Forklift Trucks 20-30 Tonnes: Operator S Manual

Forklift Trucks 20-30 tonnes
Publ. no IDCD03.03GB
Operator's manual in original language OPERATOR´S MANUAL
DCD 200-300
1 Foreword......................................................................................................... 3
1.1 About the operator’s manual ...................................................................... 3
1.2 About the documentation kit ....................................................................... 6
1.3 Inspection and maintenance ...................................................................... 7
2 Safety .............................................................................................................. 9
2.1 Safety and emergency equipment ............................................................ 11
2.2 CE-marking .............................................................................................. 12
2.3 ANSI/ASME marking ................................................................................ 13
2.4 Keep in mind ............................................................................................ 14
3 Overview ....................................................................................................... 23
3.1 Description DCD 200-300 ........................................................................ 23
3.2 Plates ....................................................................................................... 30
4 Instruments and controls ............................................................................ 39
4.1 Overviews ................................................................................................. 40
4.2 Warning and indicator lights ..................................................................... 45
4.3 Instruments ............................................................................................... 47
4.4 Ignition key lock (43) ................................................................................ 48
4.5 Switches ................................................................................................... 49
4.6 Gear and travel direction selector (2) ....................................................... 54
4.7 Multi-function lever (5) .............................................................................. 56
4.8 Load handling ........................................................................................... 57
4.9 Pedals ...................................................................................................... 66
4.10 Steering wheel (4) .................................................................................... 70
4.11 Driver’s seat (9) ........................................................................................ 74
4.12 Heating unit/Air conditioning ..................................................................... 80
4.13 KCS system .............................................................................................. 85
5 Handling........................................................................................................ 91
5.1 Running-in ................................................................................................ 93
5.2 Daily inspection ........................................................................................ 94
5.3 Error codes ............................................................................................... 95
5.4 Operating ................................................................................................ 126
5.5 Load handling ......................................................................................... 150
6 Inspection and maintenance..................................................................... 165
6.1 Daily inspection ...................................................................................... 166
6.2 Maintenance ........................................................................................... 170
6.3 Service ................................................................................................... 199
7 Transporting the machine ......................................................................... 201
7.1 Towing .................................................................................................... 202
7.2 Lifting and transporting the machine ...................................................... 206
7.3 Service position ...................................................................................... 208
7.4 Long-term storage .................................................................................. 209
8 Environment and standards...................................................................... 211
9 Specifications............................................................................................. 215
10 Terminology................................................................................................ 225
11 Index............................................................................................................ 229
1 Foreword 3
1 Foreword
1 Foreword
mm mm mm mm mm mm
1.1 About the operator’s manual

General
page
–
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

–
This operator’s manual applies to machine DCD 200-300.

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 modify specifications and equipment
without prior notice. All information and data in the manual are valid at
the time of publication.
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.
Operator’s manual DCD 200-300, 2006 - IDCD03.03GB

4 1 Foreword – 1.1.1 Reading instructions
1.1.1 Reading instructions

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

The warnings provide information on potential dangers that, if not
heeded, could lead to personal injury or product damage.
DANGER
Situation that could lead to severe personal injury or
death if regulation is not followed.
WARNING
Situation that could lead to personal injury if regula-
tion is not followed.
CAUTION
Situation that could lead to product damage if regula-
tion is not followed.
Important information
–
Important information is denoted with NOTE and is intended to facili-

tate the work process, handling or to increase understanding of the
information.
NOTE
Important information not related to safety.
IDCD03.03GB Operator’s manual DCD 200-300, 2006 -

1 Foreword – 1.1.1 Reading instructions 5
Read the operator’s manual

–
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the Operator’s manual.
000262
Read the operator’s manual
Read the Maintenance manual
–
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the Maintenance manual.
001128
Read the Maintenance manual
Optional equipment
–
There is a wide range of optional equipment for the machine. Each de-
000264
scription of optional equipment in the operator’s manual is marked with
a symbol and contains an explanatory text. The symbol is highly visible
Indicates optional equipment and is placed next to the text and figure item in question.
See the machine card for complete specifications of the machine’s
product alternatives and optional equipment.

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

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

• Operator’s manual DCD 200-300 (in cab with machine)
• Maintenance manual DCD 200-300
• Spare parts catalogue with machine card
There is supplementary documentation that can be ordered for the
machine:
• Workshop manual DCD 200-300.
• Supplier documentation for e.g. engine, transmission, and drive
axle.
Ordering documentation
–
The documentation is ordered from the dealer for Cargotec.

Always indicate publication number when ordering.

1 Foreword – 1.3 Inspection and maintenance 7
1.3 Inspection and maintenance

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

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

and repairs), contact an authorised workshop.

8 1 Foreword – 1.3 Inspection and maintenance

2 Safety 9
2 Safety
2 Safety
mm mm mm mm mm mm
General
page
–
Safety rules are intended to reduce the risk of personal injuries as well
as damage to the load or other property.
Only personnel trained for this machine may handle, operate, perform
service or be in its vicinity during its use.
The safety information in this operator’s manual is for your information
and safety. It cannot, and is not intended to cover all possible events
during operation. Having responsible operators with the right training
is the only way to ensure safe and long-term use of the machine.
The machine was thoroughly tested and adjusted before it left the fac-
tory. This does not exclude the possibility that is has been damaged
during delivery. The machine must be thoroughly inspected before it is
used to ensure correct function.
Important to read the operator’s

–
manual
Incorrect handling can lead to personal injuries and damages to prod-
uct and/or property. Therefore, read the Operator’s Manual very thor-
oughly before starting to use the machine. The Operator’s Manual
contains important information about your Kalmar machine, handling
the machine, safety during operation, and daily maintenance of the
000262
machine. You’ll also find a lot of valuable information that will make
your work easier.
The operator’s manual should always be kept in the machine. If it’s
lost, replace it immediately with a new operator’s manual.
NOTE
Never use a machine that doesn’t have an operator’s manual.
Ask your foreman or supervisor if there’s anything in the text you do
not understand or if you feel information is missing in any area.
Intended use
–
• The machine may only be used for the purpose for which it is de-
signed and adapted, that is, to lift and transport goods (the weight
of which is not to exceed the machine’s max. permitted load ca-
pacity). If it is used in another way or in potentially dangerous en-
vironments (for example, explosive environment, area with dust
containing asbestos), special safety regulations must be followed
and the machine must be equipped for such operation.
• The machine may not be modified or rebuilt without permission
from Cargotec. For modifications approved by Cargotec, affected
plates on the machine and documentation shall be adapted to ap-
ply to the modification.

10 2 Safety
Any modification or rebuild without Cargotec’s permissions can-

cels Cargotec’s product responsibility. Modifications and rebuilds
may only be done if there is knowledge to verify and test modifi-
cations and rebuilds. Modifications and rebuilds shall be docu-
mented (dates and actions) and responsible organisation shall be
stated with name and address. Plates and decals shall be updat-
ed according to the machine’s new version.
• The machine may not be operated on public roads unless it has
been adapted according to national road safety regulations.
• It is always the machine owner’s responsibility to ensure that the
machine has approved fire-fighting equipment according to gov-
erning regulations.
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 warnings
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, head-
lights, and indicator system etc., do not function correctly.
• In case of defective brakes, steering or lifting equipment.
• 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 – 2.1 Safety and emergency equipment 11
2.1 Safety and emergency

equipment
General
page
–
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:
8 2 11 9 8 7 1. Reverse alarm
2. Revolving beacon/flashing beacon

The revolving beacon may also be a version that can be raised
and lowered.
3. Horn
4. Electrically powered loud air horn
5. Fire extinguisher
A fire extinguisher is normally located on the left front fender, but
may also be located on the right front fender or inside the cab.
1, 8 6 10 3 5 4 9 8 If the machine is provided with a fire extinguisher, it should be of
009491
the type ABE according to EN 3 pt. 1, 2, 4 and 5. With such a fire

extinguisher, it is possible to put out fires in both solid organic ma-
terials and fluids. Adapted fire extinguishing equipment can be or-
dered from Cargotec.
6. Seat belt
7. Buzzer in the cab to indicate an alarm or forgotten action, e.g. if
the operator leaves the operator’s seat without applying the park-
ing brake.
8. Camera with monitor

Used to provide improved visibility to the rear when operating and/
or when load handling with the machine. The monitor is normally
located inside the cab by the front right door pillar.
9c 9a 9. Exterior mirrors :
Used to provide improved visibility while manoeuvring and load
handling.
9a shows blocked area in front of machine
9b shows blocked area to the side/behind the machine
9c shows blocked area behind machine.
10. Control breaker for load handling

(servo circuits, only for controls electric servo for load handling).
009465
9b 11. Protective grating for roof window

12 2 Safety – 2.2 CE-marking
2.2 CE-marking
CE-marking
page
–
(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 have been fulfilled, Cargotec issues
and delivers an EC Declaration of Conformity for each individual ma-
chine. This Declaration of Conformity also covers attachments and op-
tions manufactured by Cargotec. The documentation is valuable and
should be kept in a safe location and saved at least 10 years. The doc-
umentation should always accompany the machine when it is sold.
See example of EC Declaration after 11 Index.
Anyone making modifications that affect the safety of the machine as-
sumes responsibility for them. If the machine is used for purposes or
012876
with attachments other than that specified in these instructions, safety

must be ensured in each individual case. The machine owner is re-
Machine plates for CE-marking sponsible for ensuring that the machine is used as specified in the op-
erator’s manual. In some cases, the type of use may require a new
CE-marking and the issue of a new EU Declaration of Conformity.
For additional information, see standards under chapter
8 Environment and standards.

2 Safety – 2.3 ANSI/ASME marking 13
2.3 ANSI/ASME marking

ANSI/ASME marking
page
–
(only applies to machines for the North American market).

This machine is ANSI/ASME-marked. This means that upon delivery
it fulfils the basic safety requirements of ANSI/ASME B56.1.
Anyone making modifications that affect the safety of the machine also
assumes responsibility for them.
If the machine is used for purposes or with attachments other than
those specified in these instructions, safety must be ensured in each
individual case. The machine owner is responsible for ensuring that
the machine is used as specified in the operator’s manual.
For additional information, see standards under chapter
8 Environment and standards.
012877
Machine plates for ANSI/ASME marking

14 2 Safety – 2.4 Keep in mind
2.4 Keep in mind

Interrupted operation and/or parking
page
–
WARNING
Always turn off the electric power when the machine
is left, e.g. when parking or at the end of the shift.
Risk of fire!
Turn off the electric power with the battery

disconnector.
NOTE
Always check that a gear is not engaged before turning the start
key or resetting the control breaker for load handling.
NOTE
Never leave the operator’s station without first applying the park-
ing brake (ON position).
NOTE
Always remove the start key if the machine is to be left
unattended.

2 Safety – 2.4 Keep in mind 15
During work shifts

–
DANGER
Forks or other attachments are work tools that handle
large loads.
Extreme hazard to personal health and risk of proper-

ty damage!
Make sure that no persons stand or walk under a

raised work attachment, regardless of whether it’s
loaded or not.
DANGER
External equipment may only be used if it is approved
by Cargotec.

ty damage!
Only use equipment that is approved by Cargotec.
DANGER
The parking brake should not be applied when the
machine is in motion.
Very sudden braking. Risk of machine tipping over,

load tipping over or 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.

ty damage!
Keep in mind:
• Always check that no persons are in the way of the

machine or its accessories. Also check that the
area upwards is free. Stop the machine if there are
unauthorised persons or vehicles within the work
area.
• The operator must always face in the travel direc-

tion 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, via-
ducts, docksides, ramps, doors, etc.
• Always operate carefully so that the attachment

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

view mirrors and camera ( ).

WARNING
Transporting loads is associated with major risks.
Risk of roll-over and tipping over! Risk of load dam-

age to property! Fatal danger!
Respect the lifting capacity of the machine and exer-

cise the greatest caution during load handling:
• The machine must only be operated on a level sur-

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

tion. Always operate carefully, keep in mind the
width and height so that the mast or forks/attach-
ment does/do not collide with posts, power lines,
etc.
• Do not transport the load in high position since

this may cause the machine to roll or tip over.
• Always operate with the load facing uphill on an

uphill or downhill gradient, never operate or turn
across a gradient.
• 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.
Local regulations may apply when handling spe-

cial loads. Learn about them, and follow them.

WARNING
The machine’s load capacity is limited.
Risk of roll-over and tipping over!
It is prohibited to exceed the machine’s load capacity.

See marking plate and load diagram.
WARNING
The strength of the roof window may be significantly
reduced in the event of exposure to substances con-
taining: aromatic hydrocarbons, ketones, esters and
chlorinated hydrocarbons.
Low strength! Danger!
Check the outside surface of the roof window at reg-

ular intervals. Clean only with windscreen washer flu-
id or a mild cleaning agent. Rinse thoroughly with
plenty of lukewarm water. Replace a damaged roof
window immediately if it’s cracked or scratched!
WARNING
Lifting loads in very windy conditions is associated
with great danger.
Risk of roll-over and tipping over! Fatal danger!
Avoid lifting loads at 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 facilities. Use exhaust venting
equipment!

WARNING
Work position on the machine is located up high.
Risk of falling and body injury!
Always use the steps and handles when you climb up

or down from the machine. Always 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
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 operator door(s) during the work

shift.
WARNING
Passengers are only allowed in the cab if there is a
specific passenger seat. It is prohibited to carry pas-
sengers on the machine outside the cab or on the
load.
Risk of personal injury!
Passenger in cab shall use a permanently mounted

extra seat for passengers and seatbelt.

WARNING
The machine’s hydraulic system contains a high-
pressure accumulator.
Always be very careful when working with the hydrau-

lic system, and avoid standing close to hydraulic
components or hoses. Before working on the hydrau-
lic system, the accumulator 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!
Risk of short-circuiting! Warning - generation of oxy-

hydrogen gas! Sparks and fire hazard! Oxy-hydrogen
gas is very explosive!
Batteries should always be provided with protective

caps over the terminals and connections. Connect
the positive (plus) terminals first. Then connect the
negative (minus) terminals to prevent sparks that may
ignite the hydrogen gas.
WARNING
The machine uses oils and lubricants.
Health hazard in the event of protracted skin contact!
Avoid skin contact with oils and lubricants. Use pro-

tective gloves.

WARNING
Fire extinguishers contain dry chemicals.
Risk of breathing difficulties when using in an en-

closed space!
Use the fire extinguisher from the outside and into the
area that is to be extinguished. After use, ventilate the
space thoroughly.
CAUTION
Cracks or scratches result in reduced strength of the
roof window.
Low strength!
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 perform-

ance! Unwanted movement of parked machine!
Following emergency braking with the parking brake,

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

it must always be reset to restore the machine’s park-
ing brake function.

WARNING
Optional equipment such as two-way radio, RMI, tele-
phone, 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 per-

sons 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 ap-
proved by Cargotec.

3 Overview 23
3 Overview
3 Overview
mm mm mm mm mm mm
3.1 Description DCD 200-300

General
page
–
The DCD 200-300 machine is a forklift truck with so-called heavy ca-
pacity for all types of load handling. It has a maximum lift capacity of
20 to 30 tonnes. The machine has a lifting mast. There are three lifting
mast options and these are available in different lifting heights:
1. Duplex
2. Duplex Free Lift
3. Triplex Free Lift
This section provides a short presentation of the machine’s parts, see
General page 24.
3.1.1 Identification of the machine

Type designation of forklift truck
page
–
Each Cargotec machine has a type designation. Type designation

DCD 250-12 (LB) (example) indicates the following:
• D – Diesel engine
• C – Counterweight forklift
• D – Generation
• 250 – Lift capacity, decitonne
• 12 – Distance to centre of gravity, in decimetres
• (LB) – Low-profile machine
Machine card
–
When ordering and after putting the machine into operation, it is pos-
sible to modify and adapt Cargotec machines in different ways with
product alternatives and optional equipment. This makes it possible to
satisfy a very wide range of customers.
A machine card is delivered together with the spare parts catalogue.
The machine card contains a complete specification of the machine’s
The machine card must be updated when the machine is modified and
Cargotec must be informed.

24 3 Overview – 3.1.2 Overview description
3.1.2 Overview description

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

which are pointed out in the overview figure below.
5
7
001524
1 2 3 4
1. Steering axle
2. Engine
3. Transmission
4. Drive axle
5. Load handling, lifting mast
6. Load handling, fork carriage
7. Cab

3 Overview – 3.1.2 Overview description 25
Engine
–
The machine has several engine alternatives. The engines are straight
6-cylinder, turbocharged low-emission engines with intercooler. The
engine provides power for propulsion and working hydraulics.
The machine is equipped with one of the following engine alternatives:
• Volvo TAD750 (181 kW)
• Cummins QSB6.7 (194 kW)
Transmission
–
The transmission is available as manual or fully automatic with a

torque converter. It has 3 forward gears and 3 reverse gears. The hy-
draulic pumps for working hydraulics are mounted on the
transmission.
The machine is equipped with the transmission alternative Dana
TE17000.
Drive axle
–
The drive axle (front axle) is equipped with a differential and hub re-
ductions of the planetary gear type.
Brakes
–
The machine has one brake circuit and is equipped with hydraulically
operated brakes. The brake units consist of fully sealed oil-cooled disc
brakes with external cooling.
The parking brake is controlled electro-hydraulically and brakes with a
disc brake. The disc brake acts on the drive axle’s input shaft. The
parking brake is applied automatically (with spring force) in the event
of voltage drop and in the event of loss of hydraulic pressure, and it is
disengaged with hydraulic pressure.
Steering
–
The machine is steered with the steering axle (rear axle). A double-
acting hydraulic cylinder acts on the wheel pair. Steering is progres-
sive, i.e. a quick movement of the steering wheel gives a greater steer-
ing angle per steering wheel turn. This makes the machine easier to
operate in tight areas.
Load handling
–
The mast and fork carriage are used for load handling. The load is
moved vertically and is tilted (angled) forward or back.
The fork assembly is equipped with side shift and fork spreading.
The forks have roller brackets and as an alternative there is a shank
system with a pin type or hook mounting.
Electrical system
–
The electrical system consists of electrical and electromagnetic com-

ponents such as battery, switches, cable harnesses, solenoid valves,
fuses and relays. It has a computer-based control and monitoring sys-
tem which monitors and controls certain of the machine’s functions.

Control system, KCS

–
The machine is equipped with KCS, an electronic control system that

monitors and handles certain systems in the machine requiring KCS,
e.g. engine and transmission.
The control system facilitates and streamlines maintenance and
operation.
Cab
–
The cab is available in one version: Spirit Delta. Instrumentation and

equipment can be customised.
Spirit Delta is an enclosed operator’s station built of a supporting frame
to withstand falling loads. It is equipped with a fresh air system with fil-
tered inlet and recirculation as well as heating or air
conditioning ( ).
The roof window is made of high-strength material and withstands
heavy blows, e.g. from falling objects.
Hydraulic system
–
The hydraulic system includes sub-functions brakes, steering, load

handling and cab. The system consists of a feed circuit with hydraulic
tank, hydraulic pump (gear pump) filter and accumulator.

Other equipment
–
6, 12, 29 1, 2, 24 8, 11
16, 22, 23, 27
14
21, 25
13 26
3, 18
3, 19, 28
16, 36
35
20
16
007351
20 37 7 4 38 15, 16 39 5
1 Rear view mirror
2 Extra internal rear view mirror
3 External rear view mirrors

4 Horn
Located under cab.
5 Electrically powered loud air horn

The horn is located on the cab’s right-hand side (under the side
window) and the electrically powered compressor under the cab.
6 Roof window extra strong (12 mm)

Standard roof window is 6 mm.
7 Passenger seat
8 Laminated front windscreen
9 Tinted windows
(Not positioned in figure).
10 Openable window pane, left door


11 Sun visor, front windscreen

Can be moved up or down using the string on the right side. Can
be affixed in the desired position.
12 Sun visor, roof window

Can be pulled out to fasten in two hooks at the front edge of the
roof window.
13 Sun visor, rear window

Can be moved up or down using the string on the right side. Can
be affixed in the desired position.
14 Audio system
Instructions are included.
15 Writing table with light

For handling paper in the cab. The desk and lighting are located
to the right in the cab. In some cases, depending on other equip-
ment, they may be located on the left-hand side.
16 Camera with monitor

Used to provide more visibility rearward for manoeuvring and
load handling with the machine. The camera is positioned on the
counterweight or cab and/or on the lifting equipment. The monitor
is located in the cab.
17 Socket 12/24V DC (Not positioned in figure)

The socket is fused and marked. Four sockets are located in the
left-hand instrument panel, on the upper section of the front door
pillars, as well as the right-hand side’s lower plastic cover.
18 External handle for cab instep
19 Steps between tilt cylinders
20 Mud flap, steering and drive wheels
21 Protective grille for mast working lights

22 Working lights, cab roof, rear edge, 2 lamps
23 Extra working lights, cab roof rear edge, 2, 4 or 6 lamps
24 Extra working lights, cab roof, front edge, 2 lamps

25 Mast working lights, 2 lights
26 Extra mast working lights, 2 lamps

27 Extra working lights for container handling, 4 lamps
On the cab roof, rear edge.
28 Extra working light between the tilt cylinders, 1 lamp
29 Adjustable searchlight

30 Tool kit
31 Heater: (Not positioned in figure)

A: 230 V for connecting an engine heater with or without cab
heater (located at instep on left-hand side)
B: Socket for cab heater
C: Cab heater
D: Oil heater hydraulic tank, high voltage 220/380 V
32 Extra exhaust cleaning: (Not positioned in figure)

A: Catalytic converter, replaces standard muffler
B: Particle filter, exhaust cleaner located on right-hand side (re-
places silencer and end-pipe)
33 Slip protection on e.g., steps.
34 Aluminium non-slip plates for lamp protection and front wings
35 Grating for headlights
36 Grating for rear lights
37 Litter container
38 Revolving operator’s station
39 Baseplate, cab
Mounted between cab and frame.

30 3 Overview – 3.2 Plates
3.2 Plates
Product plates
page
–
The following shows what plates should be on the machine when op-
erating within EU/EEA, more variants are available for other markets.
When ordering spare parts and when enquiring via telephone or cor-
respondence, the model designation and serial number should be giv-
en according to the plates. The plates’ spare part number is indicated
on each respective plate.
012969
4 1, 2, 5
1 Machine plate (example), A54516

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)
Q, C, D, H = Approved load at lifting height (H) at respective dis-
tance (so-called load centre) horizontally and vertically from mast
012871
and forks (D and C).

Machine plate can only be ordered with complete engraving.
2 Additional plate for machine (example), A54560
Specifications about the machine’s approved lifting equipment.
NOTE
The plate’s design depends on type of attachment.
S/N = Serial number for the machine
A = Identification number for attachment
H = Lifting height
D = Centre of gravity distance
Q = Lift capacity
012872
C = Centre of gravity height. Distance from forks to load’s vertical

centre of gravity.
Plate can only be ordered with complete engraving.

3 Overview – 3.2 Plates 31
3 Additional plate for capacity (example), A33808

Specifications about the machine’s approved lifting equipment.
The plate is in the cab for the operator’s information. Matches
plates item 1 and item 2.
NOTE
012955
The plate’s design depends on type of attachment.
S/N = Serial number for the machine
H = Lifting height
D = Centre of gravity distance
Q = Maximal load
C = Height of centre of gravity. Distance from forks/load’s under-
side up to load’s centre of gravity.
4 Type plate for mounted attachment (example), A54854
S/N = Serial number for the attachment / Year of manufacture
H = Maximum hydraulic pressure to attachment
Q = Maximal load
012873
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)
5 Plate for certified sound level (example), A54572
LWA (external) = Total sound intensity at machine.
Legal requirements within EU/EEA.
012884

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 warn-
ings and should also follow the instructions and information given on
the plates.
Make sure warning and information symbols on the machine and its
components always are easy to see and legible. Plates that have been
damaged, illegible or painted over must be replaced immediately.
1 1
5 2, 3 4
012975
1 6 2 6 3 2 1
Chassis, cab
1 Lift point, 423049.0100
Attaching point for lifting device when lifting the machine. Lift
points are found:
• mast
000276
• rear
2 Warning! A26939.0100
Warning! Read the operator’s manual for information.
000277

3 Warning! A54527.0200
Air conditioning. Filling of refrigerant requires special compe-
tence and authorisation (follow national legislation and local
rules).
1 = Refrigerant, type
2 = Amount, kg
1 3 = Pressure, bar
2
The plate is also on the condenser, compressor and at the air in-
3
let (front edge of cab) as plate A30770.0200.
012874
4 Plate for non-ionising radiation, A57336.0100

012968
Safety
5 Warning! A36203.0100
- No passengers allowed. Passengers may only ride in the cab if
it’s equipped with a permanently mounted passenger seat.
- Do not jump. Always stay in the machine when there’s a risk of
roll-over and hold on to the steering wheel.
000847

6 Fire extinguisher, A43461.0100

Indicates where extinguishing shall take place in case of fire in
the engine compartment. Nozzle for extinguisher is pushed
though the plate.
001833
A43461.0100
15 15 15 13 7, 8 11 16 9 15
10 14
012976
12
Safety
7 Warning! A32441.0100
Do not stand on the marked area (condenser).
001491
Engine
8 Filling point, fuel, 450202.0100
D
000286
450202.0100

9 Warning! A30530.0100
Rotating fan.
000287
10 Warning! A30532.0200
Hot surfaces.
000850
11 Filling point, engine oil, A32439.0300

Located under the hood.
000851
12 Automatic stop of engine, 923934.0745

005456
Power transmission, wheels

13 Filling point, transmission oil, 455949.0100
000852
455949.0100
14 Warning! A30533.0200
Rotating parts.
000853

15 Inflation pressure, factory-installed tyres

A32049.0700 0.9 MPa
A32049.0100 1.0 MPa
001523
NOTE
Read chapter 6 Inspection and maintenance regarding safe-
ty when handling wheels.
The conditions for inflation pressure change if factory-
mounted tyres are replaced with another tyre brand! Contact
Cargotec. The plate for tyre air pressure must be replaced
with a plate with the applicable tyre pressure!
Electrical system
16 Battery disconnector, A30537.0100
In position 0, the battery’s plus terminal is disconnected.
000285
17 20 19
18
012977
Hydraulic system
17 Filling point hydraulic oil, 450203.0100
000292

18 Warning! A36163.0100
Pressure. Always release the pressure from the accumulator be-
fore working on the hydraulic system.
002497
19 Hydraulic pressure, A54518
Indicates set pressures for the machine. Information is engraved.
012878

Lifting mast and attachment

20 Warning! A30771.0100
Do not walk under the load, attachment or forks. Do not stand on
the forks.
DANGER
Forks or other attachments (with or without loads) are
easily operated and highly forceful tools.

000858 ty damage!
Make sure that no person stands under a raised at-

tachment, whether it is loaded or not.

4 Instruments and controls 39
4 Instruments and controls
4 Instruments and
mm mm mm mm mm mm
controls
General
page
–
Do not operate the machine before you know the position and function
of instruments and controls, and completely understand how they are
used!
This chapter gives general information about instruments, switches,
controls and other equipment in the machine’s cab.
NOTE
Thoroughly read the following chapter about instruments and
controls.
Optional equipment
There is a wide range of optional equipment for the machine. Each de-
000264
scription of optional equipment in the operator’s manual is marked with

a symbol and contains an explanatory text. The symbol is highly visible
Indicates optional equipment and is placed next to the text and figure item in question.
See the machine card for complete specifications of the machine’s

40 4 Instruments and controls – 4.1 Overviews
4.1 Overviews
General
page
–
Cab instrumentation and panels depend on equipment level:

(Alternative placement may arise according to customer
specifications)

4 Instruments and controls – 4.1.1 Spirit Delta 41
4.1.1 Spirit Delta

Cab overview Spirit Delta
page
–
1 2 3 4A 5
R
1 4 5
14 2 3
7A
4B 7B
006910
13 12 11 10 9 8
1 Left instrument panel
2 Gear and travel direction selector
3 Steering wheel panel
4A Steering wheel
4B Joystick or mini steering wheel
5 Multi-function lever
6 Parking brake
7A Control for load handling
7B Alternative controls for load handling
8 Arm rest
9 Driver’s seat
10 Accelerator pedal
Accelerator pedal with function for selecting direction of travel (forward/reverse)
11 Brake pedals
12 Clutch pedal
Inching pedal
13 Electronic box with fuses and relays
14 Hour meter

42 4 Instruments and controls – 4.1.1 Spirit Delta
Left instrument panel
30 31 32 33 15 Control for heating
16 Control for fan
17 Control for defroster/cab
18 AC cooling control
27 28 29
19 .. 26
19 Recirculation/fresh air switch
(Only for heating unit with cooling AC)
18
17 20 Switch for cooling AC
16
15 Switch for extra working lights
21 Switch for working lights on mast
30 31 32 33
24 Switch, revolving beacon
27 28 29 25 Switch for flashing hazard lights

19 .. 26
26 Switch for headlights
006908
TO DE
AU MO
34 27 Switch for seat heating

(May be fitted in driver’s seat)
Left-hand dashboard panel, upper with heating unit
and lower with air conditioning
28 Switch for central lubrication
29 Switch for supplemental heating
30 Spare
31 Spare
32 Spare
33 Socket for 12/24V
34 Air conditioning ECC

See Section 4.12.1.2 Air conditioning ECC.

4 Instruments and controls – 4.1.1 Spirit Delta 43
Steering wheel panel

There is an integrated buzzer under the steering wheel panel (not vis-
ible). It is activated if:
• starting attempts are made with a gear engaged and parking
brake not activated
• the parking brake is not activated when the operator leaves the
driver’s seat
• the machine has low coolant level, low brake pressure or a park-
ing brake fault
• an error code is generated, in which case a short sound signal is
triggered
35 36 37 38 39 40 41 42 43
35 Warning lamp for exhaust cleaning (particle filter)
36 Warning lamp for air filter replacement
37 Indicator light for tilt control
38 Warning lamp for low battery charging
F 39 Indicator light for high beams

N
R
40 Indicator light for direction indicators
1 2
R
3
41 Display for KCS control system
4
42 Alarm indicator for control system, KCS
5
43 Ignition
006903
44 45 46 47 48 49 44 Switch for revolving driver’s seat

45 Switch, engagement and disengagement of alternative travel
direction selector
Switch, engagement and disengagement of alternative gear

selector
46 Switch for inching
47 Function keys, KCS control system
48 Switch for windscreen wiper, rear
49 Switch for windscreen wiper, roof

44 4 Instruments and controls – 4.1.1 Spirit Delta
Right-hand instrument panel
51 52 53 54 55 56 57 58 59
51 Switch for switching off the reverse alarm
52 Switch for the raising/lowering the driver’s seat
54 Switch for electrically heated rear view mirrors
007728
55 Spare
Right-hand instrument panel 56 Spare
57 Spare
58 Spare
59 Spare
Control for load handling

For more controls for load handling and their functions,
see section 4.8 Load handling.

4 Instruments and controls – 4.2 Warning and indicator lights 45
4.2 Warning and indicator lights

General
page
–
This section describes the warning lamps and indicator lights in the
cab. They indicate the status of sub-systems/systems. An illuminated
warning lamp should be attended to immediately. An illuminated indi-
cator light informs of imminent action.
Warning lamps and indicator lights are grouped in the steering wheel
panel.
Numbers in brackets refer to the positions in Cab overview Spirit Delta
page 41.
Warning lamp for exhaust cleaning (35)

–
The lamp (red) is illuminated when the particle filter needs to be

cleaned or there is another problem. The warning lamp has no symbol.
Determine the cause and take appropriate action. For cleaning, see
section 5.4.9 Stopping the machine - parking or see the separate man-
ual for the particle filter.
Warning lamp for air filter replacement (36)

–
The lamp (red) is illuminated when the air filter needs to be replaced
or there is another problem. Determine the cause and take appropriate
action. Contact service.
004254
Buzzer in the cab’s instrument panel activated at the same time as this
light.
Indicator light for tilt control (37)

–
The light (orange) shows the status of tilt control (tilt auto). Tilt control
is activated/deactivated by switches on the electric servo control for
load handling. The indicator light has no symbol.
The light (orange) may also be on the mast .

Tilt control status is shown in accordance with:
• The light flashes. The mast’s vertical position is being adjusted.
• The light illuminates with a constant glow. The mast is in a vertical
position.
• The light is off. Tilt control is not active.

46 4 Instruments and controls – 4.2 Warning and indicator lights
Warning lamp for low battery charging (38)

–
The light (red) warns in case of missing charge to the batteries. The
light is activated if the voltage from the alternator is lower than the bat-
tery voltage.
000297
Determine the cause and take appropriate action. Contact service.
NOTE
Do not operate with an activated light for low battery charging.
Indicator light for high beams (39)

–
The light (blue) is activated when the high beams are on.
000309
Indicator light for direction indicators (40)

–
The lamp (green) flashes when the direction indicators or hazard lights
are on.
000310
Alarm indicator for control system, KCS (42)

–
The indicator light (red) calls the operator’s attention. It illuminates with
a steady glow when an error code is shown in the display for the con-
trol system, KCS.
000402
The warning lamp (red) shows that the control system has one or sev-
eral error codes, active or passive. For more information, see section
4.13 "Control system, KCS".
The indicator light is active for as long as there are active error codes
("STOP", "Warning" or "Information").
Indicator light for locked twistlocks (81)

–
The light (green) shows that twistlocks on the attachment are locked
(load is secured). The indicator light has no symbol.
Indicator light for alignment attachment (82)

–
The light (orange) shows that the attachment has contact with the load
(ready to lock twistlocks). The indicator light has no symbol.
Indicator light for unlocked twistlocks (83)

–
The light (red) shows that twistlocks on the attachment are released
(load is unsecured). The indicator light has no symbol.

4 Instruments and controls – 4.3 Instruments 47
4.3 Instruments
General
page
–
This section describes the analogue instruments available in the cab.

They show, with gauges or digits, levels/status of systems.
page 41.
Hour meter (14)

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

48 4 Instruments and controls – 4.4 Ignition key lock (43)
4.4 Ignition key lock (43)

General
page
–
This section describes the ignition.

page 41.
Ignition’s function
–
P No function.
Power to switch for supplemental heating .

0 Stop position. Everything switched off, key can be re-
moved.
F
I Operating position.
N
R
Electric power to all electrical functions. Control units for
R
engine and transmission are now ready for start.
1 2 3
4 5
Preheating is used in the event of cold weather. The en-
gine’s intake air is heated by preheating coils to a suitable
temperature. During preheating the preheating symbol is
shown in the display. Wait until the preheating symbol goes
out before turning the key to position III.
0 II No function.
P I III Start position.
Engagement of starter motor for starting the engine.
II NOTE
The machine has an electric restart interlock that pro-
tects the starter motor from engaging when the engine
007005
III is rotating.
Conditions for starter motor engagement are that the
Start key
gear selector is in neutral position and that the engine
isn’t already running.

4 Instruments and controls – 4.5 Switches 49
4.5 Switches
General
page
–
This section describes the switches in the cab. Each switch controls a
function. Contrast for background lighting is adjusted with the function
keys "-/4" and "+/5" for the control and monitoring system
page 41.
Switch for parking brake (6)

–
Switch (red) for applying parking brake.

Position 0 – Parking brake off.
000331
Position 1 – Parking brake on.
0 1
Switch for extra working lights (20)
–
Switch (green) for extra working lights.

Position 0 – Lights off.
Position 1 – Lights on.
000319
0 1
Switch for working lights on mast (21)
–
Switch (green) for working lights on mast.

000318
0 1
–

000319
0 1
–

000319
0 1

50 4 Instruments and controls – 4.5 Switches
Switch, revolving beacon (24)

–
Switch (green) for revolving beacon used to attract attention in con-

nection with hazards.
Position 0 – Revolving beacon off.
000321
0 1 Position 1 – Revolving beacon on.
Switch for flashing hazard lights (25)

–
Switch (red) for flashing hazard lights used to attract attention in con-
nection with parking hazard.
Position 0 – Flashing hazard lights off.
000322
0 1 Position 1 – Flashing hazard lights on.
Switch for headlights (26)

–
Switch (green) for headlights. Also activates rear lights and side run-
ning lights.
Position 0 – Headlights off.
000323
0 1 Position 1 – Headlights on.
Switch for seat heating (27)

–
Switch (green) for seat heating.

Certain seat models have the switch directly on the seat and then have
a different appearance.
000324
0 1 Position 0 – Seat heating off.

Position 1 – Seat heating on.
Switch for central lubrication (28)

–
Switch (green) for central lubrication of machine. Rocker switch. The

lamp in the switch illuminates when lubrication is performed.
Position 0 – Central lubrication takes place with a preset interval.
000325
0 1 Position 1 – The pump for central lubrication performs a sequence for

lubrication.
Switch for revolving driver’s seat (44)

–
Switch (green) for revolving driver’s seat.

Position 0 – Rest position.
Position 1 – Turning to right.
001279
1 0 2 Position 2 – Turning to left.

Switch for the engagement and disengagement

–
of an alternative travel direction selector (45)

2-positon switch
Switch (green) for the engagement and disengagement of an alterna-
tive travel direction selector.
Position 0 - Normal travel direction selector is engaged, that is, alter-
009493
native travel direction selector is disengaged. The light in the switch is
0 1
off.
NOTE
For active lever or mini-wheel the normal travel direction selector
is automatically replaced by the travel direction selector on the
armrest console. The switch should be set to position 0 in order
for the travel direction selector on the armrest console to work.
Position 1 - Alternative travel direction selector is engaged. Then the
normal travel direction selector is disengaged. The light in the switch
is illuminated.
Switch for the engagement and disengagement

–
of two alternative travel direction selectors (45)

3-positon switch
Switch for the engagement and disengagement of 2 alternative travel
direction selectors
Position 0 - Normal travel direction selector is engaged, that is, alter-
012620
native travel direction selector is disengaged. The light in the switch is

0 1 2
off.
NOTE
For active lever or mini-wheel the normal travel direction selector
is automatically replaced by the travel direction selector on the
armrest console. The switch should be set to position 0 in order
for the travel direction selector on the armrest console to work.
Position 1 - Alternative travel direction selector in the speed pedal is
engaged. Then the normal travel direction selector is disengaged. The
light in the switch is illuminated.
Position 2 - Alternative travel direction selector on or adjacent to the
lifting lever is engaged. Then the normal travel direction selector is dis-
engaged. The light in the switch is illuminated.

52 4 Instruments and controls – 4.5 Switches
Switch, engagement and disengagement of

–
alternative gear selector (45)
Switch (green) for engagement and disengagement of alternative gear

selector.
NOTE
The same switch as for the engagement and disengagement of
alternative travel direction selector is used for the engagement
and disengagement of the alternative gear selector.
Position 0 – Normal gear and travel direction selector is engaged, i.e.
alternative gear selector is disengaged. The light in the switch is off.
NOTE
The alternative gear selector on the joystick or mini-wheel is en-
gaged automatically when the joystick control or mini-wheel is ac-
tivated and when the switch for the engagement and
disengagement of the alternative gear selector is in position 0.
Position 1 – Alternative gear selector on control for load handling
(4-lever, 5-lever, electric servo). When the normal gear and travel di-
rection selector is disengaged. The light in the switch is switched on.
Switch for inching (46)

–
Switch (green) for inching.

Position 0 – Inching off.
Position 1 – Inching on.
007191
0 1
Switch for windscreen wiper, rear (48)
–
Switch (green) for windscreen wiper on rear window

Position 0 – Windscreen wiper off.
Position 1 – Windscreen wiper on.
000891
0 1
Switch for windscreen wiper, roof (49)
–
Switch (green) for windscreen wiper on roof window.

Position 0 – Windscreen wiper off.
Position 1 – Windscreen wiper on.
000892
0 1
NOTE
The wiper should not be used when the window is dry on cabs
with polycarbonate plastic roof window.

Switch for switching off the reverse alarm (51)

–
Switch (green) for switching off the machine’s reverse alarm.

Position 0 - Reverse alarm on.
002899
0 1
Position 1 - Reverse alarm off.
Switch for the raising/lowering the driver’s seat

–
(52)
Switch (green) for the raising/lowering the driver’s seat.

Position 0 - Rest position.
002448
Position 1 - Raising.
1 0 2 Position 2 - Lowering.

–

000319
0 1
Switch, electrically heated rear view mirrors (54)
–
Switch (green) for electrical heating of rear view mirrors.

Position 0 – Heating of rear view mirrors off.
001634
0 1
Position 1 – Heating of rear view mirrors on (symbol lit).

54 4 Instruments and controls – 4.6 Gear and travel direction selector (2)
4.6 Gear and travel direction

selector (2)
General
page
–
This section describes the functions of the gear and travel direction
1 2 F
selector.
3
There are two alternative gear and travel direction selectors:
• gear control
006999
R
• RMH
page 41.
000898

4 Instruments and controls – 4.6 Gear and travel direction selector (2) 55
Shifting program (mode) and travel direction

–
Selecting shifting mode and direction of travel takes place with the
gear and direction of travel selector.
Selecting direction of travel:
• F – Forward
• N – Neutral
• R – Reverse (acoustic warning signal ). The back-up light is

activated as long as R is engaged.
The transmission limits the change of travel direction until the correct
speed and engine speed have been achieved, normally 3 km/h and
1500 rpm, by adopting neutral position. There may be differences in
speed and engine speed limits between different models.
There is manual or automatic transmission. For manual shifting, gear
selection is handled manually by the operator. For automatic shifting,
gear selection is handled automatically by the transmission according
to gear position 1, 2 or 3 selected by the operator.
Selection of gear (manual) or gear position (automatic):
• 1 – Manual: first gear. Automatic: locked to first gear.
• 2 – Manual: second gear. Automatic: shifts between first and sec-
ond gear.
• 3 – Manual: third gear. Automatic: shifts between first, second and
third gear.
If the machine is equipped with automatic gearing then manual gear-
shifting can be selected. This takes place by means of using the serv-
ice code to go into the KCS menu system in the display and selecting
"AUTOMATIC GEAR SHIFT OFF" value 1.

56 4 Instruments and controls – 4.7 Multi-function lever (5)
4.7 Multi-function lever (5)

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

page 41.
Windscreen wiper and washer

–
Windscreen wipers and washer are controlled with the multi-function

lever (position 5). Turn the control to the following positions:
• 0 – No wiper action
• J – Interval wiper action
• I – Continuous wiper action
012953
• II – Continuous wiper action (position II has the same speed as

position I)
• Push the control towards the steering wheel to wash windscreen,
roof window and rear window.
Light control, horn and direction indicators

–
The multi-function lever (position 5) is used to select light control and

horn.
• With headlights on: the multi-function lever is used for switching
between high and low beam. Move the control toward yourself to
switch between high and low beam, and back.
• With headlights off: the multi-function lever is used to flash with
the headlights. Move the control toward yourself for high beam
006998
A flash, return is automatic.

• Press the button (position A) for the horn. The horn in the multi-
function lever can be deactivated in the software.
• Move the lever rearward or forward for the left and right direction
indicator.

4 Instruments and controls – 4.8 Load handling 57
4.8 Load handling

General
page
–
This section describes the functions of the control for load handling.
The controls control functions when handling forks or other attach-
ments. It is possible to vary the speed of the different hydraulic func-
tions, e.g. lift, tilt, etc., by varying the extent of the lever deflection. It is
also possible to vary the hydraulic functions’ speed with the engine
rpm.
NOTE
Position of a control is need-adapted and may thus differ from this
section. See plates on machine.
• Control with up to 5 levers page 58.
• Electric servo with up to 5 levers page 59.
• Electric servo with control lever page 60.
• Control lever page 61.
• Buttons for optional functions page 62.
• Key for bypass (76) page 65.

The following instrumentation (inside and outside the cab) is available
for load handling:
• Indicator lights for sidelift attachment page 63.
• Indicator lights for attachment page 64.
• Operating menu for scales

See section 4.13 KCS system.
page 41.

58 4 Instruments and controls – 4.8.1 Control for load handling
4.8.1 Control for load handling

Control with up to 5 levers
page
–
1. Lift / lower
LIFT – pull the lever backwards.
LOWER – push the lever forwards.
The lowering speed can be varied only with the lever deflec-
tion – the engine speed has no influence.
2. Tilt
BACK – pull the lever backwards.
FORWARD – push the lever forwards.
3. Side shift
LEFT – push the lever forwards.
RIGHT – pull the lever backwards.
The forks cannot be side-shifted if fork spreading is at
maximum.
6 1 2 3 4 5
4. Spreading (positioning)
OUT – move the lever forwards.
7 IN – pull lever backwards.
Spreading locks when one of the forks reaches its end posi-
tion. Side shift to the centre and spread again.
Spreading sidelift attachment

INCREASE SPREADING – move the lever forward.
DECREASE SPREADING – pull the lever backwards.
5. Levelling
FORK UP – pull the lever backwards.
FORK DOWN – move the lever forwards.
Levelling acts on the right or left fork.
Locking/releasing twistlocks for sidelift attachments.

003927
RELEASE TWISTLOCKS – push the lever forwards.

LOCK TWISTLOCKS – pull the lever backwards.
6. Selecting direction of travel

Travel direction FORWARD – set switch forward.
Travel direction NEUTRAL – set switch in middle.
Travel direction REVERSE – set switch backward.
7. Selecting gear
GEAR 1 – set the switch down.
GEAR 2 – set the switch in the centre.
GEAR 3 – set the switch up.

4 Instruments and controls – 4.8.1 Control for load handling 59
Electric servo with up to 5 levers

–
Electric servo uses fingertip-operated linear levers.

1. Lift / lower
LIFT – pull the lever backwards.
LOWER – push the lever forwards.
The lowering speed can only be varied with the lever deflection –
the engine speed has no influence.
2. Tilt
BACK – pull the lever backwards.
FORWARD – pull the lever FORWARDS.
3. Side shift
LEFT – pull the lever forwards.
RIGHT – pull the lever backwards.
The forks cannot be side-shifted if fork spreading is at maximum.
1 2 3 4 5 6 4. Spreading (positioning)
7
OUT – move the lever forwards.
IN – pull lever backwards.
8
Spreading locks when one of the forks reaches its end position.
Side shift to the centre – spread again.
5. Levelling
FORK UP – pull the lever backwards.
FORK DOWN – move the lever forwards.
Fork levelling acts on the right or left fork.
6. Breaker switch for load handling (servo circuits)

8. Selecting gear
GEAR 1 – set the switch backward.
005212
GEAR 2 – set the switch in the centre.

GEAR 3 – set the switch forward.

Electric servo with control lever

–
The control lever controls functions when handling the forks and
sidelift attachments. Its function diagram is need-adapted and may
therefore differ from this section. See the plates on the machine.
5A 1B 5B
3A 3B
2A 2B
4A
4B
005213
5C 1A 5D
1A. Lift
1B. Lower
2A. Tilt backwards
2B. Tilt forwards
3A. Side shift, left
3B. Side shift, right
4A. Spreading, increase
4B. Spreading, decrease
5A. Levelling, left, down
5B. Levelling, right, down
5C. Levelling, left, up
5D. Levelling, right, up

4 Instruments and controls – 4.8.1 Control for load handling 61
Control lever
–
The control lever controls functions when handling the forks and
sidelift attachments. Its function diagram is need-adapted and may
therefore differ from this section. See the plates on the machine.
1B
2A 2B 3A 3B
4A 5A
1A
012964
4B 5B
1A. Lift
1B. Lower
2A. Tilt backwards
2B. Tilt forwards
3A. Side shift, left
3B. Side shift, right
4A. Levelling, fork down
4B. Levelling, fork up
5A. Spreading, increase
5B. Spreading, decrease


Buttons for optional functions

–
Buttons for optional features are present if necessary on the lever con-
trol (position A). Function and number of buttons are need-adapted.
004247
Hydraulic servo controls
A
006991
Electric servo controls

4 Instruments and controls – 4.8.2 Other information for load handling 63
4.8.2 Other information for load handling

Indicator lights for sidelift attachment
page
–
A B C
003930
There is a light panel with indicator lights on the sidelift attachment that
is used when handling loads with the attachment. The panel uses col-
oured lights to indicate if and when twistlocks are locked/unlocked, i.e.
if the load is secured/not secured.
A. Twistlocks locked (load secured), green.
B. Alignment attachment’s corners, orange.
C. Twistlocks unlocked (load not secured), red.
D. Light panel.
E. Twistlock.
F. Sidelift attachment assembly.

64 4 Instruments and controls – 4.8.2 Other information for load handling
Indicator lights for attachment

–
There are three indicator lights that are used for load handling with the
77 78 79 80 81 82 83 attachment. They are located on a panel by the control for load han-
dling. The panel uses coloured lights to indicate if and when twistlocks
are locked/unlocked, i.e. if the load is secured/not secured.
76 Key for by-pass of load handling functions
77 Indicator light, auto shutdown

76 78 Switch stop at 30’
79 Spare
80 Spare
A 81 Indicator light for locked twistlocks, green
82 Indicator light for alignment attachment, yellow

004258
B 83 Indicator light for unlocked twistlocks, red
A Panel for indicator lights, attachment
B The control for load handling

4 Instruments and controls – 4.8.2 Other information for load handling 65
Key for bypass (76)

–
Bypassing the machine’s safety features.

The driver may, if the situation so requires, disconnect all safety fea-
tures on the machine.
002447
0 1 Position 0 provides normal function.
Position 1 provides:
• Possibility to lock or open twistlocks without alignment.
• Possibility to adjust length of attachment when twistlocks are
locked.
• Possibility to lift, without indication of locked or open twistlocks.
• The option to engage gear without the driver’s seat sensor indicat-
ing that someone is sitting in it.
The key’s position indicates when the bypass of load handling func-
tions is activated.
WARNING
Safety features are blocked.
No safety system is engaged!
Only use bypass in emergency situations!
WARNING
Bypass of load handling functions must not be used
when lifting or transporting loads.

ty damage.
Only use the bypass in emergency situations.

66 4 Instruments and controls – 4.9 Pedals
4.9 Pedals
General
page
–
This section describes the machine’s foot-operated functions.

page 41.
F
4 3 2 1
L 0
R
R
4 3
006934
11 12 46 11 10
10. Accelerator pedal
11. Brake pedals
12. Clutch pedal (inching pedal )
46. Switch for inching
R
1 4 5
2 3
11
007023
10
Extra pedals by the turnable driver’s seat

10. Accelerator pedal (normal accelerator pedal is dis-
connected)
11. Brake pedal

4 Instruments and controls – 4.9 Pedals 67
R
1 4 5
2 3
007022
11 10
Extra pedals on a turnable driver’s seat . The fig-

ure shows the driver’s seat in turned position.
10. Accelerator pedal (normal accelerator pedal is dis-
connected)
11. Brake pedals
Accelerator (10)
–
The accelerator pedal (position 10) is electronic and controls the en-
gine speed via the CAN bus and the KCS system.
Accelerator pedal with function for selecting

–
direction of travel (10)
The accelerator pedal has the same function as above. Choice of di-
rection of travel can be made using the accelerator pedal. Two switch-
es are located in the upper section of the pedal for choice of forwards
direction (left side) or reverse (right side).
001840

68 4 Instruments and controls – 4.9 Pedals
Brake pedals (11)

–
The brake pedals (position 11) are hydraulic and connected to the ma-
chine’s hydraulic system. The brake pedals are used for service brake.
The accumulators store energy so that brake pressure is also availa-
ble if the engine stops. If the accumulator pressure becomes too low
then an error code appears in the display.
The brake function is available in different versions:
• Brake without inching
The service brake is combined with the clutch pedal (position 12).
If the brake pedal is applied and the accelerator pedal is released
then the engine helps to slow down the machine.
If the clutch pedal (position 12) is depressed then drive is
declutched.
Hydraulic functions can be used with a gear engaged.
• Brake with inching . The inching function does not work with
extra pedals (with rotating or turnable driver’s seat).
Available in two versions:
– Switch (position 46) for inching.
Position 0 – Inching not activated. The brake is activated with
the brake pedal and declutch takes place when the pedal is
007191
depressed more than 70%.

0 1
Position 1 – Inching activated. Inching and braking are con-
trolled with the brake pedal. When the pedal is depressed the
drive starts to slip, so-called crawling or inching.
If the brake pedal is depressed more than 70% then drive is
declutched completely.
– Inching pedal (position 12).
The brake is activated with the brake pedal and declutch
takes place when the pedal is depressed more than 70%.
When the brake and inching pedals are applied simultane-
F
ously a microswitch is actuated and the drive starts to slip, so-
called crawling or inching.
4 3 2 1
N
L 0
R
4 3
007497
12

4 Instruments and controls – 4.9 Pedals 69
(km/h) Inching
10 Inching enables precision driving at low speed while the engine can
maintain higher revolutions, this means that power is released for the
1
working hydraulics. When inching is activated the drive starts to slip.
8
When the pedal is depressed 70% the drive is declutched completely.
2 In the event of overloading the function is disengaged.
6 Hydraulic functions can be used with a gear engaged.
4
4
3
2 0%
100%
25 50 75 100 (%)
0 07498
Inching speed depends on pedal position

1. No inching
2. Variable speed
3. Minimum speed (fixed inching)
4. Inching (stationary)

70 4 Instruments and controls – 4.10 Steering wheel (4)
4.10 Steering wheel (4)

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

are available for steering the machine:
• steering wheel with fixed or adjustable steering column ,
• joystick control ,
• mini-wheel .
page 41.
Steering wheel
–
Clockwise rotation of the steering wheel steers the machine to the

right, and vice versa.
The steering wheel’s (position 4) and instrument panel’s angle and
height can be adjusted to the desired operating position.
1. Steering wheel’s height.
1 To adjust: Move upper lever upward.
2. Steering wheel panel’s angle.
To adjust: Move upper lever downward.
3. Steering column’s angle.

2 To adjust: Loosen the lower handle and adjust to desired position.
Tighten the handle securely after adjusting.
3
001637

4 Instruments and controls – 4.10 Steering wheel (4) 71
Joystick control
–
Joystick control is an electro-hydraulic system, mounted in the left-

3a 3b 4 hand armrest, to steer the machine using a joystick. When the joystick
is moved to the right, the machine steers right, and vice versa. The
steering angle and speed are inversely proportional to the machine’s
2 5 speed, that is, low speed gives greater wheel angle, and vice versa.
The system is available in two different versions:
1 • with feedback of wheel position, i.e. when you release the joystick
to the centre position the wheels will return to the centre position.
• without feedback of wheel position, i.e. when you release the lever
to the centre position the wheels remain and have to be steered
6
back.
The standard steering wheel is equipped with a sensor that detects
any steering wheel movements in the event of an emergency situation.
As soon as the operator starts to steer with the standard steering
wheel, the joystick is disengaged and the alternative travel direction
selector and gear selector return to normal selector.
7
1. Joystick.
2. Selecting direction of travel F/N/R.
The travel direction selector on the joystick control console (arm
rest) is automatically activated when the joystick control is active.
NOTE
If the switch for the engagement and disengagement of alter-
001448
native travel direction selector (position 45) is specified, the

condition is that it is in position "0".
forward = F, middle position = N, reverse = R
3. Selection of gear. 3a = change up, 3b = change down.
(Not available with automatic gearing)
Gear selector on the joystick control console (armrest) is automat-
ically activated when the joystick control is active.
NOTE
native gear selector (position 46) is specified, the condition is
that it is in position "0".
Press 3a to change up (one press for each gear) and 3b to change
down. Gearshifting always starts with 1st gear when starting or af-
ter the travel direction selector has passed N.
4. Button for engaging joystick.
Conditions: machine speed must be below 3 km/h. If speed is over
3 km/h the joystick cannot be engaged. The lamp in the travel di-
rection selector (position 2) is illuminated with constant glow when
joystick control is engaged.
5. Sound signal.

72 4 Instruments and controls – 4.10 Steering wheel (4)
6. For optional equipment.

7. Arm rest.
Mini steering wheel

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

mounted in the left arm rest, to steer the machine using a small steer-
ing wheel. Clockwise rotation of the mini-wheel steers the machine to
the right, and vice versa. The ground wheels always follow the mini
steering wheel’s position. If the mini-wheel is released, both the mini-
wheel and the ground wheels remain in the set position.
The standard steering wheel is equipped with a sensor that detects
any steering wheel movements in the event of an emergency situation.
As soon as the operator starts to steer with the standard steering
wheel, the mini-wheel is disengaged and the alternative travel direc-
tion selector and gear selector return to normal selector.
1. Mini steering wheel.
The steering wheel’s position on the arm rest is adjustable.
2. Selecting direction of travel F/N/R.
The travel direction selector on the joystick control console (arm
rest) is automatically activated when the joystick control is active.
NOTE
native travel direction selector (position 45) is specified, the
condition is that it is in position "0".
forward = F
middle position = N
001447
reverse = R
3. Sound signal.
4. For optional equipment.
5. Selection of gear. 5a = change up, 5b = change down.
(Not available with automatic gearing)
Gear selector on the joystick control console (armrest) is automat-
ically activated when the joystick control is active.
NOTE
native gear selector (position 46) is specified, the condition is
that it is in position "0".
Press 5a to change up (one press for each gear) and 5b to change
down. Gearshifting always starts with 1st gear when starting or af-
ter the travel direction selector has passed N.

4 Instruments and controls – 4.10 Steering wheel (4) 73
6. Button for engaging the mini steering wheel.

Conditions: machine speed must be below 3 km/h. If speed is over
3 km/h the mini steering wheel cannot be engaged. The lamp in
the travel direction selector (position 2) is illuminated with con-
stant glow when the mini steering wheel is engaged.
7. Arm rest.
8. Locking lever for adjusting the mini steering wheel’s position on
the arm rest.

74 4 Instruments and controls – 4.11 Driver’s seat (9)
4.11 Driver’s seat (9)

General
page
–
This section describes the driver’s seat in the cab. The following alter-
native seats are available:
• Driver’s seat Bege is equipped with:
• mechanical adjustment of height and suspension
• air suspension
• integrated horizontal suspension (can be shut off)
• rotating 40°
• mechanically adjusted lower back (lumbar) support
• mechanically adjusted seat cushion angle
• seat belt, 2-point
• head rest
• adjustable arm rest right
• adjustable arm rest left
• seat heating
• ventilated seat and backrest cushion (air-vent). The seat re-
quires compressed air. The option includes an externally
mounted compressor on the underside of the cab floor.
• Driver’s seat Isringhausen 6500.

The seat is equipped with:
• air suspension
• air-adjusted lower back (lumbar) support
• mechanically adjustable damping
• horizontal suspension (disengageable)
• head rest

• seat heating
• integrated compressor

4 Instruments and controls – 4.11 Driver’s seat (9) 75
• Driver’s seat Grammer Actimo XXL.

The seat is equipped with:
• air suspension (height)
• air-adjusted lower back (lumbar) support
• mechanically adjustable seat length
• mechanically adjustable damping
• integrated horizontal suspension
• head rest

• seat heating
• integrated compressor
NOTE
Other alternative driver’s seats may be installed.
page 41.

Driver’s seat Bege

–
The driver’s seat (position 9) is equipped with several controls for ad-
justment as follows (adjustment is easier when nobody is sitting in the
seat):
1. Distance to pedals.
7 4
Release the seat with the lever and move the seat forwards or
backwards.
2. Height of seat.
Mechanical elevation of seat height:
Turn the knob clockwise or anticlockwise until desired height is
obtained.
Air suspension elevation of seat height:

Turn the knob anticlockwise to lower seat height. Turn the knob
clockwise to elevate seat height. The suspension adjusts auto-
matically to the operator’s body weight.
6 Exiting the cab is easier if the suspension is lowered rapidly by
means of the control for adjusting suspension travel (position 7)
being pulled to the outermost position (seat lowers to lowest lev-
el). When entering the cab, press in the control to the innermost
position (seat elevates to preset level).
5 3. Back rest angle.

1 2 3
Turn the knob until desired position is obtained.
4. Adjusting arm rest, right.
000342
Adjusting arm rest, left, is available.

Driver’s seat with adjustment possibilities 5. Variable angling of seat and back.
Turn the knob until desired position is obtained.
6. Adjustment of suspension positions in two steps (lever located on
back of seat):
Suspension active – Lever against seat’s centre line. Used during
normal operation.
Suspension locked – Lever against seat’s outside. Can only be
done when seat’s height reaches a locked position. Used when
suspension is not desired.
7. Lower back (lumbar) support.
Turn knob until desired firmness in lumbar support is obtained.

Driver’s seat Isringhausen 6500

–
The driver’s seat (position 9) is equipped with adjustment controls for

the seat as follows (adjusting is easier when nobody is sitting in the
seat):
Release the seat using the lever (1) and move the seat forwards
or backwards. To lock the seat, release the lever.
2. Elevating/lowering seat height.
Lift control (2) to raise/lower the seat.
When the desired height is obtained, release the control.
8 3. Seat cushion angle.

Lift the control (3) and adjust the angle by loading/unloading the
front part of the seat cushion.
4. Back rest angle.
Lift control (4) and adjust the angle by loading/unloading the back
rest.
5. Adjusting the damping.
Press + for more damping.
Press - for less damping.
003712
2 3 6 1 5 7 4 9 6. Seat heating.
Thermostat-controlled heat for seat and back rest.
Press the button to activate/deactivate. The indicator lamp is on in
the event of activated seat heating.
7. Lumbar support. Integrated pneumatic system.
Press the buttons (7) to fill and empty the air chambers for optimal
adaptation of the back rest to the body.
8. The arm rest’s angle is set variably with the knurled button.
9. Arm rest left

Driver’s seat Grammer Actimo XXL

–
The driver’s seat (position 9) is equipped with adjustment controls for

the seat as follows (adjusting is easier when nobody is sitting in the
seat):
8 Release the seat using the lever (1) and move the seat forwards
or backwards. To lock the seat, release the lever.
2. Adjusting the seat cushion.
Lift control (2) and adjust the seat forwards or backwards.
9 3. Elevating/lowering seat height.
Lift control (3) to raise the seat.
Press down control (3) to lower the seat.
10 When the desired height is obtained, release the control.
2
5 4. Seat cushion angle.
4
Lift control (4) and adjust the angle by loading/unloading the front
6 part of the seat cushion.
5. Back rest angle.
Lift control (5) and adjust the angle by loading/unloading the back
003710
rest.
3 1 7
6. Adjusting the damping.
Turn control (6) gradually forward for harder damping.
Turn control (6) gradually backward for softer damping.
7. Plane damping.
Turn control (7) to rear-facing position to permit damping.
Turn control (7) to forward-facing position to turn off damping.
8. Lumbar support. Integrated pneumatic system.
Press the buttons to fill and empty the air chambers for optimal ad-
aptation of the back rest to the body.
9. The arm rest’s angle is set variably with the knurled button.
10. Arm rest left

Revolving operator’s station

–
The operator’s station, with driver’s seat, can be obtained with electri-
cal rotation. The seat bracket has an integrated steering column and
steering wheel with panel. This follows round in the console during ro-
tation. The driver’s seat is no different from other seat options. The re-
volving operator’s station has double pedals. Steering wheel and hand
controls follow round during rotation.
The operator’s station is rotated with the switch for revolving opera-
tor’s station. See Switch for revolving driver’s seat (44) page 50.
007499

80 4 Instruments and controls – 4.12 Heating unit/Air conditioning
4.12 Heating unit/Air conditioning

Cab alternative
page
–
This section describes the heating unit and air conditioning:

page 41.
4.12.1 Spirit Delta

General
page
–
Cab alternative Spirit Delta can be equipped with one of the following
alternatives:
• heating unit
• heating unit with cooling AC (manual control of heating, cooling,
dehumidification and air flow)
• air conditioning ECC (automatic control of heating, cooling, dehu-
midifying and air flow)
001971
Fresh air inlet for cab
4.12.1.1 Heating unit

General
page
–
The heating unit is available as the following alternatives:

A
• heating unit
• heating unit with cooling AC

The heating unit is connected to the engine’s cooling system and pro-
vides heat when the engine is warm.
29
The fan is controlled with the rotary control (position 16) in
20 steps 0-I-II-III.
19 Heat is controlled by the rotary control (position 15) and cooling by the
18
rotary control (position 18). Air distribution is controlled with the rotary
17
control (position 17).
006935
16
15 Recirculation is switched on and off with the switch (position 19) ( ).
Panel heating unit Cooling AC is switched on and off with the switch (position 20) ( ).
The panel has a panel vent (position A).
The fresh air filter is equipped with a filter and can be equipped with a
fine filter against pollen ( ).

4 Instruments and controls – 4.12.1.1 Heating unit 81
Supplemental heating is switched in and off with the switch

(position 29) ( ) and is activated when the ignition key is in position
P and the engine is warm.
NOTE
The driver’s door and windows should be closed for satisfactory
function of the heating unit.
Control for heat (15)

–
The rotary control (position 15) handles variable setting of heat

flow. Turn clockwise to increase heat flow, anticlockwise to reduce
or switch off the heat flow.
000547
Control for fan (16)

–
The rotary control (position 16) handles fresh air inlet into the cab.
Turn clockwise to increase fan speed and thereby air supply; turn an-
ticlockwise to reduce the air supply.
The fan is operated in steps 0-I-II-III using the control.
000545
Control for defroster/cab (17)

–
The rotary control (position 17) handles the infinitely adjustable distri-
bution of fresh air to the cab towards the lower area (leg area) and de-
froster (windows). The left position is for lower cab area, centre is for
cab area and right is for defroster.
000546

82 4 Instruments and controls – 4.12.1.1 Heating unit
AC cooling control (18)

–
The rotary control (position 18) handles variable setting of cooling out-
put. Turn clockwise to increase cooling, anticlockwise to decrease or
switch off cooling.
000548
Recirculation/fresh air switch (19)

–

Switch (green) to handle air circulation in the cab.
Position 0 – Fresh air inlet open.
Position 1 – Fresh air inlet closed, cab air is recirculated.
000542
0 1
Switch for cooling AC (20)
–

Switch (green) for handling the cooling function. Rocker switch.
Position 0 – Cooling function off.
Position 1 – Cooling function on. The cooling function of the system
001837
0 1 does not start if the fan control (position 16) is in its zero position.
Switch for supplemental heating (29)

–
Switch to activate the supplemental heating function (position 29).

Position 0 - Supplemental heating on. Supplemental heating is activat-
002900
0 1 ed when the ignition key is in position 0 and the engine is warm.

Position 1 - Supplemental heating off.

4 Instruments and controls – 4.12.1.2 Air conditioning ECC 83
4.12.1.2 Air conditioning ECC

General
page
–
The air conditioning automatically regulates the inner temperature to

A
the desired temperature regardless of weather conditions. The system
will always start in AUTO mode and at 21° regardless of the setting
when switched off.
The heating unit is connected to the engine’s cooling system and pro-
vides heat when the engine is warm. The air conditioning functions are
29 controlled with the function keys.
The fresh air intake is equipped with a filter and can be equipped with
TO DE
AU MO
a fine filter for pollen ( ).

34
Supplemental heating is switched in and off with the switch
(position 29) ( ) and is activated when the ignition key is in position
P and the engine is warm.
NOTE
The driver’s door and windows should be closed for the satisfac-
006992
AUTO
MODE tory function of the air conditioning.
A. Panel vent
29. Switch for supplemental heating
34. Air conditioning ECC
AUTO mode
–
In auto mode the temperature, air distribution and fan speed are ad-
justed automatically. Selected temperature and AUTO appear in the
003702
display.
Temperature
–
Adjust with the keys to the desired temperature.

003565
Fan
–
Adjust with the keys to the desired fan speed. The speed is adjustable
between 0-100%.
003566

84 4 Instruments and controls – 4.12.1.2 Air conditioning ECC
Air distribution
–
Select the desired function with the keys. The selected air distribution
is indicated by a square under the current symbol.
003567
Air to the floor.
003568
Air to both the floor and panel vents.
003569
Air to the windscreen.
003570
Maximum defroster.
003571
Recirculation
–
Cabin air is recirculated, i.e. no fresh air is drawn into the operator’s
cab. REC appears in the display when the function is activated. Switch
003572
off the recirculation by pressing the button once again.
Switch for supplemental heating (29)

–
Switch to activate the supplemental heating function (position 29).

Position 0 - Supplemental heating on. Supplemental heating is activat-
002900
0 1 ed when the ignition key is in position 0 and the engine is warm.

Position 1 - Supplemental heating off.

4 Instruments and controls – 4.13 KCS system 85
4.13 KCS system

General
page
–
This section describes the KCS control system.

41 42
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 displayed. Upon
F generation of a new error code, the indicator for the control system
N
(position 42) illuminates. See section 5.3 Handling error codes.
R
• Operating information
R
1 2 3
Operating information includes, e.g., machine speed, engine rpm,
4 5
fuel level, etc.
The information is presented on the steering wheel panel’s display
006936
(position 41). The function keys (position 47) are used to navigate in
47
the display menus during, for example, service and troubleshooting.
41. Display for the control system (KCS)
42. Alarm indicator for the control system
page 41.
47. Function keys for the control system (KCS)
Steering wheel panel’s differing appearance is one
example.
4.13.1 Operating menus

General
page
–
The operating menu with engine speed, speed, current gear, time and
50
fuel level is shown after starting the machine. Menus are selected with
the function keys for right arrow and left arrow. With each press of the
key, the display changes to the next menu. To quickly return to the
original display, press and hold in the function key for Reset (R).
82 ˚C This section describes the information that can be obtained from the
different operating menus. The figures show example data.
2.4 bar
NOTE
-/+
60 ˚C The availability of the menus is dependent on the machine’s
- +
equipment.
28.7 V
2 L/H
1430 km
+
12 L/H 300 h
(+/-) 1.2
75 t
007359
158 t

86 4 Instruments and controls – 4.13.1.1 Operating menu
4.13.1.1 Operating menu

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

a 1650
50 rpm F1 d b. Shows current speed in km/h.
b 14 km/h c. Shows current time.
e d. Shows current gear position.
006993
c 12:00 am F – forward, N – neutral, R – reverse. 1-3 indicates gear position.
e. Shows current fuel level.
f. Shows when preheating is active.
1650
50 rpm F1 g. Flashes when the parking brake is activated.
14 km/h 006994
f g
4.13.1.2 Operating menu for engine

Description
page
–
a. Shows current engine coolant temperature in °C.
82 ˚C a b. Shows current engine oil pressure in bar.
2.4 bar b
007339
4.13.1.3 Operating menu for transmission and

electrical system
Description
page
–
a. Shows transmission oil temperature in °C.
60 ˚C a b. Shows the current battery voltage in volts.
- +
28.7 V b
006995
4.13.1.4 Operating menu for service interval

Description
page
–
a. Displays total distance driven in km.

b. Shows number of hours to next service.
1430 km a
300 h b
007340

4 Instruments and controls – 4.13.1.5 Operating menu for scales 87
4.13.1.5 Operating menu for scales

Description
page
–
a. Shows tare weight in tonnes.
(+/-) 1.2 a The value displayed in row (b) can be reset to zero (tared) using
the function keys for minus and plus. The set value is displayed in
75.0 t b
row (a). Shows 0-3.0 tonnes.
158.0 t c b. Actual weight in tonnes (net weight).
007341
c. Total weight in tonnes (gross weight).
The value in row (b) can be added to row (c) using the function key
for Return. The value in row (c) can be reset to zero by depressing
the function keys for Reset and Return simultaneously.
Weight can be given in kilopounds .

For weighing, see section 5.4.4 Load handling functions, scales.
4.13.1.6 Operating menu for fuel consumption

Description
page
–
Menu for fuel consumption.

2 L/H a a. Displays the current (instantaneous) fuel consumption in litres/hr
or gallons/hr.
+
b. Displays the average fuel consumption in litres/hr or gallons/hr.
12 L/H
007003
b
Average fuel consumption can be reset by pressing and holding
Reset and Return simultaneously.
4.13.1.7 Operating menu for joystick control/

mini steering wheel
Description
page
–
Menu available for functions "Joystick control" or "Mini steering

wheel." Steering sensitivity is set from 1-9.
-/+ Change the sensitivity with the function keys "-/4" and "+/5".
At position 1 steering is very slow (forgiving). At position 9 steering is
007343
very fast (sensitive).

The start value is set in the service menus for joystick control/mini
steering wheel.

88 4 Instruments and controls – 4.13.1.8 Operating menu for trip computer
4.13.1.8 Operating menu for trip computer

Description
page
–
Scroll through the menus with the function keys for right arrow and left
arrow.
To reset the measurement, depress the function key for + and - simul-
taneously for two seconds. All values in the current menu are reset
simultaneously.
a. Engine speed in rpm.
0000 rpm a b. Instantaneous fuel consumption in litres/hr.
+ 00.0 l/h b c. Average fuel consumption in litres/hr. Can be reset.
00.0 l/h c
d. Driving time remaining until the tank is empty in hours. When the
011709
0:00 h d fuel level has been below 2% for 60 seconds the display shows
-:- - instead of remaining driving time. The tank symbol flashes.
e. Trip meter in km. Can be reset.
f. Average speed in km/h. Can be reset.
00.0 km e
00.0 km/h f
012963
4.13.1.9 Operating menu for statistics

Description
page
–
Start menu for statistics.

Go to display mode by pressing Enter, go back with Reset. Scroll be-
tween the different menus with the function keys for right arrow and left
arrow.
010256
To reset the measurement, depress the function key for + and - simul-
taneously for two seconds. All values in the current menu are reset si-
multaneously.
Menus for statistics
00000 h a a. Operating time for engine in hours.
00000 h b b. Operating time transmission with engine running and travel direc-
tion activated in hours.
000 %
010257
c
c. Proportion idling in %, i.e. engine speed of 700-1020 rpm and the
transmission in neutral. Can be reset.
d. Total accumulated fuel consumption in litres.
e. Accumulated fuel consumption in litres. Can be reset.
000000 l d
f. Average fuel consumption in litres/hr. Can be reset.
000000 l e
00 . 0 l/h
010258

4 Instruments and controls – 4.13.1.10 Operating menu for service 89
g. Accumulated driving distance in km.

h. Trip meter in km. Can be reset.
000000 km g
0000 . 0 km h
010259
4.13.1.10 Operating menu for service
Description
page
–
Used by service technicians.
007344

90 4 Instruments and controls – 4.13.1.10 Operating menu for service

5 Handling 91
5 Handling
5 Handling
mm mm mm mm mm mm
General
page
–
The machine is intended to be used in the way that is described in the

operator’s manual. If the machine is used in another way or in poten-
tially dangerous or hazardous conditions, for example, an explosive
environment, special safety regulations must be followed and the ma-
chine must be equipped for such conditions and environments.
NOTE
It is the operator who is responsible for ensuring that the machine
comes in for service every 500 operating hours. Procedures are
described in the maintenance manual.
The information in the chapter for handling the machine does not re-
lieve the operator of the responsibility of following laws or other nation-
al regulations for road safety and work safety.
Awareness, alertness, good judgement and respect for governing
safety regulations are prerequisites for avoiding accident risks.
Environmental impact
–
It is important that the machine is used in a way that results in minimal

environmental impact with regards to fuel consumption, exhaust 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 driving with regard to acceleration and braking.
• Minimise the time the machine runs at idling speed. Do not allow
the machine to remain at idling speed when there is a pause in the
work.

92 5 Handling
Emergency equipment
–
The following emergency equipment is available on the machine:

• Emergency exit, right door.
A
In an emergency:
1. Open the emergency exit right-hand door with handle on inside.
• Control breaker for load handling (servo circuits, only at electric
servo controls for load handling).
In an emergency:
1. Press down the control breaker (position A) immediately.
All load handling function stops.
001403
2. Restore control breaker (turn clockwise).
• Fire extinguisher
A fire extinguisher is located on a front wing or inside the cab.
In case of engine fire, press in the fire extinguisher’s nozzle
through the perforation on the plate for fire extinguisher on the
sides of the engine hood.
WARNING
Bypass of load handling functions must not be used
when lifting or transporting loads.

ty damage.
Only use the bypass in emergency situations.

5 Handling – 5.1 Running-in 93
5.1 Running-in
General
page
–
The machine should be operated with great care during the run-in pe-
riod. The purpose is to give bearing surfaces hard and polished sur-
faces, which considerably extends the service life.
Recommended run-in period is 50 hours of operating time. This gives
fewer malfunctions. Increase loading gradually during these 50 hours.
NOTE
Check the oil pressure and temperature at regular intervals.
Tyres and rims

–
For a new machine it is essential that during the first working week the
wheel nuts are retightened until they have seated properly. This
should be performed at intervals of 4-5 operating hours (up to approx.
40-50 operating hours). After which, retightening of the wheel nuts
takes place in accordance with the intervals described in the mainte-
nance manual.

94 5 Handling – 5.2 Daily inspection
5.2 Daily inspection

General
page
–
Daily inspection of the machine is extremely important in order to en-

sure 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 malfunc-
tions that have been generated or caused during an earlier work shift.
WARNING
Never operate a defective machine.

ty damage!
Report immediately to the foreman/supervisor if de-

fects are found on the machine at daily inspection!
For work instructions, see section 6.1 Daily inspection.

5 Handling – 5.3 Error codes 95
5.3 Error codes

General
page
–
Error codes indicate there is some defect/malfunction in the machine.

The error codes should be used by operators and service technicians
to identify the problem and to select a suitable action.
In case of an error code indication, it’s very important to identify the er-
ror code and to perform an action to correct the problem.
Actions in case of an error code

–
WARNING
The Stop alarm indicates a malfunction in the ma-
chine which may affect the safety of the operator and
others in the vicinity or may cause a breakdown. –
Read the error code, switch off the engine and per-
form the action according to error code table.
Warning and information alarms indicate malfunc-

tions of such character that work does not have to be
stopped. The machine’s capacity may be limited and
certain functions may not work. – Perform actions ac-
cording to error code table as soon as possible.
1 Stop the machine and identify error code level and special error
code number, see section Error code indication page 97. Then
stop the engine in the event of a Stop alarm or allow the engine
to run during a Warning or Information alarm.
NOTE
In case of a serious malfunction, the engine will be emer-
gency-stopped. After an emergency stop it is possible to re-
start the engine for approx. 25 seconds to move the
machine from an unsuitable position.
If several error codes arise from the engine then these are
shown in a rolling sequence, i.e. all active error codes are
shown at 1 second intervals in the same box.

96 5 Handling – 5.3 Error codes
2 The error code is shown automatically on the display.

C
Note all error codes. For explanation, see Display figure for error
D E code information page 98.
Scroll between error codes using the right or left arrow keys. Error
B
000389
code information disappears once its cause has been remedied.
Deactivate error code display by pressing the Reset (R) function
key:
• For Stop: if the cause of the error code remains, the error
code will reappear within one minute.
• With warning or information: if the cause of the error code re-
mains, the error code will reappear within three minutes.
• If the cause of the error code is gone, error code display will
automatically deactivate within 30 seconds.
3 Park the machine in a suitable location.
For error code level "STOP" – Stop the engine.
For error code level "WARNING" or "INFORMATION" – Allow the
engine to run or switch off the machine.
4 Read the information for the error code/error codes in the error
code table and perform the recommended actions.
• Error codes, control unit EDU 795 (KCS display) page 102
• Error codes, control unit ECU 790 page 102
• Error codes engine page 108
• Error codes transmission page 121
5 Restart the engine and check in the display that error codes are
gone according to step 2.

5 Handling – 5.3.1 Error code indication 97
5.3.1 Error code indication

General
page
–
An error code is indicated with an activated indicator for active error

41 42 codes (position 42). The error codes are divided into three error code
levels depending on their severity.
The error code levels are indicated as follows:
• STOP is indicated by a STOP sign in the display together with a
steady red glow from the indicator for the control system
B (position 42).
Error code with level Stop is shown automatically on the display.
• "Warning" is indicated by a warning triangle in the display together
with a steady red glow from the indicator for the control system
(position 42).
Error code with level Warning is shown automatically on display.
• "Information" is indicated by a spanner in the display together with
a steady red glow from the indicator for the control and monitoring
system (position 42).
Error code with level Information is shown automatically in the
display.
007192
B. Error code level symbol

41. Display for the control system (KCS)
42. Indicator for the control system (KCS)

98 5 Handling – 5.3.2 Error code information on display
5.3.2 Error code information on display

Error code display
page
–
Error code information is shown with display figures and symbols

307 which provide a clue on the error that has arisen.
The error code and figure can be removed temporarily with the Reset
(R) function key and it then disappears from the display. If the error
code is active then the indication returns in the display within
004257
1-3 minutes.
Example figure, automatic display figure

NOTE
If the error code disappears automatically then it may be due to
the following:
– output signal which generated the error is not activated any-
more, e.g. control lever is released or engine is off.
– loose connection/poor contact.
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).
D E • Field B: Error code level is shown with a symbol.

• Field C: Shows error code.
B
000389
• Field D: Shows type of error.

• Field E: Indicates which function is affected by error code.
• Book symbol means that information is available in the operator’s
manual.
Field B: Error code level

The control and monitoring system gives error code information in
three levels which are indicated with a symbol in the lower left corner
(B) on the display unit.
STOP
Indicates a serious malfunction that may affect operator safety or
cause machine breakdown. The error code shall be taken care of as
soon as possible. Stop working with the machine and contact service
as soon as possible.
The error code is shown automatically on the display.
Action in the event of STOP
C A. Park the machine immediately.
D E Note error code number.

B. Stop the engine.
000350
C. Contact service.

5 Handling – 5.3.2 Error code information on display 99
WARNING
Indicates machine malfunction that should be taken care of as soon as
possible. After finished work shift with the machine, contact service as
soon as possible.
Action in the event of Warning
C A. Take care of the error code as soon as possible but work with ma-
chine can continue safely.
D E
B. See information in error code table
000351
If error code number is not in error code table, perform action
according to step C.
C. Contact service, e.g. after work shift is finished.
INFORMATION
Information for the operator that something should be taken care of,
for example, low fuel level. Take care of the cause of the error code as
soon as possible. See chapter 6 Inspection and maintenance.
Action in the event of Information
C A. Continue work with machine.
D E B. At a suitable time, see information in error code table

000352

If error code number is not in error code table, perform action
according to step C.
C. Contact service, e.g. after work shift is finished.

100 5 Handling – 5.3.2 Error code information on display
Field C: Error code number

The control and monitoring system gives error codes from three sub-
systems:
• Machine:
C
Shown with error code number XXX in the display, see Error
D E codes, control unit EDU 795 (KCS display) page 102, Error codes,
control unit ECU 790 page 102, Error codes, control unit ECU 796
B page 104 and Error codes, control unit ECU 792 page 107.
000389 • Engine
1200 Shown with code 1200 and error code number X.X.X (position D)
in the display, see Error codes engine page 108.
D
B NOTE
000584
If several error codes arise from the engine then these are
shown in a rolling sequence, i.e. all active error codes are
shown at 1 second intervals in the same box.
• Transmission:
900 Shown with error code 900 and error code level (position D) and
error code level (position B) in the display. If several error codes
D
arise from the transmission then these are shown in a rolling se-
B quence at 1 second intervals. For error code table, see Error
001847
codes transmission page 121.
Field D: Type of error

1. Temperature too high/too low.
1 2 3
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.
5. Incorrect signal from control.
4 5 6
6. Level too high/too low.
000879

5 Handling – 5.3.2 Error code information on display 101
Field E: Indicates which function is affected by error code.

1 2 3
1. Battery voltage.
2. Hydraulic functions.
3. Communication.
4 5 6
4. ECU hardware error.
5. Lift up/down.
6. Forks tilt.
7 8 9 7. Forks side shift.
8. Forks spreading.
9. Levelling.
10 11 12 10. Engine.
11. Engine coolant.
12. Engine oil.
13 14 15 13. Engine oil pressure.

14. Transmission.
15. Oil pressure, transmission.
16. Hydraulic transmission.
16 17 18
17. Pedal.
18. Brake system.
19. Time.
19 20 21
20. Electronic scales.
21. Fuel.
22. Steering.
22 23 24 23. Clamping attachment.
24. Emergency stop.
25. Revolving driver’s seat.
25 26 27 26. Air or particle filter.

27. Fuel economy.
28. Parking brake.
28
007010

102 5 Handling – 5.3.3 Error code tables
5.3.3 Error code tables

General
page
–
Error codes are sorted in numerical order. The tables contain the fol-
lowing information:
• Code - Indicates error code.
• Description - Indicates description of the error code as well as any
limitation that can occur in the machine in the event of the error
code in question.
• Action - Indicates STOP/WARNING/INFORMATION for action ac-
cording to error code level, with or without detailed information.
If the error code number isn’t included in the error code table, contact
service.
Error codes, control unit EDU 795 (KCS display)

–
Table 1. Error codes EDU 795
Code Description Action

1 Time for service interval exceeded. INFORMATION
10 Communication error ECU 790. Impossible to continue operating. STOP!
11 Communication, error on cable ECU 790 - EDU 795. Impossible to contin- WARNING!
ue operation.
12 Communication error ECU 793. STOP!
13 Communication error ECU 794. STOP!
14 Communication ECU 796, no response. STOP!
15 Communication, cable error ECU 795 - ECU 796. WARNING!
16 Communication, cable error ECU 796 - ECU 790. WARNING!
17 Memory error, checksum EDU 795. Impossible to continue operating, dis- WARNING!
play not working.
18 Communication ECU 792, no response. STOP!
Error codes, control unit ECU 790

–
Table 2. Error codes, ECU 790

301 Voltage feed error ECU 790. Reduction of engine speed. STOP: check the fuses in accord-
ance with the operator’s manual,
as well as battery voltage and acid
content. Contact service if the
problem persists.
303 Reference voltage error, 5V, ECU 790. Reduction of engine speed. STOP!
304 Sensor error, electric scales. WARNING!
305 Error on speed sensor. Reduction of engine speed. STOP!

5 Handling – 5.3.3 Error code tables 103

306 Error on engine speed sensor. Reduction of engine speed. STOP!
307 Error on gear selector. Reduction of engine speed. STOP!
320 Defective sensor for hydrostatic drive pressure (forward). Reduction of en- STOP!
gine speed.
321 Defective sensor for hydrostatic drive pressure (reverse). Reduction of en- STOP!
gine speed.
322 Defective hydraulic pressure sensor for lifting lever. Engine speed does not WARNING!
increase when using lifting lever.
323 Short-circuit or open circuit on output signal EDC valve pump (forward). STOP!
Reduction of engine speed.
324 Short-circuit or open circuit on output signal EDC valve pump (reverse). STOP!
325 Short-circuit or open circuit on output signal PDC valve hydraulic motor. STOP!
350 Low battery voltage. WARNING!
351 High battery voltage. WARNING!
352 Low fuel level. Possible to continue operating. INFORMATION! Fill with fuel.
353 Defective sensor fuel level. Possible to continue operating. INFORMATION!
354 Low coolant level. Reduction of engine speed. STOP! Fill with coolant.
355 High hydraulic oil temperature. WARNING! Do not use hydraulic

functions before the hydraulic oil
temperature has fallen below
70 °C. Contact service if the prob-
lem recurs.
356 Defective sensor hydraulic oil temperature. Possible to continue operating. INFORMATION!
357 Brake system, accumulator pressure low. Reduction of engine speed. STOP! The pressure in the accu-
mulator, i.e. the brake pressure is
too low and service brake capacity
is limited.
Check the sealing integrity of the
accumulators if the pressure is not
built up and maintained, see chap-
ter 6 Inspection and maintenance.
Contact service.
370 Particle filter engine. Clean within 30 minutes. INFORMATION! Clean the parti-
cle filter within 30 minutes. See the
section 5.4.9 Stopping machine -
parking or see the separate manu-
al for the particle filter.


371 Particle filter, engine. Immediate cleaning. Reduction of engine speed. STOP! Clean particle filter. See
parking or see separate manual
for particle filter.
372 Particle filter, engine. High pressure. Reduction of engine speed. STOP! Clean particle filter. See
parking or see separate manual
for particle filter.
380 Error on accelerator pedal LF (Left Front). Reduction of engine speed. STOP!
381 Error on accelerator pedal RF (Right Front). Reduction of engine speed. STOP!
382 Error on accelerator pedal LR (Left Rear). Reduction of engine speed. STOP!
383 Error on accelerator pedal RR (Right Rear). Reduction of engine speed. STOP!
384 Error on servo motor for injector pump, engine. Reduction of engine speed. STOP!
390 Error on valve for variable pump for Optimum Speed/Optimum Rev, short- WARNING!
circuit or open circuit at terminal.
400 Revolving driver’s seat. Defective sensor. Only driving forward is possible. WARNING! Stop the machine.
Turn the driver’s seat to the posi-
tion for driving forward. Contact
service.
401 Overload lift and tilt. Reduction of speed. WARNING!
402 Error on parking brake. The parking brake cannot be released. STOP!
404 Sensor error, coolant level. WARNING!
405 Error on position sensor for seat turning. Limitation of function. WARNING!
406 Signal error from power cell, stub axle, tilt cylinder. Overload protection not WARNING!
working.

–

601 Voltage feed error, ECU 796. STOP!
602 Memory error, checksum ECU 796. STOP! Restart ECU 796 by
switching the ignition off and on,
load the program. Contact service
if the problem persists.
603 Reference voltage 10 V error, ECU 796. STOP!
604 Voltage feed error PWM outputs, ECU 796. Hydraulics inoperative. INFORMATION! Switch off the hy-
draulic functions. At the electric
servo, check if the control breaker
for load handling is depressed.


605 Communication error XA-PWM, K2. Hydraulic functions inoperative. INFORMATION! Restart ECU 796
by switching the ignition off and
on. Contact service if the problem
persists.
606 Communication error XA-PWM, K3. Hydraulic functions inoperative. INFORMATION! Restart ECU 796
by switching the ignition off and
on. Contact service if the problem
persists.
610 Input signal from the lever for hydraulic function 1 error. Hydraulic function INFORMATION! Do not use hy-
1 is inoperative. draulic function 1.
615 Short circuit or open circuit for control valve hydraulic function 1A at the ter- INFORMATION! Do not use hy-
minal K2:3. Hydraulic function 1 is inoperative. draulic function 1.
616 Short circuit or open circuit for control valve hydraulic function 1B at the ter- INFORMATION! Do not use hy-
626 Error on sensor for tilt control. Tilt control inoperative. INFORMATION: switch off tilt con-
trol.
627 Error on sensor for preset lifting height. Lifting height preset inoperative. INFORMATION! Switch off lifting
height preset.


628 CTX communication error. Clamping controller does not respond. Only WARNING! CTX clamping unit in-
manual clamping function possible. operative. Select manual clamp-
ing control.
630 Defective pressure sensor P1, Clamping attachment. The selected attach- WARNING! No automatic in-
ment pressure is approximate. WARNING! No automatic increase in pres- crease in pressure if the attach-
sure if the attachment pressure decreases. ment pressure decreases.
631 Defective pressure sensor P2, Clamping attachment. The selected attach- WARNING! No automatic in-
ment pressure is approximate. WARNING! No automatic increase in pres- crease in pressure if the attach-
sure if the attachment pressure decreases. ment pressure decreases.
Contact service.
632 Short circuit or open circuit for control valve hydraulic function at the termi- WARNING! Do not use hydraulic
nal K3:3. Hydraulic function clamping attachment is inoperative. function clamping attachment.
633 Short circuit or open circuit for control valve attachment pressure ON/OFF. WARNING! Do not use hydraulic
Hydraulic function clamping attachment is inoperative. function clamping attachment.
634 Short circuit or open circuit for control valve left arm ON/OFF. Hydraulic WARNING! Do not use hydraulic
function left arm is inoperative. function left arm.
635 Short circuit or open circuit for control valve right arm ON/OFF. Hydraulic WARNING! Do not use hydraulic
function right arm is inoperative. function right arm.
636 Short circuit or open circuit for control valve upper left arm ON/OFF. Hy- WARNING! Do not use hydraulic
draulic function upper left arm is inoperative. function upper left arm.
637 Short circuit or open circuit for control valve centre right arm ON/OFF. Hy- WARNING! Do not use hydraulic
draulic function centre right arm is inoperative. function right arm.
638 Short circuit or open circuit for control valve centre left arm ON/OFF. Hy- WARNING! Do not use hydraulic
draulic function centre left arm is inoperative. function left arm.
639 Short circuit or open circuit for control valve upper right arm ON/OFF. Hy- WARNING! Do not use hydraulic
draulic function upper right arm is inoperative. function upper right arm.
642 Pressure sensor clamping attachment opening, defective. Hydraulic func- WARNING! Do not use hydraulic
tion clamping attachment inoperative. function clamping attachment.
643 Pressure sensor clamping attachment closing, defective. Hydraulic function WARNING! Do not use hydraulic
clamping attachment inoperative. function clamping attachment.
644 Breaker right/left arm defective. Do not use shutdown right/left arm. WARNING! Shutdown right/left
arm inoperative.
645 Max. load exceeded. Max. speed 1 km/h. WARNING! Lower the load.
646 Upper left bypass valve on clamping attachment inoperative. Hydraulic WARNING!
function clamping attachment left side inoperative.
647 Centre left bypass valve on clamping attachment inoperative. Hydraulic WARNING!
function clamping attachment left side inoperative.
648 Left sequence valve on clamping attachment inoperative. Hydraulic func- WARNING!
tion clamping attachment left side inoperative.
650 Upper right bypass valve on clamping attachment inoperative. Hydraulic WARNING!
function clamping attachment right side inoperative.
651 Centremost right bypass valve on clamping attachment inoperative. Hy- WARNING!
draulic function clamping attachment right side inoperative.


652 Right sequence valve on clamping attachment inoperative. Hydraulic func- WARNING!
tion clamping attachment right side inoperative.
654 Pressure sensor P3 left long arm on clamping attachment defective. Hy- WARNING!
draulic function clamping attachment left side inoperative.
655 Pressure sensor P3 left short arm on clamping attachment defective. Hy- WARNING!
draulic function clamping attachment left side inoperative.
656 Pressure sensor P3 right long arm on clamping attachment defective. Hy- WARNING!
657 Pressure sensor P3 right short arm on clamping attachment defective. Hy- WARNING!
658 Fault on switch for selecting clamping pressure. Clamping pressure one is WARNING!
selected.
659 Pressure sensor P1 left arm on clamping attachment defective. No auto- WARNING!
matic increase in clamping pressure.
660 Pressure sensor P2 left arm on clamping attachment defective. No auto- WARNING!
661 Pressure sensor P1 right arm on clamping attachment defective. No auto- WARNING!
662 Pressure sensor P3 right arm on clamping attachment defective. No auto- WARNING!
900 Error code from transmission control unit. WARNING! See Error codes
transmission page 121.
1200 Error code from engine control unit. WARNING! See Error codes en-
gine page 108.

–

1501 Fault on sensor for feedback steering. Alternative steering switched off au- STOP! Use standard steering.
tomatically.
1502 Fault on joystick. Alternative steering switched off automatically. STOP! Use standard steering.
1503 Fault on potentiometer mini steering wheel. Alternative steering switched STOP! Use standard steering.
off automatically.
1504 Short circuit or open circuit on output signal for right control valve. Alterna- STOP! Use standard steering.
tive steering switched off automatically.
1505 Short circuit or open circuit on output signal for left control valve. Alternative STOP! Use standard steering.
steering switched off automatically.
1506 Voltage feed error ECU 792. Reduction of engine speed. STOP! Check the fuses in accord-
ance with the operator’s manual.
Contact service if the problem per-
sists.
1507 Reference voltage error, 5V, ECU 792. Reduction of engine speed. STOP!

Error codes engine

–
For contact with engine manufacturers, 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 5. Specifications FMI
FMI Description SAE-text

0 Too high value. Data valid, but higher than normal operating range.
1 Too low value. Data valid, but lower than normal operating range.
2 Incorrect data. Intermittent or incorrect data.
3 Electrical problem. Abnormally high voltage or short-circuit to higher voltage.
4 Electrical problem. Abnormally low voltage or short-circuit to lower voltage.
5 Electrical problem. Abnormally low current or open circuit.
6 Electrical problem. Abnormally high current or short-circuit to ground.
7 Mechanical problem. Incorrect response from mechanical system.
8 Mechanical problem or electrical prob- Abnormal frequency.

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

lem.
11 Unknown malfunction. Non-identifiable malfunction.
12 Component error. Incorrect unit or component.
13 Incorrect calibration. Values outside calibration values.
14 Unknown malfunction. Special instructions.
15 Unknown malfunction. Reserved for future use.
16 Too high value. Data valid but higher than normal operating range: Moderately severe
level
17 Too low value. Data valid but lower than normal operating range: The least severe
level
18 Too low value. Data valid but lower than normal operating range: Moderately severe
level
19 Communication error. Received network data error
20-30 Reserved for SAE allocation
31 FMI is not available or the ratio stated by Not available or the ratio exists
SPN exists.

Table 6. Error codes Volvo TAD750VE
Description Action
Display J1587
SPN/FMI
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, critically low fuel pressure. STOP
97/0 PID97/0 Water in fuel. WARNING: Drain fuel pre-fil-

ter, see 6.2.2 Fuel system.
97/4 PID97/4 Sensor water in fuel, cable open circuit or short-circuited to STOP
ground.
100/1 PID100/1 Low engine oil pressure. Reduced engine power or engine is STOP: Check oil level in en-
turned off. gine. See 6.2.6 Engine oil.
100/3 PID100/3 Sensor oil pressure cable short-circuited to voltage. STOP
100/5 PID100/5 Sensor oil pressure, cable open circuit. STOP
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. STOP
106/0 PID102/0 High boost pressure. Reduced engine power. STOP
106/3 PID102/3 Sensor boost pressure, cable short-circuited to voltage. Engine STOP
smokes more than normal at acceleration/load.
106/5 PID102/5 Sensor boost pressure, cable open circuit. Engine smokes more STOP
than normal when accelerating/under load.
108/2 PID108/2 Sensor air pressure. STOP
108/3 PID108/3 Sensor air pressure, cable short-circuited to voltage. STOP
108/4 PID108/4 Sensor air pressure, cable open circuit. STOP
110/0 PID110/0 High coolant temperature. Reduced engine power or engine is STOP: Check coolant level.
turned off. See 6.2.5 Cooling system.
110/4 PID110/4 Sensor coolant temperature, cable short-circuited to frame. Pre- STOP
heating activated even when engine is warm. Engine difficult to
start.
110/5 PID110/5 Sensor coolant temperature, cable open circuit. Preheating ac- STOP
tivated even when engine is warm. Engine difficult to start.
111/1 PID111/1 Low coolant level. Reduced engine power. STOP: Check coolant level.
See 6.2.5 Cooling system.

Description Action
Display J1587
SPN/FMI
158/1 PID158/1 Low battery voltage. Engine may be difficult to start. STOP
164/0 PID164/0 Incorrect pressure fuel injection. STOP
164/2 PID164/2 Pressure fuel injection. Engine rpm limited to 1100 rpm. STOP
164/4 PID164/4 Sensor pressure fuel injection, cable short-circuited to frame. STOP
Engine rpm limited to 1100 rpm.
164/5 PID164/5 Sensor pressure fuel injection, cable open circuit. Engine rpm STOP
limited to 1100 rpm.
190/0 PID190/0 Engine rpm too high. STOP
626/3 PID45/3 Preheating relay, cable short-circuited to voltage. Preheating STOP

cannot be activated. Engine difficult to start in cold weather.
626/4 PID45/4 Preheating relay, cable short-circuited to frame. Preheating con- STOP
stantly activated, fuse for preheating coil will blow.
626/5 PID45/5 Preheating relay, cable open circuit. Preheating cannot be acti- STOP
vated. Engine difficult to start in cold weather.
629/3 SID254/3 Internal error engine control unit. STOP

Engine off: engine cannot be started. Engine running: engine
misfires.

misfires.

misfires.
636/2 SID21/2 Sensor rpm camshaft. Irregular signal. Engine takes longer to STOP
start than normal. Engine runs normally once it has started.
636/3 SID21/3 Sensor rpm camshaft. No signal. Engine takes longer to start STOP
than normal. Engine runs normally once it has started.
636/8 SID21/8 Sensor rpm camshaft. Abnormal frequency. Engine takes longer STOP
to start than normal. Engine runs normally once it has started.
637/2 SID22/2 Sensor rpm flywheel. Irregular signal. Engine is extremely diffi- STOP
cult to start and runs rough or stops.
637/3 SID22/3 Sensor rpm flywheel. Abnormal frequency. Engine is extremely STOP
difficult to start and runs rough or stops.
637/8 SID22/8 Sensor rpm flywheel. Abnormal frequency. Engine is extremely STOP
difficult to start and runs rough or stops.

Description Action
Display J1587
SPN/FMI
Engine off: engine cannot be started. Engine on: engine goes to
idle mode and can only be stopped by using emergency stop.
639/2 SID240/2 Memory error control unit engine. STOP

May not be possible to start engine.

639/9 PSID201/ Communication error control unit engine. STOP

9


651/3 SID1/3 Electrical problem, injector cylinder 1. Engine only runs on STOP
5 cylinders and has reduced power.
651/7 SID1/7 Compression malfunction or defective injector cylinder 1. Rough STOP

running at low rpm and low load.


Description Action
Display J1587
SPN/FMI


655/7 SID5/7 Compression malfunction or defective injector cylinder 5. En- STOP

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


Description Action
Display J1587
SPN/FMI
677/3 SID39/3 Start relay on starter motor, cable short-circuited to voltage or STOP
1675/3 activated too long. Starter motor does not run.
677/4 SID39/4 Start relay on starter motor, cable short-circuited to frame. Start- STOP
1675/4 er motor does not run.
677/5 SID39/5 Starter motor relay, open circuit on cable or defective compo- STOP
1675/5 nent. Starter motor does not run.
679/3 SID42/3 Governor injection pressure, cable short-circuited to voltage. STOP

Risk of engine stop.
679/4 SID42/4 Governor injection pressure, cable short-circuited to frame. STOP
679/5 SID42/5 Governor injection pressure, cable open circuit. STOP
679/6 SID42/6 Governor injection pressure, cable short-circuited to frame. STOP
679/13 SID42/13 Governor injection pressure. Risk of engine stop. STOP
679/0 PSID97/0 Pressure relief valve. Engine rpm limited to 1100 rpm. STOP
679/7 PSID97/7 Pressure relief valve. Engine is turned off or engine rpm limited STOP
to 1100 rpm.
679/11 PSID97/ Pressure relief valve. Engine rpm limited to 1100 rpm. STOP
11
679/14 PSID97/ Pressure relief valve. Engine rpm limited to 1100 rpm. STOP
14
729/3 SID70/3 Sensor preheating, cable short-circuited to voltage. STOP
729/4 SID70/4 Sensor preheating, cable short-circuited to ground. Engine diffi- STOP
cult to start in cold weather.
729/5 SID70/5 Sensor preheating, cable open circuit. Engine difficult to start in STOP
cold weather.
1079/3 SID 232/3 Voltage feed sensor engine, cable short-circuited to voltage. STOP
1079/4 SID 232/4 Voltage feed sensor engine, cable short-circuited to frame. STOP
1080/3 PPID 211/ Voltage feed sensor engine, cable short-circuited to voltage. STOP
3
1080/4 PPID 211/ Voltage feed sensor engine, cable short-circuited to frame. STOP
4
1239/0 PSID96/0 Incorrect fuel pressure injection. Engine rpm limited to STOP
1100 rpm.

Description Action
Display J1587
SPN/FMI
1100 rpm.
1239/4 PSID96/4 Incorrect fuel pressure injection. Engine is turned off or engine STOP
rpm limited to 1100 rpm.
1100 rpm.
1239/12 PSID96/ Incorrect fuel pressure injection. Engine rpm limited to STOP
12 1100 rpm.
2791/3 PPID19/3 EGR status, cable short-circuited to voltage. STOP
2791/4 PPID19/4 EGR status, cable short-circuited to frame. STOP
2791/5 PPID19/5 EGR status, cable open circuit. STOP
2791/7 PPID19/7 EGR status. STOP
520195/5 PPID6/5 Switch engine shutdown, cable open circuit. STOP
- PPID 435/ Incorrect fuel pressure injection. Engine rpm limited to STOP
0 1100 rpm.
- PPID 435/ Incorrect fuel pressure injection. Engine rpm limited to STOP
1 1100 rpm.
Table 7. Error codes Cummins QSB6.7
Description Action
Display
SPN/FMI
84 / 10 Circuit sensor engine rpm - Abnormally wide variations. WARNING!
84 / 2 Circuit sensor engine rpm - Defective, uneven, or rough. WARNING!
91 / 0 Position sensor accelerator pedal - Abnormal frequency, pulse-width or time WARNING!

period.
91 / 1 Position sensor accelerator pedal - Abnormal frequency, pulse-width or time WARNING!

period.
91 / 19 SAE J1939 multiplexing, system error accelerator pedal sensor - CAN bus data WARNING!
error.
91 / 2 Position sensor accelerator pedal. WARNING!

Description Action
Display
SPN/FMI
91 / 3 Position sensor accelerator pedal, defective circuit - Abnormally high voltage or WARNING!
short-circuiting to higher voltage.
91 / 4 Position sensor accelerator pedal, defective circuit - Abnormally low voltage or WARNING!
short-circuiting to lower voltage.
94 / 1 Fuel pump feed pressure incorrect - Data valid, but lower than normal operating WARNING!
range.
94 / 18 Fuel pump feed pressure incorrect - Data valid, but lower than normal operating WARNING!
range.
94 / 2 Fuel pressure sensor - Defective, uneven, or rough. WARNING!
97 / 15 Water in fuel, indicator high - Data valid, but higher than normal operating range. WARNING!
97 / 3 Sensor circuit water in fuel - Abnormally high voltage or short-circuiting to higher WARNING!
voltage.
97 / 4 Sensor circuit water in fuel - Abnormally low voltage or short-circuiting to lower WARNING!
voltage.
100 / 1 Engine oil pressure low - Data valid, but higher than normal operating range. STOP! Very serious
100 / 18 Engine oil pressure low - Data valid, but lower than normal operating range. WARNING!
100 / 2 Pressure sensor engine oil, defective circuit - Defective, uneven, or rough. WARNING!
100 / 3 Pressure sensor engine oil, defective circuit - Abnormally high voltage or short- WARNING!
circuiting to higher voltage.
100 / 4 Pressure sensor engine oil, defective circuit - Abnormally low voltage or short- WARNING!
circuiting to lower voltage.
102 / 2 Fuel sensor circuit inlet manifold - Defective, uneven, or rough. WARNING!
102 / 3 Pressure sensor inlet manifold - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
102 / 4 Pressure sensor inlet manifold - Abnormally low voltage or short-circuiting to low- WARNING!
er voltage.
103 / 10 Turbo rpm - Abnormally wide variations. WARNING!
103 / 16 Turbo #1 high rpm - Data valid, but higher than normal operating range. WARNING!
103 / 18 Turbo #1 low rpm - Data valid, but lower than normal operating range. WARNING!
105 / 0 Circuit temperature sensor inlet manifold - Data valid, but higher than normal op- STOP! Very serious
erating range.
105 / 15 Temperature inlet manifold high - Data valid, but higher than normal operating WARNING!
range.

Description Action
Display
SPN/FMI
105 / 3 Temperature sensor inlet manifold - Abnormally high voltage or short-circuiting WARNING!
to higher voltage.
105 / 4 Temperature sensor inlet manifold - Abnormally low voltage or short-circuiting to WARNING!
lower voltage.
108 / 2 Sensor air pressure - Defective, uneven, or rough. WARNING!
108 / 3 Sensor air pressure - Abnormally high voltage or short-circuiting to higher WARNING!
voltage.
108 / 4 Sensor air pressure - Abnormally low voltage or short-circuiting to lower voltage. WARNING!
110 / 0 Coolant temperature engine high - Data valid, but higher than normal operating STOP! Very serious
range.
110 / 15 Coolant temperature engine high - Data valid, but higher than normal operating WARNING!
range.
110 / 16 Coolant temperature engine high - Data valid, but higher than normal operating WARNING!
range.
110 / 2 Sensor coolant engine, defective circuit - Defective, uneven, or rough. WARNING!
110 / 3 Sensor coolant engine, defective circuit - Abnormally high voltage or short- WARNING!
110 / 4 Sensor coolant engine, defective circuit - Abnormally low voltage or short- WARNING!
111 / 1 Coolant level engine low - Data valid, but lower than normal operating range. STOP! Very serious
111 / 3 Level sensor coolant circuit - Abnormally high voltage or short-circuiting to higher WARNING!
voltage.
111 / 4 Level sensor coolant circuit - Abnormally low voltage or short-circuiting to lower WARNING!
voltage.
157 / 0 Fuel pressure high - Data valid, but higher than normal operating range. WARNING!
157 / 16 Measurement injection pressure bank 1, high pressure - Data valid, but higher WARNING!
than normal operating range.
157 / 18 Measurement injection pressure bank 1, low pressure - Data valid, but lower than WARNING!
normal operating range.
157 / 2 Fuel pressure sensor defect - Defective, uneven, or rough. WARNING!
157 / 3 Measurement injection pressure bank 1, defective circuit - Abnormally high volt- WARNING!
age or short-circuiting to higher voltage.
157 / 4 Measurement injection pressure bank 1, defective circuit - Abnormally low volt- WARNING!
age or short-circuiting to lower voltage.
167 / 1 Alternator low voltage - Data valid, but lower than normal operating range. STOP! Very serious

Description Action
Display
SPN/FMI
167 / 16 Alternator high voltage - Data valid, but higher than normal operating range. WARNING!
167 / 18 Alternator low voltage - Data valid, but lower than normal operating range. WARNING!
168 / 16 Battery#1 voltage high - Data valid, but higher than normal operating range. WARNING!
168 / 18 Battery#1 voltage low - Data valid, but lower than normal operating range. WARNING!
171 / 3 Ambient temperature sensor, defective circuit - Abnormally high voltage or short- WARNING!
171 / 4 Ambient temperature sensor, defective circuit - Abnormally low voltage or short- WARNING!
190 / 0 Engine overspeeding - Data valid, but higher than normal operating range. STOP! Very serious
190 / 2 Main rpm sensor defect - Defective, uneven, or rough. WARNING!
190 / 2 Rpm/position sensor - Defective, uneven, or rough. WARNING!
251 / 2 Real-time clock, open circuit power supply - Defective, uneven, or rough. WARNING!
441 / 3 Spare temperature sensor circuit - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
441 / 4 Spare temperature sensor circuit - Abnormally low voltage or short-circuiting to WARNING!
lower voltage.
558 / 13 Idle validation circuit accelerator pedal - Values outside calibration values. WARNING!
558 / 2 Idle validation circuit accelerator pedal - Defective, uneven, or rough. WARNING!
558 / 4 Idle validation circuit accelerator pedal - Abnormally low voltage or short- WARNING!
611 / 2 Power take-off rpm switch - Defective, uneven, or rough. WARNING!
611 / 3 Voltage feed no. 4, sensor - Abnormally high voltage or short-circuiting to higher WARNING!
voltage.
611 / 4 Voltage feed no. 3, sensor - Abnormally low voltage or short-circuiting to lower WARNING!
voltage.
611 / 4 Voltage feed no. 4, sensor - Abnormally low voltage or short-circuiting to lower WARNING!
voltage.
612 / 2 Engine’s torque and position sensor circuit has lost input signals from solenoid WARNING!
sensor - Defective, uneven, or rough.
627 / 2 Open circuit power supply despite ignition in position on - Defective, uneven, or WARNING!
rough.
627 / 2 Open circuit power supply despite ignition in position on - Defective, uneven, or WARNING!
rough.
629 / 12 Engine control unit internal error - Defective unit or component. WARNING!

Description Action
Display
SPN/FMI
629 / 12 Voltage feed injector - Defective unit or component. WARNING!
630 / 2 Engine control unit, memory error - Defective, uneven, or rough. WARNING!
630 / 31 Engine control unit, RAM memory error - Not available. WARNING!
633 / 31 Fuel valve, circuit error - Not available. WARNING!
639 / 13 SAE J1939 multiplexing configuration error - Values outside calibration values. WARNING!
639 / 9 SAE J1939 multiplexing PGN time limit exceeded - Abnormal update rate. WARNING!
641 / 3 Variable Turbo Geometry valve circuit - Abnormally high voltage or short- WARNING!
641 / 4 Variable Turbo Geometry valve circuit - Abnormally low voltage or short- WARNING!
644 / 2 External rpm sensor input - Defective, uneven, or rough. WARNING!
647 / 3 Circuit error switch cooling fan - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
647 / 4 Circuit error switch cooling fan - Abnormally low voltage or short-circuiting to low- WARNING!
er voltage.
651 / 5 Injector solenoid cylinder # 1 circuit - Abnormally low current or open circuit. WARNING!
651 / 7 Injector cylinder #1 - Incorrect response from mechanical system. WARNING!
677 / 3 Start relay circuit - Abnormally high voltage or short-circuiting to higher voltage. WARNING!
677 / 4 Start relay circuit - Abnormally low voltage or short-circuiting to lower voltage. WARNING!
697 / 3 External PWM drive circuit 1 - Abnormally high voltage or short-circuiting to high- WARNING!
er voltage.

Description Action
Display
SPN/FMI
697 / 4 External PWM drive circuit 1 - Abnormally low voltage or short-circuiting to lower WARNING!
voltage.
703 / 11 Sensor spare equipment input #3 (OEM) - Non-identifiable malfunction. WARNING!
723 / 2 Engine rpm/position camshaft synchronisation error - Defective, uneven, or WARNING!

rough.
723 / 2 Engine rpm sensor (camshaft) defect - Defective, uneven, or rough. WARNING!
723 / 2 Engine rpm/position sensor - Defective, uneven, or rough. WARNING!
723 / 7 Engine rpm sensor mechanically incorrectly adjusted between camshaft and WARNING!
crankshaft - Incorrect response from mechanical system.
729 / 3 Air preheating coil circuit - Abnormally high voltage or short-circuiting to higher WARNING!
voltage.
729 / 4 Air preheating coil circuit - Abnormally low voltage or short-circuiting to lower volt- WARNING!
age.
974 / 19 SAE J1939 multiplexing, value error remote accelerator pedal sensor - Received WARNING!
data incorrect.
974 / 3 Position sensor accelerator pedal, defective circuit - Abnormally high voltage or WARNING!
974 / 4 Position sensor accelerator pedal, defective circuit - Abnormally low voltage or WARNING!
1043 / 3 Voltage feed circuit accelerator pedal or lever - Abnormally high voltage or short- WARNING!
1043 / 4 Voltage feed circuit engine rpm/position sensor - Abnormally low voltage or WARNING!
1043 / 4 Voltage feed circuit accelerator pedal or lever - Abnormally low voltage or short- WARNING!
1072 / 3 Signal engine brake circuit #1 - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
1072 / 4 Signal engine brake circuit #1 - Abnormally low voltage or short-circuiting to low- WARNING!
er voltage.
1073 / 3 Signal engine brake circuit #2 - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
1073 / 4 Signal engine brake circuit #2 - Abnormally low voltage or short-circuiting to low- WARNING!
er voltage.
1075 / 3 Fuel suction pump circuit - Abnormally high voltage or short-circuiting to higher WARNING!
voltage.

Description Action
Display
SPN/FMI
1075 / 4 Fuel suction pump circuit - Abnormally low voltage or short-circuiting to lower WARNING!
voltage.
1079 / 3 Sensor voltage feed circuit #1 - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
1079 / 4 Sensor voltage feed circuit #1 - Abnormally low voltage or short-circuiting to low- WARNING!
er voltage.
1080 / 3 Sensor voltage feed circuit #2 - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
1080 / 4 Sensor voltage feed circuit #2 - Abnormally low voltage or short-circuiting to low- WARNING!
er voltage.
1172 / 3 Turbocharger pressure temperature sensor circuit - Abnormally high voltage or WARNING!
1172 / 4 Turbocharger pressure temperature sensor circuit - Abnormally low voltage or WARNING!
1347 / 3 High-pressure fuel valve circuit - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
1347 / 4 High-pressure fuel valve circuit - Abnormally low voltage or short-circuiting to WARNING!
lower voltage.
1347 / 7 Fuel pump - Incorrect response from mechanical system. WARNING!
1347 / 7 High-pressure valve no.1 - Incorrect response from mechanical system. WARNING!
1377 / 2 Switch circuit multiple synchronisation unit - Defective, uneven, or rough. WARNING!
1378 / 31 Change oil and oil filter, conditions apply - Not available. WARNING! Service.
1388 / 3 External pressure sensor input - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
1388 / 4 External pressure sensor input - Abnormally low voltage or short-circuiting to low- WARNING!
er voltage.
2629 / 15 Boost pressure temperature output calculated - Data valid, but higher than nor- WARNING!
mal operating range.
2789 / 15 Boost pressure temperature input calculated - Data valid, but higher than normal WARNING!
operating range.

Error codes transmission

–
For transmission alternative TE17000: Error codes from control unit

for transmission has error code level "WARNING".
Table 8. Error codes TE17000
Description Action
Code
00/50 Memory error in control unit transmission. Transmission in STOP
locked neutral position ("shutdown").



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

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

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

("shutdown").
30/04 Low battery voltage. STOP
30/05 High battery voltage. WARNING
31/00 Reference voltage to sensor is too low. WARNING
31/01 Reference voltage to sensor is too high. WARNING
40/06 Incorrect direction from gear selector. Transmission in neutral. WARNING
41/06 Incorrect gear selection from gear selector. Control unit does WARNING
not allow change of gear range, however, operation of machine
is possible.
42/04 Actual gear ratio too low. One or several clutches slipping. STOP or WARNING
42/05 Actual gear ratio too high. One or several clutches slipping. STOP or WARNING
43/03 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.

Description Action
Code
43/08 Torque converter’s temperature exceeds 125 C. WARNING: Stop the machine, engage neu-
The control unit protects the transmission and does not allow tral and apply full throttle (limited to 50%) to
the temperature in the torque converter to exceeds the limit val- cool the transmission oil so that temperature
ue. Transmission in locked neutral position ("shutdown"). En- drops below 100 C (error code 43/03 disap-
gine is limited to 50% of max. rpm. pears).
When temperature in torque converter is be-
low 100 C, resume work with machine.
44/10 Position accelerator pedal message from engine’s control unit. WARNING
46/05 Max. torque at inching has been exceeded. WARNING: Stop the machine, select neu-
tral. Select gear again.
50/00 Sensor oil pressure, short-circuiting to ground. Control unit STOP

transmission activates "limp home".
50/01 Sensor oil pressure, open circuit. Control unit transmission ac- STOP
tivates "limp home".
51/00 Sensor transmission oil temperature, short-circuiting to ground. WARNING
51/01 Sensor transmission oil temperature, open circuit. WARNING
54/00 Reference voltage sensor 5V, short-circuiting to ground. WARNING
54/01 Reference voltage sensor 5V, open circuit. WARNING
60/00 Sensor rpm torque converter, short-circuiting to ground. STOP or WARNING

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

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

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

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

62/01 Sensor engine rpm, open circuit. STOP or WARNING


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

70/00 Solenoid valve VFS forward. Control unit transmission 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 reverse. Control unit transmission 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.

Description Action
Code
77/02 All gear packs disengaged. Transmission in locked neutral po- STOP
sition ("shutdown").
80/00 Solenoid valve drive, short-circuiting to ground. Transmission in STOP

80/01 Solenoid valve drive, open circuit or short-circuiting to battery. STOP

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

83/01 Solenoid valve drive, open circuit or short-circuiting to battery. STOP

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

99/xx tion ("shutdown").
95.71 Control unit transmission cannot interpret in-data. STOP
99.90 Incorrect software in control unit. STOP
For serious transmission malfunctions the control unit uses two modes
with reduced functionality to protect the transmission from damage.
These are:
• "Limp home", GPOS / CPOS in display indicates the letters LH.
In this mode, the operator can use the transmission’s two first
gears in each direction. If the malfunction occurs in a higher gear
the operator has to downshift manually to first or second gear to
continue. The control unit uses standard values for modulation.
• "Shut down", GPOS / CPOS in display indicates the letters Sd.
In this mode the transmission is permanently in neutral as there is
no oil pressure to enable gear selection.

Error codes ECC

–
Table 9. Error codes ECC
Error code Description Recommended action
Heater valve Open Open circuit in water valve or in the wiring between Contact service.
the ECC control unit and water valve.
Heater valve Short Short circuit in water valve or in the wiring between Contact service.
the ECC control unit and water valve.
Heater valve Stuck Water valve is jammed or blocked by foreign objects. Contact service.
Inside sensor Open Open circuit in sensor, cabin temperature, or the wir- Contact service.
ing between the ECC control unit and sensor, cabin
temperature.
Inside sensor Short Short circuit in sensor, cabin temperature, or the wir- Contact service.
ing between the ECC control unit and sensor, cabin
temperature.
Outside sensor Open Open circuit in sensor, outside temperature, or the Contact service.
wiring between the ECC control unit and sensor, out-
side temperature.
Outside sensor Short Short circuit in sensor, outside temperature, or the Contact service.
wiring between the ECC control unit and sensor, out-
side temperature.
Deicing sensor Open Open circuit in sensor, deicing, or the wiring between Contact service.
the ECC control unit and sensor, deicing.
Deicing sensor Short Short circuit in sensor, deicing, or the wiring between Contact service.
the ECC control unit and sensor, deicing.
Aftercoil Sensor Open Open circuit in sensor, after heat exchanger, or the Contact service.
wiring between the ECC control unit and sensor, after
heat exchanger.
Aftercoil sensor Short Short circuit in sensor, after heat exchanger, or the Contact service.
wiring between the ECC control unit and sensor, after
heat exchanger.
AC system failure Probably abnormal pressure in the refrigerant circuit. The fault might be temporary in nature
and could then be rectified by means of
resetting the ECC.
Reset the ECC by switching off the igni-
tion and restarting the truck. Go to the
error indication menu on the ECC and
press the button to lower the fan speed
for a few seconds, see Section Error
codes ECC page 125.
If the fault remains after restarting, con-
tact service.

126 5 Handling – 5.4 Operating
5.4 Operating
5.4.1 While operating
General
page
–
DANGER
The machine’s work area is large and visibility from
the operator’s cab is restricted.

ty damage!
Keep in mind:
• Always check that no persons are in the way of the

machine or its accessories. Also check that the
area upwards is free. Stop the machine if there are
unauthorised persons or vehicles within the work
area.
• The operator must always face in the travel direc-

tion 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, via-
ducts, docksides, ramps, doors, etc.
• Always operate carefully so that the attachment

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

view mirrors and camera ( ).
WARNING
Never use a machine without first performing the dai-
ly inspection.
Risk of personal injury and property damage!
For work instruction, see section 6.1 Daily inspection.

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

5 Handling – 5.4.1 While operating 127
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.
WARNING
The operator must exercise additional caution when
the reverse alarm is switched off.
Extreme danger!
Always check that no persons are in the way of the

machine or its equipment.
WARNING
Don’t let the engine idle for a long time.
Risk of engine damage!
Turn off the engine during breaks in operation and

load handling.

128 5 Handling – 5.4.1 While operating
Instructions
–
Make a habit of checking the following at regular intervals while

operating:
• that coolant temperature is within the range (approx. 82-95 °C is
41 42 normally dependent on load).
• that fuel indicator on the display shows that there is fuel in the
tank.
NOTE
The fuel indicator should never go down to empty tank.
F
N • that all warning lights are off.

R
• that signals, lighting, brake lights and direction indicators function

1 2
R
3
correctly.
4 5 • that all hydraulic functions function correctly.
• that no error codes have been generated (shown on operator’s
006936
display with error code indication and symbol).

47 See section 5.3 Error codes.
41. Display for control system, KCS • If there is extra exhaust cleaning (particle filter):
42. Indicator for control system that the warning lamp for exhaust cleaning (position 35) is not illu-
47. Function keys for control system, KCS minated continuously or that the pressure gauge for particle filter
is within red range (150 mbar). Then exhaust cleaning needs to
be cleaned, see section 5.4.9 Stopping the machine - parking or
see the separate manual for the particle filter.
The light may flash at high engine load.

5 Handling – 5.4.2 Starting engine 129
5.4.2 Starting engine

General
page
–
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 and travel direction selector to neutral position.

The gear and travel direction selector must be in neutral position,
otherwise engine cannot be started.
NOTE
If there is extra exhaust cleaning (particle filter) :
Check that the machine is not connected for cleaning.
2. Turn the start key to operating position, position I.
Now there is current to all electric functions.
In case of cold weather, preheating, i.e. glow position,
can be used. During preheating, the engine’s intake air is preheat-
ed to a suitable temperature by preheating coils. The symbol for
preheating is shown in the display.
When the symbol disappears, turn to start position, position III.
The symbol for preheating is not shown if the engine is hot or if the
ambient temperature is sufficiently high.
3. Let the starter motor crank the engine, release the key when the
engine starts.
The machine has an electric restart interlock that protects the
starter motor from engaging when the engine is rotating.
NOTE
IF THE ENGINE DOESN’T START, try again after
15-20 seconds. Don’t run the starter motor for longer than
10 seconds at each start attempt.
If the engine still doesn’t start, this indicates that there is a
malfunction which has to be located and repaired. Contact
service.

130 5 Handling – 5.4.3 Warming up
5.4.3 Warming up
General
page
–
WARNING
Never rev a cold engine at high engine speeds.
Run the engine at 1400-1500 rpm until it starts to get

warm.
WARNING
Don’t let the engine idle for a long time.
Turn off the engine during breaks in operation and

load handling.
Instructions
–
In case of extremely cold weather, the machine must not used in tough
work before operating temperature has been reached.
• It’s very important that the engine oil is warmed up and circulates
well before the turbocharger starts to operate at high rpms.
• Starting working with the machine with a certain amount of caution
until the coolant has reached normal operating temperature (ap-
prox. 82-95 °C), only then should full output be drawn from the
engine
• Warm up the hydraulic oil. Run hydraulic functions without load for
a short time before starting to work.

5 Handling – 5.4.4 Gearshifting 131
5.4.4 Gearshifting
General
page
–
There are three types of transmission for the machine:

• Manual
• Automatic with speed limitation

Speed limitation is preset. Change can only be executed by an au-
thorised service technician.
• Automatic
With automatic transmission, the system shifts to a lower/higher
gear under certain conditions, such as torque, engine speed,
travel speed, etc.
It is possible to select to use manual or automatic gearshifting. Select
automatic or manual gearshifting by going into the KCS menus with
the service code for "AUTOMATIC GEARSHIFT ECU793" and select
"AUTOMATIC GEARSHIFT OFF" value 0 or 1.
General about the automatic transmission:
• Has a built-in control and monitoring system, providing optimal op-
eration.
• Shows current gear on control and monitoring system’s display.
• Normally, starting off is in first gear. It is possible to set to start in
2nd gear in the KCS menus, as well as declutching on and off.
• Reverse lock-out prevents change of travel direction taking place
too fast, that is, prevents eventual transmission damage. Reverse
lock-out is automatic and depends on engine rpm and travel
speed.
WARNING
Change of travel direction must be made with care.
The machine has a reversing lock as standard but
transmission service life is increased if change of
travel direction takes place at a lower travel speed
and engine speed.
Risk of machine damage! Axles may fail!
Change of travel direction must occur within the limi-

tations set by the reversing lock.

132 5 Handling – 5.4.4 Gearshifting
Manual transmission, instructions

–
The machine has three forward gears and three in reverse. Use man-
ual transmission as follows:
1 Let the engine run at idling speed. Select travel direction. Travel
direction can be selected in five ways:
NOTE
Selection of travel direction selector must be performed with
the switch for engagement and disengagement of alterna-
tive travel direction selector (position 45). When the switch
is in position 1 the engine is locked against starting and so
therefore cannot be started.
A. Gear control and travel direction selector
A F
1 2 3 Move the lever forward for travel direction forward and back
for reverse.
007011
B. Gear and travel direction selector RMH

B Move the lever forward for travel direction forward and back
2 1
3 F for reverse.
007336
C. Accelerator pedal with function for selecting direction of

C F
R travel
Depress the right upper part of the pedal for travel direction
reverse and left upper part for travel direction forward.
007335

D. Travel direction selector on control for load handling (4-lever,

D F
R 5-lever, electric servo)
3
2 Move the lever forward for travel direction forward and back
1 for reverse.
D F
R
3
2
007334
1
E. Travel direction selector on joystick or mini steering

E F 3
2 wheel
R 1
Move the switch forward for travel direction forward and back
for reverse.
2 Select gear. Start in first gear, starting in higher gear may lead to
overheating. Gears can be selected in five ways:
007333
NOTE
Selection of gear selector must be performed with the switch
for engagement and disengagement of alternative gear se-
lector (position 46).
Engage a gear by turning the handle forward or backward.
To start in first gear: Turn backward to position 1.
Engage a gear by moving the lever to the left or right. To start
in first gear: Lift the lever and move to the right.
C. Gear selector on control for load handling 4-lever and 5-lever
Engage a gear by moving the switch upwards, in centre po-

sition or downwards. When starting in first gear: Switch
downwards.
D. Gear selector on control for load handling electric servo

Engage a gear by moving the switch forwards, in centre po-
sition or backwards. When starting in first gear: Switch back-
wards.
E. Gear selector on joystick control

Engage gear by depressing the buttons for gearshifting up
and down. At the start for first gear: Press once on the button
for gearshifting up.

3 Release the parking brake, carefully press the accelerator pedal

and the machine starts to move.
4 For upshifting:
Select higher gear with the control in question (turn/pull/set
switch).
For downshifting:
Select lower gear with the control in question (turn/pull/set
switch).
- Release the throttle, at which a lower gear engages when a suit-
able travel speed and engine speed have been reached.
- Apply the throttle again. Remember to apply throttle before the
lower gear engages, or there will be heavy braking.

Automatic transmission, instructions

–
The machine has three forward gears and three in reverse.

Use automatic transmission as follows:
1 Let the engine run at idling speed. Select travel direction. Travel
direction can be selected in five ways:
NOTE
Selection of travel direction selector must be performed with
the switch for engagement and disengagement of alterna-
tive travel direction selector (position 45). When the switch
is in position 1 the engine is locked against starting and so
therefore cannot be started.
A F
1 2 3 Move the lever forward for travel direction forward and back
for reverse.
007011

B Move the lever forward for travel direction forward and back
2 1
3 F for reverse.
007336
C. Accelerator pedal with function for selecting direction of

C F
R travel
Depress the right upper part of the pedal for travel direction
reverse and left upper part for travel direction forward.
007335

D. Travel direction selector on control for load handling (4-lever,

D F
R 5-lever, electric servo)
3
2 Move the lever forward for travel direction forward and back
1 for reverse.
D F
R
3
2
007334
1
3 E. Travel direction selector on mini-wheel or joystick

E F 2
R 1 Move the switch forward for travel direction forward and back
for reverse.
007333
2 Select gear position as required:

Gear position 1 means that automatic gearshifting only uses first
gear. Gear position 2 means that automatic gearshifting uses first
and second gears (1 and 2). Gear position 3 means that automat-
ic gearshifting uses all gears (1, 2 and 3).
3 Release the parking brake, carefully press the accelerator pedal
and the machine starts to move.
The machine’s speed is completely regulated via the accelerator
pedal and gears are selected automatically during both upshifts
and downshifts.

5 Handling – 5.4.5 Steering 137
Transmission adopts neutral position

–
A control breaker senses when the operator leaves the operator’s sta-
tion. The signal from the control breaker means that the transmission
automatically adopts neutral position. It is not possible to select a di-
rection of travel.
NOTE
If the buzzer sounds when the operator sits in the seat and re-
leases the parking brake then the control breaker in the seat may
be malfunctioning. It is not possible to select a direction of travel.
In which case, the function for control breaker in the driver’s seat
must be checked.
008191
Control breakers in driver’s seat
5.4.5 Steering
General
page
–
The machine has power steering. Steering movement from the steer-
ing wheel, joystick or mini steering wheel is transmitted by hydraulic
means to the steering wheels.
WARNING
The machine may not roll on a downhill grade if the
engine is off.
Hydraulic pressure for steering is missing and steer-

ing capacity is lost! Danger!
Keep the engine running for hydraulic pressure.

138 5 Handling – 5.4.6 Service brake
5.4.6 Service brake

General
page
–
The brake pedal (position 11) is used as service brake.

Use the brakes smoothly yet firmly. There is brake pressure for some
time after the engine has been switched off, accumulated during oper-
ation. If the accumulator pressure drops below a certain level then an
error code appears in the display. Check the accumulators’ sealing in-
F
tegrity if the pressure does not build up and is not maintained, see
4 3 2 1
L 0
R
chapter 6 Inspection and maintenance.
R
4 3
006934
11 12 46 11 10
Steering wheel panel with KCS

10. Accelerator pedal
11. Brake pedals
12. Clutch pedal
Inching pedal
46. Switch for inching
Service brake without inching
–
The service brake is combined with the clutch pedal.

If the clutch pedal (position 12) is depressed then drive is declutched.
If the brake pedal is applied without declutching taking place then the
engine can assist with braking the machine if the accelerator pedal is
released.

5 Handling – 5.4.6 Service brake 139
Service brake with inching

–
Switch for inching

Position 0 – Inching not activated. The brake is activated with the
brake pedal and declutch takes place when the pedal is depressed
more than 70%.
007191
Position 1 – Inching activated. Inching and braking are controlled with
0 1
the brake pedal. When the pedal is depressed the drive starts to slip,
so-called crawling or inching.
If the brake pedal is depressed more than 70% then drive is de-
clutched completely.
Inching pedal
The brake is activated with the brake pedal and declutch takes place
when the pedal is depressed more than 70%.
When the brake and inching pedals are applied simultaneously a mi-
croswitch is actuated and the drive starts to slip, so-called crawling or
inching.
F
4 3 2 1
N
L 0
R
4 3
007497
12

140 5 Handling – 5.4.7 Parking brake
5.4.7 Parking brake

General
page
–
DANGER
The parking brake should not be applied when the ma-
chine is in motion.
Very sudden braking. Risk of machine tipping over,

load tipping over or being dropped, or damage to
Stop the machine before applying the parking brake.
WARNING
Never leave the operator’s station without first apply-
ing 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 6) on the panel
for hydraulic controls. The warning lamp for applied parking brake (in
the switch) illuminates with a red glow when the parking brake is ap-
plied, and the symbol for applied parking brake is shown in the display.

5 Handling – 5.4.7 Parking brake 141
Instructions
–
The parking brake is applied when:

• The parking brake switch is depressed (warning lamp for parking
brake illuminates with a red glow and the symbol is shown in the
F display).
N
R
• The parking brake is applied automatically when the engine is
1 4 5
2 3
stopped.
An audible signal is activated if the operator gets up from the driver’s
seat without first applying the parking brake.
6 If the accumulator pressure drops below a certain level then an error
code appears in the display. In the event of an error code for low ac-
cumulator pressure the service brake’s capacity is limited. Finally, the
parking brake is applied automatically by a forceful spring in the brake
cylinder. Check the accumulators’ sealing integrity if the pressure
6 does not build up and is not maintained, see chapter 6 Inspection and
maintenance.
If the machine has to be moved, see chapter 7 Transporting the
6
machine.
009055
6. Switch for parking brake

Emergency brake
–
The parking brake can be used as an emergency brake in emergency

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

ance! Unwanted movement of parked machine!
Following emergency braking with the parking brake,

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

it must always be reset to restore the machine’s park-
ing brake function.

142 5 Handling – 5.4.8 Heating / Air conditioning
5.4.8 Heating / Air conditioning

General
page
–
This section describes handling of:

• operator’s cab Spirit Delta with:
• heating unit
• heating unit with cooling AC (manual control of heating, cool-
ing, dehumidification and air flow)
• air conditioning ECC (automatic control of heating, cooling,
dehumidifying and air flow)
NOTE
The operator’s door and windows should be closed for satisfac-
tory function of heating unit/air conditioning.
5.4.8.1 Spirit Delta with heating unit/heating

unit with cooling AC
General
page
–
The heating or air conditioning system is connected to the engine’s

A
cooling system and provides heat when the engine is warm.
• The heating unit has manual control of heat and air flow.
• Heating unit with cooling, AC, has manual control of heat,

cooling dehumidification and air flow.
29 The fan is operated with the rotary control (position 16). Heating is
20 controlled with the rotary control (position 15) and cooling with the ro-
19 tary control (position 18).
18 Air distribution is controlled with the rotary control (position 17). Recir-
17
culation is switched on and off with switch (position 19) ( ).
006935
16
15 Cooling AC is switched on and off with switch (position 20) ( ).
Panel heating unit The panel has a panel vent (position A).
NOTE
Use cooling AC (position 20) every now and then in wintertime for
lubrication and continued good function of the AC compressor.
In temperatures below -3 °C, the cooling function does not work
if the cooling circuit is cold.
Supplemental heating is switched in and off with switch (position 29)
( ) and is activated when the ignition key is in position 0 and the en-
gine is warm.

5 Handling – 5.4.8.1 Spirit Delta with heating unit/heating unit with cooling AC 143
In warm weather
–
1 Set the desired fan speed (position 16).
Use fresh air inlet (position 19).

2 Set temperature (position 15).
3 Set the defroster/cab control (position 17) to defroster.
4 Open the panel vents when required.
Very warm weather or mist on windows

–

3 Set the defroster/cab control (position 17) to defroster and aim
the panel vents towards the upper part of the cab.
In cold weather
–

3 Set the defroster/cab control (position 17) to defroster or floor.
Cooling AC
–
Cooling AC enables air conditioning with manual setting of heat, cool-

ing and fan.
NOTE
For optimum comfort when using AC, avoid aiming the cooled air
directly against the body. Aim the air against the upper section of
the cab and increase fan capacity as required. Cooling capacity
increases if recirculation position is switched on.
1. Use the fresh air inlet (position 19).
Use recirculation (position 19) in very hot weather and with high
air humidity.
2. Set temperature to cool (position 15).
3. Turn on cooling AC (position 20).
4. Set the cooling control for cooling AC (position 18) as required.
5. Open the panel vents towards the roof.

144 5 Handling – 5.4.8.1 Spirit Delta with heating unit/heating unit with cooling AC
Air drying with cooling AC

–
Cooling AC dehumidifies the air, e.g. in the event of mist on the

windows.
1. Use recirculation (position 19).
2. Turn on cooling AC (position 20).
3. Set the cooling AC control to maximum cooling effect
(position 18).
4. Set the defroster/cab control (position 17) to defroster.
5. Set maximum fan speed (position 16).
6. Set the temperature to maximum heat flow (position 15).
7. Aim the panel vents towards the roof.
Once the mist has cleared from the windows, set the desired tem-
perature (position 15) and fan speed, and direct the panel vents
as desired.
NOTE
In temperatures below -3 °C, the cooling function does not
work if the cooling circuit is cold.
Supplemental heating
–
When supplemental heating is activated, start key in position P and

engine warm, coolant is pumped through the heating system and the
fan operates at low speed. Heat is supplied to the cab until the engine
has cooled. When the coolant temperature is below approx. 40 °C all
voltage to the pump is switched off and the supply of heat stops.
NOTE
Supplemental heating is always available as long as the switch is
in position 1, and it starts as soon as the start key is in position P
and the engine temperature is above approx. 40 °C.
1. Switch on the supplemental heating (position 29). The function
starts when the engine temperature is above approx. 40 °C and
the start key is in position P.
2. Set the temperature to maximum heat flow (position 15).
3. Set the fan speed to position I (position 16).
The cab is kept warm for a longer period if fan speed is low.

5 Handling – 5.4.8.2 Spirit Delta with air conditioning ECC 145
5.4.8.2 Spirit Delta with air conditioning ECC

General
page
–
A B I C D The air conditioning automatically regulates the inner temperature to

the desired temperature regardless of weather conditions. The system
will always start in AUTO mode and at 21° regardless of the setting
when switched off.
NOTE
In temperatures below -3 °C, the cooling function does not work
AUTO
MODE
if the cooling circuit is cold.
003703
E F G H
A. Increasing temperature
B. Decreasing temperature
C. Lowering fan speed
D. Raising fan speed
E. Auto mode
F. Selecting air distribution
G. Selecting air distribution
H. Recirculation
I. Air distribution
Setting the temperature
–
Desired temperature is increased or decreased using the buttons for

setting the temperature. The temperature is adjustable between 17 °C
and 27 °C. The min. and max. temperatures are in the end positions
where no adjustment takes place, the system then only provides max-
imum cooling or maximum heating.
003565
Setting the fan speed

–
Fan speed can be adjusted manually between 0-100% with the but-
tons. At 0% the fan is completely switched off and the compressor is
disconnected. The graph in the display shows that the fan speed is se-
lected manually.
003566

146 5 Handling – 5.4.8.2 Spirit Delta with air conditioning ECC
Selecting air distribution

–
Air distribution can be adjusted manually using the buttons. An arrow

( ^ ) in the display indicates the selected air distribution. The floor mode
003567
can only be obtained manually, automatic mode operates between the
windscreen and the floor/panel vents.
The following air distribution options can be selected:
Air to the floor.
003568
Air to both the floor and ventilation nozzles.
003569
003570 Air to the windscreen.
Max defrost.
003571
Start max. defroster

–
Max. defroster is started by moving the arrow ( ^ ) furthest to the right

003571
with the buttons for selecting air distribution.

In this mode the system provides full heating and no regulation of tem-
perature takes place, AC is on and the fans give 100%.
The system will automatically return to auto mode after 9 minutes. For
a manual shutdown, briefly press the auto button.
Recirculated air
–
Recirculated air can be obtained manually by pressing the button for

recirculation. When recirculation is activated "REC" is indicated in the
003572
display. To deactivate, press the recirculation button again.
Return to auto mode

–
Auto mode is recovered by means of a short press on the auto button.

Note that there is a certain delay prior to a change in the display - do
003702
not press any more times.
NOTE
There is a certain delay before Auto is shown in the display. Do
not press repeatedly.
Auto/menu function
–
Short presses on the auto button scroll through the following functions:
1. Auto
003702
2. Cool - economy mode. Compressor is only running when neces-

sary. No heating.
3. Heat - economy mode. No operation of the compressor, only
heating.

5 Handling – 5.4.8.2 Spirit Delta with air conditioning ECC 147
Adjusting the display

–
A B C D The menu for adjusting the display is reached by means of the auto
button (position E) being pressed and held for a few seconds. The fol-
lowing can be adjusted in this menu:
1. Brightness.
2. Contrast.
3. Switching between °C and °F.
AUTO
MODE
4. Language.
Scroll through the available options with buttons for temperature (po-
003707
sition A and B) and adjust with buttons for fan (position C and D).
E Return by briefly pressing the auto button (position E).
A. Scroll in menu
B. Scroll in menu
C. Adjust values
D. Adjust values
E. Auto mode
Error indication
–
In the event of a fault on any sensor or if the pressure switch was trig-
A B C
gered "ERROR" flashes in the display.
Press and hold the auto button (position E) for a few seconds to dis-
play current error/errors as text in the display.
Scroll between error messages with buttons for temperature (position
A and B). Selected error message is indicated with an arrow in the
display.
AUTO
MODE
Cause of error is reached with the left arrow button (position F).
003708
Reset of pressure switch is performed using the button to lower the fan
speed (position C). Hold the button depressed for a few seconds to
E F
reset.
A. Scroll through error messages
Return by briefly pressing the auto button (position E).
B. Scroll through error messages
C. Reset pressure switch For error code table, see Error codes ECC page 125.
D. -
E. Auto mode
F. Cause of error
Supplemental heating
–
When supplemental heating is activated, start key in position P and en-

gine warm, coolant is pumped through the heating system and the fan
operates at low speed. Heat is supplied to the cab until the engine has
29 cooled. When the coolant temperature is below approx. 40 °C all volt-
age to the pump is switched off and the supply of heat stops.
007483
TO DE
AU MO
NOTE
Supplemental heating is always available as long as the switch is
in position 1, and it starts as soon as the start key is in position P
and the engine temperature is above approx. 40 °C.
1. Switch on the supplemental heating (position 29). The function
starts when the engine temperature is above approx. 40 °C and
the start key is in position P.
2. Temperature and fan speed are regulated automatically.

148 5 Handling – 5.4.9 Stopping engine – parking
5.4.9 Stopping engine – parking

General
page
–
NOTE
Never disconnect the main electric power with the battery discon-
nector when the engine is running! The voltage regulator may be
damaged.
WARNING
Always turn off the electric power when the machine
is left, e.g. when parking or at the end of the shift.
Danger!

disconnector.
Instructions
–
1. Stop the machine and set the gear and travel direction selector to
neutral.
2. Apply the parking brake.
3. Tilt the mast slightly forward so that the underside of the forks can
rest on the ground. Lower the forks to the ground.
4. Let the engine run 1 minute at idle speed before stopping the en-
gine so that the engine cools down slightly and the turbo bearings
are lubricated.
5. Stop the engine by turning the start key to position 0.
If the machine is going to be parked for a long time, e.g. after a
work shift is over, then the battery disconnector should be turned
to the OFF (0) position.
Certain machines are equipped with automatic engine stop:

• In case coolant temperature is too high.
• In case lubrication oil pressure is too low.
• In case the operator leaves the machine for some time with-
out stopping the engine, normally 5 minutes.

5 Handling – 5.4.9 Stopping engine – parking 149
6. If there is extra exhaust cleaning (particle filter):

Connect the cleaning unit on the machine or at the machine’s
parking site.
Connect the electrical cable and the air hose. Switch on the cur-
rent to activate cleaning.
CAUTION
Never stop clean-burning in progress.
Cleaning is complete:
• after 8 hours, ammeter shall show zero Ampere.
• after 8 hours, the indicator light shall be green.
• after 40 minutes, the indicator light shall be green.
WARNING
During cleaning hot air flows from the outlet
pipe, which may ignite flammable materials.
Risk of fire!
Do not cover filter or keep flammable materials near

filter.

150 5 Handling – 5.5 Load handling
5.5 Load handling

General
page
–
During all lifting work, make particularly sure that the max. lift capacity
is not exceeded, see machine plate or load diagram.
The forklift’s capacity is indicated by three parameters:
• position of load’s centre of gravity
300 mm
• lifting height
007362
• load’s size
Transport position The capacity varies between models and versions, see the machine
and type plates, section 3.2 Plates.
It’s important to estimate the position of the centre of gravity. If the ma-
chine appears to be side-heavy, the load should be lowered and ad-
justed with side shift so that the load’s centre of gravity is moved to a
position along the machine’s centre line.
The load handling function refers to, e.g. lifting, lowering, rotating, an-
gling and holding a load. Load handling also includes lifting devices for
handling different types of loads, e.g. sidelift attachments.
Load handling sub-functions.
• Lift/lower
007363
• Tilt
Lift and lower • Side shift
• Spreading (positioning)
• Levelling
007364
Tilt
007916
Side shift

5 Handling – 5.5 Load handling 151
007910
Spreading (positioning)
007917
Levelling

152 5 Handling – 5.5.1 Lifting load
5.5.1 Lifting load

General
page
–
There are different types of lifting tool for load handling, most common
are:
• forks
• sidelift attachments for container handling
• coil ram
WARNING
Respect the machine’s lift capacity and operate with
great care 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.
• Do not exceed the machine’s maximum load ca-

pacity, see type plate. When required, determine
the position of the centre of gravity and determine
maximum load capacity using the load diagram in
the cab.
• Never tilt the mast forward with a load on it.
• No personnel may enter or stand under a raised

load.
Risk of load tipping over, being dropped or damage to

Make sure that the load is positioned securely before

lifting.
WARNING
Check that the lifting attachment is marked with a
type plate from Cargotec or another manufacturer.
There must always be a plate fitted with capacity in-
formation for all attachments.

ty damage!
Make sure that nothing other than approved lifting at-

tachments are used.

5 Handling – 5.5.1 Lifting load 153
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 cen-
tre of gravity.
• The approach angle to the load should be as straight as
possible.
007365
• Tilt the mast forwards slightly.
• Lower the forks as low as possible and adjust the fork
spreading and insert them under the load.
• Tilt the mast backwards so that the forks are horizontal.
NOTE
When handling drums, strive to keep the forks as close to-
gether as possible.
2 Hold the machine stationary with the service brake and inching
pedal if necessary. Alternatively, apply the parking brake if de-
sired and/or set the gear in neutral. If needed, use stop blocks at
the drive wheels.
DANGER
The operator should pay take extra care when load
handling near electric power lines, viaducts, dock-
sides, ramps, doors, etc.
Extreme danger!
Use the parking brake and stop blocks!
3 Lift the load and tilt the mast backwards.

If the machine seems side heavy – lower the load and change the
lifting point using side shift so that the load’s centre of gravity is
along the machine’s centre line.
WARNING
Forks (with or without load) are easily manoeuvrable
work tools with great strength.

ty damage!

tachment, whether it is loaded or not. Exercise great
caution when operating.

154 5 Handling – 5.5.2 Transporting load
5.5.2 Transporting load

General
page
–
WARNING
Transport of loads is associated with great risks.
Risk of roll-over and tipping over! Risk of load dam-

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

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

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

tion. Always operate carefully, keep in mind the
width and height so that the mast or forks/attach-
ment does/do not collide with posts, power lines,
etc.
• Do not transport the load in high position since

this may cause the machine to roll or tip over.
• Always operate with the load facing uphill on an

uphill or downhill grade, never operate or turn
across a grade.
• Operate the machine in reverse if the transported

load obscures visibility to the front.
• No personnel may enter 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 case 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.
Local regulations may apply when handling spe-

cial loads. Learn about them and follow them.

5 Handling – 5.5.2 Transporting load 155

–
1 Lift the load slightly. Reverse away from the loading location.
2 Adjust load height and tilt angle to transport position, see Trans-
port position page 155.
Transport position
–
When the machine is to be run with or without load, assume the trans-
port position to minimise the risk of roll-over and imbalance while op-
erating. In transport position the mast is tilted back and the load is lifted
above the ground slightly, approx. 300 mm (see the figure to the left.)
The load’s centre of gravity must be centred laterally.
300 mm
007362
If the load blocks visibility ahead then the machine must be reversed.
Transport position NOTE

Local regulations may apply when handling special loads. Learn
about them and follow them.
The machine shall be run in transport position even without load to
maximise operator visibility.
For transport position without load, the mast must be vertical and the
forks lifted above the ground slightly, approx. 300 mm (see the figure
300 mm
to the left.) The forks must be side-shifted so that a fork tip is visible
through the mast, this way the full length of the machine including forks
007366
is visible.
Transport position without load
Operating on grades
–
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
Only use the service brake pedal (right-hand brake pedal) when
braking in order to obtain engine braking. Avoid using the inching
function.
• Operating with a load.
Adjust load height and tilt angle to transport position, see Trans-
port position page 155.
Always drive with the lifting attachment upwards in the grade, irre-
spective of travel direction, i.e. the truck must be reversed down a
grade.
• Operating without a load.
Lower the lifting attachment and tilt back the mast as far as
001533
possible.
Operating with a load on grades Always drive with the lifting attachment upwards in the grade, irre-
spective of travel direction, i.e. the truck must be reversed down a
grade.

156 5 Handling – 5.5.3 Unloading
Working near overhead high voltage power lines

–
Operate with extreme care in all work near overhead high voltage pow-
er lines, keeping in mind the height of the mast and load.
DANGER
If the machine comes into contact with overhead high
voltage power lines - sit down in the seat and call for
help!
Extreme danger!
Remain in the cab and wait for help.
5.5.3 Unloading
General
page
–
There are different types of lifting attachments for load handling, e.g.
forks, coil rams and sidelift attachments for container handling.

–
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.
007367
• Tilt the mast to vertical position.

2 Move forward slowly until the load is in position over the unload-
ing surface.
3 Apply the parking brake if required or hold the machine still with
the service brake and inching pedal if necessary. Alternatively,
set the gear in 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 lower the forks to trans-
port position.

5 Handling – 5.5.4 Functions for load handling 157
5.5.4 Functions for load handling

Hydraulic weight indicator
page
–
Load weight is checked in accordance with the following:
1 Lift approx. 1.5 m without load.

2 Lower approx. 5 cm to remove friction, etc.
3 Depress the foot button.
4 Check the indicator and reset to zero if necessary by turning the
knob.
5 Carry out load handling.
A-C
6 Lift approx. 1.5 m.
A
7 Lower approx. 5 cm.
B 8 Read the indicator.
C
007368
A. Weight Indicator
B. Knob
C. Foot button

158 5 Handling – 5.5.4 Functions for load handling
Scales
–
NOTE
(+/-) 1.2 a For accurate weighing the scales must be calibrated regularly
against a known weight, as large as possible. For calibration,
75.0 t b
contact service personnel.
158.0 t c Load weight is approximated with the operating menu for scales.
007341
1 Set the mast vertically.
2 Check that the current weight in the display shows 0, otherwise
reset to zero with the function keys for plus and minus.
3 Position the load at the same centre of gravity distance as for cal-
ibration.
4 Perform the lifting movement and then lower the load slowly
about 30 cm.
5 Select the operating menu for scales.
a. Shows tare weight in tonnes.
The value displayed in row (b) can be reset to zero (tared)
using the function keys for minus and plus. The set value is
displayed in row (a).
b. Actual weight in tonnes (net weight).
c. Total weight in tonnes (gross weight).
The value in row (b) can be added to row (c) using the func-
tion key for Return. The value in row (c) can be reset to zero
by depressing the function keys for Reset and Return
simultaneously.
Weight can be given in kilopounds .

Sidelift attachment
–
Max General
Points to consider when handling sidelift attachments with empty
container:
WARNING
Never use a machine if the indicator lights don’t work.
Risk of reduced safety when handling loads!
If the indicator lights are out of order then the ma-

chine must be taken out of operation and repaired.
• Before work begins, check the function of sidelift attachment’s in-

dicator lights.
001535
It is forbidden to use the attachment if the lights give incorrect in-

Transport position with side lift attachment dication or are inoperative.
Using the attachment without working indicator lights involves a
major safety risk.
• The brakes must always be operated gently and with great cau-
tion according to prevailing conditions.
• When operating without a load the sidelift attachment must be
lowered to the lowest position.
• When operating with a load the machine must be in transport po-
sition, see the figure.
• It is forbidden to operate the machine with a load in a higher posi-
tion than
in the figure. The sidelift attachment, with or without load, may
only be hoisted
higher than in the figure when stacking.
• After stacking, the sidelift attachment must always return to the
transport position (with load) or the lowest position (without load)
before the machine can be operated again.
• During all operation the mast must be at maximum tilt backwards,
see the figure.

• If forward visibility is obscured by the load then the operator must

reverse.
WARNING
Sidelift attachments (with or without load) are easily
manoeuvrable work tools with great strength.

ty damage!

tachment, whether it is loaded or not. Exercise great
caution when operating.
A B C Hoisting technique
1 Set spreading to the container length in question (position 4).
2 Drive slowly toward the container, adjust side shift (position 3).
3 Tilt the mast forward slightly (position 2), about 2°, lower the
sidelift (position 1) to the container and fit the two twistlocks into
the locking holes in the container so that both sides of the sidelift
are resting on the container. Check that the light position B is il-
luminated.
4 Lock twistlocks (position 5). Check that the light in position A is
illuminated.
5 Tilt the mast back and lift. Check that the light in position B is
1 2 3 4 5 switched off when the container is hoisted.
6 Transport the container in transport position. Reverse if the con-
tainer obscures vision.
7 Unloading the container: Set the container on the surface below.
Check that the light in position B is illuminated. Release the twist-
locks. Check that the light in position C is illuminated.
003933
NOTE
For load handling with the control lever, see the plates on the
machine.
Fork shank system

–
WARNING
Exercise caution when changing e.g. aggregates or
exchangeable forks.
Risk of crushing!

WARNING
Always make sure that forks, inverted forks or coil
ram are always stored in a safe place.
Forks
Removal
B
Proceed as follows to remove the forks:
• Place the forks in their stowage position.
• Remove the lock rings/lock pins (position A) and knock out the
pins (position C) that hold the forks to the shanks (position B).
A • Lower/tilt forward and back away from the forks.
Reassembling
Proceed as follows to reassemble the forks:
C • Always make sure that the locking pin is locked with the lock ring/
lock pin.
B
A
C
005470
A. Lock ring or lock pin

B. Fork shank
C. Locking pin

Inverted forks, coil ram or attachments

Assembly
Proceed as follows to assemble the forks:
• Operate side shift and fork spreading so that the shanks reach the
correct starting position for the forks.
• Fold out the movable locking catches (position C) down onto the
forks/coil ram.
• Operate the truck up to the forks/coil ram with the mast tilted for-
ward, correct with fork spreading and side shift so that the shanks
A fit against the upper retaining catches of the forks/coil ram (posi-
tion A).
• Lift slightly and tilt backwards, check that the shanks fully grip into
B the upper retaining catches.
B • Lift until the forks/coil ram are fully aligned with the shanks. Check
D that the lower retaining catches grip the fork assembly’s lower
beam.
• Fold in the movable locking catches and lock with the pins (posi-
A
tion B).
Removal
Proceed as follows to remove the forks:
• Position the forks/coil ram in a safe stowage location.
• Fold out the movable locking catches (position C).
• Tilt forwards so that the lower retaining catches (position D)
release.
• Lower slightly so that the upper retaining catches (position A) re-
lease and reverse away from the forks/coil ram.
L
C
005469
D
A. Upper retaining catch
B. Lock pin
C. Movable locking catch
D. Lower retaining catch

Fork-mounted top lift

–
WARNING
Exercise caution when changing e.g. aggregates or
exchangeable forks.
Risk of crushing!
WARNING
Always make sure that forks, inverted forks or coil
ram are always stored in a safe place.
Assembly
• Set fork spreading so that the forks fit the fork pockets.
• Insert the forks into the fork pockets.
• Lock the forks to the top lift with the braces behind the forks.
• Connect the hydraulic hoses and electrical cable from the top lift
to the quick couplings on the fork assembly. Check that hoses and
cables have such a routing that they cannot be damaged.
• Check the different functions of the top lift.
Removal
• Set the length setting at 20’’ (adjustable top lift).
• Set the top lift in a safe stowage location, on an empty container
for example.
• Set the rotation in centre position (or extension to min.) so that the
hydraulic pressure is equalised and it becomes easier to detach
the quick couplings. Also in this way oil spillage is avoided.
• Connect the hydraulic hoses and electrical cable from the top lift
to the quick couplings on the fork assembly. Check that hoses and
cables have such a routing that they cannot be damaged.
• Unlock the braces behind the forks, set the mast vertical and re-
verse away from the top lift.


6 Inspection and maintenance 165
6 Inspection and maintenance
6 Inspection and
mm mm mm mm mm mm
maintenance
General
page
–
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 ac-
tions are described in the maintenance manual.
It is the operator who is responsible for ensuring that the machine
comes in for service every 500 operating hours. Procedures are
described in the maintenance manual.
• 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 in order to maintain the machine’s safety and

to fulfil warranty and service agreements!
Only use spare parts and fluids approved by Cargotec

in order to fulfil warranty terms.

166 6 Inspection and maintenance – 6.1 Daily inspection
6.1 Daily inspection

General
page
–
Daily inspection of the machine is extremely important in order to en-

sure 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 malfunc-
tions that have been generated or caused during an earlier work shift.
WARNING
Never use a machine without first performing the dai-
ly inspection.

ty damage!
Report to the foreman/supervisor if defects are found

on the machine during daily inspection!
Instructions
–
Perform the following checks:

1. Visual external check of the machine. Walk around the machine
and check the following:
• Leakage from engine, transmission, drive axle, steering cylin-
der, hydraulic hoses and hydraulic cylinders
• Loose wheel studs
Following a wheel replacement, check-tightening of the bolt-
ed 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.
• If the machine is equipped with sidelift attachment; check that
sensors for twistlocks and alignment are clean and free from
grease
• Tyre pressure

6 Inspection and maintenance – 6.1 Daily inspection 167
• Damage or cracks in vital components and their mountings

such as lifting chains, fork mountings, mast and tilt cylinders
DANGER
If there are cracks in materials or welds in load bear-
ing structures then the machine must be immediately
withdrawn from operation and sent for service.

ty damage if cracks in materials or welds in load bear-
ing structures are not rectified!
• Communication equipment – direction indicators, brake

lights, headlights and reflectors with regard to damage
• Cab with regards to damage and dirty windows, rear view
mirrors
• If the machine is equipped with hydraulic oil cooler, check that
it is in working order.
2. Check fluid levels for the following fluids according to description,
see section 6.2 Maintenance. Top up, if needed, with the correct
fluid:
• Hydraulic oil
• Hydraulic oil for brake system

• Batteries’ electrolyte level
• Coolant
• Washer fluid – windows
• Engine oil
• Transmission oil
3. Check the engine’s indicator for air filter, also check and drain the
fuel prefilter, when needed. For description, see section 6.2
Maintenance.
4. Start the machine according to instructions and check:
• Instruments – warning lamps, indicators, any error codes
• Fuel level – the gauge must not show empty tank
• Lighting, direction indicators, horn, brake lights, flashing haz-
ard lights
• Windscreen wipers
• Check that mirrors are intact, clean and well-adjusted for vis-
ibility all around the machine
• Cooling function of the AC and ECC

168 6 Inspection and maintenance – 6.1 Daily inspection
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
fork spreading) to their end positions for lubrication of the cylinder
barrels and piston rods.
7. If the machine is equipped with sidelift attachment; check the lift
attachment and that:
• Indicator lights for twistlocks and alignment function.
2
WARNING
Make sure that the engine is off when working with
twistlocks.
Twistlocks can be locked automatically if all sensors

1 for alignment are activated manually at the same time.
• The alignment pins for twistlocks can be moved up and down

easily. Note that an alignment pin that binds in the upper po-
sition can indicate alignment despite the frame not being po-
sitioned against the container.
• Check the function of the twistlocks. This is carried out by lift-
ing an empty container until the "Alignment" light goes out. It
should not now be possible to release the twistlocks.
8. Check the machine’s operating hours – notify the foreman/super-
visor if the machine is close to a service interval.
9. Notify the foreman/supervisor immediately if any defects are de-
tected on the machine.
3 10. In cold weather:
• check that wiper blades have not frozen to the windscreen
5
007007
4
• remove snow from air inlets and radiator grill
1. Sensor twistlock • antifreeze in washer fluid

2. Sensor contact
• connect auxiliary heater for cab and engine
3. Lock guide
4. Lift pin 11. If there is extra exhaust cleaning (particle filter):
5. Contact pin
Short-circuit the pin on the pressure sensor and check that the sig-
nal light is on.
Cover the exhaust pipe and check that the signal light for high
back-pressure is on. If not, clean soot from the connecting pipe.

6 Inspection and maintenance – 6.1 Daily inspection 169
12. For central lubrication

Check that grease has not penetrated out from the safety valve
(position A). This is a sign that the central lubrication is not work-
ing correctly.
13. Check if any error codes are active.
See the section 5.3 Error codes.
A
009441

170 6 Inspection and maintenance – 6.2 Maintenance
6.2 Maintenance
General
page
–
The following maintenance actions are described in this chapter:

– Cleanliness, general page 172
– Fuel system, general page 174
– Windscreen washer, general page 176
– Air filter engine, general page 177
– Cooling system, general page 179
– Engine oil, general page 181
– Transmission oil, general page 183
– Hydraulic system, general page 184
– Tyres and rims, general page 185
– Accumulator, general page 188
– Central lubrication, general page 189
– Battery and battery disconnector, general page 190
– Main fuses for electrical system, general page 193
– Fuses for electrical system, general page 194
– Lighting, general page 198
Safety during maintenance

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

• Always turn off the engine during service work. Only exception is
when service work requires engine power.
• Use stop blocks at the wheels.
• No work may be done 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 opera-
tor’s manual before performing any maintenance. Each one con-
tains important information about handling and service.
• Avoid spills when draining/filling oils and fuel. Use reservoirs,
pump, hose, etc. for safe handling. Oils and fuels cause environ-
mental damage and should be taken care of by an authorized
company.
• Always drain the pressure from the accumulators before any work
on the hydraulic system.
• The unit for air inlet to the Spirit Delta cab (at front part of cab) is
provided with non-slip plate and can be used as a platform to
stand on when performing maintenance by the front part of the
cab.

6 Inspection and maintenance – 6.2 Maintenance 171
Tilting the cab

–
The cab must always be tilted past the centre of gravity position. If
space sideways is insufficient, the cab must always be secured with a
stay to prevent accidental lowering.
Preparations:
• Set the gear and travel direction selector to neutral.
• Tilt the mast forward and lower the forks.
• Apply the parking brake.
A, B C • Check that there are no loose items in the cab.

• Close the doors.
Tilting
1. Turn both lock handles (position C) so that they reach their outer
position to loosen the cab from the frame.
C
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.
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
1. Turn both lock handles (position C) so that they reach their outer
position to loosen the cab from the frame.
2. Set the pump valve (position B) in the right-hand position.
3. Use the control buttons to raise the cab to end position. Press both
buttons simultaneously.
001536
A B
Electric lowering
A. Pump rod mounting
B. Pump valve
C. Lock handle (figure shows open position) 1. Set the pump valve (position B) in the left-hand position.
2. Use the control buttons to lower the cab to contact with the frame.
Press both buttons simultaneously.
3. Turn both lock handles (position C) so that they reach their inner
position to lock the cab to the frame.

172 6 Inspection and maintenance – 6.2.1 Cleanliness
6.2.1 Cleanliness
Cleanliness, general
page
–
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 de-greaser if needed. Scrub if needed.
• 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 battery

compartment, electric components, control units,
connectors, cable joints, cylinder seals, stub axles,
axle seals and chains.
NOTE
Do not rinse off the particle filter for the exhaust system. Poison-
ous deposits may be dissolved and carried with the rinsing water.
NOTE
After washing with de-greaser, the hydraulic cylinders should be
run in and out a few times to obtain satisfactory lubrication once
again.
WARNING
taining aromatic hydrocarbons, ketones, esters or
Low strength! Danger!
Check the outside surface of the roof window at reg-

ular intervals. Clean only with windscreen washer flu-
id or a mild cleaning agent. Rinse thoroughly with
plenty of lukewarm water. Replace a damaged roof
window immediately if it’s cracked or scratched!

6 Inspection and maintenance – 6.2.1 Cleanliness 173
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 imme-
diately and contact a doctor. If the cleaning agent has
found its way into your eyes, rinse immediately with
lots of water and contact a doctor immediately.
CAUTION
Cracks or scratches result in reduced strength of the
roof window.
Low strength!
Replace a damaged roof window immediately.
CAUTION
Objects may shoot off when using compressed air for
cleaning.
Risk of injury.
Use protective goggles and protective gloves. Exer-

cise caution to avoid injury to yourself or those
nearby.
For optimum functionality the machine should also be kept clean in-
side the cab.
• Plastic material: vacuum clean, brush/wipe with lightly moistened
rag. Use mild cleaning agent and always re-wipe with a rag lightly
moistened with clean water.
• Textile material: vacuum clean, brush/clean with e.g. furniture or
carpet cleaning agent in accordance with the instructions on the
packaging.

174 6 Inspection and maintenance – 6.2.2 Fuel system
6.2.2 Fuel system

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

sources, such as cigarettes and sparks. Avoid skin
contact, use protective gloves. In case of skin contact
and spills on clothes, wash the skin and change
clothes.
001537
CAUTION
A. Refuelling point
The quality of the diesel affects the service life of the

engine.
Ensure that the right quality of diesel used.
• 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 condensation in the fuel tank. Do not use anti-con-
densation agents, for example, alcohol, in the fuel.
• Do not refuel when the engine is running.
• Make sure that the fuel nozzle is connected securely in the filler
pipe (to prevent spills and generation of static electricity).
• Clean around the filler pipe after refuelling and handle used rags,
wiped up fuel, etc. in an environmentally sound manner.
• For tank volume, see chapter 9 Specifications.

6 Inspection and maintenance – 6.2.2 Fuel system 175
Fuel prefilter, instructions
NOTE
Water separator must be drained of water if required.
DANGER
Fire hazard.
Extreme danger!
The fuel is highly flammable. Ensure that naked

flames, sparks or red-hot objects have been extin-
guished before starting work on or near the fuel sys-
tem. Do not smoke near the machine during work on
the fuel system.
1 Switch off the engine and switch off the main current.
2 Position a receptacle under the fuel prefilter.
3 Drain the water from the fuel prefilter.
009552
Open the drain cock on the underside (position A), and close the
A cock when pure fuel (no water bubbles) is running out. Only close
Volvo TAD750VE the cock manually.
A. Water separator
WARNING
Fuel on hands.
Rash and irritation.
Avoid skin contact with the fuel, use gloves.
4 Remove the collection container. Handle the fuel as environmen-

tally hazardous and fire hazardous waste.
007388
A
Cummins QSB6.7
A. Water separator

176 6 Inspection and maintenance – 6.2.3 Windscreen washer
6.2.3 Windscreen washer

Windscreen washer, general
page
–
WARNING
Only use clean water with an antifreeze agent, e.g. an-
tifreeze fluid.
A The strength of the roof window may be affected!

Danger!

taining aromatic hydrocarbons, ketones, esters or
The washer fluid reservoir (position A) is located on the left-hand side

of the engine compartment.
Instructions
Check that the reservoir contains enough washer fluid. Top up, if
needed. For volume, see section 9 Specifications.
Use antifreeze fluid in wintertime. Choose a suitable concentration (di-
lution water/antifreeze fluid) according to winter conditions and out-
009553
door temperatures.
A. Washer fluid reservoir

6 Inspection and maintenance – 6.2.4 Air filter engine 177
6.2.4 Air filter engine

Air filter engine, general
page
–
NOTE
Poorly filtered induction air quickly results in serious engine
damage.
The filter is changed by the service technician during running inspec-
tions and service. When the machine is used in dusty air, the filter may
be clogged after in a relatively short time.
In the induction system, between the engine and air filter (A), there’s
A an indicator (B) which shows red when the air filter is clogged.
The air filter has a dust reservoir (position C) which is usually emptied
during operations due to vibrations in the induction system. It can also
be emptied manually by shaking.
Instructions
Check the indicator regularly and contact service as soon as the indi-
cator shows a red signal.
The indicator can be reset to zero.
C
001539
B
A. Position of air filter container
B. Indicator for change
C. Dust reservoir

178 6 Inspection and maintenance – 6.2.4 Air filter engine
In the intake system between engine and air filter is an indicator (po-
sition A) showing a scale of how clogged the filter is. The indicator also
shows red when the filter insert should be changed.
Instructions
Check the indicator regularly and contact service as soon as the indi-
cator shows a red signal.
A
The indicator can be reset to zero.
C
009555
A. Position of air filter container

B. Indicator for change
C. Dust reservoir

6 Inspection and maintenance – 6.2.5 Cooling system 179
6.2.5 Cooling system

Cooling system, general
page
–
Coolant is filled in the system’s expansion tank (position B). The cool-
ant level should be between the MIN and MAX markings (position C)
on the expansion tank.
In case the coolant temperature is too high, the high pressure escapes
through the opening in the pressure cap (position B).
NOTE
Do not open the pressure cap until the coolant temperature has
dropped. Hot coolant may jet up and out!
If the coolant level is too low then an error code is generated in the
C A B
control system’s display (position 41):
NOTE
MAX A low coolant level may cause engine damage or may cause the
engine to stop.
MIN
Instructions
WARNING
The cooling system is pressurised. Steam or hot cool-
001540
ant may jet out.
A. Position for coolant reservoir (expansion tank) Risk of scalding/burn injuries!

B. Pressure cap for filling point Open the pressure cap (position B) very carefully
C. Level marking, MIN and MAX when the engine is warm. Wait until the coolant has
cooled down before topping up.
WARNING
Glycol and anti-corrosion agents are health-hazard-
ous.
Health hazard!
Handle with care. Avoid skin contact, use protective

glasses and protective gloves. In case of skin contact,
wash the skin.

180 6 Inspection and maintenance – 6.2.5 Cooling system
CAUTION
Different types of coolant cannot be mixed.
Risk of engine damage if different types of coolant are

mixed.
When changing and refilling coolant the coolant must

be of the same type as was used previously used. See
the spare parts catalogue for the correct part number.
Fill if necessary using ready-mixed recommended coolant. For vol-

ume, see chapter 9 Specifications.
IMPORTANT
On machines with ECC or AC it is of the utmost impor-
tance that the engine’s cooling system is refilled with
coolant containing the correct mixture of anti-freeze
fluid, otherwise there is a risk that the air conditioning
could freeze and breakdown when used.

6 Inspection and maintenance – 6.2.6 Engine oil 181
6.2.6 Engine oil

Engine oil, general
page
–
WARNING
Avoid prolonged contact with engine oil.
Health hazard!
Use protective gloves.
The engine’s oil filling point (position B) and dipstick (position A) are
under the hood. For the Volvo engine alternative on the left-hand side,
for the Cummins engine alternative on the right-hand side.
Instructions
Check the oil level when the engine is warm. The dipstick has two
markings, MAX. and MIN., the oil level should be between these
markings.
• Wipe off the dipstick before checking.
• Fill engine oil (position B) as required (for volume,
see chapter 9 Specifications).
009554
A It is recommended that oil is filled when the engine and oil are at
operating temperature. Fill – wait awhile – check on the dipstick.
Volvo TAD750VE
A. Dipstick
B. Filling point
NOTE
Fill oil with care to prevent other fluids or particles from con-
taminating the oil. Contamination means risk of engine
damage.

182 6 Inspection and maintenance – 6.2.6 Engine oil
B
007390
Cummins QSB6.7
A. Dipstick
B. Filling point

6 Inspection and maintenance – 6.2.7 Transmission oil 183
6.2.7 Transmission oil

Transmission oil, general
page
–
WARNING
Avoid prolonged skin contact with transmission oil.
Health hazard!
A Use protective gloves.
A
The transmission’s oil filler pipe (position A) and dipstick (position A)
are under the hood on the left-hand side.
Instructions
Check the oil level with the engine running at idling speed and the
007391
transmission in neutral, and at operating temperature (60-70 °C). The

dipstick has two markings, MAX and MIN, the oil level should be be-
A. Dipstick and filling point tween these markings.
• Wipe off the dipstick before checking.
NOTE
The oil dipstick is long. Use gloves.
• Fill transmission oil (position A) when required (for volume, see
chapter 9 Specifications).
It is recommended that oil is filled when the transmission is at op-
erating temperature. Fill – wait awhile – check on the dipstick.
NOTE
Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil. Other fluids or
particles in the transmission oil means a risk of transmission
damage.

184 6 Inspection and maintenance – 6.2.8 Hydraulic system
6.2.8 Hydraulic system

Hydraulic system, general
page
–
WARNING
Avoid prolonged skin contact with hydraulic oil.
Health hazard!
Use protective gloves.
C
The hydraulic oil tank is located on the machine’s right side.
Instructions
Check the oil level (position B) when all hydraulic pistons are in the re-
tracted position. The level should be in the middle of the level glass.
Top up oil (position A) as required (for volume, see chapter 9
Specifications).
A
NOTE
Work carefully when filling engine oil to prevent other fluids or
particles from contaminating the oil. Other fluids or particles in the
engine oil involve a risk of damage to the brake system or work-
ing hydraulics.
B
009454
A. Filling point
B. Level glass
C. Breather filter

6 Inspection and maintenance – 6.2.9 Tyres and rims 185
6.2.9 Tyres and rims

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

competence and authority to handle tyres!
DANGER
Penetrating objects such as crushed glass, pieces of
wood, metal shavings, etc. and mechanical defects,
such as uneven brake wear, can cause tyre damage.
Risk of tyre explosion! Extreme danger!
Check the tyres at regular intervals for external dam-

age and tyre pressure.
WARNING
Check-tighten the wheel nuts on a new wheel after
4-5 operating hours.

ty damage!
Tighten bolted joints crosswise. Contact a service

technician as needed.
CAUTION
Spare and replacement tyres must be from a manu-
facturer approved by Cargotec.
Risk of overloaded tyres!
Use tyres approved by Cargotec.

186 6 Inspection and maintenance – 6.2.9 Tyres and rims
IMPORTANT
Wheels, tyres, and rims are dimensioned and select-
ed for each machine type so that maximal wheel loads
and speeds are not exceeded. That is why it is not per-
mitted to change tyre dimension, tyre make, tyre type,
rim type, or rim brand without approval from
Cargotec.
Changing wheel:
–
Replacing the wheels, see the 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!

6 Inspection and maintenance – 6.2.9 Tyres and rims 187
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 rims.
• Drain the water separator regularly.
DANGER
Never stand in front of a tyre when inflating! Do not
exceed prescribed air pressure, which must be
checked in ambient temperature. When changing tyre
or rim version, another tyre pressure may apply, con-
tact Cargotec. The plate for tyre air pressure must be
replaced with a plate with the applicable tyre
pressure!
Extreme danger!
Always follow instructions for inflating tyres to avoid

serious accidents.
001546
1. Before inflating, make sure that the rim’s lock ring is in the correct
1 2 3 position.
NOTE
If the tyre has been completely deflated, the rim must be dis-
mantled and checked for damage. Let service personnel
change tyres as they have the competence and authorisation
0022002
to handle tyres!
1. Lock ring 2. Connect the compressor with a locking air-chuck to the nipple on
2. Side ring the tyre.
3. Conical ring 3. Stand at an angle behind the tyre and remain there until inflating
has been completed, to prevent being struck by rim parts in case
of an explosion.
4. Inflate the tyre to the prescribed pressure, see chapter 9 Specifi-
cations. When changing tyre or rim version, another tyre pressure
may apply, contact Cargotec.

188 6 Inspection and maintenance – 6.2.10 Checking the accumulator
6.2.10 Checking the accumulator

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

pressure and also to maintain brake pressure, and thus braking action,
a short time after eventual loss of hydraulic pressure.
The accumulators are precharged with nitrogen gas.
Instructions
Check the sealing integrity in accordance with the following points if
the error code for low brake pressure appears in the control system
display (position 41):
1. Start the engine and let it run until the accumulator is filled.
A
2. Stop the engine and then turn the start key to position I.
A 3. Press down the brake pedal with long pumping brake strokes, with
a slight delay between each braking action.
001547
It should be possible to brake at least six times before the error

A. Accumulator code for low brake pressure appears.
4. Start the engine, let the accumulators charge and repeat the test
a couple of times.
If it is not possible to brake six times before the error code for low brake
pressure appears, then there is some defect in the accumulators. Con-
tact service as soon as possible for troubleshooting and action
WARNING
The machine’s hydraulic system includes accumula-
tors with high pressure.
Always be very careful when working with the hydrau-

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

6 Inspection and maintenance – 6.2.11 Central lubrication 189
6.2.11 Central lubrication

Central lubrication, general
page
–
Central lubrication (replacing manual lubrication) is available in differ-

ent variants. The options are as follows:
• Manual, hand pumping lubricant at a lubrication point which is
then branched to all selected lubrication points.
• Automatic, pre-programmed lubrication unit lubricates all selected
lubrication points at preset time interval. Extra lubrication takes
place when the switch in the cab is activated.
Central lubrication comprises the following components:
• Pump unit, with lubricant reservoir.
1 • Distribution block.
• Lines, to all selected lubrication points.
• Grease nipples, at all selected lubrication points.
Maintenance for central lubrication is the filling of lubricant and check-
ing that all connected lubrication points receive sufficient lubricant.
2 Instructions
NOTE
Cleanliness when performing work on the central lubrication sys-
tem is of the utmost importance. Dirt and debris can cause dis-
009117
ruption in the system. To clean the system you can use naphtha
or light petroleum. Do not use e.g. Tri or other organic solvents
1. Pump unit such as alcohol, methanol, acetone or similar, etc.
2. Distribution block Checking the function of central lubrication:
• Make sure that there is no "Er" indication set in the display on the
reservoir. This indicates error. Contact service.
• Make sure that there is no "LL" indication set in the display on the
reservoir. This indicates that lubricant needs to be filled. See
below.
Filling lubricants:
• Fill the reservoir up to the "Max" mark through the filler nipple (po-
sition 1).
• Lubricating grease must be clean from contaminants and must not
change consistency as it ages.
001948
1. Filler nipple
2. Ventilation holes
3. Following plate

190 6 Inspection and maintenance – 6.2.12 Battery and battery disconnector
Filling lubricants with an empty reservoir:

• If the reservoir has become completely empty and is then filled,
the pump may require a longer time to provide all the lubrication
points with a sufficient amount of lubricant.
The button for extra lubrication should be used (located on the
reservoir to the left of the display).
• Check that all air under the following plate (position 3) has been
evacuated.
The following plate’s seal should clean the hole which is on the top
of the reservoir. A small amount of lubricating grease will come out
to indicate that correct ventilation has taken place.
6.2.12 Battery and battery disconnector

Battery and battery disconnector, general
page
–
WARNING
Short-circuit of battery.
Risk of explosion! Fire hazard! Risk of personal

injury!
The battery’s terminals must not be connected to

A-C each other or to common grounding point (chassis).
CAUTION
Always turn off the electric power at the end of your
shift, when working on the electrical system and
when welding on the machine.
Danger!

disconnector.
The electrical system operates at a 24 volt voltage. The voltage source

consists of two 12 volt batteries, connected in series, charged by an
alternator. The minus terminal is connected to the chassis.
The plus terminal is connected to a battery disconnector (position A).
001549
A B C
A. Battery disconnector
B. Plate to indicate battery disconnector in position on,
i.e. main power is connected, and battery disconnec-
tor in position off, i.e. main power is disconnected
C. Handle to open/close the cover lid

6 Inspection and maintenance – 6.2.12 Battery and battery disconnector 191
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 elec-
trolyte on bare skin. Wash with soap and plenty of wa-
ter. If electrolyte has splashed in eyes, rinse
immediately with plenty of water and contact a doctor
immediately.
The batteries are located inside a cover lid (position C) behind the
steps on the machine’s left-hand side.
Checking the electrolyte level is recommended. Fill as needed with
deionised water.
1. Turn off the battery voltage (position A) and open the cover.
2. Check level. Fill as needed with deionised water.
The electrolyte’s fluid level should be 10 mm over the cells.
Batteries contain substances hazardous to the environment and per-
sonal health. Therefore, discarded batteries must be handled accord-
ing to local/national regulations.
Starting with booster battery
WARNING
Handle batteries and connectors with care during
charging and starting with booster batteries. Do not
mix up the battery terminals! Follow instructions for
starting with booster batteries!
Danger of short circuit! Warning of hydrogen gas for-

mation! Sparks and fire! Hydrogen gas is very explo-
sive! Risk of explosion!
Batteries should always be provided with protective

caps over the terminals and connections. Connect
the positive (plus) terminals first. Then connect the
negative (minus) terminals to prevent sparks that may
ignite the hydrogen gas.
1. Switch off the main current with the battery disconnector

(position A).
2. Open the battery cover on the machine’s left-hand side.

192 6 Inspection and maintenance – 6.2.12 Battery and battery disconnector
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’ plus
terminal.
b. The red booster cable (+) to the booster batteries’ plus terminal.
c. The black booster cable (–) to the booster batteries’ minus
terminal.
d. The black booster cable (-) to a point some distance from the
discharged batteries, e.g. at the minus cable’s connection to the
frame or directly to the engine block.
6. Start the machine containing the booster batteries.
7. Stop the main current with the battery disconnector.
8. Try to start the engine and then run the engine at increased idling
speed for approx. 10 minutes in order 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.
Remove the cables in reverse order as when installing. One cable
at a time! Batteries must always be provided with caps over termi-
nals and connections.

6 Inspection and maintenance – 6.2.13 Main fuses for electrical system 193
6.2.13 Main fuses for electrical system

Main fuses for electrical system, general
page
–
WARNING
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.
The machine’s electrical system has one position for main fuses:
A. Main fuses for engine, 4 x 25 A.
Stop all electrical power, apart from fuse number 7 in fuse holder
F58-3, and fuse number 8 in fuse holder F58-4.
Changing the main fuse
1
When checking and changing the main fuse:
1. Turn off the main electric power with the battery disconnector.
007936
See Battery and battery disconnector, general page 190.
1. Main fuses (25 A) 2. Remove the plastic cover.

3. Check and change fuses when needed.
The fuses are 25 A.

194 6 Inspection and maintenance – 6.2.14 Fuses for electrical system
6.2.14 Fuses for electrical system

Fuses for electrical system, general
page
–
The fuses for the electrical system are located in electronic box in the
cab.
The electronic box is located behind the driver’s seat in the cab. There
are fuses for the control computers and equipment in the cab.
A B C D
008615
A. Fuse holder F58-1

B. Fuse holder F58-2
C. Fuse holder F58-3
D. Fuse holder F58-4

6 Inspection and maintenance – 6.2.14 Fuses for electrical system 195
Table 10. Fuse holder F58-1
Connection Fuse number / Size Functions
1 1 / 15A Ignition key lock, supplemental heating
2 2 / 10A Flashing hazard lights, parking brake, cab lighting.
3 3 / 15A Headlights.
4 4 / 15A Windscreen wiper front, horn, washer motor, electrically powered

wind-tone horn.
5 5 / 15A Windscreen wiper roof and rear window, reading lamp, 12V for
memory (K3773).
6 6 / 15A Rotating beacon, reversing lights, reversing alarm, mast work

lights, indicator light, air filter.
7 7 / 15A Work lights roof.
8 8 / 5A Parking brake.
1 1 / 10A Brake light.
2 2 / 10A Gearshifting, seat rotation VBFS, declutching, extra travel direc-

tion selector.
3 3 / 15A Fan heat, AC/ECC.
4 4 / 25A Condenser for air conditioning
5 5 / 10A Break contact (opening switch) driver’s seat, 24V chassis.
6 6 / 10A High beams.
7 7 / 10A Low beams.
8 8 / 10A Rear lights, side running lights.
1 1 / 5A Converter 12V.
1 / 15A Converter 12V (For converter, 20A).
2 2 / 25A Seat air compressor, seat heating, central lubrication.
3 3 / 15A Extra work lights, roof.
4 4/- -
5 5 / 15A Motor for revolving driver’s seat, driver’s seat up/down.
6 6 / 15A Control unit ECU792, steering wheel angle sensor.
7 7 / 10A Control unit ECU794 (for engine alternative Volvo TAD750VE).
8 8 / 10A Control unit ECU794 ignition on.

196 6 Inspection and maintenance – 6.2.14 Fuses for electrical system
1 1 / 15A Hydraulic oil, cooling fan.
2 2 / 15A Frame work lights.
3 3 / 10A Lifting functions (automatic clamping, extender, tilt control, locking

the upper arm, bypass), electronic scales.
4 4 / 5A Feed control unit ECU 793/APC200.
5 5 / 10A Feed control unit ECU 790, sensor for mast near max. lifting
height.
6 6 / 5A Feed control units EDU 795, ECU 790, ECU796.
7 7 / 10A Feed control unit ECU 796, control breaker for load handling,
clamping pressure sensor.
8 8 / 5A Feed control unit ECU 793/APC200.
Table 14. Fuse holder for engine alternative Cummins QSB6.7
1 1 / 5A Control unit ECU794.
2 2 / 30A Control unit ECU 794.
3 3/- -
4 4/- -
5 5/- -
6 6/- -
7 7/- -
8 8/- -
Instructions
When checking and changing fuses:
2. Remove the cover for the electronic box.
3. Remove the cover from the fuse holder.
The fuse plate gives information about each fuse.

6 Inspection and maintenance – 6.2.14 Fuses for electrical system 197
Table 15. Fuse holder (position E) for engine alternative Cummins

E QSB6.7
Connection Fuse number / Functions

Size
3 3/- -
4 4/- -
5 5/- -
007937
6 6/- -
7 7/- -
8 8/- -
Instructions
Changing the fuse for the engine
When checking and changing the fuse:
2. Remove the plastic cover.

198 6 Inspection and maintenance – 6.2.15 Lighting
6.2.15 Lighting
Lighting, general
page
–
It’s important to use the right type of light bulb for respective lighting
point, see section 9 Specifications.
Light bulbs can be changed for the following:
• Instruments
• Check lamps
• Interior lighting
• Rear light, red
• Brake light
• Indicator light for travel direction
• Position light
• Headlights, (with high and low beam)
• Reversing light, white
• Working light, glowing light
Working lights, Xenon
• Revolving beacon
Instructions
Applies for the following:
• Headlights, (with high and low beam)
• Reversing light, white
• Working lights
1 Loosen the rubber strip (position A).
2 Remove the glass (position B).
3 Change light bulb.
000579
A B
A. Rubber strip
B. Glass

6 Inspection and maintenance – 6.3 Service 199
6.3 Service
General
page
–
It’s very important that inspections and service are performed at the
recommended intervals.
Service is performed by Cargotec, or by service technicians author-
ised by Cargotec.
CAUTION
Service interval must be followed.
This is in order to maintain the machine’s safety and

to fulfil warranty and service agreements!
Use spare parts and fluids approved by Cargotec in

order to fulfil warranty terms.
Service intervals and action are described in the maintenance manual.
CAUTION
When welding on the machine, all control units shall
be disconnected to prevent damage.
Undo the connectors from the control units!

200 6 Inspection and maintenance – 6.3 Service
WARNING
The following parts must, for safety reasons, only be
replaced with original spare parts:
• Brake valve
• Drive axle
• Valve for mini-wheel/joystick control
• Control valve (Orbitrol)
• Control valve incl. priority valve
• Steering axle
• Steering cylinder
• Rims
• Solid wheels
• Control valve, hydraulic servo
• Mast, carriage
• Lift cylinder incl. load control valve
• Separate load control valve
• Lifting chains
• Chain tightener and shaft
• Tilt cylinder
• Twistlock
• Forks, fork carrier
• Breaker switch (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 201
7 Transporting the machine
7 Transporting the
mm mm mm mm mm mm
machine
Safety
page
–
DANGER
The machine must be adequately secured during
transport! The machine is heavy and can cause exten-
sive damage in the event of a fall or similar.

ty 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.

202 7 Transporting the machine – 7.1 Towing
7.1 Towing
General
page
–
DANGER
The machine cannot be operated or braked if the hy-
draulic pressure is lost, e.g., if the engine is switched
off.
Rolling machine! Extreme danger!
If possible, tow with maintained hydraulic pressure. If

it is not possible to tow with the engine running then
a towbar must be used! Only tow for short distances!
CAUTION
Do not try to start the machine by towing.
Causes serious damage to the 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 start-
ing to roll.
Extreme care must be observed during towing work to avoid personal
injuries.
When towing, keep in mind:
• The towing vehicle should be heavier than the vehicle in tow.
• If possible when towing, the engine should be running in order for
brakes and steering to function.
When the engine is switched off, there is no hydraulic pressure for
the steering function and thus the machine’s steering function is
severely limited. Also, the transmission lubrication is insufficient.
• The brakes function as long as there is pressure in the accumula-
tor, then the service brake stops functioning and the parking brake
is applied automatically. If it is necessary to move/tow the ma-
chine after that, the parking brake must be released mechanically,
see section 7.1.1 Mechanical release of parking brake.
• Only tow for very short distances.
• If it is necessary to tow the machine, the propeller shaft must be
released from transmission and drive axle.

7 Transporting the machine – 7.1.1 Mechanical release of parking brake 203
7.1.1 Mechanical release of parking brake

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

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

machine.
CAUTION
The parking brake has high spring force. If the brakes
are opened incorrectly, parts may detach and fly off
with great force.
Follow the instructions.

204 7 Transporting the machine – 7.1.2 Hydraulic release of parking brake
The parking brake is a disc brake on the drive axle’s input shaft.
1. Remove protective cover from the caliper (position A).
A B C
2. Note the nut’s position on the bolt and remove the split pin that se-
cures the nut.
3. Screw in the nut, this compresses the brake spring. Screw until
the brake pads release from the brake disc.
4. Restore the parking brake function by screwing out the nut to the
same position as in step 2. Fit new split pin.
5. Refit protective cover on the caliper.
NOTE
000835 If the parking brake has been released mechanically, the parking
brake must always be restored in order to give the machine park-
A. Protective cover ing brake function.
B. Brake disc for parking brake
C. Propeller shaft
7.1.2 Hydraulic release of parking brake

Description
page
–
The parking brake is a disc brake on the drive axle’s input shaft.
DANGER
Before starting to work with the parking brake, make
sure that the machine cannot move when the braking
action is released.
Extreme danger!
Block the wheels to avoid unwanted rolling of the

machine.

7 Transporting the machine – 7.1.2 Hydraulic release of parking brake 205
1. Check that the parking brake is off. See the indicator for the park-
ing brake in the display.
2. Screw out the control (position A) as far as possible.
3. Screw in the knobs (position B and A) as far as possible.
4. Pump with the pump rod (position C) approx. 10 times.
Restore the parking brake as follows:
1. Screw out the knobs (position A and B) as far as possible.
2. Screw in the control (position A) as far as possible.
A-C
NOTE
If the parking brake has been released hydraulically, the parking
brake must always be restored in order to provide the machine
005323 with parking brake function.
A B C
A. Control for mechanical release of parking brake
B. Control for mechanical release of parking brake
C. Pump rod

206 7 Transporting the machine – 7.2 Lifting and transporting the machine
7.2 Lifting and transporting the

machine
General
page
–
When lifting and transporting the machine, follow the safety regula-
tions in force.
DANGER
High demands are made of the lift and transport
equipment, e.g. lifting chains and hooks.
Extreme danger!
Check the equipment and its capacity, lifting slings

on the machine as well as lashing points on the trans-
port 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 main electric power with the battery disconnector.
• Remove any fragile equipment, e.g. rear view mirrors.
• If transport is to take place on a public road:
Remove the mast when transporting if height exceeds height
restriction.
• Apply parking brake.
• Secure the machine with chains for transport on, e.g. a truck. See
the plate for 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.

7 Transporting the machine – 7.2.1 Lifting machine 207
7.2.1 Lifting machine

Instructions, lift with lifting eyes on the
page
–
counterweight
There are lifting eyes on the counterweight and on the lifting mast.
1. Fit two lifting slings in the two lifting eyes of the counterweight.
2. Fit two lifting slings in the two lifting eyes of the lifting mast.
Masts with low lifting height do not have lifting eyes. The lifting
slings must then be threaded around the recess for the lift cylinder
or in some other way so that the slings are secured to the mast.
3. The lifting device must be adapted so that the lifting point runs
through the machine’s centre of gravity.
007369

208 7 Transporting the machine – 7.3 Service position
7.3 Service position

General
page
–
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.
• Fork carriage lowered and mast tilted forward.
• Engine off.
• Main electric power off (with battery disconnector).
• If necessary: lift the machine on stands or back the machine on
ramps. Stands and ramps should be the proper size for the ma-
chine’s weight.

7 Transporting the machine – 7.4 Long-term storage 209
7.4 Long-term storage

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

210 7 Transporting the machine – 7.4 Long-term storage

8 Environment and standards 211
8 Environment and
mm mm mm mm mm mm
standards
General
page
–
Ever-increasing industrialisation of our world is having a significant im-

pact on our global environment. Nature, animals and man are subject-
ed 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 environmen-
tally 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 li-
fecycle to come full circle, and for being able to recycle and make use
of material in new products. According to calculations by Cargotec,
more than 90% of the machine weight is recyclable.
Environmentally hazardous waste

Components such as batteries, oils and other chemicals, as well as
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 environmental-
ly safe manner and according to national regulations.
Oils and fluids

Oils freely discharged cause environmental damage and can also be
a fire hazard. Therefore, when emptying and draining oils or fuel, take
appropriate action to prevent unnecessary spills.
Waste oils and fluids should always be taken care of by an authorised
disposal company.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal the leaks.
Air conditioning
The refrigerant in the air conditioning for the cab accelerates the
greenhouse effect if it comes out in the open air. Special training is re-
quired for all service work on the air conditioning. Many countries also
require certification by an authority for such work. When scrapping the
air conditioning the refrigerant must be dealt with by an accredited
company.

212 8 Environment and standards
Working in a contaminated area

The machine must be equipped for work in contaminated areas (envi-
ronmentally polluted or health-hazardous area) before work is started.
Also, there are special local rules for such handling and when servic-
ing such a machine.
Standards
–
Noise, vibration, stability and visibility, etc.

This machine fulfils the harmonised standard EN 1551 "Safety of in-
dustrial trucks. Self-propelled trucks with lift capacity above 10000 kg"
and the North American standard, ANSI/ASME B56.1" Safety Stand-
ard for Low Lift and High Lift Trucks".
CE-marking
Machines for the EU/EEA market are CE-marked. This means that
upon delivery the machine fulfils the applicable "Essential Health and
Safety Requirements" specified in the EU Machine Directive,
2006/42/EC, as well as other EU directives relevant to this machine
type. For more information, see section 2.2 CE-marking.
ANSI/ASME marking
Versions of this machine for North America are ANSI/ASME-marked.
This means that, when delivered, the machine fulfils the basic safety
requirements specified in ANSI/ASME B56.1. For more information,
see section 2.3 ANSI/ASME-marking.
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 electromag-
netic interference in accordance with the harmonised standard
EN12895. The machine’s CE-marking and the declaration of conform-
ity also cover the EMC directive. If other electronic equipment is in-
stalled 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's Exhaust directive
97/68/EC and 2004/26/EC, which means that engine exhaust emis-
sions are limited in accordance with the requirements.
Machines for the North American market fulfil EPA's and CARB's ex-
haust regulations, which means that engine exhaust emissions are
limited in accordance with the requirements.

8 Environment and standards 213
Noise emissions
The machine for the EU/EEA market fulfils the EU Noise directive
2000/14/EC and 2005/88/EC which means that the machine is marked
with measured environmental noise emissions which are also limited
in accordance with the requirements for trucks with lift capacity above
10000 kg. See section 3.2 Plates.
Vibration standard
Vibration that the machine emits is measured according to the harmo-
nised standard EN 13059 where the level of vibration varies depend-
ing on the type of tyre and the driver’s seat that the machine is
equipped with. See the section 9 Specifications.

214 8 Environment and standards

9 Specifications 215
9 Specifications
9 Specifications
mm mm mm mm mm mm
Technical data
page
–
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 TAD750VE Cummins QSB6.7
Guaranteed sound power level in ac- LWA 110 dB(A) LWA 110 dB(A)
cordance with 2000/14/EC and
2005/88/EC included measurement
uncertainty 1.5 dB.
1 Engine Volvo TAD750VE Cummins QSB6.7
Output in accordance with ISO 3046 181 kW at 2300 rpm 194 kW at 2200 rpm
(effective rated output)
Torque ISO 3046 1050 Nm at 1500 rpm 990 Nm at 1400 rpm
Max. rotation speed 2200 rpm 2200 rpm
Number of cylinders 6 cylinders 6 cylinders
Alternator, output 2240 W 1960 W
Start battery, voltage – capacity 2x12 V - 140 Ah 2x12 V - 140 Ah
2 Transmission Dana-Spicer Off Highway
TE17000
No. of gears, forward – reverse 3–3
3 Power transmission Kessler
Drive axle, type Kessler D91
4 Brakes
Footbrake system – wheel affected Wet Disc Brake – drive wheel
Parking brake system – wheel affected Spring brake – drive wheels
5 Steering
Steering system Hydraulic servo
6 Wheels DCD200-250 DCD280-300
Dimension, front and rear 14.00x24/24 16.00x25

216 9 Specifications
Tyre pressure, also see pressure plate 1.0 MPa
Tyre type, front and rear Air-inflated. Spare and replacement tyres shall be of brand names approved by
Cargotec.
9 Cab Spirit Delta with Volvo TAD750VE Spirit Delta with Cummins QSB6.7
Equivalent sound pressure level in cab LpAZ 76 dB(A) LpAZ 74 dB(A)

in accordance with EN12053 with
measurement uncertainty R = 2.5 dB.
Measurement values with the standard
engine.
Whole-body vibration in accordance 0,4 - 0,7 m/s2

with EN13059 with measurement un-
certainty k = 0.3 x measured value.
Specifications oil, lubricants and

–
fluids
Any deviation from this table must be approved in writing by Cargotec.
1.2 Engine, fuel system DCD200-220 DCD240 DCD250 DCD280-300
Fuel tank, capacity 300 l 230 l 350 l 350 l
Fuel quality Diesel, according to EN590
1.7 Engine, cooling system Volvo TAD750VE Cummins QSB6.7
Coolant volume 40 l 40 l
Coolant filling point Volvo VCS coolant, ready mixed ES Compleat, Premix
for part no., see spare parts cata- for part no., see spare parts cata-
logue. logue.
1.8 Engine, lubrication system

Oil type, quality See Oils and lubricants, recommendation page 218.
Oil volume 23 l at first filling 20 l

21.5 l when changing including filter
2.6 Transmission, lubrication Dana TE17000

system
Oil type See Oils and lubricants, recommendation page 218.
Oil volume 35 l
3.3 Power transmission, drive axle Kessler D91
Oil quality See Oils and lubricants, recommendation page 218.

3.3 Power transmission, drive axle Kessler D91
Oil volume, differential

DCD200-250 30 l
DCD280-300 38 l
Oil volume, hub reduction

DCD200-250 2x4 l
DCD280-300 2x3.5 l
9 Frame, body, cab and accessories Condenser with 2 fans Condenser with 4 fans
Refrigerant air conditioning R134a
Volume refrigerant 1700 g (see plate for air 2200 g (see plate for air
conditioning) conditioning)
Lubricant air conditioning ZXL100PG
Volume, lubricant 0.27 l 0,32 l
Washer fluid, volume 2.5 l
10 Common hydraulics DCD200-220 DCD240 DCD250 DCD280
Oil quality See Oils and lubricants, recommendation page 218.
Oil additive Lubrizol 3%
Hydraulic oil tank, volume 270 l 260 l 320 l 320 l

Oils and lubricants,

–
recommendation
The service intervals indicated by Cargotec in the maintenance man-
ual only apply if oils are selected in accordance with the table below.
The table indicates recommended viscosity for different oil types, and
grades, depending on the ambient temperature.
Any deviation from this table must be approved in writing by Cargotec,
and may mean changed service intervals.
C -30 -20 -10 0 +10 +20 +30 +40 +50

Oil type, quality F -22 -4 +14 +32 +50 +68 +86 +104 +122
1.8 Engine, lubrication system *)
Volvo: VDS-2, VDS-3 -15 C SAE 15W/40
API: CH-4, CI-4
-25 C SAE 10W/30
ACEA: E4-99, E4-99 (Synthetic),
SAE 5W/30
E5, E7
Cummins: CES-20071,
CES-20072, CES-20076, -15 C SAE 15W/40
CES-20077, CES-20078
-25 C SAE 10W/30
API: CH-4/SJ, CI-4/SK
SAE 5W/30
ACEA: E5, E7
2.6 Transmission, lubrication

system
Transmission oil ATF DEXRON III (trademark)
3.3 Power transmission, drive

axle
Hypoid oil, API GL-5 and SAE 80W140
MIL-L-2105B SAE 80W90
SAE 90
SAE 85W140
10 Common hydraulics
Hydraulic oil AV 32
SS 155434 AV 46
Hydraulic oil HVLP 46

DIN 51524 HLP 68
Hydraulic oil ISO - LHV 46

ISO 6743/4 ISO - LHM 68

NOTE
Oil filters shall always be changed in connection with oil change.
Change interval for engine oil requires that the sulphur content in
the fuel does not exceed 0.5%.
*) API CH-4 or CI-4 are approved for markets outside the EU/EEA.
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
CES = Cummins Engine Standard
VDS = Volvo Drain Specification
Lubricating grease
Use universal grease of type EP according to NLGI Grade 2 (EP2) with
3-5% molybdenum sulphide mixture for all grease points except glide
plates, where lubrication paste Gleitmo 805 or equivalent should be
used. For electric connections, use connector grease 923836.0552.
Coolant
Coolant must consist of distilled water mixed with 40-60% glycol. Anti-
corrosion agent must always be added if glycol is not used. However,
anti-corrosion agents do not contain anti-freeze agent and may only
be used if the outdoor temperature is always above 0 ºC.
NB! It is important that the coolant is mixed correctly all year to ensure
adequate corrosion protection. The corrosion-protective properties
decline with time, and that is why the coolant must be replaced accord-
ing to stated intervals.
A mixture of 60% distilled water and 40% glycol gives freezing protec-
tion down to temperatures of -28 ºC.
A mixture of 40% distilled water and 60% glycol gives freezing protec-
tion down to temperatures of -54 ºC.
CAUTION
Different types of coolant cannot be mixed.
Risk of engine damage if different types of coolant are

mixed.
When changing and refilling coolant the coolant must

be of the same type as was used previously used. See
the spare parts catalogue for the correct part number.

Specifications light bulbs

–
Lamp Output (W) Socket

Instruments 3 Ba7s
Check lamps 1.2 W2x4.6d
Interior lighting 10 S8.5
Rear light, red* 5 BA15s
Brake light* 21 BA15s
Indicator light for travel direction* 21 BA15s
Position lamps 5 SV8.5
Headlights, (with high and low beam) 75/70 H4
Reversing light, white 70 H3
Work lights 70 PK22s
35 D1S Xenon tubes. Cartridge and ballast

Work lights, Xenon
replaced complete.
Revolving beacon 70 PK22s
* For change of LED, see spare parts catalogue.

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
–
SI-unit Recalculation Non-SI Recalculation SI

factor factor
Torque
Nm x 10.2 = kg·cm x 0.8664 = lb·in
Nm x 0.74 = lbf·ft x 1.36 = Nm
Nm x 0.102 = kg·m x 7.22 = lb·ft
Pressure (Pa = N/m2)
kPa x 4.0 = in.H2O x 0.249 = kPa
kPa x 0.30 = in.Hg x 3.38 = kPa
kPa x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
kp/cm2 x 14.22 = psi x 0.070 = kp/cm2
N/mm2 x 145.04 = psi x 0.069 = bar
MPa x 145 = psi x 0.00689 = MPa
Power (W = J/s)
kW x 1.36 = hp (cv) x 0.736 = kW
kW x 1.34 = bhp x 0.746 = kW
kW x 0.948 = Btu/s x 1.055 = kW
W x 0.74 = ft·lb/s x 1.36 =W
Energy (J = Nm)
kJ x 0.948 = Btu x 1.055 = kJ
J x 0.239 = calorie x 4.19 =J
Speed and acceleration
m/s2 x 3.28 = ft/s2 x 0.305 = m/s2
m/s x 3.28 = ft/s x 0.305 = m/s
km/h x 0.62 = mph x 1.61 = km/h
Horsepower/torque
Bhp x 5252 rpm = TQ (lb·ft) TQ x rpm 5252 = bhp
Temperature
ºC = (ºF – 32)/1.8 ºF = (ºC x 1.8) + 32
Flow factor
l/min (dm3/min) x 0.264 = US gal/min x 3.785 = litre/min

Conversion table length

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

–
Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 - 1000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
ft2 - 0.092903 - 0.000929 1 0.1111 144.000
yd2 - 0.83613 - 0.008361 9 1 1296.00
in2 6.4516 0.000645 - - 0.006943 0.000771 1
1 ha = 100 a – 1 mile2 = 259 ha = 2.59 km2
Conversion table volume

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

Conversion table weight

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

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

10 Terminology 225
10 Terminology
10 Terminology
mm mm mm mm mm mm
Explanations
page
–
Term Description
AC Air Conditioning. Heating unit with manual control of heating, cooling, dehumidification
and air flow.
Accumulator Reservoir that stores (accumulates) pressure for, i.e. hydraulic functions.
Anti-corrosion compound Prevents oxidation, in simple terms, rustproofing.
Attachment Part of the machine that grips the load when lifting.
Bar Unit to express pressure.
Battery disconnect switch Cuts off power supply from battery.
Buzzer Acoustic alarm to catch the operator’s attention.
Central lubrication An automatic system for lubrication of a preset number of lubrication points.
Control valve Valves that can be used to control something, for example, to release pressure and thus
lower a mast or a fork. See also control valve.
Counterweight Weights adapted to the machine’s lift capacity to constitute an opposing load when lifting.
Daily inspection Actions that should be performed daily to ensure the machine’s functionality.
Decitonne Tenth of a tonne, measure of machine’s lift capacity.
Displacement The oil volume that the pump can supply per pump revolution.
Display "Window" showing digital information, e.g. on steering wheel panel in cab (with KCS).
Drive axle Driving axle that receives the torque from the drivetrain.
Drivetrain Parts in the machine involved in power transmission; engine, torque converter, transmis-
sion, propeller shaft and drive axle with differential and hub reduction.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, which is emptied automati-
cally during operation.
ECC Electronic Climate Control. Air conditioning with automatic control of heating, cooling, de-
humidification and air flow.
ECU Electronic Control Unit
EDU Electronic Display Unit
Electric servo Load handling’s hydraulic components receive control signals from electro-mechanical
controls.
Electrolyte level Fluid level in battery cells.
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and regula-
tions.
Expansion tank Tank for coolant.
Fixed displacement Pump with fixed pump volume.
FMI Fault Message Identifier.
Fork bracket Bracket for forks, fitted on the lifting trolley.
Forks Lifting device that lifts the load.

226 10 Terminology
Term Description
Frame member Structural members in the frame.
Hanging load Lifted load.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases torque from
the drivetrain.
Hydraulic oil Oil for hydraulic system. See specifications in operator’s manual.
Hydraulic oil pump Pump in hydraulic system.
Hydraulic servo Load handling’s hydraulic components receive control signals from mechanical controls.
Hydraulic system System that uses oil pressure to transfer power to different functions.
Indicator Manual "sensor", for example, shows that a filter is clogged and needs to be changed.
KCS Kalmar Control System. An electronic control system that monitors and regulates certain
systems in the machine that require KCS, such as certain engine and transmission alter-
natives.
Levelling Forks are tilted, e.g. if load stands on uneven ground.
Lift capacity Indicates machine’s maximum lift capacity.
Lifting point Attaching point for lift device when lifting an object.
Low-emission engine Engine with low emissions of hazardous substances. Manufactured according to specified
and governing regulations.
Machine model Machine type. Specified, for example: DCD 200-300. See also Type designation.
Main fuse Located by battery. Cuts off power to all machine systems.
Maintenance Periodic maintenance actions so that machine functions safely and for a long service life.
Mast Carrier of attachment and load.
Operating time Number of hours machine has been in operation, shown on hour meter in cab.
Option Extra equipment for machine.
Pilot oil pressure A low control pressure to, for example, a valve.
Piston rod Rod that is pushed into the piston’s cylinder barrel and is acted upon by the hydraulic pres-
sure.
Planetary gear Type of transmission with gears in constant engagement.
Product alternative One of several alternatives selected for a machine, e.g., engine alternative.
Progressive steering Quick steering wheel movements give greater steering angles.
Proportional valve An electro-magnetically controlled valve. If a current is applied, the valve is activated in
proportion to the current’s amplitude. In simple terms, infinitely variable valve, as opposed
to on/off valve. For example, on transmission’s valve housing.
Recirculation Circulation in a closed system.
Refrigerant Fluid/gas in air conditioning. Must only be handled by authorised trained personnel.
Securing machine for transport Actions before transporting machine.
Serial number Unique machine designation. On machine plate.
Service position How machine should be safely positioned before service may be started.
Servo A small movement by the user results in a large angle, i.e. servo steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side shift Parallel sideways movement of forks.

10 Terminology 227
Term Description
SmartLink Software for handling KCS (Kalmar Control System).
Solenoid valve An electromagnetically controlled valve. See also proportional valve.
Spirit Delta Enclosed type of cab.
SPN Suspect Parameter Number.
Spreading (positioning) Spreading of the forks, e.g. change to relative distance between the forks.
Steering axle Wheel axle with steering.
Tilt The mast is leaned forward or backward.
Top lift Attachment, see attachment.
Torque converter Hydraulic, variable clutch.
Transmission oil Oil for transmission and torque converter. See specifications.
Trolley Lifts the load, located on the mast.
Twistlocks Two lock pins, one in each corner of the attachment, pushed down in corresponding holes
in container and twisted to lock the container when lifting.
Type designation Indicates machine type and capacity. See also machine model.
Valve slide Moveable part in valve. Determines oil’s path.
Variable displacement Adjustable volume (capacity) of a pump.
Variable pump Pump with adjustable flow rate.
Wet brakes Brake discs in oil bath.
Wheelbase Distance between drive axle and steering axle.
Working hydraulics All load handling functions, e.g. lift and lower, tilt, side shift, positioning and levelling.

228 10 Terminology

11 Index
About the documentation kit 6 Operating menu for joystick control/mini steering wheel 87
About the operator’s manual 3 Operating menu for scales 87
Air conditioning ECC 83 Operating menu for service 89
Air filter engine 177 Operating menu for service interval 86
ANSI/ASME marking 13 Operating menu for statistics 88
Battery and battery disconnector 190 Operating menu for transmission and electrical system 86
CE-marking 12 Operating menu for trip computer 88
Central lubrication 189 Operating menus 85
Checking the accumulator 188 Other information for load handling 63
Cleanliness 172 Overview 23
Control for load handling 58 Overview description 24
Cooling system 179 Overviews 40
Daily inspection 166 Parking brake 140
Daily inspection 94 Pedals 66
Description DCD 200-300 23 Plates 30
Driver’s seat (9) 74 Reading instructions 4
Engine oil 181 Running-in 93
Environment and standards 211 Safety 9
Error code indication 97 Safety and emergency equipment 11
Error code information on display 98 Service 199
Error code tables 102 Service brake 138
Error codes 95 Service position 208
Foreword 3 Specifications 215
Fuel system 174 Spirit Delta 41
Functions for load handling 157 Spirit Delta 80
Fuses for electrical system 194 Spirit Delta with air conditioning ECC 145
Gear and travel direction selector (2) 54 Spirit Delta with heating unit/heating unit with cooling AC
Gearshifting 131 142
Handling 91 Starting engine 129
Heating / Air conditioning 142 Steering 137
Heating unit 80 Steering wheel (4) 70
Heating unit/Air conditioning 80 Stopping engine – parking 148
Hydraulic release of parking brake 204 Switches 49
Hydraulic system 184 Terminology 225
Identification of the machine 23 Towing 202
Ignition key lock (43) 48 Transmission oil 183
Inspection and maintenance 165 Transporting load 154
Inspection and maintenance 7 Transporting the machine 201
Instruments 47 Tyres and rims 185
Instruments and controls 39 Unloading 156
KCS system 85 Warming up 130
Keep in mind 14 Warning and indicator lights 45
Lifting and transporting the machine 206 While operating 126
Lifting load 152 Windscreen washer 176
Lifting machine 207
Lighting 198
Load handling 150
Load handling 57
Long-term storage 209
Main fuses for electrical system 193
Maintenance 170
Mechanical release of parking brake 203
Multi-function lever (5) 56
Operating 126
Operating menu 86
Operating menu for engine 86
Operating menu for fuel consumption 87
Declaration of Conformity
We, Cargotec Sweden AB, SE-340 10 Lidhult, (Registration No. 556014-5418) herewith
declare that the machine,
Type Forklift truck

Model DCD300-12LB
Serial No A201.XXXXX
Year of construction 2010
Engine VOLVO TAD 750VE
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
Position Head Of Counterbalanced Products
Place, Date of Issue Signature

2A_TEST_O_GB
Cargotec improves the efficiency of cargo flows by offering solutions for
the loading and unloading of goods on land and at sea – wherever cargo Cargotec Sweden AB
is on the move. Cargotec’s main daughter brands for cargo handling Torggatan 3
SE-340 10, Lidhult, Sweden
Hiab, Kalmar and MacGregor are global market leaders in their fields.
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Forklift Trucks 20-30 Tonnes: Operator S Manual

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Forklift Trucks 20-30 Tonnes: Operator S Manual

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Forklift Trucks 20-30 tonnes

1.1 About the operator’s manual

Thank you for choosing Cargotec as your machine supplier. We hope

Operator’s manual, purpose

This operator’s manual applies to machine DCD 200-300.

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

About machine version

The information in this operator’s manual corresponds to the

This machine is manufactured by Cargotec Sweden AB,

Operator’s manual DCD 200-300, 2006 - IDCD03.03GB

1.1.1 Reading instructions

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

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

IDCD03.03GB Operator’s manual DCD 200-300, 2006 -

Read the operator’s manual

Operator’s manual DCD 200-300, 2006 - IDCD03.03GB

1.2 About the documentation kit

The following documentation is supplied with the machine:

The documentation is ordered from the dealer for Cargotec.

IDCD03.03GB Operator’s manual DCD 200-300, 2006 -

1.3 Inspection and maintenance

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

For other maintenance not included in this operator’s manual (service

Operator’s manual DCD 200-300, 2006 - IDCD03.03GB

IDCD03.03GB Operator’s manual DCD 200-300, 2006 -

Important to read the operator’s

Operator’s manual DCD 200-300, 2006 - IDCD03.03GB

Any modification or rebuild without Cargotec’s permissions can-

• The machine may only be operated by specially trained operators

Machine operation is prohibited:

IDCD03.03GB Operator’s manual DCD 200-300, 2006 -

2.1 Safety and emergency

A good working environment has safety and emergency equipment to

2. Revolving beacon/flashing beacon

4. Electrically powered loud air horn

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

8. Camera with monitor

10. Control breaker for load handling

9b 11. Protective grating for roof window

Operator’s manual DCD 200-300, 2006 - IDCD03.03GB

(Declaration of Conformity, only applies to machines marketed

with attachments other than that specified in these instructions, safety

IDCD03.03GB Operator’s manual DCD 200-300, 2006 -

2.3 ANSI/ASME marking

(only applies to machines for the North American market).

Machine plates for ANSI/ASME marking

Operator’s manual DCD 200-300, 2006 - IDCD03.03GB

2.4 Keep in mind

Turn off the electric power with the battery

IDCD03.03GB Operator’s manual DCD 200-300, 2006 -

During work shifts

Extreme hazard to personal health and risk of proper-

Make sure that no persons stand or walk under a

Extreme hazard to personal health and risk of proper-

Only use equipment that is approved by Cargotec.

Very sudden braking. Risk of machine tipping over,

Stop the machine before applying the parking brake.

Operator’s manual DCD 200-300, 2006 - IDCD03.03GB

Extreme hazard to personal health and risk of proper-

• Always check that no persons are in the way of the

• The operator must always face in the travel direc-

• The operator must adapt the speed to the load and

• The operator must pay extra attention and operate