, circuit error. WARNING!
412 / 3 EGR temperature sensor, circuit error. WARNING!
412 / 4 EGR temperature sensor, circuit error. WARNING!
412 / 15 EGR temperature. The least serious level. WARNING!
412 / 16 EGR temperature. Moderately serious level. WARNING!
558 / 2 Accelerator pedal idling validation circuit. Engine only running at idling speed. WARNING!
558 / 9 Accelerator pedal or idling validation circuit accelerator pedal. Engine only WARNING!
running at idling speed.
558 / 13 Accelerator pedal idling validation circuit. Engine only running at idling speed. WARNING!
611 / 2 Speed sensor validation. WARNING!

Display
612 / 2 Engine speed and position sensor circuit has lost the input from the magnetic WARNING!
sensor.
627 / 2 Open power supply circuit despite the ignition being in the on position. WARNING!
627 / 12 Injector voltage feed. WARNING!
629 / 12 Engine control unit internal error. WARNING!
633 / 31 Fuel valve, circuit error. WARNING!
639 / 2 SAE J1939 network #1. WARNING!
639 / 9 SAE J1939 multiplexing PGN time limit exceeded. WARNING!
639 / 13 SAE J1939 multiplexing, configuration error. WARNING!
641 / 7 Variable Turbo Geometry valve circuit. WARNING!
641 / 9 Variable Turbo Geometry valve circuit. WARNING!
641 / 12 Variable Turbo Geometry valve. WARNING!
641 / 15 Variable Turbo Geometry valve too high temperature (estimated). WARNING!
651 / 5 Injector solenoid cylinder #1 circuit. WARNING!
703 / 14 Sensor reserve equipment input #3 (OEM). WARNING!
723 / 2 Engine speed sensor #2. WARNING!
723 / 2 Engine speed sensor (camshaft) error. Engine power decreases. WARNING!
723 / 7 Engine speed sensor/position sensor #2 mechanically misaligned between the WARNING!
camshaft and crankshaft.
729 / 3 Air preheating element circuit. WARNING!
729 / 4 Air preheating element circuit. WARNING!
974 / 19 SAE J1939 multiplexing, value error, remote accelerator sensor. WARNING!
1075 / 3 Fuel suction pump circuit. WARNING!
1075 / 4 Fuel suction pump circuit. WARNING!
1172 / 3 Turbocharger pressure temperature sensor circuit. Engine power decreases. WARNING!
1172 / 4 Turbocharger pressure temperature sensor circuit. Engine power decreases. WARNING!
1209 / 2 Exhaust pressure sensor. WARNING!
1209 / 3 Exhaust pressure sensor, circuit error. WARNING!
1209 / 4 Exhaust pressure sensor, circuit error. WARNING!
1347 / 3 High pressure fuel valve circuit. The engine has low power output WARNING!

Display
1347 / 4 High pressure fuel valve circuit. The engine has low power output WARNING!
1347 / 7 Engine pressure fuel valve no. 1. Engine has low power output WARNING!
1377 / 2 Switch circuit. WARNING!
1623 / 9 Tachograph output axle speed. WARNING!
1623 / 19 Tachograph output axle speed. WARNING!
1675 / 31 Start interlock. WARNING!
2791 / 0 EGR-valve control unit, temperature. WARNING!
2791 / 5 EGR-valve control unit, circuit error. WARNING!
2791 / 13 EGR-valve control unit. WARNING!
2791 / 15 EGR-valve control unit, temperature. WARNING!
2797 / 13 Injector bank 1 codes. WARNING!
3242 / 0 After-treatment 1 exhaust filter inlet temperature. WARNING!
3242 / 2 After-treatment 1 exhaust filter inlet temperature. WARNING!
3242 / 3 After-treatment 1 exhaust filter temperature sensor inlet, circuit error. WARNING!
3242 / 4 After-treatment 1 exhaust filter temperature sensor inlet, circuit error. WARNING!
3242 / 15 After-treatment 1 exhaust filter inlet temperature. The least serious level. WARNING!
3242 / 16 After-treatment 1 exhaust filter inlet temperature. Moderately serious level. WARNING!
3246 / 0 After-treatment 1 exhaust filter outlet temperature. WARNING!
3246 / 2 After-treatment 1 exhaust filter outlet temperature. WARNING!
3246 / 3 After-treatment 1 exhaust filter outlet temperature, circuit error. WARNING!
3246 / 4 After-treatment 1 exhaust filter outlet temperature, circuit error. WARNING!
3246 / 16 After-treatment 1 exhaust filter outlet temperature. Moderately serious level. WARNING!
3251 / 0 Particulate filter after-treatment differential pressure circuit error. The most WARNING!
serious level.
3251 / 2 Particulate filter after-treatment differential pressure. WARNING!
3251 / 3 Particulate filter after-treatment differential pressure circuit error. WARNING!
3251 / 4 Particulate filter after-treatment differential pressure circuit error. WARNING!
3251 / 15 Particulate filter after-treatment differential pressure circuit error. The least WARNING!
serious level.
3251 / 16 Particulate filter after-treatment differential pressure circuit error. Moderately WARNING!
serious level.
3509 / 3 Voltage feed no. 1, sensor circuit. Engine power decreases. WARNING!

Display
3511 / 3 Voltage feed no. 3, sensor circuit. WARNING!
3597 / 18 ECU output power voltage feed 1. Moderately serious level. WARNING!
3610 / 2 Particulate filter after-treatment system outlet pressure. WARNING!
3610 / 3 Particulate filter after-treatment system pressure sensor outlet, circuit error. WARNING!
3610 / 4 Particulate filter after-treatment system pressure sensor outlet, circuit error. WARNING!
3703 / 31 Regeneration of exhaust filter turned off with a switch. WARNING!
3936 / 7 Particulate filter after-treatment system. WARNING!
4765 / 2 After-treatment 1 oxidation catalyst inlet temperature. WARNING!
4765 / 3 After-treatment 1 oxidation catalyst temperature sensor inlet, circuit error. WARNING!
4765 / 4 After-treatment 1 oxidation catalyst temperature sensor inlet, circuit error. WARNING!
4765 / 16 After-treatment 1 oxidation catalyst temperature sensor inlet, switched. WARNING!
4795 / 31 Particulate filter after-treatment system missing. WARNING!
4796 / 31 After-treatment system diesel oxidation catalyst missing. WARNING!
5018 / 11 Catalyst 1 System monitoring. WARNING!
5298 / 11 After-treatment system oxidation catalyst conversion efficiency. WARNING!
5571 / 7 Common rail fuel over-pressure valve. WARNING!
Tabell Error codes Volvo TAD761VE, TAD762VE and TAD1360VE

Stage 3B/Tier 4i
Error codes Volvo TAD761VE, TAD762VE and TAD1360VE Stage 3B/Tier 4i
Display
SPN/FMI J1587 Description Action
51/3 PID51/3 Position sensor, accelerator pedal. STOP
51/4 PID51/4 Position sensor, accelerator pedal STOP
51/5 PID51/5 Position sensor, accelerator pedal STOP
51/7 PID51/7 Position sensor, accelerator pedal. STOP
91/9 PID91/9 Signal from accelerator pedal. STOP
94/1 PID94/1 Fuel pressure sensor. STOP

Display
97/0 PID97/0 Water in fuel. WARNING: Drain fuel prefilter,
see 6.2.2 Fuel system.
97/3 PID97/3 Sensor, water-in-fuel. STOP
97/4 PID97/4 Sensor, water-in-fuel. STOP
98/1 PID98/1 Low engine oil level. STOP: Check the oil level in
the engine. See 6.2.6 Engine
oil.
98/3 PID98/3 Oil level sensor, engine. STOP: Check the oil level in
oil.
oil.
oil.
100/1 PID100/1 Low oil pressure in engine. Reduced engine power or engine STOP: Check the oil level in
is turned off. the engine. See 6.2.6 Engine
oil.
100/3 PID100/3 Oil pressure sensor. STOP
105/0 PID105/0 Too high charge-air temperature. Reduced engine power. STOP
105/4 PID105/4 Sensor, boost temperature. STOP
105/5 PID105/5 Sensor, boost temperature. STOP
105/16 PID105/16 Sensor, boost temperature. Reduced engine power.
106/0 PID106/0 High charge-air pressure. Reduced engine power. STOP
106/3 PID106/3 Sensor, boost pressure. The engine is smoking more than usual STOP
during acceleration/loading.
106/5 PID106/5 Sensor, boost pressure. The engine is smoking more than usual STOP
during acceleration/loading.
106/16 PID106/16 Sensor, boost pressure. STOP
107/0 PID107/0 Low air pressure. STOP
107/3 PID107/3 Sensor air pressure. STOP
108/3 PID108/3 Sensor, air pressure, cable short-circuited to voltage. STOP
108/4 PID108/4 Sensor air pressure - abnormally low voltage or short-circuiting STOP
to lower voltage.
110/0 PID110/0 High coolant temperature. Reduced engine power or engine STOP: Check the coolant
is turned off. level. See 6.2.5 Cooling
system.
110/4 PID110/4 Sensor, coolant temperature. STOP

Display
111/1 PID111/1 Low coolant level. Reduced engine power. STOP: Check the coolant
level. See 6.2.5 Cooling
system.
111/3 PID111/3 Sensor, coolant level. STOP
111/5 PID111/5 Sensor, coolant level. STOP
153/0 PID153/0 Too high crankcase ventilation pressure. The engine is switched STOP
off.
153/3 PID153/3 Sensor, crankcase ventilation pressure. STOP
153/5 PID153/5 Sensor, crankcase ventilation pressure. STOP
158/1 PID158/1 Low battery voltage, CIU. Engine may be difficult to start. STOP
158/3 PID158/3 Low battery voltage, CIU. STOP
158/4 PID158/4 Low battery voltage, CIU. STOP
172/4 PID172/4 Sensor, air temperature. STOP
172/5 PID172/5 Sensor, air temperature. STOP
175/0 PID175/0 High engine oil temperature. Reduced engine power. STOP
175/4 PID175/4 Sensor, oil temperature. STOP
190/16 PID190/16 Engine speed, value too high. STOP
354/3 PID354/3 Relative humidity. STOP
354/5 PID354/5 Relative humidity. Hygrometer shows 50%. STOP
442/4 PPID272/4 Humidity compensation for air temperature. STOP
442/5 PPID272/5 Humidity compensation for air temperature. STOP
608 SID250 J1587 communication bus. STOP
608/9 PPID98/9 Engine synchronisation, acknowledgement. STOP
608/9 PPID132/9 Signal from accelerator pedal. STOP
620/3 SID232/3 +5V voltage feed sensor, engine. STOP
626/3 PID45/3 Sensor, inlet air heater STOP
626/4 PID45/4 Sensor, inlet air heater. STOP
626/5 PID45/5 Sensor, inlet air heater. STOP
628/2 SID240/2 Memory error in engine control. STOP
628/12 SID240/12 Memory error in engine control. STOP
629/8 SID254/8 Engine control unit, internal fault. STOP
629/12 SID254/12 Engine control unit, internal fault. STOP

Display
630/2 SID253/2 Electrical fault engine (EEPROM). STOP
636/2 SID21/2 Sensor speed camshaft, irregular signal. The engine takes STOP
longer to start than normal.
636/3 SID21/3 Sensor speed camshaft, no signal. The engine takes longer to STOP
start than normal.
636/8 SID21/8 Sensor speed camshaft, abnormal frequency. The engine takes STOP
longer to start than normal. The engine is running normally
once it has started.
637/2 SID22/2 Flywheel speed sensor, no signal. The engine is extremely STOP
difficult to start and runs unevenly or stops.
637/3 SID22/3 Sensor speed flywheel, abnormal frequency. The engine is STOP
extremely difficult to start and runs unevenly or stops.
637/8 SID22/8 Sensor speed flywheel, irregular signal. The engine is extremely STOP
difficult to start and runs unevenly or stops.
639/2 SID231/2 Communication error control unit engine (J1939). STOP
639/9 PSID201/9 Communication error control unit engine (J1939). STOP
647/3 SID33/3 Cooling fan control. STOP
651/3 SID1/3 Injector cylinder 1. The engine has reduced power output. STOP
651/12 SID1/12 Injector cylinder 1, defective. The engine has reduced power STOP
output.
output.
output.
output.

Display
output.
output.
677/0 PPID3/0 Start relay on the starter motor. STOP
729/3 SID70/3 Sensor preheating. STOP
729/4 SID70/4 Sensor preheating. The engine hard to start in cold weather. STOP
729/5 SID70/5 Sensor preheating. The engine hard to start in cold weather. STOP
858/3 PSID82/3 AdBlue external filter heater. STOP
975/3 PID26/3 Fan speed. STOP
1136/0 PPID55/0 ECU temperature, control unit too hot. STOP
1136/4 PPID55/4 ECU temperature. STOP
1136/5 PPID55/5 ECU temperature. STOP
1184/0 PID173/0 High exhaust temperature. STOP
1184/4 PID173/4 Sensor exhaust temperature. STOP
1188/3 SID32/3 Wastegate, cable short-circuited to voltage. STOP
1188/3 SID32/3 Wastegate drive circuit STOP
1231/2 PSID232/2 CAN2 J1939 communication link. No AdBlue additive. STOP
1231/2 PSID248/2 CAN3 communication link. No AdBlue additive. STOP
1231/9 PSID229/9 CAN frames from UDS/ACM, timeout. No AdBlue additive. STOP

Display
1675/0 PPID3/0 Starter motor output power (Penta). STOP
1675/10 PPID3/10 Starter motor output power (Penta) or electrical problem. STOP
1761/1 PPID278/1 After-treatment reagents, level, low level, limited cooling STOP
capacity. Temperature shown as 20 °C.
1761/3 PPID278/3 After-treatment reagents, level. SCH. Temperature shown as STOP
20 °C.
1761/5 PPID278/5 After-treatment reagent, level. STOP
1761/11 PPID278 After-treatment reagent, level, unknown error. STOP
/11
1761/18 PPID278 After-treatment reagent, level. STOP
/18
2061/8 PSID77/8 AdBlue ECU EEPROM. STOP
2061/8 PPID273 After-treatment reagent, pressure, heating defect. Reduced STOP
/14 engine power
2061/12 PSID77/12 AdBlue ECU EEPROM. STOP
2061/13 PPID278 After-treatment reagent, level. STOP
/13
2061/14 PPID385 AdBlue ECU voltage, internal supply, critical fault. SCR-system STOP
/14 does not start.
2791/3 PPID19/3 Internal EGR status STOP
2791/4 PPID19/4 Internal EGR status STOP
2791/5 PPID19/5 Internal EGR status. STOP
2791/7 PPID19/7 Internal EGR status. STOP
2988/3 PPID332/3 Thermostat STOP
2988/4 PPID332/4 Thermostat. STOP
2988/5 PPID332/5 Thermostat. STOP
3031/0 PPID274/0 After-treatment reagent, tank temperature. No AdBlue added. STOP
3031/5 PPID274/5 After-treatment reagent, tank temperature, open circuit. No STOP
AdBlue added.
3051/11 PSID90/11 The SCR system's performance. STOP
3226/2 PPID270/2 NOx sensor exhaust outlet. Reduced engine power. STOP
3226/7 PPID270/7 NOx sensor exhaust outlet. Reduced engine power. STOP
3241/4 PPID386/4 Exhaust temperature sensor #1. STOP
3241/5 PPID386/5 Exhaust temperature sensor #1. STOP
3361/3 PSID89/3 AdBlue metering valve. No AdBlue added. STOP

Display
3361/7 PSID89/7 AdBlue metering valve, valve or hose clogged. No AdBlue STOP
added.
3361/10 PSID89/10 AdBlue metering valve, valve jammed. No AdBlue added. STOP
3361/14 PSID89/14 AdBlue metering valve, frozen too many times. No AdBlue STOP
added
3363/3 PSID75/3 AdBlue tank heating valve. STOP
3464/3 PSID7/3 Actuator motor accelerator control. STOP
3511/3 PSID77/3 AdBlue ECU EEPROM. ECU inner supply high. STOP
3511/4 PSID77/4 AdBlue ECU EEPROM. ECU inner supply low. STOP
3512/13 PPID273 After-treatment reagent, pressure. Reduced engine power STOP
/13
3522/16 PSID91/16 AdBlue, consumption. STOP
3522/18 PSID91/18 AdBlue, consumption. STOP
4334/1 PPID273/1 After-treatment reagent, pressure, leakage. Warning indicator STOP
and reduced engine power. Refill AdBlue.
4334/4 PPID273/4 After-treatment reagent, pressure. Warning indicator and STOP
reduced engine power. Refill AdBlue.
4334/5 PPID273/5 After-treatment reagent, pressure. Warning indicator and STOP
reduced engine power. Refill AdBlue.
4334/7 PPID273/7 After-treatment reagent, pressure, accumulated fault. Warning STOP
indicator and reduced engine power. Refill AdBlue.
4334/9 PPID273/9 After-treatment reagent. STOP
Refill AdBlue.
4334/10 PPID273 After-treatment reagent or electrical problem. Warning indicator STOP
/10 and reduced engine power. Refill AdBlue.
4334/13 PPID273 After-treatment reagent, pressure. Warning indicator and STOP
/13 reduced engine power. Refill AdBlue.
4337/0 PPID275/0 Reagent filter temperature. No AdBlue added. STOP
4354/3 PSID103/3 AdBlue ECU hose heater 1. STOP

Display
4354/14 PSID103 AdBlue ECU hose heater 1. STOP
/14
4356/14 PSID102 AdBlue ECU hose heater 3. STOP
/14
4374/0 PSID87/0 AdBlue pump motor speed. No AdBlue added. STOP
4374/1 PSID87/1 AdBlue pump motor speed. No AdBlue added. STOP
4374/10 PSID87/10 AdBlue pump motor speed, no signal from pump. No AdBlue STOP
added.
4376/3 PSID105/3 AdBlue directional control valve. STOP
4811/1 PPID8/1 Oil pressure piston cooling. STOP
4811/2 PPID8/2 Oil pressure piston cooling, incorrect data. STOP
5246/0 PSID46/0 NOx level 3, 4 or 5. Warning indication and reduced engine STOP
power.
5246/15 PSID46/15 NOx level 1 or 2. Warning indication and reduced engine power. STOP
5246/16 PSID46/16 NOx level. STOP
5394/17 PSID90/17 SCR-system's performance, metering error. Warning indication, STOP
error message on display and reduced engine power.
520192/1 PPID8/1 Low oil pressure piston cooling, engine has reduced STOP
performance.
520192/3 PPID8/3 Sensor, oil pressure piston cooling STOP
520194 PPID4 Starter motor input sensor. STOP
520195/5 PPID6/5 Sensor, ignition off (stop request). STOP
520195/18 PPID6/18 Sensor, ignition off (stop request). STOP
520223/3 PSID85/3 AdBlue ECU main relay. STOP

Display
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.
Tabell Error codes ZF 3WG161 and 3WG171
Error codes ZF 3WG161 and 3WG171
ZF code Description action

SPN/FMI (hex)
5000/12 11 Logical error on signal from gear selector and selection STOP!
of gear 1-2. The transmission is in locked neutral
position ("transmission shut down").
5001/12 10 Logic error for travel direction selector signal, 3rd STOP!
gear control. Transmission locked in neutral position
("transmission shut down") if the gear selector is
activated.
5010/12 12 Logical error on the signal from the gear selector for STOP!
the selected gear direction forward, neutral or reverse.
Transmission in locked neutral position ("transmission
shut down").
5020/12 13 Logical error on the signal from the engine's power WARNING! Restart ECU 793 by
control system. turning the ignition off and on.
Contact the service if the problem
persists.
5030/12 14 Logical error for parking status. D7930 puts the WARNING!
transmission direction coupling in the off position.
5040/12 15 Logical error on the signal from the extra gear selector for WARNING!
the selected gear direction forward, neutral or reverse.
Transmission in locked neutral position ("transmission
shut down") when extra gear selector is used.
5050/12 16 Logical error on signal from shaft connection. WARNING!
5060/3 18 Short-circuit to battery voltage or open circuit on WARNING!
customer unique function 1.
5060/4 17 Short-circuit to ground or open circuit on customer WARNING!
unique function 1.
5060/5 19 Open circuit on customer unique function 1. WARNING!
5070/3 1B Short-circuit to battery voltage or open circuit on WARNING!
5070/4 1A Short-circuit to ground or open circuit on customer WARNING!
unique function 2.
5070/5 1C Open circuit on customer unique function 2. WARNING!
5080/3 1E Short-circuit to battery voltage or open circuit on WARNING!


SPN/FMI (hex)
5080/4 1D Short-circuit to ground or open circuit on customer WARNING!
unique function 3.
5080/5 1F Open circuit on customer unique function 3. WARNING!
5090/3 32 Short circuit to battery or open circuit at input for WARNING!
declutch/inching pedal. Inching not working.
5090/4 29 Short circuit to ground or open circuit at input for WARNING!
declutch/inching pedal. Inching not working.
5100/3 23 Short-circuit to battery voltage or open circuit on load
sensor input.
5100/4 24 Short-circuit to ground or open circuit on load sensor
input.
5110/3 25 Signal input for temperature sensor, transmission oil WARNING!
sump - Abnormally high voltage or short-circuiting to
higher voltage.
5110/4 26 Signal input for temperature sensor, transmission oil WARNING!
sump - Abnormally low voltage or short-circuiting to
lower voltage.
5120/3 27 Signal input for temperature sensor, torque converter oil WARNING!
temperature - Abnormally high voltage or short-circuiting
to higher voltage.
5120/4 28 Signal input for temperature sensor, torque converter oil WARNING!
temperature - Abnormally low voltage or short-circuiting
to lower voltage.
5130/3 29 Signal input for parking brake sensor - Abnormally high WARNING!
voltage or short-circuiting to higher voltage.
5130/4 2A Short-circuit to ground on parking brake sensor input.
5140/3 31 Engine revs - Abnormally high voltage or short-circuit WARNING!
to higher voltage. Transmission limited according to
"Substitute clutch control".
5140/4 32 Engine revs - Abnormally low voltage or short-circuit WARNING!
to lower voltage. Transmission limited according to
5140/12 33 Engine revs - Logical error. Transmission limited WARNING! Restart ECU 793 by
according to "Substitute clutch control". turning the ignition off and on.
persists.
5150/3 34 Turbine speed - Abnormally high voltage or short-circuit WARNING!
to higher voltage. Speed - Logical error. The
transmission is limited in accordance with "Substitute
clutch control". In the event of an error on the output
speed sensor the transmission control unit activates
"limp home".
5150/4 35 Turbine speed - Abnormally low voltage or short-circuit to WARNING!
lower voltage. Speed - Logical error. The transmission
is limited in accordance with "Substitute clutch control".
In the event of an error on the output speed sensor the
transmission control unit activates "limp home".
5150/12 36 Internal speed - Logical error. Speed - Logical error. The WARNING! Restart ECU 793 by
transmission is limited in accordance with "Substitute turning the ignition off and on.
clutch control". In the event of an error on the output Contact the service if the problem
speed sensor the transmission control unit activates persists.
"limp home".


SPN/FMI (hex)
5160/3 37 Internal speed - Abnormally high voltage or short-circuit WARNING!
to higher voltage. Transmission limited according to
5160/4 38 Internal speed - Abnormally low voltage or short-circuit WARNING!
to lower voltage. Transmission limited according to
5160/12 39 Internal speed - Logical error. Transmission limited WARNING! Restart D7930 by
according to "Substitute clutch control". turning the ignition off and on.
persists.
5170/3 3A Output speed - Abnormally high voltage or short-circuit WARNING!
to higher voltage. Internal speed - Logical error. The
clutch control". In the event of an error on the turbine
"limp home".
5170/4 3B Output speed - Abnormally low voltage or short-circuit WARNING!
to lower voltage. Internal speed - Logical error. The
clutch control". In the event of an error on the turbine
"limp home".
5170/12 3C Output speed - Logical error. Internal speed - Logical WARNING! Restart D7930 by
error. The transmission is limited in accordance with turning the ignition off and on.
"Substitute clutch control". In the event of an error on Contact the service if the problem
the turbine speed sensor the transmission control unit persists.
activates "limp home".
5180/2 3E Speed from propeller shaft does not correspond with WARNING! Restart D7930 by
other speed sensors. Internal speed - Logical error. The turning the ignition off and on.
transmission is limited in accordance with "Substitute Contact the service if the problem
clutch control". In the event of an error on the turbine persists.
"limp home".
5200/2 40 FCAN message "Gear range select" (ZF_3_IDENT) WARNING!
contains incorrect data.
5210/2 41 D7930 receives the messages "Gear range select" WARNING!
(ZF_3_IDENT) and "Front wheel drive status" despite
the configuration indicating that the travel direction
selector is not installed.
5220/9 50 FMR1 timeout. WARNING!
5230/9 51 FMR2 timeout. WARNING!
5240/9 52 Instrument timeout. WARNING!
5250/9 53 ABS timeout. WARNING!
5260/9 54 Timeout for CAN message DCT1 from the display unit. WARNING!
5270/9 55 Timeout for CAN message DISPID1 from the display WARNING!
unit. Transmission control unit activates "limp home".
5271/9 55 DISPID1 timeout. WARNING!
5280/9 56 ENGINE CONF timeout. WARNING!
5290/9 57 EEC1 timeout. WARNING!
5313/12 2B Inching sensor signal is not correct. WARNING!


SPN/FMI (hex)
5320/2 5A Parking brake status signal. WARNING!
5340/2 5C Automatic downshifting signal. WARNING!
5350/2 5D Manual downshifting signal. WARNING!
5360/2 5E CCO request signal. WARNING!
5370/2 5F Transmission neutral request signal. WARNING!
5271/9 55 DISPID1 timeout. WARNING!
5280/9 56 ENGINE CONF timeout. WARNING!
5313/12 2B Inching sensor signal is not correct. WARNING!
5320/2 5A Parking brake status signal. WARNING!
5340/2 5C Automatic downshifting signal. WARNING!
5350/2 5D Manual downshifting signal. WARNING!
5360/2 5E CCO request signal. WARNING!
5370/2 5F Transmission neutral request signal. WARNING!
5380/2 60 Extra brake status signal. WARNING!
5390/2 61 AEB calibration signal. CAN signal for the start of WARNING!
calibration of the clutch discs is incorrect.
5400/2 62 PTO torque signal. WARNING!
5410/2 63 Operating mode signal. WARNING!
5420/2 64 Start gear signal. WARNING!
5430/2 65 Engine torque signal. Transmission limited according to WARNING!
5440/2 69 Engine torque reference signal. Transmission limited WARNING!
according to "Substitute clutch control".
5440/2 69 Engine torque reference signal. Transmission limited WARNING!
5450/2 6A Present engine torque signal. Transmission limited WARNING!
5460/2 6B Nominal friction torque signal. Transmission limited WARNING!
5470/2 6E EEC2 timeout. WARNING!
5480/3 71 Clutch K1 - Abnormally high voltage or short-circuit STOP!
to higher voltage. Transmission control unit activates
"limp home". With an ongoing fault on another gear the
transmission control unit activates "TCU shutdown".
5480/4 72 Clutch K1 - Abnormally low voltage or short-circuit to STOP!
a lower voltage. Transmission control unit activates
5480/5 73 Clutch K1 - DLM indicator light - Abnormally low current STOP!
or open circuit. Transmission control unit activates


SPN/FMI (hex)
5520/3 84 Clutch KV - Abnormally high voltage or short-circuit STOP!
5520/4 85 Clutch KV - Abnormally low voltage or short-circuit to STOP!
5520/5 86 Clutch KV - DLM indicator light - Abnormally low current STOP!
5530/3 87 Clutch KR - Abnormally high voltage or short-circuit STOP!


SPN/FMI (hex)
5530/4 88 Clutch KR - Abnormally low voltage or short-circuit to STOP!
5530/5 89 Clutch KR - DLM indicator light - Abnormally low current STOP!
5535/3 8B DLM lateral output - Abnormally high voltage or WARNING!
short-circuiting to higher voltage.
5535/4 8A DLM lateral output - Abnormally low voltage or WARNING!
short-circuiting to lower voltage.
5535/5 8C Open circuit DLM transversal output. WARNING!
5536/3 8E DLM indicator light - Abnormally high voltage or WARNING!
5536/4 8D Short-circuit to ground on DLM indicator lamp output. WARNING!
5536/5 8F DLM indicator light - Abnormally low current or open WARNING!
circuit.
5540/3 7A Short-circuit to battery voltage on clutch torque converter. WARNING!
5540/4 7B Short-circuit to ground on clutch torque converter. WARNING!
5540/5 7C Open-circuit for clutch torque converter. WARNING!
5545/3 D8 DLM longitudinal output - Abnormally high voltage or WARNING!
5545/4 D7 DLM longitudinal output - Abnormally low voltage or WARNING!
5545/5 D9 Open-circuit for DLM longitudinal output. WARNING!
5550/3 7E Short-circuit to battery voltage on the engine's reduction WARNING!
unit.
5550/4 7D Short-circuit to ground on the engine's reduction unit. WARNING!
5550/5 7F Open circuit for the engine's reduction unit. WARNING!
5560/3 92 Short-circuit to battery voltage to reverse alarm relay. WARNING!
5560/4 91 Short-circuit to ground to reverse alarm relay. WARNING!
5560/5 93 Relay reverse alarm - Abnormally low current or open WARNING!
circuit.
5570/3 95 Relay reverse alarm - Abnormally high voltage or WARNING!
5570/4 94 Relay interlock - Abnormally low voltage or WARNING!
5570/5 96 Relay interlock - Abnormally low current or open circuit. WARNING!
5580/3 98 Short-circuit to battery voltage on parking brake solenoid WARNING!
valve. The transmission control unit activates "TCU
shutdown".
5580/4 97 Short-circuit to ground on parking brake solenoid valve. WARNING!
The transmission control unit activates "TCU shutdown".
5580/5 99 Open-circuit on parking brake solenoid valve. The WARNING!


SPN/FMI (hex)
5590/3 9B Open-circuit on clutch torque converter solenoid valve. WARNING!
5590/4 9A Short-circuit to ground on clutch torque converter WARNING!
solenoid valve.
5590/5 9C Short-circuit to battery voltage on clutch torque converter WARNING!
solenoid valve.
5600/3 9E Open-circuit on retarder solenoid valve. WARNING!
5600/4 9D Short-circuit to ground on retarder solenoid valve. WARNING!
5600/5 9F Short-circuit to battery voltage on retarder solenoid WARNING!
valve.
5610/3 A2 Short-circuit to battery voltage on differential lock WARNING!
solenoid valve or shaft connection.
5610/4 A1 Short-circuit to ground on differential lock solenoid valve WARNING!
or shaft connection output.
5610/5 A3 Open-circuit on differential lock solenoid valve or shaft WARNING!
connection output.
5620/3 A6 Output for warning signal - Abnormally high voltage or WARNING!
5620/4 A4 Output for warning signal - Abnormally low voltage or WARNING!
5620/5 A5 Output for warning signal - Abnormally low current or WARNING!
open circuit.
5630/3 A8 Short-circuit to battery voltage or open circuit on WARNING!
5630/4 A7 Short-circuit to ground or open circuit on customer WARNING!
unique function 4.
5630/5 A9 Open circuit on customer unique function 4. WARNING!
5640/3 AB Short-circuit to battery voltage or open circuit on WARNING!
5640/4 AA Short-circuit to ground or open circuit on customer WARNING!
unique function 5.
5640/5 AC Open circuit on customer unique function 5. WARNING!
5650/3 AE Short-circuit to battery voltage or open circuit on WARNING!
5650/4 AD Short-circuit to ground or open circuit on customer WARNING!
unique function 6.
5650/5 AF Open circuit on customer unique function 6. WARNING!
5660/2 B1 Clutch K1 slips. Transmission control unit activates STOP!


SPN/FMI (hex)
5680/2 B5 Clutch KV slips. Transmission control unit activates STOP!
5685/2 B6 Clutch KR slips. Transmission control unit activates STOP!
5700/0 B7 High oil temperature in oil sump. WARNING! Stop and allow the
temperature to decrease or try to
reduce the temperature by driving
more gently. Check the oil level in
the transmission.
5710/0 B8 Over temperature retarder. WARNING!
5720/0 B9 Too high engine speed. WARNING!
5730/0 BA Oil filter. Voltage to the differential pressure switch WARNING! Check the oil filter.
outside the permitted limit values.
5740/0 BB Slipping on lockup clutch torque converter. WARNING!
5745/15 BC Runaway speed, output. WARNING!
5750/3 BE Short-circuit to battery voltage on engine brake. WARNING!
5750/4 BD Short-circuit to ground on engine brake. WARNING!
5750/5 BF Open-circuit on engine brake. WARNING!
5751/0 C0 Engine torque or output too high. WARNING!
5752/0 C1 Transmission output torque too high. WARNING!
5755/15 C2 Transmission input torque too high. WARNING!
5760/0 C3 High oil temperature in torque converter. WARNING! Stop and allow the
temperature to decrease or try to
reduce the temperature by driving
more gently. Check the oil level in
the transmission.
5770/3 C4 Joystick status indicator - Abnormally high voltage or WARNING!
short circuiting to higher voltage.
5770/4 C5 Joystick status indicator - Abnormally low voltage or WARNING!
short circuiting to lower voltage.
5770/5 C6 Joystick status indicator - Abnormally low current or WARNING!
open circuit.
5780/3 C8 Short-circuit to ground on over temperature neutral WARNING!
indication.
5780/4 C7 Short-circuit to battery voltage on over temperature WARNING!
neutral indication.
5780/5 C9 Open-circuit on over temperature neutral indication. WARNING!
5790/9 CA Engine retarder configuration timeout. Transmission WARNING!
limited according to "Substitute clutch control".
5800/9 CB ERC1 timeout. Transmission limited according to WARNING!
5810/3 D1 Voltage feed to sensor - Abnormally high voltage or WARNING!


SPN/FMI (hex)
5810/4 D2 Voltage feed to sensor - Abnormally low voltage or WARNING!
5820/3 D4 High battery voltage. The transmission control unit STOP!
activates "TCU shutdown".
5820/4 D3 Low battery voltage. The transmission control unit STOP!
5830/2 D5 Error on valve, voltage feed VPS1. The transmission STOP!
control unit activates "TCU shutdown".
5840/2 D6 Error on valve, voltage feed VPS2. The transmission STOP!
control unit activates "TCU shutdown".
5860/3 E3 Display output - Abnormally high voltage or WARNING!
5860/4 E4 Display output - Abnormally low voltage or short-circuiting WARNING!
to lower voltage.
5880/2 E6 Unauthorised ID request via CAN. Transmission in STOP!
neutral. The transmission control unit activates "TCU
shutdown".
5890/2 F1 General EEPROM error. WARNING!
5900/13 F2 Configuration lost. The transmission control unit STOP!
5910/13 F3 Application error. The transmission control unit activates STOP!
"TCU shutdown".
5920/13 F4 "Limp home" request. Transmission control unit activates
"limp home".
5930/7 F5 Clutch error. The transmission control unit activates STOP!
"TCU shutdown".
5930/13 F6 Calibration values from inching pedal or clutch WARNING!
modulation missing in the memory. Inching inoperative.
5940/13 F7 Substitute clutch control. Transmission limited according
to "Substitute clutch control".
E1 Open-circuit on signal from travel direction selector. The
E2 Open-circuit on signal from travel direction selector 2.
The transmission control unit activates "TCU shutdown".

For serious transmission malfunctions the control unit uses four modes
with reduced functionality to protect the transmission from damage.
These are:
• "Substitute clutch control".
In this mode, the driver can use the machine as usual. However,
gear shifting and changing of the travel direction are not under the
control of normal modulation. The control unit uses the default
values for the modulation of the clutches.
• "Limp home".
In this mode, the driver can use one of the transmission gears in
each direction, and in some cases only in one direction. In order to
continue driving with an error giving the restriction "Limp home" the
machine must be brought to a standstill, the gear selector shifted
to neutral before the gear can be selected again.
• "Transmission shut down".
In this mode the transmission is permanently in neutral position
when the solenoid valves for the clutches and parts of the voltage
feed to the transmission are switched off. Park the machine and
switch off the engine.
• "TCU shut down".
In this mode the transmission is permanently in neutral position
when all solenoid valves and all voltage supplies to the transmission
are switched off. Park the machine and switch off the engine.

148 5 Handling – Operating
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.

5 Handling – Starting engine 149
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 coolant temperature is within the interval (approx. 82-95 °C is
normally dependent on load).
• 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 engines.
• that all warning lights are off.
• that signals, lighting, brake lights and direction indicators function
correctly.
• that all hydraulic functions function correctly.
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. 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.
2. Turn the ignition key lock to operating position, position I.
Current is now supplied to all electrical functions.

150 5 Handling – Warming up
3. 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:
4. 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 85.
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.
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 75.

5 Handling – Gearshifting 151
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.
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 Instructions, page
150.
General about the automatic transmission:

• Has a built-in control system, providing optimised operation.
• Shows current gear on the control system display.
• The reversing lock prevents the travel direction being changed too
013489
quickly, i.e. prevents possible damage to the transmission. The

32 31 33 reversing lock is automatic and is dependent on engine speed
and travel speed.
30. Switch for upshift
• Shifting is variable (modulated) and gives smoother operation.
31. Switch for downshift Normally start-up takes place in first gear. Use of first gear is
governed by engine speed, amongst other things.
32. Switch for automatic shifting
33. Travel direction indicator, Forward Neutral
Reverse
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.

152 5 Handling – Gearshifting
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
b) Travel direction selector on control for load handling

Move the switch (position b):
015235
c) Travel direction selector on mini steering wheel or joystick

Move the switch (position c):
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.

5 Handling – Steering 153
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.
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 driver in the driver's seat, description, page 78.
Switch in driver's seat
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.

154 5 Handling – Service brake
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
awhile 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
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!

5 Handling – Parking brake 155
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 82.
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.
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 82.
• 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 84.
015215
Check the accumulators' sealing integrity if the pressure does

not build up and is not maintained, see chapter 6 Inspection and
1. Travel direction selector and parking brake maintenance.
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 driver in
the driver's seat, description, page 78.
If the accumulator pressure drops below a certain level an error code is

shown on 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 has to be moved see section 7 Transporting the machine.
Emergency brake
The parking brake can be used as emergency brake in emergency
situations.

156 5 Handling – Heating / Air conditioning
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.
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 For ECC: In the event of an open door, the air conditioning's cooling
compressor is switched off (cooling function and air drying stops).
Close the door and the cooling function is activated again.
012820
41 42 44 45 46 The Eberspächer function can be used to heat both the cab and engine
when the engine is not running. For the operation of Eberspächer, see
Panel for heating and air conditioning system the manufacturer's instructions.
NOTE
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.

5 Handling – Heating / Air conditioning 157
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 regulation 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, 39, 40).
Manual control is possible in five steps from Off to Max. Fan speed
is indicated by a bar in the operating menu.
NOTE
When setting the fan capacity manually, automatic control of the
air conditioning is stopped.
NOTE
When the fan is off, the cooling functions ceases (for ECC).
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 conditioning 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).

158 5 Handling – Stopping the engine - parking
3 Direct air distribution (position 18) 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.
For ECC: the cooling function will be active and help to dry the
air .
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 engines:
NOTE
Wait for two minutes before the system voltage is disconnected with
the battery disconnector so that the SCR system has time to fully
drain, this is particularly important in cold weather.

5 Handling – Revolving operator's station 159
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. If necessary program Eberspächer for the next shift.
5.4.10 Revolving operator's station

General
Turning the operator's station is primarily used to facilitate operations.
Use the rotating 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 driver 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 the permitted position.
A • For mini steering wheel/joystick control, the left-hand arm rest
0° must be lowered .
• Mini steering 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 88.
016607
Shift between forward/reverse occurs at the transition from zone C to

either zone B or D. This means that the steering angle is automatically
changed. The function of the travel direction selector is also adapted to
the position of the operator's station.
Lighting such as headlights, brake lights, reversing lights and rear 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.
Screen washing is also adapted according to the position of the

operator's station.

160 5 Handling – Revolving operator's station
Restrictions in machine functions

The machine's functions have different restrictions depending on which
zone the operator's station is located.
Tabell Restrictions in machine functions
Zone Restrictions
180°
E A No restrictions.
D
B Speed limitation can occur.
C Operations 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 161
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:

• position of load's centre of gravity
• lifting height
300 mm
• weight of the load
012658
The capacity varies between models and versions, see the machine
and type plates, section 3.2 Plates.
Transport position
NOTE
The driver must sit in the driver's seat in order for the load handling
functions to work.
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.
012659
Load handling subfunctions.

• Lift/lower
Lift and lower
• Tilt
• Side shift
• Spreading (positioning)
• Fork levelling
012660
Tilt
012661
Side shift

162 5 Handling – Load handling
012662
Spreading (positioning)
012663
Fork levelling or central levelling

5 Handling – Load handling 163
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 is not jeopardised.
When the machine approaches the stability limit, the following takes
place:
• buzzer in the cab sounds (indication to operator)
See section 2.1 Safety and emergency equipment.
• warning figure is shown on the display (indication to operator)
See section 4.11.2 Event-controlled information.
• 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 is
cleared.
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 handling the machine, see section 2.4 Keep in mind.

164 5 Handling – Lifting load
5.5.1 Lifting load

General
There are different types of lifting tool for load handling, most common
are:
• forks
• sidelift attachment for container handling
• coil ram
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.
DANGER
Make sure that the lifting equipment is marked with
the capacity data. There should 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.

5 Handling – Lifting load 165
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.
• Lower the forks as low as possible and adjust the fork
012664
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 should pay take extra care when
load handling near electric power lines, viaducts,
docksides, ramps, doors, 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
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.

166 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 does 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 167

1 Lift the load slightly. Back away from the load area.
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
167. The load's centre of gravity must be centred laterally.
Transport position
When the machine is to be run with or without load assume the transport
position to minimise the risk of roll-over and imbalance while operating.
If the load blocks visibility ahead then the machine must be reversed.
NOTE
When handling special loads local regulations may apply. Learn
300 mm
012658
about them and follow them.
Transport position
The machine shall be run in transport position even without load to

maximise operator visibility.
When in transport mode without a load, the mast must be vertical and
the forks raised slightly above ground, around 300 mm. (See figure to
the left). The forks should, if possible, be spread so that both fork tips
are visible, this means the machine's total length including forks is
300 mm
visible.
012665
Transport position without 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 167.
Always drive with the lifting attachment upwards in the grade,
irrespective 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.
Always drive with the lifting attachment upwards in the grade,
012666
irrespective of travel direction, i.e. the truck must be reversed

down a grade.
Operating with a load on grades

168 5 Handling – Unloading
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 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.
5.5.3 Unloading
General
There are different types of lifting attachments for load handling, e.g.
forks, coil rams and sidelift attachments 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 area should be as
straight as possible.
• Tilt the mast to vertical position.
2 Move forward slowly until the load is in position over the unloading
012667
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 area and raise/lower the
forks to the 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.

5 Handling – Functions for load handling 169
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 .

170 5 Handling – Functions for load handling
Tilt control
Tilt control always strives to hold the mast and 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 lift/lower function has been completed.
The function for tilt control is activated with the switch (position A).
1 Perform load handling, e.g. lift/lower 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.
A Tilt control works continuously until the function is deactivated

016674
Tilt control is deactivated:

• If the tilt control switch (position A) is pressed in.
• If the tilt function is activated with the linear lever for tilt or
control lever.
• If the driver moves from the driver's seat. Tilt control stops
after 2 seconds.
• If the hydraulic control breaker is pressed.
• In the event the lift or tilt function is overloaded.
Height warning
A The height warning warns when the set lifting height is reached.
The height warning can be adjusted in accordance with 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.
016676

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 to bypass the safety system (position
47) and use the lift function. After a few seconds the Switch to bypass
the safety system (position 47) can be deactivated, lifting and lowering
can then be performed without bypassing.
The event menu on the display is always shown when the lift height
012667 exceeds the height limitation, see Event menu height limitation,
description, page 81.

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
indication or do not work.
012668
Using the attachment without functioning indicator lights is a great

safety hazard.
Transport position with side lift attachment
• 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
A B C 1 Set spreading to the container length in question (position 4).

2 Drive slowly toward the container, adjust with side shift (position 3).
3 Tilt the mast forward slightly (position 2), lower the sidelift
attachment (position 1) to the container and fit the two twistlocks
into the locking holes in the container so that both sides of the
sidelift attachment are resting on the container. Check that the
indicator light B comes on.
4 Locked twistlocks (position 5). Check that the indicator light A
comes on.
5 Tilt the mast backward and lift. Check that the indicator light B
goes out when the container is lifted.
5
4 6 Transport the container in transport mode. Reverse if the container
3 blocks the view.
2
7 Releasing the container: Set the container down on the surface.
1 Check that the indicator light B comes on. Release the twistlocks.
Check that the indicator light C comes on.
NOTE
015237
For load handling with the control lever, see the plates on the
machine.
A Indicator light for locked twistlocks

B Indicator light, contact
C Indicator light for unlocked twistlocks
1. Control lever for lift and lower
2. Control lever for tilt
3. Control lever for side shift
4. Control lever for spreading
5. Control lever for twistlocks
Fork shank system
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.

Forks
Forks
Removal
Proceed as follows to remove the forks:

• Place the forks in their stowage position.
• Remove the lock rings/lock pins (position A) and knock out the
locking axles (position C) that hold the forks to the shanks (position
B).
B
• Lower/tilt forward and back away from the forks.
A Reassembling
Proceed as follows to reassemble the forks:

• Forks with hook bracket: Lower/tilt forward and drive forward
toward the forks. Lift and tilt backward so that the forks hook into
the fork shanks.
• Fit the locking axles (position C) lock rings/lock pins (position A).
C • Always make sure that the locking axle is locked with the lock
ring/lock pin.
007371
A Lock ring or lock pin

B Fork shank
C Locking axle

6 Inspection and maintenance 175
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.

176 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. Walk around the machine and check the following:
• Leakage from engine, 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.
• Undo the 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.
• 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 177
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; check that

sensors for twistlocks and alignment are clean and free from
grease
• Communication equipment - direction indicators, brake lights,
headlights and reflectors with regard to damage
• 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. Check fluid levels for the following fluids according to description,
see section 6.2 Maintenance. Top up, if necessary, with the correct
fluid:
• Hydraulic oil
• Batteries' electrolyte level
• Coolant
• Washer fluid - windows
• Engine oil
• Transmission oil
3. Check the engine's air filter indicator, also check and drain the fuel
prefilter if required. For description, see section 6.2 Maintenance.
4. 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.
Applies only to certain engine options.
• Lighting, direction indicators, horn, brake lights, flashing
hazard lights
All the lights on the machine can be switched on simultaneously
with the menu for machine check, see Menu for machine
check, description, page 96.
• Windscreen wipers
• Check that mirrors are intact, clean and well-adjusted for
visibility all around the machine.
• Cooling function in the ECC
5. 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

178 6 Inspection and maintenance – Daily inspection
6. 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.
7. 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.
Applies only to certain engine options.
8. If the machine is equipped with sidelift attachment; check the lift
attachment and that:
• Indicator lights for twistlocks and alignment function.
2 • The contact pins on the twistlocks can be moved easily up and

down. 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 release the twistlocks.
3
007007
5 4
1. Sensor twistlock
2. Sensor alignment
3. Lock guide
4. Lift pin
5. Contact pin

6 Inspection and maintenance – Daily inspection 179
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.
A
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
015357
detected on the machine.
WARNING
Do not use the machine if the system for locking
containers does not work.
damage!
Use of the machine must be discontinued, and it has to
be taken to a service workshop for needed actions.
12. In cold weather:

• Check that wiper blades have not frozen to the windscreen.
• Remove snow and ice from air inlets and radiator grill
• Antifreeze in washer fluid
• Disconnect the auxiliary heater for the cab and engine .
The auxiliary heater for the engine does not heat the AdBlue–
tank and hoses.
13. Check if any error codes are active.
See the section 5.3 Error codes.

180 6 Inspection and maintenance – Maintenance
6.2 Maintenance
General
The following maintenance actions are described in this chapter:
– Cleanliness, general, page 183
– Fuel system, general, page 185
– Windscreen washer, general, page 189
– Air filter engine, general, page 190
– Cooling system, general, page 192
– Engine oil, general, page 194
– Transmission oil, general, page 196
– Hydraulic system, general, page 196
– Tyres and rims, general, page 197
– Accumulator, general, page 200
– Central lubrication, general, page 201
– Battery and battery disconnector, general, page 203
– Fuses for electrical system, general, page 206
– Lighting, general, page 213
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
can damage electrical wiring, etc. and must be rinsed away
immediately if spilt.
• Always drain the pressure from the accumulators before working
on the hydraulic system.

6 Inspection and maintenance – Maintenance 181
Tilting the cab
WARNING
Never work under a cab that is not tipped over its
balanced position or secured by other means.
Risk of crush injury.
Always tilt the cab as far as possible. At the maximum
tilt angle (on a horizontal surface) the centre of gravity
of the cab means that it cannot tip back.
A, B, D C
The cab must always be tipped over its balanced position. If the
lateral space is insufficient, the cab must always be secured against
accidental lowering by means of a stay.
C
Preparations:
• 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.
A
Tilting
1. Turn both lock handles (position C) so that they end up in their
outer position to loosen the cab from the frame.
2. Turn the pump valve (position B) clockwise.
B 3. Fit the pump rod in its bracket (position A).

D
4. Pump until the cab has reached the end-position.
NOTE
Stop pumping/raising when the cab is at the end position, otherwise
the pump valve will be difficult to turn.
Lowering
1. Turn the pump valve (position B) anticlockwise.
2. Fit the pump rod in its bracket (position A).
015207
3. Pump all the way until the cab rests on the frame.
A Pump rod bracket 4. Turn both lock handles (position C) so that they end up in their
inner position in order to lock the cab to the frame.
B Pump valve
C Lock handle (figure shows the open position)
D Control buttons

182 6 Inspection and maintenance – Maintenance
Electric tipping
1. Open the hatch for cab tilting.

outer position to loosen the cab from the frame.
3. Turn the pump valve (position B) clockwise.
4. Use the control buttons (position D) to raise the cab to the end
position. Press 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. Press both buttons simultaneously.
inner position in order to lock the cab to the frame.
4. Close the cover.

6 Inspection and maintenance – Cleanliness 183
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!
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.

184 6 Inspection and maintenance – Cleanliness
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.

6 Inspection and maintenance – Fuel system 185
6.2.2 Fuel system

Fuel system, general
Fuel filling is located on the left-hand side of the machine.
Low fuel level is indicated with the event menu, see Event menu low
fuel level, description, page 83.
Low AdBlue level is indicated with the event menu, see Event menu
low AdBlue level, description, page 82. Does not apply to all engine
options.
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.
WARNING
014503
Fuel is highly flammable and health hazardous.

B A Fire hazard! Health hazard!
A Fuel filler orifice Handle with great care and avoid all possible ignition
sources, for example, cigarettes, sparks. Avoid skin
B AdBlue filling (does not apply to all engine
options) 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.

186 6 Inspection and maintenance – Fuel system
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 fill up with diesel fuel. For tank volume and fuel quality, see
section 9 Specifications.
• Never use additives in the diesel fuel.
• 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.

6 Inspection and maintenance – Fuel system 187
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.
IMPORTANT
Avoid spilling AdBlue on the machine.
AdBlue is very corrosive and harmful mainly to wiring
and electrical components.
Clean AdBlue from electrical wiring and components
immediately.
AdBlue
• Always fill with pure AdBlue. For tank volume and AdBlue quality,
see section 9 Specifications.
• 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.
• Make sure the nozzle for AdBlue is correctly fitted to the filler pipe
(avoid spillage).
• Clean around the filler pipe after refuelling and handle used rags,
wiped up fuel, etc. in an environmentally sound manner.

188 6 Inspection and maintenance – Fuel system
Fuel prefilter, 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.
015332
Cummins QSB6.7 Stage 3A/Tier 3

3 Drain the water from the filter.
Open the drain cock on the underside, close the cock when clean
fuel drains (no water bubbles). Only tighten the tap by hand.
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.
015330
Volvo TAD761VE Stage 3B/Tier 4i

6 Inspection and maintenance – Windscreen washer 189
015331
Cummins QSB6.7 Stage 3B/Tier 4i.
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 84.
012671
A Washer fluid reservoir
Instructions
1 Check the level in the reservoir. Top up with washer fluid as
required. For volume, see chapter 9 Specifications.
2 Add anti-freeze. Select a suitable concentration (dilution
water/anti-freeze fluid) according to the prevailing outdoor
temperatures.

190 6 Inspection and maintenance – Air filter, engine
6.2.4 Air filter, engine

Air filter engine, general
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 at regular intervals. Contact service if the indication

is red.
C
015334
Cummins QSB6.7
A Position for air filter reservoir
B Indicator for change
C Dust reservoir

6 Inspection and maintenance – Air filter, engine 191
C
015335
Volvo TAD761VE
A Position for air filter reservoir
B Indicator for change
C Dust reservoir

192 6 Inspection and maintenance – Cooling system
6.2.5 Cooling system

Cooling system, general
Coolant is filled in the system's expansion tank (position A). The coolant
level with a cold engine must be visible in the sight glass (position C)
on the expansion tank.
NOTE
Open very carefully as hot coolant may jet up and out.
NOTE
A low coolant level may cause engine damage or may cause the
D C B A engine to stop.
High coolant temperature is indicated with the event menu, see Event
menu engine coolant temperature, description, page 80.
015333
A Position of the coolant container (expansion

tank)
B Filling point
C Sight glass
D Sensor, coolant level
Instructions
WARNING
The cooling system is pressurised. Steam or hot
coolant may jet out.
Risk of scalding/burn injuries!
Open the filler cap very carefully when the engine is
warm. Wait until the coolant has cooled down before
topping up.
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.

6 Inspection and maintenance – Cooling system 193
CAUTION
Different types of coolant may not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, the same type
of coolant must be used as was used before.
1 Top up with ready-mixed recommended coolant as required. For

volume, see chapter 9 Specifications.
IMPORTANT
Machines with ECC are equipped with a combined
heating and cooling pack, which can lead to a risk of
freezing if the machine is run without coolant.
Risk of freezing and damage to the heating and cooling
pack!
Always use the recommended coolant.

194 6 Inspection and maintenance – Engine oil
6.2.6 Engine oil

Engine oil, general
WARNING
protective gloves.
The engine's oil filler pipe (position B) and oil dipstick (position C) are
located under the engine hood.
Instructions
1 Check the oil level (position C).
Check the oil level when the engine is warm. Turn off the engine
and wait about 5 minutes before checking the oil level. Wipe off
the oil dipstick before checking.
The oil dipstick has two markings; the oil level should be between
the two markings.
NOTE
The oil dipstick is long on certain machines. Wear gloves.
2 Top up as required with new engine oil (position B). For volume
A and quality, see chapter 9 Specifications.
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.
B
012828
Cummins QSB6.7 Stage 3A/Tier 3

A Placement filling and oil dipstick engine oil
B Oil filling
C Oil dipstick

6 Inspection and maintenance – Engine oil 195
A
B C
014515
Cummins QSB6.7 Stage 3B/Tier 4i.

A Placement filling and oil dipstick engine oil
B Oil filling
C Oil dipstick
B
014514
Volvo TAD761VE Stage 3B/Tier 4i

B Oil dipstick
C Oil filling

196 6 Inspection and maintenance – Transmission oil
6.2.7 Transmission oil

Transmission oil, general
WARNING
protective gloves.
The transmission's oil filler pipe and dipstick (position A) are under the
hood on the left-hand side.
Instructions
1 Check the oil level.
Check the oil level with the engine idling and the transmission in
neutral position and at operating temperature. Wipe off the oil
dipstick before checking.
NOTE
The oil dipstick is long. Wear gloves.
The dipstick has three markings. The lowest marked "C" is a

rough estimate of the level for cold transmission. The top two are
A marked "H" and are the markings for the maximum, MAX and
minimum, MIN, oil levels at operating temperature. The oil level
must be between MIN and MAX with a hot transmission when
idling in neutral.
2 Top up as required with new transmission oil. For volume and
quality, see chapter 9 Specifications.
Fill - wait a moment - check the oil dipstick.
NOTE
Work carefully when filling transmission oil to prevent other fluids
012675
or particles from contaminating the oil. Other fluids or particles in

the transmission oil means a risk of transmission damage.
A
A Oil dipstick and filling point transmission oil
6.2.8 Hydraulic system

Hydraulic system, general
WARNING
Avoid prolonged skin contact with hydraulic oil.
Health hazard!
Use protective gloves.
The hydraulic oil tank is located on the machine's right side.

6 Inspection and maintenance – Tyres and rims 197
Instructions
1 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.
2 Top up as required with new oil (position D). For volume and
quality, see chapter 9 Specifications.
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 involve a risk of damage to the brake system or
C A working hydraulics.
D
014542
B
A Position for hydraulic oil tank
B Sight glass
C Breather filter
D Filling point
6.2.9 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!

198 6 Inspection and maintenance – Tyres and rims
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 199
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 the 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
serious accidents.
012677

200 6 Inspection and maintenance – Checking the accumulator
1. Before inflating, make sure that the rim's lock ring is in the correct
position.
3 2
1
NOTE
If the tyre has been completely deflated, the rim must be dismantled
and checked for damage. Let service personnel change tyres, they
have the competence and authority to handle tyres!
2. Connect the compressor with a locking air-chuck to the nipple on

the tyre.
3. Stand at an angle behind the tyre and remain there until inflating
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
003770
pressure may apply, contact Cargotec.
1. Lock ring
2. Rim edge
3. Conical ring
6.2.10 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 accumulator pressure, see Event menu low accumulator
pressure, description, page 78, appears in the control system display:
1. Start the engine and let it run until the accumulator is filled.
A
2. Stop the engine.
3. Press down the brake pedal with long pumping brake strokes, with
012678
a slight delay between each braking action. Count the number of

brake applications until the accumulator is empty, i.e. when the
resistance disappears when the pedal is pressed down.
A Accumulator
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.
Contact service as soon as possible for troubleshooting and suitable
action.

6 Inspection and maintenance – Central lubrication 201
WARNING
The machine's hydraulic system contains a
high-pressure accumulator.
Always exercise extreme caution when working
with the hydraulic system and avoid unnecessarily
remaining close to hydraulic components or hoses.
The accumulator must be drained prior to work on the
hydraulic system (see Maintenance manual).
6.2.11 Central lubrication

Central lubrication, general
Central lubrication (which replaces manual lubrication) consists of

a preprogrammed lubrication device, which at the set time intervals,
lubricates all the selected lubrication points. The time interval can be
adjusted as needed via the menus, contact Cargotec Service.
Central lubrication comprises the following components:

• Pump unit, with lubricant reservoir.
• Distribution block.
• Lines, to all selected lubrication points.
• Grease nipples, at all selected lubrication points.
Maintenance for central lubrication is the filling of lubricant and checking

that all connected lubrication points receive sufficient lubricant.
1
015337
1. Pump unit

202 6 Inspection and maintenance – Central lubrication
Filling lubricants
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.
1 Fill the reservoir up to the "Max" mark through the filler nipple
(position 1).
3 2 Lubricating grease must be clean from contaminants and must not

2 change consistency as it ages.
1 015338
1. Refilling nipple
2. Ventilation hole
3. Following plate
Filling lubricants with an empty reservoir

1 If the reservoir has become completely empty and is then filled,
the pump may require a longer time to provide all the lubrication
points with a sufficient amount of lubricant.
The pump can be operated manually with the menu for machine
check, see Menu for machine check, description, page 96.
2 Check that all air under the following plate (position 3) has been
evacuated.
The following plate's seal cleans the hole in the top of the
container. A small amount of grease should come out to indicate
that proper venting has occurred.

6 Inspection and maintenance – Battery and battery disconnector 203
6.2.12 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).
A-E
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.
E Danger!
Turn off the system voltage with the battery
D disconnector. After the engine is turned off, wait a
A while before switching off the system voltage. The
diesel engine's control system performs actions,
depending on the model, up to two minutes after the
engine is turned off.
015208
B C The electrical system works with a system voltage of 24 Volt (DC). The
power source consists of two series-connected 12 Volt (DC) batteries
A Battery disconnector which are charged by an AC alternator with rectifier. The negative
B Battery cover terminal is connected to the frame.
C Handle to open/close the cover The plus terminal is connected to a battery disconnector (position A).
D Battery disconnector in the on position, i.e.
system voltage is connected. The batteries are located inside of a cover (position B) behind the steps
on the machine's left side.
E Battery disconnector in the off position, i.e.
system voltage is disconnected.

204 6 Inspection and maintenance – Battery and battery disconnector
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.

6 Inspection and maintenance – Battery and battery disconnector 205
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 Switch off the engines on both machines.
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.

206 6 Inspection and maintenance – Fuses for electrical system
6.2.13 Fuses for electrical system

Fuses for electrical system, general
The machine's electrical system is fuse-protected in three levels:
• Main fuses
• Distribution fuses
D • 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.
A • 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.
B
015339
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 207
016626
Fuse plate for the cab electronic box
016625
Fuse plate for the frame electronic box

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.
Tabell 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.
012680
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 203.
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.
Tabell Distribution fuses, battery voltage F9952-2
Fuse number /
Size Functions
1 / 50A Frame
2 / 50A Cab
Tabell Distribution fuses, ignition voltage F9954-1
Fuse number /
Size Functions
1 / 50A Frame
2 / 50A Cab
3 / 50A Control unit KFU (D7971) and Control unit
KFU (D7972)
4/- -
F9952-2
F9954-1
1 2
015340
1 2 3
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).
Tabell Fuses battery voltage frame F9958-RD
Fuse number /
Size Functions
RD1 / 15A Control unit engine (D7940) for Volvo
TAD761VE.
RD2 / 30A Power supply after-treatment system for
Volvo TAD761VE (30 A).
Control unit engine (D7940) for Cummins
QSB6.7 (10 A).
RD3 / - -
RD4 / - -
RD5 / - -
RD6 / 5A Control unit, transmission (D7930).

RD7 / - -
RD8 / 30A Electric cab tilting
Tabell Fuses ignition voltage frame F9958-BK
Fuse number /
Size Functions
BK1 / - -
BK2 / - -
RD1 BK1 GN1 BK3 / 5A Start interlock
RD2 BK2 GN2
BK4 / - -
RD3 BK3 GN3
BK5 / - -
RD4 BK4 GN4
BK6 / 5A Control unit (D7930) for transmission
RD5 BK5 GN5
BK7 / - -
RD6 BK6 GN6
RD7 BK7 GN7 BK8 / - -

RD8 BK8 GN8
Tabell Fuses options frame F9958-GN
Fuse number /
015341
Size Functions
GN1 / - -
Fuses in electronic box frame, F9958 GN2 / - -
GN3 / - -
GN4 / - -
GN5 / 10A Battery voltage before the battery

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

Fuses battery voltage cab F9968 RD
Tabell Fuses battery voltage cab F9968 RD
Fuse number /
Size Functions
RD1 / 5A Start-up
RD2 / 15A Control unit KCU (D7901)
RD3 / - -
RD4 / 5A Radio
RD5 / 10A Service/RMI
RD6 / 10A Customer-specific equipment
RD7 / - -
RD8 / 10A Loud horn
Tabell Fuses ignition voltage cab F9968 BK
Fuse number /
Size Functions
BK1 / 10A Control unit KPU (D7902)
BK2 / 10A Service/RMI
BK3 / 10 A Back-up camera
BK4 / 5A Radio
BK5 / 25A Functions driver's seat
BK6 / 10A Customer-specific equipment
BK7 / 15A Work lights

RD1 BK1 GN1
RD2 BK2 GN2

BK8 / 10A Searchlight
RD3 BK3 GN3
RD4 BK4 GN4

Tabell Fuses options cab F9968 GN
RD5 BK5 GN5 Fuse number /
RD6 BK6 GN6 Size Functions
RD7 BK7 GN7 GN1 / 25A Heated rear window
RD8 BK8 GN8
GN2 / 10A Double wiper front window
GN3 / 10A Voltage converter 12/24 VDC

GN4 / - -
015342
GN5 / 5A Revolving operator's station

Fuses in electronic box cab, F9968 GN6 / - -
GN7 / - -
GN8 / - -
Instructions
When checking and changing fuses:
2 Remove the cover from 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 left side of the machine.
Tabell Fuse engine option Cummins QSB6.7 Stage 3A/Tier 3
Fuse number /
Size Functions
1 / 125A Preheating
Tabell Fuse engine option Cummins QSB6.7 Stage 3B/Tier 4i

1 Fuse number /
Size Functions
1 / 150A Preheating
015472
Instructions
When checking and changing fuses:
2 Check and change fuses when needed.

6 Inspection and maintenance – Lighting 213
6.2.14 Lighting
Lighting, general
It's important to use the right type of light bulb for respective lighting
point, see section 9 Specifications.
Light bulbs can be changed for the following:

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

214 6 Inspection and maintenance – Service
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.

6 Inspection and maintenance – Service 215
WARNING
For safety reasons, the following spare parts may only
be replaced with genuine spare parts:
• Brake valve
• Drive axle
• Valve for mini steering wheel/joystick steering
• Steering valve (Orbitrol)
• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Rim
• Solid wheels
• Mast, carriage
• Lift cylinder incl. load control valve
• Separate load control valve
• Lifting chains
• Chain tightener and shaft
• Forks, fork carrier
• Tilt cylinder
• Twistlock
• Control breaker (for hydraulic function)
• Hydraulic cylinder, cab tilt
• Accumulator
• Tilt valve
• Main valve load handling
• Accumulator charging valve
• All control units

216 7 Transporting the machine
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.

7 Transporting the machine – Towing 217
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. Also, the 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.

218 7 Transporting the machine – Mechanical release of parking brake
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/hydraulic
accumulators should drop below a certain level.
If the machine has to be moved (towed) without sufficient pressure in

the hydraulic accumulator/hydraulic accumulators, 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.
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

7 Transporting the machine – Hydraulic release of parking brake 219
7.1.2 Hydraulic release of parking brake

Description
The parking brake is a disc brake on the drive axle's input shaft.
DANGER
Before starting to work with the parking brake, make
sure that the machine cannot move when the braking
action is released.
Block the wheels to avoid unwanted rolling of the
machine.
1 Check that the parking brake is off. See the parking brake indicator
on the display.
2 Screw out the knob (position A) as far as possible.
3 Screw in the knobs (position B and A) as far as possible.
4 Pump with the pump rod (position C) approx. 10 times.
A-C
012681
C B A
A Knob for mechanical release of the parking
brake
B Knob for mechanical release of the parking
brake
C Pump rod

220 7 Transporting the machine – Hydraulic release of parking brake
Restore the parking brake as follows:

1 Screw out the knobs (position A and B) as far as possible.
2 Screw in the knob (position A) as far as possible.
NOTE
If the parking brake has been released mechanically, the parking
brake must always be restored in order to give the machine parking
brake function.

7 Transporting the machine – Lifting and transporting the machine 221
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 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.

222 7 Transporting the machine – Lifting machine
7.2.1 Lifting machine

Instructions, lift without lifting eyes on counterweight
Machines without lifting eyes on the counterweight must be lifted as
follows:
1 Route a lifting sling around the rear of the chassis, between the
counterweight and the steering axle.
2 Fit two lifting slings in the two lifting eyes of the lifting mast.
3 The lifting device must be adapted so that the lifting point runs
through the machine's centre of gravity.
012682

7 Transporting the machine – Transporting the machine 223
Instructions, lift with lifting eyes on the counterweight
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.
3 The lifting device must be adapted so that the lifting point runs
through the machine's centre of gravity.
012683
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 trolley 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.
016665
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.

224 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.
• Trolley 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
machine on ramps. Axle stands and ramps must be dimensioned
for the machine's weight.
015209

7 Transporting the machine – Long-term storage 225
7.4 Long-term storage

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

226 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 227
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, refrigerant of type

R134a is used, with a maximum amount of 1.5 kg.
Standards
Noise, vibration, stability and visibility, etc.
This machine conforms to the harmonized standard EN-ISO 3691-1
Industrial trucks. Safety requirements and verification - Part 1:
Propelled trucks and the harmonized standard EN 16307-1 Industrial
trucks. Safety requirements and verification - Part 1: Additional
requirements for propelled industrial trucks. This machine also
complies with the North American standard ANSI/ITSDF B56.1 "Safety
Standard for Low Lift and High Lift Trucks".
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.
Exhaust emissions
Machines for the EU/EEA market fulfil EU\qs Exhaust directive
97/68/EC and 2004/26/EC, which means that the engine's exhaust
emissions have been limited according to the requirements.
Machines for the North American market fulfil EPA\qs and CARB\qs
exhaust regulations, which means that engine exhaust emissions have
been limited according to the requirements.
Noise emissions
The machine for the EU/EEA market fulfils the EU Noise directive
2000/14/EC and 2005/88/EC which means that the machine is marked
with guaranteed sound effect level, which are also limited according
to the requirements for trucks with lift capacity over 10,000 kg. See
section 3.2 Plates.

228 8 Environment and standards – Environment and standards
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.

9 Specifications 229
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.
0 Complete machine Cummins QSB6.7 Cummins QSB6.7 Cummins QSB6.7 Volvo TAD761VE
129 kW 129 kW 164 kW 160 kW
Stage 3A/Tier 3 Stage 3B/Tier 4i Stage 3B/Tier 4i Stage 3B/Tier 4i
Guaranteed sound power level LWA 107 dB(A) LWA 108 dB(A) LWA 108 dB(A) LWA 108 dB(A)
according to 2000/14/EC and
2005/88/EC including measurement
uncertainty 1.5 dB.
1 Engine Cummins QSB6.7 Cummins QSB6.7 Cummins QSB6.7 Volvo TAD761VE

129 kW 129 kW 164 kW 160 kW
Stage 3A/Tier 3 Stage 3B/Tier 4i Stage 3B/Tier 4i Stage 3B/Tier 4i
Output in accordance with ISO 3046 129 kW at 2200 129 kW at 2200 164 kW at 2200 160 kW between
(marked output) rpm rpm rpm 1300-2200 rpm
Torque ISO 3046 799 Nm at 1400 800 Nm at 1500 945 Nm at 1500 1180 Nm at 1200
rpm rpm rpm rpm
Max. rotation speed 2200 rpm 2200 rpm 2200 rpm 2200 rpm
Number of cylinders 6 cylinders
Alternator, output 1960 W 3360 W
System voltage, voltage – capacity 24 V (2x12 V / 145 Ah)
2 Transmission ZF 3WG161 ZF 3WG171

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

axle
Drive axle, type Kessler D81
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

230 9 Specifications – Specifications
DCG DCG
DCG DCG DCG DCG DCG DCG DCG DCG DCG DCG DCG DCG DCG 70- 70-
6 90 100 120 127 140 150 100 120 150 160 160 160 180 32 35
Wheels -6 -6 -6 -6 -6 -6 -12 -12 -12 -6 -9 -12 -6 E3 E4
Dimen- 11.00 - 20/16PR 12.00 - 20/20PR 12.00 12.00 -
sion, - 20/20 20/20PR
front and PRHD
rear
Tyre 0.9 MPa 1.0 MPa 0.9 MPa
pressure,
also see NB! Michelin tyres must have 1.0 MPa tyre pressure.
pressure
plate
Tyre Inflated with air. Spare and replacement tyres must be of brand names approved by Cargotec.
type,
front and
rear
9 Cab Cab Open cab

Equivalent sound pressure level LpAZ 73 dB(A) LpAZ 85 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

Position lamps - Replaced complete
Headlights, (with high and low beam) 75/70 P43t-38 (H4)

Back-up light 70 PK22s (H3)
Work lights glow lights 70 PK22s (H3)
Work lights, Xenon 35 D1S Xenon bulb. Inserts and ballast

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

9 Specifications – Specifications 231
Volumes
For oil types see Oils and lubricants, recommendation, page 233.
1.2 DCG DCG

Engine, DCG DCG DCG DCG DCG DCG DCG DCG DCG DCG DCG DCG DCG 70- 70-
fuel 90 100 120 127 140 150 100 120 150 160 160 160 180 32 35
system -6 -6 -6 -6 -6 -6 -12 -12 -12 -6 -9 -12 -6 E3 E4
Fuel tank, 152 l 170 l
volume
Fuel Diesel according to:
quality EN590,
ASTM D 975 No 1-D,
ASTM D 975 No 2-D.
WARNING
It is important that only fuel in accordance with specified standards is used.
Fuel with higher sulphur content damages the engine and after-treatment system!
Use only low sulphur fuel.
AdBlue 15 l
tank,
volume
AdBlue AdBlue, according to ISO standard 22241.
quality
1.7 Engine, cooling system Cummins Cummins Cummins Volvo TAD761VE

QSB6.7 QSB6.7 QSB6.7 160 kW
129 kW 129 kW 164 kW Stage 3B/Tier 4i
Stage 3A/Tier 3 Stage 3B/Tier 4i Stage 3B/Tier 4i
Coolant volume 26 l 28 l 28 l 35 l
Coolant filling point ES Compleat, Premix Volvo Penta
Coolant VCS,
ready-mixed
CAUTION
Risk of engine damage and damage to the cooling system if
different types of coolant are mixed.
When changing and topping up coolant, the same type of
coolant must be used as was used before.
1.8 Engine, lubrication system Cummins Cummins Cummins Volvo TAD761VE

QSB6.7 QSB6.7 QSB6.7 160 kW
129 kW 129 kW 164 kW Stage 3B/Tier 4i
Stage 3A/Tier 3 Stage 3B/Tier 4i Stage 3B/Tier 4i
Oil type, quality See Oils and lubricants, recommendation, page 233.
Oil volume incl. filter 20 l 17 l 24 l

2.6 Transmission, lubrication ZF 3WG161 ZF 3WG171

system
Oil type See Oils and lubricants, recommendation, page 233

Oil volume 28 l
3.3 Power transmission, drive axle DCG90-180/DCG70-32E3 DCG70-35E4

Oil quality See Oils and lubricants, recommendation, page 233.
Oil volume, differential 17.5 l 18.5 l
Oil volume, hub reduction 2x2 l
9 Frame, body, cab and accessories Cab

Refrigerant air conditioning R134a
Volume refrigerant 1350 g (unless otherwise indicated on the air conditioning sign)
Lubricant air conditioning ZXL100PG
Lubricant quantity air conditioning 0.18 l (depending on compressor)
Volume, washer fluid Max. 6 l
DCG DCG
10 Com- DCG DCG DCG DCG DCG DCG DCG DCG DCG DCG DCG DCG DCG 70- 70-
mon hy- 90 100 120 127 140 150 100 120 150 160 160 160 180 32 35
draulics -6 -6 -6 -6 -6 -6 -12 -12 -12 -6 -9 -12 -6 E3 E4
Oil quality See Oils and lubricants, recommendation, page 233.
Oil Lubrizol 3%
additive
Volume 215 l 220 l
hydraulic
oil tank

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 15W/40
3:
SAE 10W/30
API: CH-4/SJ, CI-4/SK
ACEA: E5, E7 SAE 5W/30
Cummins: CES-20071,
CES-20072, CES-20076,
CES-20077, CES-20078
Cummins QSB6.7 Stage 3B/Tier
4i:
SAE 15W/40
API: CJ-4
SAE 10W/30
ACEA: E9-08
Cummins: CES 20081 SAE 5W/30
Volvo: VDS-3
SAE 15W/40
SAE 5W/30
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
Hypoid oil, API GL-5 and SAE 80W90
MIL-L-2105B
SAE 90
SAE 85W140
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.
ACEA = Association des Constructeurs Européenne d'Automobiles
API = American Petroleum Institute
CES = Cummins Engine Standard
VDS = Volvo Drain Specification
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 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 damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, the same type
of coolant must be used as was used before.

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

10 Terminology 239
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. lift and lower, 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.
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.
DPF Diesel Particulate Filter. Exhaust filter used to reduce the amount of unburned soot
particles in the exhaust gases. Filter regeneration is performed automatically. Fitted
to Cummins QSB6.7 164kW Stage 3B/Tier 4i engines.
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 system with thermostat-controlled cooling,
dehumidification and heating.
EHC Electric Heat Control. Heating system with thermostat-controlled heating.
EGR Exhaust Gas Recirculation. The emission control function where a part of the exhaust
gases are led back to the engine's intake to reduce nitrogen oxide emissions (NOx) from
the engine. Fitted to Cummins Stage 3B/Tier 4i engines.
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 trolley.

240 10 Terminology – Terminology
Term Description
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.
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.
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.
Trolley 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.
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 3B/4i 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.

10 Terminology – Terminology 241
Term Description
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.
Overhead guard 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 leaned 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.

242

11 Index – Index 243
Index Event menu service . . . .

Event menu speed limitation
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
86
87
Event menu start interlock . . . . . . . . . . . . . . 86
Event menu, clamped load . . . . . . . . . . . . . . 90
A Event menus . . . . . . . . . . . . . . . . . . . . 77
About the documentation kit . . . . . . . . . . . . . . 4
About the operator's manual . . . . . . . . . . . . . . 1
Air filter, engine . . . . . . . . . . . . . . . . . . . 190 F
ANSI/ITSDF marking . . . . . . . . . . . . . . . . 10 Fire . . . . . . . . . . . . . . . . . . . . . . . . 18
Foreword . . . . . . . . . . . . . . . . . . . . . . 1
Fuel system . . . . . . . . . . . . . . . . . . . . 185
B Functions for load handling . . . . . . . . . . . . . 169
Battery and battery disconnector . . . . . . . . . . . 203 Fuses for electrical system . . . . . . . . . . . . . . 206
C G
CE-marking . . . . . . . . . . . . . . . . . . . . . 9 Gearshifting . . . . . . . . . . . . . . . . . . . . 151
Central lubrication . . . . . . . . . . . . . . . . . 201
Checking the accumulator . . . . . . . . . . . . . . 200
Cleanliness . . . . . . . . . . . . . . . . . . . . 183 H
Control for load handling . . . . . . . . . . . . . . . 62
Control system . . . . . . . . . . . . . . . . . . . 73 Handling. . . . . . . . . . . . . . . . . . . . . . 98
Cooling system . . . . . . . . . . . . . . . . . . . 192 Heating / Air conditioning . . . . . . . . . . . . 71, 156
High exhaust temperature in the engine exhaust filter . . 79
High soot level in the engine exhaust filter . . . . . . . 79
Hydraulic release of parking brake . . . . . . . . . . 219
D Hydraulic system . . . . . . . . . . . . . . . . . . 196
Daily inspection . . . . . . . . . . . . . . . 101, 176
Description . . . . . . . . . . . . . . . . . . . . 20
Driver's seat . . . . . . . . . . . . . . . . . . . . 70 I
Identification of the machine . . . . . . . . . . . . . 20
E Ignition key lock and start and
engine . . . . . . . . . .
stop button for
. . . . . . .
the
. . . . . 44
Engine oil . . . . . . . . . . . . . . . . . . . . . 194 Inspection and maintenance . . . . . . . . . . . 5, 175
Engine operating menu . . . . . . . . . . . . . . . 75 Instruments and controls. . . . . . . . . . . . . . . 35
Environment and standards . . . . . . . . . . . . . 226
Error code indication . . . . . . . . . . . . . . . . 104
Error code information on display . . . . . . . . . . . 104
Error code tables . . . . . . . . . . . . . . . . . . 112
K
Error codes . . . . . . . . . . . . . . . . . . . . 102 Keep in mind . . . . . . . . . . . . . . . . . . . . 11
Event menu AdBlue . . . . . . . . . . . . . . . 79, 83
Event menu air filter air conditioning system . . . . . . 84
Event menu arm rest . . . . . . . . . . . . . . . . 89 L
Event menu battery charging . . . . . . . . . . . . . 88
Event menu brake temperature . . . . . . . . . . . . 78 Lifting and transporting the machine . . . . . . . . . . 221
Event menu control breaker . . . . . . . . . . . . . 87 Lifting load . . . . . . . . . . . . . . . . . . . . . 164
Event menu engine coolant temperature . . . . . . . . 80 Lifting machine . . . . . . . . . . . . . . . . . . . 222
Event menu heating rear view mirrors/rear windscreen . . 86 Lighting . . . . . . . . . . . . . . . . . . . . . . 213
Event menu height limitation . . . . . . . . . . . . . 81 Load handling . . . . . . . . . . . . . . . . . 61, 161
Event menu height warning . . . . . . . . . . . . . 80 Long-term storage . . . . . . . . . . . . . . . . . 225
Event menu intermittent wiper . . . . . . . . . . . . 87
Event menu low accumulator pressure . . . . . . 78, 82
Event menu low AdBlue level. . . . . . . . . . . . . 82 M
Event menu low coolant level engine . . . . . . . . . 88 Maintenance . . . . . . . . . . . . . . . . . . . . 180
Event menu low fuel level . . . . . . . . . . . . . . 83 Mechanical release of parking brake . . . . . . . . . 218
Event menu low washer fluid level . . . . . . . . . . 84 Menu for active error codes . . . . . . . . . . . . . 93
Event menu mini-wheel/joystick control, description . . . 89 Menu for date and time . . . . . . . . . . . . . . . 90
Event menu no driver in the seat . . . . . . . . . . . 83 Menu for inactive error codes. . . . . . . . . . . . . 94
Event menu oil temperature hydraulics . . . . . . . . 80 Menu for machine check . . . . . . . . . . . . . . . 96
Event menu oil temperature transmission . . . . . . . 80 Menu for services and settings . . . . . . . . . . . . 96
Event menu open door . . . . . . . . . . . . . . . 83 Menu for statistics and operating time history . . . . . . 94
Event menu overload lift . . . . . . . . . . . . . . . 81 Menus for customer settings . . . . . . . . . . . . . 90
Event menu overload lift and tilt. . . . . . . . . . . . 81 Multi-function lever . . . . . . . . . . . . . . . . . 60
Event menu overload tilt . . . . . . . . . . . . . . . 81
Event menu parking brake . . . . . . . . . . . . . . 82
Event menu preheating . . . . . . . . . . . . . . . 85
Event menu raise/lower cab temperature . . . . . . . 85
O
Event menu raise/lower fan speed . . . . . . . . . . 85 Operating . . . . . . . . . . . . . . . . . . . . . 148
Event menu release the parking brake . . . . . . . . . 84 Operating menu customer settings . . . . . . . . . . 77
Event menu rotate the operator's station . . . . . . . . 88 Operating menu electrical system . . . . . . . . . . . 76
Event menu seat belt . . . . . . . . . . . . . . . . 82 Operating menu scales . . . . . . . . . . . . . . . 76

244 11 Index – Index
Operating menu trip computer work shift . . . . . . . . 75 Steering wheel . . . . . . . . . . . . . . . . . . . 67

Operating menus . . . . . . . . . . . . . . . . . . 75 Stopping the engine - parking . . . . . . . . . . . . 158
Overview . . . . . . . . . . . . . . . . . . . . . 20 Switches . . . . . . . . . . . . . . . . . . . . . 46
Overview description . . . . . . . . . . . . . . . . 21
T
P
Terminology . . . . . . . . . . . . . . . . . . . . 239
Parking brake . . . . . . . . . . . . . . . . . . . 154 The event menu parking brake not activated and no driver
Pedals . . . . . . . . . . . . . . . . . . . . . . 65 in the driver's seat . . . . . . . . . . . . . . . . . 78
Plates . . . . . . . . . . . . . . . . . . . . . . . 27 Towing . . . . . . . . . . . . . . . . . . . . . . 217
Transmission and hydraulics operating menu . . . . . . 76
Transmission oil . . . . . . . . . . . . . . . . . . 196
R Transporting load . . . . . . . . . . . . . . . . . . 166
Reading instructions . . . . . . . . . . . . . . . . . 2 Transporting the machine . . . . . . . . . . . 216, 223
Revolving operator's station . . . . . . . . . . . . . 159 Travel direction selector and parking brake . . . . . . . 58
Running-in . . . . . . . . . . . . . . . . . . . . . 100 Tyres and rims . . . . . . . . . . . . . . . . . . . 197
S U
Safety . . . . . . . . . . . . . . . . . . . . . . . . 6 Unloading . . . . . . . . . . . . . . . . . . . . . 168
Safety and emergency equipment. . . . . . . . . . . . 8
Service . . . . . . . . . . . . . . . . . . . . . . 214
Service brake . . . . . . . . . . . . . . . . . . . 154 W
Service position . . . . . . . . . . . . . . . . . . 224
Shut off regeneration of the engine exhaust filter . . . . 85 Warming up . . . . . . . . . . . . . . . . . . . . 150
Specifications . . . . . . . . . . . . . . . . . . . 229 Warning and indicator lights . . . . . . . . . . . . . 41
Starting engine . . . . . . . . . . . . . . . . . . . 149 While operating. . . . . . . . . . . . . . . . . . . 148
Steering . . . . . . . . . . . . . . . . . . . . . . 153 Windscreen washer . . . . . . . . . . . . . . . . . 189

Declaration of Conformity
We, Cargotec Sweden AB, SE-340 10 Lidhult, (Registration No. 556014-5418) herewith
declare that the machine,
Type
Model DCG160-12
Serial No A404.XXXXX
Year of construction 2013
Engine Volvo TAD761VE
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 160 / 2050 kW/rpm

Measured sound power level LWA 108 dB
Guaranteed sound power level LWA 109 dB
Name
Position Head Of Counterbalanced Products
InfoString: 2A / KAT / O / G / GB / 20130529 / 135620
Authorized to compile the technical file
Place, Date of Issue Signature
Blnk.lxf
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 9-18 tonnes

Operator's Manual DCG 90-180 IDCG01.04GB

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 90-180 IDCG01.04GB

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

IDCG01.04GB Operator's Manual DCG 90-180

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

Operator's Manual DCG 90-180 IDCG01.04GB

1.2 About the documentation kit

There is supplementary documentation that can be ordered for the

Always indicate publication number when ordering.

IDCG01.04GB Operator's Manual DCG 90-180

1.3 Inspection and maintenance

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

Operator's Manual DCG 90-180 IDCG01.04GB

Important to read the operator's manual

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

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

IDCG01.04GB Operator's Manual DCG 90-180

• The machine may not be operated on public roads unless it has

Operator's Manual DCG 90-180 IDCG01.04GB

2.1 Safety and emergency equipment

The machine may be equipped with the following safety equipment:

IDCG01.04GB Operator's Manual DCG 90-180

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 90-180 IDCG01.04GB

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

IDCG01.04GB Operator's Manual DCG 90-180

2.4 Keep in mind

For machines with SCR-system (emission control):

During work shifts

Operator's Manual DCG 90-180 IDCG01.04GB

IDCG01.04GB Operator's Manual DCG 90-180

Operator's Manual DCG 90-180 IDCG01.04GB

IDCG01.04GB Operator's Manual DCG 90-180

Operator's Manual DCG 90-180 IDCG01.04GB

IDCG01.04GB Operator's Manual DCG 90-180

Operator's Manual DCG 90-180 IDCG01.04GB

IDCG01.04GB Operator's Manual DCG 90-180

Fire prevention measures

Make it a habit to make a visual inspection of the engine and engine

Action after fire

Operator's Manual DCG 90-180 IDCG01.04GB

The DCG 70-32E3-70-35E4 machine is a machine with mast for

This section provides a short presentation of the machine's parts, see

3.1.1 Identification of the machine