DRF Operations Manual

DRF 400-450
Publ. no IDRF03.01GB
1 Foreword .................................................................................................. 3
1.1 About the Operator’s manual .................................................................... 3
1.2 About the documentation kit .................................................................... 6
1.3 Inspection and maintenance ..................................................................... 6
2 Safety ....................................................................................................... 7
2.1 Safety and emergency equipment ............................................................ 8
2.2 CE-marking ............................................................................................... 10
2.3 ANSI/ASME-marking ................................................................................ 10
2.4 Keep in mind ............................................................................................ 11
3 Overview ................................................................................................ 17
3.1 Description DRF 400-450 ......................................................................... 17
3.2 Plates ........................................................................................................ 23
4 Instruments and controls ...................................................................... 29
4.1 Warning and indicator lights .................................................................... 34
4.2 Instruments .............................................................................................. 38
4.3 Ignition ..................................................................................................... 39
4.4 Switches ................................................................................................... 40
4.5 Gear selector and
multi-function lever .................................................................... 48
4.6 Control lever ............................................................................................ 50
4.7 Pedals ....................................................................................................... 53
4.8 Steering wheel ......................................................................................... 54
4.9 Operator’s seat ........................................................................................ 57
4.10 Heating/Air conditioning .......................................................................... 60
4.11 Control and monitoring system ............................................................... 63
5 Handling ................................................................................................. 75
5.1 Running-in ................................................................................................ 77
5.2 Daily inspection ........................................................................................ 78
5.3 Error codes ............................................................................................... 79
5.4 Operating ............................................................................................... 112
5.5 Load handling ......................................................................................... 123
6 Inspection and maintenance ............................................................... 141
6.1 Daily inspection ...................................................................................... 142
6.2 Maintenance .......................................................................................... 145
6.3 Service .................................................................................................... 170
7 Transport of machine .......................................................................... 171
7.1 Towing .................................................................................................... 172
7.2 Lifting and transporting machine ........................................................... 174
7.3 Service position ...................................................................................... 186
7.4 Long-term storage ................................................................................. 186
8 Environment and standards ................................................................ 187
9 Specifications....................................................................................... 189
10 Terminology ......................................................................................... 199
1 Foreword 3
1 Foreword
1 Foreword
mm mm mm mm
1.1 About the Operator’s

manual
General
page
–
Thank you for choosing Kalmar Industries as your machine supplier.

We hope that we’ll meet your expectations.
This Operator’s manual contains information that you must keep in
mind for safe handling and optimal use of your new machine.
Purpose of the Operator’s manual

–
This Operator’s manual applies to machine DRF 400-450.

The Operator’s manual describes how the machine should be oper-
ated and maintained in a correct manner.
Storage
–
The Operator’s manual should always be kept in the machine.
About the machine version

–
The information in this Operator’s manual corresponds to the ma-

chine’s design and appearance at the time of delivery from Kalmar
Industries. Due to customer adaptations, there may be variations
and/or deviations.
Kalmar Industries reserves the right to modify specifications and
equipment without prior notice. All information and data in the man-
ual are valid at the time of publication.
Copyright
–
Kalmar Industries AB
Duplication of the content in this manual, in whole or in part, is
strictly prohibited without written permission from Kalmar
Industries AB.
Duplication by any means, such as copying, printing, etc., is strictly
prohibited.
Manufacturer
–
This machine is manufactured by Kalmar Industries AB,

Torggatan 3, SE-340 10 Lidhult, Sweden.
Operator’s manual DRF 400-450 IDRF03.01GB

4 1 Foreword – 1.1.1 Reading Instructions
1.1.1 Reading Instructions

Warning information
page
–
This Operator’s manual contains warnings that involve your safety.

The warnings provide information on potential dangers that, if not
heeded, could lead to personal injury or product damage.
D AN GE R
Situation that could lead to severe personal injury or
death if regulation is not followed.
W AR N IN G
Situation that could lead to personal injury if regula-
tion is not followed.
CAUTION
Situation that could lead to product damage if regu-
lation is not followed.
Important information
–
Important information is denoted with NOTE and is intended to facil-

itate the work process, handling or to increase understanding of the
information.
NOTE
Important information not related to safety.
IDRF03.01GB Operator’s manual DRF 400-450

1 Foreword – 1.1.1 Reading Instructions 5
Read 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 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

Optional equipment
–
There is a wide range of optional equipment for the machine. Each
000264
description of optional equipment in the Operator’s manual is
marked with a symbol and contains an explanatory text. The symbol
Indicates optional equipment is highly visible and is placed next to the text and figure item in
question.
See the machine card for complete specifications of the machine’s
product alternatives and optional equipment.

6 1 Foreword – 1.2 About the documentation kit
1.2 About the documentation

kit
The documentation kit
page
–
The following documentation is supplied with the machine:

• Operator’s manual DRF 400-450 (in cab with machine)
• Maintenance manual DRF 400-450
• Spare parts catalogue with machine card
There is supplementary documentation that can be ordered for the
machine:
• Manual kit with Workshop manual DRF 400-450 and suppliers’
documentation for engine, transmission and drive axle.
• Workshop manual DRF 400-450.
All documentation can be ordered from Kalmar Industries.
Ordering of documentation
–
Copies of the Operator’s manual and maintenance manual can be

ordered from Kalmar Industries:
Kalmar Industries AB, SE-341 81 Ljungby, Sweden.
Always indicate publication number when ordering.
1.3 Inspection and maintenance

General
page
–
For satisfactory function of the machine to the lowest cost, mainte-

nance must be performed correctly. Intervals for inspection and
maintenance refer to normal environment and operating conditions.
Maintenance work described in this operator’s manual can be per-
formed by the operator, see chapter 6 Inspection and maintenance.
This section describes the running checks and actions that the oper-
ator should perform in connection with starting work shifts.
Maintenance
–
For other maintenance not included in this Operator’s manual (serv-

ice and repairs), contact an authorized brand name workshop.

2 Safety 7
2 Safety
2 Safety
mm mm mm mm
General
page
–
Safety rules are intended to reduce the risk of personal injuries as

well as damage to the load or other property.
Important to read the Operator’s

–
manual
Incorrect handling can lead to personal injuries and damages to
product and/or property. Therefore, read the Operator’s manual
very thoroughly before starting to use the machine. The Operator’s
manual contains important information about your Kalmar machine,
handling the machine, safety during operation, and daily mainte-
000262
nance of the machine. You’ll also find a lot of valuable information

that will make your work easier.
The Operator’s manual should always be kept in the machine. If it’s
lost, replace it immediately with a new Operator’s manual.
NOTE
Never use a machine that doesn’t have an Operator’s manual.
Ask your foreman or supervisor if there’s anything in the text you do
not understand or if you feel information is missing in any area.
Intended use
–
• The machine may only be used for the purpose for which it is de-
signed and adapted, that is, to lift and transport goods (the
weight of which is not to exceed the machine’s max. allowed
load capacity). If it’s used in another way or in potentially
dangerous environments (for example, explosive environment,
area with dust containing asbestos), special safety regulations
must be followed and the machine must be equipped for such
operation.
• The machine may not be modified or rebuilt so that its function
or performance is altered, for example, areas that affect lift ca-
pacity, visibility conditions from the cab, protective equipment,
brakes, steering or lift equipment, without specific permission
from Kalmar Industries. When modifications/rebuilds authorized
by Kalmar Industries have been performed, the affected machi-
ne plates and documentation shall be adapted so that they are
valid for the modification/rebuild.
The machine may only be modified or rebuilt if Kalmar Industries
accepts product responsibility (without any other manufacturer
assuming the product responsibility). Modifications and rebuilds
may only be performed if there is knowledge for implementing
and testing modifications and rebuilds. Modifications and

8 2 Safety – 2.1 Safety and emergency equipment
rebuilds shall be documented (date and actions) and the respon-

sible organization shall be indicated with name and address.
Plates and decals shall be updated according to the machine’s
new version.
• 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 according to
governing regulations.
• The machine is designed for use in outdoor temperatures -40 to
40 °C, relative humidity 10 to 90% and max. wind speeds 12.2
m/s. In case of deviation from this, contact Kalmar Industries.
Operator requirements
–
• The machine may only be operated by specially trained opera-

tors who have the management’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
regulations.
Prohibited operation of machine

–
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 the machine has been repaired, modified or adjusted without
the supervisor’s/work management’s permission.
• If the machine is fitted with tyres not approved by
Kalmar Industries.
• Overload system (OP) for load handling is not working.
2.1 Safety and emergency

equipment
General
page
–
A good working environment has safety and warning equipment to

make the operator’s work easier and safer.
The machine may be equipped with the following equipment:
1. Back-up alarm
2. Rotating beacon
3. Horn
4. Electrically powered loud air horn

2 Safety – 2.1 Safety and emergency equipment 9
5. Fire extinguisher
A fire extinguisher may also be located externally.
If the machine is provided 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 or-
ganic materials and fluids. Adapted fire extinguishing equipment
can be ordered from Kalmar Industries.
6. Seatbelt
For hydraulic vertically adjustable cab, there’s always a seatbelt
and safety chains by the doors.
7. Buzzer in cab to indicate alarm, overload or forgotten action, for
example, leaving cab without applying the parking brake.
8. TV-camera with monitor

Used to give improved rearward visibility during operation of the
machine. Monitor is located inside the cab on the left side.
9. Back-up light
10. External rear-view mirrors
Used to give improved visibility when operating and load han-
dling. One rear-view mirror on each side.
11. Control breaker for hydraulics
Cuts off all power supply and control signals to hydraulics.
12. Emergency exit, right door and rear window ( )

(Not positioned in figure).
2
7
1, 8, 9 11
4
003637
5 6 3 10

10 2 Safety – 2.2 CE-marking
2.2 CE-marking
CE-marking
page
–
(Declaration of Conformity, only applies to machines sold

within the EU/EEA).
This machine is CE-marked. This means that, when delivered, it ful-
fills the applicable "Essential Health and Safety requirements", stat-
ed in EU’s Machine directive, 98/37/EG as well as other applicable
EU directives for the machine type.
As proof that the requirements have been fulfilled, an EU Declaration
of Conformity is supplied, issued by Kalmar Industries for each and
every machine. This EU Declaration of Conformity also covers at-
tachments and options made by Kalmar Industries. The documenta-
tion is valuable and should be kept in a safe location and saved for
003584
0
at least 10 years. The documentation should always accompany the
machine when it is sold.
Machine plates for CE-marking, machine and Any person performing modifications or changes affecting the ma-
attachment chine’s safety is also responsible for the same. Safety must be en-
sured in each separate case if the machine is used for other
purposes or with other attachments than described in these instruc-
tions. The machine owner is responsible for ensuring that the ma-
chine is used as described in the Operator’s Manual. Areas of use
may in certain cases require new CE-marking as well as issuance of
a new EU Declaration of Conformity.
For further information, see standards in section 8 Environment and
standards.
2.3 ANSI/ASME-marking
ANSI/ASME-marking
page
–
Only applies to machines for the North American market).

Kalmar Industries AB
SE-341 81 Ljungby Sweden
This machine is ANSI/ASME-marked. This means that, when deliv-
M ered, it fulfills the basic safety requirements according to ANSI/
S/N
ASME B56.1.
Q kg
W kg Any person performing modifications or changes affecting the ma-

L4 mm L5 mm L6 mm chine’s safety is also responsible for the same.
H4 mm
kg Safety must be ensured in each separate case if the machine is used
H mm
kg for other purposes or with other attachments than described in
H
H mm
kg these instructions. The machine owner is responsible for ensuring
H mm
kg that the machine is used as described in the Operator’s Manual.
H mm
003585
"In compliance
L kg For further information, see standards in section 8 Environment and
standards.
A32653.7200
with ANSI/ASME B56.1 Part III"
Machine plates for ANSI/ASME-marking, machine

and attachment

2 Safety – 2.4 Keep in mind 11
2.4 Keep in mind

During work shifts
page
–
D AN GE R
The attachment is a tool that handles heavy loads.
Never walk under a suspended load!
Fatal danger and risk of property damage!
D AN GE R
The machine’s work area is large and visibility from
the operator’s cab is restricted.
Keep in mind:
• Always check that no persons are in the way of

the machine or its equipment.
• The operator must always face in the travel di-

rection and should operate with special care
where persons or vehicles may appear.
• The operator shall adjust travel speed according
to the nature of the load, visibility conditions,
road conditions, etc.
• The operator should pay extra attention and

operate with special care near electrical power
lines, viaducts, docksides, ramps, gates/doors,
etc.
• Always operate carefully so that the attachment

does not collide with posts, power lines, etc.
• Use available visibility equipment such as rear-

view mirrors and TV-camera when
reversing.

12 2 Safety – 2.4 Keep in mind
W AR N IN G
Transport of loads is associated with great risks.
Risk of roll-over and tipping over! Risk of load dam-
age to property!
Respect the machine’s lift capacity and operate

with great care during load handling:
• The machine shall only be operated on even sur-

faces, intended for the machine’s total weight
and ground pressure.
• All loads should be carried in the transport posi-
tion. Always operate carefully, keep in mind the
width and height, so that the boom or attach-
ment does not collide with posts, power lines,
etc.
• Do not transport the load in high position 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 transpor-

ted load obscures visibility to the front.
• No personnel may enter/stand under a raised

load.
• The operator should avoid powerful acceleration

and braking.
• The operator should always adjust the speed

when turning to prevent skidding and risk of
roll-over or tipping over.
In case the machine rolls over or tips, always

stay in the cab. Do NOT try to jump out of the cab
until the machine has stopped moving.

W AR N IN G
The machine’s load capacity is limited!
Risk of roll-over and tipping over!
It is prohibited to exceed the machine’s load capac-

ity. See marking plate and load diagram. The ma-
chine’s stability limit may be exceeded if the
overload protection system is not working.
W AR N IN G
The strength of the roof window may be significant-
ly reduced in case of exposure to substances con-
taining aromatic hydrocarbons, ketones, esters or
chlorinated hydrocarbons.
Low strength! Danger!
Check the outside surface of the roof window at

regular intervals. Clean only with windshield wash-
er fluid or a mild cleaning agent. Rinse thoroughly
with plenty of lukewarm water. Replace a damaged
roof window immediately if it’s cracked or
scratched!
W AR N IN G
Lifting loads in very windy conditions and high wind
speed is associated with great difficulties. Avoid lift-
ing loads when wind speeds exceed 12.2 metres
per second.
W AR N IN G
The machine emits exhausts during operation. If
possible, avoid operating the machine indoors in
poorly ventilated facilities. Use exhaust venting
equipment!
Health hazards in poorly ventilated facilities!

W AR N IN G
Work position on the machine is located up high.
Always use the steps and handles when you climb
up or down from the machine. Always face the ma-
chine. Do not jump!
Risk of falling and body injury!
W AR N IN G
Always close the operator door(s) during the work
shift.
Risk of personal injury and crushing in case of roll-

over and tipping!
W AR N IN G
Passengers are only allowed in the cab if there is a
permanently mounted extra passenger seat. It is
prohibited to carry passengers on the machine out-
side the cab or on the load.
Risk of personal injury!
W AR N IN G
The cab has the sliding cab feature, manual or hy-
draulic ( ). The cab shall ALWAYS be in its rear-
most position when operating.
Warning - risk of crushing!
For manual sliding cab, always make sure that the

cab is locked in its rearmost position before operat-
ing, and that the locks on both sides are secured
with the lock pins.
For hydraulic longitudinal displacement, the cab

may be positioned as desired (locking is automatic)
during stationary load handling.

W AR N IN G
The machine’s hydraulic system includes accumula-
tors with high pressure.
Always be very careful when working with the hy-

draulic system, and avoid standing close to hydrau-
lic components or hoses. Before working on the
hydraulic system, the accumulators must be
drained (see Maintenance manual).
W AR N IN G
Handle batteries and connectors with great care
during charging and boosting (auxiliary start).
Risk of short-circuiting and generation of hydrogen

gas!
Batteries should always be provided with protective

caps over the terminals and connections. Connect
the positive (plus) terminals first. Then connect the
negative (minus) terminals to prevent sparks that
may ignite the hydrogen gas.
W AR N IN G
The machine contains oils and lubricants. Avoid skin
contact with oils and lubricants. Wear protective
gloves.
Health hazard in case of long-term skin contact!
CAUTION
Cracks or scratches result in reduced strength of
the roof window. Replace a damaged roof window
immediately.
Low strength!

CAUTION
The parking brake can be used as an EMERGENCY
BRAKE.
Brake pads wear out and lose their braking perform-
ance! Unwanted movement of parked machine!
Following emergency braking with the parking

brake, check the brake pads as soon as possible,
change if needed! Braking action of the parking
brake may be lost as the brake pads may have been
worn down.
If the parking brake has been released mechanical-

ly, it must always be reset to restore the machine’s
parking brake functions.
NOTE
Mobile phone and communication radio may be used in the
cab.
The equipment should not be used while operating or handling
loads, as your concentration on operating is reduced.
Kalmar Industries will not assume any responsibility for optional
equipment not installed by Kalmar Industries or non-approved
installations.
Interrupted operation and/or parking

–
NOTE
Never leave the operator’s seat without first applying the park-
ing brake (ON position).
NOTE
Always remove the start key if the machine is to be left
unattended.

3 Overview 17
3 Overview
3 Overview
mm mm mm mm
3.1 Description DRF 400-450

General
page
–
Machine DRF 400-450 is a reachstacker for handling containers and

trailer goods (for bottom lift attachment). It has a lift capacity of 40 to
45 tonnes and a lift height of up to 5 or 6 containers (8’6"-containers).
3.1.1 Identification of the machine

Type designation of reachstacker
page
–
Each Kalmar machine has a type designation. Example: type desig-

nation DRF 450-65S5XS indicates the following:
• D – Diesel engine
• R – Reachstacker
• F – Generation
• 450 – Lift capacity, 1st row, decitonne
• 65 – Axle distance, decimetre
• S – Spreading, adjustable top lift
• 5 – Max. no. of containers when stacking
• X – Extra counterweight
• S – Support jacks
Machine card
–
It is possible to modify and adapt Kalmar Industries’ machines in dif-

ferent ways with product alternatives and optional equipment. This
makes it possible to satisfy a very wide range of customers.
A machine card is delivered together with the spare parts catalogue.
The machine card contains a complete specification of the ma-
chine’s product alternatives and optional equipment.
The machine card shall be updated when the machine is modified
and Kalmar Industries shall be informed.

18 3 Overview – 3.1.2 Overview description
3.1.2 Overview description

General
page
–
This section provides a short presentation of the machine’s parts,

which are pointed out in the overview figure below.
7 6
003670
1 2 3 4 5
1. Steering axle
2. Engine
3. Transmission
4. Drive axle
5. Attachment
6. Boom
7. Cab

3 Overview – 3.1.2 Overview description 19
Engine
–
The machine has several engine options. The engines are straight
6-cylinder, turbocharged low-emission engines with intercooler. The
engine provides power for propulsion and working hydraulics.
The machine is equipped with one of the following engine options:
• Volvo TAD1250VE
• Volvo TWD1240VE
• Cummins QSM11
Transmission
–
The transmission is fully automatic with a torque converter. It has

4 forward gears and 4 reverse gears. The hydraulic pumps for work-
ing hydraulics are mounted on the transmission.
The machine is equipped with Dana TE32000.
Drive axle
–
The drive axle (front axle) is equipped with a differential and hub re-
ductions of the planetary gear type.
Brakes
–
The machine has one brake circuit and is equipped with hydraulically
operated brakes. The brake units consist of fully sealed oil-cooled
disc brakes with external cooling.
The parking brake is controlled electro-hydraulically and brakes with
a disc brake. The disc brake acts on the drive axle’s input shaft.
The parking brake is applied by spring force and is released with hy-
draulic pressure. The parking brake is applied automatically if the ig-
nition is turned off.
Steering
–
The machine is steered with the rear axle. A double-acting hydraulic

cylinder acts on the wheel pair. Steering is progressive, that is, a
quick movement of the steering wheel gives a greater steering angle
per steering wheel turn. This makes the machine easier to operate
in tight areas.
Load handling
–
The boom and attachment are used for load handling. The boom is
operated vertically (angle) and longitudinally (length).
Attachments are available in different versions. The attachment
holds the load. Securing of the load and operation of the attachment
is controlled electro-hydraulically.

One of the following alternatives is selected for the machine:

• Top lift attachment with sideshift ±800 mm.
• Top lift attachment with hydraulic levelling (with sideshift
±800 mm).
• Top lift attachment with overheight legs.
• Bottom lift attachment (handles containers and trailers).
• Tool carrier (handles different lifting tools).
Electrical system
–
The electrical system consists of electrical and electromagnetic

components such as battery, switches, cable harnesses, solenoid
valves, fuses and relays.
Control and monitoring system

–
The machine has a computer-based control and monitoring system

for monitoring and controlling the machine’s functions as well as
handling all functions in the machine, such as power electronics,
drivetrain and hydraulic system. The control and monitoring system
facilitates maintenance.
Cab
–
The cab is available in one version. Instrumentation and equipment

(steering wheel, operator’s seat, fresh air system) are customer-
adaptable and model-adapted.
• Cab Spirit Delta
Spirit Delta is a closed cab constructed of a structural frame to
withstand falling loads in accordance with applicable standards.
It is equipped with a fresh air system with filtered inlet, recircu-
lation as well as heating and air conditioning ( ).
The roof window is made of high-strength material and with-
stands heavy blows, for example, from falling objects.
The cab can be moved fore-aft, either manually or hydraulically
( ), or vertically adjustable ( ).
Hydraulic system
–
The hydraulic system is divided in two parts, working hydraulics and

brake system.
The working hydraulics consist of hydraulics for steering, load han-
dling and cab functions. The working hydraulics are supplied from
four variable axial piston pumps and a fixed gear-pump for cleaning
and cooling of the hydraulic oil. The hydraulic oil is cleaned with low-
pressure filter in the hydraulic tank and/or high-pressure filter ( )
after the hydraulic pumps.
The brake system is separated from the working hydraulics with its
own tank, fixed gear-pump, high-pressure filter, accumulators and
cooler.

3 Overview – 3.1.2 Overview description 21
Other equipment
–
17 23 1 26, 27 5, 22 35 15, 16 26, 27 11 12 14 13
006439
6, 17 18 3 4 2 24, 25 28, 29 28, 29 23, 24 2 20 31 7 35 36
1 Interior rear-view mirror

2 External rear-view mirrors
3 Horn
Located under cab.
4 Noise insulation under engine compartment
5 Electrically powered loud air horn

Located at leading edge cab.
6 Back-up alarm
7 Passenger seat
8 Tinted windows (Not positioned in figure)
9 Openable window left door (Not positioned in figure)
10 Openable window right door (Not positioned in figure)
11 Sun visor, front windshield

Adjustable up-down with string. Select position with string lock.
12 Sun visor, roof window

Can be pulled out to leading edge. Secured in position with two
hooks.
13 Sun visor rear window

Adjustable up-down with string. Select position with string lock.
14 Sound system, 24 VDC

User’s instructions supplied.
15 Writing table with light
16 Printer for load printouts
17 TV-camera with monitor

For improved rearward visibility. The camera is located on the
counterweight and the monitor is located inside the cab.

18 Socket 24 VDC
The socket is located on the right side behind the operator’s
seat and is routed across a fuse.
19 Slip-protection on steps (Not positioned in figure)
Can be equipped with optional slip-protection on tank and
counterweights
20 Steps with rail by cab steps
21 Steps with rail by mudguard

(Not positioned in figure)
Located on left side.
22 Steps to cab roof
23 Work lights cab roof, 2 lights
24 Work lights front fender, 2 lights
25 Extra work lights front fender, 2 or 4 lights

Replaces headlight front fender.
26 Work lights boom, 2 lights
27 Extra work lights boom, 2 lights

28 Work lights attachment, 2 lights
29 Extra work lights attachment, 2 lights
30 Work lights bottom lift attachment, 2 lights

(Not positioned in figure)
31 Lockable tank cap
32 Tool kit (Not positioned in figure)

Located in battery compartment on left side.
33 Auxiliary heater: (Not positioned in figure)

Equipment kit 1: engine and cab heater
Equipment kit 2: start interlock, engine and cab heater, tank
warmer hydraulics and brake system
34 Pause heater (Not positioned in figure).
35 Central lubrication machine and attachment
36 Elevated air inlet with or without pre-cleaner

3 Overview – 3.2 Plates 23
3.2 Plates
Product plates Europe
page
–
The following shows the product plates that should be fitted on the
machine when operating in Europe. When ordering spare parts and
when enquiring per telephone or correspondence, the model desig-
nation and serial number shall be given according to the plates. The
plates’ spare part number is indicated on respective plate.
003672
1, 3 1, 3
1 Machine plate (example), A32653

M= Machine model
S/N= Serial number/Year of manufacture
Q = Machine’s classed lift capacity acc. to EN1459
W = Machine’s operating weight (without load)
L = Distance between leading edge of wheels and load’s centre
of gravity
H = Classed lift height
Field H and L indicate how big a load the machine can handle at
006486
a specified attachment height (H) and distance from the ma-

0
chine’s leading edge (L).

Machine plate can only be ordered with complete engraving.
2 Type plate for attachment (example)
S/N= Serial number/Year of manufacture.
Lower field indicates year of manufacture.
Type plate can only be ordered with complete engraving.
006487
3 Additional plate for optional equipment (example)

Plate appearance depends on type of optional equipment.
L4 mm L5 mm L6 mm
Example plate is for machine with support jacks.
H4 mm
H mm S/N= Serial number/Year of manufacture.

H mm A= Identification number for attachment.
H
H mm
H= Lift height.
H mm
006488
L= Distance from machine’s leading edge (lift capacity).

L A32654.0300
Plate can only be ordered with complete engraving.

24 3 Overview – 3.2 Plates
Warning and information plates

–
The following figures show the warning texts and information texts
that are located on the machine. The operator shall 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 always are easy to see and legible. Plates that have
been damaged, illegible or painted over must be replaced
immediately.
1b 1a 1b 19 1b 1a 1b
14 5 16 20 14 14 17 6 20 10 8 14
18 20 1a
4
2 9 12 11 13,15 003674
7
Chassis, cab
1 Lift point, 423049.0100
Attaching point for lifting device when lifting the machine and
boom. For lifting machine (1a):
• front part of frame
000276
• rear part of frame by boom mounting

For lifting boom (1b):
• front part of boom
• rear part of boom
2 Warning! A26939.0200
Emergency lowering, see section 6.2 9 Hydraulic system for
000278
information.

3 Warning! A30536.0300
No passengers allowed. Passengers may only ride in the cab if
it’s equipped with a permanently mounted passenger seat.
000280
4 Warning! A30770.0100
Air conditioning. Filling of refrigerant requires special compe-
tence and authorization (follow national legislation and local
000281
rules).
5 Warning! A30770.0200
Air conditioning. Located on right frame member.
Filling of refrigerant requires special competence and authori-
zation (follow national legislation and local rules).
000282
6 Warning! A30770.0300
Air conditioning. Filling of refrigerant requires special compe-
tence and authorization (follow national legislation and local
rules).
1= Refrigerant, type
2= Amount, kg
1
3= Pressure, bar
2
3
006490
Safety
7 Warning! A32442.0100
Do not jump. Always stay in the machine when there’s a risk of
roll-over and hold on to the steering wheel.
000284

Electrical system
8 Battery disconnector, A30537.0300
In position 0, the battery’s plus terminal is disconnected.
004841
9 Plate battery voltage, A30534.0200
Turn off the battery voltage (with battery disconnector) when
removing/installing boom. Otherwise sparks and short-
circuiting may occur.
001979
A30534.0200
Engine
10 Filling point, fuel, 450202.0100
D
000286
450202.0100
11 Warning! A30530.0100
Rotating fan.
000287
12 Warning! A30532.0100
Hot surfaces.
000288
13 Filling point, engine oil, A32439.0500

000289
Power transmission, wheels

14 Air pressure tyres 1.0 MPa, A32049.0100
NOTE
000290
Read chapter 6 Inspection and maintenance regarding

safety when handling wheels.
If factory-installed tyres are replaced with another tyre
brand, then the conditions for tyre pressure change! Con-
tact Kalmar Industries. Plate for air pressure in tyres must
be replaced with plate which has current pressure!

15 Filling point, transmission oil, A32439.0200
000291
Hydraulic system
16 Filling point, hydraulic oil, 450203.0100
17 Pressure hydraulics, 920643.0024 (plate below)
000292
Indicates set pressures for machine. Information is engraved.
MPa
MPa
MPa MPa MPa

MPa
MPa
MPa MPa 000293
920643.0024
18 Warning! A30529.0100
Pressure. Always release the pressure from the accumulators
before working on the hydraulic system.
Work with the hydraulic system shall always be done by author-
ized personnel!
000294

Attachment
19 Warning! A30533.0200
Rotating parts.
000853
20 Warning! A32440.0100
Do not walk or stand under a suspended load.
D AN GE R
The attachment is a tool that handles heavy loads.

Never walk under hanging loads.
000296

4 Instruments and controls 29
4 Instruments and controls
4 Instruments and
mm mm mm mm
controls
General
page
–
Do not operate the machine before you know the position and func-
tion 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.

30 4 Instruments and controls
Overview
–
1 2 3 4 5
15
12 13 12 11 10 9 8 7 6
006457
14
Overview
1 Left instrument panel
2 Gear selector and multi-function lever
3 Steering wheel panel
4 Steering wheel
5 Direction indicators
6 Panel for hydraulic functions
7 Control breaker for hydraulics
8 Switch for parking brake
9 Control lever
10 Operator’s seat
11 Accelerator
12 Brake pedals
13 Clutch pedal
14 Electrical distribution box with fuses and relays
15 Hour meter (operating hours)
A Joystick or mini steering wheel

Instrument panel
16 Switch for fan
17 Switch for heat
18 Switch for air distribution
29 30 31 19 Switch, work lights cab roof
24..28
20 Switch, work lights attachment
19..23
21 Switch, work lights boom
18
17 22 Switch, rotating beacon
006456
16 23 Switch, flashing hazard lights
Instrument panel 24 Switch, headlights
25 Switch for seat heating

26 Spare
27 Spare
28 Switch for pause heater

29 Spare
30 Spare
31 Socket 12 VDC

32 4 Instruments and controls
Steering wheel panel

32 Warning light, low battery charging
36
35 33 Warning light, low brake pressure
34
33 34 Indicator light for active error codes
32
35 Warning light, by-pass of hydraulic functions
36 Indicator light, activated steering with joystick or mini-wheel
37..41 49 37 Warning light, high coolant temperature
42..46 38 Warning light, low oil pressure in engine
47 48 39 Indicator light, preheating

40 Warning light, low coolant level engine
41 Warning light, high oil temperature in transmission
42 Warning light, low fuel level
50 51 52 53
43 Warning light, high temperature hydraulic oil
44 Indicator light, high beams
45 Indicator light, direction indicators
46 Indicator light, parking brake
47 Indicator light, locked twistlocks (secured load)
48 Indicator light, alignment (attachment / load)
64 49 Indicator light, unlocked twistlocks (load released)
54
63 50 Panel, warning and indicator lights
55
62 51 Display, control and monitoring system
56
52 Indicator, control and monitoring system
005073
61 60 59 58 57
53 Ignition
Steering wheel panel with panel for warning and in- 54 Switch for defroster
dicator lights
55 Switch, windshield wiper roof, interval
56 Switch, windshield wiper roof, continuous
57 Switch, interior lighting
58 Switch, windshield wiper rear, interval
59 Switch, windshield wiper rear, continuous
60 Function keys, control and monitoring system
61 Travel direction indicator, Forward Neutral Reverse
62 Switch, shifting program A, Automatic shifting
63 Switch, shifting program 1, locked to 1st gear
64 Switch, shifting program 2, locked to 2nd gear

Panel for hydraulic functions
65 Switch, bottom lift attachment, front legs

65 66 67 68
66 Switch, bottom lift attachment, rear legs
67 Switch, rotation stop
69..72 Switch, height limitation
Switch, LC-limitation (load centre)

68 Spare
73
69 Switch, twistlocks, automatic/manual locking
74
76 70 Switch, bottom lift attachment, clamping position
75
006454
Switch for lowering overheight legs
Panel for hydraulic functions 71 Switch for 30’ stop
72 Switch, hydraulic sliding cab
Switch, hydraulic vertically adjustable cab
73 Indicator light, support jacks
74 Switch, support jacks
75 Switch for automatic spreading 20’ to 40’

76 Switch, by-pass of hydraulic functions

34 4 Instruments and controls – 4.1 Warning and indicator lights
4.1 Warning and indicator lights

General
page
–
This section describes the warning and indicator lights in the cab.
The lights indicate status of sub-systems/systems. An activated
warning light should be attended to immediately. An activated indi-
cator light informs of imminent action.
All lights in the panel are activated briefly at start. Warning and indi-
cator lights are concentrated in a panel on the steering wheel panel
(position 50).
Numbers in brackets refer to the positions in the section Overview
page 30.
Warning light, low battery charging (32)

–
The light (red) warns in case of missing charge to the batteries. The
light is activated if the voltage from the alternator is lower than the
000297
battery voltage.
If the warning light remains lit, switch off the engine and contact
service.
NOTE
Do not operate with an activated light for low battery charging.
Warning light, low brake pressure (33)

–
The light (red) is activated when the pressure in the accumulator,

that is, the brake pressure is too low. After the light has been acti-
000298
vated, the capacity of the service brake is limited.

Check the accumulators’ sealing if the pressure does not build up
and isn’t maintained, see chapter 6 Inspection and maintenance.
Indicator light for active error codes (34)

–
The indicator light (orange) indicates that the control and monitoring
system has one or more error codes, active or passive. For detailed
000299
information, see section 5.3 Handling error codes.

The indicator light is activated for as long as there are active error
codes (STOP, WARNING or INFORMATION).
Warning light, by-pass (35)

–
The warning light (orange) shows that by-pass of safety functions for
hydraulics is in progress.
000300
NOTE
By-pass can only continue for 60 seconds at a time.

4 Instruments and controls – 4.1 Warning and indicator lights 35
Indicator light, activated joystick or mini

–
steering wheel (36)
The indicator light (green) lit when joystick steering or mini-wheel

steering is activated.
000301
Warning light, high coolant temperature (37)
–
The light (red) is activated if engine coolant temperature is too high.

Determine the cause and take appropriate action.
000302
If the warning light remains lit, switch off the engine to allow the
coolant to cool. If the indicator remains lit when the machine is re-
started, contact service.
Warning light, low oil pressure in engine (38)

–
If the light (red) is activated during operation, pressure is very low.

Stop the engine immediately. Determine the cause and take appro-
000303
priate action. Contact service.
Indicator light, preheating (39)

–
For engine alternative Volvo TAD1250VE and Volvo TWD1240VE

The light (orange) is activated during the engine’s preheating period.
When needed, preheating warms the engine’s inlet air to a suitable
000304
temperature with a heating coil when the ignition is in position II.

When needed, the engine’s control unit activated preheating during
a time period.
Engine can be started, position III (start position), regardless of if pre-
heating is in progress, not activated (no need) or has been finished.
Warning light, low coolant level engine (40)

–
If the light (red) is activated while operating, the coolant level is too
low.
Check and top up, if needed. For action, see chapter 6 Inspection
000305
and maintenance.
For engine alternative Volvo TWD1240VE: If there is no coolant in the
expansion tank, the engine turns off. The engine can be started and
run for another 20 seconds before the engine shuts off again.
Warning light, high oil temperature in

–
transmission (41)
The light (red) is activated if the transmission oil temperature is too
high. Stop the machine and let the engine run at idle speed. Deter-
mine the cause and take appropriate action. Contact service.
000306

36 4 Instruments and controls – 4.1 Warning and indicator lights
Warning light, low fuel level (42)

–
The light (orange) indicates when the fuel level is low. The machine
should be refuelled as soon as possible. For action, see chapter 6 In-
spection and maintenance.
000307
Approx. 10% of the fuel remains, which corresponds to approx.
3 hours operating time, when the light is first activated.
Warning light, high temperature hydraulic oil

–
(43)
The light (red) is activated if the hydraulic oil temperature is too high.
Stop the machine and let the engine run at idle speed. Determine the
000308
cause and take appropriate action. Contact service.
Indicator light, high beams (44)

–
The light (blue) is activated when the high beams are on.
000309
Indicator light, direction indicators (45)

–
The light (green) flashes when the direction indicators or hazard

lights are on.
000310
Indicator light, parking brake (46)

–
The light (red) is activated when the parking brake is applied.

If the indicator light flashes, the parking brake has been applied au-
000311
tomatically (not by the operator) when the machine has stopped. To

release the parking brake, turn on and turn off the parking brake
with the switch for parking brake (position 8).
Indicator light, locked twistlocks (47)

–
The indicator light (green) is activated when the twistlocks are

locked and the load is secured.
000312
Indicator light, alignment (48)

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

alignment with the load.
000313
Indicator light, unlocked twistlocks (49)

–
The indicator light (red) is activated when twistlocks are unlocked

and the load is released.
000314

4 Instruments and controls – 4.1 Warning and indicator lights 37
Indicator, control and monitoring system (52)

–
The indicator light (red) alerts the operator. It’s activated in case of
event-controlled information or it flashes when an error code of the
000402
level STOP or WARNING is shown on the display for the control and
monitoring system.
See section 4.11 Control and monitoring system for detailed
information.
Travel direction indicator, Forward Neutral

–
Reverse (61)
The letters F (Forward), N (Neutral) or R (Reverse) are activated for
each respective travel direction.
000403
Indicator light, support jacks (73)

–
The indicator light (green) is activated when the support jacks are
completely lowered.
000315

38 4 Instruments and controls – 4.2 Instruments
4.2 Instruments
General
page
–
This section describes the analogue instruments in the cab. The

gauges or digits indicate levels/status of systems.
page 30.
Hour meter (15)

–
The hour meter shows the number of hours that the engine has been
running.
The meter is used to determine when the machine is due for period-
ic maintenance. All times in periodic maintenance are based on the
machine’s operating time in hours.
001342

4 Instruments and controls – 4.3 Ignition 39
4.3 Ignition
General
page
–
This section describes the ignition (position 53).

page 30.
Ignition’s function
–
P No function.
0 Stop position. Ignition off, that is, everything is shut off.
The key can be removed.
I Operating position.
Current to all electric functions. Control units for engine
and transmission are now active.
II For engine alternative Volvo TAD1250VE and
Volvo TWD1240VE: Preheating mode
Preheating warms the engine’s inlet air to a suitable tem-
perature with a heating coil. The light for preheating (po-
sition 39) indicates if preheating is activated.
When needed, the engine’s control unit activated pre-
0 heating during a time period.
P Engine can be started, position III (start position), regard-

I
less of if preheating is in progress, not activated (no need)
or has been finished.
For engine alternative Cummins QSM11: No function
II
III Start position.
Engagement of starter motor for engine start.
000317
III The engine should not be started (key to start position)

until the warning and indicator lights, see Overview page
30, have completed start-up mode (light and go out
again).
Note that a light may remain lit to indicate status.
NOTE
The machine is equipped with an electric restart in-
terlock, which prevents engagement of the starter
motor when the engine is rotating.
Condition for starter motor to engage is that the
transmission is in neutral position and that the en-
gine isn’t already running.

40 4 Instruments and controls – 4.4 Switches
4.4 Switches
General
page
–
This section describes the switches in the cab. Each switch controls
a function. Contrast for background lighting is adjusted with the
function keys "-/4" and "+/5" for the control and monitoring system.
page 30.
Switch for parking brake (8)

–
Switch (red) for applying parking brake.

002206 Position 0 – Parking brake off.
Position 1 – Parking brake on.
0 1
Switch for fan (16)
–
For description, see Heating/Air conditioning page 60.

004686
1 0 2
Switch for heat (17)
–

004687
1 0 2
Switch, height limitation (18)
–

004688
1 0 2
Switch for work lights cab roof (19)
–
Switch (orange) for work lights on the cab roof as well as extra work
lights on front fender.
Work lights are turned off after idling for 5 minutes, extra work lights
000318
after 2 minutes. Work lights are turned on again at throttle applica-

0 1 tion, gearshifting or activation of any load handling function.
Position 0 – Lights off.
Position 1 – Lights on.

4 Instruments and controls – 4.4 Switches 41
Switch for work lights attachment (20)

–
Switch (orange) for work lights on the attachment. Also activates

rear lights and side running lights.
000319
0 1
tion, gearshifting or activation of any load handling function.
Switch for work lights boom (21)

–
Switch (orange) for work lights on the boom. Also activates rear
lights and side running lights.
000320
0 1
tion, gearshifting or activation of any load handling function.
Switch for rotating beacon (22)

–
Switch (green) for rotating beacon, used to draw attention to ma-

chine and to warn for potential hazards or dangers.
Position 0 – Rotating beacon off.
000321
0 1 Position 1 – Rotating beacon on.
Switch for flashing hazard lights (23)

–
Switch (red) for flashing hazard lights, used to draw attention to ma-
chine in connection with parking hazard.
Position 0 – Flashing hazard lights off.
000322
0 1 Position 1 – Flashing hazard lights on.
Switch for headlights (24)

–
Switch (green) for headlights. Also activates rear lights and side run-
ning lights.
Position 0 – Headlights off.
000323
0 1 Position 1 – Headlights on.
Switch for seat heating (25)

–
Switch (orange) for seat heater. Switch may be located on the seat.
Position 0 – Seat heater off.
Position 1 – Seat heater on.
000324
0 1

Switch for pause heater (28)

–
004922
0 1
Switch for defroster (54)
–
003470
Switch, windshield wiper roof, interval (55)
–
Switch (green) for windshield wiper on roof window. Interval wiper

function.
000326
Interval wiper is activated/deactivated with press of a key. Time in-

terval for wiping is controlled by windshield wiper front windshield.
NOTE
The interval is controlled by the interval selected for the front
windshield.
Switch, windshield wiper roof, continuous (56)

–
Switch (green) for windshield wiper on roof window. Continuous

wiper function.
000327
Wiper is activated/deactivated with press of a key.
Switch, interior lighting (57)

–
Switch (green) for interior lighting in cab.

Lighting is activated/deactivated with press of a key.
000330
Switch, windshield wiper rear, interval (58)

–
Switch (green) for windshield wiper on rear window. Interval wiper

function.
000328
Interval wiper is activated/deactivated with press of a key. Time in-

terval for wiping is controlled by windshield wiper front windshield.
NOTE
The interval is controlled by the interval selected for the front
windshield.

Switch, windshield wiper rear, continuous (59)

–
Switch (green) for windshield wiper on rear window. Continuous

wiper function.
000329
Wiper is activated/deactivated with press of a key.
Switch for shifting program A (62)

–
Switch (green) for selecting shifting program A, automatic shifting.

Active shifting program is indicated with a light-emitting diode.
000413
Switch for shifting program 1 (63)
–
Switch (green) for selecting shifting program 1, which means that

gear position is locked to 1st gear.
000414
Switch for shifting program 2 (64)

–
Switch (green) for selecting shifting program 2, which means that

gear position is locked to 2nd gear.
000415
Switch, bottom lift attachment, front legs (65)

–
Switch (green) controls the front legs on the bottom lift attachment.
The front legs hold the load together with the rear pair of legs. Rock-
er switch.
000405
Position 1 – Front legs are lowered. Switch must be pressed down

1 0 2
during the entire movement.
Position 0 – Legs are stationary.
Position 2 – Front legs are raised. Switch must be pressed down dur-
ing the entire movement.
Switch, bottom lift attachment, rear legs (66)

–
Switch (green) controls the rear legs on the bottom lift attachment.
The rear legs hold the load together with the front pair of legs. Rock-
er switch.
000406
Position 1 – Rear legs are lowered. Switch must be pressed down

1 0 2
Position 2 – Rear legs are raised. Switch must be pressed down dur-

Switch for rotation stop, height limitation and

–
LC-limitation (67)
Switch (green) activates by-pass of rotation stop, height limitation

and LC-limitation (load centre), see section 5.5.4 Functions for load
handling.
000331
Position 0 – Attachment can rotate ±25°, lift height limited and LC-
0 1
limitation active.
Position 1 – Rotation stop is by-passed and free rotation of attach-
ment is possible, free lift height and LC-limitation not active.
Switch, twistlocks, automatic/manual locking

–
(69)
Switch (green) for locking twistlocks. The switch has a rocker func-
tion in position 2.
Position 1 – Twistlocks are locked automatically when there is align-
000408
ment with the load. The parking brake must be OFF, see position 8
1 0 2
and indicator light for parking light, position 46.
Position 0 – Locking of twistlocks not activated.
Position 2 – Twistlocks are locked manually. Rocker switch.
Switch, bottom lift attachment, clamping

–
position (70)
Switch (green) controls clamping position of the leg pairs on the bot-
tom lift attachment. Rocker switch.
Position 1 – Leg pairs release load. Switch must be pressed down
000409

1 0 2
Position 2 – Leg pairs clamp around the load. Switch must be
pressed down during the entire movement.
Switch for lowering overheight legs (70)

–
The switch (green) controls the legs on a top lift attachment with
overheight legs. Each leg has a twistlock which must all indicate un-
locked twistlocks, see indicator light for unlocked twistlocks posi-
tion 49, to enable operation of the legs. Rocker switch.
006496
1 0 2
Position 1 – Legs are lowered. Switch must be pressed down during
the entire movement.
Position 2 – Legs are raised. Switch must be pressed down during

Switch for 30’ stop (71)

–
Switch (green) for 30’ stop. This function is used to adapt the attach-
ment’s spreading to container size (need adaptation). Distance for
30-35
spreader stop is preset in control unit.
000410
Damping is activated shortly before preset value for stop. To contin-
0 1
ue spreading, perform continuous spreading function once again
with the control lever to desired position (end-position is 40’).
Position 0 – Spreading stop not activated.
Position 1 – Spreading stop activated. During spreading in progress,
automatic stop takes place at 30’.
Switch, hydraulic sliding cab (72)

–
Switch (green) for hydraulic sliding cab. Rocker switch. The opera-
tor’s door(s) shall be closed and the control breaker for hydraulics
not activated.
000332
Position 1 – Cab slides forward. Switch must be pressed down dur-

1 0 2
Position 0 – Cab is stationary.
Position 2 – Cab slides rearward. Switch must be pressed down dur-
NOTE
The cab can only be moved if the doors are closed.
Switch, hydraulic vertically adjustable cab (72)

–
Switch (green) for hydraulic vertically adjustable cab. Rocker switch.

The operator’s door(s) shall be closed and the control breaker for hy-
draulics not activated.
001613
Position 1 – Cab is lifted. Switch must be pressed down during the

1 0 2
entire movement.
Position 0 – Cab is stationary.
Position 2 – Cab is lowered. Switch must be pressed down during
NOTE
The cab can only be moved if the doors are closed.

Switch, support jacks (74)

–
Switch (green) for support jacks. Rocker switch. The parking brake
must be OFF, see position 8, and indicator light for parking light, po-
sition 46.
000404
Position 1 – Support jacks are lowered. Switch must be pressed
1 0 2
down during the entire movement. The indicator light for support
jacks is activated when the legs are down (position 73).
Position 0 – Support jacks are stationary.
Position 2 – Support jacks are raised. Switch must be pressed down
Switch for automatic spreading 20’ to 40’ (75)

–
Switch (green) for automatic spreading of attachment to 40’. This

function is used to give automatic spreading of attachment at in-
stantaneous function selection with the control lever.
000411
Damping is activated shortly before any spreading stop (function for

0 1
30’ stop must be activated). To continue spreading to end-position
40’, perform instantaneous function selection with the control lever.
A buzzer in the boom nose sounds at automatic spreading. To cancel
an on-going automatic 20’ to 40’ spreading, activate spreading in or
out with the control lever.
Position 0 – Automatic spreading 20’ to 40’ not activated.
Position 1 – Automatic spreading 20’ to 40’ activated. Is function for
30’ stop activated, spreading stop takes place.
NOTE
Automatic spreading can only be activated with closed doors
and released parking brake.

Switch for by-passing (76)

–
Switch for by-passing various functions. Rocker switch, can only be

activated for 60 seconds.
Position 0 – By-pass not activated.
Position 1 – By-pass activated.
By-passing the safety system allows:
• lowering of load in case of overload
0 • locking and opening of twistlocks without complete alignment
1 • extension (spreading) 20’–40’ with locked twistlocks
• bottom lift without complete alignment
006854
W AR N IN G
Safety features are blocked.
No safety system is activated! Risk of roll-over and
tipping over!
Only use by-pass in emergency situations!

48 4 Instruments and controls – 4.5 Gear selector and multi-function lever
4.5 Gear selector and

multi-function lever
General
page
–
This section describes the functions of the gear and multi-function

lever.(position 2).
page 30.
Shifting program and travel direction

–
Shifting program and travel direction are selected with the gear and
F multi-function lever.
Selection of travel direction:
• F – Forward
• N – Neutral
• R – Reverse with back-up alarm (audible warning signal)
Three different shifting programs can be selected with the following
switches on the steering wheel panel (position 3):
R • 2 – Shifting locked in 2nd gear (position 64)
• 1 – Shifting locked in 1st gear (position 63)
• A – Automatic shifting (position 62)
000337
Headlight control and horn

–
Headlights and horn are controlled with the gear and multi-function
lever.
• With headlights on: Gear and multi-function lever is used to
switch between high and low beams. Move the control towards
yourself to switch between high and low beams, and back.
• With headlights off: Gear and multi-function lever is used to flash
000339
A
with the headlights. Move the control away from yourself for
high beam flash, return is automatic.
A. Horn
• Push button for horn (position A).

4 Instruments and controls – 4.5 Gear selector and multi-function lever 49
Windshield wiper and washer

–
Windshield wipers and washer are controlled with the gear and mul-
2 ti-function lever. Turn the control to the following positions:
3 1
0 • 0 – No wiping front windshield. Controls slow interval wiping for
roof window and rear window if switch for roof window (posi-
tion 55) and/or rear window (position 58) is activated.
• 1 – Slow interval wiping front windshield. Controls slow interval
wiping for roof window and rear window if switch for roof win-
000338
dow (position 55) and/or rear window (position 58) is activated.
• 2 – Fast interval wiping front windshield. Controls fast interval
• 3 – Continuous wiping, front windshield. Controls fast interval
• Push the control toward the steering wheel. – Washing of wind-
shield.
Controls washing of windshield and rear window if switch for
roof window (position 55 or 56) and/or rear window (position 58
or 59) is activated. Wiping goes temporarily to continuous wip-
ing when washing windshields.
Wiper function stops after two minutes if the operator leaves the
seat. The wiper function is reactivated when the operator sits in the
seat again and throttles up, selects a gear or uses any hydraulic
function from the control lever.

50 4 Instruments and controls – 4.6 Control lever
4.6 Control lever

General
page
–
This section describes the functions of the control lever (position 9).
Several hydraulic functions are controlled by switches.
It’s possible to vary the speed of the different hydraulic functions,
i.e. lift, lower, etc., by varying the extent of the lever deflection. It’s
also possible to vary the speed of the hydraulic functions with the
engine speed (rpm).
page 30.
30-35
W AR N IN G
30-35
In an emergency situation! In case of unwanted ac-

tivation/movement of a function.
Risk of personal injury and/or property damage!
IMMEDIATELY TURN OFF all working hydraulics by

006770
pressing the CONTROL BREAKER for hydraulics (po-

9 7
sition 7).
7. Control breaker for hydraulics
9. Control lever
NOTE
For hydraulic vertically adjustable cab: The doors shall be
closed or the cab in the bottom (lowered) position, otherwise
all functions are disconnected.
For hydraulic sliding cab: The doors shall be closed or the cab
in the rear position, otherwise all functions are disconnected.

4 Instruments and controls – 4.6 Control lever 51
Functions control lever

–
1 2a 3 4
2b
5 6
7 8 9 10
000333
1. Adjustable tilt attachment
2. Locking of:
a. tilt
b. levelling
3. Rotation attachment
4. Sideshift attachment
5. Synchronized lift
6. Boom out or in
7. Hydraulic levelling attachment

8. Extension (spreading) attachment 20’-40’
9. Release of twistlocks
If there is no alignment, the button controls the horn.
10. Lift or lower boom

52 4 Instruments and controls – 4.6 Control lever
Light panel on boom for top lift attachment

–
There is a light panel on the boom that is helpful when handling

A B C loads with the top lift attachment. The panel uses coloured lights to
indicate if and when twistlocks are locked/unlocked, that is, if the
load is secured/not secured.
A Twistlocks locked (load secured), green.

B Alignment attachment’s four corners, orange.
C Twistlocks unlocked (load not secured), red.
D Overheight legs raised, white.
006497
Light panel on boom, top lift attachment

Light panel on boom for bottom lift attachment
–
There is a light panel on the boom that is helpful when handling

A B C loads with the bottom lift attachment. The panel uses coloured lights
to indicate if and when the legs have alignment and clamping posi-
tion, that is, when the load is secured/not secured.
A Twistlocks locked (load secured), green.

B Alignment attachment’s four corners, orange.
C Twistlocks unlocked (load not secured), red.
E H
D Alignment left leg front, green.
E Alignment right leg front, green.
D I F Alignment left leg rear, green.
G Alignment right leg rear, green.
F K H Clamping position front leg pair, orange.
000416
G I Front leg pair raised, white.

J
Light panel on boom, bottom lift attachment J Clamping position rear leg pair, orange.
K Front leg pair lowered, orange.
NOTE
Lights D, E, F and G must be activated within 4 seconds when
lifting, otherwise the lift attempt is aborted. Lower load to the
ground. Lights D, E, F, G, H and J must be unaffected before a
new lift attempt is made.

4 Instruments and controls – 4.7 Pedals 53
4.7 Pedals
General
page
–
This section describes the machine’s foot-operated functions.

page 30.
000340
12 13 12 11
11. Accelerator
12. Brake pedal
13. Clutch pedal
Accelerator (11)
–
The accelerator pedal (position 11) is electronic and controls the

injectors.
For the hydraulic functions lift/lower boom and boom in/out, the
system automatically increases throttle application in order to pro-
vide a hydraulic power boost.
Brake pedals (12)

–
The brake pedals (position 12) are mechanical and are connected to
the separate hydraulic that makes up the brake system. The brake
pedals are used for service brake.
The accumulators ensure that there’s always brake pressure availa-
ble, even in case of a temporary engine stop. If the accumulator
pressure drops below a certain level, the warning light for low brake
pressure (position 33) is activated.
Clutch pedal (13)

–
The brake pedal is combined with a separate clutch pedal (position

13). The pedal is used to disengage the transmission, which makes
it possible to use the hydraulic functions when a gear is engaged.

54 4 Instruments and controls – 4.8 Steering wheel
4.8 Steering wheel

General
page
–
This section describes controls for steering. The following alterna-

tives are available for steering the machine:
• steering wheel (position 4) with either fixed or adjustable steer-
ing wheel shaft .
• joystick (position A)
• mini steering wheel (position A)

page 30.
Steering wheel
–
Clockwise rotation of the steering wheel steers the machine to the

right, and vice versa.
The steering wheel’s and instrument panel’s angle and height can be
adjusted to the desired operating position.
1. Steering wheel’s height.
1
To adjust: Move upper lever upward.
2. Steering wheel panel’s angle.
To adjust: Move upper lever downward.
3. Steering column’s angle.

2 To adjust: Loosen the lower handle and adjust to desired posi-
tion. Tighten the handle securely after adjusting.
3
000341
Adjustment possibilities for steering wheel

4 Instruments and controls – 4.8 Steering wheel 55
Joystick
–
Joystick steering is an electro-hydraulic system, mounted in the left

3 4
armrest, to steer the machine using a joystick. When the joystick is
2 moved to the right, the machine steers right, and vice versa. The
steering angle is inversely proportional to the machine’s speed, that
is, low speed gives greater wheel angle, and vice versa.
1 The standard steering wheel is equipped with sensors that detect
eventual steering wheel movements in case of an emergency situa-
tion. As soon as the operator starts to steer with the standard steer-
ing wheel, the joystick is disconnected. The indicator light for
activated joystick or mini-wheel steering (position 36) goes out on
the panel for warning and indicator lights.
1. Joystick.
2. Travel direction selector F/N/R.
forward = F
5 middle position = N
rearward = R
3. Button for engaging joystick steering.
Conditions: Machine speed must be below 3 km/h. If speed is
over 3 km/h, joystick steering cannot be engaged. Indicator light
for activated joystick or mini-wheel steering (position 36) is acti-
vated on the panel for warning and indicator lights when joystick
000900
steering is engaged.
4. Audible signal.
5. Armrest.

56 4 Instruments and controls – 4.8 Steering wheel
Mini steering wheel

–
Mini steering wheel (mini-wheel) is an electro-hydraulic system,

3 4
mounted in the left armrest, to steer the machine using a small
steering wheel. Clockwise rotation of the mini-wheel steers the ma-
2
chine to the right, and vice versa. The ground wheels always follow
the mini-wheel’s position. If the mini-wheel is released, both the
1 mini-wheel and the ground wheels remain in the current position.
The standard steering wheel is equipped with sensors that detect
eventual steering wheel movements in case of an emergency situa-
tion. As soon as the operator starts to steer with the standard steer-
ing wheel, the joystick is disconnected. The indicator light for
activated joystick or mini-wheel steering (position 36) goes out on
the panel for warning and indicator lights.
1. Mini steering wheel.
Mini-wheel’s position on armrest is adjustable.
2. Travel direction selector F/N/R.
5
forward = F
middle position = N
rearward = R
3. Button for engaging mini-wheel.
Conditions: Machine speed must be below 3 km/h. If speed is
over 3 km/h, mini-wheel steering cannot be engaged. Indicator
000583
light for activated joystick or mini-wheel steering (position 36) is

activated on the panel for warning and indicator lights when
mini-wheel steering is engaged.
4. Audible signal.
5. Armrest.

4 Instruments and controls – 4.9 Operator’s seat 57
4.9 Operator’s seat

General
page
–
This section describes the operator’s seat (position 10). The follow-
ing alternative seats are available:
• Operator’s seat Bege. The seat is equipped with:
• mechanical adjustment
• air suspension
• seatbelt
• head restraint
• armrest left
• seat heat
• Operator’s seat Isringhausen. The seat is equipped with:
• mechanical adjustment
• air suspension (external compressor)
• air-adjusted lower back (lumbar) support
• seatbelt
• seat heat
• head restraint
• armrest left
page 30.

58 4 Instruments and controls – 4.9 Operator’s seat
Operator’s seat Bege

–
The operator’s seat (position 10) is equipped with several controls

for adjustment as follows (adjusting is easier when nobody is sitting
in the seat):
1. Distance to pedals.
7 4
Release the seat with the lever and move the seat fore or aft.
2. Height of seat.
Mechanical elevation of seat height:
Turn the knob clockwise or counter-clockwise until desired
height is obtained.
Air suspension elevation of seat height:

Turn the knob counter-clockwise to lower seat height. Turn the
knob clockwise to elevate seat height. The suspension adjusts
automatically to the operator’s body weight.
Exiting the cab is easier if the air is let out of the suspension. Pull
6 the control to the outermost position (seat drops to lowest lev-
el). When entering the cab, press in the control to the innermost
position (seat elevates to pre-set level).
3. Backrest angle.
Turn the knob until desired position is obtained.
1 2 5 3 4. Armrest right angle.
5. Variable angling of seat and back.
Turn the knob until desired position is obtained.
000342
6. Adjustment of suspension travel in two steps (lever located on

Operator’s seat with adjustment possibilities back of seat):
Suspension active – Lever against seat’s centre line. Used during
normal operation.
Suspension locked – Lever against seat’s outside. Can only be
done when seat’s height reaches a locked position. Used when
suspension is not desired.
7. Lower back (lumbar) support.
Turn knob until desired firmness in lumbar support is obtained.

4 Instruments and controls – 4.9 Operator’s seat 59
Operator’s seat Isringhausen 6800

–
The operator’s seat (position 10) is equipped with several controls

for adjustment as follows (adjusting is easier when nobody is sitting
in the seat):
1. Distance to pedals.
Release the seat with the lever (1) and move the seat fore or aft.
To lock the seat, release the lever.
2. Adjusting seat cushion.
Lift the control (2) and adjust the seat fore or aft.
3. Lowering seat height.
Lift the control (3) to lower the seat. The seat remains in the low-
er position.
11 Press down control (3) to raise seat to previous position.

12 4. Seat cushion’s angle.
Lift control (4) and adjust the angle by loading/unloading the
seat cushion’s front part.
5. Raising seat height.
10 Lift control (5) to raise the seat, infinitely variable.
Press down control (5) to lower the seat, infinitely variable.
When desired height is obtained, release the control.
34 567 6. Backrest angle.

006492
9 8 2
Lift control (6) and adjust the angle by loading/unloading the
backrest.
7. Adjusting damping.
Lift control (7) for maximal damping.
Press down control (7) for minimal damping.
8. seat heat.
Thermostat-controlled heat for seat and backrest.
Press down the button for activation/deactivation. Activated
seat heat is indicated with light in the switch.
9. Level damping
Slide the control to the right and left, respectively, to activate/
deactivate level damping.
10. Lower back (lumbar) support. Integrated pneumatic system.
Press the button to fill and drain, respectively, the air chambers
for optimal body adaptation of the backrest.
11. The armrest angle is infinitely variable with the knob.
12. Armrest left

60 4 Instruments and controls – 4.10 Heating/Air conditioning
4.10 Heating/Air conditioning

General
page
–
This section describes the function of:

A
• The heating system, EHC, is automatic and has thermostat-con-
trolled control of heat and fresh air.
• The air conditioning, ECC. It is automatic and has thermo-

stat-controlled control of cooling and heat as well as air dehu-
midification (air dryer).
The heating system / air conditioning gets heat from the engine’s
cooling system and gives heat when the engine is warm. Cooling
performance is generated by the AC compressor (for ECC).
The system is controlled by fan, heat and air distribution as well as
function for recirculation and defroster:
• Fan speed is adjusted with switch for fan (position 16).
18 • Heat (and cooling performance for ECC) is controlled with switch
for heat (position 17).
17
004690
• Air distribution to the cab is adjusted with switch for air distribu-
16
tion (position 18). The fresh air inlet is provided with a filter and
A. Panel nozzle can be equipped with a fine-filter against pollen (fan’s ca-
16. Switch for fan pacity is reduced).
17. Switch for heat
• Recirculation of cab air is activated/deactivated by pressing on
18. Switch for air distribution
the function key for Enter by the operating menu for air
conditioning.
• Defroster for fast demisting of windows is activated/deactivated
with the switch for defroster (position 54).
NOTE
Operator’s door and windows shall be closed for satisfactory
function of the system.
For ECC: In case of open door, the air conditioning’s compres-
sor is turned off (cooling function and air drying stops). Close
the door and the AC compressor is reactivated.
page 30.
001839
Fresh air inlet for cab

4 Instruments and controls – 4.10 Heating/Air conditioning 61
Operating menu for heating /air conditioning

–
system
The operating menu is shown automatically in the display when
switch for fan, heat or air distribution is activated. This can be select-
ed for constant display with function keys for arrow right and arrow
left.
004916
For detailed description, see Operating menu for heating /air condi-
tioning system page 68.
Switch for fan (16)

–
Switch (green) for fan handles setting of fan speed for the cab.
Setting of fan speed:
• Automatic control, AUTO.
004686
1 0 2 • Manual control in 13 steps from off to max. Fan speed is shown
by the bar’s height in the operating menu for heating / air con-
ditioning system.
Position 1 – Increases fan speed.
Position 0 – Fan speed unchanged.
Position 2– Reduces fan speed. Activates automatic control, AUTO,
from off.
Operating menu for air conditioning is shown automatically in the
display when switch is used, see Operating menu for heating /air
conditioning system page 68. Display stops after 3 seconds if switch
is not used again.
Switch for heat (17)

–
Switch (green) for heat handles setting of reference value for cab
temperature. Setting takes place in steps of 0.5 °C.
The temperature range is 17 °C to 27 °C. Setting of min. and max.
004687
respectively, shuts off automatic climate control (control of fan, heat

1 0 2
and air distribution) and sets the heat valve in min. and max. posi-
tion, respectively.
Position1 – Higher temperature setting. When needed, the cab’s air
is cooled to set temperature (for ECC).
Position 0 – Temperature setting unchanged.
Position 2 – Lower temperature setting. When needed, the cab’s air
is cooled to set temperature (for ECC).
is not used again.

62 4 Instruments and controls – 4.10 Heating/Air conditioning
Switch, height limitation (18)

–
Switch (green) for air distribution handles distribution of fresh air to

the cab. The air is distributed to the lower parts of the cab (legs), cab
space (panel) and upper cab space (windshield).
004688
Position 1 – Controls air distribution to upper cab space (windshield).
1 0 2
Position 0 – Setting air distribution unchanged.
Position 2 – Controls air distribution to lower cab space (leg).
Recirculation is activated/deactivated by pressing on the function
key for Enter when the operating menu for air conditioning is shown.
is not used again.
Switch for defroster (54)

–
The switch for defroster, located on the steering wheel panel is used
for fast demisting of the windows. When the defroster is activated
the function controls fan, temperature and damper position.
003470
The defroster is activated/deactivated with a key press or with any

of the other switches for the system. The defroster function is shut
off automatically after 6 minutes.
A symbol for defroster active is shown in display (top right).
Switch for pause heater (28)

–
Switch (green) for pause heater. The cab fan gives heat from the en-
gine’s cooling system during short-term parking of the machine.
Position 0 – Pause heater not activated.
004922
0 1 Position 1 – Pause heater pre-activated. User instruction:

• Park the machine. Let the engine run.
• Set desired temperature (position 17).
• Press in the switch for pause heater (position 28).
• Turn off the engine, that is, turn off the ignition.
The pause heater is now activated and strives to maintain preset
temperature for the cab.
If the cab temperature drops 6 °C below preset temperature,
the pause heater stops working since the engine’s cooling sys-
tem no longer can deliver the needed heat.
NOTE
The higher the preset cab temperature, the shorter the op-
erating time for the pause heater.

4 Instruments and controls – 4.11 Control and monitoring system 63
4.11 Control and monitoring

system
General
page
–
This section describes the control and monitoring system.

50 51 52
The machine is equipped with an electronic system for control and
monitoring of the machine’s different functions.
The system gives the operator information in the form of:
• Error code information
Three levels of error code information can be shown. In case of
a new error code, the indicator for the control and monitoring
system (position 52) is activated, as well as the indicator light for
active error codes on the panel for warning and indicator lights
(position 50). See section 5.3 Handling error codes.
• Operating information
Operating information includes, for example, machine speed,
engine rpm, fuel level, etc.
006493
• Event-controlled information
60
Event-controlled information is, e.g., alignment and overload.
50. Panel for warning and indicator lights
51. Display for control and monitoring system The information is presented on the steering wheel panel’s display
52. Indicator for control and monitoring system (position 51). The function keys (position 60) are used to navigate in
60. Function keys for control and monitoring system the display menus during, for example, service and troubleshooting.
page 30.
4.11.1 Information menus

General
page
–
A menu is shown in the display after start of the machine. Menus are
selected with the function keys for right arrow and left arrow. With
1
each press of the key, the display changes to the next menu. To re-
2
turn to the original display, press and hold in the function key
Reset (R).
This section describes the information that can be obtained from the
different operating menus.
006762
Example of available information menus

64 4 Instruments and controls – 4.11.1.1 Information menu for engine and transmission
4.11.1.1 Information menu for engine and

transmission
Description
page
–
a. Shows current engine speed (rpm).

a c b. Shows current speed in km/h (in display kilometre per hour, kph).
b c. Shows current gear.
d
Travel direction and shifting program are shown on steering
003472
e wheel panel (positions 61-64).
d. Shows current fuel level.
e. Shows current time.
Setting clock
–
1. Go to setting mode by holding in Enter for 3 seconds. Date,

month, year (a) are shown in setting mode.
2. Scroll with <- / -> between hours, minutes, 12/24 h display, date,
month and year.
a
003573
3. Adjust values with +/-.

4. Press Enter by minutes to set seconds to 0.
5. Leave setting mode by pressing Reset.
4.11.1.2 Information menu for dynamic scale

Description
page
–
The operating menu for dynamic scale is shown in display when lift-
a ing load (top lift attachment and bottom lift attachment). The load is
weighed regardless of boom position.
c a. Shows weight in tonnes. Accuracy is 1% of load capacity, that is,

b
000357
approx. +/-0.5 tonnes.

b. Shows extension in m from leading edge of front wheel to load
centre.
c. The bar shows loading of the machine in percentage of permit-
ted load.
4.11.1.3 Information menu for engine

Description
page
–
a. Shows coolant temperature in °C.

b. Shows engine oil pressure in bar.
a
c. Shows oil level (only for engine alternative Volvo TAD1250VE).
b Operating menu shows oil level at engine start. If the oil level
006758
c should drop during operation, this is indicated with an error

code for low oil level engine.
NOTE
Dropping oil level during operation is not shown in this op-
erating menu.

4 Instruments and controls – 4.11.1.4 Information menu for transmission and hydraulics 65
4.11.1.4 Information menu for transmission

and hydraulics
Description
page
–
a. Shows temperature of transmission oil in °C.

b. Shows temperature of hydraulic oil in °C.
a
000356
b
4.11.1.5 Operating menu for container

counter
Description
page
–
a. Counter 1 for number of container lifts. Used to count number

of lifts during a work shift.
Reset counter with function key for Enter, select "Reset C1" and
a press function key for Enter to reset counter to zero.
000568
b. Counter 2 for number of container lifts. Used to count the total

b
amount of machine lifts during a selected time period.
Example from information menu for load handling
Reset counter with function key for Enter, select "Reset C2" and
press function key for Enter to reset counter to zero.
The display indicates which counter has been selected. Press func-
tion key for Reset (R) to return to normal display.
For bottom lift attachment C1 counts number of top lifts and C2

number of bottom lifts.
4.11.1.6 Operating menu for system voltage

Description
page
–
Shows the current system voltage in volt.

000354
Example from information menu for electrical

system

66 4 Instruments and controls – 4.11.1.7 Information menu for dynamic scale
4.11.1.7 Information menu for dynamic scale

Description
page
–
a. Shows the load’s weight in tonnes. Accuracy is 1% of load ca-

a
pacity, that is, approx. +/-0.5 tonnes.
b b. Shows extension of boom in metres.
c c. Shows extension from centre of front wheel to load centre in
000570
d metres.
d. Shows boom angle in degrees.
Example from information menu for dynamic scale
The load is weighed regardless of the boom’s position.
4.11.1.8 Information menu statistics

Description
page
–
Start display for statistics menu.

003575
Display of statistics
–
Go to display mode by pressing Enter, go back with Reset. Scroll be-

tween the different menus with the function keys for arrow right and
arrow left.
• Operating hours engine (hours).
• Operating hours engine, machine parked and idling (hours).
• Operating hours engine with gear activated (hours).
• Operating hours hydraulic functions activated (hours).
003697
• Accumulated fuel consumption (litres).

• Fuel consumption (litres).
Press function key for Enter to reset measuring.
• Instantaneous fuel consumption (litres per hour).
006759
• Accumulated driving distance (km).

• Trip meter (km).
Press function key for Enter to reset measuring.
003699

4 Instruments and controls – 4.11.1.9 Information menu for printer 67
• Number of top lifts.

• Number of bottom lifts.
003700
4.11.1.9 Information menu for printer
Description
page
–
The information menu for the printer is a main menu with two
sub-menus.
The main menu is always shown first in the display.
Select the menu "Save weight" with the function key for plus (+). Re-
turn to the main menu with the function key for minus (-).
Select the menu "Print last loads" with the function key for minus (-).
005070
Repeated selection gives printout of several load indications. Return

to the main menu with the function key for plus (+).
Printer in cab
• Print current load (main menu)
a. Indicates current load.
b. Indicates function keys that give selection.
To print the current load, press function key for Enter.
004881
a b
• Save current load

To save the current load, press function key for Enter.
004880
• Print last loads

c. Indicates number of load indications for printout.
Use the function key for plus and minus (+/-), respectively, to in-
dicate the desired number of recent loads for printing (position c).
004882
c Total weight for load is indicated.

To print, press function key for Enter.

68 4 Instruments and controls – 4.11.1.10 Information menu for service interval
4.11.1.10 Information menu for service interval

Description
page
–
• Shows total operating time in hours.

• Shows number of hours to next service.
003696
4.11.1.11 Information menu for service
Description
page
–
Used by service technicians and for showing error codes. For show-
ing error codes, see section 5.3 Handling error codes.
000056
4.11.1.12 Operating menu for heating /air

conditioning system
Description
page
–
The operating menu is shown automatically in the display when

a e switch for fan, heat or air distribution is activated. This can be select-
f ed for constant display with function keys for arrow right and arrow
b left.
c g
004689
Recirculation is activated/deactivated by pressing function key for

d
Enter.
Example of information menu for air conditioning a. The bar shows the setting for fan speed, automatic (AUTO) or
manual control (in 13 steps 0-12).
b. Indicates set reference value for cab temperature.
c. Symbol for setting of fan.
d. Indicates if fan is in AUTO mode.
e. Symbol indicates if defroster is active or not.
f. Arrow shows setting for distribution of fresh air to the cab. Indi-
cation shows toward the lower parts of the cab (legs), cab space
(panel) and upper cab space (windshield).
g. Symbol indicates if recirculation is active or not.

4 Instruments and controls – 4.11.2 Event-controlled information 69
4.11.2 Event-controlled information

General
page
–
The control and monitoring system draws the operator’s attention to

important information. The warning/information is shown on the
control and monitoring system’s display when needed.
Start interlock
–
The menu is shown at start attempt. For start, enter your 5-digit
code.
003574
Warning for overload forward

–
The warning figure indicates that the load on the steering axle is too
low. The lift capacity has reached 100% according to the load curve
for the machine.
Load handling functions are limited and only function for boom in is
000358
allowed.
In case the figure is shown, the machine’s load functions are limited:
• Retract the boom to reduce the risk of tipping.
In an emergency situation, the by-pass switch (position 76) can
be used to lower the load.
W AR N IN G
Safety features are blocked.
No safety system is activated! Risk of roll-over and

tipping over!
Only use by-pass in emergency situations!

70 4 Instruments and controls – 4.11.2 Event-controlled information
Warning for overload on steering axle

–
The warning figure indicates that the load on the steering axle is too
high, which means reduced lateral stability during operation.
In case of overload on the steering axle speed is limited dynamically
depending on the pressure on the steering axle (for electronic over-
000359
load system) . The bar shows current overload on the steering
axle. Speed limitation is activated when the display is shown. Speed
For mechanical overload system limitation is proportional to the bar’s indication, that is, at MIN per-
mitted speed is higher than at MAX when the system gives maximal
speed limitation.
In case the display is shown (and speed limitation occurs):
• Reduce speed.
• Lower the attachment (to reduce boom angle).
• Move load or attachment forward to reduce pressure on the
004910
steering axle.
For electronic overload system

NOTE
In case of high load on the steering axle, wear of steering
axle and tyres is high and lateral stability is low.
Alignment top lift attachment

–
The figure is shown when one to three corner points on the attach-
ment have contact with the load at alignment. Points with contact
are filled in.
When all four corner points have contact, the figure disappears and
the load can be locked. Display figure can be removed with function
000360
key for Reset (R).

In case the figure is shown:
• Operate attachment until full alignment is obtained.
Load cannot be secured (lock twistlocks) before full alignment.
The load can be locked when all four corner points have contact.

Alignment bottom lift attachment

–
The figure shows when one to seven sensors on the attachment

have alignment and/or clamping position. Point shows alignment
and arrow shows clamping position for respective lift corner. The lift
corners with contact are filled in.
When correct alignment is obtained and clamping position is active,
000572
the figure disappears and the load can be lifted. Display figure can
be removed with function key for Reset (R).
• Operate the attachment’s legs until full alignment is obtained.
The load cannot be lifted before full alignment. The load can be
lifted for 4 seconds without correct alignment. Then the lift func-
tion is disconnected.
The load can be clamped and lifted when all four lift corners
have contact.
NOTE
When transporting a load with bottom lift attachment, the
machine’s speed is limited to max. second gear and
10 km/h.
Twistlocks
–
The figure is shown when the sensors for twistlocks can’t detect if
twistlocks are in locked or unlocked position. Figure is shown during
lift.
When all sensors have contact, the display figure disappears.
000571

• Operate attachment until full alignment is obtained and twist-
locks are in correct position.
• Open and lock twistlocks (use by-pass if needed).
Support jacks
–
The display is shown when support jacks are neither in raised nor
lowered position.
Operate the support jacks up or down, see section 5.5.4 Functions
for load handling. For automatic raising / lowering, throttle up (above
1000 rpm) and press once up / down on the switch for support jacks
000573
(position 74). For automatic raising / lowering, AUTO is shown on

display.
Display figure can be removed with function key for Reset (R).

Height limitation
–
The figure is shown when set maximum lift height has been reached.
Lower or retract boom. The function can be by-passed, see section
5.5.4 Functions for load handling. Display figure can be removed
with function key for Reset (R).
000574
Fixed scale
–
The figure is shown when correct boom extension and key for meas-
uring is pressed in, see section 5.5.4 Functions for load handling. The
load’s weight is calculated by the control and monitoring system.
006761
Open door
–
The figure is shown if:

• doors are not closed at hydraulic sliding cab. The cab cannot be
operated before the doors are closed.
• doors are not closed at function for automatic spreading 20’ to
000576
40’. Automatic spreading cannot be operated until doors are

closed.
In case the figure is shown, close door(s). Then the figure disappears.
Rotation stop
–
The figure is shown when rotation of the attachment reaches al-

lowed rotation limit ±25° (function for rotation stop limitation is ac-
tive). When rotation of the attachment is within the interval for
rotation stop limitation, the display figure disappears. The function
can be by-passed, see section 5.5.4 Functions for load handling. Dis-
001449
play figure can be removed with function key for Reset (R).
Automatic spreading 20’ to 40’

–
The figure is shown when automatic spreading of attachment 20’ to

40’ is in progress. Display figure can be removed with function key
for Reset (R).
006765

Speed limitation at tilt lock/levelling lock

–
Only for tilt lock/levelling lock

At tilt lock/levelling lock is not suitable to operate the machine at
speeds faster than 5 km/h. This since it gives increased wear. There-
fore, the control and monitoring system limits the machine’s speed.
The figure is shown when the machine’s speed is limited to max.
004911
5 km/h. Reduce speed below 5 km/h or disengage lock function,
thus speed limitation and the display stops. The lock function is han-
For tilt lock dled by the control lever.
004912
For levelling lock


5 Handling 75
5 Handling
5 Handling
mm mm mm mm
General
page
–
The machine is intended to be used in the way that is described in

the operator’s manual. If the machine is used in another way or in
potentially dangerous or hazardous conditions, for example, an ex-
plosive environment, special safety regulations must be followed
and the machine must be equipped for such conditions and
environments.
NOTE
It is the operator who is responsible for ensuring that the ma-
chine comes in for service at the prescribed service interval.
The service interval is every 500 operating hours. Procedures
are described in the maintenance manual.
The information in the chapter regarding handling the machine does
not relieve the operator of the responsibility of following laws or oth-
er national regulations for road safety and work safety.
Awareness, alertness, good judgement and respect for governing
safety regulations are prerequisites for avoiding accident risks.
Emergency equipment
–
The following emergency equipment is available on the machine:
• Emergency exit, right door and rear window ( ).

In an emergency:
1. Open the emergency exit right door with handle on inside.
2. In case the doors are blocked by lift cylinders, open the emer-
gency exit rear window by removing the split pin and handle on
respective side of the rear window, see figure.
For a machine with hydraulic vertically adjustable cab, there is
a hammer for breaking the window instead of a window that can
000382
be opened.
Emergency exit rear window

76 5 Handling
• Control breaker
In an emergency:
1. Press down the control breaker (position 7) immediately.
All power transmission and control signals to hydraulics stop.
Reset control breaker (turn clockwise).
30-35
30-35
006770
9 7
7. Control breaker
9. Control lever
• Emergency lowering valve (Hydraulic vertically adjustable

of cab)
If the cab should get stuck in the raised position, it can be low-
ered manually using an emergency lowering valve (position A).
It’s located at the front in the engine compartment (under the
front cover plate for the engine compartment).
1. Remove any lock lug.
2. Turn the emergency lowering valve. The cab is lowered.
A
• Fire extinguisher
Located within easy reach!
001978

5 Handling – 5.1 Running-in 77
5.1 Running-in
General
page
–
The machine should be operated with great care during the run-in
period. The purpose is to give bearing surfaces hard and polished
surfaces, which considerably extends the service life.
Recommended run-in period is 10 hours of operating time. This gives
fewer malfunctions.
Engine
–
A new engine shall always be handled with great care – it must have
a run-in period. Avoid running the engine at full load during the first
10 hours. Then, loading of the engine can be increased gradually.
NOTE
Check the oil pressure and temperature at regular intervals.
Oil and filter shall be changed for the first time after 50 operating
hours.
Thereafter, oil and filter change takes place at the service interval,
after 500 operating hours.
For engine alternative Volvo TAD1250VE there may be deviations
from the service interval. Depends on the oil grade used in the en-
gine (contact service). Engine TAD1250VE should be run with oil
specification VDS-3. The engine can be run with oil specification
VDS-2 (ACEA E5), however, this shortens the service interval to
400 hours.
Transmission
–
The filter is to be replaced for the first time at the 50-hour check. Oil
is changed after 1000 hours.

78 5 Handling – 5.2 Daily inspection
5.2 Daily inspection

General
page
–
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 mal-
functions that have been generated or caused during an earlier work
shift.
W AR N IN G
Never operate a defective machine.
Risk of personal injury and property damage!

Report immediately to the foreman/supervisor if de-
fects are found on the machine at daily inspection!
For work instructions, see section 6.1 Daily inspection.

5 Handling – 5.3 Error codes 79
5.3 Error codes

General
page
–
Error codes indicate there is some defect/malfunction in the ma-

chine. The error codes should be used by operators and service
technicians to identify the problem and to perform a suitable action.
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.
Error codes are shown automatically on the display and end up in an
error code list under the operating menu for service.
Actions in case of an error code

–
CAUTION
STOP indicates a malfunction in the machine which
may affect safety of the operator and others in the
vicinity or may cause a breakdown. – Turn off the
engine and perform action according to error code
table.
"Warning" and "Information" indicate malfunctions

of such character that work does not have to be
stopped. The machine’s capacity may be limited
and certain functions may not work. – Perform ac-
tions according to error code table as soon as
possible.
1 Stop the machine and let the engine run at idle speed.
Identify error code level, see section 5.3.1 Error code indication.
• In case of STOP – Continue to step 4.
• In case of WARNING or INFORMATION – Continue to step 2.
NOTE
If several error codes come from the engine, the error
code level is shown for the most serious error code.
2 Navigate to the operating menu for service using the function
keys arrow left or arrow right. Hold down the function key Enter
for at least two seconds. The error code list is shown.
000056
Information menu for service

80 5 Handling – 5.3 Error codes
3 Note all error codes. For explanation, see Display figure for er-
ror code information page 82.
Error code number together with X(Y). X shows sequence
number for displayed error code and (Y) shows total number of
active error codes. Scroll between the error codes with the
001998
function keys arrow right and arrow left. The error code indica-
tion disappears when the cause of an error code has been
Example figure, error code list corrected.
Leave the error code list by pressing the function key Reset (R).
4 Perform action according to error code level:
STOP, critical malfunction!
A. Park the machine immediately.
Note error code number.
B. Turn off engine.
C. Contact service.
WARNING, not a critical malfunction.
A. Take care of error code as soon as possible but work
with machine can continue safely.
B. See information in error code table:
- Error codes machine page 85
- Error codes engine page 96
- Error codes from transmission page 108
If error code number is not in error code table, perform
action according to step C.
C. Contact service, e.g., after finished work shift.
INFORMATION, not a critical malfunction.
A. Continue work with machine.
B. At a suitable time, see information in error code table:
- Error codes machine page 85
- Error codes engine page 96
- Error codes from transmission page 108
If error code number is not in error code table, perform
action according to step C.
C. Contact service, e.g., after finished work shift.
5 Check: Start the engine and check that the error code has dis-
appeared acc. to step 2.

5 Handling – 5.3.1 Error code indication 81
5.3.1 Error code indication

General
page
–
Error code is indicated with an activated indicator light for active er-
51 52
ror codes (position 34). The error codes are divided into three error
code levels depending on their severity.
The error code levels are shown as follows:
• Stop is indicated with a STOP sign on the display together with
B flashing red light from the indicator for the control and monitor-
ing system (position 52) as well as activated indicator light for
active error codes (position 34).
• WARNING is indicated with a warning triangle on the display to-
34 gether with flashing red light from the indicator for the control
and monitoring system (position 52) as well as activated indica-
tor for active error codes (position 34).
• Information is indicated with activated indicator light for active
error codes (position 34).
005075
B. Symbol error code level

34. Indicator light for active error codes
51. Display for control and monitoring system
52. Indicator for control and monitoring system
5.3.2 Error code information on display

Error code display
page
–
Error code information is shown with display figures in two ways:

• Automatically in display at STOP and WARNING.
The error code is confirmed with function key Reset (R). When
the error code is confirmed, the display returns to the previous
selected menu. If the error code is active, it’s stored in the error
code list under operating menu for service.
002207
If the error code remains active, the figure returns in the display
Example of automatic figure in display within 3-5 minutes.
• In the error code list under operating menu for service.

Active error codes are stored in the error code list. Navigate to
the operating menu for service. Display the error code list by
pressing in function key Enter for 2 seconds. Navigate in the er-
ror code list with function keys arrow right and arrow left. Leave
001998
the error code list by pressing function key for Reset (R).
Example of display in the error code list

NOTE
If error code isn’t included in the error code list, it may be
due to the following:
- condition for error detection no longer exists, e.g., control
lever is released or engine is off.
- loose connection/poor contact

82 5 Handling – 5.3.2 Error code information on display
Display figure for error code information

–
The control and monitoring system’s display is divided into four

C fields where the information is shown (see figure to the left).
D E • Field B: Error code level.

• Field C: Error code number.
B
000389
• Field D: Type of error.
• Field E: Affected function.
• Book symbol means that information is available in the
Operator’s Manual.
Field B: Error code level

The control and monitoring system gives error code information in
three levels which are indicated with a symbol in the lower left cor-
ner (B) on the display unit.
• STOP
C Indicates a serious malfunction that may jeopardize the opera-
tor’s safety or cause machine failure. Error code shall be taken
D E
care of immediately.
The error code is shown automatically on the display.
000350
• WARNING
C Indicates malfunction in machine that should be taken care of as
soon as possible.
D E
The error code is shown automatically on the display.
000351
• INFORMATION
C Information to operator about something that should be taken
care of, e.g., broken bulb. Take care of the cause at a suitable
D E time. Action instruction is often found in chapter 6 Inspection
and maintenance.
000352
The error code is stored in the error code list under operating
menu for service.

5 Handling – 5.3.2 Error code information on display 83
Field C: Error code number

The control and monitoring system gives error codes from three
sub-systems:
• Machine:
XXX
Shown with error code number XXX on display, see Error codes
D E machine page 85.
006499
• Engine:
XX/YY Shown with error code number XXX/YY on display, see Error
codes engine page 96.
D
B NOTE
001343
If several error codes come from the engine, the error code
level is shown for the most serious error code.
• Transmission:
XXX/YY Shown with error code number XX/YY on display, see Error
codes from transmission page 108.
D
B
001344
Field D: Type of error

1. Temperature too high/too low.
1 2 3
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.
4 5 6 5. Incorrect signal from control.

6. Incorrect signal to bulb.
7. Incorrect signal, for example, open circuit.
7
000396

84 5 Handling – 5.3.2 Error code information on display
Field E: Affected function

1. Attachment
1 2 3
2. Rotation of attachment
3. Sideshift attachment
4. Extension (spreading) attachment
4 5 6 5. Levelling attachment
6. Twistlocks
7. Adjustable tilt attachment
7 8 9 8. Bottom lift attachment
9. Bottom lift attachment, clamping position
10. Bottom lift attachment, legs up/down
10 11 12 11. Boom up/down

12. Boom in/out
13. Pressure sensor lift cylinder (overload system, OP)
14. Non-existent overload system
13 14 15
15. Support jacks up/down
16. Hydraulic functions
17. Brake system
16 17 18
18. Steering
19. Engine
20. Transmission
19 20 21 21. Central lubrication
22. Control unit
23. Hardware-related error
22 23 24 24. Cab
25. Air conditioning
26. Fuel system
25 26 27 27. Headlights
28. Windshield wipers
29. Battery voltage
28 29 30 30. Bulb for lighting

000397

5 Handling – 5.3.3 Error code tables 85
5.3.3 Error code tables

General
page
–
Error codes are sorted in numerical order. The tables contain the fol-
lowing information:
• Code - Indicates error code.
• 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 ac-
cording to error code level, with or without detailed information.
Error codes machine

–
Code Description Action

1 No contact with control unit attachment. Attachment functions not STOP
working.
2 No contact with control unit attachment option. Levelling and tilt not STOP
working.
3 No contact with control unit attachment left leg pair. Left side of bottom STOP
lift attachment not working.
4 No contact with control unit attachment right leg pair. Right side of bot- STOP
tom lift attachment not working.
5 No contact with control unit frame rear. Lights rear, hydraulic oil cool- STOP
ing, overload system, extension not working.
6 No contact with control unit frame front option. Sliding cab, support STOP
jacks, joystick, mini-wheel and cab lift not working.
7 No contact with control unit frame front. Front lights, lift, extension, STOP
brake lights, brake cooling not working.
8 No contact with control unit KID. Controls in steering wheel panel and STOP
display not working.
11 CAN segment 1. WARNING
20 Accelerator pedal has to be calibrated. Poor sensitivity in accelerator INFORMATION

pedal.
21 No contact with control unit transmission. Gear selection not working. STOP

86 5 Handling – 5.3.3 Error code tables

22 No contact with control unit engine. Engine does not respond to com- STOP
mands from cab.
23 Machine is not configured. No controls in cab are working. STOP
24 Incorrect voltage feed to cab fan. Cab fan not working. INFORMATION: Check fuse F58-
5:C3. See 6.2.14 Fuses for electrical
system.
25 Communication error with control unit engine at active error code. INFORMATION: Turn ignition off and
Error code is stored in control unit engine. on.
26
27
28
29
30
31 Voltage feed incorrect to control unit cab. Controls in cab not working. STOP: Check fuse F58-4:A1. See
6.2.14 Fuses for electrical system.
32 Analogue controls cab. Analogue controls in cab not working (mini- STOP
wheel/joystick, control lever and controls for air conditioning).
33 No feed of control breaker voltage to control unit cab. Control breaker WARNING: Check fuse F58-3:H8. See
cannot be disengaged. All hydraulic functions are blocked. 6.2.14 Fuses for electrical system.
34 Switch parking brake. Parking brake cannot be released. WARNING: Use by-pass to release
the parking brake.
35 Communication error with control unit transmission at active error INFORMATION: Turn ignition off and
code. on.
36
Error code is stored in control unit transmission.
37
38
39
40
41 Wiper rear not working. INFORMATION
42 Rotating beacon not working. INFORMATION: Check the light. See

6.2.15 Lighting.
43 Work light left cab not working.
44 Work light right cab not working.
45 Wiper front not working. INFORMATION
46 Cab fan not working. INFORMATION
47 Recirculation damper for ventilation not working. INFORMATION
48 Water valve. Heat in cab cannot be adjusted. INFORMATION
49 Water valve. Heat in cab cannot be adjusted. INFORMATION
50 Air distribution in cab cannot be adjusted. INFORMATION


53 Windshield washer rear and roof not working. INFORMATION
55 Reduced or no background lighting in instruments and controls. INFORMATION: Check lights for
background lighting. See 6.2.15
Lighting.
56 LED control lever for adjustable tilt. INFORMATION: Check light. See
6.2.15 Lighting.
57 LED control lever for locking tilt/levelling. INFORMATION: See 6.2.15 Lighting.
60 Seat heat not working. INFORMATION
61 Extra work lights boom not working. INFORMATION
63 No ignition voltage to the machine’s control units. STOP
64 No control breaker voltage to the machine’s control units. STOP
65 No control breaker voltage to the machine’s control units. STOP
66 Windshield washer not working. INFORMATION
67 Wiper roof not working. INFORMATION
68 Pause heater not working. INFORMATION
69 No voltage feed to engine and transmission. STOP
71 Interior lighting in cab not working. INFORMATION: Check the light. See
6.2.15 Lighting.
74 Horn/loud horn not working. INFORMATION
75 Relay for ignition has jammed in position on. Control unit cab is still sup- STOP
plied with voltage and thus active.
80 Incorrect pressure in air conditioning. Air conditioning not working. INFORMATION
85 Accelerator pedal. Engine rpm limited to idle. STOP
87 Control lever for lift and lower. Lift and lower not working. WARNING
88 Control lever for extension. Extension not working. WARNING
89 Control lever for rotation. Rotation not working. WARNING
90 Control lever for tilt. Adjustable tilt not working. WARNING
92 Joystick or mini-wheel. Joystick or mini-wheel not working. WARNING
93 Mini-wheel. Mini-wheel not working. WARNING
94 Water valve cab heat. Cab heat cannot be adjusted. INFORMATION
96 Sensor cab temperature. Temperature control cab not working. INFORMATION
97 Sensor outdoor temperature. Temperature control cab not working. INFORMATION
98 Sensor temperature outlet fan. Temperature control cab not working. INFORMATION


99 Sensor temperature refrigerant. Temperature control cab not working. INFORMATION
101 Redundant voltage feed left control unit frame front. STOP: Turn ignition off and on.
102 Redundant voltage feed right control unit frame front. STOP: Turn ignition off and on.
103 Voltage feed control unit frame front. No power supply to components STOP: Check fuse F58-2:A1. See
from control unit frame front. 6.2.14 Fuses for electrical system.
104 Control breaker voltage to control unit frame front. Control breaker can- WARNING: Check fuse F58-3:B2. See
not be disengaged. All hydraulic functions blocked. 6.2.14 Fuses for electrical system.
105 Voltage feed sensor. Regeneration lift, weight indicator and overload STOP
system not working.
106 Cooling fan brake oil not working. WARNING
107 Left high beam not working. INFORMATION: Check the light. See
6.2.15 Lighting.
108 Right high beam not working. INFORMATION: Check the light. See
6.2.15 Lighting.
110 Low beam right and left not working. INFORMATION: Check the light. See
6.2.15 Lighting.
111 Solenoid valve boom up. Lift not working. WARNING
112 Solenoid valve boom down. Lower not working. WARNING
113 Solenoid valve boom out. Extension out not working. WARNING
114 Solenoid valve boom in. Extension in not working. WARNING
115 Solenoid valve blocking lift left. Lift and lower not working. WARNING
116 Solenoid valve blocking lift right. Lift and lower not working. WARNING
117 Solenoid valve regeneration lift left. Regeneration lift not working. WARNING
118 Solenoid valve regeneration lift right. Regeneration lift not working. WARNING
119 Solenoid valve parking brake. Parking brake cannot be released. STOP
120 Direction indicator left front. Direction indicator front left not working. INFORMATION: Check the light. See
6.2.15 Lighting.
121 Direction indicator right front. Direction indicator front right not INFORMATION: Check the light. See
working. 6.2.15 Lighting.
122 Running light left front. Running light front left not working. INFORMATION: Check the light. See
6.2.15 Lighting.
123 Running light right front. Running light front right not working. INFORMATION: Check the light. See
6.2.15 Lighting.
124 Voltage feed sensor. Parking brake, brake lights and release not work- STOP
ing. Warning for low brake pressure.
133 Sensor hydraulic pressure lift cylinder left. Overload system not work- STOP
ing. All lift functions run at reduced speed. Error code 150 activated.


134 Sensor hydraulic pressure lift cylinder left. Overload system not work- STOP
135 Sensor hydraulic pressure lift cylinder right. Overload system not work- STOP
136 Sensor hydraulic pressure lift cylinder right. Overload system not work- STOP
137 Solenoid valve boom down. Lower not working. WARNING
138 Solenoid valve boom up. Lift not working. WARNING
139 Solenoid valve boom out. Extension out not working. WARNING
140 Solenoid valve boom in. Extension in not working. WARNING
145 Sensor boom angle. Overload system not working. STOP
146 Sensor boom length. Overload system not working. STOP
147 High brake oil temperature. Reduced braking performance. WARNING: Check that cooling fan
works. Check that radiator is not
clogged. Check brake oil level. See
6.2.8 Oil brake system.
148 Sensor brake oil temperature WARNING
149 Incorrect load curve or load curve missing. Lift and lower as well as ex- STOP
tension not working.
150 Overload system not working. All lift functions run at reduced speed. STOP: Retract the boom completely.
Gives indication at Reset of error codes for overload system. Indication Lower the load slowly. Unload con-
of this error code cannot be removed with Reset. tainer. Contact service. NOTE!
Overload system is disengaged.
151 Voltage feed control unit frame rear. STOP: Turn ignition off and on.
152 Voltage feed control unit frame rear. STOP: Turn ignition off and on.
153 Voltage feed control unit frame rear. No power supply to components STOP: Check fuse F58-2:C3. See
from control unit frame rear. 6.2.14 Fuses for electrical system.
154 Voltage feed control unit frame rear. WARNING: Turn ignition off and on.
155 Voltage feed sensor. Overload system and weight indicator not STOP
working.
156 Cooling fan hydraulic oil. Cooling fan hydraulic oil not working. WARNING
157 Work light boom left not working. INFORMATION: Check the light. See
6.2.15 Lighting.
158 Work light boom right not working. INFORMATION: Check the light. See
6.2.15 Lighting.
159 Back-up light left not working. INFORMATION: Check the light. See
6.2.15 Lighting.
160 Back-up light right not working. INFORMATION: Check the light. See
6.2.15 Lighting.


161 Voltage feed sensor overload system. Overload system indicates over- STOP
load.
162 Voltage feed position sensor boom. Damping in/out/1.5m not working. INFORMATION
163 Solenoid valve regeneration extension. Regeneration extension not WARNING

working.
164 Solenoid valve blocking extension. Extension not working. WARNING
165 Back-up alarm not working. INFORMATION
166 Solenoid valve top hydraulics. Attachment functions not working. WARNING
167 Brake light left not working. INFORMATION: Check the light. See
6.2.15 Lighting.
168 Brake light right not working. INFORMATION: Check the light. See
6.2.15 Lighting.
169 Running light left rear not working. INFORMATION: Check the light. See
6.2.15 Lighting.
170 Running light right rear not working. INFORMATION: Check the light. See
6.2.15 Lighting.
171 Rear light left not working. INFORMATION: Check the light. See
6.2.15 Lighting.
172 Tail light right not working. INFORMATION: Check the light. See
6.2.15 Lighting.
173 Direction indicator left rear not working. INFORMATION: Check the light. See
6.2.15 Lighting.
174 Direction indicator right rear not working. INFORMATION: Check the light. See
6.2.15 Lighting.
175 Sensor steering axle. Overload system indicates overload. STOP
178 Solenoid valve unloading pump. Unloading of hydraulic oil pumps at WARNING
boom not working.
183 Sensor boom angle. Overload system not working. STOP
184 Sensor boom length. Overload system not working. STOP
191 Magnetic clutch AC compressor. Air conditioning not working. INFORMATION
192 Magnetic clutch AC compressor. Air conditioning not working. INFORMATION
193 Start relay starter motor. Starter motor not working. WARNING
197 High temperature hydraulic oil. WARNING: Check that cooling fan
works. Check that radiator is not
clogged. Check brake oil level. See
6.2.8 Oil brake system.
198 Sensor hydraulic oil temperature. Incorrect temperature display. WARNING


199 Sensor fuel level. Incorrect display of fuel volume (empty or full). INFORMATION: Check fuel volume
manually in tank. See 6.2.2 Fuel sys-
tem.
201 Voltage feed control unit frame option. STOP: Turn ignition off and on.
202 Voltage feed control unit frame option. STOP: Turn ignition off and on.
203 Voltage feed control unit frame option. No power supply to components STOP: Check fuse F58-2:D4. See
from control unit frame option. 6.2.14 Fuses for electrical system.
204 Voltage feed control unit frame option. Control breaker for hydraulics STOP: Check fuse F58-3:D4. See
cannot be disengaged. All hydraulic functions blocked. 6.2.14 Fuses for electrical system.
211 Solenoid valve cab front/up. Hydraulic sliding cab or cab lift not working. WARNING
212 Solenoid valve cab rear/down. Hydraulic sliding cab or cab lift not WARNING
working.
213 Solenoid valve steering left. Joystick or mini-wheel not working. WARNING
214 Solenoid valve steering right. Joystick or mini-wheel not working. WARNING
215 Solenoid valve support jack up. Support jacks not working. WARNING
216 Solenoid valve support jack down. Support jacks not working. WARNING
217 Solenoid valve cab tilt up. Cab tilt not working. WARNING
218 Solenoid valve cab tilt down. Cab tilt not working. WARNING
219 Solenoid valve disengagement of hydraulic oil pumps. WARNING
220 Voltage feed position sensor support jacks. If indication support jacks INFORMATION
up is missing, gear cannot be selected to operate machine.
221 Voltage feed cab lift. Cannot be indicated that cab is in lowered posi- INFORMATION
tion. Door must be closed so that boom can be lowered. Speed limita-
tion activated.
237 Solenoid valve cab front/up. Hydraulic sliding cab or cab lift not working. WARNING
238 Solenoid valve cab rear/down. Hydraulic sliding cab or cab lift not WARNING
working.
239 Solenoid valve steering left. Joystick or mini-wheel not working. WARNING
240 Solenoid valve steering right. Joystick or mini-wheel not working. WARNING
251 Voltage feed control unit attachment. STOP: Turn ignition off and on.
253 Voltage feed control unit attachment. STOP: Check fuse F58-3:A1. See
6.2.14 Fuses for electrical system.
254 Voltage feed control unit attachment. No attachment functions INFORMATION: Check fuse F58-
working. 3:A1. See 6.2.14 Fuses for electrical
system.
257 Work light attachment right not working. INFORMATION: Check the light. See
6.2.15 Lighting.


258 Work light attachment left not working. INFORMATION: Check the light. See
6.2.15 Lighting.
259 Buzzer automatic spreading 20’ to 40’. INFORMATION: Check the light. See
6.2.15 Lighting.
260 Extra work light attachment not working. INFORMATION: Check the light. See
6.2.15 Lighting.
261 Solenoid valve rotation clockwise. Rotation of attachment not working. WARNING
262 Solenoid valve rotation counter-clockwise. Rotation of attachment not WARNING

working.
263 Solenoid valve spreading out. Spreading not working. WARNING
264 Solenoid valve spreading in. Spreading not working. WARNING
265 Solenoid valve sideshift right. Sideshift of attachment not working. WARNING
266 Solenoid valve sideshift left. Sideshift of attachment not working. WARNING
267 Solenoid valve lock twistlocks. Twistlocks not working. WARNING
268 Solenoid valve open twistlocks. Twistlocks not working. WARNING
269 Solenoid valve tilt lock 1. Tilt lock not working. WARNING
270 Solenoid valve tilt lock 2. Tilt lock not working. WARNING
271 Voltage feed position sensor attachment. WARNING
272 Indicator light twistlocks open not working. WARNING: Check the light. See
6.2.15 Lighting.
273 Indicator light alignment not working. WARNING: Check the light. See
6.2.15 Lighting.
274 Indicator light twistlocks locked not working. WARNING: Check the light. See
6.2.15 Lighting.
287 Solenoid valve rotation clockwise. Rotation of attachment not working. WARNING
288 Solenoid valve rotation counter-clockwise. Rotation of attachment not WARNING

working.
289 Solenoid valve spreading out. Spreading not working. WARNING
290 Solenoid valve spreading in. Spreading not working. WARNING
298 Twistlock left in middle position. Lift and extension not working. WARNING: Check that left twistlock
sensors are clean and free from
grease.
299 Twistlock right in middle position. Lift and extension not working. WARNING: Check that right twistlock
sensors are clean and free from
grease.
300 Sensor alignment. Twistlocks not working. WARNING: Check that the alignment
sensors are clean and free of grease.
Check that the alignment pins are
not stuck in alignment position.


303 Voltage feed control unit attachment. Control breaker for hydraulics STOP: Check fuse F58-3:A1. See
311 Solenoid valve levelling right. Levelling not working. WARNING
312 Solenoid valve levelling left. Levelling not working. WARNING
313 Solenoid valve tilt out. Adjustable tilt not working. WARNING
314 Solenoid valve tilt in. Adjustable tilt not working. WARNING
315 Solenoid valve levelling 1. Levelling not working. WARNING
316 Solenoid valve levelling 2. Levelling not working. WARNING
317 Incorrect output signal auxiliary attachment. WARNING
354 Voltage feed control unit attachment. Control breaker for hydraulics WARNING: Check fuse F58-3:A1. See
357 Work light left lift leg not working. INFORMATION: Check the light. See
6.2.15 Lighting.
358 Solenoid valve levelling. Levelling not working. WARNING
360 Solenoid valve operating position left. Left lift leg not working. WARNING
363 Solenoid valve front knee left in. Left lift leg not working. WARNING


364 Solenoid valve front knee left out. Left lift leg not working. WARNING
365 Solenoid valve rear knee left in. Left lift leg not working. WARNING
366 Solenoid valve rear knee left out. Left lift leg not working. WARNING
367 Solenoid valve front leg left down. Left lift leg not working. WARNING
368 Solenoid valve front leg left up. Left lift leg not working. WARNING
369 Solenoid valve rear leg left down. Left lift leg not working. WARNING
370 Solenoid valve rear leg left up. Left lift leg not working. WARNING
371 Indicator light alignment lift leg right front not working. INFORMATION: Check the light. See
6.2.15 Lighting.
372 Indicator light alignment lift leg right rear not working. INFORMATION: Check the light. See
6.2.15 Lighting.
373 Indicator light alignment lift leg left front not working. INFORMATION: Check the light. See
6.2.15 Lighting.
374 Indicator light alignment lift leg left rear not working. INFORMATION: Check the light. See
6.2.15 Lighting.
375 Solenoid valve clamp left shut. Left lift leg not working. WARNING
376 Solenoid valve clamp left open. Left lift leg not working. WARNING
377 Voltage feed position sensor left leg pair. WARNING
404 Voltage feed control unit attachment. Control breaker for hydraulics WARNING: Check fuse F58-3:A1. See
407 Work light right lift leg not working. INFORMATION: Check the light. See
6.2.15 Lighting.
410 Solenoid valve operating position right. Right lift leg not working. WARNING
413 Solenoid valve front knee right in. Right lift leg not working. WARNING
414 Solenoid valve front knee right out. Right lift leg not working. WARNING
415 Solenoid valve rear knee right in. Right lift leg not working. WARNING
416 Solenoid valve front knee right out. Right lift leg not working. WARNING
417 Solenoid valve front leg right down. Right lift leg not working. WARNING


418 Solenoid valve front leg right up. Right lift leg not working. WARNING
419 Solenoid valve rear leg right down. Right lift leg not working. WARNING
420 Solenoid valve rear leg right up. Right lift leg not working. WARNING
421 Indicator light front legs raised not working. INFORMATION: Check the light. See
6.2.15 Lighting.
422 Indicator light front legs lowered not working. INFORMATION: Check the light. See
6.2.15 Lighting.
423 Indicator light clamping position lift leg front not working. INFORMATION: Check the light. See
6.2.15 Lighting.
424 Indicator light clamping position lift leg rear not working. INFORMATION: Check the light. See
6.2.15 Lighting.
425 Solenoid valve clamp right shut. Right lift leg not working. WARNING
426 Solenoid valve clamp right open. Right lift leg not working. WARNING
427 Voltage feed position sensor right leg pair. WARNING
451 Voltage feed control unit display. WARNING: Turn ignition off and on.
452 Voltage feed control unit display. WARNING: Turn ignition off and on.
460 Communication error with control unit KID (D795). Incorrect values in STOP
operating menus.
461 Communication error with control unit KID (D795). Error codes from oth- STOP
er control units cannot be shown.
500 Time for service. INFORMATION: Bring machine to

service.

Error codes engine

–
For contact with engine suppliers, use Volvo/Cummins code.

• Display indicates error code acc. to SAE J1939
SPN / FMI
• Flash indicates error code according to engine supplier specified
flash code.
• J1587 indicates error code acc. to SAE J1587 (for Volvo: Vodia).
PID, PPID, SID, PSID / FMI
Table 1. Specifications FMI
FMI Description SAE-text

0 Too high value. Data valid, but higher than normal operating range.
1 Too low value. 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 prob- Abnormal frequency.

lem.
9 Communication error. Abnormal update rate.
10 Mechanical problem or electrical prob- Abnormally wide variations.

lem.
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 Unknown malfunction. Reserved for future use.
Table 2. Error codes Volvo TAD1250VE and Volvo TWD1240VE
Description Action
Display Flash J1587

94/FMI 3.6 PID94/FMI Fuel pressure. STOP
94/FMI 3.8 PID94/FMI Fuel pressure. STOP

Description Action
Display Flash J1587

97/1 2.1 PID97/1 Water in fuel. WARNING: Drain fuel pre-fil-
ter, see 6.2.2 Fuel system.
97/3 2.9 PID97/3 Water in fuel or clogged fuel line (low fuel WARNING: Drain fuel pre-fil-
pressure). ter, see 6.2.2 Fuel system.
98/FMI 5.7 PID98/FMI Oil level. STOP: Check oil level in en-
gine. See 6.2.6 Engine oil.
98/FMI 5.9 PID98/FMI Oil level. STOP: Check oil level in en-
100/1 6.6 PID100/1 Low engine oil pressure. Engine is shut off. STOP: Check oil level in en-
100/3 3.1 PID100/3 Sensor oil pressure cable short-circuited to STOP

voltage.
100/4 3.1 PID100/4 Sensor oil pressure, open circuit or short-circuit STOP
to ground.
102/0 3.5 PID102/0 High charge-air pressure. STOP
102/1 3.5 PID102/1 Low boost pressure. Reduced engine power. STOP
102/3 3.4 PID102/3 Sensor boost pressure, cable short-circuited to STOP

voltage. Engine smokes more than normal at ac-
celeration/load.
102/4 3.4 PID102/4 Sensor boost pressure, cable short-circuited STOP

ground or open circuit. Engine smokes more
than normal at acceleration/load.
105/3 3.2 PID105/3 Sensor charge-air temperature, cable short- STOP

circuited to voltage or open circuit.
105/4 3.3 PID105/4 Sensor charge-air temperature, cable short- STOP

circuited to ground or open circuit.
105/FMI 6.2 PID105/ Charge-air temperature. STOP

FMI
106/FMI 3.4 PID106/ Boost pressure. STOP

FMI
106/FMI 3.5 PID106/ Boost pressure. STOP

FMI
110/0 6.1 PID110/0 High coolant temperature. For engine alterna- STOP: Check coolant level.
tive TWD1240VE: engine shuts down. See 6.2.5 Cooling system.
110/3 3.3 PID110/3 Sensor coolant temperature, cable short- STOP

circuited to voltage or open circuit. Preheating is
activated even if engine is warm.

Description Action
Display Flash J1587

110/4 3.3 PID110/4 Sensor coolant temperature, cable short- STOP
circuited to ground. Preheating is activated even
if engine is warm.
111/1 2.2 PID111/1 Low coolant level. For engine alternative STOP: Check coolant level.
TWD1240VE: engine shuts down. See 6.2.5 Cooling system.
111/FMI 2.3 PID111/ Coolant level. STOP

FMI
158/FMI 3.9 PID158/ Battery voltage. STOP

FMI
175/0 5.8 PID175/0 High engine oil temperature. Reduced engine STOP
power.
175/3 3.7 PID175/3 Sensor oil temperature, cable short-circuited to STOP

voltage or open circuit.
175/4 3.7 PID175/4 Sensor oil temperature, cable short-circuited to STOP

ground.
608/FMI - PPID98/ Start / stop, redundance. STOP

FMI
608/FMI 2.8 PPID132/ Signal from accelerator pedal, redundance. STOP

FMI
620/3 9.3 SID232/3 Voltage feed to sensor, cable short-circuited to STOP

voltage. Several error codes for sensor
malfunction.
620/4 9.3 SID232/4 Voltage feed to sensor, cable short-circuited to STOP

ground. Several error codes for sensor
malfunction.
626/3 5.4 PID45/3 Preheating relay, cable short-circuited to volt- STOP

age. Preheating cannot be activated.
626/4 5.4 PID45/4 Preheating relay, cable short-circuited to STOP

ground. Preheating constantly activated.
626/5 5.4 PID45/5 Preheating relay open circuit on cable or defec- STOP
tive component. Preheating cannot be activated.
629/FMI 9.9 SID254/ Internal error, engine control unit. STOP

FMI Engine off: engine cannot be started. Engine
running: engine misfires.
630/2 9.9 SID253/2 Electrical problem. Reduced engine power. STOP
630/12 9.9 SID253/12 Electrical problem. Reduced engine power. STOP

Description Action
Display Flash J1587

636/3 2.5 SID21/3 Sensor rpm camshaft. No signal. Engine takes STOP
longer to start than normal. Engine runs normal-
ly once it has started.
636/8 2.5 SID21/8 Sensor rpm camshaft. Abnormal frequency. En- STOP
gine takes longer to start than normal. Engine
runs normally once it has started.
637/2 2.4 SID22/2 Sensor rpm flywheel. Irregular signal. Engine is STOP
extremely difficult to start and runs rough or
stops.
637/3 2.4 SID22/3 Sensor rpm flywheel. Abnormal frequency. En- STOP
gine is extremely difficult to start and runs rough
or stops.
637/8 2.4 SID22/8 Sensor rpm flywheel. Abnormal frequency. En- STOP
gine is extremely difficult to start and runs rough
or stops.
639/FMI 6.5 SID231/ Internal error, engine control unit. STOP

FMI Engine off: engine cannot be started. Engine on:
engine goes to idle mode and can only be
stopped by using emergency stop.
639/FMI 9.9 SID240/ Memory error control unit engine. STOP

FMI May not be possible to start engine.
651/2 7.1 SID1/2 Electrical problem, injector cylinder 1. Engine STOP

only runs on 5 cylinders and has reduced power.



651/7 7.1 SID1/7 Compression malfunction or defective injector STOP

cylinder 1. Rough running at low rpm and low
load.




Description Action
Display Flash J1587



load.






load.






load.



Description Action
Display Flash J1587




cylinder 5. Engine runs on 5 cylinders, sounds
rough and has reduced power.






load.

677/FMI 6.3 PPID3/ Starter motor. STOP

FMI
1485/3 5.1 PPID5/3 Main relay, cable short-circuited to voltage. In- STOP
strument panel loses voltage when ignition key
is turned to start position. Engine does not start.
520192/ 6.8 PPID8/ Piston cooling. STOP

FMI FMI
520192/ 6.7 PPID8/ Piston cooling. STOP

FMI FMI
520194/ 4.7 PPID4/ Starter motor (start request). STOP

FMI FMI
520195/ 4.8 PPID6/ Ignition off (stop request). STOP

FMI FMI

Table 3. Error codes Cummins QSM11
Description Action
Display Flash J1587

84/2 241 PID084/2 Sensor speed, data invalid. Engine rpm limit- WARNING
ed to max. rpm without gear.
84/10 242 PID084/10 Sensor speed, incorrect signal. Engine rpm WARNING
limited to max. rpm without gear.
91/3 131 PID091/3 Accelerator pedal, cable short-circuited to STOP

voltage. Engine does not respond to throttle.
91/4 132 PID091/4 Accelerator pedal, cable short-circuited to STOP

ground. Engine does not respond to throttle.
91/8 147 PID091/8 Accelerator pedal, too low frequency. Engine STOP
does not respond to throttle.
91/8 148 PID091/8 Accelerator pedal, too high frequency. Engine STOP
does not respond to throttle.
91/19 287 SID091/2 Problem with accelerator pedal. Engine only STOP
runs on idle.
97/3 428 PID097/3 Sensor water in fuel, cable short-circuited to WARNING

voltage.
97/4 429 PID097/4 Sensor water in fuel, cable short-circuited to WARNING

ground.
97/15 418 PID097/15 Water in fuel. Risk of reduced engine power. WARNING: Drain fuel pre-filter,
see 6.2.2 Fuel system.
100/1 415 PID100/1 Low engine oil pressure. Engine power is re- STOP: Check oil level in engine.
duced gradually, after 30 seconds engine is See 6.2.6 Engine oil.
shut off.
100/2 435 PID100/2 Sensor oil pressure, data error. No warning in WARNING
case of low oil pressure.
100/3 135 PID100/3 Sensor oil pressure, cable short-circuited to WARNING

voltage. No warning in case of low oil pres-
sure.
100/4 141 PID100/4 Sensor oil pressure, cable short-circuited to WARNING

ground or open circuit. No warning in case of
low oil pressure.
100/18 143 PID100/1 Low engine oil pressure. WARNING: Check oil level in en-
102/2 433 PID102/2 Sensor boost pressure indicates high boost WARNING
pressure when other engine data indicate
that pressure should be low. Reduced engine
power.

Description Action
Display Flash J1587

102/3 122 PID102/3 Sensor boost pressure, cable short-circuited WARNING
to voltage. Reduced engine power.
102/4 123 PID102/4 Sensor boost pressure, cable short-circuited WARNING

to ground or open circuit. Reduced engine
power.
103/16 595 PID103/0 Incorrect overspeed protection for turbo- WARNING

charging. Reduced engine power.
105/0 155 PID105/0 Inlet air too warm. Engine power is reduced STOP
gradually, after 30 seconds engine is shut off.
105/3 153 PID105/3 Sensor charge-air temperature, cable short- WARNING

circuited to voltage or open circuit. No warn-
ing at high coolant temperature.
105/4 154 PID105/4 Sensor charge-air temperature, cable short- WARNING

circuited to ground or open circuit. No warn-
108/2 295 PID108/2 Sensor air pressure, data error. Reduced en- WARNING
gine power.
108/3 221 PID108/3 Sensor air pressure, cable short-circuited to WARNING

voltage. Reduced engine power.
108/4 222 PID108/4 Sensor air pressure, cable short-circuited to WARNING

ground. Reduced engine power.
110/0 151 PID110/0 High coolant temperature. Engine power is STOP: Check coolant level. See
reduced gradually, after 30 seconds engine is 6.2.5 Cooling system.
shut off.
110/3 144 PID110/3 Sensor coolant temperature, cable short- WARNING

circuited to voltage or open circuit. No warn-
110/4 145 PID110/4 Sensor coolant temperature, cable short- WARNING

circuited to ground. No warning at high cool-
ant temperature.
111/1 235 PID111/1 Low coolant level. Engine power is reduced STOP: Check coolant level in en-
gradually, after 30 seconds engine is shut off. gine. See 6.2.5 Cooling system.
111/2 422 PID111/2 Sensor coolant level, data error. No warning WARNING: Check coolant level
at low coolant level. in engine. See 6.2.5 Cooling sys-
tem.
166/2 951 PID166/2 Power difference between cylinders. Rough INFORMATION

idling.
167/1 598 PID167/1 Low battery voltage. STOP

Description Action
Display Flash J1587

167/16 596 PID167/0 High battery voltage. WARNING
167/18 597 PID167/1 Low battery voltage or restart of engine re- WARNING
peatedly due to low battery voltage.
168/16 442 PID168/0 Voltage feed to control unit engine too high. WARNING
168/18 441 PID168/1 Voltage feed to control unit engine too low. WARNING
175/0 214 PID175/0 High engine oil temperature. Engine power is STOP
reduced gradually, after 30 seconds engine is
shut off.
175/3 212 PID175/3 Sensor oil temperature, cable short-circuited WARNING

to voltage or open circuit. No warning at high
oil temperature engine.
175/4 213 PID175/4 Sensor oil temperature, cable short-circuited WARNING

to ground. No warning at high oil temperature
engine.
188/4 466 SID032/4 Solenoid valve 1 wastegate. Reduced engine WARNING

power.
190/0 234 PID190/0 High engine rpm. Fuel supply restricted until STOP: Use less throttle.
engine rpm is below permitted engine rpm.
190/10 121 PID190/10 Sensor rpm/ignition position, one of two sig- WARNING
nals missing.
190/2 115 PID190/2 Sensor rpm/ignition position, both signals STOP

missing. Engine stops and cannot be started.
191/16 349 PID191/0 Incorrect calibration value. Speed limitation WARNING: Reduce throttle.
activated.
191/18 489 PID191/1 Speed warning for low speed. WARNING: Increase throttle.
251/2 319 PID251/2 Internal error, engine control unit. INFORMATION
441/3 293 PID441/3 Extra sensor temperature, cable short- WARNING

circuited to voltage. No warning at high tem-
perature control unit.
441/4 294 PID441/4 Extra sensor temperature, cable short- WARNING

circuited to ground. No warning at high tem-
perature.
558/13 432 SID230/13 Sensor accelerator pedal idle switch, calibra- STOP
tion error. Engine only runs at idle.
558/2 431 SID230/2 Sensor accelerator pedal idle switch, data WARNING
error.

Description Action
Display Flash J1587

558/4 551 SID230/4 Sensor accelerator pedal idle switch, cable WARNING
short-circuited to ground. Engine does not re-
spond to throttle.
608/2 412 SID250/2 Communication error Control unit engine. INFORMATION
626/11 381 SID237/11 Control relay preheating. Preheating not WARNING

working
627/2 434 SID251/2 Voltage feed to control unit engine disap- WARNING
pears without ignition off. Reduced engine
power. Difficult to start or engine stops.
629/12 111 SID254/12 Internal error control unit engine. Engine does STOP
not start.
629/12 343 SID254/12 Internal error, engine control unit. WARNING
630/2 341 SID253/2 Internal error control unit engine. Reduced WARNING
engine power. Difficult to start or engine
stops.
632/3 255 SID017/3 Solenoid valve fuel shut-off, cable short- WARNING
circuited to voltage.
632/4 254 SID017/4 Solenoid valve fuel shut-off, cable short- STOP
circuited to ground. Engine shuts down.
639/9 285 SID231/9 Communication error Control unit engine. WARNING
639/13 286 SID231/13 Communication error Control unit engine. WARNING
644/2 237 SID030/2 Accelerator pedal, sensor outside valid range. WARNING
Engine shuts down.
647/4 245 SID033/4 Fan clutch, cable short-circuited to ground. WARNING

Cooling fan constantly activated.
651/5 322 SID001/5 Electrical problem, injector cylinder 1. Engine WARNING

only runs on 5 cylinders, has reduced power.




Description Action
Display Flash J1587








702/3 527 SID040 Extra input/output 2, cable short-circuited to WARNING

PID154/3 voltage.
703/3 529 SID051/3 Extra input/output 2, cable short-circuited to WARNING

voltage.
974/3 133 PID029/3 Extra accelerator pedal, cable short-circuited STOP

to voltage. Engine does not respond to
throttle.
974/4 134 PID029/4 Extra accelerator pedal, cable short-circuited STOP

to ground. Engine does not respond to
throttle.
974/19 288 PID029/2 Problem with accelerator pedal. Engine does STOP
not respond to throttle.
1043/3 387 PID221/3 Accelerator pedal reference voltage, short- WARNING

circuited to voltage. Engine runs at idle.
1043/4 443 SID221/4 Accelerator pedal reference voltage, short- WARNING

circuited to ground. Engine runs at idle.
1072/11 388 SID070/11 Signal engine brake 1, short-circuited to WARNING

ground.
1073/11 392 SID029/11 Signal engine brake 2, short-circuited to WARNING

ground.

Description Action
Display Flash J1587

1079/3 386 SID232/3 Reference voltage, short-circuited to voltage. WARNING
Reduced engine power.
1079/4 352 SID232/4 Reference voltage, short-circuited to ground. WARNING

Reduced engine power.
1080/3 227 SID232/3 Reference voltage to sensor short-circuited WARNING

to voltage. Reduced engine power. No warn-
ing at low oil pressure or low coolant level.
1080/4 187 SID232/4 Reference voltage to sensor short-circuited WARNING

to ground. Reduced engine power. No warn-
ing at low oil pressure or low coolant level.

power.

power.

power.
1265/4 223 SID085/4 Solenoid valve oil-burn, cable short-circuited WARNING

to ground.
1319/2 419 PID102/2 Incorrect value sensor boost pressure. Re- WARNING
duced engine power.
1377/2 497 SID114/2 Error in control unit transmission. WARNING
1380/17 219 PID017/1 Low oil level engine. INFORMATION: Check oil level in
engine. See 6.2.6 Engine oil.
1383/31 611 SID151/11 Engine overheated. INFORMATION: Turn off engine

with ignition.
1384/31 299 SID029/14 Engine shutdown. WARNING: Turn off engine with
ignition.
1387/3 297 PID223/3 Extra sensor pressure, cable short-circuited WARNING

to voltage. No warning in case of oil pressure.
1387/4 298 PID223/4 Extra sensor pressure, cable short-circuited WARNING

to ground. No warning in case of oil pressure.
1484/31 211 SID216/11 Error codes in other control units. INFORMATION

Error codes from transmission

–
Description Action
Code
00/50 Memory error in control unit transmission. Transmission in STOP
locked neutral position ("shutdown").



20/60 Sensor oil pressure. Transmission in locked neutral position STOP

("shutdown").
20/61 Sensor oil pressure. Transmission in locked neutral position STOP

("shutdown").
21/02 Solenoid valves VFS. Transmission in locked neutral position WARNING

("shutdown").
30/04 Low battery voltage. STOP
30/05 High battery voltage. WARNING
31/00 Reference voltage to sensor is too low. WARNING
31/01 Reference voltage to sensor is too high. WARNING
40/06 Incorrect direction from gear selector. Transmission in WARNING

neutral.
41/06 Incorrect gear selection from gear selector. Control unit WARNING
does not allow change of gear range, however, operation of
machine is possible.
42/04 Actual gear ratio too low. One or several clutches slipping. STOP or WARNING
42/05 Actual gear ratio too high. One or several clutches slipping. STOP or WARNING
43/03 Sensor temperature torque converter WARNING
43/07 Torque converter’s temperature exceeds 100 °C. WARNING: Note the error and try to
reduce temperature in torque con-
verter by operating calmly.

Description Action
Code
43/08 Torque converter’s temperature exceeds 125 °C. WARNING: Stop the machine, engage
The control unit protects the transmission and does not al- neutral and apply full throttle (limited
low the temperature in the torque converter to exceeds the to 50%) to cool the transmission oil so
limit value. Transmission in locked neutral position ("shut- that temperature drops below 100 °C
down"). Engine is limited to 50 % of max. rpm. (error code 43/03 disappears).
When temperature in torque convert-
er is below 100 °C, resume work with
machine.
44/10 Position accelerator pedal message from engine’s control WARNING

unit.
46/05 Max. torque at inching has been exceeded. WARNING: Stop the machine, select
neutral. Select gear again.
50/00 Sensor oil pressure, short-circuiting to ground. Control unit STOP

transmission activates "limp home".
50/01 Sensor oil pressure, open circuit. Control unit transmission STOP
activates "limp home".
51/00 Sensor transmission oil temperature, short-circuiting to WARNING

ground.
51/01 Sensor transmission oil temperature, open circuit. WARNING
54/00 Reference voltage sensor 5V, short-circuiting to ground. WARNING
54/01 Reference voltage sensor 5V, open circuit. WARNING
60/00 Sensor rpm torque converter, short-circuiting to ground. STOP or WARNING

If several rpm signals or the engine rpm signal are incorrect,
control unit transmission activates "limp home".
60/01 Sensor rpm torque converter, open circuit. STOP or WARNING

61/00 Sensor rpm output shaft, short-circuiting to ground. STOP or WARNING

61/01 Sensor rpm output shaft, open circuit. STOP or WARNING

62/00 Sensor engine rpm, short-circuiting to ground. STOP or WARNING


Description Action
Code
62/01 Sensor engine rpm, open circuit. STOP or WARNING
63/00 Sensor rpm turbine, short-circuiting to ground. STOP or WARNING

63/01 Sensor rpm turbine, open circuit. STOP or WARNING

70/00 Solenoid valve VFS forward. Control unit transmission acti- STOP: Stop the machine and shift to
vates "limp home". neutral. Select reverse gear.
71/00 Solenoid valve VFS 2/4. Control unit transmission activates STOP: Stop the machine and shift to
"limp home". neutral. Select reverse gear.
72/00 Solenoid valve VFS reverse. Control unit transmission acti- STOP: Stop the machine and shift to

Description Action
Code
77/02 All gear packs disengaged. Transmission in locked neutral STOP

position ("shutdown").
80/00 Solenoid valve drive, short-circuiting to ground. Transmis- STOP

sion in locked neutral position ("shutdown").
80/01 Solenoid valve drive, open circuit or short-circuiting to bat- STOP

tery. Transmission in locked neutral position ("shutdown").
81/00 Solenoid valve gear selection 2/4, short-circuiting to ground. STOP: Stop the machine and shift to
Control unit transmission activates "limp home". neutral. Select reverse gear.
81/01 Solenoid valve gear selection 2/4, open circuit or short- STOP: Stop the machine and shift to
circuiting to battery. Control unit transmission activates neutral. Select reverse gear.
"limp home".
82/00 Solenoid valve gear selection 1/3, short-circuiting to ground. STOP: Stop the machine and shift to
Control unit transmission activates "limp home". neutral. Select reverse gear.
82/01 Solenoid valve gear selection 1/3, open circuit or short- STOP: Stop the machine and shift to
circuiting to battery. Control unit transmission activates neutral. Select reverse gear.
"limp home".
83/00 Solenoid valve drive, short-circuiting to ground. Transmis- STOP

sion in locked neutral position ("shutdown").
83/01 Solenoid valve drive, open circuit or short-circuiting to bat- STOP

tery. Transmission in locked neutral position ("shutdown").
90/xx - 99/xx Transmission malfunction. Transmission in locked neutral STOP or INFORMATION

position ("shutdown").
95.71 Control unit transmission cannot interpret in-data. STOP
99.90 Incorrect software in control unit. STOP
Control unit transmission can generate two states with reduced

functionality to protect the transmission in case of serious malfunc-
tions:
• "Limp home", indicated in display with "LH".
In this state, only gears 1-2 can be used in both directions. If the
malfunction occurs at a higher gear, manual downshifting is re-
quired to gear 1 or 2.
• "Shutdown", indicated in display with Sd".
In this mode, the transmission is permanently in neutral position
as there is no oil pressure to enable gear selection.

112 5 Handling – 5.4 Operating
5.4 Operating
5.4.1 While operating
General
page
–
D AN GE R
The machine’s work area is large and visibility from
the operator’s cab is restricted.
Keep in mind:
• Always check that no persons are in the way of

the machine or its equipment.
• The operator must always face in the travel di-
rection and should operate with special care
where persons or vehicles may appear.
• The operator shall adjust travel speed according

to the nature of the load, visibility conditions,
road conditions, etc.
• The operator should pay extra attention and

operate with special care near electrical power
lines, viaducts, docksides, ramps, gates/doors,
etc.
• Always operate carefully so that the attachment
does not collide with posts, power lines, etc.
• Use available visibility equipment such as rear-

view mirrors and TV-camera when reversing.
W AR N IN G
Never use a machine without first performing the
daily inspection.
For work instruction, see section 6.1 Daily inspec-

tion. Notify the foreman/supervisor if defects are
found on the machine during daily inspection!

5 Handling – 5.4.1 While operating 113
Instructions
–
Make a habit of checking the following at regular intervals while op-

51 52 erating:
• that coolant temperature is within the interval (approx. 70 °C).
• that fuel indicator on the display shows that there is fuel in the
tank.
NOTE
The fuel indicator should never go down to empty tank.
• that all warning lights are off.
• that horn, lighting, brake lights and direction indicators function
correctly.
006494 • that all hydraulic functions function correctly.
• that no error codes have been generated (shown on operator’s
display with error code indication and symbol). See section 5.3
51. Display for control and monitoring system
Handling error codes.
52. Indicator for control and monitoring system,
STOP or WARNING The control and monitoring system can, when needed, set speed
limitations for the machine. This happens at:
• high load on steering axle (overload on steering axle), dynamic
limitation
• tilt lock alt. levelling lock (locked to 5 km/h)

• pressed down control breaker
• transport with bottom lift, see Transporting load page 129
• raised cab, see Functions for load handling page 134 .

114 5 Handling – 5.4.2 Starting engine
5.4.2 Starting engine

General
page
–
W AR N IN G
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 gear selector and multi-function lever in neutral position.

Gear selector and multi-function lever must be in neutral, other-
wise engine cannot be started.
2. Turn the start key to operating position, position I.
Current is now supplied to all electrical functions.
3. Turn the start key to preheating position, position II.
In case of cold weather, preheating can be used. During pre-
heating the engine’s inlet air is preheated using a heating coil to
a suitable temperature to facilitate start.
For engine alternative Volvo TAD1250VE and Volvo TWD1240VE:
If needed, the engine’s control unit activates preheating for a
time period. The light for preheating (position 39) indicates if
preheating is activated.
Engine can be started, position III (start position), regardless of if
preheating is in progress, not activated (no need) or has been
finished.
Engine alternative Cummins QSM11 does not have preheating.
4. Turn the start key to start position, position III.
Let the starter motor crank engine, release the key when engine
starts. The machine has electric restart interlock that protects
the starter motor from engaging when the engine is rotating.
Note that some warning or indicator light may remain on after
start to indicate status. The light for preheating may remain on
for awhile during operation in cold weather, as preheating may
be active during initial operation.
NOTE
IF THE ENGINE DOESN’T START, try again after 15-20 sec-
onds. Don’t run the starter motor for longer than 10 sec-
onds at each start attempt.
If the engine still doesn’t start, this indicates that there is a
malfunction which has to be located and repaired. Contact
service.

5 Handling – 5.4.3 Warming up 115
5.4.3 Warming up
General
page
–
CAUTION
Never rev a cold engine at high engine speeds.
Risk of engine damage!

Run the engine at 1400-1500 rpm until it starts to
get warm.
Instructions
–
In case of extremely cold weather, the machine must not used in

tough work before operating temperature has been reached.
• It’s very important that the engine oil is warmed up and circu-
lates well before the turbocharger starts to operate at high
rpms.
• Start working with the machine when the coolant has reached
normal operating temperature (approx. 75 °C).
• Warm up the hydraulic oil. Run hydraulic functions without load
for a short time before starting to work.

116 5 Handling – 5.4.4 Gearshifting
5.4.4 Gearshifting
General
page
–
The machine is equipped with an automatic transmission. The sys-

tem shifts to a higher/lower gear under certain conditions such as
torque, engine rpm, travel speed, etc.
F
General about the automatic transmission:
• Has a built-in control and monitoring system, giving optimized
drive.
• Shows current gear on control and monitoring system’s display.
R 64
• Reverse lock-out prevents change of travel direction taking
63
place too fast, that is, prevents eventual transmission damage.
006495
62 Reverse lock-out is automatic and depends on engine rpm and
62. Switch for shifting program A travel speed.
63. Switch for shifting program 1 • Shifting is variable (modulated) and gives smoother operation.
64. Switch for shifting program 2 Normally start takes place in 2nd gear. Use of 1st gear is control-
led by, e.g., engine speed.
Instructions
–
1. Let the engine idle. Select travel direction, move lever forward
(F) or backward (R).
2. Select shifting program: A, 1 or 2.
The operator can limit gearshifting by selecting shifting program
on the steering wheel panel’s keys.
Shifting program A (position 62) – automatic shifting between all
gears.
Shifting program 1 (position 63) – gear is locked to 1st gear.
Shifting program 2 (position 64) – gear is locked to 2nd gear.
NOTE
In certain circumstances, the transmission may be forced
to reduce speed due to a problem.
The control unit may then put the transmission in "limp
home" mode.

5 Handling – 5.4.5 Steering 117
5.4.5 Steering
General
page
–
The machine is equipped with servo steering. The steering wheel

movements are transferred hydraulically to the steering wheels on
the ground.
W AR N IN G
The machine may not roll on a downhill grade if the
engine is off.
There is no hydraulic pressure or steering capacity!

Danger!
Keep the engine running for hydraulic pressure.
5.4.6 Service brake

General
page
–
The brake pedal (position 12) used as service brake.

Use brakes smoothly yet firmly. Brake pressure that has accumulat-
ed during operation may remain for some time after the engine has
been turned off. If the accumulator pressure drops below a certain
level, the indicator light for low brake pressure (position 33) is acti-
vated on the panel. Check the accumulators for leaks if pressure
isn’t built up and maintained, see chapter 6 Inspection and mainte-
nance.
The brake pedal is combined with a separate clutch pedal (position
13). When the brake and clutch pedals are pressed down at the
same time, the transmission is disengaged. Before drive is disen-
gaged, the drive functions as an engine brake.
000340
12 13 12 11
11. Accelerator (throttle pedal)
12. Brake pedals
13. Clutch pedal

118 5 Handling – 5.4.7 Parking brake
5.4.7 Parking brake

General
page
–
W AR N IN G
Never leave the operator’s seat without first apply-
ing the parking brake.
Risk of machine starting to roll! Danger!
The parking brake is operated with the switch (position 8) on the

panel for hydraulic functions (position 6). The indicator light for park-
ing brake (position 46) is activated with a red light when the parking
brake is applied.
Instructions
–
The parking brake is applied when:

• The switch for parking brake is pressed down (indicator light for
parking brake is activated with a red light).
• The ignition is turned off (to 0 position).
When the ignition is turned on again, the parking brake is applied
30-35 without the switch for parking brake being activated. The indica-
tor light for parking brake flashes to indicate that the parking
brake switch should be turned on and then off to release the
parking brake. Check the accumulators for leaks if pressure isn’t
built up and maintained; see chapter 6 Inspection and mainte-
8 nance.
An audible signal is activated if the operator gets up from the oper-
ator’s seat without first applying the parking brake.
33 46
If the accumulator pressure drops below a certain level, the warning
light for low brake pressure is activated (position 33). The service
brake’s capacity is limited when the light is activated. Finally, the
parking brake is applied automatically by a forceful spring in the
brake cylinder.
If the machine has to be moved, see chapter 7 Transporting the
machine.
003680
8. Switch for parking brake

33. Warning light for low brake pressure
46. Indicator light for parking brake

5 Handling – 5.4.8 Heating/Air conditioning 119
Emergency brake
–
The parking brake can be used as an emergency brake in emergency

situations.
CAUTION
The parking brake can be used as an EMERGENCY
BRAKE.
Brake pads wear out and lose their braking perform-

ance! Unwanted movement of parked machine!
Following emergency braking with the parking
brake, check the brake pads as soon as possible,
change if needed! Braking action of the parking
brake may be lost as the brake pads may have been
worn down.
If the parking brake has been released mechanical-

ly, it must always be reset to restore the machine’s
parking brake functions.
5.4.8 Heating/Air conditioning

General
page
–
Heating (EHC) / climate control unit (ECC) receives heat from the en-
A gine’s cooling system and gives heat when the engine is warm. For
ECC, cooling performance is generated by the AC compressor.
The system is controlled by switches for fan, heat and air distribu-
tion. In addition, there are functions for recirculation and defroster.
For ECC: In case of open door, the air conditioning’s compressor is
turned off (cooling function and air drying stops). Close the door and
the AC compressor is reactivated.
18
17
004690
16
A. Panel nozzle
16. Switch for fan
17. Switch for heat
18. Switch for air distribution

120 5 Handling – 5.4.8 Heating/Air conditioning
Normal weather conditions

–
1 Set desired temperature (position 17).

Set the temperature within temperature range 17 °C to 27 °C.
See position B on display.
Setting of min. and max. respectively, shuts off automatic cli-
mate control (control of fan, temperature and air distribution)
and sets the heat valve in min. and max. position, respectively.
004918
2 Switch (green) for fan handles setting of fan speed for the cab.
Fan speed can be set for:
• automatic control, AUTO. See position C on display.
• manual control in 13 steps from off to max. Fan speed is
shown by the bar’s height in the operating menu for heat-
ing / air conditioning system. See position C on display.
Recommendation: Set the fan to automatic control, AUTO, for
C
optimal function of the system. Automatic control
is activated when lowering with the switch from fan off.
004919
C
NOTE
When the fan is off, the cooling functions ceases (for ECC).
3 Set air distribution (position 18) and panel nozzles as desired for
a comfortable operator climate. See position E on display.
4 Normally, recirculation (function key for Enter) and defroster
(position 54) do not have to be used.
Defroster - position D on display
Recirculation - Position F on display
D
E
F
004920

5 Handling – 5.4.8 Heating/Air conditioning 121
Mist on windows
–
1 Set a warm temperature (position 17).

2 Set a fan speed to a faster position (position 16).
3 Set air distribution (position 18) and panel nozzles (position A)
at the front windshield to get good visibility through the
windows.
004915
4 Check that recirculation is not engaged. Recirculation may im-

pair effective demisting.
The symbol for recirculation shall not be shown in the informa-
tion menu for heating / air conditioning. See position H on
G display.
To activate/deactivate recirculation, press on the function key
for Enter when the information menu is shown. See position G.
H
004917
5 Activate defroster (position 54).

The defroster controls the function fan, temperature and damp-
er position to optimally heat and faster dry the air at the front
windshield for faster demisting. The function is active for
6 minutes.
I The symbol for defroster is shown in the information menu for
heating / air conditioning, and is indicated in the switch. See po-
sition I on display.
004921
NOTE
The defroster function is active for 6 minutes.
Check that temperature control returns to set value when
the defroster is turned off.
6 In case of a lot of mist, set the panel nozzles (position A) at the
front windshield for optimal demisting.

122 5 Handling – 5.4.9 Stopping engine – parking
5.4.9 Stopping engine – parking

General
page
–
NOTE
Never disconnect the main electric power with the battery dis-
connector when the engine is running! The voltage regulator
may be damaged.
Instructions
–
1. Stop the machine and move the gear selector and multi-function
lever to neutral position.
2. Apply the parking brake.
3. Run in the boom completely and lower it to its lowest position.
4. For hydraulic sliding cab or hydraulic vertically adjustable cab
: Return the cab to its original position.
5. 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.
6. Stop the engine by turning the start key to position 0.
In case the machine is going to be parked for a long time, the
battery disconnector should be turned to the OFF (0) position.
When idling:
• The engine is shut off at idle running for longer than 3 to 10
minutes (adjustable).
• Work lights are shut off after 5 minutes.
• Extra work lights are shut off after 2 minutes.

5 Handling – 5.5 Load handling 123
5.5 Load handling

General
page
–
During all lifting work, make sure that the max. lift capacity is not ex-
ceeded, see machine plate or load diagram.
The reachstacker’s capacity is indicated by two parameters:
• number of containers in height
• load size and its centre of gravity in relation to the machine
The capacity varies between models and versions; see the machine
and type plates, section 3.2 Plates.
It’s 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 sideshift so that the load’s centre of gravity is moved
to a position along the machine’s centre line.
000364
The load handling function refers to, for example, lifting, lowering,
rotating, angling and holding a load. Load handling also includes help
functions when handling loads, for example, support jacks.
Load handling sub-functions.
003680
• Lift/lower
Lift and lower

• Extension
003682
Extension
• Sideshift
001113
Sideshift
• Spreader
001114
Spreader

124 5 Handling – 5.5 Load handling
• Rotation
Rotation stop ±25°
003683
Rotation
• Damping
Damping with tilt lock
003684
Damping with adjustable tilt
Tilt Damping with adjustable tilt and tilt lock

• Mechanical levelling ±5°
Hydraulic levelling
001117
Levelling
• Twistlocks
004868
Twistlocks
Overload system
–
The machine is equipped with a warning system, LLMC (Longitudinal

Load Moment Control). The warning system shall ALWAYS be func-
tional! The system is used for stationary load handling, in order to
not jeopardize the machine’s stability in the forward direction.
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.
• boom movement is interrupted.
In this position the boom, and thus the load, can only be retract-
ed until the buzzer stops sounding and the display figure disap-
pears.
NOTE
Retract the boom before it is lowered! Applies to all load
handling!
LLMC is not intended for controlling lateral stability or stability during
operation. As well, it does not take sloping ground conditions into
consideration.
For advice on handling the machine, see section 2.4 Keep in mind.

5 Handling – 5.5.1 Lifting load 125
5.5.1 Lifting load

General
page
–
There are two types of attachments which differ in lift handling:

• top lift attachment
For a top lift attachment, the attachment must be aligned with
all four corners against the container both when locking and re-
leasing the twistlocks. When releasing, the container must
stand securely with all four corners on the ground surface.
• bottom lift attachment
For a bottom lift attachment, all four legs must be in clamping
position and be aligned with the load before starting to lift.
W AR N IN G
Never use a machine if the indicator lights don’t
work.
Risk of reduced safety when handling loads!
If the indicator lights don’t work, stop work with

the machine and repair.
W AR N IN G
The machine’s load capacity is limited.
It is prohibited to exceed the machine’s load capac-

ity. See marking plate and load diagram. The ma-
chine’s stability limit may be exceeded if the
overload protection system is not working.

126 5 Handling – 5.5.1 Lifting load
Instructions for top lift attachment

–
1 Run the machine forward towards the stack of containers, as

A B C close as possible. Strive to line up the machine’s centre with
the centre of the container.
2 Hold the machine stationary with the service brake and clutch
pedal. Alternatively, apply the parking brake if desired and/or
shift to neutral gear.
000365
3 Place the attachment slightly above the container. Adjust with
A B C rotation, sideshift and boom in/out.
4 Set spreading to container length in question.
Right light, C – Twistlocks unlocked, red light activated, indi-
cates that load is not secured.
000366
5 Lower the attachment on the container.
A B C This is indicated on the display with the symbol for alignment.
000468
000367
6 Middle light, B – Alignment, orange light activated, indicates

when all four corner boxes have correct alignment against the
container.
7 Lock twistlocks with the switch for twistlocks (position 69).
If automatic locking of twistlocks is used, locking is automatic
when the attachment is aligned with the load.
Locking alternative is selected with the switch for automatic or
manual locking (position 69).
NOTE
For automatic locking of twistlocks, the parking brake
must be released.

5 Handling – 5.5.1 Lifting load 127
8 Right light, C – Twistlocks unlocked, off.

Left light, A – Twistlocks locked, is activated with green light
and indicates that load is secured and ready for lifting.
The lift function is disconnected when both right light, C –
Twistlocks unlocked, and left light, A – Twistlocks locked, are
off. Left light, A – Twistlocks locked, is activated with green light
when the locking process has been completed.
CAUTION
Do not start to lift if light C "Twistlocks unlocked" is
on, or if any of the lights A "Twistlocks locked" or B
"Alignment" are off.
Load is not secured!
Try to lock twistlocks once again.
9 Ready for lifting.

When the container is lifted, the light for alignment (position B)
should go out.
Instructions for bottom lift attachment

–
1 Lower the rear leg pair.

D E H I
Light I – Front leg pair raised, white light activated, indicates
F G J K that front leg pair is raised.
2 Place the attachment’s rear legs slightly under the load. Adjust
with rotation, sideshift and boom in/out.
3 Run the machine forward towards the load until clamping posi-
tion is indicated for rear leg pair. Strive to line up the machine’s
centre with the centre of the load.
Light J – Clamping position rear leg pair, orange light activated,
000418
indicates when rear leg pair has clamping position against load.
4 Hold the machine stationary with the service brake and clutch
D E H I pedal. Alternatively, apply the parking brake if desired and/or
shift to neutral gear.
F G J K
000419

128 5 Handling – 5.5.1 Lifting load
5 Lower front leg pair.

D E H I
Light K – Front leg pair lowered, orange light activated, indi-
F G J K cates that legs are lowered.
6 Secure load by setting legs in clamping position.
Lights H and J – Clamping position front and rear leg pair, yellow
lights activated, indicate clamping position.
Light K indicates that front legs are lowered.
000420
7 Ready for lifting.
D E H I
When load is lifted, lights D, E, F and G – Alignment legs against
F G J K load, should light up within 4 seconds.
Lights H, I, J and K are off at full alignment of rear leg pair against
the load, that is, lights H and J – Clamping position front and
rear leg pair, and light K – Front legs lowered, go off.
NOTE
Lights D, E, F and G must be activated within 4 seconds
000421
when lifting, otherwise the lift attempt is aborted. Lower

load to the ground. Lights D, E, F, G, H and J must be unaf-
fected before a new lift attempt is made.
Instructions for lifting with slings

–
Attachment points or hooks are located at each twistlock/corner

box on the attachment. These are used in conjunction with lifting
slings. The maximum weight when lifting with slings is 40 tonnes.
Bear in mind the following when lifting with slings:
• The equipment used to lift with slings must be the correct size
as well as approved for such usage and the load to be lifted.
• Use slings that are as short as possible.
• The load must always be lifted vertically using all four corners
with the load equally distributed to the four lifting points (see
Max 15˚ figure).
• When lifting and transporting a load hanging in "slings", drive
slowly (below 5 km/h) and pay close attention to the position of
the load.
002564

5 Handling – 5.5.2 Transporting load 129
5.5.2 Transporting load

General
page
–
W AR N IN G
Transport of loads is associated with great risks.
Risk of roll-over and tipping over! Risk of load dam-

age to property!
Respect the machine’s lift capacity and operate

with great care during load handling:
• The machine shall only be operated on even sur-

faces, intended for the machine’s total weight
and ground pressure.
• All loads should be carried in the transport posi-

tion. Always operate carefully, keep in mind the
width and height, so that the boom or attach-
ment does not collide with posts, power lines,
etc.
• When transporting, the load’s centre of gravity

shall always be centred sideways (laterally).
• Do not transport the load in high position 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 transpor-

ted load obscures visibility to the front.
• No personnel may enter/stand under a raised

load.
• The operator should avoid powerful acceleration

and braking.
• The operator should always adjust the speed

when turning to prevent skidding and risk of
roll-over.
In case the machine rolls over or tips, always

stay in the cab. Do NOT try to jump out of the cab
until the machine has stopped moving.
Note that the illustrations in this section show transport with top lift
attachment and container. Instructions also apply to transport with
bottom lift attachment and load.

130 5 Handling – 5.5.2 Transporting load
Instructions for top lift and bottom lift

–
1 Lift the load slightly. Back away from the stack.

D E H I Top lift: when load is lifted, the middle light, B – Alignment, (or-
F G J K ange), is off. Then the function for twistlocks is disconnected.
Bottom lift: when lifting, lights D, E, F, and G for alignment and
clamping position are on. Lights H, I, J and K are not activated
at full alignment of the leg pairs against the load.
A B C
000368
2 Adjust load height and boom to transport position.

D E H I
F G J K
D AN GE R
Load handling requires extreme care when loading
A B C
and at high load handling height, that is, long boom
extension.
Risk of tipping or rolling over! Fatal danger!
When a load is to be lowered, ALWAYS retract the

boom BEFORE lowering the boom.
000369
3 The correct transport position is with the load as far down and
D E H I in as possible without obstructing visibility; see Transport posi-
tion page 131. The load’s centre of gravity should be centred
F G J K
sideways (laterally).
NOTE
A B C When transporting a load with the OHC-attachment’s fold-
able extended twistlocks down, the centre of gravity is
moved farther from the attachment’s rotation point. This
affects damping of the attachment. Adjust the speed. If
possible, do not transport loads for long distances with
twistlock in lowered position.
NOTE
000370
When transporting loads with bottom lift attachment, machine

speed is limited to max. 2nd gear and 10 km/h.

5 Handling – 5.5.2 Transporting load 131
Transport position
–
When the machine is to be operated with a load, transport position

shall be assumed, which minimizes the risk of roll-over and imbal-
ance during operation. In transport position, the boom is completely
retracted, the load’s centre of gravity is centred sideways (laterally)
and the load is lifted for good forward visibility (see illustration to the
left). All transport shall take place with the cab in the rear position.
When transporting a load hanging in "slings", drive slowly (below 5
km/h) and pay close attention to the position of the load.
000363 Operating on grades

It is important to operate with extreme care on grades since there’s
an increased risk of tipping and rolling over.
NOTE
When braking, use only the service brake pedal (right-hand
brake pedal). Do not operate service brake in combination with
clutch pedal.
• When operating with a load.
Lower the load as low as possible without compromising visibil-
ity. Retract the boom as far as possible.
Always operate with the load against the grade (see figure), re-
gardless of travel direction.
• When operating without a load.
Lower and retract the boom as far as possible.
Always operate with the attachment in the direction of the
grade (down), regardless of travel direction.
Working near overhead high voltage power lines

Operate with extreme care in all work near overhead high voltage
power lines, keeping in mind the extensive reach capacity of the
005066
boom and attachment.
D AN GE R
If the machine comes into contact with overhead
high voltage power lines - sit down in the seat and
call for help!
Danger to life!
Remain in the cab and wait for help.

132 5 Handling – 5.5.3 Unloading
5.5.3 Unloading
General
page
–
There are two types of attachments which differ in lift handling:

• top lift attachment
• bottom lift attachment
Instructions for top lift attachment

–
1 Run towards the stack of containers, as close as possible.
A B C 2 Lift the load over the stack.

Strive to center the load over the stack. Approach angle to-
wards container is operator’s choice.
000371
3 Apply the parking brake if desired, or hold the machine station-

ary with the service brake and clutch pedal. Alternatively, shift
A B C
to neutral.
4 Position the load over the stack. Adjust with rotation, sideshift
and boom in/out.
000372
5 Lower the load.

A B C When alignment is obtained, the middle light, B – Alignment, is
activated.
6 Open twistlocks. Left light, A – Twistlocks locked, goes off
(green) when release of twistlocks is initiated. Right light, C –
Twistlocks unlocked, is activated (red) when twistlocks are
completely open.
Never lift when twistlocks are in the process of being released.
000373

5 Handling – 5.5.3 Unloading 133
Instructions for bottom lift attachment

–
1 Run towards the unloading site, as close as possible.

D E H I
2 Lift the load to suitable height.
F G J K Strive to center the load over the unloading site.
000422
3 Apply the parking brake if desired, or hold the machine station-
D E H I ary with the service brake and clutch pedal. Alternatively, shift
to neutral.
F G J K
4 Position the load over the unloading site. Adjust with rotation,
sideshift and boom in/out.
000423
5 Lower the load.

D E H I
Alignment of legs against load disappears, which is indicated by
F G J K lights D, E, F and G.
6 Leave clamping position for legs to release load.
Lights H, I, J and K are activated once again when full alignment
of the leg pairs against the load ceases.
Lights H and J are off to indicate that clamping position is no
longer active.
Lights K is activated to indicate that the front leg pair is lowered.
000424
7 Raise front leg pair.

D E H I
Light K goes off to indicate that the front leg pair is no longer
F G J K lowered.
Light I is activated to indicate that the front leg pair is raised.
8 Back away from the load and raise the rear leg pair.
000425

134 5 Handling – 5.5.4 Functions for load handling
5.5.4 Functions for load handling

Support jacks
page
–
Both support jacks (position B) are mounted at the front in the frame
and their function is to stabilize the machine during load handling.
The support jacks are operated with the switch for support jacks (po-
A
sition A).
The parking brake must be OFF, see indicator light for parking brake.
1 Run toward the load handling site and stop the machine.
2 Lower the support jacks with the switch.
Hold in the switch during the entire movement.
During the movement, the information figure (position C) is
shown on the control and monitoring system’s display. When
B the support jacks are down, this is indicated in the hydraulic
panel by the indicator light for support jacks. The information
figure on the display disappears.
C
3 Perform load handling.
4 Raise the support jacks with the switch.
The indicator light goes off. During the movement, the informa-
003685
tion figure (position C) is shown. The information figure on the

display disappears when the support jacks have been raised.
For automatic raising / lowering, throttle up (above 1000 rpm) and
press once up / down on the switch for support jacks (position A).
For automatic raising / lowering, AUTO is shown on display.
Hydraulic sliding cab

–
The moveable cab improves visibility during load handling. The cab
is operated with the switch for hydraulic sliding cab (position A).
A The operator’s door(s) shall be closed and the control breaker for hy-
2 Move the cab with the switch.
3 Perform load handling.
NOTE
003686
Move the cab while the machine is stationary!

Hydraulic sliding cab

5 Handling – 5.5.4 Functions for load handling 135
Hydraulic vertically adjustable cab

–
Hydraulic vertically adjustable cab improves visibility during load

handling. The cab is operated with the switch for hydraulic vertical
A adjustment of cab (position A).
The operator’s door(s) shall be closed and the control breaker for hy-
1 Close the doors and secure safety chains on the insides of the
doors.
Use the seatbelt.
003687 3 Move the cab with the switch.

Hydraulic vertically adjustable cab 4 Perform load handling.
If the cab is not in the lowest position, that is, raised, the ma-
chine’s speed is limited to max. 2nd gear and 10 km/h.
NOTE
Move the cab while the machine is stationary!
D AN GE R
When entering under raised cab.
Danger to life!
A
Secure the cab with the lock lugs (position A) on the
sides of the cab frame.
001977
A. Lock lug
If the cab should jam in the raised position, it can be lowered manu-
ally with an emergency lowering valve, see Emergency equipment
page 75.

LC-limitation
–
LC-limitation prevents the load from being lifted over the cab (stand-
ard for vertically adjustable cab). When the load reaches a certain
distance from the machine, synchronized lift (lower boom or in-
crease boom extension) is activated automatically.
Use switch for LC-limitation (position A) for by-passing the
LC-limitation.
W AR N IN G
The load may strike the cab when the LC-limitation
has been by-passed.
Danger! LC-limitation disengaged!

Avoid by-passing the LC-limitation.
A
001927

Rotation stop
–
Rotation stop limits the rotational movement of the attachment

±25°. When the limit for rotation stop is reached, the rotational
movement stops and the figure is shown on the display.
Use switch for rotation stop (position A) for by-passing rotation stop.
The figure for rotation stop disappears from the display when the ro-
tation of the attachment is within the interval for rotation stop
A limitation.
003688

Fixed scale
–
Fixed scale weighs the load at a defined position. The position is in-
dicated by the event figure for fixed scale.
1 Lift load and run in the boom completely.

2 Press in the trigger (position A) on the joystick.
Event figure for fixed scale is shown.
A 3 Lift or lower the boom.
Arrow indications (position C) indicate if the boom needs to be
raised (arrow up) or lowered (arrow down).
When the boom is at the correct height, this is indicated by both
B
arrow up and arrow down being shown at the same time. Then
C the boom movement stops automatically.
4 Run out the boom. The trigger shall be pressed in for the event
figure for fixed scale to be shown.
The weight indication flashes (position B) until correct boom ex-
D tension is reached.
When extension is in correct position, this is indicated by the
006763
weight indication becomes larger and flashing stops. Then ex-

tension stops automatically.
5 Read off the measured weight.
The weight indication is indicated with larger text and is shown
with steady display (position D).
The load is calculated by the control and monitoring system.
Accuracy is 1% of the max. load capacity, that is,
approx. +/-0.5 ton.
6 Release the trigger for weighing and continue load handling.
The event figure for fixed scale disappears from the display.

Height limitation
–
Height limitation limits how high the boom can be raised. The height
limitation is adjustable according to the customer’s needs.
When the boom reaches a certain preset height (position A), the lift
movement is stopped and the figure is shown on the display. Lower
or retract the boom to continue load handling.
A
If there’s a need to lift above the preset height limitation, the func-
tion can be by-passed with the switch for height limitation (position
B). When the height limitation has been passed (grey area in figure,
approx. 70 cm.), lift, lower or extension can be operated without
by-passing.
The figure on the display is always shown when the lift height ex-
ceeds the height limitation.
B
001133


6 Inspection and maintenance 141
6 Inspection and maintenance
6 Inspection and
mm mm mm mm
maintenance
General
page
–
This chapter describes:

• DAILY INSPECTION– performed by the operator.
Daily inspection describes the running inspection that signifi-
cantly 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.
Advanced maintenance is performed according to a service
schedule and by trained service technicians. Advanced mainte-
nance actions are described in the service manual.
It is the operator who is responsible for ensuring that the ma-
chine comes in for service at the prescribed service interval. The
service interval is every 500 operating hours. Procedures are de-
scribed in the maintenance manual.
• ERROR CODE INFORMATION – read off by the operator.
Error code information is read off by the operator from the con-
trol and monitoring 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 Kalmar Industries may
be used.
This is to fulfil warranty and service contracts!

Only use spare parts and fluids approved by Kalmar
Industries to fulfil warranty terms.

142 6 Inspection and maintenance – 6.1 Daily inspection
6.1 Daily inspection

General
page
–
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 mal-
functions that have been generated or caused during an earlier work
shift.
W AR N IN G
Never use a machine without first performing the
daily inspection.

Notify the foreman/supervisor if defects are found
on the machine during daily inspection!
Instructions
–
Perform the following checks:

1. Visual external check of the machine. Walk around the machine
and check the following:
• That sensors for twistlocks and alignment are clean and free
from grease
• Leakage from engine, transmission, drive axle, steer cylin-
der, hydraulic hoses and hydraulic cylinders
• Loose wheel studs
Following a wheel replacement, check-tightening of the
wheel studs/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, for example, glass, metal filings, etc.
• Tyre pressure
• Rear steering axle mounting is clean and both sensors for
mechanical overload system are free from grease
• Lift boom’s mounting points and glide plates with regards to
damage
• Communication equipment - direction indicators, brake
lights, headlights and reflectors with regards to damage
• Cab with regards to damage and dirty windows.

6 Inspection and maintenance – 6.1 Daily inspection 143
2. Check fluid levels for the following fluids according to descrip-

tion, see section 6.2 Maintenance. Top up, if needed, with the
correct fluid:
• Hydraulic oil
• Oil for brake system
• Batteries’ electrolyte level
• Coolant
• Washer fluid – windows
• Engine oil
• Transmission oil
3. Check the engine’s indicator for air filter, also check and drain
the fuel prefilter, when needed. For description, see section 6.2
Maintenance.
4. Start the machine according to instructions and check:
• Instruments – warning lights, indicators, eventual error co-
des on display
• Fuel level – the gauge must not show empty tank
• Lighting, direction indicators, horn, brake lights, flashing ha-
zard lights
• Windshield wipers
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
6. Check the attachment’s functions and that:
• Indicator lights for twistlocks and alignment function
• Contact pins at twistlock can be moved easily up and down.
Note that a contact pin that binds in the upper position can
indicate alignment 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 "Alignment" goes out.
Now, it shouldn’t be possible to release the twistlocks.
7. Run all functions with hydraulic cylinders (boom lift/lower/in/out
and sideshift) to their end-positions for lubrication of the cylin-
der barrels and piston rods.

144 6 Inspection and maintenance – 6.1 Daily inspection
8. For central lubrication

Check that grease has not penetrated out from the safety valve
(position A). That’s a sign that the central lubrication is not work-
ing correctly.
9. Check the machine’s operating hours – notify the foreman/su-
pervisor if the machine is close to a service interval.
A 10. Notify the foreman/supervisor immediately if any defects are

detected on the machine.
11. In cold weather:
• check that wiper blades have not frozen to the windshield
• remove snow from air inlets and cooling/radiator grill
• anti-freeze in washer fluid
• connect an auxiliary heater for cab and engine

006835
Electrical box for auxiliary heater is located by the cab steps

Example figure of unit for central lubrication on the left side of the machine.
12. Check if any error codes are active.
See section 5.3 Handling error codes.

6 Inspection and maintenance – 6.2 Maintenance 145
6.2 Maintenance
General
page
–
The following maintenance actions are described in this chapter:

– Cleanliness, general page 147
– Fuel system, general page 148
– Windshield washer, general page 150
– Air filter engine, general page 151
– Cooling system, general page 152
– Engine oil, general page 153
– Transmission oil, general page 154
– Oil, brake system, general page 155
– Hydraulic system, general page 156
– Tyres and rims, general page 158
– Accumulators, general page 161
– Battery and battery disconnector, general page 162
– Main fuses for electrical system, general page 164
– Fuses for electrical system, general page 165
– Lighting, general page 169
Safety during maintenance

–
Observe the following when maintenance work is to be performed:

• Always turn off the engine during service work. Only exception
is when service work requires engine power.
• No work may be done on the machine without the right know-
ledge and skills to do the work correctly. Service performed in-
correctly 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 ope-
rator’s manual before performing any maintenance. Each one
contains important information about handling and service.
• Avoid spills when draining/filling oils and fuel. Use reservoirs/
tanks, pump, hose, etc. for safe handling. Oils and fuels cause
environmental damage and should be taken care of by an aut-
horized company.
• Always drain the pressure from the accumulators before any
work on the hydraulic system.
• The unit for air inlet to the cab (at front part of cab) is provided
with slip-protection and can be used as a platform to stand on
when performing maintenance by the front part of the cab.

146 6 Inspection and maintenance – 6.2 Maintenance
Cab movement
–
The cab can be moved forward for better visibility and access in the
engine compartment. There is:
• manual cab movement
• hydraulic cab movement
• hydraulic vertically adjustable cab

For hydraulic cab movement, the movement is controlled with a hy-
A draulic function on the panel for hydraulic functions. See section 4
Instruments and controls and section 5 Handling.
Instructions for manual cab movement
1. Select neutral gear with gear and multi-function lever.
3. Close the doors.
4. Remove the pin (position B) from the lock handle.
5. Open the lock handle (position C).
Loosen the lock handle on both sides.
000270
6. Push cab forward.

B C
A. Position lock handle
B. Lock pin
C. Lock handle for securing cab
D AN GE R
The cab is very heavy and the machine must not be
moved without first securing the cab.
Fatal danger! Risk of crushing!
Secure the cab, both sides, with the lock handles

and pins before starting to operate the machine.

6 Inspection and maintenance – 6.2.1 Cleanliness 147
6.2.1 Cleanliness
Cleanliness, general
page
–
Dirt has a negative impact on performance. Experience shows that

clean machines have less malfunctions.
The machine should be washed regularly for optimal function. Keep
the following in mind when washing the machine:
• Use mild cleaning agents.
Use a de-greaser if needed. Scrub if needed.
• Use a high-pressure washer, wide water jet.
Do not use a high-pressure washer on the battery compartment,
electrical 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.
W AR N IN G
Low strength! Danger!
Check the outside surface of the roof window at

regular intervals. Clean only with windshield wash-
er fluid or a mild cleaning agent. Rinse thoroughly
with plenty of lukewarm water. Replace a damaged
roof window immediately if it’s cracked or
scratched!
CAUTION
Cleaning agents contain different solvents.
Health hazard.
Provide for adequate ventilation when cleaning the

machine. Avoid skin contact, use protective gloves.

148 6 Inspection and maintenance – 6.2.2 Fuel system
CAUTION
Cracks or scratches result in reduced strength of
the roof window.
Low strength!
Replace a damaged roof window immediately.
6.2.2 Fuel system

Fuel system, general
page
–
The filler pipe is located on the machine’s left side.
NOTE
Make sure that the area around the tank cap is clean when
refuelling.
W AR N IN G
Fuel is highly flammable and health hazardous.
Fire hazard! Health hazard!
Handle with great care and avoid all possible igni-

tion sources, for example, cigarettes, sparks. Avoid
skin contact, use protective gloves. In case of skin
contact and spills on clothes, wash the skin and
change clothes.
006430
A
• Always fill up with diesel fuel.
A. Refuelling point
• 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-con-
densation 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.
• For tank volume and fuel quality, see section 9 Specifications.

6 Inspection and maintenance – 6.2.2 Fuel system 149
Fuel pre-filter, instructions
NOTE
The water separator should be drained of water every 50 oper-
ating hours.
D AN GE R
Fire hazard.
Danger to life!
The fuel is highly flammable. Do not smoke near the

Engine alternative Volvo TAD1250VE machine during work on the fuel system.
1 Turn off the system voltage with the battery disconnector.

The engine shall be off.
See Battery and battery disconnector, general page 162.
2 Place a collection container under the fuel pre-filter.
3 Drain the water from the fuel pre-filter.
Open the drain valve on the underside, close the valve when
clean fuel drains (no water bubbles).
W AR N IN G
Fuel on hands.
Rash and irritation.
Avoid skin contact with the fuel, use gloves.
Engine alternative Volvo TWD1240VE

4 Remove the collection container. Handle the fuel as environme-
ntally hazardous and fire hazardous waste.

150 6 Inspection and maintenance – 6.2.3 Windshield washer
Engine alternative Cummins QSM11
6.2.3 Windshield washer

Windshield washer, general
page
–
CAUTION
Only use clean water with an anti-freeze agent, for
example, washer fluid.
The strength of the roof window may be affected!

A
The washer fluid reservoir (position A) is located on the left rear on

the cab.
Instructions
• Check the lever in the reservoir. Top up with coolant as needed.
004913
For volume, see section 9 Specifications.

• Add anti-freeze. Select a suitable concentration (dilution water/
A. Washer fluid reservoir anti-freeze fluid) according to the winter conditions and outdoor
temperatures.

6 Inspection and maintenance – 6.2.4 Air filter, engine 151
6.2.4 Air filter, engine

Air filter engine, general
page
–
NOTE
Poorly filtered induction air can very quickly result in serious en-
gine damage.
The filter is changed by the service technician during running inspec-
tions and service. When the machine is used in dusty air, the filter
may be clogged after in a relatively short time.
In the induction system, between the engine and air filter (position
A) there’s an indicator (position B) which shows red when the air fil-
ter is clogged.
The air filter has a dust reservoir (position C) which normally is emp-
tied during operation by vibrations in the induction system. It can
also be emptied manually by shaking it.
Instructions
Check the indicator at regular intervals. Contact service in case the
indication is red.
C
B
006433
A. Position for air filter reservoir

B. Indicator for change
C. Dust reservoir

152 6 Inspection and maintenance – 6.2.5 Cooling system
6.2.5 Cooling system

Cooling system, general
page
–
Coolant is filled in the system’s expansion tank (position A). The

coolant level should be between the MIN and MAX markings (posi-
tion C) on the expansion tank.
NOTE
Open very carefully as hot coolant may jet up and out.
A If the coolant level becomes too low, the warning light for low cool-
ant level (position 40) lights up on the instrument panel.
NOTE
B A low coolant level may cause engine damage or may cause the
engine to stop.
C
Instructions
004851
W AR N IN G
A. Position for expansion tank
B. Filling point
The cooling system is pressurized. Steam or hot
C. Level marking, MIN and MAX coolant may jet out.
Risk of scalding/burn injuries!
Open the filler cap (position B) very carefully when

the engine is warm. Wait until the coolant has
cooled down before topping up.
• Check the level in the expansion tank. Top up as needed with

water (add at least 40 % glycol). For volume, see section 9 Spec-
ifications.
• Anti-corrosion agent must always be added if glycol isn’t used.
However, anti-corrosion agents do not contain anti-freeze and
may only be used if the outdoor temperature always is above
0 °C.

6 Inspection and maintenance – 6.2.6 Engine oil 153
6.2.6 Engine oil

Engine oil, general
page
–
W AR N IN G
Avoid prolonged skin contact with engine oil.
Health hazard!
A Use protective gloves.
The engine’s oil filler pipe (position B) and dipstick (position C) are lo-
cated under the service cover in front of the cab.
Instructions
• Check the oil level (position C).
Check the oil level when the engine is warm. Wipe off the dip-
stick before checking.
The dipstick has two markings, MAX and MIN, between which
the oil level should be.
NOTE
The oil dipstick is long. Use gloves.
• Top up as needed with new engine oil (position B). For volume
000378
B C and quality, see section 9 Specifications.
A. Position for filling and level check Top up – wait awhile – check on the dipstick.
B. Filling point
C. Dipstick (figure shows dipstick for engine alterna- NOTE
tive Volvo TAD1240VE) Work carefully when filling engine oil to prevent other fluids
Engine alternative Volvo TAD1250VE has the dipstick or particles from contaminating the oil. Other fluids or par-
on the right side of the engine and level figure in ticles in the engine oil means a risk of engine damage.
display.

154 6 Inspection and maintenance – 6.2.7 Transmission oil
6.2.7 Transmission oil

Transmission oil, general
page
–
W AR N IN G
Avoid prolonged skin contact with transmission oil.
Health hazard!
A
Use protective gloves.
The transmission’s oil filler pipe and dipstick (position B) are located
under the service cover in front of the cab.
Instructions
• Check the oil level (position B).
Check the oil level with the engine at idle, the transmission in
neutral position and at operating temperature (approx. 60 °C in
display). Wipe off the dipstick before checking.
The dipstick has two markings, MAX and MIN, between which
the oil level should be.
NOTE
004871
B The oil dipstick is long. Use gloves.
A. Position for filling and checking level • Top up as needed with new transmission oil (position B). For vol-
B. Dipstick and filling point ume and quality, see section 9 Specifications.
Top up – wait awhile – check on the dipstick.
NOTE
Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil. Other fluids
or particles in the transmission oil means a risk of transmis-
sion damage.

6 Inspection and maintenance – 6.2.8 Oil, brake system 155
6.2.8 Oil, brake system

Oil, brake system, general
page
–
W AR N IN G
Avoid prolonged skin contact with the oil.
Health hazard!
A
The tank for the brake system is located on the machine’s left side.
Instructions
• Check the oil level (position E).
The level should be in the middle of the level glass.
• Top up as needed with new oil (position C). For volume and qual-
ity, see section 9 Specifications.
• Check that the oil cooler (position B) isn’t clogged. Clean as
needed.
NOTE
Work carefully when filling brake oil to prevent other fluids or
particles from contaminating the oil. Other fluids or particles in
the brake oil means a risk of damage to the brake system.
000380
B C D E
A. Oil tank for brake system
B. Oil cooler
C. Filling point
D. Breather filter
E. Level glass oil tank

156 6 Inspection and maintenance – 6.2.9 Hydraulic system
6.2.9 Hydraulic system

Hydraulic system, general
page
–
W AR N IN G
Avoid prolonged skin contact with hydraulic oil.
Health hazard!
A B
000381
C D C E F G
A. Position for oil cooler The hydraulic oil tank is located on the machine’s right side.
B. Position for hydraulic tank Instructions
C. Cleaning filter hydraulic oil • Check the oil level (position E). All hydraulic pistons should be in
retracted position (pushed in).
D. Filling point hydraulic tank (spare)
The level should be in the middle of the level glass.
E. Level glass hydraulic tank
• Top up as needed with new oil (position F). For volume and qual-
F. Filling point hydraulic tank
ity, see section 9 Specifications.
G. Breather filter
• Check that the filters for the oil cooler (position C) are not clog-
ged. Clean as needed.
NOTE
Work carefully when filling hydraulic oil to prevent other fluids
or particles from contaminating the oil. Other fluids or particles
in the hydraulic oil means a risk of damage to the working hy-
draulic system.

6 Inspection and maintenance – 6.2.9 Hydraulic system 157
Emergency lowering of boom

–
As long as there is servo pressure in the hydraulic system, as well as

battery voltage, the boom can be lowered using the control lever in
the cab. In case the hydraulic functions stop working, emergency
can take place with manual control of valves.
NOTE
Operate the boom with constant adjustment of the valves dur-
ing the entire boom movement (to use the remaining servo
pressure). In case of repeated valve adjustments, the servo
pressure is lost and no functions can be performed.
A
D AN GE R
Manual operation entails risks!
Risk of crushing, machine tipping/rolling over! Fatal

danger!
Avoid manual lowering. If manual lowering cannot

be avoided, work very carefully.
A Instructions for emergency lowering of boom:

1. Two persons, one on the right and one on the left side of the
C
machine, position themselves to control the solenoid valve for
B D respective lift cylinder (position A).
2. Turn the control to position C, unlocked but closed.
E 3. Turn the control counter-clockwise to open the valve (area B).
000578
This releases pressure in the lift cylinders. NOTE! Perform this

at the same time at both lift cylinders.
A. Control for operating solenoid valve lift cylinder
Boom lowers slowly.
B. Area where valve opens proportionally with the
control’s position When control is released, the control returns to closed,
C. Valve closed (unlocked) position C.
D. Area where valve is closed 4. When lowering is finished, turn the control to position E.
E. Valve closed (locked)

158 6 Inspection and maintenance – 6.2.10 Tyres and rims
6.2.10 Tyres and rims

Tyres and rims, general
page
–
D AN GE R
Changing tyres is high-risk work.
Fatal danger!
Tyre changes shall be performed by service person-
nel, with competence and authority to handle tyres!
D AN GE R
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! Fatal danger!
Check the tyres at regular intervals for external

damage and tyre pressure.
W AR N IN G
After the first 4-5 operating hours with a new
wheel, the wheel nuts shall be check-tightened. For
tightening torque, see Maintenance manual.

Tighten bolted joints crosswise. Contact a service
technician as needed.
CAUTION
Spare and replacement tyres should be of brand
names approved by Kalmar Industries.
Risk of overloaded tyres!
Use tyres approved by Kalmar Industries.

6 Inspection and maintenance – 6.2.10 Tyres and rims 159
Changing wheels
D AN GE R
Deflate tyres first before changing them.
Deflate tyres by loosening and removing the valve.
D AN GE R
If the rims are damaged, tyre handling is extremely
dangerous!
Let service personnel change tyres; they have the

competence and authority to handle tyres!
Changing rear wheel:

• Lift the machine under the steering axle by the wheel in ques-
tion. Support under the axle in an adequate way.
Use suitable lifting equipment when lifting the machine!
• Deflate the tyre by loosening and removing the valve.
• Remove the bolted joint and the clamps that secure the wheel.
Use suitable lifting equipment to secure the wheel when
removing!
000383

160 6 Inspection and maintenance – 6.2.10 Tyres and rims
Changing front wheel:

• Lift the machine under the drive axle by the wheel in question.
Support under the axle in an adequate way.
Use suitable lifting equipment when lifting the machine!
• Deflate the tyre by loosening and removing the valve.
Both the inner and outer tire must be deflated of air pressure!
• Remove the bolted joint and the clamps that secure the wheel.
For twin tires, there are spacer rings between the drive wheels.
Use suitable lifting equipment to secure the wheel when
001456
removing!
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 mi-
nimizes the risk of corrosion on rims.
• Drain the water separator regularly.
D AN GE R
Never stand in front of a tyre when inflating it! Do
not exceed the prescribed air pressure. When
changing tyre or rim version, another tyre pressure
may apply. Contact Kalmar Industries.
Danger to life!
Always follow the instructions for inflating tyres to

avoid serious accidents.
000384

6 Inspection and maintenance – 6.2.11 Checking accumulators 161
1. Before inflating, make sure that the rim’s lock ring is in the cor-
1 2 3 rect position.
NOTE
If the tyre has been completely deflated, the rim must be
dismantled and checked for damage. Let service personnel
change tyres as they have the competence and authoriza-
0022002
tion to handle tyres!
1. Lock ring 2. Connect the compressor hose with a self-locking chuck to the
2. Rim edge tyre.
3. Tapered rim course 3. Move to the side and stay to the side of the tyre until inflating
has been completed.
4. Inflate the tyre to the prescribed pressure; see chapter 9 Speci-
fications. When changing tyre or rim version, another tyre pres-
sure may apply; contact Kalmar Industries.
6.2.11 Checking accumulators

Accumulators, general
page
–
The function of the accumulators (position A) is to maintain even

brake pressure and also to maintain brake pressure, and thus brak-
ing action, a short time after eventual loss of hydraulic pressure.
A The accumulators are precharged with nitrogen gas.

Instructions
Check sealing according to the following points if the warning light
for low brake pressure (position 33) lights up:
1. Start the engine and let it run until the accumulators are filled.
Warning light for low brake pressure (position 33) goes off.
2. Stop the engine and then turn the start key to position I.
3. Press down the brake pedal with long pumping brake strokes,
with a slight delay between each braking action.
4. It should be possible to brake at least eight times before the light
for low brake pressure lights up.
5. Start the engine, let the accumulators charge and repeat the
test a couple of times.
000385
A
A. Accumulators for brake system

162 6 Inspection and maintenance – 6.2.12 Battery and battery disconnector
If it is not possible to brake eight times before the warning light for
low brake pressure lights up, there is a defect in the accumulators.
Contact service as soon as possible for troubleshooting and suitable
action.
W AR N IN G
The machine’s hydraulic system includes accumula-
tors with high pressure.
Always be very careful when working with the hy-

draulic system, and avoid standing close to hydrau-
lic components or hoses. Before working on the
hydraulic system, the accumulators must be
drained (see Maintenance manual).
6.2.12 Battery and battery disconnector

Battery and battery disconnector, general
page
–
W AR N IN G
The battery’s terminals may not be connected to
each other or in common to ground (frame). This re-
sults in short-circuiting of the battery (which means
loss of its capacity).
A Fire hazard! Risk of personal injury!
006463
A. Battery disconnector
CAUTION
Always turn off the machine’s system voltage with
the battery disconnector at the end of the work
shift, when working on the electrical system and
when welding on the machine.
Danger!
The electrical system operates with a system voltage of 24 VDC. The

voltage source consists of two series-connected 12 VDC batteries
that are charged by an alternator. The minus terminal is connected
to the frame.
The plus terminal is connected to a battery disconnector (position A).
The batteries are located inside of a cover behind the steps on the
machine’s left side.

6 Inspection and maintenance – 6.2.12 Battery and battery disconnector 163
Checking electrolyte level in battery
W AR N IN G
The battery’s electrolyte contains corrosive sulphu-
ric acid.
Risk of corrosive injury! Health hazard!
Immediately remove any electrolyte in contact with

bare skin. Wash with soap and plenty of water. If
electrolyte has splashed into the eyes, rinse imme-
diately with plenty of water and seek immediate
medical attention.
Checking the electrolyte level is recommended. Fill as needed with

deionized water.
1. Turn off the machine’s system voltage with the battery discon-
nector (position A) and then open the cover.
2. Checking the electrolyte level is recommended. Fill as needed
with deionized 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 ac-
cording to local/national regulations.
Starting with booster battery
W AR N IN G
Handle batteries and connectors with care during
starts with booster batteries. Do not mix up the bat-
tery terminals! Follow instructions for starting with
booster battery!
Risk of short-circuiting! Warning for generation of

hydrogen gas! Spark generation and fire hazard!
1. Turn off the machine’s system voltage with the battery discon-
nector (position A) and then open the cover.
2. Check that booster batteries are connected in series to system
voltage 24 VDC. Do not disconnect installation cables at the
machine’s batteries (assumed to be discharged)!
3. Connect in the following order:
a. The red booster cable (+) to the discharged batteries’ plus
terminal.
b. The red booster cable (+) to the booster batteries’ plus
terminal.

164 6 Inspection and maintenance – 6.2.13 Main fuses for electrical system
c. The black booster cable (-) to the booster batteries’ minus

terminal.
d. The black booster cable (-) to a point some distance from the
discharged batteries, e.g., at the minus cable’s connection to
the frame or directly to the engine block.
4. Try to start the engine and then run the engine at increased idle
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.
5. Turn off engine.
Remove the cables in reverse order as when installing. One ca-
ble at a time! Batteries shall always be provided with caps over
terminals and connections.
6.2.13 Main fuses for electrical system

Main fuses for electrical system, general
page
–
CAUTION
Never use fuses with too high ampere rating.
Risk of damage or cable fire!

Follow instructions on the fuse plate for fuse type
and ampere rating.
The machine’s electrical system has one position for main fuses and
two positions for boom and attachment fuses:
C A B A. Main fuses in electrical distribution box on frame, 4 fuses 50 A.
Cuts off all electric power.
B. Fuses at mounting of boom to frame (left side), 2 fuses 25 A.
Cuts off electric power to attachment.
C. Fuses at boom outer (left side), 2 fuses 25 A.
Cuts off electric power to attachment.
Changing main fuse/fuse
When checking and changing main fuse/fuse:
004878
1. Turn off the system voltage with the battery disconnector.

A. Main fuse in electrical distribution box on frame
B. Fuse boom, fuse by inside boom mounting frame
C. Fuse attachment, fuse by boom outer 2. Remove the plastic cap (position A).
3. Check fuses, change as needed.
Fuses are rated at 25 or 50 A.

6 Inspection and maintenance – 6.2.14 Fuses for electrical system 165
6.2.14 Fuses for electrical system

Fuses for electrical system, general
page
–
The machine’s electrical system is divided into three electric power

circuits:
• Battery voltage, so-called 30-voltage
• Ignition voltage, so-called 15-voltage
• Control breaker voltage, so-called 15E-voltage
Each one of these three circuits has separate fuses and fuse holders
(position B, C and D).
The fuses for the electrical system are located in the electrical dis-
tribution box on the side of the machine and in an electrical distribu-
tion box in the cab.
The electrical distribution box is located behind the operator’s seat
in the cab. There are fuses for the control units and equipment in the
A cab.
004879
D C B
A. Fuses in cab
B. 15E-fuses (control breaker voltage), 58-3
C. 15-fuses (ignition voltage), 58-2
D. 30-fuses (battery voltage), 58-1

166 6 Inspection and maintenance – 6.2.14 Fuses for electrical system
A1 30A CAB
A48498.0100
B2
C3 15A ENGINE
F58-1 30 MAIN POWER

D4 10A ENGINE
E5 5A TRANSMISSION
F6 15A ENGINE, OPT
G7
H8
A1 25A KDU,FRONT (KALMAR DISTRIBUTION UNIT)
B2 5A ENGINE,ECC
F58-2 15 SUPPLY POWER
C3 25A KDU,REAR (KALMAR DISTRIBUTION UNIT)
D4 10A KDU,OPT (KALMAR DISTRIBUTION UNIT)
E5 5A TRANSMISSION
F6
G7
H8 5A ENGINE
A1 25A ATTACHMENT
B2 10A KDU,FRONT (KALMAR DISTRIBUTION UNIT)

F58-3 15E SUPPLY POWER
C3
D4 10A KDU,OPT (KALMAR DISTRIBUTION UNIT)
E5
EMERGENCY
F6
G7
006846
H8 5A FEEDBACK K3009-1 (K2)
Fuse plate at electrical distribution box for frame (left) and cab (right)
Table 4. Fuse holder 58-4 (cab)
Connection Fuse number / Size Functions
1 1 / 10A Control unit cab (KCU)
2 2 / 5A Control unit cab (KCU), start-up
3 3 / 10A Service
4 4/-
Customer-specific equipment
5 5 / 10A
Radio
6 6 / 25A
Seat heat
7 7 / 10A
Work light boom
8 8 / 15A
Air suspension operator’s seat

6 Inspection and maintenance – 6.2.14 Fuses for electrical system 167
Table 5. Fuse holder 58-5 (cab)
1 1 / 25A Control unit cab (KCU)
2 2 / 10A Control unit KIT
3 3 / 15A Air conditioning, fan
4 4 / 5A Air conditioning, recirculation
5 5 / 10A Service
6 6 / 5A
Lighting writing table
7 7 / 10A
Voltage converter 12 VDC
8 8 / 10A
Loud horn
Table 6. Fuse holder 58-1 (30-voltage)
1 1 / 30A Cab
2 2/- -
3 3 / 15A Engine
4 4 / 10A Engine
5 5 / 5A Transmission
6 6/- Engine
7 7/- -
8 8/- -
Table 7. Fuse holder 58-2 (15-voltage)
1 1 / 25A Control unit frame (KDU) front
2 2 / 5A Engine, air conditioning
3 3 / 25A Control unit frame (KDU) rear
4 4 / 10A Control unit frame (KDU) option
5 5 / 5A Transmission
6 6/- -
7 7/- -
8 8 / 5A Engine

168 6 Inspection and maintenance – 6.2.14 Fuses for electrical system
Table 8. Fuse holder 58-3 (15E-voltage)
1 1 / 25A Attachment
2 2 / 10A Control unit frame (KDU) front
3 3/- -
4 4 / 10A Control unit frame (KDU) option
5 5/- -
6 6/- -
7 7/- -
8 8 / 5A Feedback relay K3009-1 (K2)
Instructions
When checking and changing fuses:
1. Turn off the system voltage with the battery disconnector.
2. Remove the cover from the electrical distribution box.
3. Check fuses, change as needed.
The fuse plate gives information about each fuse.

6 Inspection and maintenance – 6.2.15 Lighting 169
6.2.15 Lighting
Lighting, general
page
–
It’s important to use the right type of light bulb for each lighting
point; see chapter 9 Specifications.
Light bulbs can be changed for the following:
• Interior lighting
• Rear lights, red
• Brake lights
• Direction indicators
• Running lights
• Headlights (for high and low beams)
• Back-up light, white
• Work light glowing light
Work light Xenon

• Rotating beacon

170 6 Inspection and maintenance – 6.3 Service
6.3 Service
General
page
–
It’s very important that inspections and service are performed at the
recommended intervals.
Service is performed by Kalmar Industries, or by service technicians
authorized by Kalmar Industries.
CAUTION
Service intervals must be followed.
This is to fulfil warranty and service contracts!
Use spare parts and fluids approved by Kalmar In-

dustries to fulfil warranty terms.
Service is performed at intervals of 500 hours and actions are de-

scribed in the maintenance manual.
For engine alternative Volvo TAD1250VE there may be deviations
from the service interval. Depends on the oil grade used in the en-
gine (contact service). Engine TAD1250VE should be run with oil
specification VDS-3. The engine can be run with oil specification
VDS-2 (ACEA E5), however, this shortens the service interval to
400 hours.
CAUTION
When welding on the machine, all control units shall
be disconnected to prevent damage.
Unplug the connectors from the control units!

7 Transport of machine 171
7 Transport of machine
7 Transport of machine
mm mm mm mm
Safety
page
–
D AN GE R
The machine shall be adequately secured during
transport!
The machine is heavy and can cause extreme dam-
age in case of a fall and similar. Follow the instruc-
tions to secure the machine for transport.
W AR N IN G
Always close the operator door(s) at transport.
Danger!
W AR N IN G
The cab has the sliding cab feature, manual or hy-
draulic ( ). The cab shall ALWAYS be secured and
locked when transporting.
Risk that unsecured cab moves, which results in

great danger!
For manual sliding cab, always make sure that the

cab is locked in its rearmost position before trans-
port, and that the locks on both sides are secured
with the lock pins.
For hydraulic longitudinal displacement, the cab

may be positioned as desired (locking is automatic)
when stationary.

172 7 Transport of machine – 7.1 Towing
7.1 Towing
General
page
–
D AN GE R
The machine cannot be operated or braked if the hy-
draulic pressure is lost, e.g., if the engine is off.
Rolling machine! Fatal danger!
If possible, tow with maintained hydraulic pressure.

If it’s not possible to tow with the engine running, a
tow bar must be used! Only tow for short distances!
CAUTION
Do not try to start the machine by towing.
Serious damage to engine and power transmission!
Start the engine according to instructions in the op-

erator’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 person-
al 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 off, there’s no hydraulic pressure to the
steering function and thus the machine’s steering function is se-
verely limited. Also, transmission lubrication is insufficient.
• The brakes function as long as there’s pressure in the accumu-
lator, then the service brake stops functioning and the parking
brake is applied automatically. If it’s necessary to move/tow the
machine after that, the parking brake must be released mechan-
ically, see section 7.1.1 Mechanical release of parking brake.
• Only tow for very short distances.
• If it’s necessary to tow the machine, the propeller shaft must be
disconnected from the transmission.

7 Transport of machine – 7.1.1 Mechanical release of parking brake 173
7.1.1 Mechanical release of parking brake

Description
page
–
The parking brake is applied automatically by a forceful spring in the

brake cylinder if the pressure in the hydraulic accumulator should
drop below a certain level.
If the machine has to be moved (towed) without sufficient pressure
in the hydraulic accumulator, the parking brake must be released
mechanically (manually).
D AN GE R
Before starting to work with the parking brake,
make sure that the machine cannot move when the
braking action is released.
Rolling machine! Fatal danger!
Block the wheels to avoid unwanted rolling of the

machine.
CAUTION
The parking brake has spring pre-load. If the brakes
are opened incorrectly, parts may detach and shoot
out with high force. Follow instructions.
The parking brake is a disc brake on the drive axle’s input shaft.
A B C
1. Remove protective cover from caliper (position A).
2. Note the nut’s position on the bolt and remove the split pin that
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. Reinstall protective cover on caliper.
NOTE
000835
The parking brake must always be restored in order to give the

A. Protective cover machine parking brake function if the parking brake has been
B. Brake disc for parking brake released mechanically.
C. Propeller shaft

174 7 Transport of machine – 7.2 Lifting and transporting machine
7.2 Lifting and transporting

machine
General
page
–
When lifting and transport of machine, follow the governing safety

instructions.
D AN GE R
High demands are made of the lift and transport
equipment, e.g., lifting chains, hooks, etc.
Danger to life!
Check the equipment and its capacity, lifting slings

on the machine as well as lashing points on the
transport and machine.
D AN GE R
Overload of load equipment.
Danger to life!
Lifting equipment should be dimensioned for the

load. Never walk under a suspended load.
The following actions are recommended when the machine is to be

transported:
• Turn off the main electric power with the battery disconnector.
• Apply the parking brake.
• Remove any fragile equipment, for example, rear-view mirrors.
Transport of machine on public road takes place according to the
following:
1. Lift of attachment. see Removing top lift attachment page 175.
Lift of boom. see Removing boom page 177.
NOTE
Only needed if transport takes place on public road.
2. Secure the machine for transport on, e.g., a truck.
Note the machine’s weight, see machine plate.
Place the machine, boom and attachment on the transport. See
Lashing down for transport page 180.
3. Lift boom: see Installing boom page 183.
Lift attachment. see Installing top lift attachment page 184.

7 Transport of machine – 7.2.1 Lifting machine 175
7.2.1 Lifting machine

Instructions
page
–
The machine shall be lifted as follows:

1. Lay two lifting slings in both front lifting eyes on the frame.
2. Lay two lifting slings in both rear lifting eyes on the frame (at the
boom mounting).
3. The lifting device must be adapted so that the lifting point runs
through the machine’s centre of gravity.
001848
7.2.2 Transport of machine

Removing top lift attachment
page
–
W AR N IN G
Pressurized oil system. Always depressurize the hy-
draulic system before starting to work in the hy-
draulic system!
1 Park the machine with the boom fully retracted in its lowest po-
sition and the attachment in right position.
2 Turn off the engine and open the relief valve for the attachment.
Relief valve attachment opens a connection between the at-
tachment’s pressure feed and tank. This is used to drain the
pressure in the hoses for the attachment before working on the
hydraulic system. The relief valve is located at the trailing edge
of the lift beam in front of the transmission.
3 Turn the start key to position I and activate the hydraulic func-
002269
tions to depressurize the hydraulic system.
Relief valve for attachment 4 Turn the start key to position 0 and turn off the main electric po-
wer with the battery disconnector.
5 Place a collection container under the valve block on the boom
nose to collect any oil spills.

176 7 Transport of machine – 7.2.2 Transport of machine
6 Mark up and disconnect the attachment’s hydraulic connec-

tions from the damping block.
NOTE
Plug all connections to protect the hydraulic system from
impurities.
7 Disconnect the cable harness for the attachment from control

unit attachment.
Remove the cable harness’ clamping from the boom.
NOTE
Plug all contacts to protect these from dirt and moisture.
8 Disconnect the tilt cylinders from the attachment.
Remove the tilt cylinders’ pins and turn aside the tilt cylinders.
If needed, use a puller to press out the pin. Refit the pins in the
tilt cylinder.
9 Remove the collection container, handle the waste oil as envi-
ronmentally hazardous waste.
10 Connect lifting equipment securely to the attachment’s lifting
eyes.
11 Adjust the lifting equipment to take the weight/stress off the
pins on the rotation bar.
12 Remove the rotation bar’s pins.
Remove the lock bolts and pull out the pins. If needed, use two
bolts in the threaded holes to pull out the pin.
13 Lift aside the attachment. Place it on wooden blocks or similar
so that the twistlocks are not damaged.
14 Refit the rotation bar’s pins in the rotation bar.

7 Transport of machine – 7.2.2 Transport of machine 177
Removing boom
–
11 1 2 10
12
003690
9 8 7 8 6 5 4 3
1. Outer boom 7. Lift cylinder
2. Inner boom 8. Mounting lift cylinder
3. Tilt cylinder right side 9. Rear boom mounting
4. Mounting attachment 10. Front lifting eyes
5. Tilt cylinder left side 11. Rear lifting eyes
6. Extension cylinder 12. Valve block boom nose
D AN GE R
A lift cylinder weighs approx. 2 tons.
Danger to life!
Use wooden blocks as protection between cab and

lift cylinder when the lift cylinder is lowered or lift-
ed. Secure the lift cylinders with tensioning straps
in between these.

W AR N IN G
The boom may move when the pins are removed.
Make sure that the pins are relieved of stress. Stand

to the side of the boom mounting so that the
mounting protects in case of a movement.
CAUTION
The boom may drop.
Be certain to compensate for the lift cylinder’s car-
rying of the boom by lifting the boom’s leading edge
with the lifting equipment.
CAUTION
Short-circuiting. Use contacts with blind plugs at
both ends to isolate and protect all connectors that
are parted.
Product damage, moisture and dirt.
The instruction requires that the top lift attachment has been re-
moved, see Removing top lift attachment page 175.
1 Place a collection container under the hydraulic oil connections
at the boom’s rear mounting to collect any spills.
2 Clean, mark up, disconnect and plug the hydraulic hoses at the
boom’s rear mounting. Loosen the hoses from the hose bracket.
Right side, hydraulic hoses for boom.
Left side, hydraulic hoses for attachment.
NOTE
Plug all connections to protect the hydraulic system from
impurities.
3 Remove the collection container, handle spills as environmen-
tally hazardous waste.

4 Mark up and disconnect the cable harness from the boom at

the rear mounting.
NOTE
Plug all contacts to protect these from dirt and moisture.
5 Slide the cab completely forward.
6 If the machine is equipped with position sensor for boom angle,

remove the sensors’ bracket and the sensor so that is not da-
maged when the boom is placed on the ground.
If the machine is equipped with analogue sensor, leave the sen-
sor on the boom but fixate the sensor’s arm with a cable tie.
7 Connect lifting equipment securely at the front of the boom. Lift
the front of the boom so that the lift cylinders are relieved.
8 Connect lifting equipment to the lift cylinder.
9 Disconnect the lift cylinders from the boom.
Angle sensor Remove the lock bolt and the pin. If needed, use a puller to pull
out the pin.
10 Carefully lower each lift cylinder so that it rests against the
edge on the lower mounting.
Use wooden blocks as protection between cab and lift cylinder
when the lift cylinder is lowered or lifted. Secure the lift cylin-
ders with tensioning straps in between these.
11 Refit the pin in the boom’s bearing.
12 Connect lifting equipment securely in the lifting eyes in the
boom’s trailing edge. Lift slightly to relieve the boom’s rear
bearings.
13 Remove the pins for the boom mounting.
14 Lift away the boom, lower the front part and place it on a secure
surface, e.g., wooden blocks.

15 Depressurize the tilt cylinders.

Loosen the hydraulic hoses’ connections at the valve block on
the boom nose.
Place a collection container under the valve block to collect any
oil spills.
NOTE
The tilt cylinders must be drained to be able to lay down
the rear part of the boom.
16 Lower the rear part of the boom and place it on a secure surfa-
ce, e.g., wooden blocks.
17 Tighten the tilt cylinders’ hydraulic hoses at the valve block on
the boom nose.
18 Remove the collection containers, handle the waste oil as envi-
Valve block boom nose
Lashing down for transport
–
The instruction requires that the top lift attachment and boom have
been removed, see Removing top lift attachment page 175 and Re-
moving boom page 177.
When transporting the machine, boom and attachment shall be
transported separately. The machine shall 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.
3. Turn off the main electric power with the battery disconnector.
4. Secure the front part of the machine adequately in the front of
the chassis and in the intended tie-down points on the trailer.
Cross the chains when securing for optimal stability.
Lashing down machine, front

5. Secure the rear part of the machine adequately in the rear of the
chassis and in the intended tie-down points on the trailer.
Lashing down machine, rear

6. Fold in the rear-view mirrors and remove protruding parts such
as rotating beacon to avoid damage during the transport.
7. Place the boom’s rear part on anchored pallets or similar.
Secure the boom’s rear part adequately in the boom’s lifting
eyes and in the intended tie-down points on the trailer.
Lashing down boom, rear

8. Secure the boom’s front part adequately in the boom’s lifting

eyes and in the intended tie-down points on the trailer.
Lashing down boom, front

9. Place the attachment on wooden blocks or similar to protect the
twistlocks.
Secure both sides of the attachment adequately in the attach-
ment lifting eyes and in the intended tie-down points on the
trailer.
Lashing down of attachment

Installing boom
–
W AR N IN G
Pressurized oil system. Always depressurize the hy-
draulic system before starting to work in the hy-
draulic system!
The instruction requires that top lift attachment and boom are not
assembled, that is, are separate.
1 Place the cab in the front position.
2 Turn off the engine and open the relief valve for the attachment.
3 Turn the start key to position I and activate the hydraulic func-
tions to depressurize the hydraulic system.
4 Turn the start key to position 0 and turn off the main electric po-
wer with the battery disconnector.
5 Connect lifting equipment at the leading edge and trailing edge
of the boom.
6 Lift the boom into place over the machine.
7 Adjust the boom’s position so that the holes for the boom’s be-
arings in the boom and frame are lined up.
NOTE
If sensor boom angle is still on the boom, fit the sensor’s
arm in the lock screw without turning the sensor’s arm.
8 Fit the rear pins for the boom’s bearing.
9 Disconnect the lifting equipment from the boom’s trailing edge.
10 Lower the boom’s leading edge so that it is horizontal.
002269
11 Connect lifting equipment to one of the lift cylinders.

Relief valve for attachment 12 Line up the lift cylinder’s upper mounting in the boom.
Lift the lift cylinder into place, if needed adjust the angle of the
boom.
13 Fit the lift cylinder’s pin.
14 Lower the boom and disconnect the lifting equipment from the
boom.
15 Place a collection container under the hydraulic oil connections
at the boom’s rear mounting to collect any spills.
16 Connect the boom’s hydraulic hoses to the machine.
NOTE
Check that the O-rings are intact, clean and in correct
position.
17 Connect the cable harness to the boom.

18 If the machine is equipped with position sensor for boom angle,

fit the bracket and sensor boom angle.
19 Grease the boom’s rear bearings with grease EP2.
20 Check that the tilt cylinders’ hoses are securely tightened.
21 Remove the collection containers, handle the waste oil as envi-
Installing top lift attachment

–
CAUTION
Do not overfill! The hydraulic oil level is checked
with the boom completely lowered and retracted.
Leakage and environmental damage
The instruction requires that the boom is mounted on the machine,

see Installing boom page 183. The boom shall be in lowered position.
1 Remove the rotation bar’s pins from the rotation bar.
2 Clean and grease the bearing surfaces for mounting and tilt cy-
linders on the attachment with grease EP2.
3 Connect lifting equipment securely to the attachment’s lifting
eyes.
4 Lift the attachment into place. Position the attachment so that
the holes for the pins in the boom line up with the holes for the
pins in the rotation bar.
5 Clean and grease the attachment’s mounting pins with grease
EP2 before installing.
6 Fit the attachment’s mounting pins and fit the lock bolts.
7 Clean and apply aluminium paste, e.g., Loctite 8150, on the tilt
cylinders’ link bearings and pins.
8 Connect the tilt cylinders to the attachment.
Line up the tilt cylinder and press in the pin. Fit the lock bolt. If
needed, loosen the hydraulic connections on the tilt cylinder to
be able to adjust the tilt cylinder’s length.

9 Remove the plugs and connect the hydraulic hoses to the valve
block on the boom nose.
NOTE
Check that the O-rings are intact, clean and in correct
position.
10 Connect the cable harness to control unit attachment.
11 Grease the attachment’s bearing with grease EP2.
12 Turn on the main electric power with the battery disconnector.
13 Start the engine.
14 Check that the hydraulic connections seal tightly.
15 Check the attachment’s functions.
16 Check the hydraulic oil level with the lift cylinders completely
down and the extension cylinder completely in. The oil level
should be at the top of the level glass. Top up if needed.

186 7 Transport of machine – 7.3 Service position
7.3 Service position

General
page
–
Service position is used for service, maintenance and other situa-

tions when the machine needs to be secured.
Service position means:
• Machine parked, that is, applied parking brake.
• Boom fully retracted and lowered to horizontal position.
• Engine off.
• Main electric power turned off with the battery disconnector.
003695
Machine with fully retracted and lowered boom
7.4 Long-term storage

General
page
–
For long-term storage of the machine, contact Kalmar Industries.

8 Environment and standards 187
8 Environment and standards
8 Environment and
mm mm mm mm
standards
General
page
–
Ever-increasing industrialization of our world is having a significant

impact on our global environment. Nature, animals and humans are
exposed daily to great risks in connection with handling of chemicals
in different forms.
There are still no environmentally safe chemicals, such as oils and
coolants, available on the market. Therefore, all who handle, oper-
ate, perform service on or repair vehicles must use the tools, meth-
ods and assistive devices necessary to protect the environment in
an environmentally sound manner.
By following the simple rules below, you contribute to protecting
and caring for our environment:
Recycling
Deposit discarded materials for recycling or destruction.
Environmentally hazardous waste

Components such as batteries, plastics and other items that may
constitute environmentally hazardous waste shall be taken care of
in an environmentally sound manner.
Discarded batteries contain substances hazardous to personal
health and the environment. Therefore, handle batteries in an envi-
ronmentally 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 author-
ized 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 system for the cab adds to the
greenhouse effect and may never be intentionally released into open
air. Special training is required for all service work on the air condi-
tioning system. Many countries require special certification by an
authority for such work.

188 8 Environment and standards
Working in a contaminated area

Used cab filters and engine air filters from machines operating in
contaminated conditions, with asbestos or other hazardous dust,
shall be put into tight-sealing plastic bags before being deposited in
the designated area. The machine shall be equipped for work in a
contaminated area (environmentally contaminated or hazardous to
personal health) before work is started. In addition, special local reg-
ulations apply when handling and servicing such a machine.
Standards
–
Sound/noise, vibrations, stability and visibility, etc.

This machine fulfils applicable standards in accordance with EN1459
"Safety of industrial trucks - Self-propelled variable reach trucks".
CE-marking
Machine for EU/EEA market is CE-marked. This means that, when
delivered, it fulfills the applicable "Essential Health and Safety re-
quirements", stated in EU’s Machine directive, 98/37/EG as well as
other applicable EU directives. For more information, see section 2.2
CE-marking.
ANSI/ASME-marking
Machine for North America is ANSI/ASME-marked. This means that,
when delivered, it fulfills the basic safety requirements according to
ANSI/ASME B56.1. For more information, see section 2.3 ANSI/
ASME-marking.
EMC, electromagnetic interference

EU’s EMC-directive about "Electromagnetic compatibility",
89/336/EG, gives a general description of the requirements that may
be made of the machine from a safety perspective, where the limit
values have been established in international standards. A machine
or device that fulfills the requirements shall be CE-marked.
Machines from Kalmar Industries are especially tested with regards
to electromagnetic interference according to harmonized standard
EN12895. The machine’s CE-marking and declaration of conformity
also includes the EMC-directive. If other electronic equipment is in-
stalled on the machine, it must be CE-marked as well as tested on
the machine with regards to electromagnetic interference, and must
be approved by Kalmar Industries.
Exhaust emissions
Machine for EU/EEA market fulfills EU’s Exhaust directive 97/68/EG,
which means that the engine’s exhaust emissions are reduced ac-
cording to the requirements.
Machine for the North American market fulfills EPA’s and CARB’s ex-
haust rules, which means that the engine’s exhaust emissions are
reduced according to the requirements.

9 Specifications 189
9 Specifications
9 Specifications
mm mm mm mm
Technical data
page
–
Machine weights and dimensions vary according to how the ma-

chine is equipped and is shown in detail in the product specification
and spec. sheet for the machine in question.
1 Engine Volvo TAD1250VE Volvo TWD1240VE Cummins QSM11
Power acc. to ISO 3046 (net power) 247 kW at 1900 rpm 256 kW at 2000 rpm 261 kW at 2000 rpm
Torque ISO 3046 1760 Nm at 1400 rpm 1751 Nm at 1200 rpm 1830 Nm at 1100-1400
rpm
No. of cylinders 6 cylinders 6 cylinders 6 cylinders
Alternator, rating 2240 W (28 V / 80 A) 2240 W (28 V / 80 A) 2800 W (28 V / 100 A)
System voltage, voltage–capacity 24 V (2x12 V / 140 Ah) 24 V (2x12 V / 140 Ah) 24 V (2x12 V / 140 Ah)
2. Transmission Dana-Spicer Off Highway TE32000
No. of gears, forward – reverse 4–4
3. Power transmission Merritor Kessler
Drive axle, type Merritor, PRC7534W4H Kessler D102
4. Brakes
Service brake system – wheel brake Wet Disc Brake – drive wheels
Parking brake system – wheel brake Spring brake – drive wheels
5. Steering
Steering system Hydraulic-servo
6. Wheels DRF420 DRF400/450 DRF450. x
Dimension, front and rear 18.00x25/36 18.00x25/40 18.00x33/36
Tyre pressure, also see pressure plate 1.0 MPa
Tyre type, front and rear Air-inflated. Spare and replacement tyres shall be of a brand approved by
Kalmar Industries.
9. Cab Spirit Delta
Equivalent sound pressure level in cab. Value with standard engine. max. 70 dB(A)

190 9 Specifications
Specifications, oil, lubricants and

–
fluids
Any deviation from this table must be approved in writing by Kalmar
Industries.
1.2 Engine, fuel system

Fuel tank, volume 550 l
Fuel quality Diesel, according to EN590
1.7 Engine, cooling system Volvo TAD1250VE Volvo TWD1240VE Cummins QSM11
Coolant volume 40 l 68 l 40 l
Coolant filling point Water, add at least 40 % glycol
1.8 Engine, lubrication system

Oil volume 35 l 35 l 34 l
Oil type, quality See Recommended oils and lubricants page 192.
2.6 Transmission, lubrication TE32000

system
Oil volume 80 l
3.3 Power transmission, drive Merritor, PRC7534W4H Kessler D102

axle
Differential, oil volume 50 l 65 l
Hub reduction, oil volume 2x10 l 2x12 l
4 Brakes
Brake oil tank, volume 140 l
7 Load handling
Planetary gear hydraulic motor, 1.6 l
oil volume
Disc brake hydraulic motor, oil volume 0.6 l

9 Frame, body, cab and accesso-

ries
Refrigerant, volume 2000 g
Refrigerant air conditioning R134a
Lubricant air conditioning Zexel PAG-oil
Washer fluid, volume 5l
10 Common hydraulics
Hydraulic oil tank, volume 600 l
Hydraulic oil system, volume 940 l (total, incl. tank)

Recommended oils and lubricants

–
The service intervals indicated by Kalmar Industries in the mainte-

nance manual only apply if oils are selected according to the table
below. The table indicates recommended viscosity for different oil
types and qualities depending on the ambient temperature.
Any deviation from this table must be approved in writing by Kalmar
Industries, and may mean changed service intervals.
°C -40 -30 -20 -10 0 +10 +20 +30 +40

Oil type, quality °F -40 -22 -4 +14 +32 +50 +68 +86 104
1.8 Engine, lubrication system
Volvo TWD1240VE: VDS-2 / ACEA E5 (Note 1) SAE 15W40
Volvo TAD1250VE: VDS-3 (Note 2) SAE 5W30 (motor oil)
Cummins QSM11: API CH-4 / ACEA E5

2.6 Transmission, lubrication system
ATF Dexron III DEXRON III (brand name)
3.3 Power transmission, drive axle

API GL-5 SAE 80W140
SAE 75W90
4 Brakes (UTTO-oil, Note 3)

GM Allison C-4 SAE 5W30 (transmission oil)
John Deere J20 C, D
Caterpillar TO-4
7 Load handling
Oil planetary gear hydraulic motor, SAE 80W140
hypoid oil API GL-5 SAE 75W90
Disc brake hydraulic motor,
See 10 Common hydraulics below
10 Common hydraulics
DIN 51524 Part 3 HVLP ISO VG 68
ISO VG 46 HV
ISO VG 32
NOTE
Oil filters shall always be changed in connection with oil
change.
Change interval for engine oil requires that the sulphur content
in the fuel does not exceed 0.5%.

Note 1: Lubrication oil must meet both requirements. API CH-4 or CI-
4 are approved for markets outside Europe (instead of ACEA E5).
Note 2: The same oil as for Volvo TWD1240VE may be used on the
condition that the change interval is reduced to 400 hours.
Note 3: The oil in the brake system has to meet one of the quality
requirements.
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
VDS = Volvo Drain Specification
Grease: Use a grease of the type EP acc. to NLGI Grade 2 (EP2) with
3-5% molybdenum sulphide content for all grease points except
glide plates, where lubrication paste Gleitmo 805 or similar shall be
used. For electric connections, use connector grease 923836.0552.
Specifications, light bulbs

–
Light Rating Socket

(W)
Control lights 1.2 W2x4.6d
Interior lighting 10 S8.5
Rear lights 5 BA15s
Brake lights 21 BA15s
Direction indicators 21 BA15s
Running lights 5 W2.1x9.5d
Headlights (for high and low 75/70 P43t-38

beams)
Back-up light 70 PK22s
Work light glowing light 70 PK22s
35W D1S Xenon tubes.

Work light Xenon
Insert incl. ballast is
replaced complete.
Rotating beacon 70 PK22s

Unit explanations
–
Unit Abbreviation
Newtonmeter Nm
Kilopoundmeter kpm
Kilopascal kPa
Megapascal MPa
Kilowatt kW
Kilojoule kJ
British thermal unit Btu
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Metre m
Kilometer km

Conversion SI-units
–
SI-unit Conversion factor Non-SI Conversion 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/cm2 x 14.22 = psi x 0.070 = kp/cm2
N/mm2 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
ºC = (ºF – 32)/1.8 ºF = (ºC 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 mm
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
1ha = 100a – 1mile2 = 259ha = 2.59km2

9 Specifications – 9 Specifications 197
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
1gal (US) = 3785.41cm3 = 231in3 = 0.83267gal (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
1ton (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 = 735.56Dry (mmHg) = 0.96784atm

198 9 Specifications – 9 Specifications

10 Terminology 199
10 Terminology
10 Terminology
mm mm mm mm
Explanations
page
–
Term Description
Accumulator Reservoir that stores (accumulates) pressure for, e.g. hydraulic functions.
Anti-corrosion compound Prevents oxidation, in simple terms, rustproofing.
Attachment Part of the machine that grabs the load when lifting.
Axle distance Distance between drive axle and steering axle.
Bar Unit to express pressure.
Battery disconnector Cuts off power supply from battery.
Boom Lifting member moveable vertically and in-out. Bracket for attachment.
Bottom lift attachment "Lifting legs" that can be raised/lowered for handling loads. Grabs load from below.
Buzzer Acoustic alarm to attract the operator’s attention.
Control valve Valves that can be used to control something, for example, to release pressure and
thus lower a boom or a fork. See also control valve.
Daily inspection Actions that should be performed daily to ensure the machine’s functionality.
Decitonne Tenth of a tonne, measure of machine’s lifting capacity.
Display "Window" showing digital information, i.e. on steering wheel panel 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, trans-
mission, propeller shaft and drive axle with differential and hub reduction.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, which is emptied auto-
matically during operation.
ECC Electric Climate Control. Climate control unit with thermostat-controlled cooling, de-
humidification and heating.
EHC Electric Heat Control. Heater unit with thermostat-controlled heating.
Electrolyte level Fluid level in battery cells.
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Expansion tank Tank for coolant.
Fixed displacement Pump with fixed pump volume.
FMI Fault Message Identifier.
Hanging load Lifted load.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases torque
from the drivetrain.
Hydraulic oil Oil for hydraulic system. See specifications in operator’s manual.
Hydraulic oil pump Pump in hydraulic system.
Hydraulic system System that uses oil pressure to transfer power to different functions.
Indicator Manual "sensor", for example, shows that a filter is clogged and needs to be changed.

200 10 Terminology
Term Description
LC Load centre
Levelling Attachment is tilted, for example if load stands on uneven ground.
Lift capacity Indicates machine’s maximal lift capacity.
Lifting point Attaching point for lift device when lifting an object.
Low-emission engine Engine with low emissions of hazardous substances. Manufactured according to spec-
ified and governing regulations.
Machine model Machine type. Indicated, for example: DRF 400-450. See also type designation.
Main fuse Located by the battery. Cuts off power to all machine systems.
Maintenance Periodic maintenance actions for correct and safe machine function, as well as long
machine life.
Mast Carrier of attachment and load.
OP Overload Protection. Overload system to warn in case the machine is overloaded.
Operating hours Number of hours machine has been in operation, shown on hour meter in cab.
Option Extra equipment selected to supplement machine.
Overload system A warning system, LLMC (Longitudinal Load Moment Control). The system is used for
stationary load handling, to not jeopardize the machine’s forward stability. LLMC is not
designed to control lateral stability or stability when operating.
Pilot oil pressure A low control pressure to, for example, a valve.
Planetary gear Type of transmission with gears in constant engagement (constant mesh).
Product alternative One of several alternatives is selected for a machine, e.g. engine alternative.
Proportional valve An electro-magnetically controlled valve. If a current is applied, the valve is activated
in proportion to the current’s amplitude. In simple terms, infinitely variable valve, as
opposed to on/off. For example, found on transmission’s valve housing.
Reachstacker Machine with special top lift attachment for containers.
Refrigerant Fluid/gas in air conditioning. May only be handled by authorized trained personnel.
Rotation bar Rotating unit on attachment, rotates attachment in relation to lift boom.
Securing machine for transport Actions before transporting machine.
Serial number. Unique machine designation. On machine plate.
Service position How machine should be positioned safely before service may be started.
Servo A small user movement results in a big machine movement, e.g. servo steering (power
steering).
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Sideshift Parallel sideways movement of attachment.
Solenoid valve An electro-magnetically controlled valve. See also proportional valve.
Spirit Delta Enclosed type of cab.
SPN Suspect Parameter Number.
Spreader Widening of attachment.
Steering axle Wheel axle with steering.
Tilting Load is leaned forward or backward.
Torque converter Hydraulic, variable clutch.

10 Terminology 201
Term Description
Transmission oil Oil for transmission and torque converter. See specifications, operator’s manual.
Twistlocks Four locking pins, one in each corner of the attachment, pushed down in correspond-
ing holes in container and twisted to lock the container when lifting.
Type designation Indicates machine type and capacity. See also machine model.
UTTO-oil Universal Tractor Transmission Oil.
Valve slide Moveable part in valve. Determines oil’s path.
Variable displacement Adjustable volume (capacity) of a pump.
Variable pump Pump with adjustable flow rate.
Wet brakes Brake discs in oil-bath.
Working hydraulics All load handling functions, that is, lift and lower, tilt, sideshift, spreading (extension)
and levelling.

202 10 Terminology

11 Index
About the documentation kit 6 Mechanical release of parking brake 173
About the Operator’s manual 3 Oil, brake system 155
Air filter, engine 151 Operating 112
ANSI/ASME-marking 10 Operating menu for container counter 65
Battery and battery disconnector 162 Operating menu for heating /air conditioning system 68
CE-marking 10 Operating menu for system voltage 65
Checking accumulators 161 Operator’s seat 57
Cleanliness 147 Overview 17
Control and monitoring system 63 Overview description 18
Control lever 50 Parking brake 118
Cooling system 152 Pedals 53
Daily inspection 142 Plates 23
Daily inspection 78 Reading Instructions 4
Description DRF 400-450 17 Running-in 77
Engine oil 153 Safety 7
Environment and standards 187 Safety and emergency equipment 8
Error code indication 81 Service 170
Error code information on display 81 Service brake 117
Error code tables 85 Service position 186
Error codes 79 Specifications 189
Event-controlled information 69 Starting engine 114
Foreword 3 Steering 117
Fuel system 148 Steering wheel 54
Functions for load handling 134 Stopping engine – parking 122
Fuses for electrical system 165 Switches 40
Gear selector and Terminology 199
multi-function lever 48 Towing 172
Gearshifting 116 Transmission oil 154
Handling 75 Transport of machine 171
Heating/Air conditioning 119 Transport of machine 175
Heating/Air conditioning 60 Transporting load 129
Hydraulic system 156 Tyres and rims 158
Identification of the machine 17 Unloading 132
Ignition 39 Warming up 115
Information menu for dynamic scale 64 Warning and indicator lights 34
Information menu for dynamic scale 66 While operating 112
Information menu for engine 64 Windshield washer 150
Information menu for engine and transmission 64
Information menu for printer 67
Information menu for service 68
Information menu for service interval 68
Information menu for transmission and hydraulics 65
Information menu statistics 66
Information menus 63
Inspection and maintenance 141
Inspection and maintenance 6
Instruments 38
Instruments and controls 29
Keep in mind 11
Lifting and transporting machine 174
Lifting load 125
Lifting machine 175
Lighting 169
Load handling 123
Long-term storage 186
Main fuses for electrical system 164
Maintenance 145
Kalmar Industries Sverige
Torggatan 3 SE-340 10 Lidhult, Sweden
Tel: +46 372 260 10. Fax: +46 372 259 77.
www.kalmarind.com

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DRF 400-450

1.1 About the Operator’s

Thank you for choosing Kalmar Industries as your machine supplier.

Purpose of the Operator’s manual

This Operator’s manual applies to machine DRF 400-450.

The Operator’s manual should always be kept in the machine.

About the machine version

The information in this Operator’s manual corresponds to the ma-

This machine is manufactured by Kalmar Industries AB,

Operator’s manual DRF 400-450 IDRF03.01GB

1.1.1 Reading Instructions

This Operator’s manual contains warnings that involve your safety.

Important information is denoted with NOTE and is intended to facil-

IDRF03.01GB Operator’s manual DRF 400-450

Read operator’s manual

Read the maintenance manual

There is a wide range of optional equipment for the machine. Each

Operator’s manual DRF 400-450 IDRF03.01GB

1.2 About the documentation

The following documentation is supplied with the machine:

Copies of the Operator’s manual and maintenance manual can be

1.3 Inspection and maintenance

For satisfactory function of the machine to the lowest cost, mainte-

For other maintenance not included in this Operator’s manual (serv-

IDRF03.01GB Operator’s manual DRF 400-450

Safety rules are intended to reduce the risk of personal injuries as

Important to read the Operator’s

nance of the machine. You’ll also find a lot of valuable information

Operator’s manual DRF 400-450 IDRF03.01GB

rebuilds shall be documented (date and actions) and the respon-

• The machine may only be operated by specially trained opera-

Prohibited operation of machine

Machine operation is prohibited:

2.1 Safety and emergency

A good working environment has safety and warning equipment to

4. Electrically powered loud air horn

IDRF03.01GB Operator’s manual DRF 400-450

8. TV-camera with monitor

12. Emergency exit, right door and rear window ( )

Operator’s manual DRF 400-450 IDRF03.01GB

(Declaration of Conformity, only applies to machines sold

Only applies to machines for the North American market).

W kg Any person performing modifications or changes affecting the ma-

Machine plates for ANSI/ASME-marking, machine

IDRF03.01GB Operator’s manual DRF 400-450

2.4 Keep in mind

Fatal danger and risk of property damage!

• Always check that no persons are in the way of

• The operator must always face in the travel di-

• The operator should pay extra attention and

• Always operate carefully so that the attachment

• Use available visibility equipment such as rear-

Operator’s manual DRF 400-450 IDRF03.01GB

Respect the machine’s lift capacity and operate

• The machine shall only be operated on even sur-

• Do not transport the load in high position since

• Always operate with the load facing uphill on an

• Operate the machine in reverse if the transpor-

• No personnel may enter/stand under a raised

• The operator should avoid powerful acceleration

• The operator should always adjust the speed

In case the machine rolls over or tips, always

IDRF03.01GB Operator’s manual DRF 400-450

It is prohibited to exceed the machine’s load capac-