IDCF03 - 03GB - DCF80-100 Operator Manual

Empty Container Handler
8-10 tonnes
Publ. no IDCF03.03GB
Operator's manual in original language OPERATOR´S MANUAL
DCF 80-100
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, DCF 80-100 .......................................................................... 23
3.2 Plates ....................................................................................................... 30
4 Instruments and controls ............................................................................ 39
4.1 Warning and indicator lights ..................................................................... 44
4.2 Instruments ............................................................................................... 47
4.3 Ignition (53) .............................................................................................. 48
4.4 Switches ................................................................................................... 49
4.5 Gear selector and multi-function lever (2) ................................................ 55
4.6 Hydraulic control (9) ................................................................................. 57
4.7 Pedals ...................................................................................................... 62
4.8 Steering wheel (4) .................................................................................... 63
4.9 Driver’s seat (10) ...................................................................................... 66
4.10 Heating / Air conditioning ......................................................................... 69
4.11 Control system ......................................................................................... 72
5 Handling........................................................................................................ 79
5.1 Running-in ................................................................................................ 81
5.2 Daily inspection ........................................................................................ 82
5.3 Error codes ............................................................................................... 83
5.4 Operating ................................................................................................ 113
5.5 Load handling ......................................................................................... 126
6 Inspection and maintenance..................................................................... 145
6.1 Daily inspection ...................................................................................... 146
6.2 Maintenance ........................................................................................... 150
6.3 Service ................................................................................................... 175
7 Transporting the machine ......................................................................... 177
7.1 Towing .................................................................................................... 178
7.2 Lifting and transporting the machine ...................................................... 181
7.3 Service position ...................................................................................... 184
7.4 Long-term storage .................................................................................. 185
8 Environment and standards...................................................................... 187
9 Specifications............................................................................................. 191
10 Terminology................................................................................................ 201
11 Index............................................................................................................ 205
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 machine.
Operator’s manual, purpose

–
This operator’s manual applies to machine DCF 80-100.

The operator’s manual describes how the machine should be
operated and maintained in a correct manner.
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 ma-

chine’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 DCF 80-100 IDCF03.03GB

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
regulation is not followed.
CAUTION
Situation that could lead to product damage if
regulation is not followed.
Important information
–
Important information is denoted with NOTE and is intended to facili-

tate the work process, handling or to increase understanding of the
information.
NOTE
Important information not related to safety.
Read the operator’s manual

–
The symbol to the left is used in certain cases on the machine and
refers to important information in the operator’s manual/maintenance
000262
manual.
Read the operator’s manual/maintenance manual

Read the Maintenance manual
–
The symbol to the left is used in certain cases on the machine and
refers to important information in the Maintenance manual.
001128
Read the Maintenance manual
IDCF03.03GB Operator’s manual DCF 80-100

1 Foreword – 1.1.1 Reading instructions 5
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 DCF 80-100 (in cab with machine)
• Maintenance manual DCF 80-100
• Spare parts catalogue with machine card
There is supplementary documentation that can be ordered for the
machine. The following is included:
• Workshop manual DCF 80-100.
• Supplier documentation for engine, transmission, and drive axle.
Ordering documentation
–
The documentation is ordered from the dealer for Cargotec.

Always indicate publication number when ordering.

1 Foreword – 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
operator 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
apply 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
governing regulations.
• The machine is designed for use in outdoor temperatures -30 °C
to 40 °C, relative humidity 10 to 90%, and max. wind speeds
12.2 m/s. In case of higher wind speeds, contact Cargotec.
Operator requirements
–
• The machine may only be operated by specially trained operators

who have the work supervisor’s permission to operate the
machine.
• Laws and regulations regarding driver’s licenses, operator ID, etc.
must always be followed.
• The operator must be aware of and follow all local safety rules.
• The operator must follow the manufacturer’s instructions.
• The operator should read and understand the machine’s 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 work environment has safety and emergency equipment to

facilitate and make the operator’s work safe. The machine shall be
equipped with the following equipment.
6,7,11
2
8
3
1
10
008112
5 9
1. Reverse alarm
2. Rotating beacon
3. Horn
4. Electrically powered high-volume horn
5. Fire extinguisher
If the machine is provided with a fire extinguisher, it should be of
the type ABE according to EN 3 pt. 1, 2, 4 and 5. With such a fire
extinguisher, it is possible to put out fires in both solid organic
materials and fluids. Adapted fire extinguishing equipment can be
ordered from Cargotec.
6. Seat belt
7. Buzzer in the cab to indicate an alarm or forgotten action, e.g., if
the operator leaves the cab without applying the parking brake.
8. Camera with monitor

Used to give improved rearward visibility during operation of the
machine. Monitor is located inside the cab on the left side.
9. External rear view mirrors
Used to give better visibility when operating.
10. Flashing brake lights when reversing
11. Breaker switch for load handling (servo circuits)
Cuts off all power supply and control signals to hydraulics.

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, when delivered, the
machine meets all applicable "Essential Health and Safety Require-
ments", stated in EU’s Machine directive, 2006/42/EC, as well as other
EU-directives applicable to the machine type in question.
As proof that the requirements have been fulfilled, Cargotec issues
and delivers an EC Declaration of Conformity for each individual ma-
012891
chine. This Declaration of Conformity also covers attachments as well
as options manufactured by Cargotec. The documentation is valuable
and should be kept in a safe location and saved at least 10 years. The
Machine plate for CE-marking documentation 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
assumes responsibility for them. If the machine is used for purposes
or with attachments other than that 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. 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 Environ-
ment 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 the same.
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.
012900 For additional information, see standards under chapter 8 Environ-

Machine plate for ANSI/ASME-marking ment and standards.

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
Never leave the operator’s station without first applying the
parking brake (ON position).
NOTE
Always remove the start key if the machine is to be left
unattended.

2 Safety – 2.4 Keep in mind 15
During work shifts

–
DANGER
The attachment is a tool that handles heavy loads.
Extreme hazard to personal health and risk of

property damage!
Never walk under a suspended load. Never walk

under a raised attachment, whether it is loaded or not.
DANGER
External equipment may only be used if it is approved
by Cargotec.

property 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.

property 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

direction and should operate with special care
where persons or vehicles may appear.
• The operator must adapt the speed to the load and

ground conditions, visibility and wind
conditions, etc.
• The operator must pay extra attention and operate

with special care near electric power lines,
viaducts, docksides, ramps, 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

damage to property! Fatal danger!
Respect the lifting capacity of the machine and

exercise the greatest caution 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 attachment
• Do not transport the load in high position since

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

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

load obscures visibility to the front.
• No personnel may encroach or stand under a

raised load.
• The operator shall avoid forceful acceleration and

heavy braking to prevent risk off tipping and
roll-over.
• The operator shall always adapt the speed when

turning to prevent risk off skidding as well as
tipping and roll-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! Fatal danger!
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 case of exposure to substances contain-
ing: aromatic hydrocarbons, ketones, esters and
chlorinated hydrocarbons.
Low strength! Fatal 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
passengers 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
Be careful with a lateral sliding cab. Before the cab is
moved, make sure that no person is in the risk area
outside the cab – risk of crushing.
It is forbidden to operate the forklift with open doors

when the cab is outside the middle position.
It is forbidden to exit the cab when it is outside its

middle position, except in emergencies.
WARNING
The machine’s hydraulic system includes
accumulators with high pressure.
Always be very careful when working with the 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).
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-hy-
drogen 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.
Hazardous to health in case of long-term skin contact!

Risk when refuelling!
Avoid skin contact with oils and lubricants. Use

protective gloves.
WARNING
Fire extinguishers contain dry chemicals.
Risk of breathing difficulties when using in an

enclosed space!
Use the fire extinguisher from the outside and into the
area 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
parking brake function.

WARNING
Optional equipment such as two-way radio, RMI,
telephone, etc. may emit non-ionising radiation.
Risk of interference with active or non-active medical

products.
Use two-way radio, RMI, telephone, etc., when no

persons with active or non-active medical products
are nearby.
NOTE
When persons with active or non-active medical products are not
nearby, telephone and two-way radio may be used in the cab.
Equipment should not be used during operation or load handling
as this takes away from the operator’s concentration.
Cargotec will not assume any responsibility for installed optional
equipment, which is not installed by Cargotec or an installer
approved by Cargotec.

3 Overview 23
3 Overview
3 Overview
mm mm mm mm mm mm
3.1 Description, DCF 80-100

General
page
–
Machine DCF 80-100 is a forklift for handling empty containers. It has

a maximum lift capacity of 8 to 10 tonnes. The machine has a lifting
mast. There are two alternative lifting masts (different lifting heights):
1. Duplex
2. Triplex
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 mast container handler
page
–
Every machine from Cargotec has a type designation. The type

designation indicates the following:
DCF 100-45E7 (example)
• D - Diesel engine
• C - Counterweight forklift
• F - Generation
• 100 - Lift capacity, decitonne
• 45 - Wheelbase
• E - Empty container
• 7 - Lifting height, no. of containers when stacking
Machine card
–
When ordering and after putting the machine into operation, it’s possi-
ble to modify and adapt Cargotec’s 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.
DCF 80-100
1. Steering axle
2. Engine
3. Transmission
4. Drive axle
5. Load handling, lifting mast
6. Load handling, attachment
7. Cab
6
008114
1 2 3 4

3 Overview – 3.1.2 Overview description 25
Engine
–
The engine is a 6-cylinder turbocharged, low-emission engine with

intercooler. The engine provides power for propulsion and working
hydraulics.
DCF 80-100 is equipped with one of the following engine alternatives:
• Volvo TAD760VE.
• Cummins QSB6.7 .
Transmission
–
The transmission is fully automatic with a torque converter. TE17 has

3 forward gears and 3 reverse gears. The hydraulic pumps for working
hydraulics are mounted on the transmission.
DCF 80-100 is equipped with one of the following transmission
alternatives:
• TE17 (together with Volvo TAD760VE or Cummins QSB6.7)
Drive axle
–
The drive axle (front axle) is equipped with a differential and hub
reductions 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 electrohydraulically 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 case of
voltage loss and loss of hydraulic pressure, and is released with
hydraulic pressure.
Steering
–
The machine is steered with the rear axle. A double-acting hydraulic

cylinder acts on the wheel pair. Steering is linear, that is, the steering
angle is dependent on the number of steering wheel turns.
Load handling
–
Mast and sidelift attachment are used for load handling. Loads are
controlled vertically, sideways, and tilted (angled) forward or back-
ward. The sidelift attachments have either twistlocks or hooks with
lock lugs for securing the load. The attachments are adjustable be-
tween 20’ and 40’. Securing of loads and operation is handled
electrically and hydraulically.
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
system which monitors and controls the machine’s functions.

Control system
–
The machine has an electrical system with a n electronic control and

monitoring system that handles all systems in the machine, such as
power electronics, drivetrain, and hydraulic system. The control and
monitoring system facilitates maintenance and makes it more
effective.
Cab
–
The cab is available in one version. Instrumentation and equipment

(steering wheel, operator’s seat, fresh air system) can be adapted to
customers as well as models.
• Cab Spirit Delta
Spirit Delta is an enclosed operator’s station built of a supporting
frame to withstand falling loads. It is equipped with a fresh air sys-
tem with filtered inlet and recirculation as well as electronic control
of heat or cooling ( ).
The roof window is made of high-strength material and withstands
heavy blows, e.g., from falling objects.
The cab can be tilted fore-aft ( ).
Hydraulic system
–
The hydraulic system includes the sub-functions of brakes and

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

Other equipment
–
19 36 32 21,22
7 13 12 1,37 11,34
29
38,39
2,14
35
26 15
5
39
012845
6 27 4 3 18,20,28,30,31
1 Rear-view mirror, internal in cab
2 PC-holder
3 External rear-view mirrors. Used to give better visibility when
operating.
4 Horn
Located under cab.
5 Electrically powered high-volume horn

Located at top of trailing roof edge.
6 Reverse alarm
7 Passenger seat
8 Tinted windows
(Not positioned in figure).
9 Openable window, left door

10 Openable window right door

11 Sun visor, front windscreen

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

Can be pulled out to fasten in two hooks at the front edge of the
window.
13 Sound unit, 24 VDC

Instructions are included.
14 Writing table with light

For handling paperwork in the cab. The table is located to the
right in the cab.
15 Socket 24 VDC
The socket is located by the right door and is fused.
16 Slip-protection on steps, profiles on the sides and counterweights
17 Steps with rail by the left fender

18 Headlights, 2 lights
19 Work lights cab roof, 4 lights
20 Extra work lights front fender, 2 lights

21 Mast working lights, 2 lights
22 Extra mast working lights, 2 lamps

23 Work lights hook attachment, 4 lights
24 Work lights twistlock attachment, 2 lights
25 25 24
25 Extra work lights carriage, twistlock attachment, 2 lights
24 26 Back-up lights, 2 lights

27 Brake lights, 2 lights
28 Running lights, 4 lights
29 Rotating beacon, 1 light
30 Direction indicators, 4 lights
31 Hazard lights direction indicators, 4 lights
23 32 Seat heating
33 Tool kit
23
23
Located in the battery compartment.
011123
23

34 Laminated front windscreen

35 Lockable doors
36 Door with air-damper on right and left side
37 Interior lighting with "fade-away"
38 Reading light
39 Camera with monitor

Used to give better visibility to the rear, forward, or both to the
rear, and forward. The camera is located on the counterweight
and/or the front fender. The screen (monitor) is located inside the
cab. If there are cameras for both front and back, it switches
depending on travel direction.
40 Courtesy lighting
Courtesy lighting is controlled with the switch for courtesy lighting
on the steps or when the interior lighting is turned on.

30 3 Overview – 3.2 Plates
3.2 Plates
Product plates, Europe
page
–
The following shows product plates that should be installed on ma-

chines when used in Europe. When ordering spare parts and in case
of enquiries per telephone or correspondence, always state model
designation according to the plates. The plates’ part numbers are giv-
en by each plate. Replace any sign that has been damaged, unclear,
or painted over.
DCF 80-100
008107
1 2
1 Machine plate, A54516.0300

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 lifting height (H)
W = Machine’s operating weight (without load)
Q, D, C, H = Approved load at lifting height (H) at respective dis-
tance (so-called load centre) horizontally and vertically from mast
012891
and attachment (D and C).

Machine plate can only be ordered with complete engraving.

3 Overview – 3.2 Plates 31
2 Additional plate for attachment, A54560.0700

Specifications about the machine’s approved lifting equipment.
NOTE
The plate’s design depends on type of attachment.
012892
S/N= Serial number/Year of manufacture
A = Identification number for attachment
H = Lifting height
D = Centre of gravity distance
Q = Lift capacity
C= Height of centre-of-gravity. Distance from container’s
connection point to load’s centre-of-gravity.
Plate can only be ordered with complete engraving.
3 Additional plate for capacity, A33808.0800
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
012958
The plate’s design depends on type of attachment.

S/N= Serial number
A = Identification number for attachment
H = Lifting height
D = Centre of gravity distance
Q = Maximal load
C= Height of centre-of-gravity. Distance from container’s
connection point to load’s centre-of-gravity.
Plate can only be ordered with complete engraving.

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.
DCF 80-100
1 1
21 11 4 10 7 9 15 16 21
2
3
6
11
012997
17 5,19 12 14 13 8 11 17 17 8 13 14 18 17
20
Chassis, cab
1 Lift point, 423049.0100
Attaching point for lifting device when lifting the machine. Lift
points are found:
• mast
000276
2 Warning! A26939
Warning! Read the operator’s manual for information.
005223

3 Warning! A30536.0400
No passengers allowed. Passengers may only ride in the cab if
005225
it’s equipped with a permanently mounted passenger seat.
4 Warning! A30770.0200
Air conditioning. Located on the inside of left frame member.
Filling of refrigerant requires special competence and authorisa-
tion (follow national legislation and local rules).
000282
5 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
012885
3
inlet (front edge of cab) as plate A30770.0200.
6 Plate for non-ionising radiation, A57336.0100

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

8 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
9 Warning! A32441.0100
Do not stand on the marked area.
001491
10 Warning! A30531.0200
Risk of crushing.
005225
Electrical system
11 Plate battery voltage, A30534.0200
Turn off the battery voltage (with battery disconnector) when
removing/installing mast. Otherwise sparks and short-circuiting
001979
A30534.0200
may occur.
Engine
12 Filling point, fuel, 450202.0100
D
000286
450202.0100
13 Warning! A30530.0200
Rotating fan.
008149
A30530.0200
14 Warning! A30532.0200
Hot surfaces.
000850

15 Filling point, engine oil, A32439.0300
000851
Power transmission, wheels
16 Filling point, transmission oil, 455949.0100
000852
455949.0100
17 Inflation pressure, factory-installed tyres

A32049.0100 1.0 MPa
NOTE
000290
Read section 6 “Inspection and maintenance” for safety when

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

012893
19 Hydraulic pressure, A54518.0600
Indicates set pressures for the machine. Information is engraved.
20 Warning! A30529.0100
Pressure. Always release the pressure from the accumulators
before working on the hydraulic system.
000294

Lifting mast and attachment

21 Warning! A30771.0100
Do not walk under loads or attachments.
DANGER
Forks or other attachments (with or without loads) are
easily operated and highly forceful tools.

property damage!
Make sure that no person stands under a raised

000858 attachment, 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
Overview Spirit Delta

–
1 2 3 4 5
15
12 13 12 11 10 9 8 7 6
008108
14
Overview
1 Left instrument panel
2 Gear selector and multi-function lever
3 Steering wheel panel
4 Steering wheel
5 Direction indicators
6 Panel for hydraulic functions
7 Control breaker for hydraulics
8 Switch for parking brake
9 Control lever
10 Driver’s seat
11 Accelerator
12 Brake pedals
13 Clutch pedal
14 Electronic box with fuses and relays
15 Hour meter
A Joystick or mini steering wheel

Left instrument panel

16 Switch for fan
17 Switch for heat
18 Switch for air distribution
24..28 29 30 31 19 Switch, work lights cab roof

19..23
Extra work lights front fender
18 20 Switch work lights carriage and attachment
012966
17
16 Extra work lights carriage and attachment
Left instrument panel 21 Switch for work lights mast
Extra work lights mast

22 Switch, rotating beacon
23 Switch for flashing hazard lights
24 Switch for headlights
25 Switch for heat in seat
26 Switch for electrically heated rear view mirrors

27 Spare
28 Switch for pause heater

29 Spare
30 Spare
31 Socket 12 VDC

42 4 Instruments and controls
Steering wheel panel

32 Warning lamp for low battery charging
36
35 33 Warning lamp for low brake pressure
34
33 34 Indicator for active error codes
32
35 Warning lamp, by-pass of hydraulic functions
36 Indicator light, activated steering with joystick or mini-wheel

37 Warning lamp, high coolant temperature
37..41 49
38 Warning lamp for low oil pressure engine
42..46 39 Indicator light for preheating
47 48 40 Warning lamp for low coolant level engine
41 Warning lamp for high oil temperature transmission
42 Warning lamp, low fuel level
50 51 52 53 43 Warning lamp, high temperature hydraulic oil
44 Indicator light for high beams
45 Indicator light for travel direction indication
46 Indicator light for parking brake
47 Indicator light, locked twistlock/lock lugs (secured load)
48 Indicator light, alignment (attachment/load)
49 Indicator light, unlocked twistlock/lock lugs (load released)
64
54 50 Panel, warning and indicator lights
63 51 Display, control and monitoring system
55
62 52 Indicator, control and monitoring system
56
008132
61 60 59 58 57 53 Ignition
54 Switch for defroster
Steering wheel panel
55 Switch, windscreen wiper roof, interval
56 Switch, windscreen wiper roof, continuous
57 Switch, interior lighting
58 Switch, windscreen wiper rear, interval
59 Switch, windscreen wiper rear, continuous
60 Function keys, control and monitoring system
61 Travel direction indicator, Forward Neutral Reverse
62 Gearshifting program A, automatic shifting
63 Shifting program 1, locked to first gear
64 Shifting program 2, locked to second gear

Panel for hydraulic functions

65 Lift/lower
65
66 66 Tilt
67
68 67 Side shift
69 68 Levelling
70 69 Opening of twistlock/Opening and locking of lock lugs
(attachment)
71 70 Switch for horn
72
73 71 Switch for twistlocks/lock lugs, automatic/manual locking
74
75 72 Switch for spreading 20’-40’ (attachment)
76 73 Switch for stop spreading at 30’ (attachment)
77 74 Spare
75 Switch for automatic/manual cab tilt

008130
8 78 79 78
76 Switch for manual cab tilt
Panel for hydraulic functions and control levers
electric servo 77 Switch for automatic spreading 20’-40’
78 Switch, by-pass of hydraulic functions
Key for by-pass of hydraulic functions

79 Switch for control breaker
69
75
71
73
78
76
78
77
008174
8 79 70
Panel for hydraulic functions and control lever

44 4 Instruments and controls – 4.1 Warning and indicator lights
4.1 Warning and indicator lights

General
page
–
This section describes the warning and indicator lights in the cab. The
lights indicate status of sub-systems/systems. An activated warning
light should be attended to immediately. An activated indicator light
informs of imminent action.
All lights in the panel are activated briefly at start. Warning and indica-
tor lights are concentrated in a panel on the steering wheel panel
(position 50).
Numbers in brackets refer to the positions in Overview Spirit Delta
page 40.
Warning lamp, low battery charging (32)

–
The light (red) warns in case of missing charge to the batteries. The
light is activated if the voltage from the alternator is lower than the
battery voltage.
000297
NOTE
Do not operate with an activated light for low battery charging.
Warning lamp, low brake pressure (33)

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

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

–
The warning lamp (orange) shows that by-pass of hydraulic functions

is in progress.
000300
NOTE
By-pass can only continue for 60 seconds at a time.

4 Instruments and controls – 4.1 Warning and indicator lights 45
Indicator light, activated joystick or mini steering

–
wheel (36)
The indicator light (green) is active when joystick steering or

mini-wheel steering is activated.
000301
Warning lamp, high coolant temperature (37)
–
The light (red) is activated if the engine’s coolant temperature should

becomes too high. Make sure that the cause is determined and fixed.
For actions, see section 6 "Inspection and maintenance".
000302
Warning lamp for low oil pressure engine (38)
–
If the light (red) is on during operation, the pressure is very low. Stop
immediately and make sure that the cause is determined and fixed as
soon as possible. For action, see section 6 "Inspection and
000303
maintenance".
Indicator light, preheating (39)

–
The light (orange) is on during the engine’s preheating period.

000304
Warning lamp, low coolant level engine (40)

–
If the light (red) is activated while operating, the coolant level is too
low. Check and top up, if needed. For action, see section 6 "Inspection
and maintenance".
000305
Warning lamp for high oil temperature

–
transmission (41)
The light (red) lights if the transmission’s oil temperature is too high.
Stop the machine and let the engine idle. Make sure that the cause is
determined and fixed.
000306
Warning lamp, low fuel level (42)

–
The light (orange) indicates when the fuel level is low. The machine
should be refuelled as soon as possible. For action, see
section 6 "Inspection and maintenance".
000307
Approx. 17% of the fuel remains, which corresponds to approx.

5 hours operating time, when the light is first activated.
Warning lamp, high temperature hydraulic oil

–
(43)
The light (red) is activated if the hydraulic oil temperature is too high.
Stop the machine and let the engine idle. Make sure that the cause is
000308
determined and fixed.

46 4 Instruments and controls – 4.1 Warning and indicator lights
Indicator light, high beams (44)

–
The light (blue) is activated when the high beams are on.
000309
Indicator light for travel direction indication (45)
–
The light (green) flashes when direction indicators or flashing hazard

lights are on.
000310
Indicator light, parking brake (46)
–
The lamp (red) lights up when the parking brake is applied.

000311 If the indicator light flashes, the parking brake has been applied auto-
matically (not by the operator) when the machine has stopped. To re-
lease the parking brake, turn on and turn off the parking brake with the
switch for parking brake (position 8).
Indicator light for locked twistlock (47)

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

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

alignment with the load.
000313
Indicator light for unlocked twistlock (49)

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

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

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

4 Instruments and controls – 4.2 Instruments 47
4.2 Instruments
General
page
–
This section describes the analogue instruments in the cab. They

indicate with gauges or digits levels/status of sub-systems/systems.
page 40.
Hour meter (15)

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

48 4 Instruments and controls – 4.3 Ignition (53)
4.3 Ignition (53)

General
page
–
This section describes the ignition.

page 40.
Ignition’s function
–
P No function.
0 Stop position. Everything switched off, key can be removed.
I Operating position.
Electric power to all electric functions. Control units for
engine and transmission are now ready for start.
II Preheating position (only applies to Volvo engines).
In preheating position, the engine warms the engine’s induc-
tion air with a heating coil to suitable temperature. During
preheating, the light for preheating (position 39) is on.
III Start position.
Engagement of starter motor for starting the engine.
The engine should not be started (key to start position) until
0 the warning and indicator lights are off, see Overview Spirit
Delta page 40. Note that all lights do not necessarily have to
P I
be off.
NOTE
II
The machine has an electric restart interlock that pro-
tects the starter motor from engaging when the engine
is rotating.
003689
III Conditions for starter motor engagement are that the

transmission is in neutral position and that the engine
isn’t already running.

4 Instruments and controls – 4.4 Switches 49
4.4 Switches
General
page
–
This section describes the switches in the cab. Each switch controls a
function. Contrast for background lighting is adjusted with the function
keys "-/4" and "+/5" for the control and monitoring system.
page 40 and on.
Direction indicators (5)

–
Direction indicators (black) for indicating direction of travel.

Move the lever back to neutral position when direction of travel
indication should cease.
LEFT – push the lever upwards.
RIGHT – push the lever downwards.
008177
Switch for parking brake (8)

–
Switch (red) for applying parking brake.

Position 0 – Parking brake off.
Position 1 – Parking brake on.
000331
0 1
Switch for work lights cab roof (19)
–
Switch (orange) for work lights cab roof. Also activates rear lights and
side running lights.
000319
0 1 Work lights are disengaged when idling (work lights are turned off after
5 minutes and extra work lights are turned off after 2 minutes).
Position 0 – Lighting off.
Position 1 – Lighting on.
Switch for work lights carriage and attachment

–
(20)
Switch (orange) for work lights carriage and attachment. Also
activates rear lights and side running lights.
Extra work lights carriage and attachment as options.

000319

50 4 Instruments and controls – 4.4 Switches
Switch for work lights mast (21)

–
Switch (orange) for work lights on the mast. Also activates rear lights
and side running lights.
As option, also extra work lights mast.
000318
Switch for rotating beacon (22)

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

connection with hazards.
Position 0 – Rotating beacon off.
000321
0 1 Position 1 – Rotating beacon on.
Switch for flashing hazard lights (23)

–
Switch (red) for flashing hazard lights used to attract attention in

connection with parking hazard.
Position 0 – Flashing hazard lights off.
000322
0 1 Position 1 – Flashing hazard lights on.
Switch for headlights (24)

–
Switch (green) for headlights. Also activates rear lights and side
running lights.
Position 0 – Headlights off.
000323
0 1 Position 1 – Headlights on.
Switch for heat in seat (25)

–
Switch (orange) for heat in seat.

Position 0 – Seat heat off.
Position 1 – Seat heat on.
000324
0 1
Switch electrically heated rear-view mirrors (26)
–
Switch (green) for electrical heating of rear-view mirrors (position 26).

Position 0 – Heating of rear-view mirrors off.
006057
0 1
Position 1 – Heating of rear-view mirrors on (symbol lit).

Switch, windscreen wiper roof, interval (55)

–
Switch (green) for windscreen wiper on roof window. Interval wiping.

Interval wiper is activated/deactivated with press of a key. Time inter-
000326
val for wiping is controlled by windscreen wiper front windscreen.
NOTE
The interval is controlled by the interval selected for front
windscreen.
Switch, windscreen wiper roof, continuous (56)

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

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

–
Switch (green) for interior lighting in cab.

Lighting is activated/deactivated with press of a key.
000330
Also controls courtesy lighting .
Switch, windscreen wiper rear, interval (58)

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

Interval wiper is activated/deactivated with press of a key. Time inter-
000328
val for wiping is controlled by windscreen wiper front windscreen.
NOTE
The interval is controlled by the interval selected for front
windscreen.
Switch, windscreen wiper rear, continuous (59)

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

wiping.
000329
Wiper is activated/deactivated with press of a key.
Gearshifting program A (62)

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

Active shifting program is indicated with a light-emitting diode.
000413
Shifting program 1 (63)

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

Shifting program 2 (64)

–
Switch (green) for selecting shifting program 2, which means that gear
position is locked to 2nd gear.
000415
Switch for horn (70)

–
Switch (red) for horn. Rocker switch.

The horn is activated with press of a key.
008176
Switch for twistlock, automatic/manual
–
locking (71)
Switch (green) for locking twistlock. The switch has a rocker function
in position 2.
000408
1 0 2 Position 1 – Twistlock is locked automatically when there is alignment

with the load. The parking brake must be OFF, see position 8 and
indicator light for parking light, position 46.
Position 0 – Locking of twistlock not activated.
Position 2 – Twistlock is locked manually. Button with rocker function.
Switch for lock lugs, automatic/manual

–
locking (71)
Switch (green) for locking lock lugs. The switch has a rocker function
in position 2.
012849
1 0 2 Position 1 – Lock lugs are locked automatically when there is align-

ment with the load. The parking brake must be OFF, see
position 8 and indicator light for parking light, position 46.
Position 0 – Locking of lock lugs not activated.
Position 2 – Lock lugs are locked manually. Button with rocker
function.
Switch for spreading 20’-40’ (72)

–
Switch (green) for spreading between 20’-40’. Spreading stops in the

position it is in when the switch is let up. Rocker switch.
This function is used to adapt the attachment to the container’s width.
005002
1 0 2 Position 0 – Spreading not activated.

Position 1 – Spreading out activated. Spreading’s outer end-position
is at 40’.
Position 2 – Spreading in activated. Spreading’s inner end-position is
at 20’.

Switch for spreading stop at 30’ (73)

–
Switch (green) for spreading stop for attachment at 30’ or 35’.
30-35 This function is used to adapt the attachment’s spreading to the

container’s size. The attachment’s stop for extension can be adapted
000410
according to use.
0 1
Spreading to stop ceases after 3 seconds when damping engages.
Position 0 – Spreading stop not activated.
Position 1 – Spreading stop is activated. During hydraulic movement
in progress, automatic stop takes place at 30’ or 35’ (depends on
pre-set stops, most common is 30'). Perform hydraulic movement
again to continue spreading (to stop at next stop).
Switch for automatic/manual cab tilt (75)

–
Switch (yellow) for automatic/manual cab tilt.

This switch is used to select whether the cab should be tilted
automatically or manually.
004464
0 1 Position 0 – Automatic cab tilt. The cab is tilted automatically when the
attachment is at a certain lifting height.
Position 1 – Manual cab tilt. The cab is tilted using the switch for
manual cab tilt position 76.
Switch for manual cab tilt (76)

–
Switch (yellow) for manual cab tilt. Rocker switch.

Position 1 – Cab down. Button ’rocks’ back.
Position 0 – Cab tilt not activated.
004465
1 0 2 Position 2 – Cab up. Button ’rocks’ back.
Switch for automatic spreading 20’ to 40’ (77)

–
Switch (green) for automatic spreading between 20’ to 40’.

This switch is used to activate automatic spreading.
002011
0 1
Position 0 – Automatic spreading stop not activated.
Position 1 – Automatic spreading activated. Spreading is activated
with switch for spreading 20’-40’.

Switch for by-passing (78)

–
Switch (green) for by-passing various functions. Rocker switch, can

only be activated for 60 seconds.
As option, key is available to control the by-pass function.
006183
0 1 Position 0 – By-pass not activated.
Hydraulic panel with electric servo Position 1 – By-pass activated.
• 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.
• Possibility to engage gear without the sensor in the operator’s
seat indicating that someone is sitting in it.
WARNING
Safety features are blocked.
No safety system is engaged!
Only use by-pass in emergency situations!
Switch for control breaker (79)

–
Switch for control breaker cuts off electric power to all load handling
functions. Reset by turning the switch clockwise.
002084

4 Instruments and controls – 4.5 Gear selector and multi-function lever (2) 55
4.5 Gear selector and

multi-function lever (2)
General
page
–
This section describes the functions of the gear and multi-function

lever.
page 40.
Shifting program (mode) and travel direction

–
Shifting program and travel direction are selected with the gear and
F multi-function lever.
Selecting direction of travel:
• F – Forward
• N – Neutral
• R – Reverse (acoustic warning signal ). The back-up light is

activated as long as R is engaged.
Three different shifting programs can be selected with the following
R
switches on the steering wheel panel (position 3):
• 2 – Shifting locked in 2nd gear (position 64)
• 1 – Shifting locked in 1st gear (position 63)
• A – Automatic shifting (position 62)
000337
Windscreen wiper and washer

–
Control of windshield wiper and washing takes place with gear

2 selector and multi-function lever (position 2).
3 1
0 • 0 – No wiping front windshield. Controls slow interval wiping for
roof window and rear window if position 55 and/or 58 is activated.
• 1 – Slow interval wiping front windscreen. Controls slow interval
wiping for roof window and rear window if position 55 and/or 58 is
activated.
000338
• 2 – Fast interval wiping front windscreen. Controls fast interval

activated.
• 3 – Continuous wiping front windscreen. Controls fast interval
activated.
• For washing front windshield, push control towards steering
wheel. If interval wiping (position 55 and 58) or continuous wiping
(position 56 and 59) of roof window and rear window are activated,
they are also washed. Wiping temporarily goes to continuous
wiping when washing windows.

56 4 Instruments and controls – 4.5 Gear selector and multi-function lever (2)
Headlight control and horn

–
Selection of light-beam adjustment and horn are controlled with the

multi-function lever (position 2). Turn the control to the following
positions:
• With headlights on: Gear and multi-function lever is used to switch
between high and low beams. Move the control towards yourself
to switch between high and low beams, and back.
000339
A
• With headlights off: Gear and multi-function lever is used to flash
with the headlights. Move the control toward yourself for high
A. Horn
beam flash, return is automatic.
• Press on the button for horn (position A). Horn in gear and mul-
ti-function lever may be deactivated in software.

4 Instruments and controls – 4.6 Hydraulic control (9) 57
4.6 Hydraulic control (9)

General
page
–
This section describes the functions of the hydraulic control.

The control levers control attachment functions hydraulically. There
are a number of alternatives for hydraulic controls:
• Electric servo with three or four levers
• Control lever
By varying the size of the lever deflection, it is possible to vary speed
of the different hydraulic functions, lift, tilt, etc. It’s also possible to vary
the hydraulic functions’ speed with the engine rpm.
page 40 and on.
NOTE
For hydraulic lateral sliding cab: Doors shall be closed, otherwise
all hydraulic functions are cut off

58 4 Instruments and controls – 4.6 Hydraulic control (9)
Hydraulic controls with electric servo

–
Electric servo makes it possible to use small fingertip-controlled linear

levers for the working hydraulics’ different functions.
a. Lift/lower.
LIFT – pull the lever backwards.
LOWER – push the lever forwards.
Lowering speed can only be varied with lever deflection - engine
speed has no effect.
b. Tilt.
REVERSE – pull the lever backwards.
d FORWARD – push the lever forwards.
c
b
a c. Sideshift.
e LEFT – push the lever forwards.

RIGHT – pull the lever backwards.
d. Levelling
RIGHT side up – pull back lever.
LEFT side up – push lever forward.
e. Switch for control breaker
f. Opening locked twistlock/lock lugs, attachment
WARNING
In the event of an emergency! In the event of
undesired activation/movement of a function.
Extreme hazard to personal health/risk of property

f damage!
IMMEDIATELY TURN OFF all working hydraulics by

pressing down the CONTROL BREAKER for
hydraulics (position e).
008110

Functions, control lever

–
1 2 3
5 6 7 8
008143
Twistlock attachment
1. Side shift
2. Length adjustment 20’-40’
3. Lower
4. Tilt forward
5. Levelling
6. Lock/Open twistlocks
7. Tilt backward
8. Lift
WARNING
Risk of personal injury and/or property damage!

pressing the CONTROL BREAKER for hydraulics.

60 4 Instruments and controls – 4.6 Hydraulic control (9)
Functions, control lever

–
1 2 3 4
6 7 8
008144
Hook attachment with lock lugs
1. Levelling
2. Side shift
3. Lock/Open lock lugs
4. Lower
5. Tilt forward
6. Length adjustment 20’-40’
7. Tilt backward
8. Lift
WARNING
Risk of personal injury and/or property damage!

pressing the CONTROL BREAKER for hydraulics.

Light panel on side lift attachment with

–
twistlocks
On the twistlock attachment, there is a light panel which is of use when
A B C
load handling. The panel indicates with coloured lights if and when
twistlocks are locked/unlocked and when attachment has alignment
with the container.
A Twistlocks locked, green.

B Alignment, orange.
C Twistlocks unlocked, red.
008166
Light panel on side lift attachment with twistlocks

Light panel on hook attachment with lock lugs
–
On the hook attachment, there is a light panel which is of use when

A B C
load handling. The panel indicates with coloured lights if and when
lock lugs are locked/unlocked and when attachment has alignment
with the container.
A Lock lugs locked, green.

B Alignment lower and upper container, orange.
C Lock lugs unlocked, red.
008134
Light panel on hook attachment with lock lugs

62 4 Instruments and controls – 4.7 Pedals
4.7 Pedals
General
page
–
This section describes the machine’s foot-operated functions.

page 40.
003679
12 13 12 11
11. Accelerator
12. Brake pedal
13. Clutch pedal
Accelerator (11)
–
The accelerator pedal (position 11) is electronic and controls the

injection pump.
For the hydraulic function lift, with the machine declutched or gear in
neutral, the system gives automatic throttle increase for higher
hydraulic power.
Brake pedals (12)

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

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

13). Use to declutch the transmission, which makes it possible to use
the hydraulic functions when a gear is engaged.

4 Instruments and controls – 4.8 Steering wheel (4) 63
4.8 Steering wheel (4)

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

are available for steering the machine:
• steering wheel with fixed steering column
• steering wheel with adjustable steering column
• joystick
• mini steering wheel

page 40.
Steering wheel
–
Clockwise rotation of the steering wheel steers the machine to the

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

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

64 4 Instruments and controls – 4.8 Steering wheel (4)
Joystick
–
Joystick steering is an electrohydraulic system, mounted in the left

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

4 Instruments and controls – 4.8 Steering wheel (4) 65
Mini steering wheel

–
Mini steering wheel (mini-wheel) is an electrohydraulic system, mount-

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

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

66 4 Instruments and controls – 4.9 Driver’s seat (10)
4.9 Driver’s seat (10)

General
page
–
This section describes the driver’s seat. The following alternative

seats are available:
• Driver’s seat Bege. The seat is equipped with:
• mechanical adjustment
• seat belt
• air suspension
• head restraint
• armrest left
• seat heat
• Driver’s seat Isringhausen. The seat is equipped with:
• mechanical adjustment
• air suspension (external compressor)
• air-adjusted lower back (lumbar) support
• seat belt
• seat heat
• head restraint
• armrest left
page 40.

4 Instruments and controls – 4.9 Driver’s seat (10) 67
Driver’s seat Bege

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

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

68 4 Instruments and controls – 4.9 Driver’s seat (10)
Driver’s seat Isringhausen

–
The operator’s seat is equipped with adjustment controls for the seat
as follows (adjusting is easier when nobody is sitting in the seat):
1. Distance to pedals.
Release seat using the lever and move the seat fore or aft. To lock
the seat, release the lever.
2. Adjusting seat cushion.
Lift control and adjust the seat fore or aft.
3. Lowering seat height.
Lift the control to lower the seat. The seat remains in the lowest
position.
Press down control to raise seat to previous position.
11 4. Seat cushion angle

12 Lift control and adjust the angle by loading/unloading the front part
of the seat cushion.
5. Raising seat height.
Lift control to raise the seat, infinitely variable.
10
Press down control to lower the seat, infinitely variable.
When desired height is obtained, release the control.
6. Back rest angle.
567 Lift control and adjust the angle by loading/unloading the back
234
003471
9 8
rest.
7. Adjusting damping.
Lift control for maximal damping.
Press down control for minimal damping.
8. Seat heating.
Thermostat-controlled heat for seat and backrest.
Press down button to activate/deactivate. Control light is on in
case of activated seat heating.
9. Plane damping
Slide the control to the right and left, respectively, to
activate/deactivate level damping.
10. Lumbar support. Integrated pneumatic system.
Press the button to fill or empty the air chambers for optimal body
fit of the back support.
11. The armrest’s angle is variable with the knurled button.
12. Armrest left .

4 Instruments and controls – 4.10 Heating / Air conditioning 69
4.10 Heating / Air conditioning

General
page
–
This section describes the function of:

A
• Air conditioning system, ECH. Automatic with
thermostat-controlled control of heat and fresh air.
• Air conditioning system, ECC. Automatic with thermo-

stat-controlled control of cooling and heating as well as air drying.
The heating system / air conditioning gets heat from the engine’s
cooling system and gives heat when the engine is warm. Cooling
performance is generated by the AC compressor (for ECC).
The system is controlled by fan, heat and air distribution as well as
function for recirculation and defroster:
• Fan speed is adjusted with switch for fan (position 16).
• Heat (and cooling performance for ECC) is controlled with switch
18 for heat (position 17).
17 • Air distribution to the cab is adjusted with switch for air distribution
(position 18). The fresh air inlet is provided with a filter and can be
008133
16
equipped with a fine-filter against pollen (fan’s capacity is
A. Panel nozzle
reduced).
16. Switch for fan
17. Switch for heat • Recirculation of cab air is activated/deactivated by pressing on the
18. Switch for air distribution function key for Enter by the operating menu for air conditioning.
• Defroster for fast demisting of windows is activated/deactivated
with the switch for defroster (position 54).
NOTE
Operator’s door and windows shall be closed for satisfactory
function of the system.
For ECC: In case of open door, the air conditioning’s compressor
is turned off (cooling function and air drying stops). Close the
door and the AC compressor is reactivated.
page 40.
001839
Fresh air inlet for cab

70 4 Instruments and controls – 4.10 Heating / Air conditioning
Operating menu for heating / air conditioning

–
system
The operating menu is shown automatically in the display when switch
for fan, heat or air distribution is activated. This can be selected for
constant display with function keys for arrow right and arrow left.
For detailed description, see Description page 76.
004916
Switch for fan (16)
–
Switch (green) for fan handles setting of fan speed for the cab.
Setting of fan speed:
• Automatic control, AUTO.
004686
1 0 2 • Manual control in 13 steps from off to max. Fan speed is shown
by the bar’s height in the operating menu for heat/air conditioning
system.
Position 1 – Increases fan speed.
Position 0 – Fan speed unchanged.
Position 2 – Reduces fan speed. Activates automatic control, AUTO,
from off.
Operating menu for air conditioning is shown automatically in the
display when switch is used, see Description page 76. Display stops
after 3 seconds if switch is not used again.
Switch for heat (17)

–
Switch (green) for heat handles setting of reference value for cab
temperature. Setting takes place in steps of 0.5 °C.
The temperature range is 16 °C to 27 °C. Setting of min. and max.
004687
respectively, shuts off automatic climate control (control of fan, heat

1 0 2
and air distribution) and sets the heat valve in min. and max. position,
respectively.
Position 1 – Higher temperature setting. When needed, the cab’s air is
cooled to set temperature (for ECC).
Position 0 – Temperature setting unchanged.
Position 2 – Lower temperature setting. When needed, the cab’s air is
cooled to set temperature (for ECC).
Operating menu for air conditioning is shown automatically in the
display when switch is used, see Description page 76. Display stops
after 3 seconds if switch is not used again.

4 Instruments and controls – 4.10 Heating / Air conditioning 71
Switch, height limitation (18)

–
Switch (green) for air distribution handles distribution of fresh air to the
cab. The air is distributed to the lower parts of the cab (legs), cab
space (panel) and upper cab space (windshield).
004688
Position 1 – Controls air distribution to upper cab space (windshield).
1 0 2
Position 0 – Setting air distribution unchanged.
Position 2 – Controls air distribution to lower cab space (leg).
Recirculation is activated/deactivated by pressing on the function key
for Enter when the operating menu for air conditioning is shown.
Operating menu for air conditioning is shown automatically in the dis-
play when switch is used, see Description page 76. Display stops after
3 seconds if switch is not used again.
Switch for defroster (54)

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

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

–
Switch (green) for pause heater. The cab fan gives heat from the
engine’s cooling system during short-term parking of the machine.
Position 0 – Pause heater not activated.
004922
0 1 Position 1 – Pause heater is pre-activated with press of a button. User

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

72 4 Instruments and controls – 4.11 Control system
4.11 Control system

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

50 51 52
The machine is equipped with an electronic system for control and
monitoring of the machine’s different functions.
The system gives the operator information in the form of:
• Error code information
Three levels of error code information can be shown. In case of a
new error code, the indicator for the control and monitoring sys-
tem (position 52) is activated, as well as the indicator for active
error codes on the panel for warning and indicator lights
(position 50). See section 5.3 Error codes.
• Operating information
Operating information includes, e.g., machine speed, engine rpm,
fuel level, etc.
006493
• Event-controlled information
60
Event-controlled information is, e.g., overload.
50. Panel for warning and indicator lights
51. Display for control and monitoring system The information is presented on the steering wheel panel’s display
52. Indicator for control and monitoring system (position 51). The function keys (position 60) are used to navigate in
60. Function keys for control and monitoring system the display menus during, for example, service and troubleshooting.
page 40.
4.11.1 Operating menus

General
page
–
After start of the machine, Operating menu engine and transmission is

shown in the display. Menus are chosen with the function keys for ar-
1 2
row right and arrow left. For every press of a key, the display switches
to the next menu.
This section describes the information that can be obtained from the
different operating menus.
008165
Example of available operating menus

4 Instruments and controls – 4.11.1.1 Operating menu for engine and transmission 73
4.11.1.1 Operating menu for engine and

transmission
Description
page
–
a. Shows current engine speed (rpm).
a c b. Shows current speed in km/h (in display kilometre per hour, kph).
b c. Shows current gear.

d Travel direction and shifting program are shown on steering wheel
003472
e panel (positions 61-64).
d. Shows current fuel level.
e. Shows current time.
Setting clock
–
1. Go to setting mode by holding in Enter for 3 seconds. Date,

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

4. Press Enter by minutes to set seconds to 0.
5. Leave setting mode by pressing Reset.
4.11.1.2 Operating menu for engine

Description
page
–
Applies to Volvo TAD760VE, Cummins QSB6.7.

a. Shows coolant temperature in °C.
a
b. Shows engine oil pressure in bar.
b
000355
4.11.1.3 Operating menu for oil temperature

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

b. Shows temperature of hydraulic oil in °C.
a
000356

74 4 Instruments and controls – 4.11.1.4 Operating menu electrical system
4.11.1.4 Operating menu electrical system

Description
page
–
Shows the current system voltage in volt.
000354
Example from operating menu for electrical system
4.11.1.5 Operating menu for container counter

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

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

b
amount of machine lifts during a selected time period.
Example from information menu for load handling
Reset counter with function key for Enter, select "Reset C2" and
press function key for Enter to reset counter to zero.
The display indicates which counter has been selected. Press function
key for Reset (R) to return to normal display.
4.11.1.6 Operating menu for service interval

Description
page
–
• Shows total operating time in hours.

• Shows number of hours to next service.
003696

4 Instruments and controls – 4.11.1.7 Operating menu statistics 75
4.11.1.7 Operating menu statistics

Description
page
–
• Start display for statistics menu.
003575
Display of statistics
–
Go to display mode by pressing enter, go back with reset. Scroll

between menus with <- / ->.
• Operating hours engine.
• Operating hours engine, machine parked and idling.
• Operating hours engine with gear activated.
• Operating hours hydraulic functions activated.
003697
• Accumulated fuel consumption.

• Fuel consumption, can be reset.
• Instantaneous fuel consumption, l/h.
Press function key for Enter to reset measuring.
006759
• Accumulated driving distance.

• Trip meter, can be reset.
Press function key for Enter to reset measuring.
003699
• Number of containers.
008167
4.11.1.8 Operating menu for service

Description
page
–
Used by service technicians and for showing error codes. For showing
error codes, see section 5.3 Handling error codes.
000056

76 4 Instruments and controls – 4.11.1.9 Operating menu for heating system/air conditioning system
4.11.1.9 Operating menu for heating system/air

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

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

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

important information. The warning/information is shown on the
control and monitoring system’s display when needed.
Start interlock
–
The menu is lit at start attempt.

1. To start, enter your 5-digit code.
003574
Alignment sidelift attachment, twistlocks

–
The figure is shown when a corner of the attachment has alignment

against the load. The lift corner with alignment is filled in.
When both corners have alignment, the display disappears and the
load can be locked. Display can be removed with function key for
Reset (R).
008135
In case the figure is shown:

• Operate attachment until full alignment is obtained.
Load cannot be secured (lock twistlocks) before full alignment.
When both corners have alignment, the load can be locked.

4 Instruments and controls – 4.11.2 Event-controlled information for sidelift attachment 77
Locked/unlocked twistlocks
–
The figure is shown when the sensors for twistlocks can’t detect if
twistlocks are in locked or unlocked position. Figure is shown during
lift.
When all sensors have contact, the display disappears. That is, when
twistlock is in open or locked position.
000571
• Open and lock twistlocks (use by-pass if needed).
Alignment sidelift attachment, hooks with lock lugs

–
The figure is shown when one of the sensors receives a signal.

a
When all corners are aligned, two for lifting a container and four for
double lifting, the load can be locked. When locking is correctly imple-
mented the display figure in the display disappears. Display figure can
c be removed with function key for Reset (R).
b a. Filled symbol indicates two containers at the height in front of the

attachment.
008170
b. Filled in symbol shows alignment against right and left side of the
container (bottom container when lifting two containers).
c. Filled in symbol shows alignment against right and left side of the
upper container (when lifting two containers).
• Operate attachment until full alignment is obtained.
Open door
–
The figure is shown when door(s) is open at cab tilt and during
automatic spreading 20’-40’. When doors are closed, the display
disappears.
000576
• Close door(s).
The cab cannot be tilted and automatic spreading 20’-40’ cannot
be used unless the doors are closed.
Automatic spreading 20’-40’

–
The figure is shown when spreading takes place with automatic

spreading 20’-40’ activated.
007083

78 4 Instruments and controls – 4.11.2 Event-controlled information for sidelift attachment
Height limitation
–
The figure is shown when set maximum lifting height has been
reached. Lower the mast. The function can be by-passed, see section
5.5.4 Functions for load handling. Display figure can be removed with
function key for Reset (R).
008175
Height warning
–
The figure is shown when the maximum set lifting height has been
reached. Display figure can be removed with function key for
Reset (R).
008175

5 Handling 79
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
machine 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
relieve the operator of the responsibility of following laws or other
national regulations for road safety and work safety.
Awareness, alertness, good judgement and respect for governing
safety regulations are prerequisites for avoiding accident risks.
Environmental impact
–
It is important that the machine is used in a way that results in minimal

environmental impact with regards to fuel consumption, exhausts, and
noise emissions. Therefore, keep the following in mind:
• Plan the work and optimise machine use.
• Avoid operating with full throttle when transporting.
• Do not rev the engine unnecessarily when load handling.
• Optimise operation with regard to acceleration and braking.
• Minimise the time that the machine idles. Do not allow the
machine to idle when there is a break in the work.

80 5 Handling
Emergency equipment
–
The following emergency equipment is available on the machine:

• Emergency exit, right door.
In an emergency:
Open the emergency exit, right door, with the handle on the inside.
• Breaker switch for load handling (servo circuits)

In an emergency:
1. Press down the control breaker immediately.
002084
All load handling function stops.
2. Restore control breaker (turn clockwise).
• Fire extinguisher
Located on the left front fender.

5 Handling – 5.1 Running-in 81
5.1 Running-in
General
page
–
The machine should be operated with great care during the run-in
period. The purpose is to give bearing surfaces hard and polished
surfaces, which considerably extends the service life.
Recommended run-in period is 10 hours of operating time. This gives
fewer malfunctions.
Engine
–
A new engine shall always be handled with great care – it must have
a run-in period. Avoid running the engine at full load during the first
10 hours. Then, loading of the engine can be increased gradually.
NOTE
Check the oil pressure and temperature at regular intervals.
Oil and filter shall be changed the first time at the first service interval,
after 50 operating hours.
Transmission
–
The filter is to be replaced for the first time at the 50-hour check. Oil is
changed after 1000 hours.
Tyres and rims

–
For a new machine it is extremely important that the wheel nuts are
check-tightened during the first work until they have ’set.’ This shall be
done at intervals of 4-5 operating hours (up to approx. 40-50 operating
hours). Then the wheel nuts are check-tightened according to intervals

82 5 Handling – 5.2 Daily inspection
5.2 Daily inspection

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

ensure that it is safe both for the operator and its surroundings.
Every operator should perform checks before a new work shift. In this
way, operators can avoid running defective machines with malfunc-
tions that have been generated or caused during an earlier work shift.
WARNING
Never operate a defective machine.

property damage!
Report immediately to the foreman/supervisor if

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

5 Handling – 5.3 Error codes 83
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
error code and to perform an action to correct the problem.
Error codes are shown automatically on the display and end up in an
error code list under the operating menu for service.
The error code for level stop, or warning, is shown automatically in the
display and is indicated by a flashing red light from the indicator. Error
code for level information is not shown in the display but is indicated
with an adjustable spanner in the display together with an illuminated
indicator for active error codes (position 34). All error code levels are
included in an error code list under the operating menu for service, see
Error code display page 85.
Action in the event of error code

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

such character that work does not have to be
stopped. The machine’s capacity may be limited and
certain functions may not work. Perform actions
according –to error code table as soon as possible.
1 Stop the machine and identify error code level, see section
5.3.1 Error code indication.
In case of stop – Note the error code, turn off the engine and
proceed to step 4.
In case of warning or information – Leave the engine running.
NOTE
If several error codes come from the engine, the error code level
is shown for the most serious error code.
2 Navigate to the operating menu for service using the function
keys arrow left or arrow right. Hold down the function key Enter
for at least two seconds. The error code list is shown.
000056
Operating menu for service

84 5 Handling – 5.3.1 Error code indication
3 Note all error codes. For explanation, see Display figure for error
code information page 85.
Error code number together with X(Y). X shows sequence
number for displayed error code and (Y) shows total number of
active error codes. Scroll between the error codes with the func-
001998
tion keys arrow right and arrow left. The error code information
disappears when the cause of the error code has been corrected.
Example figure, error code list
Leave the error code list by pressing the function key Reset (R).
4 Read the information for the error code/error codes in the error
code table and perform the recommended actions.
• Error codes machine page 89
• Error codes engine page 96
• Error codes transmission page 109
5 Start the engine and check that the error code has disappeared
from the error code list according to step 2.
5.3.1 Error code indication

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

51 52
codes (position 34). The error codes are divided into three error code
levels depending on their severity.
The error code levels are shown as follows:
• Stop is indicated with a STOP sign on the display together with
B flashing red light from the indicator for the control and monitoring
system (position 52) as well as activated indicator for active error
codes (position 34).
Error code with level Stop is shown automatically on the display.
34 • Warning is indicated with a warning triangle on the display togeth-
er with flashing red light from the indicator for the control and mon-
itoring system (position 52) as well as activated indicator light for
active error codes (position 34).
Error code with level Warning is shown automatically on display.
• Information is indicated with an adjustable wrench in the display
together with lit Indicator for active error codes (position 34).
005075
Error code with level information is shown error code list under
B. Symbol error code level operating menu for service.
34 Indicator for active error codes
51 Display for control and monitoring system
52 Indicator for control and monitoring system

5 Handling – 5.3.2 Error code information on display 85
5.3.2 Error code information on display

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

• Automatically in display.
The error code is confirmed with function key Reset (R). When the
error code is confirmed, the display returns to the previous select-
ed menu. If the error code is active, it’s stored in the error code list
under operating menu for service.
003817
If the error code is active and of the level stop or warning, the
Example figure, automatic display figure display returns within 3-5 minutes.
• In the error code list under operating menu for service.

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

Example figure, display in error code list
NOTE
If error code isn’t included in the error code list, 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
C Indicates a serious malfunction that may affect operator safety or
cause machine breakdown. The error code shall be taken care of
D E
immediately. Stop working with the machine and contact service
immediately.
000350
The error code is shown automatically on the display.

86 5 Handling – 5.3.2 Error code information on display
• Warning
C Indicates machine malfunction that should be taken care of as
soon as possible. After finished work shift with the machine,
D E
contact service as soon as possible.
The error code is shown automatically on the display.
000351
• Information
C Information for the operator that something should be taken care
of, for example, a defective bulb. Take care of the cause of the
D E error code as soon as possible. See chapter 6 Inspection and
maintenance.
000352
The error code is stored in the error code list under operating
menu for service.
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 on display, see Error codes
D E machine page 89.
B
000389
• Engine:
XX/YY Shown with error code number XXX/YY on display, see Error
codes engine page 96.
D
B NOTE
001343
If several error codes come from the engine, the error code level
is shown for the most serious error code.
• Transmission:
XXX/YY Shown with error code number XX/YY on display, see Error codes
transmission page 109.
D
B
001344

5 Handling – 5.3.2 Error code information on display 87
Field D: Type of error

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

6. Incorrect signal from battery.
7. Incorrect signal from spool.
8. Level too high/too low.
7 8 9 9. Incorrect signal to bulb.
10. Incorrect signal, for example, open circuit.
11. Incorrect signal to engine.
10 11
002058

88 5 Handling – 5.3.2 Error code information on display
Field E: Affected function

1. Attachment
1 2 3
2. Side shift, attachment
3. Levelling attachment
4. Length adjustment attachment
4 5 6
5. Twistlocks/lock lugs
6. Attachment up/down
7. Tilt mast
7 8 9 8. Overload protection
9. Hydraulic functions
10. Brake system
10 11 12 11. Steering
12. Engine
13. Transmission
14. Central lubrication
13 14 15
15. Control unit
16. Hardware-related error
17. Cab
16 17 18
18. Air conditioning
19. Fuel system
20. Headlights
19 20 21 21. Windscreen wipers
22. Battery voltage
23. Bulb for lighting
22 23
008164

5 Handling – 5.3.3 Error code tables 89
5.3.3 Error code tables

General
page
–
Error codes are sorted in numerical order. The tables contain the
following information:
• Error code (Code).
• Description of error code (Description).
• What limitation may result in the machine for relevant error code
(Limitation).
• Operator’s action in case of an error code (Action).
If the error code number isn’t included in the error code table, contact
service.
Error codes machine

–
Table 1. Error codes from machine
Code Description Action

1 No contact with control unit frame D797-1. STOP
2 No contact with control unit frame option D797-2. STOP
3 No contact with control unit attachment D791-1. STOP
8 No contact with KID D795. Controls in steering wheel panel and STOP
display not working.
11 Defective CAN segment 1. WARNING
20 Accelerator pedal for driving forward needs to be calibrated. Engine INFORMATION

rpm limited to idle.
21 No contact with control unit transmission D793. Gear selection not STOP
working.
22 No contact with control unit engine D794. Engine does not respond STOP
to commands from cab.
23 Machine is not configured. No controls in cab are working. STOP
24 Incorrect voltage feed to cab fan. Cab fan not working. INFORMATION: Check fuse F58-5:C3.
See 6.2.14 Fuses for electrical system.

90 5 Handling – 5.3.3 Error code tables

25 Communication error with control unit engine D794 at active error INFORMATION: Turn ignition off and on.
code.
26
Error code is stored in control unit engine.
27
28
29
30
31 Voltage feed incorrect to control unit cab D790-1. Controls in cab not STOP: Check fuse F58-5:A1. See
working. 6.2.14 Fuses for electrical system.
32 Analogue controls cab. Analogue controls in cab do not work (accel- STOP
erator pedal, mini-wheel/joystick, control levers electric servo/control
lever and controls for air conditioning system).
33 No feed of control breaker voltage to control unit cab D790-1. Control WARNING: Check fuse F58-3:H8. See
breaker cannot be disengaged. All hydraulic functions are blocked. 6.2.14 Fuses for electrical system.
34 Switch parking brake. Parking brake cannot be released. WARNING: Use by-pass to release the
parking brake.
35 Communication error with control unit transmission D793 at active INFORMATION: Turn ignition off and on.
error code.
36
Error code is stored in control unit transmission.
37
38
39
40
41 Wiper rear not working. INFORMATION
42 Rotating beacon not working. INFORMATION: Check the light. See

6.2.15 Lighting.
43 Back-up light cab left not working.
44 Back-up light cab right not working.
45 Wiper front not working. INFORMATION
46 Cab fan not working. INFORMATION
47 Recirculation damper for ventilation not working. INFORMATION
48 Water valve. Heat adjustment in cab not working. INFORMATION
49 Water valve. Heat adjustment in cab not working. INFORMATION
50 Air distribution in cab cannot be adjusted. INFORMATION
53 Windscreen washer rear and roof not working. INFORMATION
54 Bulb in switch flashing hazard lights not working. INFORMATION
55 Reduced or no background lighting in instruments and controls. INFORMATION: Check lights for
background lighting. See 6.2.15 Lighting.


56 Work light 20’ not working. INFORMATION: Check the light. See
6.2.15 Lighting.
57 LED-control lever for levelling lock. Indication levelling lock in joystick
not working.
60 Seat heating not working. INFORMATION
61 Work light 40’ not working. INFORMATION: Check the light. See
6.2.15 Lighting.
63 No ignition voltage to the machine’s control units. STOP
64 No control breaker voltage to the machine’s control units. STOP
65 No control breaker voltage to the machine’s control units. STOP
66 Washer front not working. INFORMATION
67 Wiper roof not working. INFORMATION
68 Pause heater not working. INFORMATION
69 No voltage feed to engine and transmission. STOP
71 Interior lighting in cab not working. INFORMATION: Check the light. See
6.2.15 Lighting.
75 Relay for ignition has jammed in position on. Control unit cab is still STOP
supplied with voltage and thus active.
80 Incorrect pressure in air conditioning. Air conditioning not working. INFORMATION
82 Fan speed cannot be adjusted. INFORMATION
83 Temperature is controlled to 22 C. INFORMATION
84 Air distribution cannot be adjusted. INFORMATION
85 Accelerator pedal for driving forward not working. Engine rpm limited STOP
to idle.
87 Control lever for lift and lower. Lift and lower not working. WARNING
88 Control lever for tilt. Tilt not working. WARNING
89 Control lever for sideshift. Sideshift not working. WARNING
90 Control lever for extension left. Extension left not working. WARNING
91 Control lever for levelling. Levelling not working. WARNING
92 Joystick or mini-wheel. Joystick or mini-wheel not working. WARNING
93 Mini-wheel. Mini-wheel not working. WARNING
94 Water valve cab heat. Cab heat cannot be adjusted. INFORMATION
95 Control lever for extension right. Extension right not working. WARNING
96 Sensor cab temperature. Temperature control cab not working. INFORMATION
97 Sensor outdoor temperature. Temperature control cab not working. INFORMATION


98 Sensor temperature outlet fan. Temperature control cab not working. INFORMATION
99 Sensor temperature refrigerant. Temperature control cab not INFORMATION

working.
101 Redundant voltage feed left control unit frame D797-1. STOP: Turn ignition off and on.
102 Redundant voltage feed right control unit frame D797-1. STOP: Turn ignition off and on.
103 Voltage feed control unit frame D797-1. No power supply to STOP: Check fuse F58-2:A1. See
components from control unit frame front. 6.2.14 Fuses for electrical system.
104 Control breaker voltage to control unit frame D797-1. Control breaker WARNING: Check fuse 58-2:A1. See
cannot be disengaged. All hydraulic functions blocked. 6.2.14 Fuses for electrical system.
105 Voltage feed sensor. Pressure sensor lift cylinder. STOP
106 Cooling fan hydraulic oil not working. WARNING
107 Work light mast not working. INFORMATION: Check the light. See
6.2.15 Lighting.
108 High beams not working.
109 Low beams not working.
111 Running lights not working.
112 Cooling fan oil brake system not working. WARNING
113 Control valve load handling. Lift and lower not working. WARNING
114 Control valve load handling. Tilt not working. WARNING
115 Direction indicator left not working. INFORMATION: Check the light. See
6.2.15 Lighting.
116 Direction indicator right not working.
117 Starter motor not working. WARNING
118 Tail lights not working. INFORMATION: Check the light. See
6.2.15 Lighting.
119 Brake light left not working.
120 Brake light right not working.
121 Back-up alarm not working. INFORMATION
122 Magnetic clutch AC compressor. Air conditioning not working. INFORMATION
123 Magnetic clutch AC compressor. Air conditioning not working. INFORMATION
124 Disengagement hydraulic oil pump working hydraulics not working. WARNING
125 Regenerating lift right not working. WARNING
126 Regenerating lift left not working. WARNING
132 The machine’s data file is missing. Certain machine functions do not STOP
work.
133 Sensor hydraulic pressure lift cylinder. Scale, regenerating and STOP
slacken chain logics not working. Overload system not working. Error
code 150 is activated.


134 Sensor hydraulic pressure tilt cylinder. Overload system not working. STOP
Error code 150 is activated.
135 Feedback from cooling fan oil brake system. WARNING
137 Control valve load handling. Lift not working. WARNING
138 Control valve load handling. Lower not working. WARNING
139 Control valve load handling. Tilt in not working. WARNING
140 Control valve load handling. Tilt out not working. WARNING
141 Solenoid valve parking brake. Parking brake cannot be released. STOP
142 Disengagement of hydraulic oil pump for attachment not working. WARNING
143 Spreading and twistlocks on top lift attachment not working. WARNING
144 Spreading and twistlocks on top lift attachment not working. WARNING
145 High oil temperature in brake system. Reduced braking capacity. If WARNING: Check that cooling fan works.
temperature continues to increase, speed limitation will take place. Check that radiator is not clogged. Check
oil level in brake system. See 6.2.8 Oil
brake system.
146 Sensor oil temperature in brake system. Incorrect temperature WARNING

display. Immediate speed limitation.
147 High hydraulic oil temperature. WARNING: Check that cooling fan works.
Check that cooler is not clogged. Check
hydraulic oil level. See 6.2.9 Hydraulic
system.
148 Sensor hydraulic oil temperature. Incorrect temperature display. WARNING
149 Sensor fuel level. Incorrect display of fuel volume (empty or full). INFORMATION: Check fuel volume
manually in tank. See 6.2.2 Fuel system.
150 Overload protection not working. STOP: Turn ignition off and on.
151 Voltage feed to control unit frame option D797-2. STOP: Turn ignition off and on.
152 Voltage feed to control unit frame option D797-2. STOP: Turn ignition off and on.
153 Voltage feed control unit frame option D797-2. No power supply to STOP: Check fuse F58-2:C3. See
components from control unit frame option. 6.2.14 Fuses for electrical system.
154 Control breaker voltage to control unit frame option D797-2. Control WARNING: Check fuse F58-3:E5. See
breaker cannot be disengaged. All hydraulic functions blocked. 6.2.14 Fuses for electrical system.
155 Voltage feed sensor. STOP
160 Extra work light frame front not working. INFORMATION: Check the light. See
6.2.15 Lighting.
161 Solenoid valve steering right. Joystick or mini-wheel not working. STOP
162 Solenoid valve steering left. Joystick or mini-wheel not working. STOP
163 Lift trolley not working. WARNING
164 Lower trolley not working. WARNING


165 Control valve load handling. Sideshift right not working. WARNING
166 Control valve load handling. Sideshift left not working. WARNING
167 Control valve load handling. Spreading in not working. WARNING
168 Control valve load handling. Spreading out not working. WARNING
169 Cab tilt. Indication position of cab not working. WARNING
173 Cab tilt. Cab tilt up not working. WARNING
174 Cab tilt. Cab tilt down not working. WARNING
187 Control valve joystick/mini-wheel. Joystick or mini-wheel not STOP

working.
188 Control valve load handling. Lift and lower not working. WARNING
189 Control valve load handling. Sideshift not working. WARNING
190 Control valve load handling. Spreading not working. WARNING
251 Voltage feed control unit attachment D791-1. STOP
254 Voltage feed to control unit attachment D791-1. Control breaker WARNING
cannot be disengaged. All hydraulic functions blocked.
255 Voltage feed sensor. STOP
256 Central lubrication attachment not working. INFORMATION
257 Work light attachment left not working. INFORMATION: Check the light. See
6.2.15 Lighting.
258 Work light attachment right not working.
259 Warning signal automatic spreading not working. WARNING
261 Control valve attachment (spreading). Spreading left in attachment WARNING

not working.
262 Control valve attachment (spreading). Spreading left out attachment WARNING
not working.
263 Control valve attachment (spreading). Spreading right in attachment WARNING

not working.
264 Control valve attachment (spreading). Spreading right out WARNING

attachment not working.
265 Control valve attachment (spreading). Levelling left attachment not WARNING
working.
266 Control valve attachment (spreading). Levelling right attachment not WARNING
working.
267 Control valve attachment (sideshift). Sideshift left attachment not WARNING
working.


268 Control valve attachment (sideshift). Sideshift right attachment not WARNING
working.
269 Control valve attachment (twistlock/lock lug). Locking of twist- WARNING

lock/lock lug not working.
270 Control valve attachment (twistlocks/lock lug). Unlocking of twist- WARNING

lock/lock lug not working.
271 Control valve attachment. Sensor on attachment not working. WARNING
272 Indicator light open twistlock/lock lug not working. WARNING
273 Indicator light locked twistlock/lock lug not working. WARNING
274 Indicator light alignment attachment not working. WARNING
287 Control valve attachment (spreading). Spreading left attachment not WARNING
working.
288 Control valve attachment (spreading). Spreading right attachment WARNING

not working.
289 Control valve attachment (sideshift). Sideshift attachment not WARNING

working.
290 Control valve attachment (spreading). Levelling attachment not WARNING

working.
291 Indicator light alignment attachment upper not working. WARNING
298 Twistlock left in middle position. Lift and spreading not working. WARNING: Check that left twistlock
sensors are clean and free from grease.
299 Twistlock right in middle position. Lift and spreading not working. WARNING: Check that right twistlock
sensors are clean and free from grease.
300 Sensor alignment indicates unreasonable resistance. Twistlocks not WARNING: Check that the alignment sen-
working. sors are clean and free from grease. Check
that the alignment pins are not stuck in
alignment position.
451 Voltage feed control unit KID D795. WARNING: Turn ignition off and on.
452 Voltage feed control unit KID D795. WARNING: Turn ignition off and on.
460 Communication error with control unit KID D795. Incorrect values in STOP
operating menus.
461 Communication error with control unit KID D795. Error codes from STOP
other control units cannot be shown.
500 Time for service. Bring in the machine for service.

Error codes engine

–
For contact with engine 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 2. 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 Abnormal frequency.

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

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

Table 3. Error codes Volvo TAD760VE
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 STOP
more 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. STOP
Preheating activated even when engine is warm. Engine
difficult to start.
110/5 PID110/5 Sensor coolant temperature, cable open circuit. Preheating STOP
activated 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.
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

Description Action
Display J1587
SPN/FMI
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 STOP
constantly activated, fuse for preheating coil will blow.
626/5 PID45/5 Preheating relay, cable open circuit. Preheating cannot be STOP
activated. 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 long- STOP
er to start than normal. Engine runs normally once it has started.
637/2 SID22/2 Sensor rpm flywheel. Irregular signal. Engine is extremely STOP
difficult to start and runs rough or stops.
637/3 SID22/3 Sensor rpm flywheel. Abnormal frequency. Engine is extremely STOP
637/8 SID22/8 Sensor rpm flywheel. Abnormal frequency. Engine is extremely STOP
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.

Description Action
Display J1587
SPN/FMI
639/9 PSID201/9 Communication error control unit engine. STOP
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. STOP
Rough 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.
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. STOP
1675/4 Starter motor does not run.
677/5 SID39/5 Starter motor relay, open circuit on cable or defective STOP
1675/5 component. Starter motor does not run.
679/3 SID42/3 Governor injection pressure, cable short-circuited to voltage. STOP

Risk of engine stop.

Description Action
Display J1587
SPN/FMI
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.
729/3 SID70/3 Sensor preheating, cable short-circuited to voltage. STOP
729/4 SID70/4 Sensor preheating, cable short-circuited to ground. Engine STOP
difficult 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 211/3 Voltage feed sensor engine, cable short-circuited to voltage. STOP
1080/4 PPID 211/4 Voltage feed sensor engine, cable short-circuited to frame. STOP
1239/0 PSID96/0 Incorrect fuel pressure injection. Engine rpm limited to STOP
1100 rpm.
1100 rpm.
1239/4 PSID96/4 Incorrect fuel pressure injection. Engine is turned off or engine STOP
rpm limited to 1100 rpm.
1100 rpm.
1100 rpm.
2047/xx Undetectable error code from engine. Error codes over 2047 STOP
cannot be shown on display.
Possible error codes: 2791, 520195.
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

Description Action
Display J1587
SPN/FMI
- PPID 435/0 Incorrect fuel pressure injection. Engine rpm limited to STOP
1100 rpm.
- PPID 435/1 Incorrect fuel pressure injection. Engine rpm limited to STOP
1100 rpm.
Table 4. 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!
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

Description Action
Display
SPN/FMI
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 WARNING!
100/4 Pressure sensor engine oil, defective circuit - Abnormally low voltage or WARNING!
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 WARNING!
lower 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 STOP! Very serious
operating range.
105/15 Temperature inlet manifold high - Data valid, but higher than normal operating WARNING!
range.
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 pressured - 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!

Description Action
Display
SPN/FMI
110/3 Sensor coolant engine, defective circuit - Abnormally high voltage or WARNING!
110/4 Sensor coolant engine, defective circuit - Abnormally low voltage or 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 low - 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 WARNING!
voltage or short-circuiting to higher voltage.
157/4 Measurement injection pressure bank 1, defective circuit - Abnormally low WARNING!
voltage or short-circuiting to lower voltage.
167/1 Alternator low voltage - Data valid, but lower than normal operating range. STOP! Very serious
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 WARNING!
171/4 Ambient temperature sensor, defective circuit - Abnormally low voltage or WARNING!
190/0 Engine overspeeding - Data valid, but higher than normal operating range. STOP! Very serious
190/2 Main rpm sensor defective - 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.

Description Action
Display
SPN/FMI
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 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!
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 defect - 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 WARNING!
641/4 Variable Turbo Geometry valve circuit - Abnormally low voltage or 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.

Description Action
Display
SPN/FMI
647/4 Circuit error switch cooling fan - Abnormally low voltage or short-circuiting to WARNING!
lower 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 WARNING!
higher voltage.
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 WARNING!
voltage.
974/19 SAE J1939 multiplexing, value error remote accelerator sensor - Received data WARNING!
incorrect.

Description Action
Display
SPN/FMI
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 or lever - Abnormally high voltage or short-circuiting to higher WARNING!
voltage.
1043/4 Voltage feed circuit engine rpm/position sensor - Abnormally low voltage or WARNING!
short-circuit to lower voltage.
1043/4 Voltage feed circuit accelerator pedal or lever - Abnormally low voltage or WARNING!
short-circuit to lower voltage.
1072/3 Signal engine brake circuit #1 - Abnormally high voltage or short-circuiting to WARNING!
higher voltage.
1072/4 Signal engine brake circuit #1 - Abnormally low voltage or short-circuiting to WARNING!
lower 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 WARNING!
lower voltage.
1075/3 Fuel suction pump circuit - Abnormally high voltage or short-circuiting to higher WARNING!
voltage.
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 WARNING!
lower 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 WARNING!
lower 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.

Description Action
Display
SPN/FMI
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 WARNING!
lower voltage.
2047/xx Undetectable error code from engine. Error codes over 2047 cannot be shown STOP
on display.
Possible error codes: 2789.
2629/15 Boost pressure temperature output calculated - Data valid, but higher than WARNING!
normal operating range.
2789/15 Boost pressure temperature input calculated - Data valid, but higher than normal WARNING!
operating range.

Error codes transmission

–
For transmission alternative TE17: Error codes from control unit for
transmission has error code level "WARNING".
Table 5. Error codes TE17
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.
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 cool the transmission oil so that temperature
value. Transmission in locked neutral position ("shutdown"). drops below 100 C (error code
Engine is limited to 50% of max. rpm. 43/03 disappears).
When temperature in torque converter is
below 100 C, resume work with machine.

Description Action
Code
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
neutral. Select gear again.
50/00 Sensor oil pressure, short-circuiting to ground. Control unit STOP
transmission activates "limp home".
50/01 Sensor oil pressure, open circuit. Control unit transmission STOP
activates "limp home".
51/00 Sensor transmission oil temperature, short-circuiting to 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
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.

Description Action
Code
71/00 Solenoid valve VFS 2. Control unit transmission activates STOP: Stop the machine and shift to neutral.
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.
77/02 All gear packs disengaged. Transmission in locked neutral STOP
position ("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.

Description Action
Code
82/01 Solenoid valve gear selection 1/3, open circuit or STOP: Stop the machine and shift to neutral.
short-circuiting to battery. Control unit transmission activates Select reverse gear.
"limp 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 STOP or INFORMATION
99/xx position ("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.

5 Handling – 5.4 Operating 113
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.

property 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

direction and should operate with special care
where persons or vehicles may appear.
• The operator must adapt the speed to the load and

ground conditions, visibility and wind
conditions, etc.
• The operator must pay extra attention and operate

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

• Use available visibility-enhancing equipment

such as rearview mirrors and camera .
WARNING
Never use a machine without first performing the
daily 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!

114 5 Handling – 5.4.1 While operating
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.
Instructions
–
Make a habit of checking the following at regular intervals while

51 52 operating:
• that coolant temperature is within the interval
(approx. 75-80 °C/167-176 °F).
• that fuel indicator on the display shows that there is fuel in the
tank.
NOTE
The fuel indicator should never go down to empty tank.
• that all warning lights are off.
• that horn, lighting, brake lights and direction indicators function
correctly.
006494
• that all hydraulic functions function correctly.
51. Display for control and monitoring system • that no error codes have been generated (shown on operator’s
52. Indicator for control and monitoring system, STOP display with error code indication and symbol). See section
or WARNING 5.3 Error codes.

5 Handling – 5.4.2 Starting engine 115
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 selector and multi-function lever in neutral position.

Gear selector and multi-function lever must be in neutral,
otherwise engine cannot be started.
2. Turn the start key to operating position, position I.
Now there is current to all electric functions.
3. Turn the start key to preheating position, position II.
In case of cold weather, preheating can be used. During preheat-
ing the engine’s inlet air is preheated using a heating coil to a
suitable temperature to facilitate start.
For engine alternative Volvo TAD760VE
When needed, the engine’s control unit activates preheating for a
time period. The light for preheating (position 39) indicates if
preheating is activated.
Engine can be started, position III (start position), regardless of if
preheating is in progress, not activated (no need) or has been
finished.
For engine alternative Cummins QSB6.7
Has automatic preheating without indicator to the operator.
4. Turn the start key to start position, position III.
Let the starter motor crank engine, release the key when engine
starts. The machine has electric restart interlock that protects the
starter motor from engaging when the engine is rotating.
Note that some warning or indicator light may remain on after start
to indicate status. The light for preheating may remain on for
awhile during operation in cold weather, as preheating may be
active during initial operation.
NOTE
IF THE ENGINE DOESN’T START, try again after
15-20 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 mal-
function which has to be located and repaired. Contact service.

116 5 Handling – 5.4.3 Warming up
5.4.3 Warming up
General
page
–
CAUTION
Never rev a cold engine at high engine speeds.
Risk of engine damage!
Run the engine at 1400-1500 rpm until it starts to get

warm.
Instructions
–
In cold temperatures the machine may not be used for tough work until
the engine and hydraulics are at operating temperature.
If the machine operates in temperatures below -10 °C, an engine
heater and hydraulic oil heater should be installed.
Engine
Start the engine and let it idle for approx. 10 min., never rev a cold
engine since this causes risk of engine damage. Then run the engine
warm by letting it run at approx. 1400-1500 rpm until the engine starts
to become warm. It is very important that the engine is warmed and
circulates correctly before the turbocharger starts to operate at high
rpm.
Start working with the machine when the coolant has reached normal
operating temperature, approx. 75 °C. (See description, page 71.)
Hydraulic system
Never operate a hydraulic function in the cold until the hydraulic oil is
warm, since there is a risk of damage and leakage in the hydraulic
system.
When the engine has reached operating temperature, warm the hy-
draulic oil by operating the mast slowly up and down. Full use of the
hydraulic function may not take place until the tank temperature is
+1 °C.
After this, all other hydraulic functions should be run slowly so that
warm oil circulates through the whole system, and this should be
repeated at least ten times.

5 Handling – 5.4.4 Gearshifting 117
5.4.4 Gearshifting
General
page
–
The machine is equipped with an automatic transmission. The system

shifts to a higher/lower gear under certain conditions such as torque,
engine rpm, travel speed, etc.
F
General about the automatic transmission:
• Has a built-in control and monitoring system, providing optimal
operation.
• Shows current gear on control and monitoring system’s display.
R 64
• Shifting is variable (modulated) and gives smoother operation.
63
006495
• Operating:
62
– For machine with TE17, operation starts with first gear.
62. Switch for shifting program A
63. Switch for shifting program 1 • Reverse lock-out prevents change of travel direction taking place
64. Switch for shifting program 2 too fast, that is, prevents eventual transmission damage. Reverse
lock-out is automatic and depends on engine rpm and travel
speed.
Instructions
–
1. Let the engine idle. Select travel direction, move lever forward (F)
or backward (R).
See section 4 Instruments and controls for detailed information
about gearshifting.
2. Select shifting program: A, 1 or 2. See Overview Spirit Delta,
page 38.
The operator can limit gearshifting by selecting shifting program
on the steering wheel panel’s keys.
Shifting program A (position 62) – automatic shifting between all
gears.
Shifting program 1 (position 63) – gear is locked to 1st gear.
Shifting program 2 (position 64) – gear is locked to 2nd gear.
NOTE
In certain circumstances, the transmission may be forced to re-
duce speed due to a problem. The control unit may then put the
transmission in "limp home" mode.

118 5 Handling – 5.4.4 Gearshifting
Transmission assumes neutral position

–
A breaker senses when the operator leaves the operator’s station. The
signal from the breaker means that the transmission automatically as-
sumes neutral position. It is not possible to select any travel direction.
008191
Control breakers in driver’s seat
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.
The machine can be operated in emergency mode by means of
by-passing the safety system (override). Activate the by-pass
switch (82), select travel direction and drive the machine to the
workshop. Speed is limited to 10 km/h.
0
0
1
1
WARNING
007043
82 82
82. Switch for bypassing. Safety features are blocked.
Key for bypassing . No safety system is engaged!
Only use by-pass in emergency situations!

5 Handling – 5.4.5 Steering 119
5.4.5 Steering
General
page
–
The machine is equipped with servo steering. The steering wheel

movements are transferred hydraulically to the steering wheels on the
ground.
WARNING
The machine may not roll on a downhill grade if the
engine is off.
Hydraulic pressure for steering is missing and

steering capacity is lost! Danger!
Keep the engine running for hydraulic pressure.
5.4.6 Service brake

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

Use the brakes in a smooth but firm way. Brake pressure remains for
awhile after the engine has been turned off, accumulated during oper-
ation. If the accumulator pressure drops below a certain level, the in-
dicator light for low brake pressure (position 33) is activated on the
panel. When the light is activated the service brake’s capacity is limit-
ed. The buzzer sounds and speed is limited. Finally, the parking brake
is applied automatically by a forceful spring in the brake cylinder.
Check the sealing of the accumulators if the pressure is not built up
and maintained, see section 6 Inspection and maintenance.
The brake pedal is combined with a separate clutch pedal
(position 13). When the brake and clutch pedals are pressed down at
the same time, the transmission is disengaged. Before drive is disen-
gaged, the drive functions as an engine brake.
003679
12 13 12 11
11. Accelerator (throttle pedal)
12. Brake pedals
13. Clutch pedal

120 5 Handling – 5.4.7 Parking brake
5.4.7 Parking brake

General
page
–
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.
WARNING
Never leave the operator’s seat without first applying
the parking brake.
Risk of machine starting to roll! Danger!
Apply the parking brake before leaving the operator’s

station.
The parking brake is operated with the switch (position 8) on the panel
for hydraulic functions (position 6). The indicator light for parking brake
(position 46) is activated with a red light when the parking brake is
applied.

5 Handling – 5.4.7 Parking brake 121
Instructions
–
The parking brake is applied when:

• the switch for parking brake is pressed down (indicator light for
parking brake is activated with a red light).
30-3
5
• The ignition is turned off (to 0 position).
When the ignition is turned on again, the parking brake is applied
without the switch for parking brake being activated. The indicator
8 light for parking brake flashes to indicate that the parking brake
switch should be turned on and then off to release the parking
8 brake. Check the accumulators for leaks if pressure isn’t built up
33 46
and maintained; see chapter 6 Inspection and maintenance.
An audible signal is activated if the operator gets up from the driver’s
seat without first applying the parking brake.
If the accumulator pressure drops below a certain level, the warning
lamp for low brake pressure is activated (position 33). The service
brake’s capacity is limited when the light is activated. Finally, the park-
ing brake is applied automatically by a forceful spring in the brake
cylinder.
If the machine has to be moved, see section 7 Transporting the
008137
machine.
8. Switch for parking brake

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

122 5 Handling – 5.4.8 Heating / Air conditioning
Emergency brake
–
At speeds below 8 km/h, the parking brake can be used as an

emergency brake and in emergencies.
WARNING
At speeds below 8 km/h, 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
5.4.8 Heating / Air conditioning

General
page
–
The heating system/air conditioning gets heat from the engine’s cool-
A ing system and gives heat when the engine is warm. Cooling perform-
ance is generated by the AC compressor (for ECC).
The system is controlled by switches for fan, heat and air distribution.
In addition, there are functions for recirculation and defroster.
18
17
008133
16
A. Panel nozzle
16. Switch for fan
17. Switch for heat
18. Switch for air distribution

5 Handling – 5.4.8 Heating / Air conditioning 123
Normal weather conditions

–
1 Set desired temperature (position 17).

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

124 5 Handling – 5.4.8 Heating / Air conditioning
Mist on windows
–
1 Set a warm temperature (position 17).

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

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

The defroster controls the function fan, temperature and damper
position to optimally heat and faster dry the air at the front wind-
screen for faster demisting. The function is active for 6 minutes.
The symbol for defroster is shown in the operating menu for
I heating/air conditioning, and is indicated in the switch. See
position I on display.
NOTE
004921
The defroster function is active for 6 minutes. Check that tem-

perature control returns to set value when the defroster is turned
off.
6 In case of a lot of mist, set the panel nozzles (position A) at the
front windshield for optimal demisting.

5 Handling – 5.4.9 Stopping engine – parking 125
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.
Instructions
–
1. Stop the machine and move the gear selector and multi-function
lever to neutral position.
2. Apply the parking brake.
3. Lower the attachment completely and tilt the mast forward.
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.
In case the machine is going to be parked for a long time, the
battery disconnector should be turned to the OFF (0) position.
When idling:
• The engine turns off when idling for longer than 5 minutes.
• Work lights are disengaged when idling.

Work lights are turned off after 5 minutes.
Extra work lights are turned off after 2 minutes.

126 5 Handling – 5.5 Load handling
5.5 Load handling

General
page
–
During all lifting work, it is important to remember to not exceed

maximal lift capacity. Load handling also includes lifting tools.
The machine’s capacity is indicated by three parameters:
• position of load’s centre of gravity
• lifting height
• load’s size
The capacity varies between models and versions, see the machine
and type plates, section 3.2 Plates.
It’s important to estimate the position of the centre of gravity. If the
machine appears to be side-heavy, the load should be lowered and
adjusted with side shift so that the load’s centre of gravity is moved to
a position along the machine’s centre line.
008138

5 Handling – 5.5 Load handling 127
The function load handling refers to, e.g., to lift, lower, rotate, angle or
hold loads.
Load handling sub-functions.
• Lift/lower
• Side shift
• Spreading (positioning)
• Tilt
• Levelling
009149
Lift and lower
009437
Side shift
009438
Spreading (positioning)

128 5 Handling – 5.5 Load handling
009150
Tilt 008168
Levelling

5 Handling – 5.5.1 Lifting load 129
5.5.1 Lifting load

General
page
–
There are two types of sidelift attachments for load handling

• Twistlock attachment
• Hook attachment with lock lugs
When lifting with a sidelift attachment, the attachment must have
alignment with the container both when locking and releasing
twistlocks / lock lugs. When releasing, the container must also
stand on solid ground. The sidelift attachment is equipped with in-
dicator lights that indicate these different positions. The indicator
lights are located to the right on the sidelift attachment and on the
steering wheel panel in the cab.
The lifting speed is faster when lifting only the attachment or light
loads.
There is a sensor that senses the last metre for upper end position
and then automatically reduces the speed.
This manual describes lifting using sidelift attachment with twistlocks
and hook connection.
WARNING
Do not use a machine where the indicator lights are
out of order.
Danger of reduced safety during load handling!
If the indicator lights don’t work, stop work with the

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

See type plate and load diagram.
NOTE
When loading or unloading a container on a leaning trailer,
compensate with sideshift.

130 5 Handling – 5.5.1 Lifting load
Instructions for sidelift attachment with twistlocks

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

close as possible. Strive to line up the machine’s centre line with
the centre of the container.
2 Hold the machine stationary with the service brake and clutch
pedal. Alternatively, apply the parking brake if desired and/or shift
to neutral gear.
3 For adjustable attachment, adjust with spreading to relevant
A C container length.
B Right light, C – Twistlocks unlocked, red light activated, indicates
that load is not secured.
4 Place the attachment slightly over the container. Adjust with
sideshift and tilt.
5 Lower the attachment on the container.
008115
6 The middle light, B – Alignment, illuminates in orange and indi-

cates when the attachment has correct alignment against the
container. The display for the control and monitoring system
shows by means of symbols which twistlock has become aligned,
see Overview Spirit Delta, page 38 (position 51).
7 Lock twistlocks with switch for twistlocks, see Overview Spirit
Delta, page 38 (position 71).
If automatic locking of twistlocks is used, locking is automatic
A C when the attachment is aligned with the load.
B Locking options are selected with switches for automatic or
manual locking, see Overview Spirit Delta, page 38 (position 71).
NOTE
For automatic locking of twistlocks, the parking brake must be re-
leased.
008116

8 Right light, C – Twistlocks unlocked, off.

Left light, A – Twistlocks locked, is activated with green light and
indicates that load is secured and ready for lifting.
The lift function is disengaged when both right light, C – Twist-
locks unlocked, and left light, A – Twistlocks locked, are off.
A
B
C
WARNING
Do not start to lift if light C "Twistlocks unlocked" is
on, or if any of the lights A "Twistlocks locked" or
B "Alignment" are off.
The load is not secured!
Try to lock twistlocks once again.

008117
9 Ready for lifting.

When the container is lifted, the light (position B) for alignment
shall go off. The load’s centre-of-gravity shall be centred laterally
(sideways).
A C
B
008118

Instructions for sidelift attachment with hook

–
connection
1 Run the machine forward towards the stack of containers, as
close as possible. Strive to line up the machine’s centre line with
the centre of the container.
2 Hold the machine stationary with the service brake and clutch
pedal. Alternatively, apply the parking brake if desired and/or shift
to neutral gear.
3 For adjustable attachment, adjust with spreading to relevant
B1
container length.
A C
B2 Right light, C – lock lugs unlocked, red light activated, indicates
that load is not secured.
4 Place the attachment vertically. Adjust with levelling, sideshift,
and tilt.
5 Run forward until the sidelift has contact with the container. Lift
slightly, so that the container rests on booth hooks.
008119
6 The middle lights, B1 (upper container), B2 (lower container) –

Alignment, illuminate in orange and indicate when the attachment
has correct alignment against the container. The display for the
control and monitoring system shows by means of symbols which
hook/lug has become aligned, see Overview Spirit Delta, page 38
(position 51).
7 Lock the lock lugs with switch for lock lugs, see Overview Spirit
Delta, page 38 (position 71).
B1
A C The lock lugs lock in the upper hole on the container.
B2 If automatic locking of lock hooks is used, locking is automatic
when the attachment is aligned with the load.
Locking options are selected with switches for automatic or man-
ual locking, see Overview Spirit Delta, page 38 (position 71).
NOTE
For automatic locking of lock hooks, the parking brake must be
released.
008120

8 When handling double containers, the lock lugs both containers.

The attachment itself senses if it is one or two containers that has
alignment and shall be locked. For locking, alignment is required
for both. When lifting double containers, only light B2 goes off.
B1
A C
B2
008123
9 Right light, C – Lock hooks unlocked, off.

Left light, A – Lock hooks locked, is activated with green light and
indicates that load is secured and ready for lifting.
WARNING
B1 Do not start to lift if light C "Lock hooks unlocked" is
A C on, or if any of the lights A "Lock hooks locked" or
B2 B "Alignment" are off.
The load is not secured!
Try to lock the lock hooks once again.

008121

10 Ready for lifting.

When the container is lifted, the middle light, B2, for alignment
shall go off. The load’s centre-of-gravity shall be centred laterally
(sideways).
Reduction of speed and hydraulic movement occurs in the event
of incorrect locking.
B1
A C
B2
008122

5 Handling – 5.5.2 Transporting load 135
5.5.2 Transporting load

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

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

cise the greatest caution 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 attachment
• Do not transport the load in high position since

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

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

load obscures visibility to the front.
• No personnel may encroach or stand under a

raised load.
• The operator must avoid forceful acceleration and

sudden braking.
• The operator shall always adapt speed when turn-

ing to prevent skidding, and risk of roll-over. Al-
ways adapt the speed to current conditions for
load, visibility, ground surface, etc.
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.

136 5 Handling – 5.5.2 Transporting load
Instructions for sidelift

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

When lifting, the middle light, B – Alignment, (orange), is off. Then
the function for twistlocks is disengaged. The function for opening
lock lugs still works but is disengaged when travel speed exceeds
5 km/h.
2 Adjust load height and tilt angle to transport position, see
Transport position page 136.
A C
B
008118
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
operating.

When transporting, the mast is tilted back and the load is lifted for good
forward visibility, see figure to the left. The load’s centre-of-gravity
shall be centred laterally (sideways).
008125

The machine shall be run in transport position even without load to

maximise operator visibility.
In transport position without load, the mast shall be vertical and the
attachment raised for good forward visibility, see figure to the left.
008126
Operating on grades
–
It is important to be extremely careful when operating on grades as

there is a greater risk of roll-over and tipping over. Keep in mind the
angle of the ramp.
NOTE
When braking, use only the service brake pedal (right-hand brake
pedal). Do not operate service brake in combination with clutch
pedal.
• Operating with a load.
Adjust load height and tilt angle to transport position, see
Transport position page 136.
Always operate with the load facing the grade (see figure),
regardless of travel direction.
• Operating without a load.
Always operate with the lifting equipment down the grade
(downward), regardless of travel direction.
008127

138 5 Handling – 5.5.2 Transporting load
Lift of 45’ empty container with hook attachment

–
1. Set length adjustment to 40 foot position.

2. Run slowly toward the container. Adjust sideways.
3. Set the mast vertical. Align the hooks in the container’s lift holes.
Run forward until the sidelift has alignment with the container.
Check that the lights B2 are on. Lift slightly so that the container
rests on both hooks.
4. Do not try to lock the lock lugs!
5. Tilt back and lift. Light C goes on since the lock lugs are not
locked.
6. Adjust the lifting height to transport position. The speed is
008150 reduced. Operate with extreme care.
Locking of hook attachment with tightly packed

–
containers
After a container is lifted out between tightly packed containers, e.g.,

on a truck, it is possible to lock the lock lugs without alignment being
required. This only applies to lifting one container.
When handling double containers, the containers must be set down
and the attachment must be adjusted so that alignment is achieved.
Lock the lock lugs at correct alignment.
Indicator light is green and indicates that locking is correct.
NOTE
008151

Unloading tightly spaced containers with hook

–
attachment
1. Set length adjustment to container length in question.
2. Run slowly toward the container. Adjust sideways.
3. Set the mast vertical. Align the hooks in the container’s lift holes.
Run forward until the sidelift has alignment with the container.
Check that the orange lights go on (B2 for lift of one container,
B1+B2 for lift of 2 containers). Lift slightly so that the container
rests on both hooks.
4. Do not try to lock the lock lugs!
5. Lift out the container carefully with reduced speed so that the lock
holes on both sides are in the clear.
6. Set down the container and adjust so that the sidelift has align-
ment. Check that the orange lights go on (B2 for lift of one
container, B1+B2 for lift of 2 containers).
7. Lock the lock lugs. Light A is on with green light.
8. Ready for lifting.
When the container is lifted, the middle light B2 for alignment shall
008151
go off. The load’s centre-of-gravity shall be centred laterally

(sideways).
Handling standard containers with wide body

–
attachment
To handle standard containers with machine equipped with wide body

attachment, a gauge piece must be installed on the attachment.
To install the gauge piece:
1. Fasten the gauge piece (position 1) on the attachment.
2. Lock the gauge piece with the pin (position 2).
2 1
012852
Twistlocks
1. Gauge piece
2. Pin

140 5 Handling – 5.5.3 Unloading
Working near overhead high voltage power lines

–
Operate with extreme care in all work near overhead high voltage
power lines, keeping in mind the height of the mast and load.
DANGER
If the machine comes into contact with overhead high
voltage power lines - sit down in the seat and call for
help!
Extreme danger!
Remain in the cab and wait for help.
5.5.3 Unloading
page
–
1 Run forward towards the stack of containers, as close as possi-

ble. Strive to line up the lifted container’s centre line with the
centre of the container stack.
2 Lift the load over the stack.
Strive to centre the load over the container stack.
3 Apply the parking brake if desired, or hold the machine stationary
with the service brake and clutch pedal. Alternatively, shift to
neutral.
A C
B 4 Move the load into position over the stack. Adjust with sideshift
and tilt.
008128

5 Handling – 5.5.3 Unloading 141
5 Lower the load.

When alignment is obtained, the middle light, B – Alignment, is
activated.
Alignment is required for twistlock. However, not for lock lugs, but
then speed is reduced.
6 Open twistlocks/lock lugs manually with the switch, see Overview
Spirit Delta, page 38 (position 69).
A C When releasing twistlocks/lock lugs with activated manual

B locking of twistlocks/lock lugs, you must:
a. Activate switch open locked twistlock/lock lugs until red light
is on.
b. Lift until yellow light goes off before switch open twist-
lock/lock lugs is released.
When releasing twistlocks/lock lugs with automatic manual
locking of twistlocks/lock lugs, you only have to:
a. Activate switch open locked twistlock/lock lugs.
Left light, A – Twistlocks/lock lugs locked, goes off (green) when
008117
releasing twistlocks/lock lugs is initiated. Right light, C – Twist-

locks/lock lugs unlocked, is lit (red) when twistlocks/lock lugs are
completely open.
Never lift when twistlocks/lock lugs are in the process of being
released.
NOTE
Automatically locked twistlocks/lock lugs are also opened
manually.

142 5 Handling – 5.5.4 Functions for load handling
5.5.4 Functions for load handling

Cab tilt
page
–
Cab tilt facilitates visibility during load handling. The cab is tilted up to
obtain a more ergonomic operating position. With switch (position 75)
select automatic tilt or manual tilt. For automatic tilt, the cab is tilted au-
tomatically when the attachment at a pre-set lifting height. For manual
cab tilt, the cab is tilted with switch (position 76).
For automatic cab tilt, speed must not exceed 5 km/h, operator doors
must be closed and the parking brake not activated.
If the cab is not in its lowest position, that is, tilted, machine speed is
limited to max. second gear and 5 km/h.
NOTE
008152
Move the cab while the machine is stationary!
WARNING
Entering under tilted cab.
Extreme danger!
Check that nobody is under or near the tilted cab.

Visibility is reduced!

5 Handling – 5.5.4 Functions for load handling 143
Height limitation
–
Height limitation limits how high the mast can be raised. The height
limitation can be adjusted in accordance with customer requirements.
When the mast reaches a certain preset height (position A), the lifting
movement is stopped and the figure in the display is shown. Lower the
mast for continued load handling.
A
If it is necessary to lift above the height limitation then the function can
be by-passed. Activate the by-pass switch (position 78) and use the
lifting function. After several seconds the switch (position 78) can be
deactivated, lifting and lowering can then be controlled without
by-pass.
The figure in the display is always shown when the lifting height
exceeds the height limitation.
78
78
008172

144 5 Handling – 5.5.4 Functions for load handling
Height warning
–
The height warning warns when the maximum set lifting height is
A
reached. The height warning can be adjusted in accordance with
customer requirements.
When the mast reaches a certain preset height (position A), the
machine warns and the figure in the display is shown.
The figure in the display is always shown when the lifting height
exceeds the maximum set lifting height.
008173

6 Inspection and maintenance 145
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
actions 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
• ERROR CODE INFORMATION – read off by the operator.
Error code information is read off by the operator from the control
system’s display in the cab. Depending on the type of error code,
it is handled by the operator or a service technician.
NOTE
All time information refers to operating time, that is, the time
shown by the hour meter on the panel.
CAUTION
Only spare parts approved by Cargotec may be used.
This is to maintain the machine’s safety as well as to

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

to fulfil warranty terms.

146 6 Inspection and maintenance – 6.1 Daily inspection
6.1 Daily inspection

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

ensure that it is safe both for the operator and its surroundings.
Every operator should perform checks before a new work shift. In this
way, operators can avoid running defective machines with malfunc-
tions that have been generated or caused during an earlier work shift.
WARNING
Never use a machine without first performing the
daily inspection.
Risk of personal injury and property damage!
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
cylinder, 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 tire wear
• Any penetrating glass, metal filings, etc., in the tires
• Tyre pressure
• 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-carry-
ing structures/structural elements, the machine shall
be taken out of use immediately and taken to service.
Fatal danger and risk of property damage if cracks in

materials or welds in load-carrying structures/struc-
tural elements are not repaired!

6 Inspection and maintenance – 6.1 Daily inspection 147
• If the machine is equipped with sidelift; check that sensors for

twistlocks and alignment are clean and free from grease
• Communication equipment – direction indicators, brake
lights, headlights and reflectors with regards to damage
• Cab with regards to damage and dirty windows, rear-view
mirrors
2. Check fluid levels for the following fluids according to description,
see section 6.2 Maintenance. Top up, if 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 that the engine’s indicator for air filter, also check and drain
the fuel pre-filter as needed (Volvo engine) and the fuel filter
(Cummins engine). For description, see section 6.2 Maintenance.
4. Start the machine according to instructions and check:
• Instruments – warning lamps, indicators, eventual error codes
on display
• Fuel level – the gauge must not show empty tank
• Lighting, direction indicators, horn, brake lights, flashing
hazard lights
• Windscreen wipers
• Check that mirrors are intact, clean and well-adjusted for
visibility all around the machine
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, lower, sideshift, tilt
and spreading) to their end-positions for lubrication of the cylinder
barrels and piston rods.

148 6 Inspection and maintenance – 6.1 Daily inspection
7. If the machine is equipped with sidelift; check the lift attachment

and that:
• Indicator lights for twistlocks/lock lugs and alignment work
WARNING
5A 2 5B 1
Make sure that the engine is off when working with
twistlocks/lock hooks.
3
Twistlock/lock lugs can lock automatically if all sen-
sors for alignment are activated at the same time.
4
• Alignment pins by twistlocks/lock lugs can move easily up and
down. Note that an alignment pin that binds in the upper po-
sition may indicate alignment even if the frame does not have
contact with the container.
008139
• Check that the twistlock is working by lifting a container until

Twistlocks the "Alignment" light goes out. The display for the control and
1. Lock mechanism monitoring system, see Overview Spirit Delta, page 38
2. Sensor alignment (position 51), shows by means of symbols which twistlock has
3. Alignment pin become aligned. It should now not be possible to disengage
4. Lift pin the twistlocks.
5. Lock guide, A-open twistlocks, B-locked twistlocks
• Check that the lock lugs are working by moving in towards
2
double containers until the "Alignment" light illuminates. The
display for the control and monitoring system, see Overview
Spirit Delta, page 38 (position 51), shows by means of sym-
1 bols which ones are aligned. Check that the alignment pins
have contact against the containers.
• Check that twistlock/lock lugs open/lock works. This is done
by pressing in the override button (not for lock lugs) and check
that green light is on at locked twistlock/lock lugs and red light
is on at open twistlock/lock lugs.
• Check that the override button works. This is done by press-
ing in the override button and checking that warning lamp for
5 by-pass of hydraulic functions (position 35) is on.
3 8. Check the machine’s operating hours – notify the foreman/super-

visor if the machine is close to a service interval.
4
9. Notify the foreman/supervisor immediately if any defects are
detected on the machine.
008140
Hook attachment
1. Lock mechanism
2. Sensor alignment
3. Alignment pin
4. Lift hook
5. Lock guide, lock lugs

6 Inspection and maintenance – 6.1 Daily inspection 149
WARNING
Do not use the machine if the system for locking
containers does not work.

property damage!
Use of the machine must be discontinued, and it has

to be taken to a service workshop for needed actions.
10. In cold weather:

• check that wiper blades have not frozen to the windscreen
• remove snow from air inlets and radiator grill
• anti-freeze in washer fluid
• connect auxiliary heater for cab and engine

Electrical box for auxiliary heater is located by the cab steps
on the left side of the machine.
11. Check if any error codes are active.
See the section 5.3 Error codes.

150 6 Inspection and maintenance – 6.2 Maintenance
6.2 Maintenance
General
page
–
The following maintenance actions are described in this chapter:

– Cleanliness, general page 151
– Fuel system, general page 153
– Windscreen washer, general page 155
– Air filter engine, general page 156
– Cooling system, general page 157
– Engine oil, general page 159
– Transmission oil, general page 161
– Hydraulic system, general page 162
– Tyres and rims, general page 163
– Accumulators, general page 166
– Battery and battery disconnector, general page 167
– Main fuses for electrical system, general page 169
– Fuses for electrical system, general page 170
– Lighting, general page 174
Safety during maintenance

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

• Always turn off the engine during service work. Only exception is
when service work requires engine power.
• No work may be done on the machine without the right 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
contains 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.

6 Inspection and maintenance – 6.2.1 Cleanliness 151
6.2.1 Cleanliness
Cleanliness, general
page
–
Dirt has a negative impact on performance. Experience shows that

clean machines have less malfunctions.
The machine should be washed regularly for optimal function. Keep
the following in mind when washing:
• 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
After washing with de-greaser, the hydraulic cylinders should be
run in and out a few times to obtain satisfactory lubrication once
again.
WARNING
ing aromatic hydrocarbons, ketones, esters, or
Low strength! Danger!
Check the outside surface of the roof window at reg-

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

152 6 Inspection and maintenance – 6.2.1 Cleanliness
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

inside the cab.
• Plastic material: vacuum clean, brush/wipe with lightly moistened
rag. Use mild cleaning agent and always wipe down with a lightly
moistened rag and clean water.
• Textile material: vacuum clean, brush/clean with e.g. furniture or
carpet cleaning agent in accordance with the instructions on the
packaging.

6 Inspection and maintenance – 6.2.2 Fuel system 153
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
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.
A
CAUTION
The quality of the diesel affects the service life of the
engine.
008145
Make sure that correct diesel quality is used.

A. Refuelling point
• 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.

154 6 Inspection and maintenance – 6.2.2 Fuel system
Fuel pre-filter (Volvo engine) and fuel filter (Cummins engine)

instructions
NOTE
The water separator should be drained of water every 50 operat-
ing hours.
DANGER
A Fire hazard.
Extreme danger!
The fuel is highly flammable. Make sure that open

flames, sparks, or glowing/red-hot objects have been
extinguished before starting work on or near the fuel
B system. Do not smoke near the machine during work
007323
on the fuel system.

Engine alternative Volvo TAD760VE
A. Fuel filter 1 Turn off the engine and the main electric power with the battery
B. Drain valve disconnector.
2 Place a container under the filter (position A).
3 Drain the water from the filter.
Open the drain valve (position B) on the underside, close the
valve when clean fuel drains (no water bubbles).
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.
Engine alternative Cummins QSB6.7

A. Fuel filter
B. Drain valve

6 Inspection and maintenance – 6.2.3 Windscreen washer 155
6.2.3 Windscreen washer

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

Danger!

ing aromatic hydrocarbons, ketones, esters, or
The washer fluid reservoir is located on the back of the cab’s left rear
side. Other placements may occur.
Instructions
A
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
(dilution water/antifreeze fluid) according to winter conditions and
outdoor temperatures.
008146
A. Washer fluid reservoir

156 6 Inspection and maintenance – 6.2.4 Air filter engine
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
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
indicator shows a red signal.
C
B
008147
A. Position for air filter holder

B. Indicator for change
C. Dust reservoir
D. Cover

6 Inspection and maintenance – 6.2.5 Cooling system 157
6.2.5 Cooling system

Cooling system, general
page
–
Coolant is filled in the system’s expansion tank (position A). The cool-
ant level should be between the MIN and MAX markings (position D)
on the expansion tank.
NOTE
Do not open the pressure cap until the coolant temperature has
dropped. Hot coolant may jet up and out!
If the coolant level becomes too low then the warning lamp for coolant
level on the instrument panel illuminates, see Overview Spirit Delta,
page 38 (position 40).
NOTE
A low coolant level may cause engine damage or may cause the
engine to stop.
Instructions
WARNING
A
The cooling system is pressurised. Steam or hot

coolant may jet out.
Risk of scalding/burn injuries!
Open the filler cap (position C) very carefully when

the engine is warm. Wait until the coolant has cooled
down before topping up.
WARNING
008148
B C D
A. Position for coolant reservoir (expansion tank) Glycol and anti-corrosion agents are
B. Pressure cap health-hazardous.
C. Filling point Health hazard!
D. Level marking, MIN and MAX
Handle with care. Avoid skin contact, use protective
glasses and protective gloves. In case of skin contact,
wash the skin.

158 6 Inspection and maintenance – 6.2.5 Cooling system
CAUTION
Different types of coolant may not be mixed.
Risk of engine damage if different types of coolant are

mixed.
When changing and topping up coolant, the same

type of coolant must be used as was used before. See
Spare parts catalogue for correct part number.
When needed, top up with ready-mixed recommended coolant. For

volume, see section 9 Specifications.
IMPORTANT
On machines with ECC or AC it is of the utmost 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 159
6.2.6 Engine oil

Engine oil, general
page
–
WARNING
Avoid prolonged contact with engine oil.
Health hazard!
Use protective gloves.
B A
The engine’s oil filler pipe (position B) and dipstick (position C) are
located under the engine hood.
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.
NOTE
The dipstick is long on certain machines. Use gloves.
008155
C
TAD760VE
A. Position for filling and level check
B. Filling point
C. Dipstick

160 6 Inspection and maintenance – 6.2.6 Engine oil
• Fill engine oil (position B) when needed (for volume, see

chapter 9 Specifications.
It is recommended that oil is filled when the engine and oil are at
operating temperature. Fill – wait awhile – check on the dipstick.
NOTE
Fill oil with care to prevent other fluids or particles from
contaminating the oil. Contamination means risk of engine dam-
age.
B
008157
QSB6.7
B. Filling point
C. Dipstick

6 Inspection and maintenance – 6.2.7 Transmission oil 161
6.2.7 Transmission oil

Transmission oil, general
page
–
WARNING
Avoid prolonged skin contact with transmission oil.
Health hazard!

A
B
The transmission’s oil filler pipe and dipstick (position B) are located
under the engine hood.
Instructions
Check the oil level with the engine running at idle speed and the trans-
mission in neutral and at operating temperature (approx. 85 °C). The
dipstick has two markings, MAX. and MIN., the oil level should be
between these markings.
• Wipe off the dipstick before checking.
008156
NOTE
A. Position for filling and level check The oil dipstick is long. Use gloves.
B. Dipstick and filling point • Fill transmission oil (position B) when needed (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.

162 6 Inspection and maintenance – 6.2.9 Hydraulic system
6.2.9 Hydraulic system

Hydraulic system, general
page
–
WARNING
Avoid prolonged skin contact with hydraulic oil.
Health hazard!
The hydraulic oil tank is located on the machine’s right side.

Instructions
G • Check the oil level (position DE). All hydraulic pistons should be
F in retracted position (pushed in).
E
The level should be in the middle of the level glass.
D
C • Top up as needed with new oil (position F). For volume and
B quality, see section 9 Specifications.
A
• Check that the oil cooler isn’t clogged.
Clean as needed.
NOTE
Work carefully when filling hydraulic oil to prevent other fluids or
particles from contaminating the oil. Other fluids or particles in the
hydraulic oil means a risk of damage to the working hydraulics.
H
008158
A. Fine-filter
B. Oil cooler
C. Cleaning filter hydraulic oil
D. Level glass hydraulic tank
E. Breather filter
F. Filling point hydraulic tank
G. Hydraulic tank
H. Filling point hydraulic tank (spare)

6 Inspection and maintenance – 6.2.10 Tyres and rims 163
6.2.10 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

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

property damage!
Tighten bolted joints crosswise. Contact a service

technician as needed.
CAUTION
Spare and replacement tyres should be of brand
names approved by Cargotec.
Risk of overloaded tyres!
Use tyres approved by Cargotec.

164 6 Inspection and maintenance – 6.2.10 Tyres and rims
IMPORTANT
Wheels, tires, and rims are dimensioned and selected
for each machine type so that maximal wheel loads
and speeds are not exceeded. That is why it is not per-
mitted to change tire dimension, tore make, tire type,
rim type, or rim brand without approval from
Cargotec.
Changing wheel:
–
Changing wheels, see Maintenance manual.
DANGER
When changing tyres, deflate first.
Deflate tyres by loosening and removing the valve.
DANGER
Rim damage makes wheel handling extremely
dangerous!
Let service personnel change tyres, they have the

competence and authority to handle tyres!

6 Inspection and maintenance – 6.2.10 Tyres and rims 165
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 minimizes
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 is to be
checked at 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

008153
serious accidents.
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 disman-
tled and checked for damage. Let service personnel change
tyres, they have the competence and authorization to handle
004873
tyres!
1. Lock ring 2. Connect the compressor with a locking air-chuck to the nipple on
2. Rim edge the tyre.
3. Tapered rim course 3. Move to the side and stay to the side of the tyre until inflating has
been completed.
4. Inflate the tyre to the prescribed pressure, see chapter 9 Specifi-
cations. When changing tyre or rim version, another tyre pressure
may apply, contact Cargotec.

166 6 Inspection and maintenance – 6.2.11 Checking accumulators
6.2.11 Checking accumulators

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

A
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 warning lamp for low brake pressure illuminates, see Overview
Spirit Delta, page 38 (position 33):
1. Start the engine and let it run until the accumulators are filled.
Warning lamp for low brake pressure goes out, see Overview
Spirit Delta, page 38 (position 33).
008159
2. Stop the engine and then turn the start key to position I.
3. Press down the brake pedal with long pumping brake strokes, with
A. Accumulators for brake system
a slight delay between each braking action.
4. It should be possible to brake at least eight times before the light
for low brake pressure lights up.
5. Start the engine, let the accumulators charge and repeat the test
a couple of times.
If it is not possible to brake eight times before the warning lamp for low
brake pressure lights up, there is a defect in the accumulators. Contact
service as soon as possible for troubleshooting and suitable action.
WARNING
The machine’s hydraulic system includes
accumulators with high pressure.
Always be very careful when working with the 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 – 6.2.12 Battery and battery disconnector 167
6.2.12 Battery and battery disconnector

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

injury!
The battery’s terminals may not be connected to each

other or to common ground (chassis).
B
CAUTION
008160
A
A. Battery disconnector Always turn off the electric power at the end of your
B. Battery cover shift, when working on the electrical system and
when welding on the machine.
Danger!
Turn off the electric power with the battery

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).
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
water. If electrolyte has splashed in eyes, rinse imme-
diately with plenty of water and contact a doctor
immediately.
The batteries are located inside of a cover (position B) behind the

steps on the machine’s left side.

168 6 Inspection and maintenance – 6.2.12 Battery and battery disconnector
Checking the electrolyte level is recommended. Fill as needed with

deionized water.
1. Turn off the battery voltage (position A) and open the cover.
2. Check level. Fill as needed with deionized water.
The electrolyte’s fluid level should be 10 mm over the cells.
Batteries contain substances hazardous to the environment and
personal health. Therefore, discarded batteries must be handled
according to local/national regulations.
Starting with booster battery
WARNING
Handle batteries and connectors with care when
charging and during starts with booster batteries. Do
not mix up the battery terminals! Follow instructions
for starting with booster battery!
Risk of short-circuiting! Warning - generation of

oxy-hydrogen gas! Sparks and fire hazard! Oxy-hy-
drogen gas is very explosive! 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. Turn off the main electric power and open the cover.
2. Check that the booster batteries are connected in series so that
they supply 24 V. Do not disconnect the ordinary cables to the
machine’s battery.
3. Connect in the following order:
a. The red booster cable (+) to the discharged battery
b. The red booster cable (+) to the booster battery.
c. The black booster cable (–) to the booster battery.
d. The black booster cable to a point some distance from the
discharged battery, e.g., at the minus cable’s connection to the
frame or directly to the engine block.
4. Start the engine.
Do not move the connections during the start attempt – risk of
sparks. Do not lean over any of the batteries.
5. Disconnect the cables in the reverse order as to when connecting
them.

6 Inspection and maintenance – 6.2.13 Main fuses for electrical system 169
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.
A A. Main fuses in electrical distribution box on frame, 4 fuses 50 A.

Cuts off all electric power.
Changing main fuse/fuse
When checking and changing main fuse/fuse:
1. Turn off the main electric power (position A).
2. Remove the plastic cover.
3. Check and change fuses when needed.
The fuses are 50 A.
008161
A. Main fuse in electrical distribution box on frame
Connection terminal blocks on frame and carriage

page
–
The connection terminal blocks for the electrical system are located on
the front of the frame and the rear of the carriage. They are used for
fitting/removing the mast and carriage.
Connecting/disconnecting the cables in the connection terminal
blocks.
1. Turn off the main electric power.
2. Remove the plastic cover.
3. Unscrew the nuts and fit/remove the cables.
4. Screw on the nuts and press on the cover.
NOTE
Risk for large currents in the connection terminal blocks when the
main current is switched on.
008171
Connection terminal blocks on frame and carriage

170 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 machine’s electrical system is divided into three electric power

circuits:
• Battery voltage, so-called 30-voltage
• Ignition voltage, so-called 15-voltage
• Control breaker voltage, so-called 15E-voltage
Each one of these three circuits has separate fuses and fuse holders
(position B, C and D).
The fuses for the electrical system are located in the electrical distri-
bution box on the side of the machine and in an electrical distribution
box in the cab.
The electrical distribution box is located behind the driver’s seat in the
cab. There are fuses for the control units and equipment in the cab.
A
012846
B C D
A. Fuses in cab
B. 15E-fuses (control breaker voltage)
C. 15-fuses (ignition voltage)
D. 30-fuses (battery voltage)

6 Inspection and maintenance – 6.2.14 Fuses for electrical system 171
A1 30A CAB
A42174.0300
B2 5A
C3 15A ENGINE
F58-1 30 MAIN POWER

D4 10A ENGINE
E5 5A TRANSMISSION
F6
G7
H8
A1 30A KDU, FRONT (KALMAR DISTRIBUTION UNIT)
B2 5A
SUPPLY POWER
F58-2 15 SUPPLY POWER
C3 25A KDU, OPT (KALMAR DISTRIBUTION UNIT) A1 10A KCU (KALMAR CAB UNIT)
923935.0185
D4 10A OPT B2 5A KCU,START UP (KALMAR CAB UNIT)
F58-4 15
E5 5A SWITCHES & SENSORS C3 10A SERVICE
CAB
D4 10A OPT CUSTOMER
F6 5A TRANSMISSION
E5 10A OPT RADIO
MAIN POWER
G7 5A ENGINE
F6 25A OPT SEAT HEATER, TURNABLE SEAT
F58-4 30
H8 5A ENGINE
G7 15A OPT WORK LIGHT
CAB
H8 15A OPT AIRCUSHIONED SEAT
A1 25A KDU, ATTACHMENT (KALMAR DISTRIBUTION UNIT)
B2 5A OPT A1 25A KCU (KALMAR CAB UNIT)
F58-5 15 SUPPLY POWER CAB

F58-3 15E SUPPLY POWER
C3 5A ATTACHMENT B2 10A KIT (KALMAR INFORMATION TERMINAL)
D4 C3 15A ECC, FAN (ELECTRONIC CLIMATE CONTROL)
D4 5A ECC, RECIRC (ELECTRONIC CLIMATE CONTROL)

E5 5A KDU, OPT CHASSI (KALMAR DISTRIBUTION UNIT)
EMERGENCY
E5 10A SERVICE
F6
F6 5A OPT MAP READING LIGHT
G7
G7 10A OPT CONVERTER 12V
010443
H8 5A FEEDBACK K2
H8 10A OPT COMPRESSOR HORN
Fuse plate at electrical distribution box for frame (left) and cab (right)
Table 6. Fuse holder 58-4 (cab)
Connection Fuse number / Size Functions
1 1 / 10A Control unit cab (KCU)
2 2 / 5A Control unit cab (KCU), start-up
3 3 / 10A Service
4 4 / 10A
Customer-specific equipment
5 5 / 10A
Radio
6 6 / 25A
Seat heating, revolving driver’s seat
7 7 / 15A
Work lights, cab roof
8 8 / 15A
Air suspension, driver’s seat

172 6 Inspection and maintenance – 6.2.14 Fuses for electrical system
Table 7. Fuse holder 58-5 (cab)
1 1 / 25A Control unit cab (KCU)
2 2 / 10A Control unit KIT
3 3 / 15A Air conditioning, fan
4 4 / 5A Air conditioning, recirculation
5 5 / 10A Service / Customer-specific equipment
6 6 / 5A
Lighting, writing table
7 7 / 10A
Voltage converter 12 VDC
8 8 / 10A
Loud horn
Table 8. Fuse holder 58-1 (30-voltage)
1 1 / 30A Cab
2 2/- -
3 3 / 15A Engine
4 4 / 10A Engine
5 5 / 5A Transmission
6 6 / 15A
Cooling fan for brake system
7 7/- -
8 8/- -
Table 9. Fuse holder 58-2 (15-voltage)
1 1 / 30A Control unit frame (KDU)
2 2/- -
3 3 / 25A
Control unit frame, option (KDU)
4 4/- -
5 5 / 5A Sensor
6 6 / 5A Transmission
7 7 / 5A Engine
8 8 / 5A Engine

6 Inspection and maintenance – 6.2.14 Fuses for electrical system 173
Table 10. Fuse holder 58-3 (15E-voltage)
1 1 / 25A KDU attachment
2 2 / 5A -
3 3/- -
4 4/- -
5 5 / 5A Control unit frame, option (KDU)
6 6/- -
7 7/- -
8 8 / 5A Feedback relay K3009-1 (K2)
When checking and changing fuses:

1. Turn off the main electric power.
See Battery and battery disconnector, general page 167.
2. Remove the cover from the electrical distribution box.
3. Remove the cover from the fuse holder.
4. Check and change fuses when needed.
The fuse plate gives information about each fuse.

174 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:
• Interior lighting
• Rear light, red
• Brake light
• Indicator light for travel direction
• Position light
• Headlights (for high and low beams)
• Reversing light, white
• Working lights
• Rotating beacon
Instructions
Applies for the following:
• Headlights (for high and low beams)
• Reversing light, white
• Working lights
1 Loosen the rubber strip (position A).
B A 2 Remove the glass (position B).
3 Change light bulb.
002085
A. Rubber strip
B. Glass

6 Inspection and maintenance – 6.3 Service 175
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
authorized by Cargotec.
CAUTION
Service interval must be followed.
This is to maintain the machine’s safety as well as to

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

fulfil warranty terms.
Service intervals and actions are described in the maintenance

manual.
CAUTION
When welding on the machine, all control units shall
be disconnected to prevent damage.
Undo the connectors from the control units!

176 6 Inspection and maintenance – 6.3 Service
WARNING
For safety reasons, the following spare parts may
only be replaced with genuine spare parts:
• Brake valve
• Drive axle
• Valve for mini-wheel/joystick steering
• Steering valve (Orbitrol)
• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Rim
• Solid wheels
• Mast, carriage
• Lift cylinder incl. load control valve
• Valve block lift
• Lifting chains
• Chain tensioner and axle
• Tilt cylinder
• Twistlock, lifting hook
• Control breaker (for hydraulic function)
• Emergency stop
• Hydraulic cylinder, cab tilt
• Accumulator
• Tilt valve
• Main valve load handling
• Accumulator charging valve
• All control units

7 Transporting the machine 177
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
extensive damage in case of a fall and similar.

property 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.

178 7 Transporting the machine – 7.1 Towing
7.1 Towing
General
page
–
DANGER
The machine cannot be operated or braked if the
hydraulic pressure is lost, e.g., if the engine is off.
Rolling machine! Extreme danger!
If possible, tow with maintained hydraulic pressure. If

it’s not possible to tow with the engine running, a tow
bar must be used! Only tow for short distances!
CAUTION
Do not try to start the machine by towing.
Causes serious damage to engine and power

transmission!
Start the engine according to instructions in the

operator’s manual.
If it’s not possible to have the engine running when towing, a tow bar
must be used.
Before taking actions and after finished towing, the parking brake must
be applied and the wheels blocked to prevent the machine from
starting to roll.
Extreme care must be observed during towing work to avoid personal
injuries.
When towing, keep in mind:
• The towing vehicle should be heavier than the vehicle in tow.
• If possible when towing, the engine should be running in order for
brakes and steering to function.
When the engine is off, there’s no hydraulic pressure to the steer-
ing function and thus the machine’s steering function is severely
limited. Also, transmission lubrication is insufficient.
• The brakes work as long as there is pressure in the accumulators,
then the service brake cease to function and the parking brake is
applied automatically. After that, if it’s necessary to move/tow the
machine, the parking brake has to be released mechanically, see
section 7.1.1 "Mechanical release of parking brake".
• Only tow for very short distances.
• If it’s necessary to tow the machine, the propeller shaft must be
disconnected from both transmission and drive axle.

7 Transporting the machine – 7.1.1 Mechanical release of parking brake 179
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 accumulators should
drop below a certain level.
If the machine has to be moved (towed) without sufficient pressure in
the hydraulic accumulators, the parking brake must be released
mechanically (manually).
DANGER
Before starting to work with the parking brake, make
sure that the machine cannot move when the braking
action is released.
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.

180 7 Transporting the machine – 7.1.1 Mechanical release of parking brake
The parking brake is a disc brake on the drive axle’s input shaft.
A B C
1. Remove protective cover from the caliper (position B).
2. Note the adjusting screw’s position.
3. Loosen the lock nut.
4. Screw out the adjusting screw, this compresses the brake spring.
Screw until the brake pads release from the brake disc.
5. Restore the parking brake function by screwing in the adjusting
007274
screw to the same position as in step 2.
6. Refit protective cover on the caliper.
A. Brake disc for parking brake
B. Protective cap over adjusting screw
C. Parking brake caliper NOTE
The parking brake may have to be adjusted again. See
Maintenance manual.
NOTE
If the parking brake has been released mechanically, the parking
brake must always be restored in order to give the machine

7 Transporting the machine – 7.2 Lifting and transporting the machine 181
7.2 Lifting and transporting the

machine
General
page
–
When lifting and transporting the machine, follow the safety

regulations 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
transport and machine.
DANGER
Overload of load equipment.
Extreme danger!
Lifting equipment should be dimensioned for the

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

transported:
• Turn off the main electric power (battery disconnector).
• Remove any fragile equipment, e.g., rear-view mirrors.
• If transport is to take place on a public road:
Make sure that laws and regulations are followed with regards to
height, weight, width, and axle load limitations.
• Apply parking brake.
• Secure the machine for transport on, e.g., a trailer, with chains.
See plate for machine’s weight.
Front: Attach the chains in the eyes on frame left and right side (by
leading edge wheel housing) or around the drive axle.
NOTE
Cross the chains when securing for optimal stability.
Rear: Secure chains in towing eye (by vertical counterweight), alt.
around the steering axle.

182 7 Transporting the machine – 7.2.1 Lifting machine
7.2.1 Lifting machine

Instructions, lifting with lifting eyes
page
–
The forklift is provided with two lifting eyes on the mast.

1. Use the lifting eyes on the mast and secure chains around
counterweight/rear wheels to secure the lifting device.
2. The lifting device must be adapted so that the lifting point runs
through the machine’s centre of gravity.
012847

7 Transporting the machine – 7.2.2 Transporting the machine 183
7.2.2 Transporting the machine

Instructions, transporting on trailer
page
–
The forklift shall be transported on a trailer that is wide enough to

support the drive axle’s inner wheel.
1. Reverse the forklift up on the trailer.
2. Secure the front part of the forklift using chains provided with
hooks and tensioner devices. Secure the chains in a safe way in
the chassis and in the intended attaching points on the trailer.
3. Secure the rear part of the forklift using chains provided with
hooks and tensioner devices. Secure the chains in the tow bar and
in the intended attaching points on the trailer.

184 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.
• Attachment lowered and mast tilted forward.
• Engine off.
• Main electric power off (with battery disconnector).

7 Transporting the machine – 7.4 Long-term storage 185
7.4 Long-term storage

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

186 7 Transporting the machine – 7.4 Long-term storage

8 Environment and standards 187
8. Environment and standards
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 life
cycle to come full circle, and for being able to recycle and make use of
material in new products. According to calculations by Cargotec, more
than 90% of the machine weight is recyclable.
Environmentally hazardous waste

Components such as batteries, oils, and various chemicals and other
items that may constitute environmentally hazardous waste must be
handled and taken care of in an environmentally safe and sound
manner.
Discarded batteries contain substances hazardous to personal health
and the environment. Therefore, handle batteries in an 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 authorized
disposal company.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal the leaks.
Air conditioning
The refrigerant in the air conditioning for the cab adds to the "green-
house effect" if released into the open air. Special training is required
for all service work on the air conditioning. Many countries also require
certification by a governing authority for such work. When scrapping
an air conditioning unit, the refrigerant shall be taken care of by a
certified company.

188 8 Environment and standards
Working in a contaminated area

The machine shall 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
servicing such a machine.
Standards
–
Noise, vibration, stability and visibility, etc.

This machine meets the harmonised standard EN 1551 "Safety of in-
dustrial trucks. Self-propelled trucks over 10000 kg lift capacity" and
the North American standard ANSI/ASME B56.1 "Safety Standard for
Low Lift and High Lift Trucks".
CE-marking
Machines for the EU/EEC 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 harmonised standard EN12895.
The machine’s CE-marking and declaration of conformity also cover
the EMC directive. If other electronic equipment is installed on the ma-
chine, 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/EEC market fulfil EU's Exhaust directive
97/68/EC and 2004/26/EC, which means that the engine’s exhaust
emissions have been limited according to the requirements.
Machines for the North American market fulfil EPA's and CARB's ex-
haust regulations, which means that engine exhaust emissions have
been limited according to the requirements.

8 Environment and standards 189
Noise emissions
The machine for the EU/EEA market fulfils the EU Noise directive
2000/14/EC which means that the machine is marked with measured
environmental noise emissions which are also limited according to the
requirements for trucks with lift capacity over 10 000 kg. See
section 3.2 Plates.
Vibration standard
Vibrations emitted by the machine are measured according to harmo-
nised standard EN 13059, where the level of vibrations varies depend-
ing on with which type of tyres and operator’s seat the machine is
equipped. See section 9 Specifications.

190 8 Environment and standards

9 Specifications 191
9. Specifications
9 Specifications
mm mm mm mm mm mm
Technical data
page
–
Machine weights and dimensions vary according to how the machine

is equipped and is shown in detail in the product specification and spec
sheet for the machine in question.
1. Engine Volvo TAD760VE Cummins QSB6.7
Output according to ISO 3046 180kW at 2200 rpm 164 kW at 2200 rpm
(net output)
Torque ISO 3046 1100 Nm at 1500 rpm 949 Nm at 1500 rpm
Number of cylinders 6 cylinders 6 cylinders
Alternator, output 1920 W 1680 W
Start battery, voltage – capacity 2x12 V – 140 Ah 2x12 V – 140 Ah
2. Transmission Dana-Spicer Off Highway TE17
No. of gears, forward – reverse 3–3
3. Power transmission
Drive axle, type Kessler D81

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
Dimension, front and rear 14.00x24
Tyre pressure, also see pressure plate 1.0 MPa
Tyre type, front and rear Air-inflated. Spare and replacement tires shall be made
Brand name approved by Cargotec.

192 9 Specifications
9. Cab Spirit Delta with Volvo TAD760VE Spirit Delta with Cummins QSB6.7
Equivalent sound pressure level in cab LpAZ 69 dB(A) LpAZ 65 dB(A)

according to EN12053 with measure-
ment uncertainty R= 2.5 dB. Meas-
urement value with standard engine.
Whole-body vibrations according to 0,4 - 0,7 m/s2

EN13059 with measurement uncer-
tainty 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
Fuel tank, capacity 450 l
Fuel quality Diesel, according to EN590
1.7 Engine, cooling system Volvo TAD760VE Cummins QSB6.7
Coolant volume 22 l 29 l
Coolant, filling point Volvo Penta Coolant VCS, ES Compleat, Premix

ready-mixed for part no., see spare parts
for part no., see spare parts catalogue.
catalogue.
1.8 Engine, lubrication system Volvo TAD760VE Cummins QSB6.7
Oil type, quality See Recommended oils and lubricants page 194.
Oil volume 23 l 20 l
2.6 Transmission, lubrication TE17

system
Oil type See Recommended oils and lubricants page 194.
Oil volume 37 l
3.3 Power transmission, drive axle Kessler D81 - Kessler D91
Oil quality See Recommended oils and lubricants page 194.
Oil volume, differential 42 l - 54 l
Oil volume, hub reduction 2x4 l - 2x4 l
4.8 Brake system


7 Load handling
9 Frame, body, cab and accessories

Refrigerant air conditioning R134a
Volume refrigerant See the plate for air conditioning
Lubricant air conditioning ZEXEL PAG oil ZXL100
Washer fluid, volume 5l
10 Common hydraulics
Hydraulic oil tank, volume 360 l
Hydraulic oil system, volume 450 l

Recommended oils and lubricants

–
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 -40 -30 -20 -10 0 +10 +20 +30 +40

Oil type, quality °F -40 -22 -4 +14 +32 +50 +68 +86 104
1.8 Engine, lubrication system
Volvo TAD760VE: VDS-3 SAE 15W40
Cummins QSB6.7: API CH-4 / ACEA E5 SAE 5W30 (motor oil)
2.6 Transmission, lubrication system

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

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

*) The oil in the brake system has to meet one of the quality
requirements.
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute VDS = Volvo Drain Specification
Lubricating grease
Use universal grease of type EP according to NLGI Grade 2 (EP2) with
3-5% molybdenum sulfide 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 and may only be used
if the outdoor temperature is always above 0 ºC.
NOTE! It is important that the coolant is mixed correctly all year to en-
sure adequate corrosion protection. The corrosion-protective proper-
ties decline with time, and that is why the coolant must be replaced
according to stated intervals.
A mixture of 60% distilled water and 40% glycol gives freezing
protection down to temperatures of -28 ºC.
A mixture of 40% distilled water and 60% glycol gives freezing
protection down to temperatures of -54 ºC.
CAUTION
Different types of coolant may not be mixed.
Risk of engine damage if different types of coolant are

mixed.
When changing and topping up coolant, the same

type of coolant must be used as was used before. See
Spare parts catalogue for correct part number.

Specifications light bulbs

–
Lamp Output (W) Socket

Check lamps 1.2 W2x4.6d
Interior lighting 10 S8.5
Rear lights* 5 BA15s
Brake light* 21 BA15s
Direction indicators* 21 BA15s
Position lamps 5 W2.1x9.5d
Headlights (for high and low beams) 75/70 H4
Back-up light 70 H3
Working light, glowing light 70 PK22s
35W D1S Xenon tubes.

Working lights, Xenon
Insert incl. ballast is replaced
complete.
Rotating 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 201
10. Terminology
10 Terminology
mm mm mm mm mm mm
Explanations
page
–
Term Description
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.
Battery disconnect switch Cuts off power supply from battery.
Buzzer Acoustic alarm to catch the operator’s attention.
Control valve Valves that can be used to control something, for example, to release pressure and thus
lower a boom or a fork. See also control valve.
Daily inspection Actions that should be performed daily to ensure the machine’s functionality.
Decitonne Tenth of a tonne, measure of machine’s lift capacity.
Display "Window" showing digital information, i.e. on steering wheel panel in cab.
Drive axle Driving axle that receives the torque from the drivetrain.
Drivetrain Parts in the machine involved in power transmission; engine, torque converter,
transmission, 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
automatically during operation.
ECC Electric Climate Control. Climate control unit with thermostat-controlled cooling,
dehumidification and heating.
EHC Electric Heat Control. Heater unit with thermostat-controlled heating.
Electrolyte level Fluid level in battery cells.
End-positions As far out or away as an object can be moved, e.g. end-positions for tilt cylinders.
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Expansion tank Reservoir for coolant, with space for the coolant’s volume change due to temperature
differences.
Fixed displacement Non-adjustable volume (capacity) in a pump.
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 system System that uses oil pressure to transfer power to different functions.
Indicator Mechanical "sensor", displays, e.g., that a filter is clogged and needs to be changed.
LC Load centre.
Levelling Attachment is tilted, for example if load stands on uneven ground.

202 10 Terminology
Term Description
Lift capacity Indicates machine’s maximal lift capacity.
Lifting point Attaching point for lift device when lifting an object.
Lock hooks Two hooks that are inserted down/in holes in the container to secure the container when
lifting.
Low-emission engine Engine with low emissions of hazardous substances. Manufactured according to specified
and governing regulations.
Machine model Machine type. Indicated, e.g.: DCF 80-100. 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 trolley, 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.
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 electromagnetically controlled valve. If a current is applied, the valve is activated in
proportion to the current’s amplitude. In simple terms, infinitely variable valve, as opposed
to on/off. For example, found on transmission’s valve housing.
Recirculation Circulate over and over again.
Refrigerant Fluid/gas in air conditioning. May 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 Power amplifier. A small movement by the user results in a big movement, e.g., power
steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side shift Parallel sideways movement of attachment.
Sidelift Attachment, see attachment.
Solenoid valve An electromagnetically controlled valve. See also proportional valve.
Spirit Delta Enclosed type of cab.
Spreading (positioning) Widening of attachment.
Steering axle Wheel axle with steering.
Tilting The mast is leaned forward or backward.
Torque converter Hydraulic, variable clutch.
Transmission oil Oil for transmission and torque converter. See specifications, operator’s manual.
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.

10 Terminology 203
Term Description
Type designation Indicates machine type and capacity. See also machine model.
Valve slide Moveable part in valve. Determines oil’s path.
Wet brakes Brake discs in oil bath.
Wheelbase Distance between drive axle and steering axle.
Working hydraulics All load handling functions, that is, lift and lower, tilt, sideshift, spreading (extension) and
levelling.

204 10 Terminology

11 Index
About the documentation kit 6 Operating menu for service interval 74
About the operator’s manual 3 Operating menu statistics 75
Air filter engine 156 Operating menus 72
ANSI/ASME-marking 13 Overview 23
Battery and battery disconnector 167 Overview description 24
CE-marking 12 Parking brake 120
Checking accumulators 166 Pedals 62
Cleanliness 151 Plates 30
Control system 72 Reading instructions 4
Cooling system 157 Running-in 81
Daily inspection 146 Safety 9
Daily inspection 82 Safety and emergency equipment 11
Description, DCF 80-100 23 Service 175
Driver’s seat (10) 66 Service brake 119
Engine oil 159 Service position 184
Environment and standards 187 Specifications 191
Error code indication 84 Starting engine 115
Error code information on display 85 Steering 119
Error code tables 89 Steering wheel (4) 63
Error codes 83 Stopping engine – parking 125
Event-controlled information for sidelift attachment 76 Switches 49
Foreword 3 Terminology 201
Fuel system 153 Towing 178
Functions for load handling 142 Transmission oil 161
Fuses for electrical system 170 Transporting load 135
Gear selector and multi-function lever (2) 55 Transporting the machine 177
Gearshifting 117 Transporting the machine 183
Handling 79 Tyres and rims 163
Heating / Air conditioning 122 Unloading 140
Heating / Air conditioning 69 Warming up 116
Hydraulic control (9) 57 Warning and indicator lights 44
Hydraulic system 162 While operating 113
Identification of the machine 23 Windscreen washer 155
Ignition (53) 48
Inspection and maintenance 145
Inspection and maintenance 7
Instruments 47
Instruments and controls 39
Keep in mind 14
Lifting and transporting the machine 181
Lifting load 129
Lifting machine 182
Lighting 174
Load handling 126
Long-term storage 185
Main fuses for electrical system 169
Maintenance 150
Mechanical release of parking brake 179
Operating 113
Operating menu electrical system 74
Operating menu for container counter 74
Operating menu for engine 73
Operating menu for engine and transmission 73
Operating menu for heating system/air conditioning system
76
Operating menu for oil temperature 73
Operating menu for service 75
Declaration of Conformity
We, Cargotec Sweden AB, SE-340 10 Lidhult, (Registration No. 556014-5418) herewith
declare that the machine,
Type Containerhandler
Model DCF100-45E7
Serial No A301.XXXXX
Year of construction 2010
Engine VOLVO TAD 760VE
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 1459 Safety of industrial trucks

– Self propelled variable reach trucks.
Name
Position Head Of Counterbalanced Products
Place, Date of Issue Signature

2A_TEST_R_GB
Blnk.lxf
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.
tel. +46 372 260 00
Cargotec’s global network offers extensive services that ensure the fax +46 372 263 90
continuous, reliable and sustainable performance of equipment. www.cargotec.com

IDCF03 - 03GB - DCF80-100 Operator Manual

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IDCF03 - 03GB - DCF80-100 Operator Manual

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Empty Container Handler

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 DCF 80-100.

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

About machine version

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

This machine is manufactured by Cargotec Sweden AB,

Operator’s manual DCF 80-100 IDCF03.03GB

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-

Read the operator’s manual

Read the operator’s manual/maintenance manual

Read the Maintenance manual

IDCF03.03GB Operator’s manual DCF 80-100

Operator’s manual DCF 80-100 IDCF03.03GB

1.2 About the documentation kit

The following documentation is supplied with the machine:

The documentation is ordered from the dealer for Cargotec.

IDCF03.03GB Operator’s manual DCF 80-100

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 DCF 80-100 IDCF03.03GB

IDCF03.03GB Operator’s manual DCF 80-100

Important to read the operator’s

Operator’s manual DCF 80-100 IDCF03.03GB

Any modification or rebuild without Cargotec’s permissions can-

• The machine may only be operated by specially trained operators

Machine operation is prohibited:

IDCF03.03GB Operator’s manual DCF 80-100

2.1 Safety and emergency

A good work environment has safety and emergency equipment to

4. Electrically powered high-volume horn

8. Camera with monitor

Operator’s manual DCF 80-100 IDCF03.03GB

(Declaration of Conformity, only applies to machines marketed

IDCF03.03GB Operator’s manual DCF 80-100

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

012900 For additional information, see standards under chapter 8 Environ-

Operator’s manual DCF 80-100 IDCF03.03GB

2.4 Keep in mind

Turn off the electric power with the battery

IDCF03.03GB Operator’s manual DCF 80-100

During work shifts

Extreme hazard to personal health and risk of

Never walk under a suspended load. Never walk

Extreme hazard to personal health and risk of

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 DCF 80-100 IDCF03.03GB

Extreme hazard to personal health and risk of

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

• The operator must always face in the travel

• The operator must adapt the speed to the load and

• The operator must pay extra attention and operate

• Always operate carefully so that the attachment

• Use available visibility equipment such as rear

IDCF03.03GB Operator’s manual DCF 80-100

Risk of roll-over and tipping over! Risk of load