Idcf07 01GB

Forklift trucks 28-52 tonnes
Publ. no IDCF07.01GB
Operator's Manual in original OPERATOR'S MANUAL
DCF 280-520
1 Foreword ................................................................................................................................ 1
1.1 About the operator's manual.............................................................................................. 1
1.2 About the documentation kit .............................................................................................. 3
1.3 Inspection and maintenance .............................................................................................. 4
2 Safety ..................................................................................................................................... 5
2.1 Safety and emergency equipment ..................................................................................... 7
2.2 CE-marking ........................................................................................................................ 9
2.3 ANSI/ITSDF marking ....................................................................................................... 10
2.4 Keep in mind ..................................................................................................................... 11
2.5 Fire................................................................................................................................... 19
3 Overview............................................................................................................................... 21
3.1 Description ....................................................................................................................... 21
3.2 Plates ............................................................................................................................... 28
4 Instruments and controls ...................................................................................................... 36
4.1 Warning and indicator lights............................................................................................. 41
4.2 Instruments ...................................................................................................................... 44
4.3 Ignition ............................................................................................................................. 45
4.4 Switches .......................................................................................................................... 46
4.5 Gear selector and multi-function lever ............................................................................. 52
4.6 Hydraulic control .............................................................................................................. 54
4.7 Pedals .............................................................................................................................. 58
4.8 Steering wheel ................................................................................................................. 59
4.9 Driver's seat ..................................................................................................................... 62
4.10 Heating / Air conditioning ................................................................................................. 66
4.11 Control system ................................................................................................................. 69
5 Handling ............................................................................................................................... 75
5.1 Running-in ....................................................................................................................... 77
5.2 Daily inspection................................................................................................................ 78
5.3 Error codes ...................................................................................................................... 79
5.4 Operating ........................................................................................................................ 116
5.5 Load handling ................................................................................................................ 127
6 Inspection and maintenance............................................................................................... 146
6.1 Daily inspection.............................................................................................................. 147
6.2 Maintenance .................................................................................................................. 151
6.3 Service ........................................................................................................................... 179
7 Transporting the machine ................................................................................................... 181
7.1 Towing............................................................................................................................ 182
7.2 Lifting and transporting the machine.............................................................................. 184
7.3 Service position.............................................................................................................. 186
7.4 Long-term storage.......................................................................................................... 187
8 Environment and standards................................................................................................ 188
9 Technical data..................................................................................................................... 191
10 Terminology ........................................................................................................................ 201
11 Index.................................................................................................................................... 205
Operator's Manual DCF 280-520 IDCF07.01GB

IDCF07.01GB Operator's Manual DCF 280-520
1 Foreword 1
1 Foreword
1.1 About the operator's manual
General
Thank you for choosing Cargotec as your machine supplier. We hope
that we'll meet your expectations.
This Operator's manual contains information that you must keep in

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

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

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

The information in this operator's manual corresponds to the machine's
design and appearance at the time of delivery from Cargotec. Due to
customer adaptations, there may be variations and/or deviations.
Cargotec reserves the right to make changes to specifications and

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

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

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

2 1 Foreword – Reading instructions
1.1.1 Reading instructions

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

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

The symbol to the left is used in certain cases on the machine and
001128
refers to important information in the Maintenance manual.
Read the Maintenance manual
Optional equipment
There is a range of optional equipment available for the machine.
000264
Each description of optional equipment in the manual is marked with

a symbol, and contains an explanatory text. The symbol is positioned
Indicates optional equipment visibly by the text and image in question.
See the machine card for complete specifications of the machine’s

product alternatives and optional equipment.

1 Foreword – About the documentation kit 3
1.2 About the documentation kit

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

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

4 1 Foreword – Inspection and maintenance
1.3 Inspection and maintenance

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

performed by the operator, see chapter 6 Inspection and maintenance.
This section describes the running checks and actions that the operator
should perform in connection with starting work shifts.
Maintenance
For other maintenance not included in this operator's manual (service
and repairs), contact an authorised workshop.

2 Safety 5
2 Safety
General
Safety rules are intended to reduce the risk of personal injuries as well
as damage to the load or other property.
Only personnel trained for this machine may handle, operate, perform
service or be in its vicinity during its use.
The safety information in this operator's manual are intended for your
information and safety. It cannot, and is not intended to, cover all
possible events during operation. Responsible operators with the right
training is the only way to ensure the safe and prolonged use of the
machine.
The machine was thoroughly tested and adjusted before it left the
factory. This does not preclude the possibility that it has been damaged
during delivery. The machine must undergo a thorough inspection in
order to ensure correct function before being put into service.
Important to read the operator's manual

An improper handling can lead to personal injury and/or damage to
the product or property. Please read this Operator's manual carefully
before using the machine. The operator's manual contains important
information about your Kalmar machine, the machine's handling,
safety during work and about the machine's daily inspection. In
000262
addition, you will obtain a lot of valuable information that makes it

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

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

not understand or if you feel information is missing in any area.
Intended use
• The machine must only be used for what it is designed and
manufactured for, i.e. to lift and transport goods (whose weight
does not exceed the machine's maximum permitted load
capacity). If it is used in any other way or in potentially dangerous
environments (e.g. an explosive environment, an area with
asbestos dust) then special safety rules must be followed and the
machine must be equipped for such operations.
• The machine must not be modified or changed without permission
from Cargotec. In the event of modifications approved by Cargotec
the signs on the machine and documentation affected must be
adapted to apply to the modification.
In the event of modification or conversion without Cargotec's
permission Cargotec's product liability ceases to apply.
Modification and conversion may only be made if the knowledge
exists to verify and test the modifications and conversions.
Modifications and conversions must be documented (date and
action) and the organisation responsible must be stated with name
and address. Signs and stickers must be updated in accordance
with the machine's new design.

6 2 Safety – Safety
• The machine may not be operated on public roads unless it has

been adapted according to national road safety regulations.
• It is always the machine owner's responsibility to ensure that the
machine has approved fire-fighting equipment in accordance with
the regulations in force.
• The machine is intended for use in outside temperatures of -30 °C
to 40 °C and in relative humidity 10 to 90%. In the event of high
wind speeds, contact Cargotec.
Operator requirements
• The machine may only be operated by specially trained operators
who have the work supervisor's permission to operate the machine.
• Laws and regulations regarding driver's licenses, operator ID, etc.
must always be followed.
• The operator must be aware of and follow all local safety rules.
• The operator must follow the manufacturer's instructions.
• The operator should read and understand the machine's warning
and information plates as well as understand and be able to use
the machine's safety and warning equipment.
Prohibited operation
Machine operation is prohibited:
• If safety and warning equipment such as rear view mirrors,
headlights, etc., do not function correctly.
• In case of defective brakes, steering or lifting equipment.
• If there are unauthorised persons or vehicles within the machine's
work area.
• If the machine has been repaired, modified or adjusted without the
supervisor's/work management's permission.
• If the machine is equipped with tyres not approved by Cargotec.

2 Safety – Safety and emergency equipment 7
2.1 Safety and emergency equipment

General
A good working environment has safety and emergency equipment
to make the operator's work easier and safer. The machine may be
equipped with the following safety equipment.
4 6,7,8,11 2 1,10 8
012500
5 3
1. Back-up alarm
2. Revolving beacon
3. Horn
4. Electrically powered high-volume horn
5. Fire extinguisher
If the machine is supplied with a fire extinguisher, it should be of
the type ABE according to EN3 pt. 1, 2, 4, and 5. With such a
fire extinguisher, it is possible to put out fires in both solid organic
materials and fluids. Adapted fire extinguishing equipment can be
ordered from Cargotec.
6. Seat belt
7. Buzzer in the cab to indicate an alarm or forgotten action, e.g. if
the operator leaves the cab without applying the parking brake.
8. Camera with monitor :
Used to provide improved rearward vision when manoeuvring the
machine. The monitor is located inside the cab on the left-hand
side.

8 2 Safety – Safety and emergency equipment
9. External rear view mirrors

9a Used to provide improved visibility while manoeuvring and load
handling.
9a 9a shows blocked area in front of machine.

9b
9b shows blocked area at side of machine.
9c shows blocked area behind machine.
9a
9b 9c
9b
9a
012501
9b 9c
Low-profile model
9b
9a
012502
9c Central cab
9b
007330
High-profile model
10. Flashing brake lights when reversing
11. Breaker switch for load handling (servo circuits) :
Cuts off all power supply and control signals to hydraulics.

2 Safety – CE-marking 9
2.2 CE-marking
CE-marking
(Declaration of Conformity, only applies to machines marketed
within EU/EEA).
This machine is CE-marked. This means that upon delivery it fulfils

the applicable "Essential Health and Safety Requirements" specified
in the EU Machine Directive, 2006/42/EC, as well as other EU
directives relevant to this machine type.
As proof that the requirements are fulfilled, the machine is provided

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

also assumes responsibility for them. If the machine is used for
014580
other purposes or with other tools than what is specified in these

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

Environment and standards.

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

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

meets the essential safety requirements as set out in ANSI/ITSDF
B56.1.
Anyone making modifications that affect the safety of the machine

also assumes responsibility for them.
If the machine is used for other purposes or with other tools than what
is specified in these instructions, safety must be ensured in each
individual case. The machine owner is responsible that the machine
014581
is used in accordance with the instructions in the operator's manual.
Machine plates for ANSI/ITSDF marking For additional information, see standards under chapter 8
Environment and standards.

2 Safety – Keep in mind 11
2.4 Keep in mind

Interrupted operation and/or parking
WARNING
Always turn off the electric power when the machine is
left, e.g. when parking or at the end of the shift.
Risk of fire!
Turn off the electric power with the battery disconnector.
NOTE
Never leave the operator's station without first applying the parking
brake (ON position).
NOTE
Always remove the start key if the machine is to be left unattended.
During work shifts
DANGER
Forks or other attachments are work tools that handle
large loads.
Extreme hazard to personal health and risk of property
damage!
Make sure that no persons stand or walk under a raised
work attachment, regardless of whether it is loaded
or not.
DANGER
External equipment may only be used if it is approved
by Cargotec.
damage!
Only use equipment that is approved by Cargotec.

12 2 Safety – Keep in mind
DANGER
The parking brake should not be applied when the
machine is in motion.
Very heavy braking. Risk of machine tipping, load
tipping over, being dropped or damage to property or
extreme danger!
Stop the machine before applying the parking brake.
DANGER
The machine’s work area is large and visibility from the
operator’s cab is restricted.
damage!
Keep in mind:
• Always check to ensure no one is in the way of
the machine or its accessories. Also check that
the area upwards is unobstructed. If there are
unauthorised persons or vehicles within the work
area then the machine must be stopped.
• The operator must always face in the travel
direction and should operate with special care
where persons or vehicles may appear.
• The operator must adapt the speed to the load and
ground conditions, visibility, and wind conditions,
etc.
• The operator must pay extra attention and operate
with special care near electric power lines, viaducts,
docksides, ramps, doorways, etc.
• Always operate carefully so that the attachment
does not collide with posts, power lines, etc.
• Use available visibility-enhancing equipment such
as rear view mirrors and camera ( ).

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

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

WARNING
No lowering of load handling equipment when control
is activated.
Risk of crushing! Make sure that nobody is under the
load handling equipment.
If the load handling equipment is blocked so that it
cannot be lowered to its original position, contact the
Cargotec Service organisation!
WARNING
Cab doors must always be closed when operating.
Risk of personal injury and crushing in case of roll-over
and tipping!
Always close the doors during the work shift.
WARNING
Passengers may only be carried in the cab provided
that there is a seat available for passengers. Do not
carry passengers on the machine outside the cab or
on the load.
Risk of personal injury!
A passenger in the cab must use a permanently
mounted extra passenger seat and seatbelt.
WARNING
Exercise care with the side shifting cab. Before the cab
is moved, make sure that no person is in the risk area
outside the cab risk of crushing.
It is forbidden to operate the forklift with open doors
when the cab is outside the middle position.
It is forbidden to exit the cab when it is outside its
middle position, except in emergencies.

WARNING
The machine's hydraulic system includes accumulators
with high pressure.
Always be very careful when working with the hydraulic
system, and avoid standing close to hydraulic
components or hoses. Before working on the hydraulic
system, the accumulators must be drained (see
Maintenance manual).
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!
Danger of short circuit! Warning - risk of hydrogen gas
forming! Sparking and danger of fire! Hydrogen is very
explosive!
Batteries must always be equipped with covers over
terminals and connections. Connect positive terminals
first. Then connect the negative terminals in order to
avoid sparks that could ignite the hydrogen gas.
WARNING
The machine uses oils and lubricants.
Health hazard in the event of protracted skin contact!
Avoid skin contact with oils and lubricants. Use
protective gloves.
CAUTION
AdBlue can irritate with skin and eye contact and if
inhaled.
Health hazard!
Handle carefully and avoid skin contact, wear protective
gloves. In the event of any contact with the skin and
spillage on clothing, wash the skin with large quantities
of water and change contaminated clothing and gloves.
In the event of eye contact, rinse thoroughly with
water for several minutes and seek medical advice
if necessary. If inhaled, breathe fresh air and seek
medical advice if necessary.

WARNING
Fire extinguishers contain dry chemicals.
Risk of breathing difficulties when using in an enclosed
space!
Use the fire extinguisher from the outside and into the
area to be extinguished. After use, ventilate the space
thoroughly.
CAUTION
Cracks or scratches result in reduced strength of the
roof window.
Low strength!
Replace a damaged roof window immediately.
CAUTION
The parking brake can be used as an EMERGENCY
BRAKE.
Brake pads wear out and lose their braking
performance! Unwanted movement of parked machine!
After emergency braking with the parking brake the
brake shoe linings must be checked as soon as
possible and replaced if necessary. Braking action of
the parking brake may be lost as the brake shoe linings
may have been worn down.
If the parking brake has been released mechanically
then it must always be reset to restore the machine's
parking brake function.
WARNING
Optional equipment such as two-way radio, RMI,
telephone, etc. may emit non-ionising radiation.
Risk of interference with active or non-active medical
products.
Use two-way radio, RMI, telephone, etc. when no
persons with active or non-active medical products
are nearby.

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
approved by Cargotec.

2 Safety – Fire 19
2.5 Fire
Action in the event of fire
DANGER
In the event of fire the operator's safety must not be
compromised.
If given the opportunity, take the following action at
the slightest sign of fire:
1. Stop the machine and turn the ignition key to stop
position.
2. Leave the cab.
3. Switch off the system voltage with the battery
disconnector.
4. Alert the rescue services.
5. Try to extinguish the fire.
If this is not possible, leave the machine and the
risk area.
DANGER
Smoke can be extremely toxic.
Smoke subdues, suffocates and can kill people! Smoke
can cause damage to lungs and respiratory organs
even in small quantities.
Avoid breathing fumes, do not stand in the smoke.
Use breathing apparatus for fire fighting and work with
burnt material.

20 2 Safety – Fire
Fire prevention measures
DANGER
Residue from fuel, oils, grease or other flammable
materials on the engine or in the engine compartment
is a fire hazard.
Fire hazard!
Remove residue of flammable materials in the engine
compartment as soon as they are detected. Be extra
careful on hot surfaces such as exhaust systems,
manifolds or turbochargers. If leakage of oil, fuel or
coolant is detected, the reason should be investigated
and the fault corrected before starting the engine.
Make it a habit to make a visual inspection of the engine and engine

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

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

3 Overview 21
3 Overview
3.1 Description
General
Machine DCF 280-520 is a forklift truck of a heavy capacity for all types
of load handling. It has a maximum lifting capacity of 28 to 52 tonnes.
The machine has a one lift mast. There are three optional lift masts
(different lift 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 22.
3.1.1 Identification of the machine

Type designation of forklift truck
Each machine from Cargotec has a type designation. Type designation
DCF 330-12 (LB) (example) indicates the following:
• D - Diesel engine
• C - Counterweight forklift
• F - Generation
• 330 - Lift capacity, decitonne
• 12 - Distance to centre of gravity, in decimetres
• (LB) - Low-profile machine
Machine card
Cargotec machines are adaptable in different ways with product
alternatives and optional equipment. This is in order to satisfy as broad
a customer base as possible.
A machine card is supplied together with the spare parts catalogue.

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

and Cargotec must be informed.

22 3 Overview – Overview description
3.1.2 Overview description

General
This section provides a short presentation of the machine's parts,
which are pointed out in the overview figure below.
012503
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

3 Overview – Overview description 23
Engine
The engine is a straight 6-cylinder turbocharged low emission engine
with intercooler. The engine provides the power for propulsion and
hydraulics.
DCF 280–330 is equipped with the engine Volvo TAD762VE.
DCF 370-520 is equipped with the engine Volvo TAD1360VE.
Transmission
The transmission is fully automatic with torque converter. TE17 has
3 forward gears and 3 reverse gears while TE32 has 4 forward gears
and 4 reverse gears. The hydraulic pumps for work hydraulics are
located on the transmission.
DCF 280-330 is equipped with Dana TE17.
DCF 370-520 is equipped with Dana TE32.
Drive axle
The drive axle (front axle) is equipped with a differential and hub
reductions of the planetary gear type.
Brakes
The machine has a brake circuit and is equipped with hydraulically
operated brakes. The brake units consist of fully enclosed oil-cooled
disc brakes with external cooling.
The parking brake is electro-hydraulically operated and brakes with a

disc brake. The disc brake acts on the drive axle's input shaft. The
parking brake is applied by spring force and released by hydraulic
pressure. Parking brake application is automatic if the ignition key
lock is switched off.
Steering
The machine is steered with the rear axle. A double-acting hydraulic
cylinder acts on the wheel pair. The steering is linear, that is, the
steering angle is dependent on the number of steering wheel turns.
Load handling
The mast and fork carriage are used during load handling. The fork
mount sits on the fork carriage and this can be equipped with e.g. forks,
inverted forks, coil ram, top-lift attachment mounted on the fork carriage
either on the forks or on the inverted forks. The load is manoeuvred
vertically, laterally and tilted (angled) forwards or backwards. Fork
spacing is changed by moving the right-hand fork. There are two types
of top-lift attachment, fixed (20" or 40") or adjustable between 20" and
40". The top-lift attachment has twistlocks to secure the load. The
securing of the load and operation of the attachment are managed
electrically and hydraulically.
Electrical system
The electrical system consists of electrical and electromagnetic
components such as battery, switches, cable harnesses, solenoid
valves, fuses and relays.

Control system
The machine has a computer-based control and monitoring system for
monitoring and controlling the machine's functions as well as handling
all functions in the machine, such as power electronics, drivetrain
and hydraulic system. The control and monitoring system facilitates
maintenance.
Cab
The cab is available in one version. Instrumentation and equipment is
customizable, and model adapted.
• Cab Spirit Delta
Spirit Delta is an enclosed operator's station built of a supporting
frame to withstand falling load in accordance with the standards in
force. It is equipped with a fresh air system with filtered air intake
and recirculation and heating and air conditioning ( ).
The roof window is made of high-strength material and withstands
heavy blows, e.g. from falling objects.
The cab can be moved sideways ( ).
Hydraulic system
The hydraulic system includes the sub-functions of brakes and working
hydraulics.
The working hydraulics include hydraulics for steering, load handling

and cab functions.
The work hydraulics are supplied from two fixed vane pumps and the
brake system is supplied from a vane pump.
For some machines the brake system is separate from the work
hydraulics and has, in addition to its own vane pump, its own tank,
filter, accumulators, and cooler .

Other equipment
27,34 22 18 16 6,7,8 13,15
29,30
31
5
17
3,4
40 2
40
012504
10,32,33,35,36 41 23 20,21 1 26,28,33,35,36
1. Horn
Located under cab.
2. Electrically powered high-volume horn
Located at top of trailing roof edge.
3. PC-holder
4. Writing table with light
To manage paper in the cab. The table is positioned to the right
in the cab.
5. Reading light
6. Interior lighting with “fade-away”
7. Rear-view mirror, internal in cab
8. Extra rear-view mirror, internal in cab

9. External rear view mirrors. Used to provide improved visibility

9a while manoeuvring and load handling.
9a shows blocked area in front of machine.
9a 9b 9b shows blocked area at side of machine.
9c shows blocked area behind machine.
9a
9b 9c
9b
9a
9b 9c
012501
Low-profile model
012502
9b
Central cab
9a
9c
9b
007330
High-profile model
10. Back-up alarm
11. Openable window, left door
(Not positioned in figure).
12. Openable window right door
13. Laminated front windscreen
14. Tinted windows
15. Sun visor, front windscreen
Adjustable up and down with cord right-hand side. Stops in the
selected position.
16. Sun visor, roof window
Can be pulled out to fasten in two hooks at the front edge of the
window.
17. Lockable doors
18. Door with air-damper on right and left side
19. Long handle in front of door (Not positioned in figure).
20. Seat heating
21. Passenger seat

22. Sound system, 24 VDC

Instructions are included.
23. Socket 12/24 VDC
The socket is located by the right door and is fused.
24. Slip-free surface on steps (Not positioned in figure).
Extra slip-protection on tanks and fenders .
25. Steps with rail by the left fender
26. Headlights, 2 lights
27. Work lights cab roof, 4 lights
28. Extra work lights front fender, 2 lights
29. Mast working lights, 2 lights
30. Extra mast working lights, 2 lamps
31. Back-up lights, 2 lights
32. Brake lights, 2 lights
33. Running lights, 4 lights
34. Rotating beacon, 1 light
35. Direction indicators, 4 lights
36. Hazard lights direction indicators, 4 lights
37. Tool kit
Located in the battery compartment.
38. Auxiliary heater: (Not positioned in figure)
Equipment kit 1: engine and cab heater.
Equipment kit 2: start interlock, engine and cab heater, hydraulic
system tank heater.
39. Lockable tank cap (Not positioned in figure).
40. Mudguard
41. Nut protection
42. Pause heater (Not positioned in figure).
43. Central lubrication (Not positioned in figure).
44. Elevated air inlet with pre-cleaner (Not positioned in figure).
45. Camera with monitor
Used to provide increased visibility backwards, forwards or
both backwards and forwards. The camera is positioned on the
counterweight and/or the from fender. The monitor is located
inside the cab. If cameras are fitted on both the front and back, the
direction of travel determines which one is used.
46. LED lights (Not positioned in figure).

28 3 Overview – Plates
3.2 Plates
Product plates
Below are the product signs that must be on the machine when
operating within the EU/EES, there are more variations available for
other markets. When ordering spare parts and in case of enquiries per
telephone or correspondence, always state model designation and
serial number in accordance with the plates. The plates' part numbers
are stated on each respective plate. Plates that have been damaged,
illegible or painted over must be replaced immediately.
014085
1, 2, 4
1. Machine plate (example), A54516
T = Machine type
M = Machine model
S/N = Serial number for the machine / Year of manufacture
Q, D, H = Indicates classed load capacity (Q) according to
EN1551 at centre of gravity distance (D) up to lift height (H)
W = Machine's operating weight (without load)
P = Engine power
Q, C, D, H = Approved load at lifting height (H) at respective
013973
distance (so-called load centre) horizontally and vertically from

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

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

3 Overview – Plates 29
• Additional plate for attachment, top lift, A54560
013976
• Additional plate for attachment, top lift, inverted forks, A54560
013977
3. 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
013978
D = Approved centre of gravity distance from fork/attachment

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

Warning and information plates

The following figures show the warning texts and information texts
that are located on the machine. The operator shall be aware of the
warnings and should also follow the instructions and information given
on the plates.
Make sure warning and information symbols on the machine and its
components are always easy to see and are legible. Plates that have
been damaged, illegible or painted over must be replaced immediately.
DCF 280-330
15 5 14 2
3
8
15 18 14 17 9
1 11 7 12 1 23 23 1 4 21 6 1
013698
19 10 20 19 19 22 13 10 19

DCF 370-520
3
8
9
1 5,14,15 12 1 23 23 1 4,11 12 16,18 11 5,14,15 17 1
013699
19 10 20 19 2 2 19 22 13 10 21 6 19
Frame, cab
Frame, cab
1. Lift point, 423049.0100
Attaching point for lift device when lifting of machines. There
are lifting points on:
000276
• mast
• rear
2. Warning! A26939
Warning! Read the operator's manual for information.
005223
3. Warning! A30536.0400
No passengers allowed. Passengers may only travel in the
005225
cab provided that it is equipped with a permanently mounted

passenger seat.
4. Warning! A30770.0100
Air conditioning. Filling of refrigerant requires special competence
and authorisation (follow national legislation and local rules).
000281

5. Warning! A30770.0200
Air conditioning. Located on the inside of left frame member.
Filling of refrigerant requires special competence and
authorisation (follow national legislation and local rules).
000282
6. Warning! A54527.0200
Air conditioning. Filling of refrigerant requires special competence
and authorisation (follow national legislation and local rules).
1 = Refrigerant, type
2 = Amount, kg
3 = Pressure, bar
The plate is also on the condenser, compressor and at the air
1 inlet (front edge of cab) as plate A30770.0200.
2
014528
7. Cab tilt 307900.0700

012843
8. Plate for non-ionising radiation, A57336.0100

012968
Safety
Safety
9. Warning! A32442.0100
Do not jump. Always stay in the machine when there is a risk of
roll-over and hold on to the steering wheel.
000284

10. Fire extinguisher, A43461.0100

Specifies where extinguishing is to be performed with a fire in the
engine compartment. The nozzle for extinguishing is pushed
through the sign.
001833
A43461.0100
11. Warning! A32441.0100

Do not stand on the marked area.
001491
12. Warning! A30531.0200

Risk of crushing.
005225
Engine
Engine
13. Filling point, fuel, 450202.0100
D
000286
450202.0100
14. Warning! A30530.0100

Rotating fan.
000287
15. Warning! A30532.0100

Hot surfaces.
000288
16. Filling point, engine oil, A32439.0500

000289

17. Warning! Filling point, coolant, A57775.0100

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

Power transmission, wheels
18. Filling point, transmission oil
455949.0100 (DCF 280-330)
000852
455949.0100
A32439.0200 (DCF 370-500)

000291
19. Inflation pressure, factory-fitted tyres

A32049.0100 1.0 MPa
NOTE
000290
Read chapter 6 Inspection and maintenance regarding safety

when handling wheels.
The conditions for inflation pressure change if factory-fitted
tyres are replaced with another tyre brand! Contact Cargotec.
The plate for tyre air pressure must be replaced with a plate
with the applicable tyre pressure!
Hydraulic system
Hydraulic system
20. Filling point hydraulic oil, 450203.0100
000292

21. Pressure hydraulics,

Indication of the machine's set pressures. The figures are
engraved.
A54518.1700 (DCF370-500),
A54518.0500 (DCF 280-330)
014582
22. Warning! A30529.0100

Pressure. Always release the pressure from the accumulators
before working on the hydraulic system.
Work with the hydraulic system shall always be performed by
authorised personnel!
000294
Lifting mast and attachment

Lifting mast and attachment
23. Warning! A30771.0100
Do not walk under the load or forks. Do not stand on the forks.
DANGER
Forks or other attachments are work tools that handle
large loads.
damage!
Make sure that no persons stand or walk under a
raised work attachment, regardless of whether it is
000858
loaded or not.

36 4 Instruments and controls
4 Instruments and controls

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

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

4 Instruments and controls – Instruments and controls 37
Overview
1 2 3 4 5
15
12 13 12 10 11 9 6 8
013922
14
Overview
1. Left instrument panel
2. Gear selector and multi-function lever
3. Steering wheel panel
4. Steering wheel
5. Direction indicators
6. Panel for hydraulic functions
7. Control breaker for hydraulics
8. Switch for parking brake
9. Hydraulic control
10. Driver's seat
11. Accelerator
12. Brake pedals
13. Clutch pedal
14. Electronic box with fuses and relays
15. Hour meter (operating hours)
A Joystick or mini steering wheel

38 4 Instruments and controls – Instruments and controls
Left instrument panel

Left instrument panel
16. Switch for fan
17. Switch for heat
24..28 29 30 31 18. Switch for air distribution
19. Switch, work lights cab roof
19..23
20. Spare
18 21. Switch for work lights mast
012966
17 Extra work lights mast
16
Left instrument panel 22. Switch, revolving beacon
23. Switch for flashing hazard lights
24. Switch for headlights
25. Switch for heat in seat
(May be placed on operator's seat)
26. Switch for electrically heated rear view mirrors
27. Spare
28. Switch for pause heater
29. Spare
30. Spare
31. Socket 12 VDC

4 Instruments and controls – Instruments and controls 39
Steering wheel panel

Steering wheel panel
36
35
34 32. Warning light, low battery charging
33
32 33. Warning lamp for low brake pressure
34. Indicator light for active error codes
35. Warning lamp, by-pass of hydraulic functions
36. Indicator light, activated steering with joystick or mini-wheel
37..41 49 37. Warning lamp, high coolant temperature
38. Warning lamp, low oil pressure in engine
42..46 39. Indicator light for preheating
47 48 40. Warning lamp for low coolant level engine
41. Warning lamp, high oil temperature in transmission
42. Warning lamp, low fuel level
43. Warning lamp, high temperature hydraulic oil
50 51 52 53 44. Indicator light, high beams
45. Indicator light for direction indicators
46. Indicator light, parking brake
47. Indicator light, locked twistlocks (secured load)
48. Indicator light, alignment (attachment / load)
49. Indicator light, unlocked twistlocks (load released)
50. Panel, warning and indicator lights
51. Control system display
64
54 52. Control system indicator
63 53. Ignition
55
62 54. Switch for defroster
56
55. Switch, windscreen wiper roof, interval
005073
61 60 59 58 57
56. Switch, windscreen wiper roof, continuous
Steering wheel panel 57. Switch, interior lighting
58. Switch, windscreen wiper rear, interval
59. Switch, windscreen wiper rear, continuous
60. Control system function keys
61. Travel direction indicator, Forward Neutral Reverse
62. Switch, shifting program A, Automatic shifting
63. Switch, shifting program 1, locked to 1st gear
64. Switch, shifting program 2, locked to 2nd gear

40 4 Instruments and controls – Instruments and controls
Panel for hydraulic functions
65 Panel for hydraulic functions

66
67 65. Lift/lower
68
66. Tilt
67. Side shift
68. Fork spreading
69. Opening the twistlock (attachment)
70. Switch for horn
71. Switch for twistlocks, automatic/manual locking
70
72. Switch for spreading 20'-40' (attachment)
73. Switch for stop spreading at 30' or 35' (attachment)
74. Switch for revolving operator's station
Switch for hydraulic lateral sliding cab
75. Switch, by-pass of hydraulic functions
Key for by-pass of hydraulic functions
76. Switch for control breaker
013923
8 75 7 75 71
Panel for hydraulic functions and control levers hydraulic 73
servo
65
66 75
67 74
68
75
69
70
71
72
013925
73 8 7 70
Panel for hydraulic functions and control lever

74
013924
8 75 7 75
Panel for hydraulic functions and control levers electric
servo

4 Instruments and controls – Warning and indicator lights 41
4.1 Warning and indicator lights

General
This section describes the warning lamps and indicator lights in the
cab. They indicate the status of subsystems/systems. An illuminated
warning lamp should be attended to immediately. An illuminated
indicator light informs of imminent action.
All lights in the panel are activated briefly when starting. Warning
and indicator lights are concentrated in a panel on the steering wheel
panel (position 50).
Numbers in brackets refer to the positions in Overview, page 37.
Warning lamp, low battery charging (32)

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

The light (red) is activated when the pressure in the accumulator, that
is, the brake pressure is too low. After the light has been activated,
the service brake's capacity is limited.
000298
Check the accumulators' sealing integrity if the pressure does not build
up and is not maintained, see chapter 6 Inspection and maintenance.
Indicator light for active error codes (34)

The indicator light (orange) shows that the control system has one
or several error codes, active or passive. For more information, see
section 5.3 Error codes.
000299
The indicator light is activated for as long as there are active error
codes (STOP, WARNING or INFORMATION).
Warning lamp, by-pass (35)

The warning lamp (orange) shows that by-pass of safety functions for
hydraulics is in progress.
000300
NOTE
By-pass can only continue for 60 seconds at a time.
Indicator light, activated joystick or mini steering

wheel (36)
000301
The indicator light (green) lit when joystick steering or mini-wheel

steering is activated.

42 4 Instruments and controls – Warning and indicator lights
Warning lamp, high coolant temperature (37)

The light (red) is activated if engine coolant temperature is too high.
Determine the cause and take appropriate action.
000302
If the warning lamp continues to be activated, switch off the engine
to allow the coolant to cool down. If the indication remains at restart,
contact service.
Engine power output is restricted at high coolant temperature.
Warning lamp, low oil pressure in engine (38)

If the light (red) is activated during operation, pressure is very
low. Stop the engine immediately. Determine the cause and take
appropriate action. Contact service.
000303
The engine's power is restricted at low oil pressure. Very low oil
pressure in the engine leads to engine shutdown.
Indicator light, preheating (39)

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

a time period.
Engine can be started, position III (start position), regardless of if

preheating is in progress, not activated (no need) or has been finished.
Warning lamp, low coolant level engine (40)

If the light (red) is activated while operating, the coolant level is
too low. Check and top up, if needed. For action, see section 6
"Inspection and maintenance.
000305
The engine's power is restricted at low coolant level.
Warning lamp, high oil temperature in

transmission (41)
The lamp (red) lights if the transmission oil temperature is too high.
Stop the machine and let the engine idle. Determine the cause and
take appropriate action. Contact service.
000306
Warning lamp, low fuel level (42)

The light (orange) indicates when the fuel level is low. The machine
should be refuelled as soon as possible. For action, see chapter 6
Inspection and maintenance.
000307
Approx. 14% (DCF280-330) or 12% (DCF370-520) of the fuel

remains, which corresponds to approx. 5 hours operating time, when
the light is first activated.
Warning lamp, high temperature hydraulic oil (43)

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

4 Instruments and controls – Warning and indicator lights 43
Indicator light, high beams (44)

The light (blue) is activated when the high beams are on.
000309
Indicator light, direction indicators (45)
The lamp (green) flashes when the direction indicators or hazard
lights are on.
000310
Indicator light, parking brake (46)
The light (red) is activated when the parking brake is applied.
000311
If the indicator light flashes, the parking brake has been applied
automatically (not by the operator) when the machine has stopped.
To release the parking brake, turn on and turn off the parking brake
with the switch for parking brake (position 8).
Indicator light for locked twistlocks (47)

The indicator light (green) is activated when the twistlocks are locked
and the load is secured.
000312
Indicator light, alignment (48)

The indicator light (orange) is activated when the attachment has
alignment with the load.
000313
Indicator light for unlocked twistlocks (49)

The indicator light (red) is activated when twistlocks are unlocked
and the load is released.
000314
Indicator, control and monitoring system (52)

The indicator light (red) alerts the operator. It illuminates if there is
event-controlled information or flashes when a STOP or WARNING
level error code is shown on the control system display.
000402
See section 4.11 Control system for detailed information.
Travel direction indicator, Forward Neutral

Reverse (61)
The letters F (Forward), N (Neutral) or R (Reverse) are activated for
each respective travel direction.
000403

44 4 Instruments and controls – Instruments
4.2 Instruments
General
This section describes the analogue instruments in the cab. The
gauges or digits indicate levels/status of sub-systems/systems.
Hour meter (15)

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

4 Instruments and controls – Ignition 45
4.3 Ignition
General
This section describes the ignition key lock (position 53).
Ignition's function
P No function.
0 Stop position. Ignition off, i.e. everything is switched off.
The key can be removed.
I Operating position.
Electric power to all electrical functions. Control units for
engine and transmission are now active.
II Preheating heats the engine intake air to a suitable
temperature with the heating element. The lamp for
preheating (position 39) indicates if preheating is
activated.
When needed, the engine's control unit activated
preheating during a time period.
Engine can be started, position III (start position),
regardless of if preheating is in progress, not activated
(no need) or has been finished.
0
III Start position.
P I Engagement of starter motor for engine start.
The engine should not be started (key to start position)
until the warning and indicator lights, see Overview, page
37, have completed start-up mode (light up and go out
II again). Note that a light may remain illuminated in order
to indicate status.
NOTE
000317
III
The machine is equipped with an electric restart
interlock, which prevents engagement of the starter
motor when the engine is rotating.
Condition for starter motor to engage is that the
transmission is in neutral position and that the engine
isn't already running.

46 4 Instruments and controls – Switches
4.4 Switches
General
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 system.
Direction indicators (5)

Direction indicator for indicating travel direction.
Move the lever back to neutral position when direction of travel

indication should cease.
LEFT - Push the lever upwards.
RIGHT - Push the lever downwards.

008177
Control breaker for hydraulics (7)

Switch for control breaker cuts off electric power to all load handling
functions. Reset by turning the switch clockwise.
002084
Switch for parking brake (8)

Switch (red) for applying parking brake.
Position 0 - Parking brake off.

002206
0 1 Position 1 - Parking brake on.
Switch for fan (16)

For description, see 4.10 Heating / Air conditioning, page 66.
004686
1 0 2
Switch for heat (17)

004687
1 0 2

4 Instruments and controls – Switches 47
Switch, height limitation (18)

004688
1 0 2
Switch for work lights cab roof (19)

Switch (green) for work lights on the cab roof as well as extra work
lights on front wing. Also activates tail lights and side running lights.
Work lights are turned off after idling for 5 minutes, extra work lights
000318
after 2 minutes. Work lights are turned on again at throttle application,
0 1 gearshifting or activation of any load handling function.
Position 0 - Lighting off.
Position 1 - Lighting on.
Switch for work lights mast (21)

Switch (green) for working lights on the mast. Also activates tail lights
and side running lights.
As option, also extra work lights mast.

000318
0 1 Work lights are turned off after idling for 5 minutes, extra work lights
after 2 minutes. Work lights are turned on again at throttle application,
gearshifting or activation of any load handling function.
Position 0 - Lighting off.
Position 1 - Lighting on.
Switch for revolving beacon (22)

Switch (green) for revolving beacon used to attract attention in
connection with hazards.
Position 0 - Revolving beacon off.

000321
0 1 Position 1 - Revolving beacon on.
Switch for flashing hazard lights (23)

Switch (red) for flashing hazard lights used to attract attention in
connection with parking hazard.
Position 0 - Flashing hazard lights off.

000322
0 1 Position 1 - Flashing hazard lights on.
Switch for headlights (24)

Switch (green) for headlights. Also activates tail lights and side
running lights.
Position 0 - Headlights off.

000323
0 1 Position 1 - Headlights on.

Switch for seat heating (25)
Switch (orange) for seat heating. Switches can be located on the seat.
000324
Position 0 - Seat heater off.
0 1
Position 1 - Seat heater on.
Switch electrically heated rear-view mirrors (26)
Switch (green) for electrical heating of rear view mirrors.
006057
Position 0 - Heating of rear view mirrors off.
0 1
Position 1 - Heating of rear view mirrors on (symbol lit).
Switch for pause heater (28)

004922
0 1
Switch for defroster (54)

003470
Switch, windscreen wiper roof, interval (55)

Switch (green) for windscreen wiper on roof window. Intermittent
wiping.
000326
Wiping stops after 2 minutes if the operator leaves the driver's seat.
Reactivates when the operator sits down or applies the accelerator.
Intermittent wiping is activated/deactivated with press of a key.

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

Switch (green) for windscreen wiper on roof window. Continuous
wiping.
000327
Wiper is activated/deactivated with press of a key.
Switch, interior lighting (57)

Switch (green) for interior lighting in cab.
Lighting is activated/deactivated with press of a key.

000330

Switch, windscreen wiper rear, interval (58)

Switch (green) for windscreen wiper on rear window. Intermittent
wiping.
000328
Intermittent wiping is activated/deactivated with press of a key.

The time interval for wiping is controlled by windscreen wiper front
windscreen.
NOTE
The interval is controlled by the interval selected for the windscreen.
Switch, windscreen wiper rear, continuous (59)

Switch (green) for windscreen wiper on rear window. Continuous
000329 wiping.
Wiper is activated/deactivated with press of a key.
Switch for shifting program A (62)

Switch (green) for selecting shifting program A, automatic shifting.
Active shifting program is indicated with a light-emitting diode.

000413
Switch for shifting program 1 (63)

Switch (green) for selecting shifting program 1, which means that
gear position is locked to 1st gear.
000414
Switch for shifting program 2 (64)

Switch (green) for selecting shifting program 2, which means that
gear position is locked to 2nd gear.
000415
Switch for twistlocks, automatic/manual locking

(71)
Switch (green) for locking the twistlocks. The switch is spring-loaded
in position 2.
Position 1 - Twistlocks are locked automatically when there is

000408
alignment with the load. The parking brake must be OFF, see position
1 0 2 8 and indicator light for parking brake, position 46.
Position 0 - Locking of twistlocks not activated.
Position 2 - Twistlocks are locked manually. Button spring-returns.

Switch for spreading 20'-40' (72)
Switch (green) for spreading between 20'-40'. Spreading stops in the

position it is in when the switch is let up. Rocker switch.
005002
1 0 2 This function is used to adapt the attachment to the container's width.
Position 1 - Spreading out is activated. The outer end position on

spreading is at 40'.
Position 0 - Spreading not activated.
Position 2 - Spreading in is activated. The inner end position on

spreading is at 20'.
Switch for spreading stop at 30' (73)
30-35
Switch (green) for spreading stop for attachment at 30' or 35'.
000410
This function is used to adjust the spreading of the attachment to

0 1 the container size (needs adapted). The distance for the spreading
stop is preset in the control unit.
Damping is activated shortly before preset value for stop. To continue

spreading, perform continuous spreading function once again with the
control lever to desired position (end-position is 40').
Position 0 – Spreading stop not activated.
Position 1 – Spreading stop activated. During the ongoing spreading,

stopping is performed automatically at 30' or 35".
Switch for revolving operator's station (74)
Switch (green) for revolving operator's station.

001279
Position 1 - Turning to left.

1 0 2
Position 0 - Rest position.
Position 2 - Turning to right.
Switch for hydraulic lateral sliding cab (74)
Switch (green) for hydraulic lateral sliding cab. The switch is

momentary. Operator door (s) must be closed, control breaker for
000332
1 0 2 hydraulics not activated, parking brake released, and speed below

5 km/h.
Position 1 - The cab moves to the right. The switch must be pressed
and held throughout the movement.
Position 0 – Cab is stationary.
Position 2 - The cab moves to the left. The switch must be pressed
and held throughout the movement.
NOTE
The cab can only be moved if the doors are closed.

Switch for by-passing (75)

Switches (green) for by-passing various functions. The switch is
spring-loaded and can only be active for 60 seconds.
As option, key is available to control the by-pass function.
006183
0 1 Position 0 - By-pass not activated.
Hydraulic panel with electric servo Position 1 - By-pass activated.

• locking and opening of twistlocks without complete alignment
• 20'-40' spreading with locked twistlocks
• lift without indication of locked or open twistlocks
• selection of gear without the sensor in the operator's seat
indicating that someone is sitting in the seat.
WARNING
Safety features are blocked.
No safety system is activated! Risk of roll-over and
tipping over!
Only use bypass in emergency situations!

52 4 Instruments and controls – Gear selector and multi-function lever
4.5 Gear selector and multi-function

lever
General
This section describes the functions of the gear and multi-function
lever (position 2).
Shifting program and travel direction

Shifting program and travel direction are selected with the gear and
F multi-function lever.
Selecting direction of travel:

• F - Forward
• N - Neutral
• R - Reverse (with reverse alarm audible warning signal ). The
back-up light is activated as long as R is engaged.
Three different shifting programs can be selected with the following

switches on the steering wheel panel (position 3):
R • 2 - Shifting locked in 2nd gear (position 64)
• 1 - Shifting locked in 1st gear (position 63)
• A - Automatic shifting (position 62)
000337
Headlight control and horn

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

• Push button for horn (position A).
A. Horn

4 Instruments and controls – Gear selector and multi-function lever 53
Windscreen wiper and washer

Control of windscreen wiper and washing takes place with gear
2 selector and multi-function lever. Turn the control to the following
3 1 positions:
0 • 0 – No wiping of windscreen. Controls slow interval wiping for
roof window and rear window if switch for roof window (position
55) and/or rear window (position 58) is activated.
• 1 - Slow interval wiping of windscreen. Controls slow interval
wiping for roof window and rear window if switch for roof window
000338
(position 55) and/or rear window (position 58) is activated.
• 2 - Fast interval wiping of windscreen. Controls fast interval
• 3 - Continuous wiping of windscreen. Controls fast interval
• Move the control towards the steering wheel - Washing the
windscreen. Controls washing of roof window and rear window
if switch for roof window (position 55 or 56) and/or rear window
(position 58 or 59) is activated. Wiping temporarily changes over
to continuous wiping with window flushing.
The window wiper function stops after two minutes if the operator
leaves the seat. The wiper function is reactivated when the operator
sits in the seat again and throttles up, selects a gear or uses any
hydraulic function from the control lever.

54 4 Instruments and controls – Hydraulic control
4.6 Hydraulic control

General
This section describes the functions of the hydraulic control (position 8).
The control levers govern the trolley and forks hydraulically. There are
a number of alternative hydraulic controls:
• Hydraulic control with up to five levers
• Electric servo with up to five levers
• Control lever
It is possible to vary the speed of the different hydraulic functions, i.e.
lift, tilt, etc., by varying the extent of the lever deflection. It is also
possible to vary the speed of the hydraulic functions with the engine
speed (rpm).
NOTE
For hydraulic lateral sliding cab: Doors shall be closed, otherwise all
hydraulic functions are cut off.
Hydraulic control with levers

A Lift/lower.
LIFT - pull the lever backwards.
LOWER - push the lever forwards.
The lowering speed can be varied only with the lever angle -
the engine speed has no influence.
B Tilt.
REVERSE - pull the lever backwards.
FORWARD - push the lever forwards.
C Sideshift.
A LEFT - push the lever forwards.

B C D E RIGHT - pull the lever backwards.
It is not possible to sideshift the forks if fork spreading is in
max. or min. position.
D Fork spreading.
OUTWARDS - push the lever forwards.
INWARDS - pull the lever backwards.
Moving the right-hand fork. Side shift to the required left-hand
F fork position and then spread again.
E Optional hydraulic function.
E.g. separate spreading, connect attachment, levelling fork,
etc.
F Control breaker for hydraulics.
WARNING
In an emergency! In the event of undesired
activation/movement of a function.
Risk of personal injury and/or property damage!
009300
IMMEDIATELY TURN OFF all working hydraulics by

pressing the CONTROL BREAKER for hydraulics.

4 Instruments and controls – Hydraulic control 55
Hydraulic controls with electric servo
Electric servo makes it possible to use small fingertip-controlled linear

levers for the working hydraulics' different functions.
A. Lift/lower.
LIFT - pull the lever backwards.
LOWER - push the lever forwards.
D/E F Lowering speed can only be varied with lever deflection - engine
C speed has no effect.
B B. Tilt.
A
REVERSE - pull the lever backwards.
H FORWARD - pull lever FORWARD.
C. Sideshift.
LEFT - pull lever forward.
RIGHT - pull the lever backwards.
It is not possible to sideshift the forks if fork spreading is in max.
or min. position.
D. Fork spreading.
OUTWARDS - push the lever forwards.
INWARDS - pull the lever backwards.
Moving the right-hand fork. Side shift to the required left-hand
fork position and then spread again.
E. Rotation, attachment
RIGHT side forward - push the lever forwards.
LEFT side forward - pull the lever backwards.
F. Optional hydraulic function.
E.g. separate spreading, connect attachment, levelling fork, etc.
012548
G
G. Opening locked twistlocks, attachment
H. Control breaker for servo circuits.
WARNING

56 4 Instruments and controls – Hydraulic control
Functions, control lever
9 1 2 3
10 4
5 6 7 8
012549
1. Sideshift left 6. Spreading in
2. Sideshift right 7. Tilt in
3. Lower 8. Lift
4. Tilt out 9. Optional hydraulic function
5. Spreading out 10. Optional hydraulic function
WARNING

4 Instruments and controls – Hydraulic control 57
Functions, control lever
The control lever controls functions when handling the forks and top-lift
attachments. Its function diagram is need-adapted and may therefore
differ from this section. See the plates on the machine.
1 2 3 4 5
11 12
14
13
6 7 8 9 10
014599
1. Rotation 8. Tilt backward
2. Sideshift left 9. Lift
3. Sideshift right 10. Tilt forward
4. Lower 11. Twistlocks locked (load secured), green
5. Release of twistlocks 12. Twistlocks unlocked (load not secured), red.
6. Spreading out 13. Alignment attachment's four corners, orange
7. Spreading in 14. Control breaker for servo circuits
Light panel on top lift attachment

A lamp panel is fitted to the top-lift attachment which assists load
A B C handling. The panel indicates with coloured lights if and when
twistlocks are locked/unlocked i.e. when the load is secured/released.
A Twistlocks locked (load secured), green.

B Alignment attachment's four corners, orange.
C Twistlocks unlocked (load not secured), red.
000336
Light panel on top lift attachment

58 4 Instruments and controls – Pedals
4.7 Pedals
General
This section describes the machine's foot-operated functions.
003679
12 13 12 11
11. Accelerator
12. Brake pedal
13. Clutch pedal
Accelerator (11)
The accelerator pedal (position 11) is electronic and controls the
injection pump.
For the hydraulic function lift, with the machine declutched or gear
in neutral, the system gives automatic throttle increase for higher
hydraulic power.
Brake pedals (12)

The brake pedals (position 12) are mechanical and connected to the
hydraulic system. The brake pedals are used for service brake.
The accumulators ensure that there is always brake pressure available,

even in the event of a temporary engine stop. If the accumulator
pressure drops below a certain level, the warning lamp for low brake
pressure (position 33) is activated.
Clutch pedal (13)

The brake pedal is combined with a separate clutch pedal (position
13). The pedal is used to disengage the transmission, which makes it
possible to use the hydraulic functions when a gear is engaged.

4 Instruments and controls – Steering wheel 59
4.8 Steering wheel

General
This section describes controls for steering. The following alternatives
are available for steering the machine:
• steering wheel with fixed steering column.
• steering wheel with adjustable steering column .
• joystick (position A)
• mini steering wheel (position A)
Steering wheel
Clockwise rotation of the steering wheel steers the machine to the
right, and vice versa.
The steering wheel's and instrument panel's angle and height can be
adjusted to the desired operating position.
1. Steering wheel's height.
1 To adjust: Move upper lever upward.
2. Steering wheel panel's angle.
To adjust: Move upper lever downward.
3. Steering column's angle.
To adjust: Loosen the lower handle and adjust to desired position.
Tighten the handle securely after adjusting.
2
3
000341
Adjustment possibilities for steering wheel

60 4 Instruments and controls – Steering wheel
Joystick
3 4
2 Joystick control is an electro-hydraulic system, mounted in the left

arm rest, to control the machine with a joystick. When the joystick is
moved to the right, the machine steers to the right and vice versa.
The steering angle is inversely proportional to machine speed, i.e. a
1
low speed gives a greater wheel angle and vice versa.
The standard steering wheel is equipped with sensors that detect any
steering wheel movement in an emergency situation. If the driver
starts to steer using the standard steering wheel, joystick steering is
disengaged. Indicator lamp for activated joystick or mini-steering
wheel (position 36) goes out on the panel for warning and indicator
lamps.
1. Joystick.
2. Travel direction selector F/N/R.
forward = F
5 middle position = N
reverse = R
3. Button for engaging joystick steering.
Conditions: The speed must be below 3 km/h. If the speed
exceeds 3 km/h joystick steering cannot be enegaged. The
indicator lamp for activated joystick or mini-steering wheel
steering (position 36) on the panel for warning and indicator lights
comes on when joystick steering is engaged.
4. Sound signal.
000900
5. Arm rest.

4 Instruments and controls – Steering wheel 61
Mini steering wheel

3 4
Mini-steering wheel control is an electro-hydraulic system, mounted
2
in the left arm rest, to steer the machine with a steering wheel.
Clockwise rotation of the steering wheel steers the machine to the
right, and vice versa. The wheels always follow the position of the
1 mini-steering wheel. If the steering wheel is released, both the
mini-steering wheel and the wheels remain in the set position.
The standard steering wheel is equipped with sensors that detect any
steering wheel movement in an emergency situation. If the driver
starts to steer using the standard steering wheel, joystick steering is
disengaged. Indicator lamp for activated joystick or mini-steering
wheel (position 36) goes out on the panel for warning and indicator
lamps.
1. Mini steering wheel.
The steering wheel's position on the arm rest is adjustable.
2. Travel direction selector F/N/R.
5
forward = F
middle position = N
reverse = R
3. Button for engaging the mini steering wheel.
Conditions: The speed must be below 3 km/h. If the speed
exceeds 3 km/h mini-steering wheel cannot be enegaged. The
indicator lamp for activated joystick or mini-steering wheel
steering (position 36) on the panel for warning and indicator lights
000583
comes on when mini-steering wheel steering is engaged.

4. Sound signal.
5. Arm rest.

62 4 Instruments and controls – Driver's seat
4.9 Driver's seat

General
This section describes the operator's seat (position 10). The following
alternative seats are available:
• Driver's seat Bege. The seat is equipped with:
• mechanical adjustment
• seat belt
• air suspension
• head rest
• armrest left
• seat heat
• Driver's seat Isringhausen. The seat is equipped with:
• mechanical adjustment
• air suspension (external compressor)
• air-adjusted lower back (lumbar) support
• seat belt
• seat heat
• head rest
• armrest left

4 Instruments and controls – Driver's seat 63
Driver's seat Bege

The operator's seat (position 10) is equipped with several controls
for adjustment as follows (adjusting is easier when nobody is sitting
in the seat):
1. Distance to pedals.
7 4 Release the seat with the lever and move the seat forwards or
backwards.
2. Height of seat.
Mechanical elevation of seat height:
Turn the knob clockwise or anticlockwise until desired height is
obtained.
Air suspension elevation of seat height:
Turn the knob anticlockwise to lower the height. Turn clockwise
to raise the height. The suspension automatically responds to the
weight of the operator.
Exiting the cab is easier if the air is let out of the suspension. Pull
the control to the outermost position (seat drops to lowest level).
When entering the cab, press in the control to the innermost
position (seat elevates to preset level).
6 3. Back rest angle.
Turn the knob until desired position is obtained.
4. Armrest right angle.
5. Variable angling of seat and back.
Turn the knob until desired position is obtained.
1 2 5 3 6. Adjustment of suspension travel in two steps (lever located on
back of seat):
Suspension active - Lever against seat's centre line. Used during
normal operation.
000342
Suspension locked - Lever against seat's outside. Can only be

done when seat's height reaches a locked position. Used when
Driver's seat with adjustment possibilities suspension is not desired.
7. Lower back (lumbar) support.
Turn knob until desired firmness in lumbar support is obtained.

64 4 Instruments and controls – Driver's seat
Driver's seat Isringhausen

The operator's seat (position 10) is equipped with several controls
for adjustment as follows (adjusting is easier when nobody is sitting
in the seat):
1. Distance to pedals.
Release the seat with the lever (1) and move the seat fore or aft.
To lock the seat, release the lever.
2. Adjusting the seat cushion.
Lift control (2) and adjust the seat forwards or backwards.
3. Lowering seat height.
Lift control (3) to lower the seat. The seat remains in the lower
position.
Press down control (3) to raise seat to previous position.
4. Seat cushion angle.
11 Lift control (4) and adjust the angle by loading/unloading the front
part of the seat cushion.
12
5. Raising seat height.
Lift control (5) to raise the seat, infinitely variable.
Press down control (5) to lower the seat, infinitely variable.
When the desired height is obtained, release the control.
10
6. Back rest angle.
Lift control (6) and adjust the angle by loading/unloading the
backrest.
7. Adjusting the damping.
567
234
006492
Lift control (7) for maximal damping.

9 8
Press down control (7) for minimal damping.
8. Seat heat.
Thermostat-controlled heat for seat and back rest.
Press down the button for activation/deactivation. Activated seat
heat is indicated with light in the switch.
9. Plane damping.
Slide the control to the right and left, respectively, to
activate/deactivate level damping.
10. Lumbar support. Integrated pneumatic system.
Press the button to fill and drain, respectively, the air chambers
for optimal body adaptation of the backrest.
11. The armrest angle is infinitely variable with the knob.
12. Arm rest left.

4 Instruments and controls – Driver's seat 65
Revolving operator's station
Operator's station, with driver's seat, is available electrically turnable.

The seat console has an integrated steering column and steering
wheel with panel. This follows around with the console when turning.
The driver's seat does not differ from other seat options. The turnable
driver's position has doubled pedals.
The operator's station is rotated with the switch for revolving operator's
station. See Panel for hydraulic functions, page 40 (position 74).
001626

66 4 Instruments and controls – Heating / Air conditioning
4.10 Heating / Air conditioning

General
This section describes the function of:
A
• Air conditioning system, EHC. Automatic with thermostat control
of heating and fresh air.
• Air conditioning system, ECC. Automatic with
thermostat-controlled control of cooling and heating as well as
air drying.
The heating/air conditioning system receives heat from the engine's

cooling system and provides heat when the engine is warm. Cooling
performance is generated by the AC compressor (for ECC).
The system is controlled by fan, heat and air distribution as well as

function for recirculation and defroster:
• Fan speed is adjusted with switch for fan (position 16).
• Heat (and cooling performance for ECC) is controlled with switch
for heat (position 17).
18 • Air distribution to the cab is adjusted with the switch for air
distribution (position 18). The fresh air inlet is provided with filter
17 and can be equipped with fine filter against pollen (fan's
004690
capacity is reduced).
16
• Recirculation of cab air is activated/deactivated by pressing on the
function key for Enter by the operating menu for air conditioning.
A. Panel nozzle
• Defroster for fast demisting of windows is activated/deactivated
16. Switch for fan with the switch for defroster (position 54).
17. Switch for heat

18. Switch for air distribution
NOTE
Operator's door and windows shall be closed for satisfactory
function of the system.
For ECC: In the event of an open door, the air conditioning's AC
compressor is switched off (cooling function and air drying stops).
Close the door and the AC compressor is reactivated.

001839
Fresh air inlet for cab
Operating menu for heating /air conditioning

system
The operating menu for the heating/air conditioning system is shown
automatically in the display when the switch for fan, heating or air
distribution is activated. It can also be selected for constant display
with function keys for arrow right and arrow left.
For detailed description, see Description, page 73.

004916

4 Instruments and controls – Heating / Air conditioning 67
Switch for fan (16)

Switch (green) for fan handles setting of fan speed for the cab.
Setting of fan speed:

• Automatic control, AUTO.
004686
1 0 2 • Manual control in 13 steps from off to max. Fan speed is shown
by the bar's height in the operating menu for the heating/air
conditioning system.
Position 1 - Increases fan speed.
Position 0 - Fan speed unchanged.
Position 2 - Reduces fan speed. Activates automatic control, AUTO,

from off.
Operating menu for air conditioning is shown automatically in the

display when switch is used, see Description, page 73. Display stops
after 3 seconds if switch is not used again.
Switch for heat (17)

Switch (green) for heat handles setting of reference value for cab
temperature. Setting takes place in steps of 0.5 °C.
The temperature range is 16 °C to 27 °C. Setting of min. and max.

004687
respectively, switches off automatic climate control (control of fan,

1 0 2 heat and air distribution) and sets the heat valve in min. and max.
position, respectively.
Position 1 - Higher temperature setting. When needed, the cab's air is

cooled to set temperature (for ECC).
Position 0 - Temperature setting unchanged.
Position 2 - Lower temperature setting. When needed, the cab's air is

cooled to set temperature (for ECC).

Switch, height limitation (18)

Switch (green) for air distribution handles distribution of fresh air to
the cab. The air is distributed to the lower parts of the cab (legs), cab
space (panel) and upper cab space (windscreen).
004688
Position 1 - Controls air distribution to upper cab space (windscreen).

1 0 2
Position 0 - Setting air distribution unchanged.
Position 2 - Controls air distribution to lower cab space (leg).
Recirculation is activated/deactivated by pressing on the function key

for Enter when the operating menu for air conditioning is shown.


68 4 Instruments and controls – Heating / Air conditioning
Switch for pause heater (28)
Switch (green) for pause heater. The cab fan emits heat from the
engine's cooling system during short-term parking of the machine.
004922
0 1 Position 0 - Pause heater not activated.
Position 1 – Pause heater pre-activated. User instruction:

• Park the machine. Keep the engine running.
• Set desired temperature (position 17).
• Press in the switch for pause heater (position 28).
• Turn off the engine, that is, turn off the ignition.
The pause heater is now activated and strives to maintain preset
temperature for the cab.
If the cab temperature falls 6 °C below the preset temperature,
the pause heater stops working since the engine's cooling system
can no longer deliver the heat required.
NOTE
The higher the preset cab temperature, the shorter the
operating time for the pause heater.
Switch for defroster (54)

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

the other switches for the system. The defroster function is switched
off automatically after 6 minutes.
A symbol for defroster active is shown in display (top right).

4 Instruments and controls – Control system 69
4.11 Control system

General
This section describes the control system.
50 51 52
The machine is equipped with an electronic system for control and
monitoring of the machine's different functions.
The system gives the operator information in the form of:

• Error code information
Three levels of error code information can be shown. In the event
of a new error code, the indicator for the control and monitoring
system (position 52) is activated, as well as the indicator light for
active error codes on the panel for warning and indicator lights
(position 50). See the section 5.3 Error codes.
• Operating information
Operating information includes, for example, machine speed,
engine rpm, fuel level, etc.
• Event-controlled information
Event-controlled information is, e.g., open doors.
006493
60 The information is presented on the steering wheel panel's display

(position 51). The function keys (position 60) are used to navigate in
50. Panel, warning and indicator lights the display menus for service and troubleshooting, for example.
51. Control system display Numbers in brackets refer to the positions in Overview, page 37.
52. Control system indicator
60. Control system function keys
4.11.1 Operating menus

General
After starting the machine, Operating menu engine and transmission
is shown in the display. Menus are selected with the function keys
for right arrow and left arrow. With each press of the key, the display
1 2
U
changes to the next menu. To return to the original display, press and
hold in the Reset (R) function key.
This section describes the information that can be obtained from the
different operating menus.
014251
Example of available operating menus

70 4 Instruments and controls – Operating menus
4.11.1.1 Operating menu for engine and transmission
Description
a. Shows current engine speed (rpm).
a c b. Shows current speed in km/h (in display kilometre per hour, kph).
b d c. Shows current gear.
e Travel direction and shifting program are shown on steering
wheel panel (positions 61-64).
013965
f U d. Shows current fuel level.
e. Shows the current AdBlue level.
f. Shows current time.
Setting clock
1. Go to setting mode by holding in Enter for 3 seconds. Date,
month, year (a) are also shown in setting mode.
2. Scroll <- / -> with between hours, minutes, 12/24 h display, date,
month and year.
a 3. Adjust values with +/-.
003573
4. Press Enter at minutes to set seconds to 0.

5. Leave setting mode by pressing Reset.
4.11.1.2 Operating menu for scales
Description
a
a. Shows tare weight in tonnes.
b The value shown on the row (b) can be reset (tared) by pressing
the function keys for minus and plus simultaneously. If the keys
are pressed again the values (a) and (b) switch. The desired
c
006669
value can also be scrolled using the minus and plus keys. The
set value is displayed on row (a and b).
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 function
key for Return. The value in row (c) can be reset to zero by
depressing the function key for Reset.
4.11.1.3 Operating menu for engine
Description
Applies to the Volvo TAD762VE.
a. Shows coolant temperature in °C.
a b. Shows engine oil pressure in bar.
b
000355

4 Instruments and controls – Operating menus 71
Description
Applies to the Volvo TAD1360VE.
a. Shows coolant temperature in °C.
a
b. Shows engine oil pressure in bar.
c. Shows oil level.
b
006758
Full bar with jagged line at top indicates 100%.
c
Empty bar indicates 0%.
The operating menu shows the oil level when starting the engine.
If the oil level drops during the operating time, this is indicated
with an error code for low oil engine.
NOTE
Dropping oil level during operation is not shown in this operating
menu.
4.11.1.4 Operating menu for transmission and

hydraulics
Description
a. Shows temperature of transmission oil in °C.
b. Shows temperature of hydraulic oil in °C.
a
000356
4.11.1.5 Operating menu for system voltage
Description
Shows the current system voltage in volt.
000354
Example from operating menu for electrical system
4.11.1.6 Operating menu for service interval
Description
• Shows total operating time in hours.

• Shows number of hours to next service.
003696

72 4 Instruments and controls – Operating menus
4.11.1.7 Operating menu for statistics
Description
Start display for statistics menu.
003575
Display of statistics
Go to the View mode by pressing Enter, and go back with Reset.
Scroll between the menus with the function keys for arrow right and
arrow left.
• Operating hours engine (hours).
• Operating hours engine, machine parked and idling (hours).
003697
• Operating hours engine, with gear activated (hours).

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

• Trip meter (km).
Press function key for Enter to reset measuring.
003699
4.11.1.9 Operating menu for service
Description
Used by service technicians and for the displaying of error codes. For
the display of error codes, see section 5.3 Error codes.
000056

4 Instruments and controls – Event-controlled information 73
4.11.1.8 Operating menu for heating/air conditioning

system
Description
The operating menu for the heating/air conditioning system is shown
a e automatically in the display when the switch for fan, heating or air
distribution is activated. It can also be selected for constant display
f with function keys for arrow right and arrow left.
b
c g Recirculation is activated/deactivated by pressing function key for
004689
d Enter.
Example of operating menu for air conditioning a. The bar shows the setting for fan speed, automatic (AUTO) or
manual control (in 13 steps 0-12).
b. Indicates set reference value for cab temperature.
c. Symbol for setting of fan.
d. Indicates if fan is in AUTO mode.
e. Symbol indicates if defroster is active or not.
f. Arrow shows setting for distribution of fresh air to the cab.
Indication shows toward the lower parts of the cab (legs), cab
space (panel) and upper cab space (windscreen).
g. Symbol indicates if recirculation is active or not.
4.11.2 Event-controlled information

General
The control system draws the operator's attention to important
information. The warning/information is shown on the control system's
display when needed.
Start interlock
The menu is shown at start attempt. To start, enter your 5-digit code.
003574
Open door
The figure is shown if:

• doors are not closed during hydraulic cab sliding. The cab cannot
be operated until the doors are closed.
000576
In the event that the display is shown, close the door(s). The display
then disappears. Display figure can be removed with function key
for Reset (R).
Warning for overload lift

The warning figure means overload of lifting equipment.
The overload system stops lift and tilt.
If the figure is shown, the machine's load functions are limited:

• In the event of overload the load can always be lowered and tilted
003811
out to evade the overload situation.

74 4 Instruments and controls – Event-controlled information
Warning for overload tilt


003810
Warning for overload lift and tilt


003812
Height limitation
The display is shown when the set maximum lift height is reached.
Lower the mast. The function can be bypassed see section 5.5.4
Functions for load handling. Display figure can be removed with
008175
function key for Reset (R).
Height warning
The display is shown when the set maximum lift height is reached.
Display figure can be removed with function key for Reset (R).
008175

5 Handling 75
5 Handling
General
The machine is intended to be used in the way that is described in
the operator's manual. If the machine is used in any other way or in
potentially dangerous environments, e.g. an explosive environment,
then special safety rules must be followed and the machine must be
equipped for such an environment.
NOTE
It is the operator who is responsible for ensuring that the machine
comes in for service according to prescribed service intervals.
Procedures are described in the maintenance manual.
The information in the chapter for handling the machine does not
relieve the operator of the responsibility of following laws or other
national regulations for road safety and work safety.
Awareness, alertness, good judgement and respect for governing

safety regulations are prerequisites for avoiding accident risks.
Environmental impact
It is important that the machine is used in a way that results in minimal
environmental impact with regards to fuel consumption, exhausts, and
noise emissions. Therefore, keep the following in mind:
• Plan the work and optimise machine use.
• Avoid operating with full throttle when transporting.
• Do not rev the engine unnecessarily when load handling.
• Optimise operation with regard to acceleration and braking.
• Minimise the time that the machine idles. Do not allow the machine
to idle when there is a break in the work.
Emergency equipment
The following emergency equipment is available on the machine:
• Emergency exit from cab, right-hand door.
In an emergency:
Open the emergency exit, right door, with the handle on the inside.

76 5 Handling – Handling
• Breaker switch for load handling (servo circuits)

In an emergency:
1. Press down the control breaker immediately.
002084
All load handling function stops.
2. Restore control breaker (turn clockwise).
• Fire extinguisher
Located on the left front fender.
WARNING
Bypass of load handling functions must not be used
when lifting or transporting loads.
damage.
Only use the bypass in emergency situations.

5 Handling – Running-in 77
5.1 Running-in
General
The machine should be operated with great care during the running-in
period. The aim is to give bearing surfaces hard and polished surfaces,
which considerably extends the service life.
Recommended running-in period is 10 hours of operating time. This

results in fewer malfunctions.
Engine
A new engine should always be handled with great care - it must have
a running-in period. Avoid running the engine at full load during the first
10 hours. The load can then be gradually increased.
NOTE
Check the oil pressure and temperature at regular intervals.
Oil and filter should be changed for the first time after 50 operating
hours.
Thereafter oil and filter changes take place according to intervals

described in the maintenance manual.
Transmission
Filters must be changed for the first time at the 50-hour inspection.
The oil and filer are then changed according to intervals described in
the maintenance manual.
Tyres and rims

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

78 5 Handling – Daily inspection
5.2 Daily inspection

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

5 Handling – Error codes 79
5.3 Error codes

General
Error codes indicate there is some defect/malfunction in the machine.
The error codes should be used by operators and service technicians
to identify faults and to implement suitable action.
In case of an error code indication, it's very important to identify the

error code and to perform an action to correct the problem.
Error codes are shown automatically on the display and end up in an

error code list under the operating menu for service.
Action in the event of error code
CAUTION
STOP indicates a malfunction in the machine which
may affect the safety of the operator and others in the
vicinity or may cause a breakdown. Read the error
code. Switch off the engine and perform action in
accordance with the error code table.
WARNING and INFORMATION alarms indicate
malfunctions of such character that work does not
have to be stopped. The machine's capacity may be
limited and certain functions may stop working. -
Perform actions according to error code table as soon
as possible.
1 Stop the machine and let the engine run at idle speed.
Identify error code level, see section 5.3.1 Error code indication.
• In the event of STOP - Continue to step 4.
• In the event of WARNING or INFORMATION - Continue to
step 2.
NOTE
If several error codes come from the engine, the error code
level is shown for the most serious error code.
2 Navigate to the operating menu for service using the function keys
arrow left or arrow right. Hold down the function key Enter for at
least two seconds. The error code list is shown.
000056
Operating menu for service

80 5 Handling – Error codes
3 Note all error codes. For explanation, see Display figure for error
code information, page 82.
Error code number together with X(Y). X shows sequence number
for displayed error code and (Y) shows total number of active error
codes. Scroll between the error codes with the function keys arrow
right and arrow left. The error code information disappears when
001998
the cause of the error code has been rectified.
Leave the error code list by pressing the function key Reset (R).
Example figure, error code list
4 Perform action according to error code level:
STOP, critical malfunction!
A Park the machine immediately.
Note error code number.
B Turn off engine.
C Contact service.
WARNING, not a critical malfunction.
A Take care of error code as soon as possible but work with
machine can continue safely.
B See information in error code table:
- Error codes machine, page 85
- Error codes engine, page 89
- Error codes transmission, page 99
If error code number is not in error code table, perform
action according to step C.
C Contact service, e.g., after finished work shift.
INFORMATION, not a critical malfunction.
A Continue work with machine.
B At a suitable time, see information in error code table:
- Error codes machine, page 85
- Error codes engine, page 89
- Error codes transmission, page 99
If error code number is not in error code table, perform
action according to step C.
C Contact service, e.g., after finished work shift.
5 Check: Start the engine and check that the error code has
disappeared acc. to step 2.

5 Handling – Error code indication 81
5.3.1 Error code indication

General
Error code is indicated with activated indicator light for active error
51 52
codes (position 34). Error codes are divided into three error code
levels based on severity.
The error code levels are shown as follows:

• Stop is indicated with a STOP sign on the display together with
flashing red light from the indicator for the control and monitoring
B system (position 52) as well as activated indicator light for active
error codes (position 34).
• WARNING is indicated with a warning triangle on the display
together with flashing red light from the indicator for the control
and monitoring system (position 52) as well as activated indicator
34 for active error codes (position 34).
• Information is indicated with activated indicator light for active
error codes (position 34).
005075
B. Error code level symbol

34. Indicator light for active error codes
52. Indicator for the control system
5.3.2 Error code information on display

Error code display
Error code information is shown with display figures in two ways:
• Automatically in display at STOP and WARNING.
The error code is confirmed using the function key Reset (R).
When the error code is confirmed, the display returns to the
previously selected menu. If the error code is active then it is
stored in the error code list under the operating menu for service.
003817
If the error code remains active, the figure returns in the display
Example of automatic figure in display within 3-5 minutes.
• In the error code list under operating menu for service.
Active error codes are stored in the error code list. Navigate to the
operating menu for service. Display the error code list by pressing
in function key Enter for 2 seconds. Navigate through the error
code list using the function keys arrow right and arrow left. Exit
the error code list by pressing the function key for Reset (R).
001998
NOTE
Example of display in the error code list
If error code isn't included in the error code list, it may be due
to the following:
– condition for error detection no longer exists, e.g.,
control lever is released or engine is off.
– loose connection/poor contact.

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

The control and monitoring system's display is divided into four fields
C where the information is shown (see figure to the left).
• Field B: Error code level.
D E
• Field C: Error code number.
B • Field D: Type of error.
000389
• Field E: Affected function.
• Book symbol means that information is available in the operator's
manual.
Field B: Error code level
Field B: Error code level
C
The control and monitoring system gives error code information in
D E three levels which are indicated with a symbol in the lower left corner
(B) on the display unit.
• STOP
000350
Indicates a serious malfunction that may jeopardise the operator's

safety or cause machine failure. The error code must be attended
to immediately.
The error code is shown automatically on the display.
• WARNING
C Indicates malfunction in machine that should be taken care of as
soon as possible.
D E The error code is shown automatically on the display.
000351
• INFORMATION
C Information to operator about something that should be taken
care of, e.g., broken bulb. Take care of the cause at a suitable
D E time. Action instruction is often found in chapter 6 Inspection
and maintenance.
The error code is stored in the error code list under operating
000352
menu for service.
Field C: Error code number

Field C: Error code number
XXX
The control and monitoring system gives error codes from three
D E sub-systems:
• Machine:
B
006499
Shown with error code number XXX on display, see Error codes
machine, page 85.
• Engine:
XX/YY Shown with error code number XXX/YY on display, see Error
codes engine, page 89.
D
NOTE
B
001343
If several error codes come from the engine, the error code level
is shown for the most serious error code.
• Transmission:
XXX/YY Shown with error code number XX/YY on display, see Error
codes transmission, page 99.
D
B
001344

5 Handling – Error code information on display 83
Field D: Type of error

Field D: Type of error
1 2 3
1. Temperature too high/too low.
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.
4 5 6
5. Incorrect signal from control.
6. Incorrect signal from battery.
7. Incorrect signal from spool.
8. Level too high/too low.
7 8 9
9. Incorrect signal to bulb.
10. Incorrect signal, for example, open circuit.
11. Incorrect signal to engine.
10 11 002058

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

Field E: Affected function
1 2 3
1. Attachment
2. Rotation, attachment
3. Side shift, attachment
4 5 6 4. Length adjustment attachment
5. Twistlocks
6. Forks up/down
7. Tilt forks
7 8 9 8. Sideshift forks
9. Spreading forks
10. Rotation forks
11. Overload protection
10 11 12
12. Hydraulic functions
13. Brake system
14. Steering
13 14 15 15. Engine
16. Transmission
17. Central lubrication
18. Control unit
16 17 18 19. Hardware-related error
20. Cab
21. Air conditioning
22. Fuel system
19 20 21 23. Headlights
24. Windscreen wipers
25. Battery voltage
22 23 24 26. Bulb for lighting
25 26
002059

5 Handling – Error code tables 85
5.3.3 Error code tables

General
Error codes are sorted in numerical order. The tables contain the
following information:
• Code - Indicates error code.
• Description - Indicates description of the error code as well as
any limitation that can occur in the machine in case of the error
code in question.
• Action - Indicates STOP/WARNING/INFORMATION for action
according to error code level, with or without detailed information.
If the error code number isn't included in the error code table, contact
service.
Error codes machine
Table Error codes from machine
Code Description Action

1 No contact with control unit frame D797-1. STOP
2 No contact with control unit frame option D797-2. STOP
8 No contact with KID D795. Controls in steering wheel panel and STOP
display not working.
11 Defective CAN segment 1. WARNING
19 Revolving driver's seat: The accelerator pedal for driving backwards WARNING
needs to be calibrated. Engine speed limited to idling speed.
20 The accelerator pedal for driving forwards needs to be calibrated. INFORMATION
Engine speed limited to idling speed.
21 No contact with control unit transmission D793. Gear selection not STOP
working.
22 No contact with control unit engine D794. Engine does not respond STOP
to commands from cab.
23 Machine is not configured. No controls in the cab are working. STOP
24 Incorrect voltage feed to cab fan. Cab fan not working. INFORMATION: Check fuse F58-5:C3.
See 6.2.14 Fuses for electrical system.
25 Communication error with control unit engine D794 at active error INFORMATION: Turn ignition off and on.
code.
26
Error code is stored in control unit engine.
27
28
29
30
31 Voltage feed incorrect to control unit cab D790-1. Controls in cab STOP: Check fuse F58-5:A1. See 6.2.14
not working. Fuses for electrical system.
32 Analogue controls cab. Analogue controls in cab do not work STOP
(accelerator pedal, mini-wheel/joystick, control levers electric
servo/control lever and controls for air conditioning system).
33 No feed of control breaker voltage to control unit cab D790-1. Control WARNING: Check fuse F58-3:H8. See
breaker cannot be disengaged. All hydraulic functions are blocked. 6.2.14 Fuses for electrical system.

86 5 Handling – Error code tables

34 Switch parking brake. Parking brake cannot be released. WARNING: Use by-pass to release the
parking brake.
35 Communication error with control unit transmission D793 at active INFORMATION: Turn ignition off and on.
error code.
36
Error code is stored in control unit transmission.
37
38
39
40
41 Wiper rear not working. INFORMATION
42 Revolving beacon not working. INFORMATION: Check the lamp. See
6.2.15 Lighting.
43 Back-up light cab left not working.
44 Back-up light cab right not working
45 Wiper front not working. INFORMATION
46 Cab fan not working. INFORMATION
47 Recirculation damper for ventilation not working. INFORMATION
48 Water valve. Heat adjustment in cab not working. INFORMATION
49 Water valve. Heat adjustment in cab not working. INFORMATION
50 Air distribution in cab cannot be adjusted. INFORMATION
52 Bypass of external top lift attachment not working. WARNING
53 Windscreen washer rear and roof not working. INFORMATION
54 Bulb in switch flashing hazard lights not working. INFORMATION
55 Reduced or no background lighting in instruments and controls. INFORMATION: Check lights for
background lighting. See 6.2.15 Lighting.
56 Work light 20' not working. INFORMATION: Check the lamp. See
6.2.15 Lighting.
57 LED-control lever for levelling lock. Indication levelling lock in joystick
not working.
58 Twistlock on external top lift attachment not working. WARNING
59 Spreading of external top lift attachment not working. WARNING
60 Seat heating not working. INFORMATION
61 Work light 40' not working. INFORMATION: Check the lamp. See
6.2.15 Lighting.
63 No ignition voltage to the machine's control units. STOP
64 No control breaker voltage to the machine's control units. STOP
65 No control breaker voltage to the machine's control units. STOP
66 Washer front not working. INFORMATION
67 Wiper roof not working. INFORMATION
68 Pause heater not working. INFORMATION
69 No voltage feed to engine and transmission. STOP
71 Interior lighting in cab not working. INFORMATION: Check the lamp. See
6.2.15 Lighting.
75 Relay for ignition key lock has jammed in position On. Control unit STOP
cab is still supplied with voltage and therefore active.
80 Incorrect pressure in air conditioning. Air conditioning not working. INFORMATION


82 Fan speed cannot be adjusted. INFORMATION
83 The temperature is adjusted to 22 °C. INFORMATION
84 Air distribution cannot be adjusted. INFORMATION
85 The accelerator pedal for driving forwards does not work. Engine STOP
speed limited to idling speed.
86 The accelerator pedal for driving backwards does not work. Engine STOP
speed limited to idling speed.
87 Control lever for lift and lower. Lift and lower not working. WARNING
88 Control lever for tilt. Tilt does not work. WARNING
89 Control lever for side shift. Side shift does not work. WARNING
90 Control lever for spreading. Spreading not working. WARNING
91 Control lever for extra load handling function. Extra load handling WARNING
function does not work.
92 Joystick or mini-wheel. Joystick or mini-wheel not working. WARNING
93 Mini steering wheel. Mini-wheel not working. WARNING
94 Water valve cab heat. Cab heat cannot be adjusted. INFORMATION
96 Sensor cab temperature. Temperature control cab not working. INFORMATION
97 Sensor outdoor temperature. Temperature control cab not working. INFORMATION
98 Sensor temperature outlet fan. Temperature control cab not working. INFORMATION
99 Sensor temperature refrigerant. Temperature control cab not INFORMATION
working.
101 Redundant voltage feed left control unit frame D797-1. STOP: Turn ignition off and on.
102 Redundant voltage feed right control unit frame D797-1. STOP: Turn ignition off and on.
103 Voltage feed control unit frame D797-1. No power supply to STOP: Check fuse F58-2:A1. See 6.2.14
components from control unit frame front. Fuses for electrical system.
104 Control breaker voltage to control unit frame D797-1. Control breaker WARNING: Check fuse 58-2:A1. See
cannot be disengaged. All hydraulic functions blocked. 6.2.14 Fuses for electrical system.
105 Voltage feed sensor. Pressure sensor for lift cylinder. STOP
106 Cooling fan hydraulic oil not working. WARNING
107 Work light mast not working. INFORMATION: Check the lamp. See
6.2.15 Lighting.
108 High beams not working.
109 Low beams not working.
111 Running lights not working.
112 Cooling fan oil brake system not working. WARNING
113 Control valve load handling. Lift and lower not working. WARNING
114 Control valve load handling. Tilt not working or lift and lower carriage WARNING
not working.
115 Direction indicator left not working. INFORMATION: Check the lamp. See
6.2.15 Lighting.
116 Direction indicator right not working.
117 Starter motor not working. WARNING
118 Tail lights not working. INFORMATION: Check the lamp. See
6.2.15 Lighting.
119 Brake light left not working.
120 Brake light right not working.
121 Back-up alarm not working. INFORMATION


122 Magnetic clutch AC compressor. Air conditioning not working. INFORMATION
123 Magnetic clutch AC compressor. Air conditioning not working. INFORMATION
124 Disengagement hydraulic oil pump working hydraulics not working. WARNING
125 Regenerating lift right not working. WARNING
126 Regenerating lift left not working. WARNING
132 The machine's data file is missing. Some functions on the machine STOP
do not work.
133 Sensor hydraulic pressure lift cylinder. Scale, regenerating and STOP
slacken chain logics not working. Overload system not working.
Error code 150 activated.
134 Sensor hydraulic pressure tilt cylinder. Overload system not working. STOP
Error code 150 activated.
135 Feedback from cooling fan oil brake system. WARNING
137 Control valve load handling. Lift not working. WARNING
138 Control valve load handling. Lower not working. WARNING
139 Control valve load handling. Tilt in or lift not working. WARNING
140 Control valve load handling. Tilt out or lower not working. WARNING
141 Solenoid valve parking brake. Parking brake cannot be released. STOP
142 Tilt not working (for hydraulic servo). WARNING
143 Spreading and twistlocks on top lift attachment not working. WARNING
144 Spreading and twistlocks on top lift attachment not working. WARNING
145 High oil temperature in brake system. Reduced braking capacity. If WARNING: Check that the cooling fan
temperature continues to increase, speed limitation will take place. works. Check that the radiator is not
clogged. Check the oil level in brake
system. See 6.2.8 Oil brake system.
146 Sensor, oil temperature in brake system. Incorrect temperature WARNING
display. Immediate speed limitation.
147 High hydraulic oil temperature. WARNING: Check that the cooling fan
works. Check that the radiator is not
clogged. Check the hydraulic oil level.
See 6.2.9 Hydraulic system.
148 Sensor hydraulic oil temperature. Incorrect temperature display. WARNING
149 Sensor fuel level. Incorrect display of fuel volume (empty or full). INFORMATION: Check fuel volume
manually in tank. See 6.2.2 Fuel system.
150 Overload protection not working. STOP: Turn ignition off and on.
151 Voltage feed to control unit frame option D797-2. STOP: Turn ignition off and on.
152 Voltage feed to control unit frame option D797-2. STOP: Turn ignition off and on.
153 Voltage feed control unit frame option D797-2. No power supply to STOP: Check fuse F58-2:C3. See 6.2.14
components from control unit frame option. Fuses for electrical system.
154 Control breaker voltage to control unit frame option D797-2. Control WARNING: Check fuse F58-3:E5. See
breaker cannot be disengaged. All hydraulic functions blocked. 6.2.14 Fuses for electrical system.
155 Voltage feed sensor. STOP
157 High beam rear not working (at revolving driver's seat). INFORMATION: Check the lamp. See
6.2.15 Lighting.
158 Low beam rear not working (at revolving driver's seat).
160 Extra work light frame front not working. INFORMATION: Check the lamp. See
6.2.15 Lighting.
161 Solenoid valve steering right. Joystick or mini-wheel not working. STOP


162 Solenoid valve steering left. Joystick or mini-wheel not working. STOP
163 Lift trolley not working. WARNING
164 Lower trolley not working. WARNING
165 Control valve load handling. Side shift right does not work. WARNING
166 Control valve load handling. Side shift left does not work. WARNING
167 Control valve load handling. Spreading in not working. WARNING
168 Control valve load handling. Spreading out not working. WARNING
169 Revolving driver's seat. Indication position on seat not working. WARNING
170 Revolving driver's seat. Change of steering angle not working. STOP
171 Revolving driver's seat. Change of steering angle not working. STOP
172 Revolving driver's seat. Tail lights front not working. INFORMATION
Lateral sliding cab not working.
173 Revolving driver's seat. Revolving of driver's seat not working. STOP
174 Revolving driver's seat. Revolving of driver's seat not working. STOP
187 Control valve joystick/mini-wheel. Joystick or mini-wheel not working. STOP
188 Control valve load handling. Lift and lower not working. WARNING
189 Control valve load handling. Side shift does not work. WARNING
190 Control valve load handling. Spreading not working. WARNING
193 Brake light right front not working (for revolving operator's seat). INFORMATION: Check the lamp. See
6.2.15 Lighting.
194 Brake light left front not working (for revolving operator's seat). INFORMATION: Check the lamp. See
6.2.15 Lighting.
451 Voltage feed control unit KID D795. WARNING: Turn ignition off and on.
452 Voltage feed control unit KID D795. WARNING: Turn ignition off and on.
460 Communication error with control unit KID D795. Incorrect values STOP
in operating menus.
461 Communication error with control unit KID D795. Error codes from STOP
other control units cannot be shown.
500 Time for service. Bring in the machine for service.
Error codes engine

For contact with engine manufacturer, use Volvo code.
• Display indicates error code acc. to SAE J1939
SPN / FMI
• J1587 indicates error code acc. to SAE J1587 (for Volvo: Vodia).
PID, PPID, SID, PSID / FMI
Table Specifications FMI
FMI Description SAE-text

0 Too high value. Data valid, but higher than normal operating range.
1 Too low value. Data valid, but lower than normal operating range.
2 Incorrect data. Intermittent or incorrect data.
3 Electrical problem. Abnormally high voltage or short-circuit to higher voltage.
4 Electrical problem. Abnormally low voltage or short-circuit to lower voltage.
5 Electrical problem. Abnormally low current or open circuit.

FMI Description SAE-text

6 Electrical problem. Abnormally high current or short-circuit to ground.
7 Mechanical problem. Incorrect response from mechanical system.
8 Mechanical problem or electrical Abnormal frequency.
problem.
9 Communication error. Abnormal update rate.
10 Mechanical problem or electrical Abnormally wide variations.
problem.
11 Unknown malfunction. Non-identifiable malfunction.
12 Component error. Incorrect unit or component.
13 Incorrect calibration. Values outside calibration values.
14 Unknown malfunction. Special instructions.
15 Unknown malfunction. Reserved for future use.
16 Too high value. Data valid, but higher than normal operating range. Moderately
serious level.
17 Too low value. Data valid but under normal operating range: The least serious level.
18 Too low value. Data valid, but lower than normal operating range. Moderately
serious level.
19 Communication error. Received network data incorrect.
20-30 Reserved for SAE-allocation.
31 FMI not available or the condition Not available or the condition exists.
indicated by SPN exists.
Table Error codes Volvo TAD761VE, TAD762VE and TAD1360VE
Description Action
Display
SPN/FMI J1587
51/3 PID51/3 Throttle position sensor, cable short-circuited to voltage. STOP
51/4 PID51/4 Throttle position sensor, cable open circuit or short-circuited STOP
to ground.
51/5 PID51/5 Throttle position sensor, cable short-circuited. Throttle fully STOP
open.
91/9 PPID132/9 Signal from accelerator pedal, communication error. STOP
94/1 PID94/1 Sensor fuel pressure, low fuel pressure. STOP
94/3 PID94/3 Sensor fuel pressure, cable short-circuited to voltage. STOP
94/5 PID94/5 Sensor fuel pressure, cable open circuit or short-circuited to STOP
ground.
94/7 PID94/7 Sensor fuel pressure, incorrect response from mechanical STOP
system.
97/0 PID97/0 Water in fuel. WARNING: Drain fuel
pre-filter, see 6.2.2 Fuel
system.
97/3 PID97/3 Sensor water in fuel, cable short-circuited to voltage. STOP
97/4 PID97/4 Sensor water in fuel, cable open circuit or short-circuited to STOP
ground.
98/1 PID98/1 Low engine oil level. STOP: Check the oil level in
the engine. See 6.2.6 Engine
oil.

Description Action
Display
SPN/FMI J1587
98/3 PID98/3 Low engine oil level, cable short-circuited to voltage. STOP: Check the oil level in
the engine. See 6.2.6 Engine
oil.
98/4 PID98/4 Low engine oil level, abnormally low voltage or short-circuit to STOP: Check the oil level in
lower voltage. the engine. See 6.2.6 Engine
oil.
98/5 PID98/5 Low engine oil level, cable open circuit or short-circuited to STOP: Check the oil level in
ground. the engine. See 6.2.6 Engine
oil.
100/1 PID100/1 Low engine oil pressure. Reduced engine power or engine is STOP: Check the oil level in
turned off. the engine. See 6.2.6 Engine
oil.
100/3 PID100/3 Sensor, oil pressure, cable short-circuited to voltage. STOP
100/5 PID100/5 Sensor oil pressure, cable open circuit or short-circuited to STOP
ground.
105/0 PID105/0 Too high charge-air temperature. Reduced engine power. STOP
105/4 PID105/4 Sensor charge-air temperature, cable short-circuited to ground. STOP
105/5 PID105/5 Sensor charge-air temperature, cable open circuit or STOP
short-circuited to ground.
106/0 PID106/0 High charge-air pressure. Reduced engine power. STOP
106/3 PID106/3 Sensor, boost pressure, cable short-circuited to voltage. STOP
106/5 PID106/5 Sensor charge-air pressure, cable open circuit. The engine is STOP
smoking more than usual during acceleration/loading.
107/0 PID107/0 Low air pressure. STOP
107/3 PID107/3 Sensor, air pressure, cable short-circuited to voltage. STOP
107/4 PID107/4 Sensor air pressure - abnormally low voltage or short-circuiting STOP
to lower voltage.
107/5 PID107/5 Sensor air pressure, cable open circuit. STOP
108/3 PID108/3 Sensor, air pressure, cable short-circuited to voltage. STOP
108/4 PID108/4 Sensor air pressure - abnormally low voltage or short-circuiting STOP
to lower voltage.
110/0 PID110/0 High coolant temperature. Reduced engine power or engine STOP: Check coolant level.
is turned off. See 6.2.5 Cooling system.
110/4 PID110/4 Sensor coolant temperature - abnormally low voltage or STOP

short-circuiting to lower voltage.
110/5 PID110/5 Sensor coolant temperature, cable open circuit. Preheating STOP
activated even when engine is warm. Engine hard to start.
111/1 PID111/1 Low coolant level. Reduced engine power. STOP: Check coolant level.
See 6.2.5 Cooling system.
111/3 PID111/3 Sensor coolant level, cable short-circuited to voltage STOP
111/5 PID111/5 Sensor coolant level, cable open circuit or short-circuited to STOP
ground.
153/0 PID153/0 Too high crankcase ventilation pressure. The engine is switched STOP
off.

Description Action
Display
SPN/FMI J1587
153/3 PID153/3 Sensor crankcase ventilation pressure, cable short-circuited STOP
to voltage.
153/5 PID153/5 Sensor crankcase ventilation pressure, cable open circuit or STOP
158/1 PID158/1 Low battery voltage, CIU, cable short-circuited to ground, faultly STOP
alternator or battery. The engine may be difficult to start.
158/3 PID158/3 Sensor battery voltage, EMS, cable short-circuited to voltage. STOP
158/4 PID158/4 Sensor battery voltage, EMS, abnormally low voltage or STOP
172/4 PID172/4 Sensor air temperature - abnormally low voltage or STOP
172/5 PID172/5 Sensor air temperature, cable open circuit or short-circuited STOP
to ground.
175/0 PID175/0 High engine oil temperature. Reduced engine power. STOP
175/4 PID175/4 Sensor oil temperature, abnormally low voltage or STOP
175/5 PID175/5 Sensor oil temperature, cable open circuit or short-circuited to STOP
ground.
190/0 PID190/0 Engine rpm too high. STOP
354/3 PID354/3 Relative humidity, cable short-circuited to voltage. STOP
354/5 PID354/5 Relative humidity, faulty connection, cable or sensor. STOP
Hygrometer shows 50%.
442/4 PPID272/4 Humidity temperature, abnormally low voltage or short-circuit STOP
to lower voltage.
442/5 PPID272/5 Humidity temperature, cable open circuit or short-circuited, fault STOP
connection or sensor. Temperature shown as 20 °C.
608 SID250 J1587 communication bus. STOP
608/9 PPID98/9 Signal from start/stopp, abnormal upadte rate. STOP
608/9 PPID132/9 Signal from accelerator pedal, abnormal update rate. STOP
608/9 PSID201/9 Internal error control unit engine (J1939 communication bus). STOP
620/3 SID232/3 +5V voltage feed sensor engine, cable short-circuited to voltage. STOP
620/4 SID232/4 +5V voltage feed sensor engine, - abnormally low voltage or STOP
628/2 SID240/2 Memory error in motor control, irregular signal. STOP
628/12 SID240/12 Memory error in motor control, faulty unit or component. STOP
629/8 SID254/8 Internal error engine control unit. STOP
Engine shut-off: the engine cannot be started. Engine running:
engine misfires.
629/12 SID254/12 Internal error engine control unit. STOP
engine misfires.
630/2 SID253/2 Electrical fault engine (EEPROM), intermittent or incorrect data. STOP
630/12 SID253/12 Electrical fault engine (EEPROM), faulty unit or component. STOP
630/14 SID253/14 Electrcial fault engine (EEPROM), Special Instructions. STOP

Description Action
Display
SPN/FMI J1587
636/2 SID21/2 Sensor speed camshaft, irregular signal. The engine takes STOP
longer to start than normal. The engine is running normally
once it has started.
636/3 SID21/3 Sensor speed camshaft, no signal. The engine takes longer to STOP
start than normal. The engine is running normally once it has
started.
636/8 SID21/8 Sensor speed camshaft, abnormal frequency. The engine takes STOP
longer to start than normal. The engine is running normally
once it has started.
637/2 SID22/2 Flywheel speed sensor, no signal. The engine is extremely STOP
difficult to start and runs unevenly or stops.
637/3 SID22/3 Sensor speed flywheel, abnormal frequency. The engine is STOP
extremely difficult to start and runs unevenly or stops.
637/8 SID22/8 Sensor speed flywheel, irregular signal. The engine is extremely STOP
difficult to start and runs unevenly or stops.
639/2 SID231/2 Communication error control unit engine (J1939). STOP

647/3 SID33/3 Cooling fan control, cable short-circuited to voltage. STOP
647/4 SID33/4 Cooling fan control, abnormally low voltage or short-circuit to STOP
lower voltage.
647/5 SID33/5 Cooling fan control, cable open circuit or short-circuited to STOP
ground.
651/3 SID1/3 Electrical fault, injector cylinder 1, cable short-circuited to STOP
voltage.
651/4 SID1/4 Compression failure or faulty injector cylinder 1, abnormally low STOP
voltage or shorted-circuit to a lower voltage.
651/5 SID1/5 Electrical problem, injector cylinder 1. Engine only runs on 5 STOP
cylinders and has reduced power.
651/12 SID1/12 Compression fault or injector failure cylinder 1. STOP
voltage.
voltage.
voltage.

Description Action
Display
SPN/FMI J1587
voltage.
voltage.
677/0 PPID3/0 Start relay on the starter motor, data valid, but above normal STOP
working range.
677/3 PPID3/3 Start relay on starter motor, cable short-circuited to voltage or STOP
activated too long. Starter motor does not run.
677/4 PPID3/4 Start relay on the starter motor, abnormally low voltage or STOP
short-circuit to lower voltage.
677/5 PPID3/5 Start relay on the starter motor, cable open circuit or STOP
677/10 PPID3/10 Start relay on the starter motor, abnormally large variations. STOP
729/3 SID70/3 Sensor preheating, cable short-circuited to voltage. STOP
729/4 SID70/4 Sensor preheating, abnormally low voltage or short-circuiting STOP
to lower voltage.
729/5 SID70/5 Sensor preheating, cable open circuit or incorrectly preheating STOP
relay. The engine hard to start in cold weather.
858/3 PSID82/3 AdBlue external filter heater, cable short-circuited to voltage. STOP
858/4 PSID82/4 AdBlue external filter heater, abnormally low voltage or STOP
short-circuited to a lower voltage.
858/5 PSID82/5 AdBlue external filter heater, cable open circuit or short-circuited STOP
to ground.
859/3 PSID107/3 AdBlue external filter heater, cable short-circuited to voltage. STOP
859/4 PSID107/4 AdBlue external filter heater, abnormally low voltage or STOP
859/5 PSID107/5 AdBlue external filter heater, cable open circuit or short-circuited STOP
to ground.
970/4 PPID6/4 Sensor ignition off (stop request), abnormally low voltage or STOP
Not applicable to TAD1360VE
975/3 PID26/3 Fan speed, cable short-circuited to voltage. STOP
1080/3 SID211/3 +5V voltage feed sensor engine, cable short-circuited to voltage. STOP

Description Action
Display
SPN/FMI J1587
1080/4 SID211/4 +5V voltage feed sensor engine, - abnormally low voltage or STOP
1136/0 PPID55/0 ECU temperature, control unit too hot. STOP
1188/3 SID32/3 Wastegate, cable short-circuited to voltage. STOP
1188/4 SID32/4 Wastegate, abnormally low voltage or short-circuit to lower STOP
voltage.
1188/5 SID32/5 Wastegate, short-circuiting to voltage, ground, or open circuit. STOP
Warning light comes on, reduced engine power.
1231/2 PSID232/2 CAN2 J1939 communication link, intermittent or incorrect data. STOP
1231/9 PSID229 CAN frames from UDS/ACM, timeout. No AdBlue additive. STOP
1675/0 PPID3/9 Starter motor output power, too high value. STOP
1675/3 PPID3/3 Starter motor output power, cable short-circuited to voltage. STOP
1675/4 PPID3/4 Starter motor output power, abnormally low voltage or STOP
1675/5 PPID3/5 Starter motor output power, cable open circuit or short-circuited STOP
to ground.
1675/10 PPID3/10 Starter motor output power, abnormally large variations. STOP
1761/3 PPID278/3 After-treatment reagents, level. SCH. Temperature shown as STOP
20 °C.
1761/5 PPID278/5 After-treatment reagents, level, cable open circuit or STOP
1761/11 PPID278 After-treatment reagents, level, no identifiable fault. STOP
/11
1761/13 PPID278 After-treatment reagents, level, low level, limited cooling STOP
/13 capacity. Temperature shown as 20 °C.
1761/14 PPID278 After-treatment reagents, level, special instructions. STOP
/14
engine switches to idle mode and can only be stopped by using
the emergency stop.
2061/12 PSID77/12 AdBlue ECU EEPROM, faulty unit or component. STOP
2061/13 PPID278 After-treatment reagent, level, values outside calibration values. STOP
/13
2061/14 PPID385 AdBlue ECU voltage, internal supply, critical fault. SCR-system STOP
/14 does not start.
2061/14 PPID273 After-treatment reagent, pressure, heating defect. Warning STOP
/14 indicator and reduced engine power.
2898/3 PPID3/3 Starter motor output power (Penta), cable short-circuited to STOP
voltage.
2898/4 PPID3/4 Starter motor output power (Penta), abnormally low voltage or STOP
2898/5 PPID3/5 Starter motor output power (Penta), cable open circuit or STOP
3031/0 PPID274/0 After-treatment reagent, tank temperature, too high temperature. STOP
No AdBlue added.

Description Action
Display
SPN/FMI J1587
3031/1 PPID274/1 After-treatment reagent, tank temperature, too low temperature. STOP
No AdBlue added.
3031/4 PPID274/4 After-treatment reagent, tank temperature, cable short-circuited STOP
to ground. No AdBlue added.
3031/5 PPID274/5 After-treatment reagent, tank temperature, open circuit. No STOP
AdBlue added.
3051/11 PSID90/11 SCR-system performance, no identifiable fault. STOP
3226/2 PPID270/2 NOx gas outlet, short-circuited cable, intermittent or incorrect STOP
data.
3241/0 PPID386/0 Exhaust temperature sensor #1, too high value. STOP
3241/2 PPID386/2 Exhaust temperature sensor #1, intermittent or incorrect data. STOP
3241/4 PPID386/4 Exhaust temperature sensor #1, abnormally low voltage or STOP
3241/5 PPID386/5 Exhaust temperature sensor #1, cable open circuit or STOP
3361/3 PSID89/3 AdBlue metering valve, short-circuited to the battery. No AdBlue STOP
added.
3361/4 PSID89/4 AdBlue metering valve, short-circuited to the ground. No AdBlue STOP
added.
3361/5 PSID89/5 AdBlue metering valve, open circuit. No AdBlue added. STOP
3361/7 PSID89/7 AdBlue metering valve, valve or hose clogged. No AdBlue STOP
added.
3361/10 PSID89/10 AdBlue metering valve, valve jammed. No AdBlue added. STOP
3363/3 PSID75/3 AdBlue tank heating valve, intermittent or incorrect data. STOP
3363/4 PSID75/4 AdBlue tank heating valve, abnormally low voltage or STOP
short-circuit to a lower voltage.
3363/5 PSID75/5 AdBlue tank heating valve, cable open circuit or short-circuited STOP
to ground.
3464/3 PSID7/3 Actuator motor throttle control, intermittent or incorrect data. STOP
3464/4 PSID7/4 Actuator motor throttle control, abnormally low voltage or STOP
3464/5 PSID7/5 Actuator motor throttle control, cable open circuit or STOP
3464/12 PSID7/12 Actuator motor throttle control, faulty unit or component. STOP
3509/3 SID232/3 Power supply sensor #1 (+5V DC), cable short-circuited to STOP
voltage.
3509/4 SID232/4 Power supply sensor #1 (+5V DC), abnormally low voltage or STOP
3510/3 SID211/3 Power supply sensor #2 (+5V DC), cable short-circuited to STOP
voltage.
3510/4 SID211/4 Power supply sensor #2 (+5V DC), abnormally low voltage or STOP
3511/3 PSID77/3 AdBlue ECU EEPROM. ECU inner supply high. STOP
3511/4 PSID77/4 AdBlue ECU EEPROM. ECU inner supply low. STOP
3512/13 PPID273 After-treatment reagent, pressure, values outside calibration STOP
/13 values.

Description Action
Display
SPN/FMI J1587
3522/0 PSID91/0 After-treatment reagent, consumption, too high value. STOP
3522/1 PSID91/1 After-treatment reagent, consumption, too low value. STOP
4334/1 PPID273/1 After-treatment reagent, pressure, leakage. Warning indicator STOP
and reduced engine power.
4334/2 PPID273/2 After-treatment reagent, pressure, reasonableness. Warning STOP
indicator and reduced engine power.
4334/4 PPID273/4 After-treatment reagent, pressure, cable short-circuited to STOP
ground. Warning indicator and reduced engine power.
4334/5 PPID273/5 After-treatment reagent, pressure, open circuit. Warning STOP
4334/7 PPID273/7 After-treatment reagent, pressure, accumulated fault. Warning STOP
4334/9 PPID273/9 After-treatment reagent, pressure, abnormal update rate. STOP
4334/10 PPID273 After-treatment reagent, pressure, abnormally large variations. STOP
/10
4337/0 PPID275/0 Reagent filter temperature, too high temperature. No AdBlue STOP
added.
4337/1 PPID275/1 Reagent filter temperature, too low temperature, electric heating STOP
not possible. No AdBlue added.
4337/2 PPID275/2 Reagent filter temperature, outside operating range. No AdBlue STOP
added.
4337/4 PPID275/4 Reagent filter temperature, cable short-circuited to ground. No STOP
AdBlue added.
4337/5 PPID275/5 Reagent filter temperature, open circuit. No AdBlue added. STOP
4354/3 PSID103/3 AdBlue ECU hose heater 1, cable short-circuited to voltage. STOP
4354/4 PSID103/4 AdBlue ECU hose heater 1, abnormally low voltage or STOP
4354/5 PSID103/5 AdBlue ECU hose heater 1, cable open circuit or short-circuited STOP
to ground.
4354/14 PSID103 AdBlue ECU hose heater 1, special instructions. STOP
/14
to ground.
4355/14 PSID84/14 AdBlue ECU hose heater 2, special instructions. STOP
to ground.
4356/14 PSID102 AdBlue ECU hose heater 3, special instructions. STOP
/14

Description Action
Display
SPN/FMI J1587
to ground.
4374/0 PSID87/0 AdBlue pump motor speed, too high speed. No AdBlue added. STOP
4374/1 PSID87/1 AdBlue pump motor speed, too low speed. No AdBlue added. STOP
4374/10 PSID87/10 AdBlue pump motor speed, no signal from pump. No AdBlue STOP
added.
4376/3 PSID105/3 AdBlue directional control valve, short-circuited to the battery. STOP
4376/4 PSID105/4 AdBlue directional control valve, short-circuited to the ground. STOP
4376/5 PSID105/5 AdBlue directional control valve, open circuit. STOP
4376/7 PSID105/7 AdBlue directional control valve, mechanical problem. STOP
4811/1 PPID8/1 Cooling piston oil pressure, too high value. STOP
4811/2 PPID8/2 Cooling piston oil pressure, intermittent or incorrect data. STOP
4811/3 PPID8/3 Cooling piston oil pressure, cable short-circuited to voltage. STOP
4811/5 PPID8/5 Cooling piston oil pressure, cable open circuit or short-circuited STOP
to ground.
5246/0 PSID46/0 Inducing level, inducing level 3, 4 or 5. Warning indication and STOP
reduced engine power.
5246/15 PSID46/15 Inducing level, inducing level 1 or 2. Warning indication and STOP
reduced engine power.
5394/1 PSID90/1 SCR-system's performance, metering error. Warning indication, STOP
error message on display and reduced engine power.
520233/3 PSID85/3 AdBlue ECU main relay, cable short-circuited to voltage. STOP
520233/4 PSID85/4 AdBlue ECU main relay, abnormally low voltage or short-circuit STOP
to a lower voltage.
520233/5 PSID85/5 AdBlue ECU main relay, cable open circuit or short-circuited STOP
to ground.
520233/6 PSID85/6 AdBlue ECU main relay, abnormally high current or short-circuit STOP
to chassis.
520192/1 PPID8/1 Low piston cooling pressure, engine stops. STOP
520192/3 PPID8/3 Sensor cooling piston pressure, cable short-circuited to voltage. STOP
520192/4 PPID8/4 Sensor cooling piston pressure, abnormally low voltage or STOP
520192/5 PPID8/5 Low cooling piston pressure, cable open circuit or short-circuited STOP
to ground.
520194/X PPID4/X Starter motor (start request). STOP
520195/4 PPID6/4 Sensor ignition off (stop request), abnormally low voltage or STOP
Not applicable to TAD1360VE

Error codes transmission
Table Error codes Dana TE13 and TE17
Description action
Code
00/50 Memory error in control unit transmission. Transmission in STOP
locked neutral position ("shut down").
20/60 Oil pressure sensor. Transmission in locked neutral position STOP
("shut down").
20/61 Oil pressure sensor. Transmission in locked neutral position STOP
("shut down").
21/02 Solenoid valves VFS. Transmission in locked neutral position WARNING
("shutdown").
30/04 Low battery voltage. STOP
30/05 High battery voltage. WARNING
31/00 Reference voltage to sensor is too low. WARNING
31/01 Reference voltage to sensor is too high. WARNING
40/06 Wrong direction from the gear selector. Transmission in neutral WARNING
position.
40/08 The direction of the driver's seat was changed when: the INFORMATION! Stop the machine, move the
parking brake was not activated, or/and the gear selector was gear selector to neutral position and activate
not in neutral position, and/or the machine was not stationary. the parking brake until the error disappears.
Transmission in neutral position.
41/06 Incorrect gear selection from the gear selector. Control unit WARNING
does not allow change of gear range, however, operation of
machine is possible.
42/04 Actual gear ratio too low. One or several clutches slipping. STOP or WARNING
42/05 Actual gear ratio too high. One or several clutches slipping. STOP or WARNING
43/03 Sensor temperature torque converter WARNING
43/07 Torque converter's temperature exceeds 100 °C. WARNING: Note the error and try to reduce
temperature in torque converter by operating
calmly.
43/08 Torque converter's temperature exceeds 125 °C. WARNING: Stop the machine, select neutral
and apply full throttle (limited to 50%) to
The control unit protects the transmission and does not allow
cool the transmission oil so that temperature
the temperature in the torque converter to exceed the maximum
drops below 100 °C (error code 43/03
limit. Transmission in locked neutral position ("shut down").
disappears).
The engine is limited to 50 % of the maximum speed.
When temperature in torque converter is
below 100 °C, resume work with machine.
44/10 Position accelerator pedal message from engine's control unit. WARNING
45/06 Faulty logic from the digital inputs for speed limitation. The INFORMATION!
control unit lowers the power to reduce speed.
46/05 Max. torque at inching has been exceeded. WARNING: Stop the machine, select neutral.
Select gear again.

Description action
Code
50/00 Sensor oil pressure, short-circuiting to ground. Transmission STOP
control unit activates "limp home".
50/01 Sensor oil pressure, open circuit. Transmission control unit STOP
activates "limp home".
51/00 Sensor transmission oil temperature, short-circuiting to ground. WARNING
51/01 Sensor transmission oil temperature, open circuit. WARNING
52/00 Analogue input 2 (cable A29) related fault: analogue input INFORMATION!
short-circuited to ground. The control unit indicates the fault
and use its lowest set value.
52/01 Analogue input 2 (cable A29) related fault: analogue input is INFORMATION!
not connected. The control unit indicates the fault and use its
lowest set value.
53/00 Analogue input 3 (cable B17) related fault: analogue input INFORMATION!
53/01 Analogue input 3 (cable B17) related fault: analogue input is INFORMATION!
lowest set value.
54/00 Reference voltage sensor 5V, short-circuiting to ground. WARNING
54/01 Reference voltage sensor 5V, open circuit. WARNING
lowest set value.
lowest set value.
60/00 Sensor rpm torque converter, short-circuiting to ground. STOP or WARNING
If several rpm signals or the engine rpm signal are incorrect,
control unit transmission activates "limp home".
60/01 Sensor rpm torque converter, open circuit. STOP or WARNING
61/00 Sensor rpm output shaft, short-circuiting to ground. STOP or WARNING
61/01 Sensor rpm output shaft, open circuit. STOP or WARNING
62/00 Sensor engine rpm, short-circuiting to ground. STOP or WARNING

Description action
Code
62/01 Sensor engine rpm, open circuit. STOP or WARNING
63/00 Sensor rpm turbine, short-circuiting to ground. STOP or WARNING
63/01 Sensor rpm turbine, open circuit. STOP or WARNING
70/00 Solenoid valve VFS front. Transmission control unit 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.
72/00 Solenoid valve VFS rear. Transmission control unit activates STOP: Stop the machine and shift to neutral.
73/00 Solenoid valve VFS 1/3. Control unit transmission activates STOP: Stop the machine and shift to neutral.
74/00 Analogue output signal 4 (line B01) related error: output signal WARNING!
is short-circuited to ground.
is not connected or short-circuited to battery.
exceeds 1400 mA.

Description action
Code
74/03 Analogue output signal 4 (line B01) related error: current value WARNING!
for output signal is not within the approved range. Incorrect
impedance.
exceeds 1400 mA.
75/03 Analogue output signal 5 (line B03) related error: current value WARNING!
impedance.
76/00 Analogue output signal 6 (line B05) related error: output signal STOP!
exceeds 1400 mA.
76/03 Analogue output signal 6 (line B05) related error: current value STOP!
impedance.
77/02 All gear packages disengaged. Transmission in locked neutral STOP
position ("shut down").
80/00 Solenoid valve drive, short-circuited to ground. Transmission STOP
in locked neutral position ("shut down").
80/01 Solenoid valve drive, open circuit or short-circuited to battery. STOP
Transmission in locked neutral position ("shut down").
81/00 Digital output signal 1 (line A15) related error: output signal is STOP! Stop the machine, select neutral
short-circuited to ground. Transmission control unit activates and then select travel direction reverse. If it
“limp home”. works, the transmission will function but in
“Limp Home” condition.
Contact service.
81/01 Digital output signal 1 (line A15) related error: output signal STOP! Stop the machine, select neutral
is not connected or short-circuited to battery. Transmission and then select travel direction reverse. If it
control unit activates “limp home”. works, the transmission will function but in
“Limp Home” condition.
Contact service.
82/00 Solenoid valve gear selection 1/3, short-circuited to ground. STOP: Stop the machine and shift to neutral.
Transmission control unit activates "limp home". Select reverse gear.
82/01 Solenoid valve gear selection 1/3, open circuit or short-circuited STOP: Stop the machine and shift to neutral.
to battery. Transmission control unit activates "limp home". Select reverse gear.
83/00 Solenoid valve drive, short-circuited to ground. Transmission STOP
in locked neutral position ("shut down").
83/01 Solenoid valve drive, open circuit or short-circuited to battery. STOP
Transmission in locked neutral position ("shut down").
90/xx - Transmission fault Transmission in locked neutral position STOP or INFORMATION
99/xx ("shut down").
95.71 Control unit transmission cannot interpret in-data. STOP

Description action
Code
99.90 Incorrect software in control unit. STOP
99.95 High CAN bus load detected: APC200 cannot process all INFORMATION!
incoming messages due to too many CAN messages.
1 Display KCS display (position D) or ECU 793.
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 state, the driver can use the transmission's first two gears in
each direction. If the fault occurs in a higher gear, the driver must
shift down manually to first or second gear in order to continue.
The control unit uses the default values for the modulation of the
clutches.
• “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.
Table Error codes Dana TE32
Description action
Code SPN/FMI
00/50 7F09D/C Memory error in control unit transmission. Transmission in STOP
locked neutral position (Shut down).
20/60 7F065/1 Oil pressure sensor. Transmission in locked neutral position STOP
(Shut down).
20/61 7F065/0 Oil pressure sensor. Transmission in locked neutral position STOP
(Shut down).
21/00 7F069/1 Oil pressure sensor has too low oil pressure. Transmission STOP
locked in neutral position (Shut-down).
21/01 7F069/0 Oil pressure sensor has too high oil pressure. Transmission STOP
22/00 7F06A/1 Oil pressure sensor has too low oil pressure. Transmission STOP
22/01 7F06A/0 Oil pressure sensor has too high oil pressure. Transmission STOP
23/00 7F06B/1 Oil pressure sensor has too low oil pressure. Transmission STOP
23/01 7F06B/0 Oil pressure sensor has too high oil pressure. Transmission STOP

Description action
Code SPN/FMI
24/00 7F06C/1 Oil pressure sensor has too low oil pressure. Transmission STOP
24/01 7F06C/0 Oil pressure sensor has too high oil pressure. Transmission STOP
30/04 7F090/1 Low battery voltage. STOP
30/05 7F090/0 High battery voltage. WARNING
31/00 7F093/1 Reference voltage to sensor is too low. WARNING
31/01 7F093/0 Reference voltage to sensor is too high. WARNING
34/00 7F0BB/1F Sensor rpm drum faulty. Transmission control unit activates STOP
Limp home.
34/01 7F0BC/1 Measured turbine rpm at start is too low. Transmission in STOP
locked neutral position (Shutdown).
34/02 7F0BD/0 Measured turbine rpm at start is too high. Transmission in STOP
locked neutral position (Shutdown).
34/03 7F0BE/1 The transmission indicates that the system pressure is STOP
missing even though it should exist. Transmission in locked
neutral position (Shut down).
34/04 7F0BE/0 The transmission indicates that the system pressure exists STOP
even though it should not. Transmission in locked neutral
position (Shut down).
40/06 7F05E/2 Wrong direction from the gear selector. Transmission in WARNING
neutral position.
40/08 7F041/1F The seat's direction was changed when the parking brake STOP: Stop the machine, select
was not activated, and/or the gear selector was not in neutral gear, and apply the parking
neutral position, and/or the machine was not at a standstill. brake until the problem disappears.
Transmission in neutral position.
41/06 7F05F/2 Incorrect gear selection from the gear selector. Transmission WARNING
control unit does not allow change of gear range, however,
operation of machine is possible.
42/04 7F080/1 Actual gear ratio too low. One or several clutches slipping. STOP or WARNING
42/05 7F080/0 Actual gear ratio too high. One or several clutches slipping. STOP or WARNING
43/03 7F063/0 Signal from Sensor engine rpm and oil temperature WARNING
transmission outside valid range.
43/07 7F063/10 Torque converter's temperature exceeds 100 °C. WARNING: Note the error and try
to reduce temperature in torque
converter by operating calmly.
43/08 7F063/0 Torque converter's temperature exceeds 120 °C. WARNING: Stop the machine,
select neutral and apply full
The control unit transmission protects the transmission and
throttle (limited to 50%) to cool
does not allow the temperature in the torque converter to
the transmission oil so that
exceed the maximum limit. Transmission in locked neutral
temperature drops below 100 °C
position (Shut down). The engine is limited to 50 % of the
(error code 43/03 disappears).
maximum speed.
When temperature in torque
converter is below 100 °C, resume
work with machine.
44/10 7F0C6/9 Incorrect signal for gas pedal position from engine control WARNING
unit.
45/06 7F048/2 Invalid combination for redundant digital speed inputs. WARNING
Control unit transmission limits the speed.

Description action
Code SPN/FMI
46/05 7F036/F Max. torque at inching has been exceeded. WARNING: Stop the machine,
select neutral. Select gear again.
47/01 7F07B/10 Transmission has exceeded the limit value for upper rpm. Let up the gas pedal and reduce
the machine's speed.
48/00 7F0B3/0 Disengaged 4WD/2WD-selector has jammed in engaged WARNING
position or the feedback signal is wrong.
48/01 7F0B3/1 Engaged 4WD/2WD-selector has jammed in engaged WARNING
position or the return signal is wrong.
49/00 7F0B4/0 Disengaged Low/High-selector has jammed in engaged WARNING
position or the feedback signal is wrong.
49/01 7F0B4/1 Engaged Low/High-selector has jammed in engaged position WARNING
or the feedback signal is wrong.
50/00 7F010/4 Sensor oil pressure, short-circuited to ground. Transmission WARNING
control unit activates Limp home.
50/01 7F010/3 Sensor oil pressure not connected. Transmission control unit WARNING
activates Limp home.
50/04 7F010/11 Sensor oil pressure, the value is below lowest calibrated WARNING
value.
50/05 7F010/F Sensor oil pressure, the value is above highest calibrated WARNING
value.
51/00 7F011/4 Sensor engine rpm and oil temperature transmission WARNING
51/01 7F011/3 Sensor engine rpm and oil temperature transmission not WARNING
connected.
51/04 7F011/11 Sensor engine rpm and oil temperature transmission, the WARNING
value is below lowest calibrated value.
51/05 7F011/F Sensor engine rpm and oil temperature transmission, the WARNING
value is above highest calibrated value.
52/00 7F012/4 Sensor oil temperature sensor short-circuited to ground. WARNING
52/01 7F012/3 Sensor oil temperature not connected. WARNING
52/04 7F012/11 Sensor oil temperature, the value is below lowest calibrated WARNING
value.
52/05 7F012/F Sensor oil temperature, the value is above highest calibrated WARNING
value.
53/00 7F013/4 Analogue input signal 3 short-circuited to ground. WARNING
53/01 7F013/3 Analogue input signal 3 not connected. WARNING
53/04 7F013/11 Analogue input signal 3, the value is below lowest calibrated WARNING
value.
53/05 7F013/F Analogue input signal 3, the value is above highest calibrated WARNING
value.
54/00 7F014/4 Reference voltage sensor 5V short-circuited to ground. WARNING
54/01 7F014/3 Reference voltage sensor 5V short-circuited to battery. WARNING
value.

Description action
Code SPN/FMI
value.
value.
value.
value.
value.
value.
value.
60/00 7F01A/6 Sensor rpm drum short-circuited to ground. STOP or WARNING
control unit transmission activates Limp home.
60/01 7F01A/5 Sensor rpm drum not connected. STOP or WARNING
60/03 7F01A/A Sensor rpm drum, value outside limit values. WARNING
60/04 7F01A/1 Sensor rpm drum, pulse count too low. WARNING
60/05 7F01A/0 Sensor rpm drum, pulse count too high. WARNING
61/00 7F01B/6 Sensor rpm output shaft short-circuited to ground. STOP or WARNING
61/01 7F01B/5 Sensor rpm output shaft not connected. STOP or WARNING
61/03 7F01B/A Sensor rpm output shaft, value outside limit values. WARNING
61/04 7F01B/1 Sensor rpm drum, pulse count too low. WARNING
61/05 7F01B/0 Sensor rpm drum, pulse count too high. WARNING
62/00 7F01C/6 Sensor engine rpm short-circuited to ground. STOP or WARNING
62/01 7F01C/5 Sensor engine rpm not connected. STOP or WARNING

Description action
Code SPN/FMI
62/03 7F01C/A Engine speed information not available. Transmission control WARNING
unit activates Limp home.
62/04 7F01C/1 Sensor engine rpm, pulse count too low. WARNING
62/05 7F01C/0 Sensor engine rpm, pulse count too high. WARNING
62/06 7F07A/1 Faulty engine speed information when the turbine speed is WARNING
calculated. Transmission control unit activates Limp home.
63/00 7F01D/6 Sensor rpm turbine short-circuited to ground. STOP or WARNING
63/01 7F01D/5 Sensor rpm turbine not connected. STOP or WARNING
63/03 7F01D/A Turbine speed sensor, value outside limit values. WARNING
63/04 7F01D/1 Sensor rpm turbine, pulse count too low. WARNING
63/05 7F01D/0 Sensor rpm turbine, pulse count too high. WARNING
70/00 7F020/4 Solenoid valve front and rear, short-circuited to each other, STOP: Stop the machine and shift
signal cable short-circuited to voltage or positive cable to neutral. Select reverse gear.
short-circuited to ground. Transmission control unit activates
Limp home.
70/01 7F020/3 Solenoid valve front and rear, positive cable short-circuited STOP: Stop the machine and shift
to battery. Transmission control unit activates Limp home. to neutral. Select reverse gear.
70/02 7F020/6 Solenoid valve front and rear, control current over 1,400 mA. STOP: Stop the machine and shift
Transmission control unit activates Limp home. to neutral. Select reverse gear.
70/03 7F020/8 Solenoid valve front and rear, control current outside STOP: Stop the machine and shift
approved interval. Incorrect impedance. Transmission to neutral. Select reverse gear.
control unit activates Limp home.
70/09 7F020/5 Solenoid valve front and rear not connected. Transmission STOP: Stop the machine and shift
control unit activates Limp home. to neutral. Select reverse gear.
71/00 7F021/4 Solenoid valve 2/4 SUPPLY, short-circuited to each other, STOP: Stop the machine and shift
signal cable short-circuited to voltage or positive cable to neutral. Select reverse gear.
Limp home.
71/01 7F021/3 Solenoid valve 2/4 SUPPLY, positive cable short-circuited to STOP: Stop the machine and shift
battery. Transmission control unit activates Limp home. to neutral. Select reverse gear.
71/02 7F021/6 Solenoid valve 2/4 SUPPLY, control current over 1,400 mA. STOP: Stop the machine and shift
71/03 7F021/8 Solenoid valve 2/4 SUPPLY, control current outside approved STOP: Stop the machine and shift
range (incorrect impedance). Transmission control unit to neutral. Select reverse gear.
71/09 7F021/5 Solenoid valve 2/4 SUPPLY not connected. Transmission STOP: Stop the machine and shift
72/00 7F022/4 Analogue input signal 2, cables short-circuited to each STOP: Stop the machine and shift
other, signal cable short-circuited to voltage or positive cable to neutral. Select reverse gear.
Limp home.
72/01 7F022/3 Analogue input signal 2, positive cable short-circuited to STOP: Stop the machine and shift
72/02 7F022/6 Analogue input signal 2, control current over 1,400 mA. STOP: Stop the machine and shift

Description action
Code SPN/FMI
72/03 7F022/8 Analogue input signal 2, control current outside approved STOP: Stop the machine and shift
range (incorrect impedance). Transmission control unit to neutral. Select reverse gear.
72/09 7F022/5 Analogue input signal 2 not connected. Transmission control STOP: Stop the machine and shift
unit activates Limp home. to neutral. Select reverse gear.
73/00 7F023/4 Solenoid valve 1/3 SUPPLY, cables short-circuited to each STOP: Stop the machine and shift
other, signal cable short-circuited to voltage or positive cable to neutral. Select reverse gear.
Limp home.
73/01 7F023/3 Solenoid valve 1/3 SUPPLY, positive cable short-circuited to STOP: Stop the machine and shift
73/02 7F023/6 Solenoid valve 1/3 SUPPLY.Transmission control unit STOP: Stop the machine and shift
activates Limp home. to neutral. Select reverse gear.
73/03 7F023/8 Solenoid valve 1/3 SUPPLY.Transmission control unit STOP: Stop the machine and shift
activates Limp home. to neutral. Select reverse gear.
73/09 7F023/5 Solenoid valve 1/3 SUPPLY not connected. Transmission STOP: Stop the machine and shift
74/00 7F024/4 Analogue input signal 4 short-circuited to ground. STOP: Stop the machine and shift
to neutral. Select reverse gear.
74/01 7F024/3 Analogue input signal 4 not connected or connected or STOP: Stop the machine and shift
positive cable short-circuited to battery. to neutral. Select reverse gear.
75/01 7F025/3 Analogue input signal 5 not connected or positive cable STOP: Stop the machine and shift
short-circuited to battery. to neutral. Select reverse gear.
76/01 7F026/3 Analogue input signal 6 not connected or positive cable STOP: Stop the machine and shift
short-circuited to battery. to neutral. Select reverse gear.
76/02 7F026/6 Analogue input signal 6, control current over 1,400 mA. STOP: Stop the machine and shift
76/03 7F026/8 Analogue input signal 6, control current outside approved STOP: Stop the machine and shift
range (incorrect impedance). to neutral. Select reverse gear.
76/09 7F026/5 Analogue input signal 6 not connected. STOP: Stop the machine and shift
77/02 7F02F/1F All gear packages disengaged. Transmission in locked STOP
neutral position (Shut down).
80/00 7F027/4 Analogue input signal 0, cable short-circuited to ground. STOP: Stop the machine and shift
80/01 7F027/3 Analogue input signal 0, positive cable short-circuited to STOP: Stop the machine and shift
80/09 7F027/5 Analogue input signal 0 not connected. Transmission control STOP: Stop the machine and shift
unit activates Limp home. to neutral. Select reverse gear.
81/00 7F028/4 Solenoid valve gear selection 2/4, short-circuited to ground. STOP: Stop the machine and shift
81/01 7F027/3 Solenoid valve gear selection 2/4, open circuit or positive STOP: Stop the machine and shift
cable short-circuited to battery. Transmission control unit to neutral. Select reverse gear.

Description action
Code SPN/FMI
81/09 7F027/5 Solenoid valve 2/4 SELECTION (Y6074) not connected. STOP: Stop the machine and shift
82/00 7F029/4 Solenoid valve 1/3 SELECTION short-circuited to ground. STOP: Stop the machine and shift
82/01 7F029/3 Solenoid valve 1/3 SELECTION, positive cable short-circuited STOP: Stop the machine and shift
to battery. Transmission control unit activates Limp home. to neutral. Select reverse gear.
82/09 7F029/5 Solenoid valve 1/3 SELECTION not connected. STOP: Stop the machine and shift
83/00 7F02A/3 Analogue input signal 0, cable short-circuited to battery. STOP: Stop the machine and shift
Transmission in locked neutral position (Shut down). to neutral. Select reverse gear.
83/01 7F02A/4 Analogue input signal 0, cable not connected or STOP: Stop the machine and shift
short-circuited to ground. Transmission in locked neutral to neutral. Select reverse gear.
position (Shut down).
90/xx - 7F000/0 Transmission fault Transmission in locked neutral position STOP or INFORMATION
99/xx (Shut down).
90/01 7F0F0/1 SYSERR_OUT_OF_TABLES -
90/02 7F0F0/2 SYSERR_DAQ_NOINIT -
90/03 7F0F0/3 SYSERR_WRONG_SIGNAL_INDEX -
90/04 7F0F0/4 SYSERR_WRONG_STATREG_INDEX -
90/05 7F0F0/5 SYSERR_WRONG_BUTTON_INDEX -
90/06 7F0F0/6 SYSERR_WRONG_TABLE_INDEX -
90/07 7F0F0/7 SYSERR_WRONG_DISPLAY_MODE -
90/08 7F0F0/8 SYSERR_WRONG_SPEED_INDEX -
90/09 7F0F0/9 SYSERR_WRONG_OUTPUT_INDEX -
90/11 7F0F0/B SYSERR_LOCAL_ARRAY_TOO_SMALL -
90/12 7F0F0/C SYSERR_TABLE_VALUE_OOR -
90/13 7F0F0/D SYSERR_INDEX_OOR -
90/14 7F0F0/E SYSERR_Y2X_NON_MONO -
90/15 7F0F0/F SYSERR_SETTING_CORRUPT -
90/16 7F0F0/10 SYSERR_ILLEGAL_ISR_ENTRY -
90/17 7F0F0/11 SYSERR_POWERFAIL -
90/18 7F0F0/12 SYSERR_DIV_BY_0_ATTEMPT -
90/19 7F0F0/13 SYSERR_ILLEGAL_FAULTCODE -
90/90 7F0A0/1F Wrong software in control unit transmission. Transmission -

in locked neutral position (Shut down).
91/01 7F0F1/1 SYSERR_OUTPUT_FEATURE_ASSIGNMENT -
91/02 7F0F1/2 SYSERR_INVALID_SHIFTLEVER -
91/03 7F0F1/3 SYSERR_INVALID_ALGORITHM_CALL -
91/10 7F0F1/6 SYSERR_INVALID_SEQUENCE -
91/11 7F0F1/7 SYSERR_INVALID_STEP -
91/12 7F0F1/8 SYSERR_INVALID_TIMEOUTACTION -
91/50 7F0F7/A SYSERR_VALUE_OOR -

Description action
Code SPN/FMI
91/51 7F0F7/B SYSERR_VALUE_OOR + OOR_SHIFTTYPE -
91/52 7F0F7/C SYSERR_VALUE_OOR + OOR_FG_PARAMETER -
91/53 7F0F7/D SYSERR_VALUE_OOR + OOR_INIT_DIV_BY_0 -
91/54 7F0F7/E SYSERR_VALUE_OOR + OOR_GDE_POINT_BLANK -
91/55 7F0F7/F SYSERR_VALUE_OOR + OOR_SEQ_DIV_BY_0 -
91/57 7F0F7/11 SYSERR_VALUE_OOR + OOR_SHIFTTIMEOUT -
91/58 7F0F7/12 SYSERR_VALUE_OOR + OOR_SEQ_SU_TOLO -
91/59 7F0F7/13 SYSERR_VALUE_OOR + OOR_SEQ_SU_TOHI -
91/60 7F0F7/14 SYSERR_VALUE_OOR + -

OOR_OFFG_DIRCLUTCH_TIMEOUT
91/61 7F0F7/15 SYSERR_VALUE_OOR + OOR_OFFG_RGCLUTCH_TIME- -
OUT
91/70 7F0F7/1E SYSERR_VALUE_OOR + OOR_SEQSGM_TIME -
92/00 7F0F2/0 SYSERR_ALGINIT -
92/01 7F0F2/1 Shifting has no direction. Transmission locked in neutral -

position (Shut-down).
92/02 7F0F2/2 Doubled direction. Transmission locked in neutral position -
(Shut-down).
92/03 7F0F2/3 Doubled shifting. Transmission locked in neutral position -
(Shut-down).
92/04 7F0F2/4 Doubled pulse pattern. Transmission locked in neutral -
92/06 7F0F2/6 Incorrect digital input signal. Transmission locked in neutral -
92/07 7F0F2/7 Digital input signal in conflict with the gear control position. -
Transmission locked in neutral position (Shut-down).
92/08 7F0F2/8 Digital input signal “Transmission locked in neutral -
position” incorrect. Transmission locked in neutral position
(Shut-down).
92/09 7F0F2/9 Digital input signal doubled allocation. Transmission locked -
in neutral position (Shut-down).
92/10 7F0F2/A Digital output signal doubled allocation. Transmission locked -
in neutral position (Shut-down).
92/11 7F0F2/B Digital output signal selected on unconfigured output. -
92/12 7F0F2/C Digital output signal incorrect. Transmission locked in neutral -
92/13 7F0F2/D Digital output signal selected on transmission cable. -
92/14 7F0F2/E Wrong assignment in speed sensor 1-2. Transmission -
locked in neutral position (Shutdown).
92/15 7F0F2/F Wrong assignment in speed sensor 3. Transmission locked -
in neutral position (Shutdown).
92/16 7F0F2/10 Doubled allocation in speed sensor. Transmission locked in -
neutral position (Shut-down).

Description action
Code SPN/FMI
92/17 7F0F2/11 Incorrect supply voltage selected. Transmission locked in -
92/18 7F0F2/12 Doubled input signal. Transmission locked in neutral position -
(Shut-down).
92/19 7F0F2/13 Cable harness pressure sensor in conflict with cable harness -
analogue input signal. Transmission locked in neutral
92/20 7F0F2/14 Incorrect configuration concerning servo motor or brake -
valve (analogue output signal 4-5-6). Transmission locked in
92/30 7F0F2/1E Incorrect configuration concerning full flow selection and -
previous digital trouble shooting. Transmission locked in
92/50 7F0F8/1 SYSERR_TRANSM_CONTROL + TC_AT- -
TEMPT_TO_LOCK_DIR_CLUTCHES
92/51 7F0F8/2 SYSERR_TRANSM_CONTROL + TC_AT- -
TEMPT_TO_LOCK_RG_CLUTCHES
92/52 7F0F8/3 SYSERR_TRANSM_CONTROL + TC_MODMODE_OVER- -
RULED_WITH_GDE_TABLE
93/00 7F0F3/0 Unsuccessful initialization of necessary control unit data in -
flash memory, caused by a memory conflict. Transmission
93/10 7F0F3/A Initiation of static data in flash memory, caused by firmware -
update or memory conflict.
93/11 7F0F3/B Initiation of stored error data in flash memory, caused by -
firmware update or memory conflict.

Description action
Code SPN/FMI
95/00 7F0F5/0 - -
95/70 7F0F5/14 SYSERR SAVE_LOG2FLASH_FAILED. Transmission -

locked in neutral position (Shutdown).
95/71 7F0F5/17 Control unit cannot interpret input data. Transmission locked STOP
in neutral position (Shutdown).
95/72 7F09B/1F SYSERR_FLASH_ILLEGAL_ADDRESSRANGE -
95/73 7F0F5/16 SYSERR_FLASH_ILLEGAL_ACCESS -
99/90 7F0F6/0 Incorrect software in control unit. STOP

99/91 7F0F6/1 SYSERR_HSL_CPU_OVERLOAD -
99/92 7F0F6/2 SYSERR_MSL_CPU_OVERLOAD -
99/93 7F0F6/3 SYSERR_LSL_CPU_OVERLOAD -
99/95 7F0CA/1F Overload of CAN-bus detected: At the time Control unit -

transmission could not handle all incoming information, due
to too many CAN requests.
99/99 7F0F6/9 SYSERR_HARDWARE_CALIBRATION -
xx/49 - Undefined failure. Control unit marks the problem - action -

depends on the failure.
E0/01 7F0E1/F Machine's speed too high to enable downshift. Reduce machine's speed to enable
downshift.
E1/01 7F0E2/F Machine's speed too high to enable change of travel Reduce machine's speed to enable
direction. change of travel direction.
E2/01 7F0E3/F Engine rpm too high to enable change of travel direction or Reduce machine's speed to enable
select same travel direction again. change or feedback of travel
direction.
E3/00 7F0E4/E Machine's speed limitation activated. -
E3/01 7F0E4/F Machine's speed limitation is activated regardless of if speed Reduce the machine's speed until
is above the limit value. it is below the limit value.
E3/02 7F0E4/10 Machine's speed higher than the upper limit value. Reduce the machine's speed until
it is below the upper limit value.
E4/00 7F0E5/11 Abnormal speed reduction. Reduce the machine's speed so
that the wheels stop sliding.
E4/01 7F0E5/F Abnormal acceleration. Reduce the machine's speed so
that the wheels stop spinning.

Description action
Code SPN/FMI
E5/01 7F0E0/D Time with active gear exceeded time for recalibration. WARNING
E6/00 7F0E6/1F The operator is not sitting in the operator's seat and the The operator should sit in the
gear selector is not in neutral and/or the parking brake is operator's seat and shift to neutral
not activated. position or ease off on the throttle.
E7/01 7F0E7/F Turbine speed exceed the limit value. Slow down the machine until
turbine speed is below the limit
value.
E8/01 7F0E8/F Conditions to switch between 2WD and 4WD not satisfied. Stop the machine.
The machine must be stationary.
E9/01 7F0E9/F Conditions to switch between High and Low not satisfied. Stop the machine.
The machine must be stationary.
E1/XX Calibration code -
E1/01-0 7F0FA - Unexpected response algorithm during calibration. WARNING: Note the problem and
5 7F0FD/ 1-5 Calibration stopped- request continued calibration.
E1/06 7F0FA - The turbine speed signal does not reach down to the lowest Press the S-button on control
7F0FD/6 value during calibration. The control unit notes the error and unit transmission to continue
calibration is stopped. calibration.
9 7F0FD/ 7-9 Calibration stopped. request continued calibration.
E1/10 7F0FA - Transmission error during calibration. Calibration stopped. Finish calibration.
7F0FD/A
3 7F0FD/1 Calibration stopped. request continued calibration.
1-13
E1/14 7F0FA - The turbine speed does not drop during calibration. The Press the S-button on control
7F0FD/E control unit notes the error and calibration is stopped. unit transmission to continue
calibration.
E1/15 7F0FA - Unexpected response algorithm during calibration. WARNING: Note the problem and
7F0FD/15 Calibration stopped. request continued calibration.
E1/16 7F0FA - The turbine speed signal is too low to start calibration. The Press the S-button on control
7F0FD/10 control unit notes the error and calibration is stopped. unit transmission to continue
calibration.
7-24
E1/25 7F0FA - Engagement's starting point is too early during calibration. Press the S-button on control
7F0FD/19 Too much pull. The control unit notes the error and calibration unit transmission to continue
is stopped. calibration.
E1/26 7F0FA - Calibration of the engagement's start point not found. The Press the S-button on control
7F0FD/1A control unit notes the error and calibration is stopped. unit transmission to continue
calibration.
E1/28 7F0FA - Turbine speed does not reach the value 0 rpm during the Press the S-button on control
7F0FD/1C closing phase of the engagement's start point. The control unit transmission to continue
unit notes the error and calibration is stopped. calibration.
E1/29 7F0FA - Turbine speed does not reach up to the right value in Press the S-button on control
7F0FD/1D the release phase of the engagement's start point during unit transmission to continue
calibration. The control unit notes the error and calibration calibration.
is stopped.

Description action
Code SPN/FMI
7F0FD/A
1-13
calibration.
calibration.
7-24
calibration.
is stopped.
7F0FD/A
1-13

Description action
Code SPN/FMI
calibration.
calibration.
7-24
calibration.
is stopped.
Control unit transmission can generate two states with reduced

functionality to protect the transmission in the event of serious
malfunctions:
• In this condition only gear 1-2 in each direction can be used. If
the error occurs in a higher gear then downshifting to gear 1 or 2
must take place manually.
• In this mode the transmission is permanently in neutral as there
is no oil pressure to enable gear selection.

116 5 Handling – Operating
5.4 Operating
5.4.1 While operating
General
DANGER
The machine’s work area is large and visibility from the
operator’s cab is restricted.
damage!
Keep in mind:
• Always check to ensure no one is in the way of
the machine or its accessories. Also check that
the area upwards is unobstructed. If there are
unauthorised persons or vehicles within the work
area then the machine must be stopped.
• The operator must always face in the travel
direction and should operate with special care
where persons or vehicles may appear.
• The operator must adapt the speed to the load and
ground conditions, visibility, and wind conditions,
etc.
• The operator must pay extra attention and operate
with special care near electric power lines, viaducts,
docksides, ramps, doorways, etc.
• Always operate carefully so that the attachment
does not collide with posts, power lines, etc.
• Use available visibility-enhancing equipment such
as rear view mirrors and camera ( ).
WARNING
inspection.
WARNING
Never operate the machine without wearing the seatbelt.
Extreme danger!
Always use the seatbelt when operating the machine,
even when you expect a short shift. The seatbelt may
not be modified.

5 Handling – Starting engine 117
Instructions
Make a habit of checking the following at regular intervals while
51 52 operating:
• that coolant temperature is within the interval (approx. 75-85 °C).
• that fuel indicator on the display shows that there is fuel in the
tank.
NOTE
The fuel level should never go down to empty tank.
• that the AdBlue indicator on the display shows that there is

AdBlue in the tank.
• that all warning lights are off.
• that horn, lighting, brake lights and direction indicators function
correctly.
006494
• that all hydraulic functions function correctly.
• that no error codes have been generated (shown on operator's
display with error code indication and symbol). See the section
52. Control system indicator - STOP or WARNING 5.3 Error codes.
When necessary, the control system can set speed limitations for the
machine. This happens in the event of the following:
• pressed down control breaker
5.4.2 Starting engine

General
WARNING
If it's difficult to start the engine, do not use start spray.
Risk of explosion!
In case of start problems, contact service.
Instructions
1. Set the gear selector and multi-function lever in neutral position.
Gear selector and multi-function lever must be in neutral, otherwise
engine cannot be started.
2. Turn the start key to operating position, position I.
Current is now supplied to all electrical functions.
3. Turn the start key to preheating position, position II.
In the event of cold weather preheating can be used. During
preheating, the engine's intake air is preheated to a suitable
temperature by heating coils in order to facilitate starting.
When needed, the engine's control unit activated preheating during
a time period. The lamp for preheating (position 39) indicates if
preheating is activated.
Engine can be started, position III (start position), regardless of if
preheating is in progress, not activated (no need) or has been
finished.

118 5 Handling – Warming up
4. Turn the start key to start position, position III.

Let the starter motor crank the engine, release the key when the
engine fires. The machine is equipped with an electric restart
interlock, which prevents engagement of the starter motor when
the engine is rotating.
Note that a warning or indicator light may remain illuminated after
start to indicate state. The lamp for preheating may continue to be
illuminated for a moment during operation in cold weather because
the preheating may be active during the initial operation.
NOTE
The time that the starter motor can be activated is max 20 seconds.
The starter motor circuit is then disconnected for 80 seconds to
protect the starter motor.
5.4.3 Warming up
General
CAUTION
Never rev a cold engine at high engine speeds.
Risk of engine damage!
Run the engine at 1400-1500 rpm until it starts to get
warm.
WARNING
Don’t let the engine idle for a long time.
Risk of engine damage!
Turn off the engine during breaks in operation and load
handling.
Instructions
In cold temperatures the machine may not be used for tough work until
the engine and hydraulics are at operating temperature.
If the machine operates in temperatures below -10 °C, an engine

heater and hydraulic oil heater should be installed.
Engine
Start the engine and let it idle for about 10 min, never rev a cold engine
as this can cause engine damage. Now warm run the engine at about
1400-1500 rpm until it starts to get warm. It is very important that the
engine is warmed up and the oil circulates well before the turbocharger
starts to operate at high revs.
Start work with the machine when the coolant has reached normal
operating temperature, approx. 75 °C). (See Operating menu for
engine.)

5 Handling – Gearshifting 119
Hydraulic system
Never operate a hydraulic function in the cold until the hydraulic oil is
warm, since there is a risk of damage and leakage in the hydraulic
system.
When the engine has reached its working temperature, warm run the
hydraulic oil by running the mast slowly up and down. Full actuation of
the hydraulic function may not be performed until the tank temperature
is +1 °C.
After this, all other hydraulic functions should be run slowly so that
warm oil circulates through the whole system, and this should be
repeated at least ten times.
5.4.4 Gearshifting
General
The machine is equipped with automatic transmission. The system
shifts to a lower/higher gear under certain conditions, such as torque,
engine speed, travel speed, etc.
F General about the automatic transmission:
• Has a built-in control and monitoring system, providing optimal
operation.
• Shows current gear on the control system display.
64 • The reversing lock prevents the travel direction being changed

R too quickly, i.e. prevents possible damage to the transmission.
63 The reversing lock is automatic and is dependent on engine
006495
speed and travel speed.

62
• Shifting is variable (modulated) and gives smoother operation.
62. Switch for shifting program A For machine with TE17, operation starts with first gear.
63. Switch for shifting program 1 For machine with TE32, operation normally starts with second
64. Switch for shifting program 2 gear. Use of first gear is governed by engine speed, amongst
other things.
Instructions
1. Let the engine idle. Select travel direction, move lever forward
(F) or backward (R).
2. Select shifting program: A, 1 or 2.
The operator can limit gearshifting by selecting shifting program on
the steering wheel panel's keys.
Shifting program A (position 62) - automatic shifting between all
gears.
Shifting program 1 (position 63) - gear is locked to 1st gear.
Shifting program 2 (position 64) - gear is locked to 2nd gear.
NOTE
In certain circumstances, the transmission may be forced to
reduce speed due to a problem. The control unit may then set
the transmission in "limp home" mode.

120 5 Handling – Steering
Transmission assumes neutral position

A control breaker senses when the operator leaves the operator's
station. The signal from the control breaker means that the
transmission automatically assumes neutral position. It is not possible
to select any travel direction.
008191
Breaker in operator's seat
NOTE
If the buzzer sounds when the operator sits in the seat and releases
the parking brake then the control breaker in the seat may be
malfunctioning. It is not possible to select any travel direction.
The machine can be operated in emergency mode by means
of by-passing the safety system (override). Activate the by-pass
switch, select travel direction and drive the machine to the
workshop. Speed is limited to 10 km/h.
WARNING
Safety features are blocked.
75 75 No safety system is activated! Risk of roll-over and
tipping over!
Only use bypass in emergency situations!
75
75
012509
75. Switch for by-passing

Key for bypassing
5.4.5 Steering
General
The machine is equipped with servo steering. The steering wheel
movements are transferred hydraulically to the steering wheels on
the ground.

5 Handling – Service brake 121
WARNING
The machine may not roll on a downhill grade if the
engine is off.
Hydraulic pressure for steering is missing and steering
capacity is lost! Danger!
Keep the engine running for hydraulic pressure.
5.4.6 Service brake

General
The brake pedals (position 12) are used as service brake.
Use the brakes in a smooth but firm way. Brake pressure remains for
awhile after the engine has been switched off, accumulated during
operation. If the accumulator pressure falls below a certain level, the
low brake pressure indicator light (position 33) on the panel comes
on. When the lamp is lit the capacity of the service brake is limited.
The buzzer sounds and speed is limited. Finally, the parking brake is
applied automatically by a forceful spring in the brake cylinder. Check
the accumulators' sealing integrity if the pressure does not build up
and is not maintained, see chapter 6 Inspection and maintenance.
The brake pedal is combined with a separate clutch pedal (position

13). The transmission is released when you press down the brake
and clutch pedals simultaneously. Before drive is disengaged, the
drive functions as an engine brake.
000340
12 13 12 11
11. Accelerator
12. Brake pedals
13. Clutch pedal
5.4.7 Parking brake

General
DANGER
The parking brake should not be applied when the
machine is in motion.
Very heavy braking. Risk of machine tipping, load
tipping over, being dropped or damage to property or
extreme danger!
Stop the machine before applying the parking brake.

122 5 Handling – Parking brake
WARNING
Never leave the operator’s seat without first applying
the parking brake.
Risk of machine starting to roll! Danger!
Apply the parking brake before leaving the operator's
station.
The parking brake is operated with the switch (position 8) on the panel
for hydraulic functions (position 6). The indicator light for parking brake
(position 46) is activated with a red light when the parking brake is
applied.
Instructions
The parking brake is applied when:
• The switch for parking brake is pressed down (indicator light for
parking brake is activated with a red light).
• The ignition is turned off (to 0 position).
When the ignition is switched on again the parking brake is
applied without the switch for parking brake being activated. The
indicator light for parking brake then flashes to indicate that the
parking brake switch should be switched on and then off in order
to release the parking brake. Check the accumulators' sealing
integrity if the pressure does not build up and is not maintained,
6 6 see chapter 6 Inspection and maintenance.
An audible signal is activated if the operator gets up from the driver's

seat without first applying the parking brake.
5
30-3
If the accumulator pressure falls below a certain level, the low brake
pressure warning lamp (position 33) comes on. When the lamp is lit
the capacity of the service brake is limited. Finally, the parking brake
is applied automatically by a forceful spring in the brake cylinder.
If the machine has to be moved, see section 7 Transporting the

6
machine.
33 46
013954
6. Switch for parking brake
Emergency brake
The parking brake can be used as emergency brake in emergency
situations.

5 Handling – Heating / Air conditioning 123
CAUTION
The parking brake can be used as an EMERGENCY
BRAKE.
Brake pads wear out and lose their braking
performance! Unwanted movement of parked machine!
After emergency braking with the parking brake the
brake shoe linings must be checked as soon as
possible and replaced if necessary. Braking action of
the parking brake may be lost as the brake shoe linings
may have been worn down.
If the parking brake has been released mechanically
then it must always be reset to restore the machine's
parking brake function.
5.4.8 Heating / Air conditioning

General
The heating (EHC) /air conditioning system (ECC) receives heat from
A the engine's cooling system and provides heat when the engine is
warm. For ECC, cooling output is generated by the AC compressor.
The system is controlled by switches for fan, heat and air distribution.
In addition to this there are functions for recirculation and defroster.
For ECC: In the event of an open door, the air conditioning's AC

compressor is switched off (cooling function and air drying stops).
Close the door and the AC compressor is reactivated.
18
17
004690
16
A. Panel nozzle
16. Switch for fan
17. Switch for heat
18. Switch for air distribution

124 5 Handling – Heating / Air conditioning
Normal weather conditions

1 Set desired temperature (position 17).
Set the temperature within temperature range 16 °C to 27 °C.
See position B on display.
Setting of min. and max. respectively, switches off automatic
climate control (control of fan, temperature and air distribution)
and sets the heat valve in min. and max. position, respectively.
004918
2 Switch (green) for fan handles setting of fan speed for the cab.
Fan speed can be set for:
• automatic control, AUTO. See position C on display.
• manual control in 13 steps from off to max. Fan speed is
shown by the bar's height in the operating menu for the
heating/air conditioning system. See position C in the display.
Recommendation: Set the fan to automatic control, AUTO, for
optimal function of the system. Automatic control is activated
C when lowering with the switch from fan off.
NOTE
004919
C When the fan is off, the cooling functions ceases (for ECC).
3 Set air distribution (position 18) and the panel nozzles as required
for a comfortable cab climate. See position E in the display.
4 Normally, recirculation (function key for Enter) and defroster
(position 54) do not have to be used.
Defroster - position D on display
Recirculation - position F on display
D
E
F
004920
Mist on windows
1 Set a warm temperature (position 17).
2 Set a fan speed to a faster position (position 16).
3 Set air distribution (position 18) and panel nozzles (position A) at

the windscreen to get good visibility through the windows.
A
004915

5 Handling – Heating / Air conditioning 125
4 Check that recirculation is not engaged. Recirculation may impair

effective demisting.
The symbol for recirculation should not be shown in the information
menu for heating / air conditioning. See position H in the display.
G To activate/deactivate recirculation, press the function key for
Enter when the operating menu is shown. See position G.
004917
5 Activate defroster (position 54).
The defroster controls the function fan, temperature and damper
position to optimally heat and more quickly dry the air at the
windscreen for faster demisting. The function is active for 6
minutes.
The symbol for defroster is shown in the operating menu for
I heating / air conditioning, and is indicated in the switch. See
position I in the display.
NOTE
004921
The defroster function is active for 6 minutes. Check that

temperature control returns to the set value when the defroster
is switched off.
6 If there is a lot of mist, direct the panel nozzles (position A) to the

windscreen for optimal demisting.

126 5 Handling – Stopping the engine - parking
5.4.9 Stopping the engine - parking

General
NOTE
Never disconnect the system voltage with the battery disconnector
when the engine is running! The voltage regulator may be damaged.
Instructions
1. Stop the machine and move the gear selector and multi-function
lever to neutral position.
2. Apply the parking brake.
3. Lower the forks (or attachment) completely and tilt the mast
forward.
4. For hydraulic lateral sliding cab, move the cab to middle position.
5. Let the engine run for a few minutes at idle speed before stopping
the engine so that the engine cools down slightly and the turbo
bearings are lubricated.
6. Stop the engine by turning the start key to position 0.
In case the machine is going to be parked for a long time, the
battery disconnector should be turned to the OFF (0) position.
NOTE
Wait a minute or two before the system voltage is disconnected
with the battery disconnector so that the SCR system has time
to drain, this is especially important in cold weather.
When idling:
• The engine is switched off at idle running for longer than 3 to
30 minutes (adjustable).
• Work lights are switched off after 5 minutes.
• Extra work lights are switched off after 2 minutes.

5 Handling – Load handling 127
5.5 Load handling

General
During all lifting work, make sure that the max. lift capacity is not
exceeded, see machine plate or load diagram.
The forklift's capacity is indicated by three parameters:

• position of load's centre of gravity
• lifting height
• load's size
The capacity varies between models and versions, see the machine
012511
and type plates, section 3.2 Plates.
It is important to estimate the position of the centre of gravity. If the

machine appears to be side-heavy, the load should be lowered and
adjusted with side shift so that the load's centre of gravity is moved
012512 to a position along the machine's centre line.
The function load handling refers to, e.g., to lift, lower, rotate, angle
or hold loads.
Load handling subfunctions.

• Lift/lower
• Tilt
• Side shift
• Spreading (using right-hand fork)
012513
• Rotation, only for top lift
Lift and lower

012514
Tilt
006950
Side shift

128 5 Handling – Lifting load
006951
Spreading (positioning)
012515
Rotation
5.5.1 Lifting load

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

• fixed 20'
• fixed 40'
• adjustable 20' - 40'
For a top lift attachment, the attachment must be aligned with
all four corners against the container both when locking and
releasing the twistlocks. When releasing, the container must also
stand securely with all four corners on the ground surface. The
top-lift attachment is equipped with indicator lights that indicate
its different positions. The indicator lights are placed to the right
on the top-lift attachment.
This manual describes lifting using forks, and lifting using the top lift
attachment fitted on inverted forks.

5 Handling – Lifting load 129
DANGER
Respect the lifting capacity of the machine and
exercise the greatest caution during load handling:
• Never handle unstable or loosely loaded goods.
Take great care when handling long, high or wide
goods to prevent the load from sliding off, being
damaged or tipping the machine.
• Remember not to exceed the maximum load
capacity, see the type plate. If necessary, estimate
the centre of gravity and determine the maximum
load capacity with the help of load diagram located
in the cab.
• Never tilt the mast forward with a load on it.
load.
Risk of load tipping over, being dropped or damage to
property or extreme danger!
Make sure that the load is positioned securely before
lifting.
DANGER
Make sure that the lifting tool is marked with the type
plate from Cargotec or another manufacturer. There
must always be a plate stating the capacity data for
all attachments.
damage!
Make sure that nothing other than approved lifting
attachments are used.
WARNING
Do not use a machine where the indicator lights are out
of order.
Danger of reduced safety during load handling!
If the indicator lights don't work, stop work with the
machine and repair.

130 5 Handling – Lifting load
Instructions for forks

1 Move forward towards the load, as close as possible.
• Aim to have the machine's centre line towards the load's
centre of gravity.
• The approach angle to the load should be as straight as
possible.
• Tilt the mast forwards slightly.
012516
• Lower the forks as low as possible and adjust the fork
spreading and insert them under the load.
• Tilt the mast backwards so that the forks are horizontal.
NOTE
When handling drums, strive to keep the forks as close together
as possible.
2 Hold the machine still with the footbrake and clutch pedal.
Alternatively, apply the parking brake if required and/or shift to
neutral. If necessary, use wheel chocks on the drive wheels.
DANGER
The operator should pay take extra care when
load handling near electric power lines, viaducts,
docksides, ramps, doors, etc.
Extreme danger!
Use the parking brake and stop blocks!
3 Lift the load and tilt the mast backwards.

If the machine seems side heavy - lower the load and change the
lifting point using side shift so that the load's centre of gravity is
along the machine's centre line.
012517
WARNING
Forks (with or without load) are easily manoeuvrable
work tools with great strength.
damage!
Make sure that no person stands under a raised
attachment, whether it is loaded or not. Take great care
when driving.
Instructions for top lift attachment

1 Run towards the stack of containers, as close as possible. Strive
to line up the machine's centre line with the centre of the container.

5 Handling – Lifting load 131
2 Hold the machine still with the footbrake and clutch pedal.
Alternatively, apply the parking brake if required and/or shift to
neutral.
3 For adjustable attachment, adjust with spreading to relevant

container length.
Right light, C - Twistlocks unlocked, red light activated, indicates
that load is not secured.
4 Position the attachment slightly above the container. Adjust with
rotation, sideshift and tilting.
5 Lower the attachment on the container.
012518
6 Middle light, B – Alignment, orange light activated, indicates when
all four corner boxes have correct alignment against the container.
7 Lock twistlocks with the switch for twistlocks.
If automatic locking of twistlocks is used, locking is automatic
when the attachment is aligned with the load.
Locking options are selected with switches for automatic or
manual locking, see Overview, page 42 (position 71).
NOTE
012519
For automatic locking of twistlocks, the parking brake must be

released.
8 Right light, C - Twistlocks unlocked, off.

Left light, A - Twistlocks locked, is activated with green light and
indicates that load is secured and ready for lifting.
The lift function is disconnected when both right light, C -
Twistlocks unlocked, and left light, A - Twistlocks locked, are off.
Left light, A - Twistlocks locked, is activated with green light when
the locking process has been completed.
CAUTION
012520
Do not start to lift if light C "Twistlocks unlocked" is

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

When the container is lifted, the light for alignment (position B)
should go out.
012521

132 5 Handling – Transporting load
5.5.2 Transporting load

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

5 Handling – Transporting load 133

1 Lift the load slightly. Back away from the load area.
2 Adjust the mast and load height to transport position.
Correct transport position is with the load as far down and in as
possible without obstructing visibility, see Transport position, page
133. The load's centre of gravity must be centred laterally.
012517
Instructions for top lift
1 Lift the load slightly. Back away from the stack.
When the load is lifted, the middle light, B - Alignment, (orange), is
off. The function for twistlocks is then disengaged.
2 Adjust load height and tilt angle to transport position. See
012521 Transport position, page 133.
Transport position
When the machine is to be run with or without load assume the
transport position to minimise the risk of roll-over and imbalance while
operating.
When in transport mode the mast is tilted back and the load lifted
slightly above the ground, about 300 mm (see figure to the left). The
load's centre of gravity must be centred laterally.
If the load blocks visibility ahead then the machine must be reversed.
NOTE
300 mm
012522
When handling special loads local regulations may apply. Learn

about them and follow them.
Transport position
The machine shall be run in transport position even without load to
maximise operator visibility.
When in transport mode without a load, the mast must be vertical and
the forks raised slightly above ground, around 300 mm. (See figure
to the left). The forks must be sideshifted so that the tips of the forks
are visible through the mast, this means the machine's overall length
including forks is visible.
012523
300 mm
Transport position without load

134 5 Handling – Transporting load

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

maximise operator visibility.
In transport position without load, the mast shall be vertical and the
attachment raised for good forward visibility, see figure to the left.
012524
Transport mode with load
012525
Transport position without load
Operating on grades
It is important to be extremely careful when operating on grades as
there is a greater risk of roll-over and tipping over. Keep in mind the
angle of the ramp.
NOTE
When braking, use only the service brake pedal (right-hand brake
pedal). Do not operate service brake in combination with clutch
pedal.
• Operating with a load.

Adjust load height and tilt angle to transport position, see
Transport position, page 133.
Always drive with the lifting attachment upwards in the grade,
irrespective of travel direction, i.e. the truck must be reversed
down a grade.
• Operating without a load.
Always operate with the lifting equipment down the grade
(downward), regardless of travel direction.
012526
Operating with a load on grades
Working near overhead high voltage power lines

Operate with extreme care in all work near overhead high voltage
power lines, keeping in mind the height of the mast and load.

5 Handling – Unloading 135
DANGER
If the machine comes into contact with overhead high
voltage power lines - sit down in the seat and call for
help!
Extreme danger!
Remain in the cab and wait for help.
5.5.3 Unloading
General
There are different types of lifting attachments for load handling, e.g.
forks and top-lift attachments for container handling.

1 Move forward and stop in front of the unloading location.
• If necessary, lift the load sufficiently for unloading, but no
higher.
• The approach angle to the load should be as straight as
possible.
• Tilt the mast to vertical position.
2 Move forward slowly until the load is in position over the unloading
surface.
012511
3 Apply the parking brake if desired, or hold the machine stationary

with the service brake and clutch pedal. Alternatively, shift to
neutral.
4 Lower the load slowly and make sure that it is standing firmly on
the unloading surface, e.g. level ground or the stack of another
load.
5 Reverse away slowly from the stack and adjust the forks to
transport position.

136 5 Handling – Unloading
Instructions for top lift attachment

1 Run towards the stack of containers, as close as possible. Attempt
to position the lifted container's centre line toward the centre of
the container stack.
2 Lift the load over the stack.
Strive to centre the load over the container stack.
3 Apply the parking brake if desired, or hold the machine stationary
with the service brake and clutch pedal. Alternatively, shift to
neutral.
4 Position the load over the stack. Adjust with rotation, sideshift
012527
and tilting.
5 Lower the load.

When alignment is obtained, the middle light, B - Alignment, is
activated.
6 Open twistlocks manually with switch, (position 69).
Left light, A - Twistlocks locked, is off (green) when releasing of
twistlocks is initiated. Right light, C - Twistlocks unlocked, is on
(red) with twistlocks fully open.
During release of twistlocks when automatic locking of twistlocks
is activated it is necessary to:
012520
a. Activate the switch to open locked twistlocks until the red

light is on.
b. Lift until the yellow light goes off before the switch to open
twistlocks is released.
Never lift when twistlocks are in the process of being released.
NOTE
Automatically locked twistlocks are also opened manually.

5 Handling – Functions for load handling 137
5.5.4 Functions for load handling

Removing the forks
1 Lower the forks so that they are resting against the surface below,
e.g. in a stand.
2 Pull the pin out from the bolt.
3 Pull the bolt out from the shaft holding the forks.
4 Pull or tap out the shaft so that the fork loosens from the fork
bracket.
5 Tilt backwards and reverse the machine away from the forks.
002049
1. Bolt
2. Pin
3. Ring pin
4. Shaft
5. Fork
6. Fork bracket
WARNING
Position the forks in a safe manner.
The forks could roll over and cause crushing injury.
Store the forks in a safe manner, e.g. in a stand.
Fitting the forks

1 Make sure that the shaft is locked with the bolt and pin.

138 5 Handling – Functions for load handling
Coupling the inverted forks/coil ram

1 Operate sideshift and fork spreading so that the fork bracket
reaches the correct position for the forks.
2 Fold out the movable locking catches down onto the forks/coil ram.
3 Tilt the mast forwards and move the machine forwards towards
the forks/coil ram. Correct with fork spreading and sideshift so
that the fork bracket aligns against the upper retaining catches for
the forks/coil ram.
4 Lift slightly and tilt backwards, check that the fork bracket fully
grips into the upper retaining catches.
5 Lift until the forks/coil ram are in full contact with the fork mount.
Make sure that the lower attachment hooks grip the fork carriage's
lower member.
6 Fold in the movable locking catches and lock with the pins.
2
3
002050
Inverted forks.
1. Upper fastening hook
2. Lock pin
3. Movable lock hook
4- Lower fastening hook

Uncoupling the inverted forks/coil ram

1 Position the forks in a safe stowage location, e.g. in a stand.
1
2 Fold out the movable locking catches down onto the forks/coil ram.
3 Tilt the mast forwards so that the lower retaining catches release.
4 Lower slightly so that the upper retaining catches release and
reverse away from the forks/coil ram.
2
3
002051
Coil ram.
1. Upper fastening hook
2. Lock pin
3. Movable lock hook
4- Lower fastening hook

Connecting kissing forks

1 Operate sideshift and fork spreading so that the brackets reach
the correct position for the forks.
2 Tilt the mast forwards and drive the machine towards the forks.
Correct with fork spreading and side shift so that the brackets fit
against the forks' fastening hook.
3 Lift slightly and tilt backwards, check that the bracket fully grips
into the upper catches.
4 Lift until the forks are in full contact with the brackets.
5 Install the pins and insert the bolts.
6 Lock with the lock pins.
4
3
2
012550
Kissing forks.
1. Fastening hook
2. Shaft
3. Bolt
4. Pin

Disconnecting kissing forks

1 Lower the forks so that they are resting against the surface below,
e.g. in a stand.
2 Pull out the pins from the bolt.
3 Pull out the bolts and pins.
4 Tilt the mast forward and lower slightly so that the catches release
and reverse away from the forks.
Connecting the top lift-attachment

1 Operate sideshift and fork spreading so that the forks reach the
correct position for the fork pockets.
2 Insert the forks into the fork pockets.
1 3 Secure the forks for the top lift-attachment with the braces behind
2 the forks. Lock with bolts and pins.
4 Connect the hydraulic hoses and electrical cable from the top-lift
attachment to the quick couplings on the fork carriage. Check that
002061
hoses and cables are routed so that they are not damaged.
5 Check the different functions for the top lift attachment.
Top-lift attachment, locking braces.
1. Bolt
2. Pin
Uncoupling the top lift-attachment

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

1. Electrical cable
2. Hydraulic hoses

Hydraulic lateral sliding cab

General
The side shifting cab simplifies visibility during land handling. The cab
is operated using the hydraulic side shifting cab switch (position 74).
Side shifting occurs from the centre position to the right.
Operator door (s) must be closed, control breaker for hydraulics not
activated, parking brake released, and speed below 5 km/h.
WARNING
Before the cab is moved, make sure that no person is in
the risk area outside the cab risk of crushing.
It is forbidden to operate the forklift with open doors
when the cab is outside the middle position.
It is forbidden to exit the cab when it is outside its
middle position, except in emergencies.
Instructions
1 Run toward the load handling site and stop the machine.
2 Move the cab with the switch.

Hold in the switch during the entire movement.
3 Carry out load handling.
NOTE
Move the cab while the machine is stationary!

Scales
b
NOTE
For calibration, contact service personnel.
c
006669
Load weight is approximated with the operating menu for scales.
1 Select the operating menu for scales.
a. Shows tare weight in tonnes.
The value shown on the row (b) can be reset (tared) by
pressing the function keys for minus and plus simultaneously.
If the keys are pressed again the values (a) and (b) switch.
The desired value can also be scrolled using the minus and
plus keys. The set value is displayed on row (a and b).
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 function
key for Return. The value in row (c) can be reset to zero by
depressing the function key for Reset.
2 Set the mast vertically.
3 Perform the lifting movement and then lower the load slowly about
30 cm.
4 Read off value (b) in operating menu for scales.

Height limitation
Height limitation limits how high the mast can be raised. The height
limitation can be adjusted in accordance with customer requirements.
When the mast reaches a certain preset height (position A), the lifting
A movement is stopped and the figure in the display is shown. Lower
the mast for continued load handling.
If it is necessary to lift above the height limitation the function can

be bypassed. Activate the bypass switch (position 75) and use the
lift function. After a few seconds the switch (position 75) can be
deactivated, lifting and lowering can then be performed without
bypassing.
The figure on the display is always shown when the lift height exceeds
the height limitation.
75
75
012528

Height warning
A
The height warning warns when the maximum set lifting height is
reached. The height warning can be adjusted in accordance with
customer requirements.
When the mast reaches a certain preset height (position A), the
machine warns and the figure in the display is shown.
The figure in the display is always shown when the lifting height
exceeds the maximum set lifting height.
012529

146 6 Inspection and maintenance
6 Inspection and
maintenance
General
This chapter describes:
• DAILY INSPECTION - performed by the operator.
Daily inspection describes the running inspection that significantly
contributes to making the machine a safe and reliable workplace.
• MAINTENANCE - performed by the operator.
Maintenance describes some simple maintenance actions.
• SERVICE - performed by trained service technician.
Advanced maintenance is performed according to a service
schedule and by service technicians. Advanced maintenance is
described in the maintenance manual.
It is the operator who is responsible for ensuring that the machine
comes in for service according to prescribed service intervals.
Procedures are described in the maintenance manual.
• ERROR CODE INFORMATION - read off by the operator.
Error code information is read off by the operator from the control
system's display in the cab. Depending on the type of error code, it
is handled by the operator or a service technician.
NOTE
All time information refers to operating time, that is, the time shown
by the hour meter on the panel.
CAUTION
Only spare parts approved by Cargotec may be used.
This is to maintain the machine's safety as well as to
meet warranty and service agreements!
Only use spare parts and fluids approved by Cargotec
to fulfil warranty terms.

6 Inspection and maintenance – Daily inspection 147
6.1 Daily inspection

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

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

148 6 Inspection and maintenance – Daily inspection
DANGER
Cracks in materials or welds in load bearing structures
can reduce the machine's strength.
damage!
If there are cracks in materials or welds in load-carrying
structures/structural elements, the machine shall be
taken out of use immediately and taken to service.
• If the machine is equipped with top lift; check that sensors for
twistlocks and alignment are clean and free from grease.
• Communication equipment - direction indicators, brake lights,
headlights and reflectors with regard to damage
• Cab with regards to damage and dirty windows, rear view
mirrors
2. Check fluid levels for the following fluids according to description,
see section 6.2 Maintenance. Top up, if necessary, with the correct
fluid:
• Hydraulic oil
• Oil for brake system
• Batteries' electrolyte level
• Coolant
• Washer fluid - windows
• Engine oil
• Transmission oil
3. Check the engine's indicator for air filter, also check and drain
the fuel prefilter, when required. For description, see section 6.2
Maintenance.
4. Start the machine according to instructions and check:
• Instruments - warning lamps, indicators, any error codes
• Fuel level - the gauge must not show empty tank
• AdBlue level - the gauge must not show empty tank
• Lighting, direction indicators, horn, brake lights, flashing
hazard lights
• Windscreen wipers
• Check that mirrors are intact, clean and well-adjusted for
visibility all around the machine.
• Cooling function in the ECC
5. Operate the machine slowly/carefully and check the following
functions:
• Brakes - check-brake at least three times
• Steering - in both directions
• Transmission - all gears - forward and reverse
• Noise from engine, transmission or drive axle
6. Run all functions with hydraulic cylinders (lift, tilt, side shift and
spreading) to their end positions for lubrication of the cylinder
barrels and piston rods.
7. Make sure that AdBlue is drained from the hoses when the
machine is turned off. The AdBlue pump can still be heard for
short time after the engine has been switched off.

6 Inspection and maintenance – Daily inspection 149
8. If the machine is equipped with top lift; check the lift attachment
and that:
1
• Indicator lights for twistlocks and alignment function.
• The contact pins on the twistlocks can be moved easily up
and down. Note that a contact pin that binds in the upper
position can indicate alignment despite the frame not being
positioned against the container.
2 • Check the function of the twistlocks. This is done by lifting an
empty container until the light "Alignment" goes out. It should
not now be possible to release the twistlocks.
5
4 3
012530
1. Sensor twistlock
2. Sensor alignment
3. Lock guide
4. Lift pin
5. Contact pin
WARNING
Make sure that the engine is off when working with
twistlocks.
Twistlocks can be locked automatically if all sensors for
alignment are activated manually at the same time.

150 6 Inspection and maintenance – Daily inspection
9. For central lubrication

Make sure grease has not seeped out from the safety valve
(position A). This is a sign that the central lubrication is not
working properly.
006835
Example figure of unit for central lubrication

10. Check the machine's operating hours - notify the
foreman/supervisor if the machine is close to a service interval.
11. Notify the foreman/supervisor immediately if any defects are
detected on the machine.
WARNING
Do not use the machine if the system for locking
containers does not work.
damage!
Use of the machine must be discontinued, and it has to
be taken to a service workshop for needed actions.
12. In cold weather:

• Check that wiper blades have not frozen to the windscreen.
• Remove snow from air inlets and radiator grill
• Antifreeze in washer fluid
• Disconnect the auxiliary heater
Electrical box for auxiliary heater is located by the cab steps
on the left side of the machine.
13. Check if any error codes are active.
See the section 5.3 Error codes.

6 Inspection and maintenance – Maintenance 151
6.2 Maintenance
General
The following maintenance actions are described in this chapter:
– Cleanliness, general, page 153
– Fuel system, general, page 155
– Windscreen washer, general, page 159
– Air filter engine, general, page 160
– Cooling system, general, page 161
– Engine oil, general, page 163
– Transmission oil, general, page 164
– Oil, brake system, general, page 166
– Hydraulic system, general, page 167
– Tyres and rims, general, page 167
– Accumulators, general, page 170
– Battery and battery disconnector, general, page 171
– Main fuses for electrical system, general, page 173
– Fuses for electrical system, general, page 174
– Lighting, general, page 178
Safety during maintenance

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

152 6 Inspection and maintenance – Maintenance
Tilting the cab
WARNING
Never work under a cab that is not tipped over its
balanced position or secured by other means.
Risk of crush injury.
Always tip the cab fully. At the maximum tip angle (on
a horizontal surface) the cab's centre of gravity means
that it is not likely to tip back.
A, B, D C
The cab must always be tipped over its balanced position. If the
lateral space is insufficient, the cab must always be secured against
accidental lowering by means of a stay.
C
Preparations:
• Set the gear and travel direction selector to neutral.
• Tilt the mast forward and lower the forks.
• Apply the parking brake.
A
• Check that there are no loose items in the cab.
• Close the doors.
Tilting
B 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. Fit the pump rod in its mounting (position A).
4. Pump until the cab has reached the end-position.
Lowering
1. Set the pump valve (position B) in the left-hand position.
D 2. Fit the pump rod in its mounting (position A).
3. Pump all the way until the cab rests on the frame.
4. Turn both lock handles (position C) so that they reach their inner
position to lock the cab to the frame.
Electric tipping
013943
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.
A. Pump rod mount
3. Use the control buttons (position D) to raise the cab to the end
B. Pump valve position. Press both buttons simultaneously.
C. Lock handle (figure shows the open position) Electric lowering
D. Control buttons
1. Set the pump valve (position B) in the left-hand position.

2. Use the control buttons (position D) to lower the cab until it makes
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 Inspection and maintenance – Cleanliness 153
6.2.1 Cleanliness
Cleanliness, general
Dirt has a negative impact on performance. Experience shows that
clean machines have fewer malfunctions.
The machine should be washed regularly for optimal function. Keep

the following in mind when washing:
• Use mild cleaning agents.
Use a degreaser if necessary. Scrub if necessary.
• Use a high-pressure washer, wide water jet.
CAUTION
High-pressure washing of sensitive components may
lead to short-circuiting and cause malfunction.
Product damage!
Do not use a high-pressure washer on the cab, radiator,
battery compartment, electric components, control
units, connectors, cable joints, cylinder seals, stub
axles, axle seals and chains.
NOTE
After washing with de-greaser, the hydraulic cylinders should be run
in and out a few times to obtain satisfactory lubrication once again.
WARNING
hydrocarbons.
Low strength! Danger!
Check the surface layer of the roof window and
clean only with washer fluid or mild detergent. Rinse
thoroughly with lukewarm water afterwards. Replace a
damaged roof window that shows cracks or scratches
immediately!
CAUTION
Cleaning agents contain different solvents.
Health-hazardous and highly flammable.
Ensure good ventilation when cleaning the machine.
Avoid skin contact, use protective gloves. If you
get dizzy when using cleaning agents, get fresh air
immediately and contact a doctor. If the cleaning agent
has found its way into your eyes, rinse immediately
with lots of water and contact a doctor immediately.

154 6 Inspection and maintenance – Cleanliness
CAUTION
Cracks or scratches result in reduced strength of the
roof window.
Low strength!
Replace a damaged roof window immediately.
CAUTION
Objects may shoot off when using compressed air for
cleaning.
Risk of injury.
Use protective goggles and protective gloves. Exercise
caution to avoid injury to yourself or those nearby.
For optimum functionality the machine should also be kept clean inside
the cab.
• Plastic material: Vacuum clean, brush/wipe with lightly moistened
rag. Use mild cleaning agent and always wipe down with a lightly
moistened rag and clean water.
• Textile material: Vacuum clean, brush/clean with e.g. furniture or
carpet cleaning agent in accordance with the instructions on the
packaging.

6 Inspection and maintenance – Fuel system 155
6.2.2 Fuel system

Fuel system, general
The filler pipe is located on the machine's left side.
NOTE
In order to prevent fuel and AdBlue being filled in the wrong tank,
the filler cap for fuel is black and for AdBlue it is blue.
NOTE
Make sure that the area around the tank cap is clean when
refuelling.
WARNING
Fuel is highly flammable and health hazardous.
Fire hazard! Health hazard!
Handle with great care and avoid all possible ignition
sources, for example, cigarettes, sparks. Avoid skin
contact, use protective gloves. In the event of skin
contact and spills on clothes, wash the skin and
change clothes.
014053
A B
A Fuel filler orifice CAUTION

B Filling AdBlue
The quality of the diesel affects the service life of the

engine.
Make sure that correct diesel quality is used.
IMPORTANT
AdBlue in the fuel tank:
• The engine will not run at full power or not at all.
• Injectors can be damaged.
• Corrosion in the exhaust system between the turbo
and the after treatment system.
• Expensive repairs.
Fuel in the AdBlue tank:
• The after-treatment system can be seriously
damaged.
• The engine no longer satisfies emission
requirements.
• Expensive repairs.

156 6 Inspection and maintenance – Fuel system
Fuel
• Always fill up with diesel fuel.
• Never use additives in the diesel fuel.
• In wintertime, try to fill up immediately after finished operation.
This prevents build-up of condensation in the fuel tank. Do not use
anti-condensation agents, for example, alcohol, in the fuel.
• Do not refuel when the engine is running.
• Make sure that the fuel nozzle is connected securely in the filler
pipe (to prevent spills and generation of static electricity).
• Clean around the filler pipe after refuelling and handle used rags,
wiped up fuel, etc. in an environmentally sound manner.
• For tank volume and fuel quality, see section 9 Specifications.
CAUTION
AdBlue can irritate with skin and eye contact and if
inhaled.
Health hazard!
Handle carefully and avoid skin contact, wear protective
gloves. In the event of any contact with the skin and
spillage on clothing, wash the skin with large quantities
of water and change contaminated clothing and gloves.
In the event of eye contact, rinse thoroughly with
water for several minutes and seek medical advice
CAUTION
AdBlue spilt on hot components evaporates quickly.
Irritating to the eyes and respiratory system.
Turn your face away. Evaporated AdBlue can have a
corrosive effect on the mucous membrane e.g. eyes
and throat. In the event of eye contact, rinse thoroughly
with water for several minutes and seek medical advice
IMPORTANT
Avoid spilling AdBlue on the ground and in
watercourses.
Spillage on the ground must be absorbed with sand or
other absorbent, non-combustible materials.

6 Inspection and maintenance – Fuel system 157
IMPORTANT
Never fill another AdBlue other than that specified in 9
Specifications.
Risk of damage to the after-treatment system!
Never start the engine if anything other than pure
AdBlue has been filled in the AdBlue tank.
AdBlue
• Always fill with pure AdBlue.
• Never use additives in the AdBlue.
• In wintertime, try to fill up immediately after finished operation.
This prevents build-up of condensation in the AdBlue tank.
• Do not refuel when the engine is running.
• Make sure the nozzle for AdBlue is correctly fitted to the filler pipe
(avoid spillage).
• Clean around the filler pipe after refuelling and handle used rags,
wiped up fuel, etc. in an environmentally sound manner.
• For tank volume and AdBlue quality, see section 9 Specifications.
Fuel prefilter, instructions
NOTE
The water separator should be drained of water when necessary or
at least every 50 operating hours.
DANGER
The fuel is highly flammable.
Fire hazard! Extreme danger!
Make sure that open flames, sparks, or red-hot/glowing
objects have been extinguished before starting work
on or near the fuel system. Do not smoke near the
machine during work on the fuel system.
1 Turn off the engine and the main system voltage with the battery
disconnector.
2 Position a receptacle under the filter.

158 6 Inspection and maintenance – Fuel system
3 Drain the water from the filter.

Open the drain cock on the underside, close the cock when clean
fuel drains (no water bubbles). Only tighten the tap by hand.
WARNING
Fuel on hands.
Rash and irritation.
Avoid skin contact with the fuel, use gloves.
4 Remove the collection container. Handle the fuel as

environmentally hazardous and fire hazardous waste.
014057
Engine alternative Volvo TAD762VE

014045
Engine alternative Volvo TAD1360VE

6 Inspection and maintenance – Windscreen washer 159
6.2.3 Windscreen washer

Windscreen washer, general
CAUTION
hydrocarbons.
The strength of the roof window may be affected!
Only use clean water with an antifreeze agent, e.g.
antifreeze fluid.
A
The washer fluid reservoir is located on the rear left side of the cab.
Other placements may arise.
Instructions
Check the level in the reservoir. When necessary, top up with washer
fluid. For volume, see section 9 Specifications.
Add anti-freeze. Select a suitable concentration (dilution

water/anti-freeze fluid) according to the winter conditions and outdoor
temperatures.
012533
A. Washer fluid reservoir

160 6 Inspection and maintenance – Air filter, engine
6.2.4 Air filter, engine

Air filter engine, general
NOTE
DCF 280-330 Poorly filtered induction air can very quickly result in serious engine
damage.
The filter is changed by the service technician during running

inspections 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.
DCF 370-520
The air filter has a dust reservoir (position C) which is normally
emptied during operation by vibration in the induction system. It can
also be emptied manually by shaking it.
Instructions
Check the indicator regularly and contact service as soon as the

indicator shows a red signal.
The indicator can be reset to zero.
C B
013948
A. Position for air filter reservoir

B. Indicator for change
C. Dust reservoir

6 Inspection and maintenance – Cooling system 161
6.2.5 Cooling system

Cooling system, general
DCF 280-330
Coolant is filled in the system's expansion tank (position A). The

coolant level should be visible in the level glass (position C) on the
expansion tank.
DCF 370-520
Coolant is filled in the system's expansion tank (position A). The

coolant level should be between the MIN and MAX markings (position
D) on the expansion tank.
C B A NOTE
Open very carefully as hot coolant may jet up and out.
If the coolant level becomes too low, the warning lamp for low coolant
level (position 40) lights up on the instrument panel.
NOTE
A low coolant level may cause engine damage or may cause the
engine to stop.
014061
Instructions
DCF 280-330
A Position of the coolant container (expansion
tank) WARNING
B Filling point
C Level glass The cooling system is pressurised. Steam or hot
coolant may jet out.
Risk of scalding/burn injuries!
Open the filler cap very carefully when the engine is
warm. Wait until the coolant has cooled down before
topping up.
WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
Handle with care. Avoid skin contact. Wear protective
glasses and protective gloves. In the event of skin
contact, wash the skin.

162 6 Inspection and maintenance – Cooling system
CAUTION
Different types of coolant may not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, the same type
of coolant must be used as was used before.
• Check the level in the expansion tank. When necessary, top up

with ready-mixed recommended coolant. For volume, see section
9 Specifications.
IMPORTANT
On machines with ECC or AC it is of the utmost
importance 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 during use.
A
012535
B C D
DCF 370-520
A Position of the coolant container (expansion
tank)
B Pressure cap
C Filling point
D Level marking MIN and MAX

6 Inspection and maintenance – Engine oil 163
6.2.6 Engine oil

Engine oil, general
DCF 280-330
DCF 280-330
WARNING
A protective gloves.
B
The engine's oil filler pipe (position B) and dipstick (position C) are
C located under the engine hood.
• Check the oil level.
Check the oil level when the engine is warm. Wipe off the dipstick
before checking.
The dipstick has two markings, MAX and MIN, between which
the oil level should be.
NOTE
The dipstick is long on certain machines. Wear gloves.
• Top up as needed with new engine oil (position B). For volume
and quality, see chapter 9 Specifications.
014268
C Top up – wait awhile – check on the dipstick.
DCF 280-330 NOTE

A Placement filling and dipstick engine oil Work carefully when filling engine oil to prevent other fluids or
particles from contaminating the oil. Other fluids or particles in
B Filling point
the engine oil means a risk of engine damage.
C Dipstick

164 6 Inspection and maintenance – Transmission oil
DCF 370-520
DCF 370-520
WARNING
B A protective gloves.
The engine's oil filler pipe (position B) is under the hood. The engine
has the oil level indicator on the display.
• Check the oil level on the display.
Check the oil level when the engine is warm.
• Top up as needed with new engine oil (position B). For volume
and quality, see chapter 9 Specifications.
Top up - wait awhile - start the machine and check the oil level
on the display.
014059
NOTE
Work carefully when filling engine oil to prevent other fluids or
DCF 370-520
particles from contaminating the oil. Other fluids or particles in
A Position for filling point the engine oil means a risk of engine damage.
B Filling point
6.2.7 Transmission oil

Transmission oil, general
WARNING
protective gloves.
A
B The transmission's oil filler pipe and dipstick are located under the
engine hood.
012538
DCF 280-330
A Position for filling point and level checking
B Dipstick and filling point

6 Inspection and maintenance – Transmission oil 165
Instructions
• Check the oil level.
Check the oil level with the engine idling and the transmission in
neutral position and at operating temperature (approx. 85 °C in
the display).
The oil dipstick has two markings - MAX and MIN. The oil level
should be between the two markings.
• Wipe off the oil dipstick before checking.
NOTE
The oil dipstick is long. Wear gloves.
• Top up as needed with new transmission oil (position B). For

volume and quality, see section 9 Specifications.
It is recommended to fill the oil when the transmission is at
operating temperature. Top up – wait awhile – check on the
dipstick.
NOTE
Work carefully when filling transmission oil to prevent other fluids
or particles from contaminating the oil. Other fluids or particles
in the transmission oil means a risk of transmission damage.
A
014060
C B
DCF 370-520
A Position for filling point and level checking
B Filling point
C Dipstick

166 6 Inspection and maintenance – Oil, brake system
6.2.8 Oil, brake system

Oil, brake system, general
WARNING
Avoid prolonged skin contact with the oil.
Health hazard!
Use protective gloves.
A The tank for the brake system is located on the machine's left side.
Instructions
D • Check the oil level (position E).
C
The level should be in the middle of the level glass.
• Top up as needed with new oil (position C). For volume and
quality, see section 9 Specifications.
B E • Check that the oil cooler (position B) is not clogged. Clean as
needed.
NOTE
012967
Work carefully when filling brake oil to prevent other fluids or

particles from contaminating the oil. Other fluids or particles in the
brake oil means a risk of damage to the brake system.
A. Oil tank for brake system
B. Oil cooler
C. Filling point
D. Breather filter
E. Sight glass oil tank

6 Inspection and maintenance – Hydraulic system 167
6.2.9 Hydraulic system

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

G
F Instructions
E • Check the oil level (position D). All hydraulic pistons should be in
D retracted position (pushed in).
C The level should be in the middle of the level glass.
B • Top up as needed with new oil (position F). For volume and
A quality, see section 9 Specifications.
• Check that the oil cooler isn't clogged.
Clean as needed.
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 working
hydraulics.
H
012541
A Fine-filter
B Oil cooler
C Cleaning filter hydraulic oil
D Level glass hydraulic tank
E Breather filter
F Filling point hydraulic tank
G Hydraulic tank
H Filling point hydraulic tank (spare)
6.2.10 Tyres and rims

Tyres and rims, general
DANGER
Changing tyres is high-risk work.
Extreme danger!
Let service personnel change tyres, they have the
competence and authority to handle tyres!

168 6 Inspection and maintenance – Tyres and rims
DANGER
Penetrating objects such as crushed glass, pieces of
wood, metal shavings, etc. and mechanical defects,
such as uneven brake wear, can cause tyre damage.
Risk of tyre explosion! Extreme danger!
Check the tyres at regular intervals for external damage
and tyre pressure.
WARNING
Check-tighten the wheel nuts on a new wheel after 4-5
operating hours.
damage!
Tighten bolted joints crosswise. Contact a service
technician as required.
CAUTION
Spare and replacement tyres should be of brand names
approved by Cargotec.
Risk of overloaded tyres!
Use tyres approved by Cargotec.
IMPORTANT
Wheels, tires, and rims are dimensioned and selected
for each machine type so that maximal wheel loads and
speeds are not exceeded. That is why it is not permitted
to change tire dimension, tore make, tire type, rim type,
or rim brand without approval from Cargotec.

6 Inspection and maintenance – Tyres and rims 169
Changing wheel:
Changing wheels, see Maintenance manual.
DANGER
When changing tyres, deflate first.
Deflate tyres by loosening and removing the valve.
DANGER
Rim damage makes wheel handling extremely
dangerous!
Let service personnel change tyres, they have the
competence and authority to handle tyres!
Inflating tyres
Care of compressor for inflating tyres:
• An air filter with water separator should be installed in the line
from the compressor used for inflating tyres. The water filter
minimises the risk of corrosion on wheel rims.
• Drain the water separator regularly.
DANGER
Never stand in front of a tyre when inflating! Do not
exceed the prescribed air pressure which must be
checked at ambient temperature. When changing
tyre or rim version, another tyre pressure may apply,
contact Cargotec. The plate for tyre air pressure
must be replaced with a plate with the applicable tyre
pressure!
Extreme danger!
Always follow instructions for inflating tyres to avoid
serious accidents.
007268

170 6 Inspection and maintenance – Checking accumulators
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
dismantled and checked for damage. Let service personnel
change tyres as they have the competence and authorisation
to handle tyres!
002202
2. Connect the compressor with a locking air-chuck to the nipple
1. Lock ring on the tyre.
2. Rim edge 3. Stand at an angle behind the tyre and remain there until inflating
has been completed. This is to avoid being hit by rim parts in the
3. Tapered rim event of an explosion.
4. Inflate the tyre to the prescribed pressure, see chapter 9
Specifications. When changing tyre or rim version, another tyre
pressure may apply, contact Cargotec.
6.2.11 Checking accumulators

Accumulators, general
The function of the accumulators (position A) is to maintain even
brake pressure and also to maintain brake pressure, and thus braking
A action, a short time after eventual loss of hydraulic pressure.
The accumulators are precharged with nitrogen gas.
Instructions
Check for leakage according to the following points if the warning

lamp for low brake pressure (position 33) lights up:
1. Start the engine and let it run until the accumulators are filled.
Warning lamp for low brake pressure (position 33) goes off.
2. Stop the engine and then turn the start key to position I.
3. Press down the brake pedal with long pumping brake strokes,
with a slight delay between each braking action.
4. It should be possible to brake at least eight times before the light
for low brake pressure lights up.
5. Start the engine, let the accumulators charge and repeat the test
a couple of times.
007269
If it is not possible to brake eight times before the warning lamp for
low brake pressure lights up, there is a defect in the accumulators.
A. Accumulators for brake system Contact service as soon as possible for troubleshooting and suitable
action.
WARNING
The machine's hydraulic system includes
accumulators with high pressure.
Always be very careful when working with the
hydraulic system, and avoid standing close to
hydraulic components or hoses. Before working
on the hydraulic system, the accumulators must be
drained (see Maintenance manual).

6 Inspection and maintenance – Battery and battery disconnector 171
6.2.12 Battery and battery disconnector

Battery and battery disconnector, general
WARNING
Short-circuiting of battery.
Risk of explosion! Fire hazard! Risk of personal injury!
The battery's terminals must not be connected to each
other or to common grounding point (chassis).
B CAUTION
Always turn off the electric power at the end of your
shift, when working on the electrical system and when
012542
A welding on the machine.

Danger!
A. Battery disconnector
Switch off the electric power with the battery
B. Battery cover disconnector.
The electrical system works with a system voltage of 24 Volt (DC).

The power source consists of two series-connected 12 Volt (DC)
batteries which are charged by an AC alternator. The negative
terminal is connected to the frame.
The plus terminal is connected to a battery disconnector (position A).
The batteries are located inside of a cover (position B) behind the

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

deionised water.
1. Turn off the machine's system voltage with the battery disconnector
(position A) and then open the cover (position B).
2. Check the level. Fill as required with deionised water.
Electrolyte's fluid surface should be 10 mm over cells.
Batteries contain substances hazardous to the environment and
personal health. Therefore, discarded batteries must be handled in
accordance with local/national regulations in force.

172 6 Inspection and maintenance – Battery and battery disconnector
Starting with booster battery
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!
Danger of short circuit! Warning - risk of hydrogen gas
forming! Sparking and danger of fire! Hydrogen is very
explosive!
Batteries must always be equipped with covers over
terminals and connections. Connect positive terminals
first. Then connect the negative terminals in order to
avoid sparks that could ignite the hydrogen gas.
1. Switch off the system voltage with the battery disconnector

(position A).
2. Open the battery cover on the machine's left-hand side.
3. Check that the engine on the machine with booster batteries is
switched off.
4. Check that the booster batteries are connected in series so that
they supply 24 VDC. Do not disconnect the normal cables to the
machine's batteries.
5. Connect in the following order:
a. The red booster cable (+) to the discharged batteries' positive
terminal.
b. The red booster cable (+) to the booster batteries' positive
terminal.
c. The black booster cable (-) to the booster batteries' negative
terminal.
d. The black booster cable (-) to a point some distance from the
discharged batteries, e.g. by the negative cable's connection to
the frame or directly to the engine block.
6. Start the machine containing the booster batteries.
7. Make the system voltage with the battery disconnector.
8. Try to start the engine and then run the engine at increased idling
speed for approx. 10 minutes to charge the batteries.
Do not move the connections during the start attempt - risk of
sparks. Do not lean over any of the batteries.
9. Switch off the engines on both machines.
Disconnect the cables in the reverse order as to when connecting
them. One cable at a time! Batteries must always be equipped
with covers over terminals and connections.

6 Inspection and maintenance – Main fuses for electrical system 173
6.2.13 Main fuses for electrical system

Main fuses for electrical system, general
CAUTION
Never use fuses with too high ampere rating.
Risk of cable damage or cable fire!
Follow instructions on the fuse plate for fuse type and
ampere rating.
A A. Main fuses in electronic box on frame, 4 fuses 50 A.

Cuts off all electric power.
Changing the main fuse
When checking and changing the main fuse:

1. Turn off the system voltage with the battery disconnector.
The engine shall be off.
See Battery and battery disconnector, general, page 171.
2. Remove the plastic cap (position A).
3. Check and change fuses when needed.
The fuses are 50 A.
007272
A. Main fuse in electrical distribution box on frame

174 6 Inspection and maintenance – Fuses for electrical system
6.2.14 Fuses for electrical system

Fuses for electrical system, general
The machine's electrical system is divided into three electric power
circuits:
• Battery voltage, so-called 30-voltage
• Ignition voltage, so-called 15-voltage
• Control breaker voltage, so-called 15E-voltage
The fuses for the electrical system are located in the electronic box
on the side of the machine and in an electronic box in the cab.
The electrical distribution box is located behind the driver's seat in the
D cab. There are fuses for the control units and equipment in the cab.
E
CAUTION
Never use fuses with too high ampere rating.
Risk of cable damage or cable fire!
Follow instructions on the fuse plate for fuse type and
ampere rating.
A
B
012543
Fuses on frame
A. 30-fuses (battery voltage), F58-1
B. 15-fuses (ignition voltage), F58-2
C. 15E-fuses (control breaker voltage),F58-3

Fuses in cab
D. 15-fuses (ignition voltage) and 30-fuses (battery
voltage), F58-4
E. 15-fuses (ignition voltage), F58-5

6 Inspection and maintenance – Fuses for electrical system 175
SUPPLY POWER
A1 10A KCU (KALMAR CAB UNIT)
923935.0185
B2 5A KCU,START UP (KALMAR CAB UNIT)
F58-4 15
C3 10A SERVICE
CAB
D4 10A OPT CUSTOMER
E5 10A OPT RADIO
MAIN POWER
F6 25A OPT SEAT HEATER, TURNABLE SEAT
F58-4 30
G7 15A OPT WORK LIGHT
CAB
H8 15A OPT AIRCUSHIONED SEAT
A1 25A KCU (KALMAR CAB UNIT)
F58-5 15 SUPPLY POWER CAB

B2 10A KIT (KALMAR INFORMATION TERMINAL)
C3 15A ECC, FAN (ELECTRONIC CLIMATE CONTROL)
D4 5A ECC, RECIRC (ELECTRONIC CLIMATE CONTROL)
E5 10A SERVICE
F6 5A OPT MAP READING LIGHT
G7 10A OPT CONVERTER 12V
014263
H8 10A OPT COMPRESSOR HORN
Fuse plate at electronic box for frame (left) and cab (right)
Table Fuse holder 58-1 (30-voltage)
Connection Fuse number / Size Functions

1 1 / 30A Cab
2 2 / 30A After-treatment system engine
3 3 / 15A Engine
4 4 / 10A Engine
5 5 / 5A Transmission
6 6 / 15A
Cooling fan for brake system
7 7/- -
8 8/- -
Table Fuse holder 58-2 (15-voltage)

1 1 / 30A Control unit frame (KDU)
2 2/- -
3 3 / 25A
Control unit frame, option (KDU)
4 4/- -
5 5 / 5A Sensor
6 6 / 5A Transmission
7 7 / 5A Engine
8 8 / 5A Engine

176 6 Inspection and maintenance – Fuses for electrical system
Table Fuse holder 58-3 (15E-voltage)

1 1/- -
2 2 / 5A -
3 3 / 5A Attachment
4 4/- -
5 5 / 5A Control unit frame, option (KDU)

6 6/- -
7 7/- -
8 8 / 5A Feedback relay K3009-1 (K2)
Table Fuse holder 58-4 (cab)

1 1 / 10A Control unit cab (KCU)
2 2 / 5A Control unit cab (KCU), start-up
3 3 / 10A Service
4 4 / 10A
Customer-specific equipment
5 5 / 10A
Radio
6 6 / 25A
Seat heating, revolving driver's seat
7 7 / 15A
Work lights, cab roof
8 8 / 15A
Air suspension, operator's seat

6 Inspection and maintenance – Fuses for electrical system 177
Table Fuse holder 58-5 (cab)

1 1 / 25A Control unit cab (KCU)
2 2 / 10A Control unit KIT
3 3 / 15A Air conditioning, fan
4 4 / 5A Air conditioning, recirculation
5 5 / 10A Service / Customer-specific equipment
6 6 / 5A
Lighting, writing table
7 7 / 10A
Voltage converter 12 VDC
8 8 / 10A
Loud horn
Instructions
When checking and changing fuses:

The engine shall be off.
See Battery and battery disconnector, general, page 171.
2. Remove the cover from the electronic box.
3. Check and change fuses when needed.
The fuse plate gives information about each fuse.

178 6 Inspection and maintenance –
6.2.15
Lighting, general
It's important to use the right type of light bulb for respective lighting
point, see section 9 Specifications.
Light bulbs can be changed for the following:

• Interior lighting
• 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
Working lights, Xenon
• Revolving beacon
Instructions
Applies for the following:

• Headlights, (with high and low beam)
1 Loosen the rubber strip (position A).
2 Remove the glass (position B).
3 Change light bulb.
000579
A B
A. Rubber strip
B. Lamp lens

6 Inspection and maintenance – Service 179
6.3 Service
General
It’s very important that inspections and service are performed at the
recommended intervals.
Service is performed by Cargotec, or by service technicians authorised

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

180 6 Inspection and maintenance – Service
WARNING
For safety reasons, the following spare parts may only
be replaced with genuine spare parts:
• Brake valve
• Drive axle
• Valve for mini-wheel/joystick steering
• Steering valve (Orbitrol)
• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Rim
• Solid wheels
• Control valve, hydraulic servo
• Mast, carriage
• Lift cylinder incl. load control valve
• Separate load control valve
• Lifting chains
• Chain tightener and shaft
• Forks, fork carrier
• Lift cylinder
• Tilt cylinder
• Twistlock
• Control breaker (for hydraulic function)
• Emergency stop
• Hydraulic cylinder, cab tilt
• Accumulator
• Tilt valve
• Main valve load handling
• Accumulator charging valve
• All control units

7 Transporting the machine 181
7 Transporting the machine

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

182 7 Transporting the machine – Towing
7.1 Towing
General
DANGER
The machine cannot be operated or braked if the
hydraulic pressure is lost, e.g., if the engine is off.
Rolling machine! Extreme danger!
If possible, tow with maintained hydraulic pressure.
If it’s not possible to have the engine running when
towing, a tow bar must be used! Only tow for short
distances!
CAUTION
Do not try to start the machine by towing.
Causes serious damage to engine and power
transmission!
Start the engine according to instructions in the
operator's manual.
Before taking actions and after finished towing, the parking brake
must be applied and the wheels blocked to prevent the machine from
starting to roll.
Extreme care must be observed during towing work to avoid personal

injuries.
When towing, keep in mind:

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

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

the hydraulic accumulator/hydraulic accumulators, the parking brake
must be released mechanically (manually).

7 Transporting the machine – Mechanical release of parking brake 183
DANGER
Before starting to work with the parking brake, make
sure that the machine cannot move when the braking
action is released.
Rolling machine! Extreme danger!
Block the wheels to avoid unwanted rolling of the
machine.
CAUTION
The parking brake has high spring force. If the brakes
are opened incorrectly, parts may detach and fly off
with great force.
Follow the instructions.
The parking brake is a disc brake on the drive axle's input shaft.
A B C 1 Remove protective cover from caliper (position A).
2 Note the nut's position on the bolt and remove the split pin that
secures the nut.
3 Screw in the nut, this compresses the brake spring. Screw until
the brake pads release from the brake disc.
4 Restore the parking brake function by screwing out the nut to the
same position acc. to item 2. Install new split pin.
5 Refit protective cover on the caliper.
NOTE
The parking brake may have to be adjusted again.
000835
See Maintenance manual.
A Protective cover
NOTE
B Brake disc for parking brake
If the parking brake has been released mechanically, the
C Connection propeller shaft parking brake must always be restored in order to give the
machine parking brake function.

184 7 Transporting the machine – Lifting and transporting the machine
7.2 Lifting and transporting the

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

transported:
• Turn off the system voltage with the battery disconnector.
• Apply parking brake.
• Remove any fragile equipment, e.g. rear view mirrors.
• Secure the machine for transport on e.g. a truck with chains. See
the sign for the machine's weight.
Front: Secure the chains in the mast, or in the front wheels, left
and right-hand sides
NOTE
Cross the chains when securing for optimal stability.
Rear: Secure chains in the towing eye by vertical counterweight,

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

7 Transporting the machine – Lifting machine 185
7.2.1 Lifting machine

Instructions
The machine must be lifted as follows:
1 Fit two lifting slings in the two lifting eyes of the counterweight.
2 Fit two lifting slings in the two lifting eyes of the lifting mast.
3 The lifting device must be adapted so that the lifting point runs
through the machine's centre of gravity.
012545
7.2.2 Transporting the machine

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

The machine must be transported on a trailer that is wide enough to
support the drive axle's inner wheel.
1. Reverse the machine up on the trailer.
2. Run the lifting trolley down completely and tilt the mast forwards
as far as possible.
3. Apply the parking brake and switch off the engine.
5. Secure the front part of the machine using chains provided with
hooks and tensioner devices. Secure the chains in a safe manner
in the chassis and in the intended attaching points on the trailer.
6. Secure the rear part of the machine using chains provided with
hooks and tensioner devices. Secure the chains in the towing bar
012546
and in the intended attaching points on the trailer.

7. Fold in the rear-view mirrors and remove protruding parts, such
as the rotating beacon, to prevent damage during transport.

186 7 Transporting the machine – Service position
7.3 Service position

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

• The machine is parked, i.e. parking brake applied.
• Lifting trolley lowered and mast tilted forward.
• Engine off.
012547
• System voltage switched off (with battery disconnector).

7 Transporting the machine – Long-term storage 187
7.4 Long-term storage

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

188 8 Environment and standards
8 Environment and
standards
General
The ever-increasing industrialisation of our world is having a significant
impact on our global environment. Nature, animals and people are
subjected daily to risks in connection with various forms of chemical
handling.
There are still no environmentally safe chemicals, such as oils and
coolants, available on the market. Therefore, all who handle, perform
service on or repair machines must use the tools, assisting devices and
methods necessary to protect the environment in an environmentally
sound manner.
By following the simple rules below, you will contribute to protecting
our environment.
Recycling
Conscientious recycling of the machine is the starting point for the life
cycle to come full circle, and for being able to recycle and make use of
material in new products. According to calculations by Cargotec, the
machine is more than 90% recyclable by weight.
Environmentally hazardous waste

Components such as batteries, oils, and various chemicals and other
items that may constitute environmentally hazardous waste must be
handled and taken care of in an environmentally safe and sound
manner.
Discarded batteries contain substances hazardous to personal health
and the environment. Therefore, handle batteries in an environmentally
safe manner and according to national regulations.
Oils and fluids

Oils freely discharged cause environmental damage and can also be a
fire hazard. Therefore, when emptying and draining oils or fuel, take
appropriate action to prevent unnecessary spills.
Waste oils and fluids should always be taken care of by an authorised
disposal company.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal the leaks.
Air conditioning
The refrigerant in the air conditioning system for the cab accelerates
the greenhouse effect if it comes out into the open air. All service
work on the air conditioning system requires specific training. Many
countries also require certification by a governing authority for such
work. When scrapping an air conditioning unit, the refrigerant shall be
taken care of by a certified company.
Working in a contaminated area

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

8 Environment and standards – Environment and standards 189
Declarations
The machine does not contain asbestos.
The machines contains lead in batteries and in electric cabling. In
certain models, there are lead castings as counterweight.
If the machine is equipped with air conditioning, refrigerant of type
R134a is used, in an amount totalling between 1-3 kg.
Standards
Noise, vibration, stability and visibility, etc.
This machine fulfils the harmonised standard EN 1551 "Safety of
machinery - Industrial trucks Self-propelled trucks over 10 000 kg lift
capacity" and the North American standard ANSI/ITSDF B56.1 "Safety
Standard for Low Lift and High Lift Trucks".
CE-marking
Machines for the EU/EES market are CE-marked. This means that
upon delivery it fulfils the applicable "Essential Health and Safety
Requirements" specified in the EU Machine Directive, 2006/42/EC, as
well as other EU directives relevant to this machine type. For more
information, see section 2.2 CE-marking.
ANSI/ITSDF marking
Machines for the North American market are ANSI/ITSDF marked.
This means that the delivery meets the essential safety requirements
as set out in ANSI/ITSDF B56.1. For more information, see section
2.3 ANSI/ITSDF marking.
EMC, electromagnetic interference

The EU's EMC directive regarding "Electromagnetic compatibility",
2004/108/EC, gives a general description of the standards that may
be required of a machine from a safety aspect, where the limit values
have been established in international standards. A machine or device
that meets these standards should be CE-marked.
Cargotec machines are especially tested with regards to
electromagnetic interference in accordance with harmonised standard
EN12895. The machine's CE-marking and declaration of conformity
also cover the EMC directive. If other electronic equipment is installed
on the machine, it must be CE-marked and tested on the machine
with regards to electromagnetic interference. It must also be approved
by Cargotec.
Exhaust emissions
Machines for the EU/EEA market fulfil EU\qs Exhaust directive
97/68/EC and 2004/26/EC, which means that the engine's exhaust
emissions have been limited according to the requirements.
Machines for the North American market fulfil EPA\qs and CARB\qs
exhaust regulations, which means that engine exhaust emissions have
been limited according to the requirements.
Noise emissions
The machine for the EU/EEA market fulfils the EU Noise directive
2000/14/EC and 2005/88/EC which means that the machine is marked
with measured environmental noise emissions which are also limited
according to the requirements for trucks with lift capacity over 10 000
kg. See section 3.2 Plates.

190 8 Environment and standards – Environment and standards
Vibration standard
Vibration emitted by the machine is measured according to harmonised

standard EN 13059, where the level of vibration varies depending on
with which type of tyres and operator's seat the machine is equipped.
See section 9 Specifications.

9 Technical data 191
9 Technical data
Data
The machine's weights and dimensions vary depending on how the
machine is equipped. Detailed information regarding this is given in the
product specification and data sheet for the machine in question.
0. Complete machine Volvo TAD762VE Volvo TAD1360VE

Guaranteed sound power level LWA 110 dB(A) LWA 111 dB(A)
according to 2000/14/EC and
2005/88/EC including measurement
uncertainty 1.5 dB.
1. Engine Volvo TAD762VE Volvo TAD1360VE

Power acc. to ISO 3046 (net power) 185 kW bewteen 1600-2200 rpm 256 kW bewteen 1500-1900 rpm
Torque ISO 3046 1178 Nm at 1200 rpm 1745 Nm at 1200 rpm
Max. rotation speed 2200 rpm 2200 rpm
Number of cylinders 6 cylinders
Alternator, output 2400 W 2640 W
System voltage, voltage – capacity 24 V (2x12 V / 140 Ah)
2. Transmission DANA TE17 DANA TE32

No. of gears, forward - reverse 3 - 3 4 – 4
3. Power transmission DCF 280-330 DCF 370-420 DCF 450-520

Drive axle, type AxleTech PRC3806W4H AxleTech PRC7534W4H Kessler D102
4. Brakes
Footbrake system – wheel affected Wet Disc Brake – drive wheel
Parking brake system – wheel affected Spring brake - drive wheel
5. Steering
Steering system Hydraulic servo
6. Wheels DCF 280-330 DCF 370-420 DCF 450-520

Dimension, front and rear 16.00x25 18.00x25 18.00x33
Tyre pressure, also see pressure plate 1.0 MPa
Tyre type, front and rear Inflated with air. Spare and replacement tyres must be of brand
names approved by Cargotec.
9. Cab Volvo TAD762VE Volvo TAD1360VE

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

192 9 Technical data – Technical data
9.6 Lighting system

Check lamps 1.2 W2x4.6d
Interior lighting 10 S8.5
Tail lights 5 BA15s
Brake light 21 BA15s
Direction indicators 21 BA15s
Tail lights, brake lights & direction indicators - Replaced complete
LED
Position lamps 5 W2.1x9.5d
- Replaced complete
Position lamps LED
Headlights, (with high and low beam) 75/70 P43t-38 (H4)
Back-up light 70 PK22s (H3)
Working lights incandescent light 70 PK22s (H3)
35 D1S Xenon tubes. Cartridge and
Work lights, Xenon ballast replaced complete.
- Replaced complete
Working lighting LED
Revolving beacon 70 PK22s (H1)

9 Technical data – Technical data 193
Volumes
Any deviation from this table must be approved in writing by Cargotec.
DCF 280-330 DCF 370-520

1.2 Engine, fuel system Volvo TAD762VE Volvo TAD1360VE
Fuel tank, volume 300 l 400 l
Fuel quality Diesel according to:
EN590,
ASTM D 975 No 1-D,
ASTM D 975 No 2-D.
AdBlue tank, volume 20 l
Quality AdBlue, according to ISO standard 22241.
1.7 Engine, cooling system Volvo TAD762VE Volvo TAD1360VE
Coolant volume 35 l 48 l
Coolant filling point Volvo Penta Coolant VCS, ready-mixed
CAUTION
Risk of engine damage and damage to the cooling system if
different types of coolant are mixed.
When changing and topping up coolant, the same type of
coolant must be used as was used before.
1.8 Engine, lubrication system Volvo TAD762VE Volvo TAD1360VE

Oil type, quality See Oils and lubricants, recommendation, page 195.
Oil volume incl. filter 27 l 36 l
2.6 Transmission, lubrication Dana-Spicer Off Highway TE17312 Dana-Spicer Off Highway TE32418
system
Oil type See Oils and lubricants, recommendation, page 195.
Oil volume transmission total 37 litres 80 litres
Oil volume transmission when changing 27 litres 60 litres
AxleTech AxleTech
3.3 Power transmission, drive axle PRC3806W4H PRC7534W4H Kessler D102
Oil quality See Oils and lubricants, recommendation, page 195.
Oil volume, differential 33 litres 50 litres 65 litres
Oil volume, hub reduction 2x10.5 litres 2x10 litres 2x12 litres
4.8 Brake system

Oil tank brake system, volume 170 l

7 Load handling
Oil volume, planetary gear, hydraulic motor 1.6 l
Oil volume, disc brake, hydraulic motor 0.6 l
9 Frame, body, cab and accessories

Refrigerant air conditioning R134a
Volume refrigerant 2000 g
Lubricant air conditioning ZEXEL PAG-oil ZXL100 (1.7 dl)
Washer fluid, volume 5 l
10 Common hydraulics DCF 280-330 DCF 370-520

Hydraulic oil tank, volume 600 l
Hydraulic oil system, volume 700 l (total, incl. tank) 800 l (total, incl. tank)

Oils and lubricants, recommendation

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

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

Oil type, quality F -40 -22 -4 +14 +32 +50 +68 +86 104
1.8 Engine, lubrication system
VDS-3 SAE 15W40
SAE 5W30 (motor oil)
2.6 Transmission, lubrication system

ATF Dexron III DEXRON III (trademark)
3.3 Power transmission, drive axle

API GL-5 SAE 80W140
SAE 75W90
4 Brakes (Note 1)
GM Allison C-4 SAE 5W30 (transmission oil)
John Deere J20 C, D
Caterpillar TO-4
7 Load handling
Oil planetary gear hydraulic motor, hypoid oil SAE 80W140
API GL-5
SAE 75W90
Disc brake hydraulic motor; See 10 Common
hydraulics below
10 Common hydraulics
DIN 51524 Part 3 HVLP ISO VG 68
ISO VG 46 HV
ISO VG 32
NOTE
Oil filters shall always be changed in connection with oil change.
Change interval for engine oil requires that the sulphur content in
the fuel does not exceed 0.5%.
Note 1: The oil in the brake system has to meet one of the quality
requirements.
API = American Petroleum Institute
VDS = Volvo Drain Specification

Lubricating grease
Use a universal grease type EP according to NLGI Grade 2 (EP2) for

all lubrication points except for lifting equipment and slide plates.
For lifting equipment use a universal grease type EP according to NLGI

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

Cargotec Spare Parts Department. 0.65 kg cartridge for grease gun
part. no 923110.0360 and 5 kg tin part. no 923595.0003.
NOTE
Select lubricant class according to the prevailing climate.
Contact grease
Use electrical contact grease part. no. 923836.0552.
Sealant silicone
Use silicone part. no. 923107.0308.
Silicone adhesive
Use silicone adhesive part. no. 923854.0100.
Coolant
Use ready-mixed recommended coolant. Choose the mixture of

coolant that is adapted for the right temperature.
CAUTION
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, the same type
of coolant must be used as was used before.

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

Conversion SI-units
Recalculation Recalculation
SI-unit factor Non-SI factor SI
Torque
Nm x 10.2 = kg·cm x 0.8664 = lb·in
Nm x 0.74 = lbf·ft x 1.36 = Nm
Nm x 0.102 = kg·m x 7.22 = lb·ft
Pressure (Pa = N/m2)
kPa x 4.0 = in.H2O x 0.249 = kPa
kPa x 0.30 = in.Hg x 3.38 = kPa
kPa x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
kp/cm 2 x 14.22 = psi x 0.070 = kp/cm2
N/mm 2 x 145.04 = psi x 0.069 = bar
MPa x 145 = psi x 0.00689 = MPa
Power (W = J/s)
kW x 1.36 = hp (cv) x 0.736 = kW
kW x 1.34 = bhp x 0.746 = kW
kW x 0.948 = Btu/s x 1.055 = kW
W x 0.74 = ft·lb/s x 1.36 = W
Energy (J = Nm)
kJ x 0.948 = Btu x 1.055 = kJ
J x 0.239 = calorie x 4.19 = J
Speed and acceleration
m/s2 x 3.28 = ft/s2 x 0.305 = m/s2
m/s x 3.28 = ft/s x 0.305 = m/s
km/h x 0.62 = mph x 1.61 = km/h
Horsepower/torque
Bhp x 5252 rpm= TQ (lb·ft) TQ x rpm 5252 = bhp
Temperature
ºC = (ºF – 32)/1,8 ºF = (ºC x 1,8) + 32
Flow factor
l/min (dm3 /min) x 0.264 = US gal/min x 3,785 = litre/min

Conversion table length

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

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

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

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

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

Conversion table pressure

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

10 Terminology 201
10 Terminology
Explanations
Term Description
Accumulator Reservoir that stores (accumulates) pressure for, i.e. hydraulic functions.
Attachment Part of the machine that grips the load when lifting.
Anti-corrosion agent Prevents oxidation, in simple terms, rustproofing.
Working hydraulics All load handling functions, that is, lift and lower, tilt, side shift, spreading (extension)
and levelling.
Wheelbase Distance between drive axle and steering axle.
Bar Unit to express pressure.
Battery disconnector Cuts off power supply from battery.
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.
Display "Window" showing digital information, i.e. on steering wheel panel in the cab.
Operating time Number of hours machine has been in operation, shown on hour meter in cab.
Drive axle Driving axle that receives the torque from the drivetrain.
Drivetrain Parts in machine involved in power transmission; engine, torque converter, transmission,
propeller shaft, and drive axle with differential and hub reduction.
ECC Electric Climate Control. Air conditioning system with thermostat-controlled cooling,
dehumidification and heating.
EHC Electric Heat Control. Heater unit with thermostat-controlled heating.
Electrolyte level Fluid level in battery cells.
Expansion tank Tank for coolant.
Fixed displacement Non-adjustable volume (capacity) in a pump.
Hanging load Lifted load.
FMI Fault Message Identifier.
Forks Lifting device that lifts the load.
Fork bracket Bracket for forks, fitted on the lifting trolley.
Main fuse Located by battery. Breaks the current to all systems in the whole machine.
Hydraulic oil Oil for hydraulic system. See specifications in operator's manual.
Hydraulic oil pump Pump in hydraulic system.
Hydraulic system System that uses oil pressure to transfer power to different functions.
Hanging load Lifted load.
Indicator Manual "sensor", for example, shows that a filter is clogged and needs to be changed.
Inverted forks Forks turned upside down, for lifting and fitting top lift.
Refrigerant Fluid/gas in air conditioning. May only be handled by authorised trained personnel.
Low-emission engine Engine with low emissions of hazardous substances. Manufactured in accordance
with regulations.
LC Load centre.
Lift capacity Indicates machine's maximum lift capacity.
Lifting point Attaching point for lift device when lifting an object.
Trolley Lifts the load, located on the mast.

202 10 Terminology – Terminology
Term Description
Solenoid valve An electro-magnetically controlled valve. See also proportional valve.
Control valve Valves that can be used to control something, for example, to release pressure and thus
lower a boom or a fork.
Machine model Machine type. Specified, for example: DCF 280-520. See also type designation.
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Torque converter Hydraulic, variable clutch.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases torque
from the drivetrain.
Pilot oil pressure A low control pressure to, for example, a valve.
Planetary gear Type of transmission with gears in constant engagement.
Product alternative One of several alternatives is selected for a machine, e.g. engine alternative.
Progressive steering Quick steering wheel movements give greater steering angles.
Proportional valve An electro-magnetically controlled valve. If a voltage is applied, the valve is activated
in proportion to the voltage amplitude. In simple terms, infinitely variable valve, as
opposed to on/off valve. For example, found on transmission's valve housing.
Frame member Structural members in the frame.
Recirculation Circulate over and over again.
Serial number Unique machine designation. On the machine plate.
Service position How machine should be safely positioned before service may be started.
Servo A small movement by the user results in a large angle, i.e. servo steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side shift Forks / attachment repositioned in parallel and laterally.
Levelling Forks / attachment tilted, for example if the load is standing on an uneven surface.
Spirit Delta Enclosed type of cab.
SPN Suspect Parameter Number.
Spreading (positioning) Spreading of forks (i.e. changing the relative inside distance between the forks) /
Widening the attachment.
Mast Carrier of lifting trolley, forks, attachment and load.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, which is emptied
automatically during operation.
Steering axle Wheel axle with steering.
Buzzer Acoustic alarm to catch the operator's attention.
Option Extra equipment for machine.
Tilting The mast is leaned forward or backward.
Top lift Attachment. See attachment.
Transmission oil Oil for transmission and torque converter. See specifications in operator's manual.
Securing machine for transport Actions before transporting machine.
Twistlocks Four locking pins, one in each corner of the attachment, pushed down in corresponding
holes in container and twisted to lock the container when lifting.
Type designation Indicates machine type and capacity. See also machine model.
Maintenance Periodic maintenance actions so that machine functions safely and for a long service life.
UTTO-oil Universal Tractor Transmission Oil.
Variable pump Pump with adjustable flow rate.
Variable displacement Adjustable volume (capacity) of a pump.

10 Terminology – Terminology 203
Term Description
Valve slide Moveable part in valve. Determines oil's path.
Wet brakes Brake discs in oil bath.
End-positions As far out or away as an object can be moved, e.g. end-positions for tilt cylinders.

204

11 Index – Index 205
Index K
Keep in mind . . . . . . . . . . . . . . . . . . . . 11
A L
About the documentation kit . . . . . . . . . . . . . . 3
About the operator's manual . . . . . . . . . . . . . . 1 Lifting and transporting the machine . . . . . . . . . . 184
Air filter, engine . . . . . . . . . . . . . . . . . . . 160 Lifting load . . . . . . . . . . . . . . . . . . . . . 128
ANSI/ITSDF marking . . . . . . . . . . . . . . . . 10 Lifting machine . . . . . . . . . . . . . . . . . . . 185
Load handling . . . . . . . . . . . . . . . . . . . 127
Long-term storage . . . . . . . . . . . . . . . . . 187
B
Battery and battery disconnector . . . . . . . . . . . 171 M
Main fuses for electrical system. . . . . . . . . . . . 173
Maintenance . . . . . . . . . . . . . . . . . . . . 151
C Mechanical release of parking brake . . . . . . . . . 182
CE-marking . . . . . . . . . . . . . . . . . . . . . 9
Checking accumulators . . . . . . . . . . . . . . . 170
Cleanliness . . . . . . . . . . . . . . . . . . . . 153 O
Control system . . . . . . . . . . . . . . . . . . . 69
Cooling system . . . . . . . . . . . . . . . . . . . 161 Oil, brake system . . . . . . . . . . . . . . . . . . 166
Operating . . . . . . . . . . . . . . . . . . . . . 116
Operating menu for engine . . . . . . . . . . . . . . 70
Operating menu for engine and transmission . . . . . . 70
D Operating menu for heating/air conditioning system . . . 73
Daily inspection . . . . . . . . . . . . . . . . 78, 147 Operating menu for scales . . . . . . . . . . . . . . 70
Description . . . . . . . . . . . . . . . . . . . . 21 Operating menu for service . . . . . . . . . . . . . 72
Driver's seat . . . . . . . . . . . . . . . . . . . . 62 Operating menu for service interval . . . . . . . . . . 71
Operating menu for statistics . . . . . . . . . . . . . 72
Operating menu for system voltage . . . . . . . . . . 71
Operating menu for transmission and hydraulics . . . . 71
E Operating menus . . . . . . . . . . . . . . . . . . 69
Engine oil . . . . . . . . . . . . . . . . . . . . . 163 Overview . . . . . . . . . . . . . . . . . . . . . 21
Environment and standards . . . . . . . . . . . . . 188 Overview description . . . . . . . . . . . . . . . . 22
Error code indication . . . . . . . . . . . . . . . . 81
Error code information on display . . . . . . . . . . . 81
Error code tables . . . . . . . . . . . . . . . . . . 85 P
Error codes . . . . . . . . . . . . . . . . . . . . 79
Event-controlled information . . . . . . . . . . . . . 73 Parking brake . . . . . . . . . . . . . . . . . . . 121
Pedals . . . . . . . . . . . . . . . . . . . . . . 58
Plates . . . . . . . . . . . . . . . . . . . . . . . 28
F
Fire . . . . . . . . . . . . . . . . . . . . . . . . 19 R
Foreword . . . . . . . . . . . . . . . . . . . . . . 1
Fuel system . . . . . . . . . . . . . . . . . . . . 155 Reading instructions . . . . . . . . . . . . . . . . . 2
Functions for load handling . . . . . . . . . . . . . 137 Running-in . . . . . . . . . . . . . . . . . . . . . 77
Fuses for electrical system . . . . . . . . . . . . . . 174
S
G Safety . . . . . . . . . . . . . . . . . . . . . . . . 5
Gear selector and multi-function lever . . . . . . . . . 52 Safety and emergency equipment. . . . . . . . . . . . 7
Gearshifting . . . . . . . . . . . . . . . . . . . . 119 Service . . . . . . . . . . . . . . . . . . . . . . 179
Service brake . . . . . . . . . . . . . . . . . . . 121
Service position . . . . . . . . . . . . . . . . . . 186
Starting engine . . . . . . . . . . . . . . . . . . . 117
H Steering . . . . . . . . . . . . . . . . . . . . . . 120
Handling. . . . . . . . . . . . . . . . . . . . . . 75 Steering wheel . . . . . . . . . . . . . . . . . . . 59
Heating / Air conditioning . . . . . . . . . . . . 66, 123 Stopping the engine - parking . . . . . . . . . . . . 126
Hydraulic control . . . . . . . . . . . . . . . . . . 54 Switches . . . . . . . . . . . . . . . . . . . . . 46
Hydraulic system . . . . . . . . . . . . . . . . . . 167
T
I Technical data . . . . . . . . . . . . . . . . . . . 191
Identification of the machine . . . . . . . . . . . . . 21 Terminology . . . . . . . . . . . . . . . . . . . . 201
Ignition . . . . . . . . . . . . . . . . . . . . . . 45 Towing . . . . . . . . . . . . . . . . . . . . . . 182
Inspection and maintenance . . . . . . . . . . . 4, 146 Transmission oil . . . . . . . . . . . . . . . . . . 164
Instruments . . . . . . . . . . . . . . . . . . . . 44 Transporting load . . . . . . . . . . . . . . . . . . 132
Instruments and controls. . . . . . . . . . . . . . . 36 Transporting the machine . . . . . . . . . . . 181, 185

206 11 Index – Index
Tyres and rims . . . . . . . . . . . . . . . . . . . 167 W

Warming up . . . . . . . . . . . . . . . . . . . . 118
Warning and indicator lights . . . . . . . . . . . . . 41
U While operating. . . . . . . . . . . . . . . . . . . 116
Unloading . . . . . . . . . . . . . . . . . . . . . 135 Windscreen washer . . . . . . . . . . . . . . . . . 159

Declaration of Conformity
We, Cargotec Sweden AB, SE-340 10 Lidhult, (Registration No. 556014-5418) herewith
declare that the machine,
Type Forklift truck

Model DCF330-12LB
Serial No A203.XXXXX
Year of construction 2011
Engine VOLVO TAD 762VE
is manufactured in conformity with the requirements in

- The Machinery Directive 2006/42/EC;
- The Electro Magnetic Compatibility Directive 2004/108/EC
the harmonised standard EN 1551 Safety of industrial trucks

- Self propelled trucks over 10 000 kg capacity.
the Outdoor Noise Directive 2000/14/EC, with use of annex VI, procedure 1 as amended by
the Directive 2005/88/EC, internal control of production with assessment of technical
documentation and periodical checking, under supervision of the Notified Body 0404:
0404 SMP- Svensk Maskinprovning

Fyrisborgsgatan 3
SE-754 50 Uppsala
Noise related value 147 / 2200 kW/rpm

Measured sound power level Lwa 108 dB
Guaranteed sound power level Lwa 109 dB
Name Dan Pettersson

Position Head Of Counterbalanced Products
Lidhult 2011-01-20
Place, Date of Issue Signature
2A_TEST_O_GB
last page
Cargotec Sweden AB
Cargotec improves the efficiency of cargo flows by offering solutions for Torggatan 3
the loading and unloading of goods on land and at sea – wherever cargo SE-340 10, Lidhult, Sweden
is on the move. Cargotec’s main daughter brands for cargo handling
Hiab, Kalmar and MacGregor are global market leaders in their fields. tel. +46 372 260 00
Cargotec’s global network offers extensive services that ensure the fax +46 372 263 90
continuous, reliable and sustainable performance of equipment. www.cargotec.com

Idcf07 01GB

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Forklift trucks 28-52 tonnes

Operator's Manual DCF 280-520 IDCF07.01GB

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

Operator's manual, purpose

Cargotec will not accept any responsibility for machine modifications

About machine version

Cargotec reserves the right to make changes to specifications and

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

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

Operator's Manual DCF 280-520 IDCF07.01GB

1.1.1 Reading instructions

Read the operator's manual

Read the operator's manual

Read the Maintenance manual

refers to important information in the Maintenance manual.

Read the Maintenance manual

Each description of optional equipment in the manual is marked with

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

IDCF07.01GB Operator's Manual DCF 280-520

1.2 About the documentation kit

There is supplementary documentation that can be ordered for the

Always indicate publication number when ordering.

Operator's Manual DCF 280-520 IDCF07.01GB

1.3 Inspection and maintenance

Maintenance work described in this operator's manual can be

IDCF07.01GB Operator's Manual DCF 280-520

Important to read the operator's manual

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

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

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

Operator's Manual DCF 280-520 IDCF07.01GB

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

IDCF07.01GB Operator's Manual DCF 280-520

2.1 Safety and emergency equipment

Operator's Manual DCF 280-520 IDCF07.01GB

9. External rear view mirrors

9a 9a shows blocked area in front of machine.

IDCF07.01GB Operator's Manual DCF 280-520

This machine is CE-marked. This means that upon delivery it fulfils

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

See example of EC Declaration after 11 Index.

Anyone making modifications that affect the safety of the machine

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

For additional information, see standards under chapter 8

Operator's Manual DCF 280-520 IDCF07.01GB

2.3 ANSI/ITSDF marking

This machine is ANSI/ITSDF marked. This means that the delivery

Anyone making modifications that affect the safety of the machine

IDCF07.01GB Operator's Manual DCF 280-520

2.4 Keep in mind

During work shifts

Operator's Manual DCF 280-520 IDCF07.01GB

IDCF07.01GB Operator's Manual DCF 280-520

Operator's Manual DCF 280-520 IDCF07.01GB

IDCF07.01GB Operator's Manual DCF 280-520

Operator's Manual DCF 280-520 IDCF07.01GB

IDCF07.01GB Operator's Manual DCF 280-520

Operator's Manual DCF 280-520 IDCF07.01GB

IDCF07.01GB Operator's Manual DCF 280-520

Operator's Manual DCF 280-520 IDCF07.01GB

Fire prevention measures

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

Action after fire