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Publ. no IDCD03.03GB
Operator's manual in original language OPERATOR´S MANUAL
DCD 200-300
1 Foreword......................................................................................................... 3
1.1 About the operator’s manual ...................................................................... 3
1.2 About the documentation kit ....................................................................... 6
1.3 Inspection and maintenance ...................................................................... 7
2 Safety .............................................................................................................. 9
2.1 Safety and emergency equipment ............................................................ 11
2.2 CE-marking .............................................................................................. 12
2.3 ANSI/ASME marking ................................................................................ 13
2.4 Keep in mind ............................................................................................ 14
3 Overview ....................................................................................................... 23
3.1 Description DCD 200-300 ........................................................................ 23
3.2 Plates ....................................................................................................... 30
4 Instruments and controls ............................................................................ 39
4.1 Overviews ................................................................................................. 40
4.2 Warning and indicator lights ..................................................................... 45
4.3 Instruments ............................................................................................... 47
4.4 Ignition key lock (43) ................................................................................ 48
4.5 Switches ................................................................................................... 49
4.6 Gear and travel direction selector (2) ....................................................... 54
4.7 Multi-function lever (5) .............................................................................. 56
4.8 Load handling ........................................................................................... 57
4.9 Pedals ...................................................................................................... 66
4.10 Steering wheel (4) .................................................................................... 70
4.11 Driver’s seat (9) ........................................................................................ 74
4.12 Heating unit/Air conditioning ..................................................................... 80
4.13 KCS system .............................................................................................. 85
5 Handling........................................................................................................ 91
5.1 Running-in ................................................................................................ 93
5.2 Daily inspection ........................................................................................ 94
5.3 Error codes ............................................................................................... 95
5.4 Operating ................................................................................................ 126
5.5 Load handling ......................................................................................... 150
6 Inspection and maintenance..................................................................... 165
6.1 Daily inspection ...................................................................................... 166
6.2 Maintenance ........................................................................................... 170
6.3 Service ................................................................................................... 199
7 Transporting the machine ......................................................................... 201
7.1 Towing .................................................................................................... 202
7.2 Lifting and transporting the machine ...................................................... 206
7.3 Service position ...................................................................................... 208
7.4 Long-term storage .................................................................................. 209
8 Environment and standards...................................................................... 211
9 Specifications............................................................................................. 215
10 Terminology................................................................................................ 225
11 Index............................................................................................................ 229
1 Foreword 3
1 Foreword
1 Foreword
mm mm mm mm mm mm
Storage
–
Copyright
–
Cargotec Sweden AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Cargotec Sweden AB.
All duplication by any means, such as copying, printing, etc., is
prohibited.
Manufacturer
–
DANGER
Situation that could lead to severe personal injury or
death if regulation is not followed.
WARNING
Situation that could lead to personal injury if regula-
tion is not followed.
CAUTION
Situation that could lead to product damage if regula-
tion is not followed.
Important information
–
NOTE
Important information not related to safety.
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the Operator’s manual.
000262
Read the operator’s manual
Read the Maintenance manual
–
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the Maintenance manual.
001128
Read the Maintenance manual
Optional equipment
–
There is a wide range of optional equipment for the machine. Each de-
000264
scription of optional equipment in the operator’s manual is marked with
a symbol and contains an explanatory text. The symbol is highly visible
Indicates optional equipment 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.
Ordering documentation
–
Maintenance
–
2 Safety
2 Safety
mm mm 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.
Only personnel trained for this machine may handle, operate, perform
service or be in its vicinity during its use.
The safety information in this operator’s manual is for your information
and safety. It cannot, and is not intended to cover all possible events
during operation. Having responsible operators with the right training
is the only way to ensure safe and long-term use of the machine.
The machine was thoroughly tested and adjusted before it left the fac-
tory. This does not exclude the possibility that is has been damaged
during delivery. The machine must be thoroughly inspected before it is
used to ensure correct function.
manual
Incorrect handling can lead to personal injuries and damages to prod-
uct and/or property. Therefore, read the Operator’s Manual very thor-
oughly 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 maintenance of the
000262
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. permitted load ca-
pacity). If it is used in another way or in potentially dangerous en-
vironments (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 without permission
from Cargotec. For modifications approved by Cargotec, affected
plates on the machine and documentation shall be adapted to ap-
ply to the modification.
Operator requirements
–
Prohibited operation
–
8 2 11 9 8 7 1. Reverse alarm
5. Fire extinguisher
A fire extinguisher is normally located on the left front fender, but
may also be located on the right front fender or inside the cab.
1, 8 6 10 3 5 4 9 8 If the machine is provided with a fire extinguisher, it should be of
009491
9c 9a 9. Exterior mirrors :
Used to provide improved visibility while manoeuvring and load
handling.
9a shows blocked area in front of machine
9b shows blocked area to the side/behind the machine
9c shows blocked area behind machine.
2.2 CE-marking
CE-marking
page
–
WARNING
Always turn off the electric power when the machine
is left, e.g. when parking or at the end of the shift.
Risk of fire!
NOTE
Always check that a gear is not engaged before turning the start
key or resetting the control breaker for load handling.
NOTE
Never leave the operator’s station without first applying the park-
ing brake (ON position).
NOTE
Always remove the start key if the machine is to be left
unattended.
DANGER
Forks or other attachments are work tools that handle
large loads.
DANGER
External equipment may only be used if it is approved
by Cargotec.
DANGER
The parking brake should not be applied when the
machine is in motion.
DANGER
The machine’s work area is large and visibility from
the operator’s cab is restricted.
Keep in mind:
WARNING
Transporting loads is associated with major risks.
WARNING
The machine’s load capacity is limited.
WARNING
The strength of the roof window may be significantly
reduced in the event of exposure to substances con-
taining: aromatic hydrocarbons, ketones, esters and
chlorinated hydrocarbons.
WARNING
Lifting loads in very windy conditions is associated
with great danger.
WARNING
The machine emits exhausts during operation.
WARNING
Work position on the machine is located up high.
WARNING
No lowering of load handling equipment when control
is activated.
WARNING
Cab doors must always be closed when operating.
WARNING
Passengers are only allowed in the cab if there is a
specific passenger seat. It is prohibited to carry pas-
sengers on the machine outside the cab or on the
load.
WARNING
The machine’s hydraulic system contains a high-
pressure accumulator.
WARNING
Handle batteries and connectors with care when
charging and during starts with booster batteries. Do
not mix up the battery terminals! Follow instructions
for starting with booster battery!
WARNING
The machine uses oils and lubricants.
WARNING
Fire extinguishers contain dry chemicals.
Use the fire extinguisher from the outside and into the
area that is to be extinguished. After use, ventilate the
space thoroughly.
CAUTION
Cracks or scratches result in reduced strength of the
roof window.
Low strength!
CAUTION
The parking brake can be used as an EMERGENCY
BRAKE.
WARNING
Optional equipment such as two-way radio, RMI, tele-
phone, etc. may emit non-ionising radiation.
NOTE
When persons with active or non-active medical products are not
nearby, telephone and two-way radio may be used in the cab.
Equipment should not be used during operation or load handling
as this takes away from the operator’s concentration.
Cargotec will not assume any responsibility for installed optional
equipment, which is not installed by Cargotec or an installer ap-
proved by Cargotec.
3 Overview
3 Overview
mm mm mm mm mm mm
The DCD 200-300 machine is a forklift truck with so-called heavy ca-
pacity for all types of load handling. It has a maximum lift capacity of
20 to 30 tonnes. The machine has a lifting mast. There are three lifting
mast options and these are available in different lifting heights:
1. Duplex
2. Duplex Free Lift
3. Triplex Free Lift
This section provides a short presentation of the machine’s parts, see
General page 24.
Machine card
–
When ordering and after putting the machine into operation, it is pos-
sible to modify and adapt Cargotec machines in different 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 machine’s
product alternatives and optional equipment.
The machine card must be updated when the machine is modified and
Cargotec must be informed.
5
7
001524
1 2 3 4
1. Steering axle
2. Engine
3. Transmission
4. Drive axle
5. Load handling, lifting mast
6. Load handling, fork carriage
7. Cab
Engine
–
The machine has several engine alternatives. 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 alternatives:
• Volvo TAD750 (181 kW)
• Cummins QSB6.7 (194 kW)
Transmission
–
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 automatically (with spring force) in the event
of voltage drop and in the event of loss of hydraulic pressure, and it is
disengaged with hydraulic pressure.
Steering
–
The machine is steered with the steering axle (rear axle). A double-
acting hydraulic cylinder acts on the wheel pair. Steering is progres-
sive, i.e. a quick movement of the steering wheel gives a greater steer-
ing angle per steering wheel turn. This makes the machine easier to
operate in tight areas.
Load handling
–
The mast and fork carriage are used for load handling. The load is
moved vertically and is tilted (angled) forward or back.
The fork assembly is equipped with side shift and fork spreading.
The forks have roller brackets and as an alternative there is a shank
system with a pin type or hook mounting.
Electrical system
–
Cab
–
Hydraulic system
–
Other equipment
–
6, 12, 29 1, 2, 24 8, 11
14
21, 25
13 26
3, 18
3, 19, 28
16, 36
35
20
16
007351
20 37 7 4 38 15, 16 39 5
7 Passenger seat
9 Tinted windows
(Not positioned in figure).
14 Audio system
Instructions are included.
29 Adjustable searchlight
30 Tool kit
(Not positioned in figure).
37 Litter container
39 Baseplate, cab
Mounted between cab and frame.
3.2 Plates
Product plates
page
–
The following shows what plates should be on the machine when op-
erating within EU/EEA, more variants are available for other markets.
When ordering spare parts and when enquiring via telephone or cor-
respondence, the model designation and serial number should be giv-
en according to the plates. The plates’ spare part number is indicated
on each respective plate.
012969
4 1, 2, 5
NOTE
The plate’s design depends on type of attachment.
S/N = Serial number for the machine
A = Identification number for attachment
H = Lifting height
D = Centre of gravity distance
Q = Lift capacity
012872
NOTE
012955
The plate’s design depends on type of attachment.
S/N = Serial number for the machine
A = Identification number for attachment
H = Lifting height
D = Centre of gravity distance
Q = Maximal load
C = Height of centre of gravity. Distance from forks/load’s under-
side up to load’s centre of gravity.
Plate can only be ordered with complete engraving.
4 Type plate for mounted attachment (example), A54854
A = Identification number for attachment
S/N = Serial number for the attachment / Year of manufacture
H = Maximum hydraulic pressure to attachment
Q = Maximal load
012873
The following figures show the warning texts and information texts that
are located on the machine. The operator shall be aware of the warn-
ings 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.
1 1
5 2, 3 4
012975
1 6 2 6 3 2 1
Chassis, cab
1 Lift point, 423049.0100
Attaching point for lifting device when lifting the machine. Lift
points are found:
• mast
000276
• rear
2 Warning! A26939.0100
Warning! Read the operator’s manual for information.
000277
3 Warning! A54527.0200
Air conditioning. Filling of refrigerant requires special compe-
tence and authorisation (follow national legislation and local
rules).
1 = Refrigerant, type
2 = Amount, kg
1 3 = Pressure, bar
2
The plate is also on the condenser, compressor and at the air in-
3
let (front edge of cab) as plate A30770.0200.
012874
Safety
5 Warning! A36203.0100
- No passengers allowed. Passengers may only ride in the cab if
it’s equipped with a permanently mounted passenger seat.
- Do not jump. Always stay in the machine when there’s a risk of
roll-over and hold on to the steering wheel.
000847
001833
A43461.0100
15 15 15 13 7, 8 11 16 9 15
10 14
012976
12
Safety
7 Warning! A32441.0100
Do not stand on the marked area (condenser).
001491
Engine
8 Filling point, fuel, 450202.0100
D
000286
450202.0100
9 Warning! A30530.0100
Rotating fan.
000287
10 Warning! A30532.0200
Hot surfaces.
000850
455949.0100
14 Warning! A30533.0200
Rotating parts.
000853
001523
NOTE
Read chapter 6 Inspection and maintenance regarding safe-
ty when handling wheels.
The conditions for inflation pressure change if factory-
mounted tyres are replaced with another tyre brand! Contact
Cargotec. The plate for tyre air pressure must be replaced
with a plate with the applicable tyre pressure!
Electrical system
16 Battery disconnector, A30537.0100
In position 0, the battery’s plus terminal is disconnected.
000285
17 20 19
18
012977
Hydraulic system
17 Filling point hydraulic oil, 450203.0100
000292
18 Warning! A36163.0100
Pressure. Always release the pressure from the accumulator be-
fore working on the hydraulic system.
002497
19 Hydraulic pressure, A54518
Indicates set pressures for the machine. Information is engraved.
012878
DANGER
Forks or other attachments (with or without loads) are
easily operated and highly forceful tools.
4 Instruments and
mm mm mm mm mm mm
controls
General
page
–
Do not operate the machine before you know the position and function
of instruments and controls, and completely understand how they are
used!
This chapter gives general information about instruments, switches,
controls and other equipment in the machine’s cab.
NOTE
Thoroughly read the following chapter about instruments and
controls.
Optional equipment
There is a wide range of optional equipment for the machine. Each de-
000264
4.1 Overviews
General
page
–
1 2 3 4A 5
R
1 4 5
14 2 3
7A
4B 7B
006910
13 12 11 10 9 8
4A Steering wheel
5 Multi-function lever
6 Parking brake
8 Arm rest
9 Driver’s seat
10 Accelerator pedal
11 Brake pedals
12 Clutch pedal
Inching pedal
14 Hour meter
18 AC cooling control
27 28 29
19 .. 26
19 Recirculation/fresh air switch
(Only for heating unit with cooling AC)
18
17 20 Switch for cooling AC
16
15 Switch for extra working lights
30 31 32 33
22 Switch for extra working lights
TO DE
AU MO
30 Spare
31 Spare
32 Spare
35 36 37 38 39 40 41 42 43
35 Warning lamp for exhaust cleaning (particle filter)
R
40 Indicator light for direction indicators
1 2
R
3
41 Display for KCS control system
4
42 Alarm indicator for control system, KCS
5
43 Ignition
006903
51 52 53 54 55 56 57 58 59
51 Switch for switching off the reverse alarm
007728
55 Spare
57 Spare
58 Spare
59 Spare
This section describes the warning lamps and indicator lights in the
cab. They indicate the status of sub-systems/systems. An illuminated
warning lamp should be attended to immediately. An illuminated indi-
cator light informs of imminent action.
Warning lamps and indicator lights are grouped in the steering wheel
panel.
Numbers in brackets refer to the positions in Cab overview Spirit Delta
page 41.
The lamp (red) is illuminated when the air filter needs to be replaced
or there is another problem. Determine the cause and take appropriate
action. Contact service.
004254
Buzzer in the cab’s instrument panel activated at the same time as this
light.
The light (orange) shows the status of tilt control (tilt auto). Tilt control
is activated/deactivated by switches on the electric servo control for
load handling. The indicator light has no symbol.
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 bat-
tery voltage.
000297
Determine the cause and take appropriate action. Contact service.
NOTE
Do not operate with an activated light for low battery charging.
The light (blue) is activated when the high beams are on.
000309
The lamp (green) flashes when the direction indicators or hazard lights
are on.
000310
The indicator light (red) calls the operator’s attention. It illuminates with
a steady glow when an error code is shown in the display for the con-
trol system, KCS.
000402
The warning lamp (red) shows that the control system has one or sev-
eral error codes, active or passive. For more information, see section
4.13 "Control system, KCS".
The indicator light is active for as long as there are active error codes
("STOP", "Warning" or "Information").
The light (green) shows that twistlocks on the attachment are locked
(load is secured). The indicator light has no symbol.
The light (orange) shows that the attachment has contact with the load
(ready to lock twistlocks). The indicator light has no symbol.
The light (red) shows that twistlocks on the attachment are released
(load is unsecured). The indicator light has no symbol.
4.3 Instruments
General
page
–
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 periodic
maintenance. All times in periodic maintenance are based on the ma-
chine’s operating time in hours.
001342
Ignition’s function
–
P No function.
R
Electric power to all electrical functions. Control units for
R
engine and transmission are now ready for start.
1 2 3
4 5
Preheating is used in the event of cold weather. The en-
gine’s intake air is heated by preheating coils to a suitable
temperature. During preheating the preheating symbol is
shown in the display. Wait until the preheating symbol goes
out before turning the key to position III.
0 II No function.
P I III Start position.
Engagement of starter motor for starting the engine.
II NOTE
The machine has an electric restart interlock that pro-
tects the starter motor from engaging when the engine
007005
III is rotating.
Conditions for starter motor engagement are that the
Start key
gear selector is in neutral position and that the engine
isn’t already running.
4.5 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
Numbers in brackets refer to the positions in Cab overview Spirit Delta
page 41.
000331
Position 1 – Parking brake on.
0 1
Switch for extra working lights (20)
–
0 1
Switch for working lights on mast (21)
–
0 1
Switch for extra working lights (22)
–
0 1
Switch for extra working lights (23)
–
0 1
000321
0 1 Position 1 – Revolving beacon on.
Switch (red) for flashing hazard lights used to attract attention in con-
nection with parking hazard.
Position 0 – Flashing hazard lights off.
000322
Switch (green) for headlights. Also activates rear lights and side run-
ning lights.
Position 0 – Headlights off.
000323
009493
native travel direction selector is disengaged. The light in the switch is
0 1
off.
NOTE
For active lever or mini-wheel the normal travel direction selector
is automatically replaced by the travel direction selector on the
armrest console. The switch should be set to position 0 in order
for the travel direction selector on the armrest console to work.
Position 1 - Alternative travel direction selector is engaged. Then the
normal travel direction selector is disengaged. The light in the switch
is illuminated.
NOTE
For active lever or mini-wheel the normal travel direction selector
is automatically replaced by the travel direction selector on the
armrest console. The switch should be set to position 0 in order
for the travel direction selector on the armrest console to work.
Position 1 - Alternative travel direction selector in the speed pedal is
engaged. Then the normal travel direction selector is disengaged. The
light in the switch is illuminated.
Position 2 - Alternative travel direction selector on or adjacent to the
lifting lever is engaged. Then the normal travel direction selector is dis-
engaged. The light in the switch is illuminated.
NOTE
The same switch as for the engagement and disengagement of
alternative travel direction selector is used for the engagement
and disengagement of the alternative gear selector.
Position 0 – Normal gear and travel direction selector is engaged, i.e.
alternative gear selector is disengaged. The light in the switch is off.
NOTE
The alternative gear selector on the joystick or mini-wheel is en-
gaged automatically when the joystick control or mini-wheel is ac-
tivated and when the switch for the engagement and
disengagement of the alternative gear selector is in position 0.
Position 1 – Alternative gear selector on control for load handling
(4-lever, 5-lever, electric servo). When the normal gear and travel di-
rection selector is disengaged. The light in the switch is switched on.
0 1
Switch for windscreen wiper, rear (48)
–
0 1
Switch for windscreen wiper, roof (49)
–
0 1
NOTE
The wiper should not be used when the window is dry on cabs
with polycarbonate plastic roof window.
002899
0 1
Position 1 - Reverse alarm off.
(52)
0 1
Switch, electrically heated rear view mirrors (54)
–
0 1
Position 1 – Heating of rear view mirrors on (symbol lit).
This section describes the functions of the gear and travel direction
1 2 F
selector.
3
There are two alternative gear and travel direction selectors:
• gear control
006999
R
• RMH
Numbers in brackets refer to the positions in Cab overview Spirit Delta
page 41.
000898
Selecting shifting mode and direction of travel takes place with the
gear and direction of travel selector.
Selecting direction of travel:
• F – Forward
• N – Neutral
This section describes the functions of the control for load handling.
The controls control functions when handling forks or other attach-
ments. It is possible to vary the speed of the different hydraulic func-
tions, e.g. lift, tilt, etc., by varying the extent of the lever deflection. It is
also possible to vary the hydraulic functions’ speed with the engine
rpm.
NOTE
Position of a control is need-adapted and may thus differ from this
section. See plates on machine.
• Control with up to 5 levers page 58.
1. Lift / lower
LIFT – pull the lever backwards.
LOWER – push the lever forwards.
The lowering speed can be varied only with the lever deflec-
tion – the engine speed has no influence.
2. Tilt
BACK – pull the lever backwards.
FORWARD – push the lever forwards.
3. Side shift
LEFT – push the lever forwards.
RIGHT – pull the lever backwards.
The forks cannot be side-shifted if fork spreading is at
maximum.
6 1 2 3 4 5
4. Spreading (positioning)
OUT – move the lever forwards.
7 IN – pull lever backwards.
Spreading locks when one of the forks reaches its end posi-
tion. Side shift to the centre and spread again.
5. Levelling
FORK UP – pull the lever backwards.
FORK DOWN – move the lever forwards.
Levelling acts on the right or left fork.
7. Selecting gear
GEAR 1 – set the switch down.
GEAR 2 – set the switch in the centre.
GEAR 3 – set the switch up.
5. Levelling
FORK UP – pull the lever backwards.
FORK DOWN – move the lever forwards.
Fork levelling acts on the right or left fork.
6. Breaker switch for load handling (servo circuits)
8. Selecting gear
GEAR 1 – set the switch backward.
005212
The control lever controls functions when handling the forks and
sidelift attachments. Its function diagram is need-adapted and may
therefore differ from this section. See the plates on the machine.
5A 1B 5B
3A 3B
2A 2B
4A
4B
005213
5C 1A 5D
1A. Lift
1B. Lower
2A. Tilt backwards
2B. Tilt forwards
3A. Side shift, left
3B. Side shift, right
4A. Spreading, increase
4B. Spreading, decrease
5A. Levelling, left, down
5B. Levelling, right, down
5C. Levelling, left, up
5D. Levelling, right, up
Control lever
–
The control lever controls functions when handling the forks and
sidelift attachments. Its function diagram is need-adapted and may
therefore differ from this section. See the plates on the machine.
1B
2A 2B 3A 3B
4A 5A
1A
012964
4B 5B
1A. Lift
1B. Lower
2A. Tilt backwards
2B. Tilt forwards
3A. Side shift, left
3B. Side shift, right
4A. Levelling, fork down
4B. Levelling, fork up
5A. Spreading, increase
5B. Spreading, decrease
Buttons for optional features are present if necessary on the lever con-
trol (position A). Function and number of buttons are need-adapted.
004247
Hydraulic servo controls
A
006991
A B C
003930
There is a light panel with indicator lights on the sidelift attachment that
is used when handling loads with the attachment. The panel uses col-
oured lights to indicate if and when twistlocks are locked/unlocked, i.e.
if the load is secured/not secured.
A. Twistlocks locked (load secured), green.
B. Alignment attachment’s corners, orange.
C. Twistlocks unlocked (load not secured), red.
D. Light panel.
E. Twistlock.
F. Sidelift attachment assembly.
There are three indicator lights that are used for load handling with the
77 78 79 80 81 82 83 attachment. They are located on a panel by the control for load han-
dling. The panel uses coloured lights to indicate if and when twistlocks
are locked/unlocked, i.e. if the load is secured/not secured.
79 Spare
80 Spare
A 81 Indicator light for locked twistlocks, green
002447
0 1 Position 0 provides normal function.
Position 1 provides:
• Possibility to lock or open twistlocks without alignment.
• Possibility to adjust length of attachment when twistlocks are
locked.
• Possibility to lift, without indication of locked or open twistlocks.
• The option to engage gear without the driver’s seat sensor indicat-
ing that someone is sitting in it.
The key’s position indicates when the bypass of load handling func-
tions is activated.
WARNING
Safety features are blocked.
WARNING
Bypass of load handling functions must not be used
when lifting or transporting loads.
4.9 Pedals
General
page
–
F
4 3 2 1
L 0
R
R
4 3
006934
11 12 46 11 10
10. Accelerator pedal
11. Brake pedals
12. Clutch pedal (inching pedal )
46. Switch for inching
R
1 4 5
2 3
11
007023
10
R
1 4 5
2 3
007022
11 10
The accelerator pedal (position 10) is electronic and controls the en-
gine speed via the CAN bus and the KCS system.
The accelerator pedal has the same function as above. Choice of di-
rection of travel can be made using the accelerator pedal. Two switch-
es are located in the upper section of the pedal for choice of forwards
direction (left side) or reverse (right side).
001840
The brake pedals (position 11) are hydraulic and connected to the ma-
chine’s hydraulic system. The brake pedals are used for service brake.
The accumulators store energy so that brake pressure is also availa-
ble if the engine stops. If the accumulator pressure becomes too low
then an error code appears in the display.
The brake function is available in different versions:
• Brake without inching
The service brake is combined with the clutch pedal (position 12).
If the brake pedal is applied and the accelerator pedal is released
then the engine helps to slow down the machine.
If the clutch pedal (position 12) is depressed then drive is
declutched.
Hydraulic functions can be used with a gear engaged.
• Brake with inching . The inching function does not work with
extra pedals (with rotating or turnable driver’s seat).
Available in two versions:
– Switch (position 46) for inching.
Position 0 – Inching not activated. The brake is activated with
the brake pedal and declutch takes place when the pedal is
007191
N
L 0
R
4 3
007497
12
(km/h) Inching
10 Inching enables precision driving at low speed while the engine can
maintain higher revolutions, this means that power is released for the
1
working hydraulics. When inching is activated the drive starts to slip.
8
When the pedal is depressed 70% the drive is declutched completely.
2 In the event of overloading the function is disengaged.
6 Hydraulic functions can be used with a gear engaged.
4
4
3
2 0%
100%
25 50 75 100 (%)
0 07498
• joystick control ,
• mini-wheel .
Numbers in brackets refer to the positions in Cab overview Spirit Delta
page 41.
Steering wheel
–
3
001637
Joystick control
–
NOTE
If the switch for the engagement and disengagement of alter-
001448
NOTE
If the switch for the engagement and disengagement of alter-
native gear selector (position 46) is specified, the condition is
that it is in position "0".
Press 3a to change up (one press for each gear) and 3b to change
down. Gearshifting always starts with 1st gear when starting or af-
ter the travel direction selector has passed N.
4. Button for engaging joystick.
Conditions: machine speed must be below 3 km/h. If speed is over
3 km/h the joystick cannot be engaged. The lamp in the travel di-
rection selector (position 2) is illuminated with constant glow when
joystick control is engaged.
5. Sound signal.
NOTE
If the switch for the engagement and disengagement of alter-
native travel direction selector (position 45) is specified, the
condition is that it is in position "0".
forward = F
middle position = N
001447
reverse = R
3. Sound signal.
4. For optional equipment.
5. Selection of gear. 5a = change up, 5b = change down.
(Not available with automatic gearing)
Gear selector on the joystick control console (armrest) is automat-
ically activated when the joystick control is active.
NOTE
If the switch for the engagement and disengagement of alter-
native gear selector (position 46) is specified, the condition is
that it is in position "0".
Press 5a to change up (one press for each gear) and 5b to change
down. Gearshifting always starts with 1st gear when starting or af-
ter the travel direction selector has passed N.
This section describes the driver’s seat in the cab. The following alter-
native seats are available:
• Driver’s seat Bege is equipped with:
• mechanical adjustment of height and suspension
• air suspension
• rotating 40°
• mechanically adjusted lower back (lumbar) support
• mechanically adjusted seat cushion angle
• seat belt, 2-point
• head rest
• adjustable arm rest right
• seat heating
• ventilated seat and backrest cushion (air-vent). The seat re-
quires compressed air. The option includes an externally
mounted compressor on the underside of the cab floor.
• head rest
• adjustable arm rest right
• head rest
• adjustable arm rest right
NOTE
Other alternative driver’s seats may be installed.
Numbers in brackets refer to the positions in Cab overview Spirit Delta
page 41.
The driver’s seat (position 9) is equipped with several controls for ad-
justment as follows (adjustment 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 forwards or
backwards.
2. Height of seat.
Mechanical elevation of seat height:
Turn the knob clockwise or anticlockwise until desired height is
obtained.
2 3 6 1 5 7 4 9 6. Seat heating.
Thermostat-controlled heat for seat and back rest.
Press the button to activate/deactivate. The indicator lamp is on in
the event of activated seat heating.
7. Lumbar support. Integrated pneumatic system.
Press the buttons (7) to fill and empty the air chambers for optimal
adaptation of the back rest to the body.
8. The arm rest’s angle is set variably with the knurled button.
rest.
3 1 7
6. Adjusting the damping.
Turn control (6) gradually forward for harder damping.
Turn control (6) gradually backward for softer damping.
7. Plane damping.
Turn control (7) to rear-facing position to permit damping.
Turn control (7) to forward-facing position to turn off damping.
8. Lumbar support. Integrated pneumatic system.
Press the buttons to fill and empty the air chambers for optimal ad-
aptation of the back rest to the body.
9. The arm rest’s angle is set variably with the knurled button.
The operator’s station, with driver’s seat, can be obtained with electri-
cal rotation. The seat bracket has an integrated steering column and
steering wheel with panel. This follows round in the console during ro-
tation. The driver’s seat is no different from other seat options. The re-
volving operator’s station has double pedals. Steering wheel and hand
controls follow round during rotation.
The operator’s station is rotated with the switch for revolving opera-
tor’s station. See Switch for revolving driver’s seat (44) page 50.
007499
Cab alternative Spirit Delta can be equipped with one of the following
alternatives:
• heating unit
• heating unit with cooling AC (manual control of heating, cooling,
dehumidification and air flow)
• air conditioning ECC (automatic control of heating, cooling, dehu-
midifying and air flow)
001971
16
15 Recirculation is switched on and off with the switch (position 19) ( ).
Panel heating unit Cooling AC is switched on and off with the switch (position 20) ( ).
The panel has a panel vent (position A).
The fresh air filter is equipped with a filter and can be equipped with a
fine filter against pollen ( ).
NOTE
The driver’s door and windows should be closed for satisfactory
function of the heating unit.
000547
The rotary control (position 16) handles fresh air inlet into the cab.
Turn clockwise to increase fan speed and thereby air supply; turn an-
ticlockwise to reduce the air supply.
The fan is operated in steps 0-I-II-III using the control.
000545
The rotary control (position 17) handles the infinitely adjustable distri-
bution of fresh air to the cab towards the lower area (leg area) and de-
froster (windows). The left position is for lower cab area, centre is for
cab area and right is for defroster.
000546
The rotary control (position 18) handles variable setting of cooling out-
put. Turn clockwise to increase cooling, anticlockwise to decrease or
switch off cooling.
000548
0 1
Switch for cooling AC (20)
–
0 1 does not start if the fan control (position 16) is in its zero position.
NOTE
The driver’s door and windows should be closed for the satisfac-
006992
AUTO
MODE tory function of the air conditioning.
A. Panel vent
29. Switch for supplemental heating
34. Air conditioning ECC
AUTO mode
–
In auto mode the temperature, air distribution and fan speed are ad-
justed automatically. Selected temperature and AUTO appear in the
003702
display.
Temperature
–
Fan
–
Adjust with the keys to the desired fan speed. The speed is adjustable
between 0-100%.
003566
Air distribution
–
Select the desired function with the keys. The selected air distribution
is indicated by a square under the current symbol.
003567
Air to the floor.
003568
Air to both the floor and panel vents.
003569
Air to the windscreen.
003570
Maximum defroster.
003571
Recirculation
–
Cabin air is recirculated, i.e. no fresh air is drawn into the operator’s
cab. REC appears in the display when the function is activated. Switch
003572
• Operating information
R
1 2 3
Operating information includes, e.g., machine speed, engine rpm,
4 5
fuel level, etc.
The information is presented on the steering wheel panel’s display
006936
(position 41). The function keys (position 47) are used to navigate in
47
the display menus during, for example, service and troubleshooting.
41. Display for the control system (KCS)
Numbers in brackets refer to the positions in Cab overview Spirit Delta
42. Alarm indicator for the control system
page 41.
47. Function keys for the control system (KCS)
Steering wheel panel’s differing appearance is one
example.
The operating menu with engine speed, speed, current gear, time and
50
fuel level is shown after starting the machine. Menus are selected with
the function keys for right arrow and left arrow. With each press of the
key, the display changes to the next menu. To quickly return to the
original display, press and hold in the function key for Reset (R).
82 ˚C This section describes the information that can be obtained from the
different operating menus. The figures show example data.
2.4 bar
NOTE
-/+
60 ˚C The availability of the menus is dependent on the machine’s
- +
equipment.
28.7 V
2 L/H
1430 km
+
12 L/H 300 h
(+/-) 1.2
75 t
007359
158 t
006993
c 12:00 am F – forward, N – neutral, R – reverse. 1-3 indicates gear position.
e. Shows current fuel level.
f. Shows when preheating is active.
1650
50 rpm F1 g. Flashes when the parking brake is activated.
14 km/h 006994
f g
2.4 bar b
007339
- +
28.7 V b
006995
300 h b
007340
(+/-) 1.2 a The value displayed in row (b) can be reset to zero (tared) using
the function keys for minus and plus. The set value is displayed in
75.0 t b
row (a). Shows 0-3.0 tonnes.
007341
c. Total weight in tonnes (gross weight).
The value in row (b) can be added to row (c) using the function key
for Return. The value in row (c) can be reset to zero by depressing
the function keys for Reset and Return simultaneously.
b
Average fuel consumption can be reset by pressing and holding
Reset and Return simultaneously.
Scroll through the menus with the function keys for right arrow and left
arrow.
To reset the measurement, depress the function key for + and - simul-
taneously for two seconds. All values in the current menu are reset
simultaneously.
a. Engine speed in rpm.
0000 rpm a b. Instantaneous fuel consumption in litres/hr.
+ 00.0 l/h b c. Average fuel consumption in litres/hr. Can be reset.
00.0 l/h c
d. Driving time remaining until the tank is empty in hours. When the
011709
0:00 h d fuel level has been below 2% for 60 seconds the display shows
-:- - instead of remaining driving time. The tank symbol flashes.
e. Trip meter in km. Can be reset.
f. Average speed in km/h. Can be reset.
00.0 km e
00.0 km/h f
012963
To reset the measurement, depress the function key for + and - simul-
taneously for two seconds. All values in the current menu are reset si-
multaneously.
Menus for statistics
00000 h b b. Operating time transmission with engine running and travel direc-
tion activated in hours.
000 %
010257
c
c. Proportion idling in %, i.e. engine speed of 700-1020 rpm and the
transmission in neutral. Can be reset.
d. Total accumulated fuel consumption in litres.
e. Accumulated fuel consumption in litres. Can be reset.
000000 l d
f. Average fuel consumption in litres/hr. Can be reset.
000000 l e
00 . 0 l/h
010258
0000 . 0 km h
010259
4.13.1.10 Operating menu for service
Description
page
–
007344
5 Handling
5 Handling
mm mm mm mm mm mm
General
page
–
NOTE
It is the operator who is responsible for ensuring that the machine
comes in for service every 500 operating hours. Procedures are
described in the maintenance manual.
The information in the chapter for handling the machine does not re-
lieve the operator of the responsibility of following laws or other nation-
al regulations for road safety and work safety.
Awareness, alertness, good judgement and respect for governing
safety regulations are prerequisites for avoiding accident risks.
Environmental impact
–
Emergency equipment
–
• Fire extinguisher
A fire extinguisher is located on a front wing or inside the cab.
In case of engine fire, press in the fire extinguisher’s nozzle
through the perforation on the plate for fire extinguisher on the
sides of the engine hood.
WARNING
Bypass of load handling functions must not be used
when lifting or transporting loads.
5.1 Running-in
General
page
–
The machine should be operated with great care during the run-in pe-
riod. The purpose is to give bearing surfaces hard and polished sur-
faces, which considerably extends the service life.
Recommended run-in period is 50 hours of operating time. This gives
fewer malfunctions. Increase loading gradually during these 50 hours.
NOTE
Check the oil pressure and temperature at regular intervals.
For a new machine it is essential that during the first working week the
wheel nuts are retightened until they have seated properly. This
should be performed at intervals of 4-5 operating hours (up to approx.
40-50 operating hours). After which, retightening of the wheel nuts
takes place in accordance with the intervals described in the mainte-
nance manual.
WARNING
Never operate a defective machine.
WARNING
The Stop alarm indicates a malfunction in the ma-
chine which may affect the safety of the operator and
others in the vicinity or may cause a breakdown. –
Read the error code, switch off the engine and per-
form the action according to error code table.
1 Stop the machine and identify error code level and special error
code number, see section Error code indication page 97. Then
stop the engine in the event of a Stop alarm or allow the engine
to run during a Warning or Information alarm.
NOTE
In case of a serious malfunction, the engine will be emer-
gency-stopped. After an emergency stop it is possible to re-
start the engine for approx. 25 seconds to move the
machine from an unsuitable position.
If several error codes arise from the engine then these are
shown in a rolling sequence, i.e. all active error codes are
shown at 1 second intervals in the same box.
000389
code information disappears once its cause has been remedied.
Deactivate error code display by pressing the Reset (R) function
key:
• For Stop: if the cause of the error code remains, the error
code will reappear within one minute.
• With warning or information: if the cause of the error code re-
mains, the error code will reappear within three minutes.
• If the cause of the error code is gone, error code display will
automatically deactivate within 30 seconds.
3 Park the machine in a suitable location.
For error code level "STOP" – Stop the engine.
For error code level "WARNING" or "INFORMATION" – Allow the
engine to run or switch off the machine.
4 Read the information for the error code/error codes in the error
code table and perform the recommended actions.
• Error codes, control unit EDU 795 (KCS display) page 102
• Error codes, control unit ECU 790 page 102
• Error codes, control unit ECU 796 page 104
• Error codes, control unit ECU 792 page 107
• Error codes engine page 108
• Error codes transmission page 121
5 Restart the engine and check in the display that error codes are
gone according to step 2.
004257
1-3 minutes.
The control and monitoring system’s display is divided into four fields
C where the information is shown (see figure to the left).
STOP
Indicates a serious malfunction that may affect operator safety or
cause machine breakdown. The error code shall be taken care of as
soon as possible. Stop working with the machine and contact service
as soon as possible.
The error code is shown automatically on the display.
Action in the event of STOP
C A. Park the machine immediately.
C. Contact service.
WARNING
Indicates machine malfunction that should be taken care of as soon as
possible. After finished work shift with the machine, contact service as
soon as possible.
The error code is shown automatically on the display.
Action in the event of Warning
C A. Take care of the error code as soon as possible but work with ma-
chine can continue safely.
D E
B. See information in error code table
• Error codes, control unit EDU 795 (KCS display) page 102
000351
• Error codes, control unit ECU 790 page 102
• Error codes, control unit ECU 796 page 104
• Error codes, control unit ECU 792 page 107
• Error codes engine page 108
• Error codes transmission page 121
If error code number is not in error code table, perform action
according to step C.
C. Contact service, e.g. after work shift is finished.
INFORMATION
Information for the operator that something should be taken care of,
for example, low fuel level. Take care of the cause of the error code as
soon as possible. See chapter 6 Inspection and maintenance.
The error code is shown automatically on the display.
Action in the event of Information
C A. Continue work with machine.
000389 • Engine
1200 Shown with code 1200 and error code number X.X.X (position D)
in the display, see Error codes engine page 108.
D
B NOTE
000584
If several error codes arise from the engine then these are
shown in a rolling sequence, i.e. all active error codes are
shown at 1 second intervals in the same box.
• Transmission:
900 Shown with error code 900 and error code level (position D) and
error code level (position B) in the display. If several error codes
D
arise from the transmission then these are shown in a rolling se-
B quence at 1 second intervals. For error code table, see Error
001847
28
007010
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 the event of the error
code in question.
• Action - Indicates STOP/WARNING/INFORMATION for action ac-
cording to error code level, with or without detailed information.
If the error code number isn’t included in the error code table, contact
service.
11 Communication, error on cable ECU 790 - EDU 795. Impossible to contin- WARNING!
ue operation.
17 Memory error, checksum EDU 795. Impossible to continue operating, dis- WARNING!
play not working.
303 Reference voltage error, 5V, ECU 790. Reduction of engine speed. STOP!
320 Defective sensor for hydrostatic drive pressure (forward). Reduction of en- STOP!
gine speed.
321 Defective sensor for hydrostatic drive pressure (reverse). Reduction of en- STOP!
gine speed.
322 Defective hydraulic pressure sensor for lifting lever. Engine speed does not WARNING!
increase when using lifting lever.
323 Short-circuit or open circuit on output signal EDC valve pump (forward). STOP!
Reduction of engine speed.
324 Short-circuit or open circuit on output signal EDC valve pump (reverse). STOP!
Reduction of engine speed.
325 Short-circuit or open circuit on output signal PDC valve hydraulic motor. STOP!
Reduction of engine speed.
352 Low fuel level. Possible to continue operating. INFORMATION! Fill with fuel.
354 Low coolant level. Reduction of engine speed. STOP! Fill with coolant.
356 Defective sensor hydraulic oil temperature. Possible to continue operating. INFORMATION!
357 Brake system, accumulator pressure low. Reduction of engine speed. STOP! The pressure in the accu-
mulator, i.e. the brake pressure is
too low and service brake capacity
is limited.
Check the sealing integrity of the
accumulators if the pressure is not
built up and maintained, see chap-
ter 6 Inspection and maintenance.
Contact service.
370 Particle filter engine. Clean within 30 minutes. INFORMATION! Clean the parti-
cle filter within 30 minutes. See the
section 5.4.9 Stopping machine -
parking or see the separate manu-
al for the particle filter.
372 Particle filter, engine. High pressure. Reduction of engine speed. STOP! Clean particle filter. See
section 5.4.9 Stopping machine -
parking or see separate manual
for particle filter.
380 Error on accelerator pedal LF (Left Front). Reduction of engine speed. STOP!
381 Error on accelerator pedal RF (Right Front). Reduction of engine speed. STOP!
382 Error on accelerator pedal LR (Left Rear). Reduction of engine speed. STOP!
383 Error on accelerator pedal RR (Right Rear). Reduction of engine speed. STOP!
384 Error on servo motor for injector pump, engine. Reduction of engine speed. STOP!
390 Error on valve for variable pump for Optimum Speed/Optimum Rev, short- WARNING!
circuit or open circuit at terminal.
400 Revolving driver’s seat. Defective sensor. Only driving forward is possible. WARNING! Stop the machine.
Turn the driver’s seat to the posi-
tion for driving forward. Contact
service.
402 Error on parking brake. The parking brake cannot be released. STOP!
405 Error on position sensor for seat turning. Limitation of function. WARNING!
406 Signal error from power cell, stub axle, tilt cylinder. Overload protection not WARNING!
working.
1502 Fault on joystick. Alternative steering switched off automatically. STOP! Use standard steering.
1503 Fault on potentiometer mini steering wheel. Alternative steering switched STOP! Use standard steering.
off automatically.
1504 Short circuit or open circuit on output signal for right control valve. Alterna- STOP! Use standard steering.
tive steering switched off automatically.
1505 Short circuit or open circuit on output signal for left control valve. Alternative STOP! Use standard steering.
steering switched off automatically.
1506 Voltage feed error ECU 792. Reduction of engine speed. STOP! Check the fuses in accord-
ance with the operator’s manual.
Contact service if the problem per-
sists.
1507 Reference voltage error, 5V, ECU 792. Reduction of engine speed. STOP!
1 Too low value. Data valid, but lower than normal operating range.
16 Too high value. Data valid but higher than normal operating range: Moderately severe
level
17 Too low value. Data valid but lower than normal operating range: The least severe
level
18 Too low value. Data valid but lower than normal operating range: Moderately severe
level
31 FMI is not available or the ratio stated by Not available or the ratio exists
SPN exists.
Description Action
Display J1587
SPN/FMI
94/1 PID94/1 Sensor fuel pressure, low fuel pressure. STOP
94/5 PID94/5 Sensor fuel pressure, cable open circuit or short-circuited to STOP
ground.
94/7 PID94/7 Sensor fuel pressure, critically low fuel pressure. STOP
97/4 PID97/4 Sensor water in fuel, cable open circuit or short-circuited to STOP
ground.
100/1 PID100/1 Low engine oil pressure. Reduced engine power or engine is STOP: Check oil level in en-
turned off. gine. See 6.2.6 Engine oil.
105/0 PID105/0 Too high charge-air temperature. Reduced engine power. STOP
106/3 PID102/3 Sensor boost pressure, cable short-circuited to voltage. Engine STOP
smokes more than normal at acceleration/load.
106/5 PID102/5 Sensor boost pressure, cable open circuit. Engine smokes more STOP
than normal when accelerating/under load.
110/0 PID110/0 High coolant temperature. Reduced engine power or engine is STOP: Check coolant level.
turned off. See 6.2.5 Cooling system.
110/4 PID110/4 Sensor coolant temperature, cable short-circuited to frame. Pre- STOP
heating activated even when engine is warm. Engine difficult to
start.
110/5 PID110/5 Sensor coolant temperature, cable open circuit. Preheating ac- STOP
tivated even when engine is warm. Engine difficult to start.
111/1 PID111/1 Low coolant level. Reduced engine power. STOP: Check coolant level.
See 6.2.5 Cooling system.
Description Action
Display J1587
SPN/FMI
158/1 PID158/1 Low battery voltage. Engine may be difficult to start. STOP
164/2 PID164/2 Pressure fuel injection. Engine rpm limited to 1100 rpm. STOP
164/4 PID164/4 Sensor pressure fuel injection, cable short-circuited to frame. STOP
Engine rpm limited to 1100 rpm.
164/5 PID164/5 Sensor pressure fuel injection, cable open circuit. Engine rpm STOP
limited to 1100 rpm.
626/4 PID45/4 Preheating relay, cable short-circuited to frame. Preheating con- STOP
stantly activated, fuse for preheating coil will blow.
626/5 PID45/5 Preheating relay, cable open circuit. Preheating cannot be acti- STOP
vated. Engine difficult to start in cold weather.
636/2 SID21/2 Sensor rpm camshaft. Irregular signal. Engine takes longer to STOP
start than normal. Engine runs normally once it has started.
636/3 SID21/3 Sensor rpm camshaft. No signal. Engine takes longer to start STOP
than normal. Engine runs normally once it has started.
636/8 SID21/8 Sensor rpm camshaft. Abnormal frequency. Engine takes longer STOP
to start than normal. Engine runs normally once it has started.
637/2 SID22/2 Sensor rpm flywheel. Irregular signal. Engine is extremely diffi- STOP
cult to start and runs rough or stops.
637/3 SID22/3 Sensor rpm flywheel. Abnormal frequency. Engine is extremely STOP
difficult to start and runs rough or stops.
637/8 SID22/8 Sensor rpm flywheel. Abnormal frequency. Engine is extremely STOP
difficult to start and runs rough or stops.
Description Action
Display J1587
SPN/FMI
639/2 SID231/2 Internal error engine control unit. STOP
Engine off: engine cannot be started. Engine on: engine goes to
idle mode and can only be stopped by using emergency stop.
651/3 SID1/3 Electrical problem, injector cylinder 1. Engine only runs on STOP
5 cylinders and has reduced power.
651/4 SID1/4 Electrical problem, injector cylinder 1. Engine only runs on STOP
5 cylinders and has reduced power.
651/5 SID1/5 Electrical problem, injector cylinder 1. Engine only runs on STOP
5 cylinders and has reduced power.
651/12 SID1/12 Electrical problem, injector cylinder 1. Engine only runs on STOP
5 cylinders and has reduced power.
652/3 SID2/3 Electrical problem, injector cylinder 2. Engine only runs on STOP
5 cylinders and has reduced power.
652/4 SID2/4 Electrical problem, injector cylinder 2. Engine only runs on STOP
5 cylinders and has reduced power.
652/5 SID2/5 Electrical problem, injector cylinder 2. Engine only runs on STOP
5 cylinders and has reduced power.
652/12 SID2/12 Electrical problem, injector cylinder 2. Engine only runs on STOP
5 cylinders and has reduced power.
653/3 SID3/3 Electrical problem, injector cylinder 3. Engine only runs on STOP
5 cylinders and has reduced power.
Description Action
Display J1587
SPN/FMI
653/4 SID3/4 Electrical problem, injector cylinder 3. Engine only runs on STOP
5 cylinders and has reduced power.
653/5 SID3/5 Electrical problem, injector cylinder 3. Engine only runs on STOP
5 cylinders and has reduced power.
653/12 SID3/12 Electrical problem, injector cylinder 3. Engine only runs on STOP
5 cylinders and has reduced power.
654/3 SID4/3 Electrical problem, injector cylinder 4. Engine only runs on STOP
5 cylinders and has reduced power.
654/4 SID4/4 Electrical problem, injector cylinder 4. Engine only runs on STOP
5 cylinders and has reduced power.
654/5 SID4/5 Electrical problem, injector cylinder 4. Engine only runs on STOP
5 cylinders and has reduced power.
654/12 SID4/12 Electrical problem, injector cylinder 4. Engine only runs on STOP
5 cylinders and has reduced power.
655/3 SID5/3 Electrical problem, injector cylinder 5. Engine only runs on STOP
5 cylinders and has reduced power.
655/4 SID5/4 Electrical problem, injector cylinder 5. Engine only runs on STOP
5 cylinders and has reduced power.
655/5 SID5/5 Electrical problem, injector cylinder 5. Engine only runs on STOP
5 cylinders and has reduced power.
655/12 SID5/12 Electrical problem, injector cylinder 5. Engine only runs on STOP
5 cylinders and has reduced power.
656/3 SID6/3 Electrical problem, injector cylinder 6. Engine only runs on STOP
5 cylinders and has reduced power.
656/4 SID6/4 Electrical problem, injector cylinder 6. Engine only runs on STOP
5 cylinders and has reduced power.
656/5 SID6/5 Electrical problem, injector cylinder 6. Engine only runs on STOP
5 cylinders and has reduced power.
Description Action
Display J1587
SPN/FMI
656/12 SID6/12 Electrical problem, injector cylinder 6. Engine only runs on STOP
5 cylinders and has reduced power.
677/3 SID39/3 Start relay on starter motor, cable short-circuited to voltage or STOP
1675/3 activated too long. Starter motor does not run.
677/4 SID39/4 Start relay on starter motor, cable short-circuited to frame. Start- STOP
1675/4 er motor does not run.
677/5 SID39/5 Starter motor relay, open circuit on cable or defective compo- STOP
1675/5 nent. Starter motor does not run.
679/0 PSID97/0 Pressure relief valve. Engine rpm limited to 1100 rpm. STOP
679/7 PSID97/7 Pressure relief valve. Engine is turned off or engine rpm limited STOP
to 1100 rpm.
679/11 PSID97/ Pressure relief valve. Engine rpm limited to 1100 rpm. STOP
11
679/14 PSID97/ Pressure relief valve. Engine rpm limited to 1100 rpm. STOP
14
729/4 SID70/4 Sensor preheating, cable short-circuited to ground. Engine diffi- STOP
cult to start in cold weather.
729/5 SID70/5 Sensor preheating, cable open circuit. Engine difficult to start in STOP
cold weather.
1079/3 SID 232/3 Voltage feed sensor engine, cable short-circuited to voltage. STOP
1079/4 SID 232/4 Voltage feed sensor engine, cable short-circuited to frame. STOP
1080/3 PPID 211/ Voltage feed sensor engine, cable short-circuited to voltage. STOP
3
1080/4 PPID 211/ Voltage feed sensor engine, cable short-circuited to frame. STOP
4
1239/0 PSID96/0 Incorrect fuel pressure injection. Engine rpm limited to STOP
1100 rpm.
Description Action
Display J1587
SPN/FMI
1239/1 PSID96/1 Incorrect fuel pressure injection. Engine rpm limited to STOP
1100 rpm.
1239/4 PSID96/4 Incorrect fuel pressure injection. Engine is turned off or engine STOP
rpm limited to 1100 rpm.
1239/7 PSID96/7 Incorrect fuel pressure injection. Engine rpm limited to STOP
1100 rpm.
1239/12 PSID96/ Incorrect fuel pressure injection. Engine rpm limited to STOP
12 1100 rpm.
- PPID 435/ Incorrect fuel pressure injection. Engine rpm limited to STOP
0 1100 rpm.
- PPID 435/ Incorrect fuel pressure injection. Engine rpm limited to STOP
1 1100 rpm.
Description Action
Display
SPN/FMI
84 / 10 Circuit sensor engine rpm - Abnormally wide variations. WARNING!
91 / 19 SAE J1939 multiplexing, system error accelerator pedal sensor - CAN bus data WARNING!
error.
Description Action
Display
SPN/FMI
91 / 3 Position sensor accelerator pedal, defective circuit - Abnormally high voltage or WARNING!
short-circuiting to higher voltage.
91 / 4 Position sensor accelerator pedal, defective circuit - Abnormally low voltage or WARNING!
short-circuiting to lower voltage.
94 / 1 Fuel pump feed pressure incorrect - Data valid, but lower than normal operating WARNING!
range.
94 / 18 Fuel pump feed pressure incorrect - Data valid, but lower than normal operating WARNING!
range.
97 / 15 Water in fuel, indicator high - Data valid, but higher than normal operating range. WARNING!
97 / 3 Sensor circuit water in fuel - Abnormally high voltage or short-circuiting to higher WARNING!
voltage.
97 / 4 Sensor circuit water in fuel - Abnormally low voltage or short-circuiting to lower WARNING!
voltage.
100 / 1 Engine oil pressure low - Data valid, but higher than normal operating range. STOP! Very serious
100 / 18 Engine oil pressure low - Data valid, but lower than normal operating range. WARNING!
100 / 2 Pressure sensor engine oil, defective circuit - Defective, uneven, or rough. WARNING!
100 / 3 Pressure sensor engine oil, defective circuit - Abnormally high voltage or short- WARNING!
circuiting to higher voltage.
100 / 4 Pressure sensor engine oil, defective circuit - Abnormally low voltage or short- WARNING!
circuiting to lower voltage.
102 / 2 Fuel sensor circuit inlet manifold - Defective, uneven, or rough. WARNING!
102 / 3 Pressure sensor inlet manifold - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
102 / 4 Pressure sensor inlet manifold - Abnormally low voltage or short-circuiting to low- WARNING!
er voltage.
103 / 16 Turbo #1 high rpm - Data valid, but higher than normal operating range. WARNING!
103 / 18 Turbo #1 low rpm - Data valid, but lower than normal operating range. WARNING!
105 / 0 Circuit temperature sensor inlet manifold - Data valid, but higher than normal op- STOP! Very serious
erating range.
105 / 15 Temperature inlet manifold high - Data valid, but higher than normal operating WARNING!
range.
Description Action
Display
SPN/FMI
105 / 3 Temperature sensor inlet manifold - Abnormally high voltage or short-circuiting WARNING!
to higher voltage.
105 / 4 Temperature sensor inlet manifold - Abnormally low voltage or short-circuiting to WARNING!
lower voltage.
108 / 3 Sensor air pressure - Abnormally high voltage or short-circuiting to higher WARNING!
voltage.
108 / 4 Sensor air pressure - Abnormally low voltage or short-circuiting to lower voltage. WARNING!
110 / 0 Coolant temperature engine high - Data valid, but higher than normal operating STOP! Very serious
range.
110 / 15 Coolant temperature engine high - Data valid, but higher than normal operating WARNING!
range.
110 / 16 Coolant temperature engine high - Data valid, but higher than normal operating WARNING!
range.
110 / 2 Sensor coolant engine, defective circuit - Defective, uneven, or rough. WARNING!
110 / 3 Sensor coolant engine, defective circuit - Abnormally high voltage or short- WARNING!
circuiting to higher voltage.
110 / 4 Sensor coolant engine, defective circuit - Abnormally low voltage or short- WARNING!
circuiting to lower voltage.
111 / 1 Coolant level engine low - Data valid, but lower than normal operating range. STOP! Very serious
111 / 3 Level sensor coolant circuit - Abnormally high voltage or short-circuiting to higher WARNING!
voltage.
111 / 4 Level sensor coolant circuit - Abnormally low voltage or short-circuiting to lower WARNING!
voltage.
157 / 0 Fuel pressure high - Data valid, but higher than normal operating range. WARNING!
157 / 16 Measurement injection pressure bank 1, high pressure - Data valid, but higher WARNING!
than normal operating range.
157 / 18 Measurement injection pressure bank 1, low pressure - Data valid, but lower than WARNING!
normal operating range.
157 / 3 Measurement injection pressure bank 1, defective circuit - Abnormally high volt- WARNING!
age or short-circuiting to higher voltage.
157 / 4 Measurement injection pressure bank 1, defective circuit - Abnormally low volt- WARNING!
age or short-circuiting to lower voltage.
167 / 1 Alternator low voltage - Data valid, but lower than normal operating range. STOP! Very serious
Description Action
Display
SPN/FMI
167 / 16 Alternator high voltage - Data valid, but higher than normal operating range. WARNING!
167 / 18 Alternator low voltage - Data valid, but lower than normal operating range. WARNING!
168 / 16 Battery#1 voltage high - Data valid, but higher than normal operating range. WARNING!
168 / 18 Battery#1 voltage low - Data valid, but lower than normal operating range. WARNING!
171 / 3 Ambient temperature sensor, defective circuit - Abnormally high voltage or short- WARNING!
circuiting to higher voltage.
171 / 4 Ambient temperature sensor, defective circuit - Abnormally low voltage or short- WARNING!
circuiting to lower voltage.
190 / 0 Engine overspeeding - Data valid, but higher than normal operating range. STOP! Very serious
251 / 2 Real-time clock, open circuit power supply - Defective, uneven, or rough. WARNING!
441 / 3 Spare temperature sensor circuit - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
441 / 4 Spare temperature sensor circuit - Abnormally low voltage or short-circuiting to WARNING!
lower voltage.
558 / 13 Idle validation circuit accelerator pedal - Values outside calibration values. WARNING!
558 / 2 Idle validation circuit accelerator pedal - Defective, uneven, or rough. WARNING!
558 / 4 Idle validation circuit accelerator pedal - Abnormally low voltage or short- WARNING!
circuiting to lower voltage.
611 / 3 Voltage feed no. 4, sensor - Abnormally high voltage or short-circuiting to higher WARNING!
voltage.
611 / 4 Voltage feed no. 3, sensor - Abnormally low voltage or short-circuiting to lower WARNING!
voltage.
611 / 4 Voltage feed no. 4, sensor - Abnormally low voltage or short-circuiting to lower WARNING!
voltage.
612 / 2 Engine’s torque and position sensor circuit has lost input signals from solenoid WARNING!
sensor - Defective, uneven, or rough.
627 / 2 Open circuit power supply despite ignition in position on - Defective, uneven, or WARNING!
rough.
627 / 2 Open circuit power supply despite ignition in position on - Defective, uneven, or WARNING!
rough.
629 / 12 Engine control unit internal error - Defective unit or component. WARNING!
Description Action
Display
SPN/FMI
629 / 12 Voltage feed injector - Defective unit or component. WARNING!
630 / 2 Engine control unit, memory error - Defective, uneven, or rough. WARNING!
630 / 31 Engine control unit, RAM memory error - Not available. WARNING!
639 / 13 SAE J1939 multiplexing configuration error - Values outside calibration values. WARNING!
639 / 9 SAE J1939 multiplexing PGN time limit exceeded - Abnormal update rate. WARNING!
641 / 3 Variable Turbo Geometry valve circuit - Abnormally high voltage or short- WARNING!
circuiting to higher voltage.
641 / 4 Variable Turbo Geometry valve circuit - Abnormally low voltage or short- WARNING!
circuiting to lower voltage.
647 / 3 Circuit error switch cooling fan - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
647 / 4 Circuit error switch cooling fan - Abnormally low voltage or short-circuiting to low- WARNING!
er voltage.
651 / 5 Injector solenoid cylinder # 1 circuit - Abnormally low current or open circuit. WARNING!
652 / 5 Injector solenoid cylinder # 2 circuit - Abnormally low current or open circuit. WARNING!
653 / 5 Injector solenoid cylinder # 3 circuit - Abnormally low current or open circuit. WARNING!
654 / 5 Injector solenoid cylinder # 4 circuit - Abnormally low current or open circuit. WARNING!
655 / 5 Injector solenoid cylinder # 5 circuit - Abnormally low current or open circuit. WARNING!
656 / 5 Injector solenoid cylinder # 6 circuit - Abnormally low current or open circuit. WARNING!
677 / 3 Start relay circuit - Abnormally high voltage or short-circuiting to higher voltage. WARNING!
677 / 4 Start relay circuit - Abnormally low voltage or short-circuiting to lower voltage. WARNING!
697 / 3 External PWM drive circuit 1 - Abnormally high voltage or short-circuiting to high- WARNING!
er voltage.
Description Action
Display
SPN/FMI
697 / 4 External PWM drive circuit 1 - Abnormally low voltage or short-circuiting to lower WARNING!
voltage.
723 / 2 Engine rpm sensor (camshaft) defect - Defective, uneven, or rough. WARNING!
723 / 7 Engine rpm sensor mechanically incorrectly adjusted between camshaft and WARNING!
crankshaft - Incorrect response from mechanical system.
729 / 3 Air preheating coil circuit - Abnormally high voltage or short-circuiting to higher WARNING!
voltage.
729 / 4 Air preheating coil circuit - Abnormally low voltage or short-circuiting to lower volt- WARNING!
age.
974 / 19 SAE J1939 multiplexing, value error remote accelerator pedal sensor - Received WARNING!
data incorrect.
974 / 3 Position sensor accelerator pedal, defective circuit - Abnormally high voltage or WARNING!
short-circuiting to higher voltage.
974 / 4 Position sensor accelerator pedal, defective circuit - Abnormally low voltage or WARNING!
short-circuiting to lower voltage.
1043 / 3 Voltage feed circuit accelerator pedal or lever - Abnormally high voltage or short- WARNING!
circuiting to higher voltage.
1043 / 4 Voltage feed circuit engine rpm/position sensor - Abnormally low voltage or WARNING!
short-circuiting to lower voltage.
1043 / 4 Voltage feed circuit accelerator pedal or lever - Abnormally low voltage or short- WARNING!
circuiting to lower voltage.
1072 / 3 Signal engine brake circuit #1 - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
1072 / 4 Signal engine brake circuit #1 - Abnormally low voltage or short-circuiting to low- WARNING!
er voltage.
1073 / 3 Signal engine brake circuit #2 - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
1073 / 4 Signal engine brake circuit #2 - Abnormally low voltage or short-circuiting to low- WARNING!
er voltage.
1075 / 3 Fuel suction pump circuit - Abnormally high voltage or short-circuiting to higher WARNING!
voltage.
Description Action
Display
SPN/FMI
1075 / 4 Fuel suction pump circuit - Abnormally low voltage or short-circuiting to lower WARNING!
voltage.
1079 / 3 Sensor voltage feed circuit #1 - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
1079 / 4 Sensor voltage feed circuit #1 - Abnormally low voltage or short-circuiting to low- WARNING!
er voltage.
1080 / 3 Sensor voltage feed circuit #2 - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
1080 / 4 Sensor voltage feed circuit #2 - Abnormally low voltage or short-circuiting to low- WARNING!
er voltage.
1172 / 3 Turbocharger pressure temperature sensor circuit - Abnormally high voltage or WARNING!
short-circuiting to higher voltage.
1172 / 4 Turbocharger pressure temperature sensor circuit - Abnormally low voltage or WARNING!
short-circuiting to lower voltage.
1347 / 3 High-pressure fuel valve circuit - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
1347 / 4 High-pressure fuel valve circuit - Abnormally low voltage or short-circuiting to WARNING!
lower voltage.
1347 / 7 High-pressure valve no.1 - Incorrect response from mechanical system. WARNING!
1377 / 2 Switch circuit multiple synchronisation unit - Defective, uneven, or rough. WARNING!
1378 / 31 Change oil and oil filter, conditions apply - Not available. WARNING! Service.
1388 / 3 External pressure sensor input - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
1388 / 4 External pressure sensor input - Abnormally low voltage or short-circuiting to low- WARNING!
er voltage.
2629 / 15 Boost pressure temperature output calculated - Data valid, but higher than nor- WARNING!
mal operating range.
2789 / 15 Boost pressure temperature input calculated - Data valid, but higher than normal WARNING!
operating range.
Description Action
Code
00/50 Memory error in control unit transmission. Transmission in STOP
locked neutral position ("shutdown").
41/06 Incorrect gear selection from gear selector. Control unit does WARNING
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
43/07 Torque converter’s temperature exceeds 100 C. WARNING: Note the error and try to reduce
temperature in torque converter by operating
calmly.
Description Action
Code
43/08 Torque converter’s temperature exceeds 125 C. WARNING: Stop the machine, engage neu-
The control unit protects the transmission and does not allow tral and apply full throttle (limited to 50%) to
the temperature in the torque converter to exceeds the limit val- cool the transmission oil so that temperature
ue. Transmission in locked neutral position ("shutdown"). En- drops below 100 C (error code 43/03 disap-
gine is limited to 50% of max. rpm. pears).
When temperature in torque converter is be-
low 100 C, resume work with machine.
44/10 Position accelerator pedal message from engine’s control unit. WARNING
46/05 Max. torque at inching has been exceeded. WARNING: Stop the machine, select neu-
tral. Select gear again.
50/01 Sensor oil pressure, open circuit. Control unit transmission ac- STOP
tivates "limp home".
Description Action
Code
63/00 Sensor rpm turbine, short-circuiting to ground. STOP or WARNING
If several rpm signals or the engine rpm signal are incorrect,
control unit transmission activates "limp home".
70/00 Solenoid valve VFS forward. Control unit transmission activates STOP: Stop the machine and shift to neutral.
"limp home". Select reverse gear.
70/01 Solenoid valve VFS forward. Control unit transmission activates STOP: Stop the machine and shift to neutral.
"limp home". Select reverse gear.
70/02 Solenoid valve VFS forward. Control unit transmission activates STOP: Stop the machine and shift to neutral.
"limp home". Select reverse gear.
70/03 Solenoid valve VFS forward. Control unit transmission activates STOP: Stop the machine and shift to neutral.
"limp home". Select reverse gear.
71/00 Solenoid valve VFS 2. Control unit transmission activates "limp STOP: Stop the machine and shift to neutral.
home". Select reverse gear.
71/01 Solenoid valve VFS 2. Control unit transmission activates "limp STOP: Stop the machine and shift to neutral.
home". Select reverse gear.
71/02 Solenoid valve VFS 2. Control unit transmission activates "limp STOP: Stop the machine and shift to neutral.
home". Select reverse gear.
71/03 Solenoid valve VFS 2. Control unit transmission activates "limp STOP: Stop the machine and shift to neutral.
home". Select reverse gear.
72/00 Solenoid valve VFS reverse. Control unit transmission activates STOP: Stop the machine and shift to neutral.
"limp home". Select reverse gear.
72/01 Solenoid valve VFS reverse. Control unit transmission activates STOP: Stop the machine and shift to neutral.
"limp home". Select reverse gear.
72/02 Solenoid valve VFS reverse. Control unit transmission activates STOP: Stop the machine and shift to neutral.
"limp home". Select reverse gear.
72/03 Solenoid valve VFS reverse. Control unit transmission activates STOP: Stop the machine and shift to neutral.
"limp home". Select reverse gear.
73/00 Solenoid valve VFS 1/3. Control unit transmission activates STOP: Stop the machine and shift to neutral.
"limp home". Select reverse gear.
73/01 Solenoid valve VFS 1/3. Control unit transmission activates STOP: Stop the machine and shift to neutral.
"limp home". Select reverse gear.
73/02 Solenoid valve VFS 1/3. Control unit transmission activates STOP: Stop the machine and shift to neutral.
"limp home". Select reverse gear.
Description Action
Code
73/03 Solenoid valve VFS 1/3. Control unit transmission activates STOP: Stop the machine and shift to neutral.
"limp home". Select reverse gear.
77/02 All gear packs disengaged. Transmission in locked neutral po- STOP
sition ("shutdown").
82/00 Solenoid valve gear selection 1/3, short-circuiting to ground. STOP: Stop the machine and shift to neutral.
Control unit transmission activates "limp home". Select reverse gear.
82/01 Solenoid valve gear selection 1/3, open circuit or short- STOP: Stop the machine and shift to neutral.
circuiting to battery. Control unit transmission activates "limp Select reverse gear.
home".
For serious transmission malfunctions the control unit uses two modes
with reduced functionality to protect the transmission from damage.
These are:
• "Limp home", GPOS / CPOS in display indicates the letters LH.
In this mode, the operator can use the transmission’s two first
gears in each direction. If the malfunction occurs in a higher gear
the operator has to downshift manually to first or second gear to
continue. The control unit uses standard values for modulation.
• "Shut down", GPOS / CPOS in display indicates the letters Sd.
In this mode the transmission is permanently in neutral as there is
no oil pressure to enable gear selection.
Heater valve Open Open circuit in water valve or in the wiring between Contact service.
the ECC control unit and water valve.
Heater valve Short Short circuit in water valve or in the wiring between Contact service.
the ECC control unit and water valve.
Heater valve Stuck Water valve is jammed or blocked by foreign objects. Contact service.
Inside sensor Open Open circuit in sensor, cabin temperature, or the wir- Contact service.
ing between the ECC control unit and sensor, cabin
temperature.
Inside sensor Short Short circuit in sensor, cabin temperature, or the wir- Contact service.
ing between the ECC control unit and sensor, cabin
temperature.
Outside sensor Open Open circuit in sensor, outside temperature, or the Contact service.
wiring between the ECC control unit and sensor, out-
side temperature.
Outside sensor Short Short circuit in sensor, outside temperature, or the Contact service.
wiring between the ECC control unit and sensor, out-
side temperature.
Deicing sensor Open Open circuit in sensor, deicing, or the wiring between Contact service.
the ECC control unit and sensor, deicing.
Deicing sensor Short Short circuit in sensor, deicing, or the wiring between Contact service.
the ECC control unit and sensor, deicing.
Aftercoil Sensor Open Open circuit in sensor, after heat exchanger, or the Contact service.
wiring between the ECC control unit and sensor, after
heat exchanger.
Aftercoil sensor Short Short circuit in sensor, after heat exchanger, or the Contact service.
wiring between the ECC control unit and sensor, after
heat exchanger.
AC system failure Probably abnormal pressure in the refrigerant circuit. The fault might be temporary in nature
and could then be rectified by means of
resetting the ECC.
Reset the ECC by switching off the igni-
tion and restarting the truck. Go to the
error indication menu on the ECC and
press the button to lower the fan speed
for a few seconds, see Section Error
codes ECC page 125.
If the fault remains after restarting, con-
tact service.
5.4 Operating
5.4.1 While operating
General
page
–
DANGER
The machine’s work area is large and visibility from
the operator’s cab is restricted.
Keep in mind:
WARNING
Never use a machine without first performing the dai-
ly inspection.
WARNING
Never operate the machine without wearing the
seatbelt.
Extreme danger!
WARNING
The operator must exercise additional caution when
the reverse alarm is switched off.
Extreme danger!
WARNING
Don’t let the engine idle for a long time.
Instructions
–
NOTE
The fuel indicator should never go down to empty tank.
F
WARNING
If it’s difficult to start the engine, do not use start
spray.
Risk of explosion!
Instructions
–
NOTE
If there is extra exhaust cleaning (particle filter) :
Check that the machine is not connected for cleaning.
2. Turn the start key to operating position, position I.
Now there is current to all electric functions.
In case of cold weather, preheating, i.e. glow position,
can be used. During preheating, the engine’s intake air is preheat-
ed to a suitable temperature by preheating coils. The symbol for
preheating is shown in the display.
When the symbol disappears, turn to start position, position III.
The symbol for preheating is not shown if the engine is hot or if the
ambient temperature is sufficiently high.
3. Let the starter motor crank the engine, release the key when the
engine starts.
The machine has an electric restart interlock that protects the
starter motor from engaging when the engine is rotating.
NOTE
IF THE ENGINE DOESN’T START, try again after
15-20 seconds. Don’t run the starter motor for longer than
10 seconds 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.
5.4.3 Warming up
General
page
–
WARNING
Never rev a cold engine at high engine speeds.
WARNING
Don’t let the engine idle for a long time.
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 circulates
well before the turbocharger starts to operate at high rpms.
• Starting working with the machine with a certain amount of caution
until the coolant has reached normal operating temperature (ap-
prox. 82-95 °C), only then should full output be drawn from the
engine
• Warm up the hydraulic oil. Run hydraulic functions without load for
a short time before starting to work.
5.4.4 Gearshifting
General
page
–
• Automatic
With automatic transmission, the system shifts to a lower/higher
gear under certain conditions, such as torque, engine speed,
travel speed, etc.
It is possible to select to use manual or automatic gearshifting. Select
automatic or manual gearshifting by going into the KCS menus with
the service code for "AUTOMATIC GEARSHIFT ECU793" and select
"AUTOMATIC GEARSHIFT OFF" value 0 or 1.
General about the automatic transmission:
• Has a built-in control and monitoring system, providing optimal op-
eration.
• Shows current gear on control and monitoring system’s display.
• Normally, starting off is in first gear. It is possible to set to start in
2nd gear in the KCS menus, as well as declutching on and off.
• Reverse lock-out prevents change of travel direction taking place
too fast, that is, prevents eventual transmission damage. Reverse
lock-out is automatic and depends on engine rpm and travel
speed.
WARNING
Change of travel direction must be made with care.
The machine has a reversing lock as standard but
transmission service life is increased if change of
travel direction takes place at a lower travel speed
and engine speed.
The machine has three forward gears and three in reverse. Use man-
ual transmission as follows:
1 Let the engine run at idling speed. Select travel direction. Travel
direction can be selected in five ways:
NOTE
Selection of travel direction selector must be performed with
the switch for engagement and disengagement of alterna-
tive travel direction selector (position 45). When the switch
is in position 1 the engine is locked against starting and so
therefore cannot be started.
A. Gear control and travel direction selector
A F
1 2 3 Move the lever forward for travel direction forward and back
for reverse.
007011
D F
R
3
2
007334
1
2 Select gear. Start in first gear, starting in higher gear may lead to
overheating. Gears can be selected in five ways:
007333
NOTE
Selection of gear selector must be performed with the switch
for engagement and disengagement of alternative gear se-
lector (position 46).
A. Gear control and travel direction selector
Engage a gear by turning the handle forward or backward.
To start in first gear: Turn backward to position 1.
B. Gear and travel direction selector RMH
Engage a gear by moving the lever to the left or right. To start
in first gear: Lift the lever and move to the right.
C. Gear selector on control for load handling 4-lever and 5-lever
1 Let the engine run at idling speed. Select travel direction. Travel
direction can be selected in five ways:
NOTE
Selection of travel direction selector must be performed with
the switch for engagement and disengagement of alterna-
tive travel direction selector (position 45). When the switch
is in position 1 the engine is locked against starting and so
therefore cannot be started.
A. Gear control and travel direction selector
A F
1 2 3 Move the lever forward for travel direction forward and back
for reverse.
007011
D F
R
3
2
007334
1
A control breaker senses when the operator leaves the operator’s sta-
tion. The signal from the control breaker means that the transmission
automatically adopts neutral position. It is not possible to select a di-
rection of travel.
NOTE
If the buzzer sounds when the operator sits in the seat and re-
leases the parking brake then the control breaker in the seat may
be malfunctioning. It is not possible to select a direction of travel.
In which case, the function for control breaker in the driver’s seat
must be checked.
008191
5.4.5 Steering
General
page
–
The machine has power steering. Steering movement from the steer-
ing wheel, joystick or mini steering wheel is transmitted by hydraulic
means to the steering wheels.
WARNING
The machine may not roll on a downhill grade if the
engine is off.
L 0
R
chapter 6 Inspection and maintenance.
R
4 3
006934
11 12 46 11 10
007191
Position 1 – Inching activated. Inching and braking are controlled with
0 1
the brake pedal. When the pedal is depressed the drive starts to slip,
so-called crawling or inching.
If the brake pedal is depressed more than 70% then drive is de-
clutched completely.
Inching pedal
The brake is activated with the brake pedal and declutch takes place
when the pedal is depressed more than 70%.
When the brake and inching pedals are applied simultaneously a mi-
croswitch is actuated and the drive starts to slip, so-called crawling or
inching.
F
4 3 2 1
N
L 0
R
4 3
007497
12
DANGER
The parking brake should not be applied when the ma-
chine is in motion.
WARNING
Never leave the operator’s station without first apply-
ing the parking brake.
The parking brake is operated with the switch (position 6) on the panel
for hydraulic controls. The warning lamp for applied parking brake (in
the switch) illuminates with a red glow when the parking brake is ap-
plied, and the symbol for applied parking brake is shown in the display.
Instructions
–
R
• The parking brake is applied automatically when the engine is
1 4 5
2 3
stopped.
An audible signal is activated if the operator gets up from the driver’s
seat without first applying the parking brake.
6 If the accumulator pressure drops below a certain level then an error
code appears in the display. In the event of an error code for low ac-
cumulator pressure the service brake’s capacity is limited. Finally, the
parking brake is applied automatically by a forceful spring in the brake
cylinder. Check the accumulators’ sealing integrity if the pressure
6 does not build up and is not maintained, see chapter 6 Inspection and
maintenance.
If the machine has to be moved, see chapter 7 Transporting the
6
machine.
009055
CAUTION
The parking brake can be used as an EMERGENCY
BRAKE.
NOTE
The operator’s door and windows should be closed for satisfac-
tory function of heating unit/air conditioning.
16
15 Cooling AC is switched on and off with switch (position 20) ( ).
Panel heating unit The panel has a panel vent (position A).
NOTE
Use cooling AC (position 20) every now and then in wintertime for
lubrication and continued good function of the AC compressor.
In temperatures below -3 °C, the cooling function does not work
if the cooling circuit is cold.
Supplemental heating is switched in and off with switch (position 29)
( ) and is activated when the ignition key is in position 0 and the en-
gine is warm.
In warm weather
–
In cold weather
–
Cooling AC
–
NOTE
For optimum comfort when using AC, avoid aiming the cooled air
directly against the body. Aim the air against the upper section of
the cab and increase fan capacity as required. Cooling capacity
increases if recirculation position is switched on.
1. Use the fresh air inlet (position 19).
Use recirculation (position 19) in very hot weather and with high
air humidity.
2. Set temperature to cool (position 15).
3. Turn on cooling AC (position 20).
4. Set the cooling control for cooling AC (position 18) as required.
5. Open the panel vents towards the roof.
NOTE
In temperatures below -3 °C, the cooling function does not
work if the cooling circuit is cold.
Supplemental heating
–
NOTE
Supplemental heating is always available as long as the switch is
in position 1, and it starts as soon as the start key is in position P
and the engine temperature is above approx. 40 °C.
1. Switch on the supplemental heating (position 29). The function
starts when the engine temperature is above approx. 40 °C and
the start key is in position P.
2. Set the temperature to maximum heat flow (position 15).
3. Set the fan speed to position I (position 16).
The cab is kept warm for a longer period if fan speed is low.
NOTE
In temperatures below -3 °C, the cooling function does not work
AUTO
MODE
if the cooling circuit is cold.
003703
E F G H
A. Increasing temperature
B. Decreasing temperature
C. Lowering fan speed
D. Raising fan speed
E. Auto mode
F. Selecting air distribution
G. Selecting air distribution
H. Recirculation
I. Air distribution
Setting the temperature
–
Fan speed can be adjusted manually between 0-100% with the but-
tons. At 0% the fan is completely switched off and the compressor is
disconnected. The graph in the display shows that the fan speed is se-
lected manually.
003566
003567
can only be obtained manually, automatic mode operates between the
windscreen and the floor/panel vents.
The following air distribution options can be selected:
Air to the floor.
003568
Air to both the floor and ventilation nozzles.
003569
003570 Air to the windscreen.
Max defrost.
003571
Recirculated air
–
NOTE
There is a certain delay before Auto is shown in the display. Do
not press repeatedly.
Auto/menu function
–
Short presses on the auto button scroll through the following functions:
1. Auto
003702
A B C D The menu for adjusting the display is reached by means of the auto
button (position E) being pressed and held for a few seconds. The fol-
lowing can be adjusted in this menu:
1. Brightness.
2. Contrast.
3. Switching between °C and °F.
AUTO
MODE
4. Language.
Scroll through the available options with buttons for temperature (po-
003707
sition A and B) and adjust with buttons for fan (position C and D).
E Return by briefly pressing the auto button (position E).
A. Scroll in menu
B. Scroll in menu
C. Adjust values
D. Adjust values
E. Auto mode
Error indication
–
In the event of a fault on any sensor or if the pressure switch was trig-
A B C
gered "ERROR" flashes in the display.
Press and hold the auto button (position E) for a few seconds to dis-
play current error/errors as text in the display.
Scroll between error messages with buttons for temperature (position
A and B). Selected error message is indicated with an arrow in the
display.
AUTO
MODE
Cause of error is reached with the left arrow button (position F).
003708
Reset of pressure switch is performed using the button to lower the fan
speed (position C). Hold the button depressed for a few seconds to
E F
reset.
A. Scroll through error messages
Return by briefly pressing the auto button (position E).
B. Scroll through error messages
C. Reset pressure switch For error code table, see Error codes ECC page 125.
D. -
E. Auto mode
F. Cause of error
Supplemental heating
–
TO DE
AU MO
NOTE
Supplemental heating is always available as long as the switch is
in position 1, and it starts as soon as the start key is in position P
and the engine temperature is above approx. 40 °C.
1. Switch on the supplemental heating (position 29). The function
starts when the engine temperature is above approx. 40 °C and
the start key is in position P.
2. Temperature and fan speed are regulated automatically.
NOTE
Never disconnect the main electric power with the battery discon-
nector when the engine is running! The voltage regulator may be
damaged.
WARNING
Always turn off the electric power when the machine
is left, e.g. when parking or at the end of the shift.
Danger!
Instructions
–
1. Stop the machine and set the gear and travel direction selector to
neutral.
2. Apply the parking brake.
3. Tilt the mast slightly forward so that the underside of the forks can
rest on the ground. Lower the forks to the ground.
4. Let the engine run 1 minute at idle speed before stopping the en-
gine so that the engine cools down slightly and the turbo bearings
are lubricated.
5. Stop the engine by turning the start key to position 0.
If the machine is going to be parked for a long time, e.g. after a
work shift is over, then the battery disconnector should be turned
to the OFF (0) position.
CAUTION
Never stop clean-burning in progress.
Cleaning is complete:
• after 8 hours, ammeter shall show zero Ampere.
• after 8 hours, the indicator light shall be green.
• after 40 minutes, the indicator light shall be green.
WARNING
During cleaning hot air flows from the outlet
pipe, which may ignite flammable materials.
Risk of fire!
During all lifting work, make particularly sure that the max. lift capacity
is not exceeded, see machine plate or load diagram.
The forklift’s capacity is indicated by three parameters:
• position of load’s centre of gravity
300 mm
• lifting height
007362
• load’s size
Transport position 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 ma-
chine appears to be side-heavy, the load should be lowered and ad-
justed with side shift so that the load’s centre of gravity is moved to a
position along the machine’s centre line.
The load handling function refers to, e.g. lifting, lowering, rotating, an-
gling and holding a load. Load handling also includes lifting devices for
handling different types of loads, e.g. sidelift attachments.
Load handling sub-functions.
• Lift/lower
007363
• Tilt
Lift and lower • Side shift
• Spreading (positioning)
• Levelling
007364
Tilt
007916
Side shift
007910
Spreading (positioning)
007917
Levelling
There are different types of lifting tool for load handling, most common
are:
• forks
• coil ram
WARNING
Respect the machine’s lift capacity and operate with
great care during load handling:
WARNING
Check that the lifting attachment is marked with a
type plate from Cargotec or another manufacturer.
There must always be a plate fitted with capacity in-
formation for all attachments.
007365
• Tilt the mast forwards slightly.
• Lower the forks as low as possible and adjust the fork
spreading and insert them under the load.
• Tilt the mast backwards so that the forks are horizontal.
NOTE
When handling drums, strive to keep the forks as close to-
gether as possible.
2 Hold the machine stationary with the service brake and inching
pedal if necessary. Alternatively, apply the parking brake if de-
sired and/or set the gear in neutral. If needed, use stop blocks at
the drive wheels.
DANGER
The operator should pay take extra care when load
handling near electric power lines, viaducts, dock-
sides, ramps, doors, etc.
Extreme danger!
WARNING
Forks (with or without load) are easily manoeuvrable
work tools with great strength.
WARNING
Transport of loads is associated with great risks.
1 Lift the load slightly. Reverse away from the loading location.
2 Adjust load height and tilt angle to transport position, see Trans-
port position page 155.
Transport position
–
When the machine is to be run with or without load, assume the trans-
port position to minimise the risk of roll-over and imbalance while op-
erating. In transport position the mast is tilted back and the load is lifted
above the ground slightly, approx. 300 mm (see the figure to the left.)
The load’s centre of gravity must be centred laterally.
300 mm
007362
If the load blocks visibility ahead then the machine must be reversed.
to the left.) The forks must be side-shifted so that a fork tip is visible
through the mast, this way the full length of the machine including forks
007366
is visible.
Transport position without load
Operating on grades
–
NOTE
Only use the service brake pedal (right-hand brake pedal) when
braking in order to obtain engine braking. Avoid using the inching
function.
• Operating with a load.
Adjust load height and tilt angle to transport position, see Trans-
port position page 155.
Always drive with the lifting attachment upwards in the grade, irre-
spective of travel direction, i.e. the truck must be reversed down a
grade.
• Operating without a load.
Lower the lifting attachment and tilt back the mast as far as
001533
possible.
Operating with a load on grades Always drive with the lifting attachment upwards in the grade, irre-
spective of travel direction, i.e. the truck must be reversed down a
grade.
Operate with extreme care in all work near overhead high voltage pow-
er lines, keeping in mind the height of the mast and load.
DANGER
If the machine comes into contact with overhead high
voltage power lines - sit down in the seat and call for
help!
Extreme danger!
5.5.3 Unloading
General
page
–
There are different types of lifting attachments for load handling, e.g.
forks, coil rams and sidelift attachments for container handling.
C
007368
A. Weight Indicator
B. Knob
C. Foot button
Scales
–
NOTE
(+/-) 1.2 a For accurate weighing the scales must be calibrated regularly
against a known weight, as large as possible. For calibration,
75.0 t b
contact service personnel.
158.0 t c Load weight is approximated with the operating menu for scales.
007341
1 Set the mast vertically.
2 Check that the current weight in the display shows 0, otherwise
reset to zero with the function keys for plus and minus.
3 Position the load at the same centre of gravity distance as for cal-
ibration.
4 Perform the lifting movement and then lower the load slowly
about 30 cm.
5 Select the operating menu for scales.
a. Shows tare weight in tonnes.
The value displayed in row (b) can be reset to zero (tared)
using the function keys for minus and plus. The set value is
displayed in row (a).
b. Actual weight in tonnes (net weight).
c. Total weight in tonnes (gross weight).
The value in row (b) can be added to row (c) using the func-
tion key for Return. The value in row (c) can be reset to zero
by depressing the function keys for Reset and Return
simultaneously.
Sidelift attachment
–
Max General
Points to consider when handling sidelift attachments with empty
container:
WARNING
Never use a machine if the indicator lights don’t work.
WARNING
Sidelift attachments (with or without load) are easily
manoeuvrable work tools with great strength.
A B C Hoisting technique
1 Set spreading to the container length in question (position 4).
2 Drive slowly toward the container, adjust side shift (position 3).
3 Tilt the mast forward slightly (position 2), about 2°, lower the
sidelift (position 1) to the container and fit the two twistlocks into
the locking holes in the container so that both sides of the sidelift
are resting on the container. Check that the light position B is il-
luminated.
4 Lock twistlocks (position 5). Check that the light in position A is
illuminated.
5 Tilt the mast back and lift. Check that the light in position B is
1 2 3 4 5 switched off when the container is hoisted.
6 Transport the container in transport position. Reverse if the con-
tainer obscures vision.
7 Unloading the container: Set the container on the surface below.
Check that the light in position B is illuminated. Release the twist-
locks. Check that the light in position C is illuminated.
003933
NOTE
For load handling with the control lever, see the plates on the
machine.
WARNING
Exercise caution when changing e.g. aggregates or
exchangeable forks.
Risk of crushing!
WARNING
Always make sure that forks, inverted forks or coil
ram are always stored in a safe place.
Forks
Removal
B
Proceed as follows to remove the forks:
• Place the forks in their stowage position.
• Remove the lock rings/lock pins (position A) and knock out the
pins (position C) that hold the forks to the shanks (position B).
A • Lower/tilt forward and back away from the forks.
Reassembling
Proceed as follows to reassemble the forks:
C • Always make sure that the locking pin is locked with the lock ring/
lock pin.
B
A
C
005470
B • Lift until the forks/coil ram are fully aligned with the shanks. Check
D that the lower retaining catches grip the fork assembly’s lower
beam.
• Fold in the movable locking catches and lock with the pins (posi-
A
tion B).
Removal
Proceed as follows to remove the forks:
• Position the forks/coil ram in a safe stowage location.
• Fold out the movable locking catches (position C).
• Tilt forwards so that the lower retaining catches (position D)
release.
• Lower slightly so that the upper retaining catches (position A) re-
lease and reverse away from the forks/coil ram.
L
C
005469
D
A. Upper retaining catch
B. Lock pin
C. Movable locking catch
D. Lower retaining catch
WARNING
Exercise caution when changing e.g. aggregates or
exchangeable forks.
Risk of crushing!
WARNING
Always make sure that forks, inverted forks or coil
ram are always stored in a safe place.
Assembly
• Set fork spreading so that the forks fit the fork pockets.
• Insert the forks into the fork pockets.
• Lock the forks to the top lift with the braces behind the forks.
• Connect the hydraulic hoses and electrical cable from the top lift
to the quick couplings on the fork assembly. Check that hoses and
cables have such a routing that they cannot be damaged.
• Check the different functions of the top lift.
Removal
• Set the length setting at 20’’ (adjustable top lift).
• Set the top lift in a safe stowage location, on an empty container
for example.
• Set the rotation in centre position (or extension to min.) so that the
hydraulic pressure is equalised and it becomes easier to detach
the quick couplings. Also in this way oil spillage is avoided.
• Connect the hydraulic hoses and electrical cable from the top lift
to the quick couplings on the fork assembly. Check that hoses and
cables have such a routing that they cannot be damaged.
• Unlock the braces behind the forks, set the mast vertical and re-
verse away from the top lift.
6 Inspection and
mm mm mm mm mm mm
maintenance
General
page
–
NOTE
All time information refers to operating time, that is, the time
shown by the hour meter on the panel.
CAUTION
Only spare parts approved by Cargotec may be used.
WARNING
Never use a machine without first performing the dai-
ly inspection.
Instructions
–
DANGER
If there are cracks in materials or welds in load bear-
ing structures then the machine must be immediately
withdrawn from operation and sent for service.
2
WARNING
Make sure that the engine is off when working with
twistlocks.
4
• remove snow from air inlets and radiator grill
009441
6.2 Maintenance
General
page
–
The cab must always be tilted past the centre of gravity position. If
space sideways is insufficient, the cab must always be secured with a
stay to prevent accidental lowering.
Preparations:
• Set the gear and travel direction selector to neutral.
• Tilt the mast forward and lower the forks.
• Apply the parking brake.
1. Turn both lock handles (position C) so that they reach their outer
position to loosen the cab from the frame.
2. Set the pump valve (position B) in the right-hand position.
3. Use the control buttons to raise the cab to end position. Press both
buttons simultaneously.
001536
A B
Electric lowering
A. Pump rod mounting
B. Pump valve
C. Lock handle (figure shows open position) 1. Set the pump valve (position B) in the left-hand position.
2. Use the control buttons to lower the cab to contact with the frame.
Press both buttons simultaneously.
3. Turn both lock handles (position C) so that they reach their inner
position to lock the cab to the frame.
6.2.1 Cleanliness
Cleanliness, general
page
–
CAUTION
High-pressure washing of sensitive components may
lead to short-circuiting and cause malfunction.
Product damage!
NOTE
Do not rinse off the particle filter for the exhaust system. Poison-
ous deposits may be dissolved and carried with the rinsing water.
NOTE
After washing with de-greaser, the hydraulic cylinders should be
run in and out a few times to obtain satisfactory lubrication once
again.
WARNING
The strength of the roof window may be significantly
reduced in the event of exposure to substances con-
taining aromatic hydrocarbons, ketones, esters or
chlorinated hydrocarbons.
CAUTION
Cleaning agents contain different solvents.
CAUTION
Cracks or scratches result in reduced strength of the
roof window.
Low strength!
CAUTION
Objects may shoot off when using compressed air for
cleaning.
Risk of injury.
For optimum functionality the machine should also be kept clean in-
side the cab.
• Plastic material: vacuum clean, brush/wipe with lightly moistened
rag. Use mild cleaning agent and always re-wipe with a rag lightly
moistened with clean water.
• Textile material: vacuum clean, brush/clean with e.g. furniture or
carpet cleaning agent in accordance with the instructions on the
packaging.
NOTE
Make sure that the area around the tank cap is clean when
refuelling.
WARNING
A
Fuel is highly flammable and health hazardous.
CAUTION
A. Refuelling point
NOTE
Water separator must be drained of water if required.
DANGER
Fire hazard.
Extreme danger!
1 Switch off the engine and switch off the main current.
2 Position a receptacle under the fuel prefilter.
3 Drain the water from the fuel prefilter.
009552
Open the drain cock on the underside (position A), and close the
A cock when pure fuel (no water bubbles) is running out. Only close
Volvo TAD750VE the cock manually.
A. Water separator
WARNING
Fuel on hands.
A
Cummins QSB6.7
A. Water separator
WARNING
Only use clean water with an antifreeze agent, e.g. an-
tifreeze fluid.
door temperatures.
NOTE
Poorly filtered induction air quickly results in serious engine
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 (A), there’s
A an indicator (B) which shows red when the air filter is clogged.
The air filter has a dust reservoir (position C) which is usually emptied
during operations due to vibrations in the induction system. It can also
be emptied manually by shaking.
Instructions
Check the indicator regularly and contact service as soon as the indi-
cator shows a red signal.
The indicator can be reset to zero.
C
001539
B
A. Position of air filter container
B. Indicator for change
C. Dust reservoir
In the intake system between engine and air filter is an indicator (po-
sition A) showing a scale of how clogged the filter is. The indicator also
shows red when the filter insert should be changed.
Instructions
Check the indicator regularly and contact service as soon as the indi-
cator shows a red signal.
A
The indicator can be reset to zero.
C
009555
Coolant is filled in the system’s expansion tank (position B). The cool-
ant level should be between the MIN and MAX markings (position C)
on the expansion tank.
In case the coolant temperature is too high, the high pressure escapes
through the opening in the pressure cap (position B).
NOTE
Do not open the pressure cap until the coolant temperature has
dropped. Hot coolant may jet up and out!
If the coolant level is too low then an error code is generated in the
C A B
control system’s display (position 41):
NOTE
MAX A low coolant level may cause engine damage or may cause the
engine to stop.
MIN
Instructions
WARNING
The cooling system is pressurised. Steam or hot cool-
001540
WARNING
Glycol and anti-corrosion agents are health-hazard-
ous.
Health hazard!
CAUTION
Different types of coolant cannot be mixed.
IMPORTANT
On machines with ECC or AC it is of the utmost impor-
tance that the engine’s cooling system is refilled with
coolant containing the correct mixture of anti-freeze
fluid, otherwise there is a risk that the air conditioning
could freeze and breakdown when used.
WARNING
Avoid prolonged contact with engine oil.
Health hazard!
The engine’s oil filling point (position B) and dipstick (position A) are
under the hood. For the Volvo engine alternative on the left-hand side,
for the Cummins engine alternative on the right-hand side.
Instructions
Check the oil level when the engine is warm. The dipstick has two
markings, MAX. and MIN., the oil level should be between these
markings.
• Wipe off the dipstick before checking.
• Fill engine oil (position B) as required (for volume,
see chapter 9 Specifications).
009554
A It is recommended that oil is filled when the engine and oil are at
operating temperature. Fill – wait awhile – check on the dipstick.
Volvo TAD750VE
A. Dipstick
B. Filling point
NOTE
Fill oil with care to prevent other fluids or particles from con-
taminating the oil. Contamination means risk of engine
damage.
B
007390
Cummins QSB6.7
A. Dipstick
B. Filling point
WARNING
Avoid prolonged skin contact with transmission oil.
Health hazard!
A Use protective gloves.
A
The transmission’s oil filler pipe (position A) and dipstick (position A)
are under the hood on the left-hand side.
Instructions
Check the oil level with the engine running at idling speed and the
007391
NOTE
The oil dipstick is long. Use gloves.
• Fill transmission oil (position A) when required (for volume, see
chapter 9 Specifications).
It is recommended that oil is filled when the transmission is at op-
erating temperature. Fill – 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 transmission
damage.
WARNING
Avoid prolonged skin contact with hydraulic oil.
Health hazard!
C
The hydraulic oil tank is located on the machine’s right side.
Instructions
Check the oil level (position B) when all hydraulic pistons are in the re-
tracted position. The level should be in the middle of the level glass.
Top up oil (position A) as required (for volume, see chapter 9
Specifications).
A
NOTE
Work carefully when filling engine oil to prevent other fluids or
particles from contaminating the oil. Other fluids or particles in the
engine oil involve a risk of damage to the brake system or work-
ing hydraulics.
B
009454
A. Filling point
B. Level glass
C. Breather filter
DANGER
Changing tyres is high-risk work.
Extreme danger!
DANGER
Penetrating objects such as crushed glass, pieces of
wood, metal shavings, etc. and mechanical defects,
such as uneven brake wear, can cause tyre damage.
WARNING
Check-tighten the wheel nuts on a new wheel after
4-5 operating hours.
CAUTION
Spare and replacement tyres must be from a manu-
facturer approved by Cargotec.
IMPORTANT
Wheels, tyres, and rims are dimensioned and select-
ed for each machine type so that maximal wheel loads
and speeds are not exceeded. That is why it is not per-
mitted to change tyre dimension, tyre make, tyre type,
rim type, or rim brand without approval from
Cargotec.
Changing wheel:
–
DANGER
When changing tyres, deflate first.
DANGER
Rim damage makes wheel handling extremely
dangerous!
Inflating tyres
–
DANGER
Never stand in front of a tyre when inflating! Do not
exceed prescribed air pressure, which must be
checked in ambient temperature. When changing tyre
or rim version, another tyre pressure may apply, con-
tact Cargotec. The plate for tyre air pressure must be
replaced with a plate with the applicable tyre
pressure!
Extreme danger!
1. Before inflating, make sure that the rim’s lock ring is in the correct
1 2 3 position.
NOTE
If the tyre has been completely deflated, the rim must be dis-
mantled and checked for damage. Let service personnel
change tyres as they have the competence and authorisation
0022002
to handle tyres!
1. Lock ring 2. Connect the compressor with a locking air-chuck to the nipple on
2. Side ring the tyre.
3. Conical ring 3. Stand at an angle behind the tyre and remain there until inflating
has been completed, to prevent being struck by rim parts in case
of an explosion.
4. Inflate the tyre to the prescribed pressure, see chapter 9 Specifi-
cations. When changing tyre or rim version, another tyre pressure
may apply, contact Cargotec.
A 3. Press down the brake pedal with long pumping brake strokes, with
a slight delay between each braking action.
001547
WARNING
The machine’s hydraulic system includes accumula-
tors with high pressure.
NOTE
Cleanliness when performing work on the central lubrication sys-
tem is of the utmost importance. Dirt and debris can cause dis-
009117
ruption in the system. To clean the system you can use naphtha
or light petroleum. Do not use e.g. Tri or other organic solvents
1. Pump unit such as alcohol, methanol, acetone or similar, etc.
2. Distribution block Checking the function of central lubrication:
• Make sure that there is no "Er" indication set in the display on the
reservoir. This indicates error. Contact service.
• Make sure that there is no "LL" indication set in the display on the
reservoir. This indicates that lubricant needs to be filled. See
below.
Filling lubricants:
• Fill the reservoir up to the "Max" mark through the filler nipple (po-
sition 1).
• Lubricating grease must be clean from contaminants and must not
change consistency as it ages.
001948
1. Filler nipple
2. Ventilation holes
3. Following plate
WARNING
Short-circuit of battery.
CAUTION
Always turn off the electric power at the end of your
shift, when working on the electrical system and
when welding on the machine.
Danger!
A B C
A. Battery disconnector
B. Plate to indicate battery disconnector in position on,
i.e. main power is connected, and battery disconnec-
tor in position off, i.e. main power is disconnected
C. Handle to open/close the cover lid
WARNING
Battery electrolyte contains corrosive sulphuric acid.
The batteries are located inside a cover lid (position C) behind the
steps on the machine’s left-hand side.
Checking the electrolyte level is recommended. Fill as needed with
deionised water.
1. Turn off the battery voltage (position A) and open the cover.
2. Check level. Fill as needed with deionised water.
The electrolyte’s fluid level should be 10 mm over the cells.
Batteries contain substances hazardous to the environment and per-
sonal health. Therefore, discarded batteries must be handled accord-
ing to local/national regulations.
Starting with booster battery
WARNING
Handle batteries and connectors with care during
charging and starting with booster batteries. Do not
mix up the battery terminals! Follow instructions for
starting with booster batteries!
WARNING
Never use fuses with too high ampere rating.
The machine’s electrical system has one position for main fuses:
A. Main fuses for engine, 4 x 25 A.
Stop all electrical power, apart from fuse number 7 in fuse holder
F58-3, and fuse number 8 in fuse holder F58-4.
Changing the main fuse
1
When checking and changing the main fuse:
1. Turn off the main electric power with the battery disconnector.
007936
The fuses for the electrical system are located in electronic box in the
cab.
The electronic box is located behind the driver’s seat in the cab. There
are fuses for the control computers and equipment in the cab.
A B C D
008615
3 3 / 15A Headlights.
5 5 / 15A Windscreen wiper roof and rear window, reading lamp, 12V for
memory (K3773).
8 8 / 5A Parking brake.
1 1 / 5A Converter 12V.
1 / 15A Converter 12V (For converter, 20A).
4 4/- -
5 5 / 10A Feed control unit ECU 790, sensor for mast near max. lifting
height.
7 7 / 10A Feed control unit ECU 796, control breaker for load handling,
clamping pressure sensor.
3 3/- -
4 4/- -
5 5/- -
6 6/- -
7 7/- -
8 8/- -
Instructions
When checking and changing fuses:
1. Turn off the main electric power with the battery disconnector.
See Battery and battery disconnector, general page 190.
2. Remove the cover for the electronic box.
3. Remove the cover from the fuse holder.
4. Check and change fuses when needed.
The fuse plate gives information about each fuse.
3 3/- -
4 4/- -
5 5/- -
007937
6 6/- -
7 7/- -
8 8/- -
Instructions
Changing the fuse for the engine
When checking and changing the fuse:
1. Turn off the main electric power with the battery disconnector.
See Battery and battery disconnector, general page 190.
2. Remove the plastic cover.
3. Check and change fuses when needed.
6.2.15 Lighting
Lighting, general
page
–
It’s important to use the right type of light bulb for respective lighting
point, see section 9 Specifications.
Light bulbs can be changed for the following:
• Instruments
• Check lamps
• Interior lighting
• Rear light, red
• Brake light
• Indicator light for travel direction
• Position light
• Headlights, (with high and low beam)
• Reversing light, white
• Working light, glowing light
• Revolving beacon
Instructions
Applies for the following:
• Headlights, (with high and low beam)
• Reversing light, white
• Working lights
1 Loosen the rubber strip (position A).
2 Remove the glass (position B).
3 Change light bulb.
000579
A B
A. Rubber strip
B. Glass
6.3 Service
General
page
–
It’s very important that inspections and service are performed at the
recommended intervals.
Service is performed by Cargotec, or by service technicians author-
ised by Cargotec.
CAUTION
Service interval must be followed.
CAUTION
When welding on the machine, all control units shall
be disconnected to prevent damage.
WARNING
The following parts must, for safety reasons, only be
replaced with original spare parts:
• Brake valve
• Drive axle
• Steering axle
• Steering cylinder
• Rims
• Solid wheels
• Mast, carriage
• Lifting chains
• Tilt cylinder
• Twistlock
• Emergency stop
• Accumulator
• Tilt valve
7 Transporting the
mm mm mm mm mm mm
machine
Safety
page
–
DANGER
The machine must be adequately secured during
transport! The machine is heavy and can cause exten-
sive damage in the event of a fall or similar.
WARNING
Operator doors must always be closed during
transport.
Danger!
7.1 Towing
General
page
–
DANGER
The machine cannot be operated or braked if the hy-
draulic pressure is lost, e.g., if the engine is switched
off.
CAUTION
Do not try to start the machine by towing.
Before taking actions and after finished towing, the parking brake must
be applied and the wheels blocked to prevent the machine from start-
ing to roll.
Extreme care must be observed during towing work to avoid personal
injuries.
When towing, keep in mind:
• The towing vehicle should be heavier than the vehicle in tow.
• If possible when towing, the engine should be running in order for
brakes and steering to function.
When the engine is switched off, there is no hydraulic pressure for
the steering function and thus the machine’s steering function is
severely limited. Also, the transmission lubrication is insufficient.
• The brakes function as long as there is pressure in the accumula-
tor, then the service brake stops functioning and the parking brake
is applied automatically. If it is necessary to move/tow the ma-
chine after that, the parking brake must be released mechanically,
see section 7.1.1 Mechanical release of parking brake.
• Only tow for very short distances.
• If it is necessary to tow the machine, the propeller shaft must be
released from transmission and drive axle.
DANGER
Before starting to work with the parking brake, make
sure that the machine cannot move when the braking
action is released.
CAUTION
The parking brake has high spring force. If the brakes
are opened incorrectly, parts may detach and fly off
with great force.
The parking brake is a disc brake on the drive axle’s input shaft.
1. Remove protective cover from the caliper (position A).
A B C
2. Note the nut’s position on the bolt and remove the split pin that se-
cures 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 as in step 2. Fit new split pin.
5. Refit protective cover on the caliper.
NOTE
000835 If the parking brake has been released mechanically, the parking
brake must always be restored in order to give the machine park-
A. Protective cover ing brake function.
B. Brake disc for parking brake
C. Propeller shaft
The parking brake is a disc brake on the drive axle’s input shaft.
DANGER
Before starting to work with the parking brake, make
sure that the machine cannot move when the braking
action is released.
Extreme danger!
1. Check that the parking brake is off. See the indicator for the park-
ing brake in the display.
2. Screw out the control (position A) as far as possible.
3. Screw in the knobs (position B and A) as far as possible.
4. Pump with the pump rod (position C) approx. 10 times.
Restore the parking brake as follows:
1. Screw out the knobs (position A and B) as far as possible.
2. Screw in the control (position A) as far as possible.
A-C
NOTE
If the parking brake has been released hydraulically, the parking
brake must always be restored in order to provide the machine
005323 with parking brake function.
A B C
A. Control for mechanical release of parking brake
B. Control for mechanical release of parking brake
C. Pump rod
When lifting and transporting the machine, follow the safety regula-
tions in force.
DANGER
High demands are made of the lift and transport
equipment, e.g. lifting chains and hooks.
Extreme danger!
DANGER
Overload of load equipment.
Extreme danger!
NOTE
Cross the chains when securing for optimal stability.
Rear: Secure chains in the towing eye by vertical counterweight,
or in the rear wheels.
counterweight
There are lifting eyes on the counterweight and on the lifting mast.
1. Fit two lifting slings in the two lifting eyes of the counterweight.
2. Fit two lifting slings in the two lifting eyes of the lifting mast.
Masts with low lifting height do not have lifting eyes. The lifting
slings must then be threaded around the recess for the lift cylinder
or in some other way so that the slings are secured to the mast.
3. The lifting device must be adapted so that the lifting point runs
through the machine’s centre of gravity.
007369
8 Environment and
mm mm mm mm mm mm
standards
General
page
–
Recycling
Conscientious recycling of the machine is the starting point for the li-
fecycle to come full circle, and for being able to recycle and make use
of material in new products. According to calculations by Cargotec,
more than 90% of the machine weight is recyclable.
Air conditioning
The refrigerant in the air conditioning for the cab accelerates the
greenhouse effect if it comes out in the open air. Special training is re-
quired for all service work on the air conditioning. Many countries also
require certification by an authority for such work. When scrapping the
air conditioning the refrigerant must be dealt with by an accredited
company.
Standards
–
CE-marking
Machines for the EU/EEA market are CE-marked. This means that
upon delivery the machine fulfils the applicable "Essential Health and
Safety Requirements" specified in the EU Machine Directive,
2006/42/EC, as well as other EU directives relevant to this machine
type. For more information, see section 2.2 CE-marking.
ANSI/ASME marking
Versions of this machine for North America are ANSI/ASME-marked.
This means that, when delivered, the machine fulfils the basic safety
requirements specified in ANSI/ASME B56.1. For more information,
see section 2.3 ANSI/ASME-marking.
Exhaust emissions
Machines for the EU/EEA market fulfil EU's Exhaust directive
97/68/EC and 2004/26/EC, which means that engine exhaust emis-
sions are limited in accordance with the requirements.
Machines for the North American market fulfil EPA's and CARB's ex-
haust regulations, which means that engine exhaust emissions are
limited in accordance with the requirements.
Noise emissions
The machine for the EU/EEA market fulfils the EU Noise directive
2000/14/EC and 2005/88/EC which means that the machine is marked
with measured environmental noise emissions which are also limited
in accordance with the requirements for trucks with lift capacity above
10000 kg. See section 3.2 Plates.
Vibration standard
Vibration that the machine emits is measured according to the harmo-
nised standard EN 13059 where the level of vibration varies depend-
ing on the type of tyre and the driver’s seat that the machine is
equipped with. See the section 9 Specifications.
9 Specifications
9 Specifications
mm mm mm mm mm mm
Technical data
page
–
Guaranteed sound power level in ac- LWA 110 dB(A) LWA 110 dB(A)
cordance with 2000/14/EC and
2005/88/EC included measurement
uncertainty 1.5 dB.
Output in accordance with ISO 3046 181 kW at 2300 rpm 194 kW at 2200 rpm
(effective rated output)
TE17000
4 Brakes
Footbrake system – wheel affected Wet Disc Brake – drive wheel
5 Steering
Steering system Hydraulic servo
Tyre type, front and rear Air-inflated. Spare and replacement tyres shall be of brand names approved by
Cargotec.
9 Cab Spirit Delta with Volvo TAD750VE Spirit Delta with Cummins QSB6.7
fluids
Any deviation from this table must be approved in writing by Cargotec.
Coolant volume 40 l 40 l
Coolant filling point Volvo VCS coolant, ready mixed ES Compleat, Premix
for part no., see spare parts cata- for part no., see spare parts cata-
logue. logue.
Oil volume 35 l
9 Frame, body, cab and accessories Condenser with 2 fans Condenser with 4 fans
Volume refrigerant 1700 g (see plate for air 2200 g (see plate for air
conditioning) conditioning)
recommendation
The service intervals indicated by Cargotec in the maintenance man-
ual only apply if oils are selected in accordance with the table below.
The table indicates recommended viscosity for different oil types, and
grades, depending on the ambient temperature.
Any deviation from this table must be approved in writing by Cargotec,
and may mean changed service intervals.
Cummins: CES-20071,
CES-20072, CES-20076, -15 C SAE 15W/40
CES-20077, CES-20078
-25 C SAE 10W/30
API: CH-4/SJ, CI-4/SK
SAE 5W/30
ACEA: E5, E7
10 Common hydraulics
Hydraulic oil AV 32
SS 155434 AV 46
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%.
*) API CH-4 or CI-4 are approved for markets outside the EU/EEA.
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
CES = Cummins Engine Standard
VDS = Volvo Drain Specification
Lubricating grease
Use universal grease of type EP according to NLGI Grade 2 (EP2) with
3-5% molybdenum sulphide mixture for all grease points except glide
plates, where lubrication paste Gleitmo 805 or equivalent should be
used. For electric connections, use connector grease 923836.0552.
Coolant
Coolant must consist of distilled water mixed with 40-60% glycol. Anti-
corrosion agent must always be added if glycol is not used. However,
anti-corrosion agents do not contain anti-freeze agent and may only
be used if the outdoor temperature is always above 0 ºC.
NB! It is important that the coolant is mixed correctly all year to ensure
adequate corrosion protection. The corrosion-protective properties
decline with time, and that is why the coolant must be replaced accord-
ing to stated intervals.
A mixture of 60% distilled water and 40% glycol gives freezing protec-
tion down to temperatures of -28 ºC.
A mixture of 40% distilled water and 60% glycol gives freezing protec-
tion down to temperatures of -54 ºC.
CAUTION
Different types of coolant cannot be mixed.
Unit explanations
–
Unit Abbreviation
Newton metre Nm
Kgf/m kpm
Kilowatt kW
Kilojoule kJ
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Metre m
Kilometre km
Conversion SI-units
–
Torque
Power (W = J/s)
Energy (J = Nm)
Horsepower/torque
Temperature
Flow factor
Unit cm m km in ft yd mile
1 mm = 0.1 cm – 1 mm = 0.001 m
Unit g kg t oz lb
10 Terminology
10 Terminology
mm mm mm mm mm mm
Explanations
page
–
Term Description
AC Air Conditioning. Heating unit with manual control of heating, cooling, dehumidification
and air flow.
Accumulator Reservoir that stores (accumulates) pressure for, i.e. hydraulic functions.
Anti-corrosion compound Prevents oxidation, in simple terms, rustproofing.
Attachment Part of the machine that grips the load when lifting.
Bar Unit to express pressure.
Battery disconnect switch Cuts off power supply from battery.
Buzzer Acoustic alarm to catch the operator’s attention.
Central lubrication An automatic system for lubrication of a preset number of lubrication points.
Control valve Valves that can be used to control something, for example, to release pressure and thus
lower a mast or a fork. See also control valve.
Counterweight Weights adapted to the machine’s lift capacity to constitute an opposing load when lifting.
Daily inspection Actions that should be performed daily to ensure the machine’s functionality.
Decitonne Tenth of a tonne, measure of machine’s lift capacity.
Displacement The oil volume that the pump can supply per pump revolution.
Display "Window" showing digital information, e.g. on steering wheel panel in cab (with KCS).
Drive axle Driving axle that receives the torque from the drivetrain.
Drivetrain Parts in the machine involved in power transmission; engine, torque converter, transmis-
sion, 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 automati-
cally during operation.
ECC Electronic Climate Control. Air conditioning with automatic control of heating, cooling, de-
humidification and air flow.
ECU Electronic Control Unit
EDU Electronic Display Unit
Electric servo Load handling’s hydraulic components receive control signals from electro-mechanical
controls.
Electrolyte level Fluid level in battery cells.
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and regula-
tions.
Expansion tank Tank for coolant.
Fixed displacement Pump with fixed pump volume.
FMI Fault Message Identifier.
Fork bracket Bracket for forks, fitted on the lifting trolley.
Forks Lifting device that lifts the load.
Term Description
Frame member Structural members in the frame.
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 servo Load handling’s hydraulic components receive control signals from mechanical controls.
Hydraulic system System that uses oil pressure to transfer power to different functions.
Indicator Manual "sensor", for example, shows that a filter is clogged and needs to be changed.
KCS Kalmar Control System. An electronic control system that monitors and regulates certain
systems in the machine that require KCS, such as certain engine and transmission alter-
natives.
Levelling Forks are tilted, e.g. if load stands on uneven ground.
Lift capacity Indicates machine’s maximum 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 specified
and governing regulations.
Machine model Machine type. Specified, for example: DCD 200-300. See also Type designation.
Main fuse Located by battery. Cuts off power to all machine systems.
Maintenance Periodic maintenance actions so that machine functions safely and for a long service life.
Mast Carrier of attachment and load.
Operating time Number of hours machine has been in operation, shown on hour meter in cab.
Option Extra equipment for machine.
Pilot oil pressure A low control pressure to, for example, a valve.
Piston rod Rod that is pushed into the piston’s cylinder barrel and is acted upon by the hydraulic pres-
sure.
Planetary gear Type of transmission with gears in constant engagement.
Product alternative One of several alternatives selected for a machine, e.g., engine alternative.
Progressive steering Quick steering wheel movements give greater steering angles.
Proportional valve An electro-magnetically controlled valve. If a 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 valve. For example, on transmission’s valve housing.
Recirculation Circulation in a closed system.
Refrigerant Fluid/gas in air conditioning. Must only be handled by authorised trained personnel.
Securing machine for transport Actions before transporting machine.
Serial number Unique machine designation. On machine plate.
Service position How machine should be safely positioned before service may be started.
Servo A small movement by the user results in a large angle, i.e. servo steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side shift Parallel sideways movement of forks.
Term Description
SmartLink Software for handling KCS (Kalmar Control System).
Solenoid valve An electromagnetically controlled valve. See also proportional valve.
Spirit Delta Enclosed type of cab.
SPN Suspect Parameter Number.
Spreading (positioning) Spreading of the forks, e.g. change to relative distance between the forks.
Steering axle Wheel axle with steering.
Tilt The mast is leaned forward or backward.
Top lift Attachment, see attachment.
Torque converter Hydraulic, variable clutch.
Transmission oil Oil for transmission and torque converter. See specifications.
Trolley Lifts the load, located on the mast.
Twistlocks Two lock pins, one in each corner of the attachment, pushed down in corresponding holes
in container and twisted to lock the container when lifting.
Type designation Indicates machine type and capacity. See also machine model.
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.
Wheelbase Distance between drive axle and steering axle.
Working hydraulics All load handling functions, e.g. lift and lower, tilt, side shift, positioning and levelling.
We, Cargotec Sweden AB, SE-340 10 Lidhult, (Registration No. 556014-5418) herewith
declare that the machine,
Serial No A201.XXXXX
Year of construction 2010
Engine VOLVO TAD 750VE
Name
Position Head Of Counterbalanced Products