Forklift trucks 18-33 tonnes

Publ. no IDCG02.03GB
Operator's manual in original OPERATOR’S MANUAL

DCG 180-330
1 Foreword ................................................................................................................................ 1
1.1 About the operator's manual.............................................................................................. 1
1.2 About the documentation kit .............................................................................................. 4
1.3 Inspection and maintenance .............................................................................................. 5
2 Safety ..................................................................................................................................... 6
2.1 Safety and emergency equipment ..................................................................................... 8
2.2 CE-marking ........................................................................................................................ 9
2.3 ANSI/ITSDF marking ....................................................................................................... 10
2.4 Keep in mind ..................................................................................................................... 11
2.5 Fire................................................................................................................................... 18
3 Overview............................................................................................................................... 20
3.1 Description ....................................................................................................................... 20
3.2 Plates ............................................................................................................................... 26
4 Instruments and controls ...................................................................................................... 34
4.1 Warning and indicator lights............................................................................................. 40
4.2 Ignition key lock and start and stop button for the engine................................................ 43
4.3 Switches .......................................................................................................................... 45
4.4 Travel direction selector and parking brake ..................................................................... 58
4.5 Multi-function lever........................................................................................................... 60
4.6 Load handling .................................................................................................................. 61
4.7 Pedals .............................................................................................................................. 66
4.8 Steering wheel ................................................................................................................. 68
4.9 Driver's seat ..................................................................................................................... 72
4.10 Heating / Air conditioning ................................................................................................. 76
4.11 Control system ................................................................................................................. 78
4.12 Optional equipment.......................................................................................................... 98
5 Handling ............................................................................................................................. 102
5.1 Running-in ..................................................................................................................... 105
5.2 Daily inspection.............................................................................................................. 106
5.3 Error codes .................................................................................................................... 107
5.4 Operating ....................................................................................................................... 213
5.5 Load handling ................................................................................................................ 234
5.6 Customer settings via display ........................................................................................ 253
6 Inspection and maintenance............................................................................................... 265
6.1 Daily inspection.............................................................................................................. 266
6.2 Maintenance .................................................................................................................. 271
6.3 Service ........................................................................................................................... 306
7 Transporting the machine ................................................................................................... 308
7.1 Towing............................................................................................................................ 309
7.2 Lifting and transporting the machine............................................................................... 311
7.3 Service position.............................................................................................................. 313
7.4 Attachment of lifting equipment...................................................................................... 314
7.5 Long-term storage.......................................................................................................... 338
8 Environment and standards................................................................................................ 341
9 Specifications ..................................................................................................................... 344
10 Terminology ........................................................................................................................ 356
11 Index.................................................................................................................................... 359

Operator’s manual DCG 180-330 IDCG02.03GB

IDCG02.03GB Operator’s manual DCG 180-330
 1 Foreword 1

1 Foreword
1.1 About the operator's manual
General
Thank you for choosing Kalmar as your machine supplier. We hope
that we will meet your expectations.

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

mind for safe handling and optimal use of your new Kalmar machine.

Operator's manual, purpose

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

Cargotec will not accept any responsibility for machine modifications

without permission from Cargotec. Further, Cargotec will not accept
any responsibility if other lifting devices, tools or work methods are
used other than those described in this manual.

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

About machine version

The information in this publication corresponds with the machine's
design and appearance on delivery from Cargotec. Deviations may
arise due to customer adaptations.

Cargotec reserves the right to make changes to specifications and

equipment without prior notice. Information provided in the manual
applies at the date of issue.

Copyright
Cargotec Sweden AB

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

prohibited without written permission from Cargotec Sweden AB.

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

prohibited.

Manufacturer
Cargotec Sweden AB, Movägen 1, SE-341 32 Ljungby, Sweden.

Operator’s manual DCG 180-330 IDCG02.03GB

2 1 Foreword – Reading instructions

1.1.1 Reading instructions

Warning information
This manual contains descriptions of warnings that apply to your safety.
Warnings provide information about potential dangers that, if the
warnings are not followed, could result in injury or product damage.

DANGER
Situation that could lead to severe personal injury or
death if regulation is not followed.

WARNING
Situation that could lead to personal injury if regulation
is not followed.

CAUTION
Situation that could lead to product damage if
regulation is not followed.

Important information
Important information is denoted with NOTE and is intended to
facilitate the work process, handling or to increase understanding of
the information.

NOTE
Important information not related to safety.

Read the operator's manual

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

Read the operator's manual

Read the Maintenance manual

The symbol to the left is used in certain cases on the machine and
001128

refers to important information in the Maintenance manual.

Read the Maintenance manual

IDCG02.03GB Operator’s manual DCG 180-330

 1 Foreword – Reading instructions 3

Optional equipment
There is a range of optional equipment available for the machine.

000264
Each description of optional equipment in the manual is marked with
a symbol, and contains an explanatory text. The symbol is positioned
Indicates optional equipment visibly by the text and image in question.

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

product alternatives and optional equipment.

Operator’s manual DCG 180-330 IDCG02.03GB

4 1 Foreword – About the documentation kit

1.2 About the documentation kit

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

There is supplementary documentation that can be ordered for the

machine:
• Workshop manual.
• Supplier documentation for engine, transmission, and drive axle.

Ordering documentation
The documentation is ordered from the dealer for Cargotec.

Always indicate publication number when ordering. The publication

number is printed down to the left on the cover and at the bottom of
all pages in the manual.

IDCG02.03GB Operator’s manual DCG 180-330

1 Foreword – Inspection and maintenance 5

1.3 Inspection and maintenance

General
Maintenance must be managed properly in order for the machine to
operate satisfactorily and at the lowest cost. Intervals for inspection
and maintenance refer to operation under normal environmental and
working conditions.

Maintenance described in this operator's manual can be performed by

the operator, see Chapter 6 Inspection and maintenance. It describes
the daily inspections that comprise ongoing checks and actions that the
operator should carry out when starting a shift.

Maintenance
For other maintenance not included in this operator's manual (service
and repairs), contact an authorised workshop.

Operator’s manual DCG 180-330 IDCG02.03GB

6 2 Safety

2 Safety
General
Safety rules are intended to reduce the risk of personal injuries as well
as damage to the load or other property.

Only personnel trained for this machine may handle, operate, perform
service or be in its vicinity during its use.

The safety information in this operator's manual is intended for your

information and safety. It cannot, and is not intended to, cover all
possible events during operation. Responsible operators with the
right training is the only way to ensure the safe and prolonged use
of the machine.

The machine was thoroughly tested and adjusted before it left the
factory. This does not preclude the possibility that it has been damaged
during delivery. The machine must undergo a thorough inspection in
order to ensure correct function before being put into service.

Important to read the operator's manual

Incorrect operation may lead to injury and product, and/or property
damage. For this reason, please read this operator's manual very
carefully before using the machine. The operator's manual contains
important information about your Kalmar machine, the machine's
handling, safety during work and about the machine's daily inspection.
000262

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

it easier for you at work.

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

a replacement must be acquired immediately.

NOTE
Never use a machine that does not have an operator's manual.

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

not understand or if you feel information is missing in any area.

IDCG02.03GB Operator’s manual DCG 180-330

 2 Safety – Safety 7

Intended use
• The machine must only be used for what it is designed and
manufactured for, i.e. to lift and transport goods whose weight
and load centre/centre of gravity do not exceed the machine's
maximum permitted load capacity. If it is used in any other way
or in potentially dangerous environments (e.g. an explosive
environment, an area with asbestos dust) then special safety rules
must be followed and the machine must be equipped for such
operations.
• The machine should not be modified or changed without permission
from Cargotec. In the event of modifications approved by Cargotec
the signs on the machine and documentation affected must be
adapted to apply to the modification.
In the event of modification or conversion without Cargotec's
permission Cargotec's product liability ceases to apply. Modification
and conversion may only be made if the knowledge exists to
verify and test the modifications and conversions. Modifications
and conversions must be documented (date and action) and the
organisation responsible must be stated with name and address.
Signs and stickers must be updated in accordance with the
machine's new design.
• The machine may not be operated on public roads unless it has
been adapted according to national road safety regulations.
• It is always the machine owner's responsibility to ensure that the
machine has approved fire-fighting equipment in accordance with
the regulations in force.
• The machine is 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 the event of deviations from this, contact Cargotec.

Operator requirements
• The machine may only be operated by specially trained operators
who have the work supervisor's permission to operate the machine.
• Laws and regulations regarding driver's licenses, operator ID, etc.
must always be followed.
• The operator must be aware of and follow all local safety rules.
• The operator must follow the manufacturer's instructions.
• The operator should read and understand the machine's warning
and information plates as well as understand and be able to use
the machine's safety and warning equipment.

Prohibited operation
Machine operation is prohibited:
• If safety and warning equipment such as rear view mirrors,
headlights, etc., do not function correctly.
• In case of defective brakes, steering or lifting equipment.
• If there are unauthorised persons or vehicles within the machine's
work area.
• If the machine has been repaired, modified or adjusted without the
supervisor's/work management's permission.
• If the machine is equipped with tyres not approved by Cargotec.

Operator’s manual DCG 180-330 IDCG02.03GB

8 2 Safety – Safety and emergency equipment

2.1 Safety and emergency equipment

General
A good work environment has safety and emergency equipment to
help make the operator's work safe, as well as safety equipment to
signal to the surrounding personnel.

The machine may be equipped with the following safety equipment:

1. Back-up alarm
2,9 12 9 7,8
2. Revolving beacon/flashing beacon
The revolving beacon on the cab is vertically adjustable.
10
3. Horn
13
4. Electrically powered loud air horn
5. Fire extinguisher
Fire extinguishers are normally located on the left-hand front
wing but can also be located on the right-hand front wing behind
the right or left-hand footsteps (or several of these locations
simultaneously).
If the machine is supplied with a fire extinguisher, it should be of
021968

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

1,9 6 11 5 3,4 1 9 extinguisher, it is possible to extinguish fires in both solid organic
materials and fluids. Adapted fire extinguishing equipment can be
ordered from Cargotec.
Fire extinguishing system . (Not identified in the figure)
Can be activated automatically, manually on the display in the cab
or with switch on the chassis.
6. Seat belt
A 3-point seat belt is available as an option for the driver's seat
with a high back rest .
7. Buzzer in the cab to indicate an alarm or forgotten action, e.g. if
the operator leaves the driver's seat without applying the parking
brake.
8. Tyre pressure monitoring system that alerts if incorrect tyre
pressure is detected .
9. Camera with monitor
Used to provide improved rearward vision when manoeuvring
and/or load handling with the machine. The monitor is usually
placed inside the cab by the front right door pillar.
10. Exterior mirrors :
Used to provide improved visibility while manoeuvring and load
handling.
10c 10a 10a shows blocked area in front of machine
10b shows blocked area to the side/behind the machine
10b
10c shows blocked area in behind machine
11. Control breaker for load handling
Cuts off all power supply and control signals to load handling.
12. Protective grating for roof window .
021972

13. Protective grating for windscreen .

IDCG02.03GB Operator’s manual DCG 180-330

 2 Safety – CE-marking 9

2.2 CE-marking
CE-marking
(Declaration of Conformity, only applies to machines marketed
within EU/EEA.)

This machine is CE marked. This means that upon delivery it fulfils the
applicable "Essential Health and Safety Requirements" specified in
the EU Machine Directive, 2006/42/EC, as well as other EU directives
relevant to this machine type.

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

with an EC Declaration of Conformity, issued by Cargotec for every
machine. The EC declaration also includes tools and options produced
by the Cargotec. The documentation is a valuable document that
must be properly preserved and saved for at least 10 years. The
documentation must always follow with the machine when it is sold.

See example of EC Declaration after 11 Index.

Anyone making modifications that affect the safety of the machine

also assumes responsibility for them. If the machine is used for other
purposes or with other tools than what is specified in these instructions,
022105

safety must be ensured in each individual case. The machine owner

Machine plates for CE marking is responsible that the machine is used in accordance with the
instructions in the operator's manual. In some cases the application
area may require a new CE marking and issue of new EC declaration
of conformity.

For additional information, see standards under chapter 8 Environment

and standards.

Operator’s manual DCG 180-330 IDCG02.03GB

10 2 Safety – ANSI/ITSDF marking

2.3 ANSI/ITSDF marking

ANSI/ITSDF marking
(Only applies to machines for the North American market.)

This machine is ANSI/ITSDF marked. This means that upon delivery it

fulfils the basic safety requirements of ANSI/ITSDF B56.1.

Anyone making modifications that affect the safety of the machine also
assumes responsibility for them.

If the machine is used for other purposes or with other tools than what
is specified in these instructions, safety must be ensured in each
individual case. The machine owner is responsible that the machine is
used in accordance with the instructions in the operator's manual.
A68645.7100

For additional information, see standards under chapter 8 Environment

and standards.
022114

Machine plates for ANSI/ITSDF marking

IDCG02.03GB Operator’s manual DCG 180-330

 2 Safety – Keep in mind 11

2.4 Keep in mind

Interrupted operation and/or parking

CAUTION
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.

For machines with SCR-system (emission control with AdBlue):

NOTE
Wait for two minutes before the system voltage is disconnected
with the battery disconnector so that the SCR system has time to
be drained of AdBlue, this is particularly important in cold weather.

NOTE
Always check that a gear is not engaged before turning the start
key or resetting the control breaker for load handling.

NOTE
Never leave the operator's station without first applying the parking
brake (ON position).

NOTE
Always remove the start key if the machine is to be left unattended.

During work shifts

DANGER
Forks or other attachments are work tools that handle
large loads.
Extreme hazard to personal health and risk of property
damage!
Make sure that no persons stand or walk under a
raised work attachment, regardless of whether it is
loaded or not.

DANGER
External equipment may only be used if it is approved
by Cargotec.
Extreme hazard to personal health and risk of property
damage!
Only use equipment that is approved by Cargotec.

Operator’s manual DCG 180-330 IDCG02.03GB

12 2 Safety – Keep in mind

DANGER
The parking brake should never be applied when the
machine is moving, unless an emergency requires it.
Very heavy braking. Risk of machine tipping, load
tipping over, being dropped or damage to property
or extreme danger!
Stop the machine before applying the parking brake.

DANGER
The machine's work area is large and visibility from
the operator's cab is restricted.
Extreme hazard to personal health and risk of property
damage!
Keep in mind:
• Always check that no persons are in the way of the
machine or its equipment. Also check that the area
upwards is free. If there are unauthorised persons
or vehicles within the work area then the machine
must be stopped.
• The operator must always face in the travel
direction and should operate with special care
where persons or vehicles may appear.
• The operator must adapt the speed to the load and
ground conditions, visibility, and wind conditions,
etc.
• The operator must pay extra attention and operate
with special care near electric power lines,
viaducts, docksides, ramps, doorways, etc.
• Always operate carefully so that the attachment
does not collide with posts, power lines, etc.
• Use available visibility-enhancing equipment such
as rear view mirrors and camera ( ).

IDCG02.03GB Operator’s manual DCG 180-330

 2 Safety – Keep in mind 13

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

WARNING
The machine's load capacity is limited.
Risk of roll-over and tipping over!
It is forbidden to exceed the machine's load capacity.
See the rating plate and load diagrams.

Operator’s manual DCG 180-330 IDCG02.03GB

14 2 Safety – Keep in mind

WARNING
The strength of the roof window may be significantly
reduced in case of exposure to substances containing
aromatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the surface layer of the roof window and
clean only with washer fluid or mild detergent. Rinse
thoroughly with lukewarm water afterwards. Replace a
damaged roof window that shows cracks or scratches
immediately!

WARNING
Lifting loads in very windy conditions is associated
with great danger.
Risk of roll-over and tipping over! Extreme danger!
Avoid lifting loads in high wind speeds.

WARNING
The machine emits exhausts during operation.
Health hazards and fatal danger in poorly ventilated
facilities!
If possible, avoid operating the machine indoors
in poorly ventilated premises. Use exhaust venting
equipment!

WARNING
Work position on the machine is located up high.
Risk of falling and bodily injury!
Always use steps and handles when you go up or
down from the machine. Always turn to face the
machine. Do not jump!

IDCG02.03GB Operator’s manual DCG 180-330

 2 Safety – Keep in mind 15

WARNING
No lowering of load handling equipment when control
is activated.
Risk of crushing! Make sure that nobody is under the
load handling equipment.
If the load handling equipment is blocked so that it
cannot be lowered to its original position, contact the
Cargotec Service organisation!

WARNING
Cab doors must always be closed when operating.
Risk of personal injury and crushing in the event of
roll-over and tipping!
Always close the doors during the work shift.

WARNING
Passengers may only be carried in the cab provided
that there is a seat available for passengers. Do not
carry passengers on the machine outside the cab or
on the load.
Risk of personal injury!
A passenger in the cab must use a permanently
mounted extra passenger seat and seatbelt.

WARNING
The machine's hydraulic system includes accumulators
with high pressure.
Risk of personal injury!
Always exercise extreme caution when working
with the hydraulic system and avoid unnecessarily
remaining close to hydraulic components or hoses.
The accumulators must be drained prior to work in the
hydraulic system (see Maintenance manual).

Operator’s manual DCG 180-330 IDCG02.03GB

16 2 Safety – Keep in mind

WARNING
Handle batteries and connectors with great care during
charging and boosting (jump starting). Do not mix
up the battery terminals! Follow the instructions for
starting with a booster battery!
Danger of short circuit! Warning - risk of hydrogen gas
forming! Danger of sparks and fire! Hydrogen gas is
very explosive!
Batteries must always be equipped with covers over
terminals and connections. Connect positive terminals
first. Then connect the negative terminals in order to
avoid sparks that could ignite the hydrogen gas.

CAUTION
The machine uses oils and lubricants.
Health hazard in the event of protracted skin contact!
Avoid skin contact with oils and lubricants. Use
protective gloves.

CAUTION
AdBlue can irritate with skin and eye contact and if
inhaled.
Health hazard!
Handle carefully and avoid skin contact, wear
protective gloves. In the event of any contact with
the skin and spillage on clothing, wash the skin with
large quantities of water and change contaminated
clothing and gloves. In the event of eye contact, rinse
thoroughly with water for several minutes and seek
medical advice if necessary. If inhaled, breathe fresh
air and seek medical advice if necessary.

WARNING
Fire extinguishers contain dry chemicals.
Risk of breathing difficulties when using in an enclosed
space!
Use the fire extinguisher from the outside and into the
area to be extinguished. After use, ventilate the space
thoroughly.

IDCG02.03GB Operator’s manual DCG 180-330

 2 Safety – Keep in mind 17

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 shoe linings wear out and lose their braking
performance! Risk of unwanted movement by the
parked machine!
After emergency braking with the parking brake the
brake shoe linings must be checked as soon as
possible and replaced if necessary. Braking action of
the parking brake may be lost as the brake shoe linings
may have been worn down.
If the parking brake has been released mechanically
then it must always be reset to restore the machine's
parking brake function.

WARNING
Optional equipment such as two-way radio, remote
control door opener, etc. may emit non-ionising
radiation. Such equipment transmits within the
frequency band 100 - 500 MHz.
Danger of interference to active medical devices (e.g.
pacemakers).
Do not use two-way radios, remote control door
opener, etc. when someone with an implanted active
medical device is in the cab.

NOTE
Cargotec will not assume any responsibility for installed optional
equipment, which is not installed by Cargotec or an installer
approved by Cargotec.

Operator’s manual DCG 180-330 IDCG02.03GB

18 2 Safety – Fire

2.5 Fire
Action in the event of fire

DANGER
In the event of fire the operator's safety must not be
compromised.
If given the opportunity, take the following action at
the slightest sign of fire:
1. Stop the machine and turn the ignition key to stop
position.
2. Leave the cab.
3. Switch off the system voltage with the battery
disconnector.
4. Alert the rescue services.
5. Try to extinguish the fire.
If this is not possible, leave the machine and the
risk area.

DANGER
Smoke can be extremely toxic.
Smoke subdues, suffocates and can kill people!
Smoke can cause damage to lungs and respiratory
organs even in small quantities.
Avoid breathing fumes, do not stand in the smoke.
Use breathing apparatus for fire fighting and work
with burnt material.

IDCG02.03GB Operator’s manual DCG 180-330

 2 Safety – Fire 19

Fire prevention measures

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

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

compartment during the daily inspection. This helps to quickly detect
if anything abnormal has happened or is about to happen. Look
particularly closely for oil, fuel, AdBlue or coolant leakage, loose bolts,
worn or poorly tensioned drive belts, loose connections, damaged
hoses and electrical cables. The inspection only takes a few minutes
and can prevent serious faults and costly repairs.

CAUTION
High-pressure washing of sensitive components may
lead to short-circuiting and cause malfunction.
Product damage!
Do not use a high-pressure washer on the cab, radiator,
battery compartment, electric components, control
units, connectors, cable joints, cylinder seals, stub
axles, axle seals and chains.

Action after fire

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

Operator’s manual DCG 180-330 IDCG02.03GB

20 3 Overview

3 Overview
3.1 Description
General
The DCG 180-330 machine is a forklift truck of heavy capacity for all
types of load handling. It has a maximum lifting capacity of 18 to 33
tonnes. The machine has a one lifting mast. There are three lifting
mast options and these come in different lifting heights:
1. Duplex
2. Duplex Free Lift
3. Triplex Free Lift

This section provides a short presentation of the machine's parts, see

General, page 21.

3.1.1 Identification of the machine

Type designation of forklift truck
Each machine from Cargotec has a type designation. Type designation
DCG 250-12 (LB) (example) indicates the following:
• D - Diesel engine
• C - Counterweight forklift
• G – Generation
• 250 – Lift capacity, decitonne
• 12 – Distance to centre of gravity, in decimetres
• (LB) - Low-profile machine

Machine card
Cargotec machines are adaptable in different ways with product
alternatives and optional equipment. This is in order to satisfy as broad
a customer base as possible.

A machine card is supplied together with the spare parts catalogue.

The machine card contains complete specifications of the machine's
product alternatives and optional equipment.

The machine card must be updated when the machine is modified

and Cargotec must be informed.

IDCG02.03GB Operator’s manual DCG 180-330

 3 Overview – Overview description 21

3.1.2 Overview description

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

018135
1 2 3 4

1. Steering axle
2. Engine
3. Transmission
4. Drive axle
5. Load handling, lifting mast
6. Load handling, lifting carriage
7. Cab

Operator’s manual DCG 180-330 IDCG02.03GB

22 3 Overview – Overview description

Engine
The engine is a straight 6-cylinder turbocharged low emission engine
with intercooler. The engine provides the power for propulsion and
hydraulics.
DCG 180–250 is equipped with one of the following engine options:
• Cummins QSB6.7 Stage 3A/Tier 3 (164 kW)
• Cummins QSB6.7 Stage 4/Tier 4f (168 kW)
• Volvo TAD871VE Stage 4/Tier 4f (185 kW)
DCG 280–330 is equipped with one of the following engine options:
• Cummins QSB6.7 Stage 3A/Tier 3 (194 kW)
• Cummins QSB6.7 Stage 4/Tier 4f (194 kW)
• Volvo TAD871VE Stage 4/Tier 4f (185 kW)

Transmission
The transmission is fully automatic with torque converter. Manual
shifting is possible with the switch on the steering wheel panel. The
transmission has 3 forward gears and 3 reverse gears. The hydraulic
pumps for working hydraulics are mounted on the transmission.
The machine is equipped with Dana TE17.

Drive axle
The drive axle (front axle) is equipped with a differential and hub
reductions of the planetary gear type.

Brakes
The machine has a brake circuit and is equipped with hydraulically
operated brakes. The brake units consist of fully enclosed oil-cooled
disc brakes with external cooling.
The parking brake is electro-hydraulically operated and brakes with a
disc brake. The disc brake acts on the drive axle's input shaft. The
parking brake is released by hydraulic pressure and is applied either
the travel direction selector by the steering wheel or automatically
(by spring force) in the event of a power failure or loss of hydraulic
pressure. Parking brake application is automatic if the ignition key
lock is switched off.

Steering
The machine is steered with the rear axle (steering axle). A
double-acting hydraulic cylinder acts on the wheel pair. The steering
is linear, that is, the steering angle is dependent on the number of
steering wheel turns.

Load handling
The mast and lifting carriage are used for load handling. The load is
manoeuvred in height and is tilted (angled) forward or backward.
The lifting carriage is normally equipped with side shift and fork
spreading.
The fork bracket is fitted on the lifting carriage and can be equipped
with e.g. forks, inverted forks, coil ram and top lift attachment fitted
either on the forks or on the inverted forks. The load is manoeuvred in
height, laterally and is tilted (angled) forward or backward. There are
two types of top lift attachment, fixed (20" or 40") or adjustable between
20" and 40". The top lift attachments have twistlocks for locking the
load. Securing the load and operating the attachment are handled
electrically and hydraulically.

IDCG02.03GB Operator’s manual DCG 180-330

3 Overview – Overview description 23

Electrical system
The electrical system consists of electrical and electromagnetic
components such as battery, switches, cable harnesses, solenoid
valves, fuses and relays.

Control system
The machine has a computer-based control system for monitoring
and controlling the machine's functions as well as handling functions
in the machine, such as power electronics, drivetrain and hydraulic
system. The control system also facilitates maintenance and provides
the operator with information about generated error or safety related
events in the machine. The operator can also see information on the
display about the current operating status of the engine, transmission
and control units.

Cab
The cab is available in two versions. Controls, instrumentation and
equipment are based on common modules whose functions are
customised.
• Cab
The enclosed cab is a closed operator position with doors built on
a supporting frame to withstand falling loads. It is equipped with a
fresh air system with filtered air intake and recirculation as well as
heater unit or air conditioning ( ).
• Open cab:
The Open cab is an open operator's station constructed of a
structural frame to withstand falling loads.

The roof window is made of high-strength material and withstands

heavy blows, e.g. from falling objects.

Hydraulic system
The hydraulic system includes the sub-functions of brakes and working
hydraulics.

The working hydraulics include hydraulics for steering, load handling

and cab functions. The working hydraulics are supplied by two variable
load sensing pumps.

The brake system has a fixed gear pump, high-pressure filter,

accumulators and cooler .

The hydraulic oil is cleaned with a return filter in the hydraulic tank.

Operator’s manual DCG 180-330 IDCG02.03GB

24 3 Overview – Overview description

Other equipment
Standard equipment

1
2
14 15 16
3 17

4 18

13

12 5
6
11

018131
7
10 9 8

1. Interior lighting Mesh pocket in right-hand door side; storage

compartment. Not available on the overhead guard.
2. Interior rear view mirror
12. Storage compartment in right-hand arm rest
3. Combined wiper, windscreen and roof
13. Storage compartment for the operator's manual.
4. Steering wheel console with three individually
Located behind the door to the right in the rear wall.
adjustable shafts with electrically adjustable height
position 14. Work lights, cab roof rear edge, directed backwards, 2
lamps
5. Storage compartment in front panel.
15. Opening window right and left-hand door
Cup holder for storage compartment in the front
panel. The cup holder can be mounted in any storage 16. Roof window standard 6 mm.
compartment.
17. Mast work lights, 2 lights
6. Storage compartment for paper in the seat console
18. Tempered safety glass in the front windscreen
7. Work console with four individually adjustable shafts
Clear windows
with electrically adjustable height and length position
19. Non-slip plate on e.g. steps and lower edge of the
8. Storage compartment in front panel
door sill
9. Horn. Located inside the front cover.
(Not positioned in figure).
10. Door handle for cab instep
11. Bottle holder in left-hand door side. Not available on
the overhead guard.

IDCG02.03GB Operator’s manual DCG 180-330

 3 Overview – Overview description 25

Optional equipment

18 19 20 21 22
2 3 4 5
1 23
6
17 7
32 24
16 8 25
15 26
9
14 12,31 27
10
13
12

021958
9 11 10 27 30 29 28

1. Audio system 20. Roof window extra strong 12 mm

2. Sun visor, rear window 21. Extra working lights, cab roof, front edge, 2 lamps
3. Sun visor, roof window 22. External rear view mirrors
4. Location for two-way radio 23. Extra mast work lights, 2 lamps
5. Seat for passenger with 2-point seat belt, to the left Protective grille for mast working lights
of the driver's seat
24. Laminated front windscreen
6. Sun visor, front windscreen
Tinted windows
7. Display for fire extinguishing system
25. Extra work light between the tilt cylinders, 1 lamp
8. Writing table with light Steps between tilt cylinders
9. Socket 12/24 VDC, 4 sockets
26. Direction indicators with position lights
10. Extra cup holder for the storage compartment in the
front panel Grating for headlights

Refrigerated storage compartment right-hand side front 27. Mud flap, steering and drive wheels
panel (in combination with ECC) 28. Central lubrication, machine
11. Electrically powered loud air horn . Located inside 29. Revolving operator's station
the front cover.
30. Baseplate, cab
12. Camera with monitor
Mounted between cab and frame.
Distance warning function for back-up camera
31. Grating for rear lights
13. Storage compartment behind the driver's seat console
32. Litter container
14. Air-suspension driver's seat with 3-point seat belt and 33. Tool kit
electrical heating (Not positioned in figure).
Head rest
34. Aluminium non-slip plates for lamp protection and
Arm rest left-hand side front wings
15. Alcolock (Not positioned in figure).
16. Extra internal rear view mirror 35. Heater: (Not positioned in figure)
17. Mesh pocket headlining; storage compartment (only A 110 V or 230 V for connecting the engine heater
with elevated roof) with or without compartment heater
18. Extra work lights, cab roof rear edge, directed B Electric or diesel-driven compartment heater. A
forwards 2 or 4 lamps pause heater is available as an optional.
Extra working lights for container handling, 4 lamps C Oil heater hydraulic tank, high voltage 230/380 V.
19. Adjustable search light D Eberspächer. Refer to the manufacturer's
Controlled electrically by remote control. instructions.

Operator’s manual DCG 180-330 IDCG02.03GB

26 3 Overview – Plates

3.2 Plates
Product plates
Below are the product signs that must be on the machine when
operating within the EU/EEA, there are more variations available for
other markets. When ordering spare parts and in case of enquiries per
telephone or correspondence, always state model designation and
serial number in accordance with the plates. The plates' part numbers
are stated on each respective plate. Plates that have been damaged,
illegible or painted over must be replaced immediately.

018136
1, 2, 5

1. Machine plate (example), A68645

T = Machine type
M = Machine model
S/N = Serial number for the machine / Year of manufacture
Q, D, H= Indicates classed load capacity (Q) according to EN1551
at centre of gravity distance (D) up to lifting height (H)
W= Machine's operating weight (without load)
P= Engine power
Q, C, D, H = Approved load at lifting height (H) at respective
022102

distance (so-called load centre) horizontally and vertically from

mast and forks (D and C).
Machine plate can only be ordered with complete engraving.
2. Additional plate for attachment, A54560
Specifications for the machine's approved lifting equipment.

NOTE
The plate's design depends on type of attachment.
013974

S/N = Serial number for machine

A = Identification number for attachment
H = Lifting height
D = Centre of gravity distance
Q = Lift capacity
C= Centre of gravity's height. Distance from the forks up to the
load's vertical centre of gravity
Plate can only be ordered with complete engraving.
• Additional plate for sidelift-attachment, A54560
013980

IDCG02.03GB Operator’s manual DCG 180-330

 3 Overview – Plates 27

• Additional plate for attachment, top lift, A54560

013976
• Additional plate for attachment, top lift, inverted forks, A54560

013977

3. Additional plate for attachment, A33808

Specifications for the machine's approved lifting equipment. The
sign is in the cab for the operator's information. Corresponds with
signs item 1 and item 2.

NOTE
016642

The plate's design depends on type of attachment.

S/N = Serial number for machine

A = Identification number for attachment
H = Lifting height
D = Centre of gravity distance
Q = Lift capacity
C= Centre of gravity's height. Distance from the forks up to the
load's vertical centre of gravity
The plate can only be ordered with data filled-in for the specific
machine.
4. Type plate for mounted attachment (example), A68652
A = Identification number for attachment
S/N = Serial number for the attachment / Year of manufacture
H = Maximum hydraulic pressure to attachment
Q = Maximal load
022103

D = Approved centre of gravity distance from front edge

fork/attachment for maximum load
COG = Centre of gravity distance for attachment's own weight
(without load)
LLC = Lost load distance due to attachment
W = Attachment's own weight (without load)
Plate can only be ordered with complete engraving.
5. Plate for certified sound level (example), A54572
LWA (external) = Total sound intensity at machine.
Legal requirements within EU/EEA.
Plate can only be ordered with complete engraving.
011937

Operator’s manual DCG 180-330 IDCG02.03GB

28 3 Overview – Plates

Warning and information plates

The following figures show the warning texts and information texts
that are located on the machine. The operator must be aware of the
warnings and should also follow the instructions and information given
on the plates.

Make sure warning and information symbols on the machine and its
components are always easy to see and are legible. Plates that have
been damaged, illegible or painted over must be replaced immediately.

5
1 1
3
1 10 10
1

9 6 2

018969
7 8 4 3 7 7
Frame, cab

Frame, cab
1. Lift point, 423049.0100
Attaching point for lift device when lifting of machines. There are
lifting points on:
• mast
000276

• rear

2. Warning! A26939.0100
Warning! Read the operator's manual for information.
000277

IDCG02.03GB Operator’s manual DCG 180-330

 3 Overview – Plates 29

3. Warning! A54527.0200
Air conditioning. Filling of refrigerant requires special competence
and authorisation (follow national legislation and local rules).
1 = Refrigerant, type
2 = Amount, kg
3 = Pressure, bar
1 The plate is also on the condenser, compressor and at the air inlet
(front edge of cab) as plate A30770.0200.
2
3

014532

4. Warning! A30531.0200
Risk of crushing.

5. Warning! A30533.0300
Risk of crushing.
015460

6. Plate for non-ionising radiation, A57336.0100 .

Must be fitted on machines equipped with two-way radio or other
form of customised optional equipment in the cab that may emit
non-ionising radiation. The sign can be ordered from Cargotec if
necessary.
012968

7. Transport lock A38769.0100.

Fastening point for machine transport lock.
016612

Operator’s manual DCG 180-330 IDCG02.03GB

30 3 Overview – Plates

8. Cab tilting 307900.0700

012843
Safety

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

10. Fire extinguisher, A43461.0100

Specifies where extinguishing is to be performed in the event of
a fire in the engine compartment. The nozzle for extinguishing is
pushed through the sign.
001833

A43461.0100

15 018970

16 13 14 16 16 12 11 14 13 16
Engine

Engine
11. Filling point, fuel, 450202.0100

D
000286

450202.0100

IDCG02.03GB Operator’s manual DCG 180-330

 3 Overview – Plates 31

12. Filling point, AdBlue (filler cap)

13. Warning! A30530.0200

Rotating fan.

008149
A30530.0200

14. Warning! A30532.0200

Hot surfaces.
000850

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

Use only ready-mixed recommended coolant.
013692

Power transmission, wheels

Power transmission, wheels

16. Inflation pressure, factory-fitted tyres
A32049.0100 1.0 MPa
000290

NOTE
Read chapter 6 Inspection and maintenance regarding safety when
handling wheels.
The conditions for inflation pressure change if factory-fitted tyres
are replaced with another tyre brand! Contact Cargotec. The
plate for tyre air pressure must be replaced with a plate with the
applicable tyre pressure!

Operator’s manual DCG 180-330 IDCG02.03GB

32 3 Overview – Plates

20 20

018971
17 19 21 18 21

Hydraulic system

Hydraulic system

000292 17. Filling point hydraulic oil, 450203.0100

18. Warning! A36163.0100

Pressure. Always release the pressure from the accumulator
before working on the hydraulic system.
002497

19. Hydraulic pressure, A54518

Indication of the machine's set pressures. The figures are
engraved.
019038

IDCG02.03GB Operator’s manual DCG 180-330

 3 Overview – Plates 33

Lifting mast and attachment

Lifting mast and attachment

20. Warning! A30771.0100
Do not walk under the load, attachment or forks. Do not stand
on the forks.

DANGER
Forks or other attachments are work tools that
handle large loads.
Extreme hazard to personal health and risk of
property damage!
Make sure that no persons stand or walk
000858 under a raised work attachment, regardless of
whether it is loaded or not.

Electrical system
21. Fuses, A61553.0400 (electronic box frame) and A60777.0100
(electronic box cab).
The machine's fuses are shown here, see Fuses for electrical
system, general, page 297.

Operator’s manual DCG 180-330 IDCG02.03GB

34 4 Instruments and controls

4 Instruments and controls

General
Do not operate the machine before you know the position and function
of instruments and controls, and completely understand how they are
used!

This chapter gives general information about instruments, switches,

controls and other equipment in the machine's cab.

NOTE
Thoroughly read the following chapter about instruments and
controls.

IDCG02.03GB Operator’s manual DCG 180-330

4 Instruments and controls – Instruments and controls 35

Cab overview

015213
1. Travel direction selector and parking brake
2. Multi-function lever
3. Steering wheel
4. Steering wheel panel
5. Display with function keys
6. Right-hand dashboard panel, front section
7. Right-hand dashboard panel, centre section
Right-hand dashboard panel with joystick, centre section
8. Right-hand dashboard panel, rear section
9. Arm rest and storage box
10. Driver's seat
11. Accelerator
12. Brake pedals
13. Joystick or mini steering wheel

Rear cab section, see Rear cab section, page 38.

Operator’s manual DCG 180-330 IDCG02.03GB

36 4 Instruments and controls – Instruments and controls

Steering wheel panel

Steering wheel panel

14. Ignition key lock
14
21 22 23 30 16 17 15. Engine start and stop button
16. Indicator light, parking brake
17. Indicator light, high beams
18
18. Indicator light for active error codes
24 19
19. Indicator light for direction indicators
25 20 20. Warning lamp, by-pass of safety system
21. Switch for combined windscreen wiper, windscreen/roof window,
26 continuous
Switch for windscreen wiper, windscreen, continuous
012692
27 28 29 32 31 33 15 22. Switch for combined windscreen wiper, windscreen/roof window,
intermittent wiping
Steering wheel panel
Switch for windscreen wiper, windscreen, intermittent wiping
23. Switch for windscreen flusher
24. Switch for windscreen wiper, roof, intermittent wiping
25. Switch, windscreen wiper roof, continuous
26. Switch, windscreen wiper rear, continuous
27. Switch for windscreen wiper, rear, intermittent wiping
28. Light sensor
29. Switch for inching
30. Switch for manual shifting up
31. Switch for manual shifting down
32. Switch for automatic shifting
33. Travel direction indicator, Forward Neutral Reverse
Right-hand dashboard panel, front section

Right-hand dashboard panel, front section

34 35 36 37 38 39 40 34. Control breaker

43
35. Switch for pause heater
36. Recirculation switch
37. Switch for defroster
38. Switch for reduced fan speed

41 42 44 45 46 39. Switch for automatic regulation of air conditioning

40. Switch for increased fan speed
41. Switch for increased temperature
42. Switch for reduced temperature
012693

43. Switch for cooling

47 48 49 50 51 52 44. Switch for air distribution, to the floor
Right-hand dashboard panel, front section
45. Switch for air distribution, to the operator
46. Switch for air distribution, to the roof
47. Switch for by-pass of safety system
48. Switch for heated rear view mirror
Switch for heated rear windscreen
49. Control lever for electrically-operated mirrors
50. Switch for mirrors cab/machine
51. Switch preventing regeneration of the engine's after-treatment
system (applies to Cummins QSB6.7 Stage 4/Tier 4f)
52. Switch for audio off (radio)

IDCG02.03GB Operator’s manual DCG 180-330

 4 Instruments and controls – Instruments and controls 37

Right-hand control panel, centre section

Right-hand control panel, centre section

53 e 53
d
c
b a
a b

f c
d
k
j
i
h
g
60
58 59
56 57 015321
62 55
54
e
Right-hand dashboard panel, centre section
a. Control for lifting/lowering f
b. Control for tilt
c. Control for side shift
d. Control for spreading
e. Control for levelling Right-hand dashboard panel, centre section with joystick
f. Travel direction selector, Forward - Neutral - a. Control for side shift/spreading
Reverse
b. Travel direction selector, Forward - Neutral - Reverse
g. Switch to open the twistlocks
c. Spare
h. Switch for tilt control
d. Switch for tilt control
i. Spare
e. Switch to open the twistlocks
j. Spare
f. Switch for alternative function "shift button"
k. Spare

53. Control for load handling

54. For machine with control levers (linear levers):
Switch for twistlocks, automatic/manual
55. Spare
56. Spare
57. Spare
58. For machine with control lever (joystick):
Switch for twistlocks, automatic/manual
59. Switch, hydraulic lateral sliding cab
60. Switch to rotate the operator's station
61. Spare
62. Switch for horn

Operator’s manual DCG 180-330 IDCG02.03GB

38 4 Instruments and controls – Instruments and controls

Right-hand control panel, rear section

Right-hand control panel, rear section

63. Switch for work lights on cab
63 64 65 66 67 68 69 70 71
64. Switch for work lights on mast
65. Switch for extra work lights
66. Switch for extra work lights on cab
67. Switch for back-up light
68. Switch for length adjustment of the right-hand control panel
69. Switch for height adjustment of steering wheel
72 73 74 75
70. Switch for height adjustment of the right-hand control panel
71. Function keys and navigation wheel for control system
72. Switch for headlights
73. Switch, interior lighting
74. Switch, revolving beacon
75. Switch for flashing hazard lights
016430

71
Right-hand dashboard panel, rear section and display

Rear cab section

Rear cab section

76. Not used.
77
The operator's manual is fitted in a pocket on the rear of the
driver's seat.
77. Electronic box with fuses and relays

76
016431

Rear cab section

Roof panel

Roof panel

78 79 80 81 82 78. Light sensor

79. Not used
016432

80. Indicator light for locked twistlocks

81. Indicator light for contact
Roof panel 82. Indicator light for unlocked twistlocks

IDCG02.03GB Operator’s manual DCG 180-330

 4 Instruments and controls – Instruments and controls 39

Roof panel

Roof panel

78 83 84 85 86 83. Indicator light for extra function

84. Indicator light for clamp 1

016669
85. Indicator light for tilt control
86. Indicator light for clamp 2
Roof panel
Control for load handling
For more controls for load handling and their functions, see Operator's
manual section 4.6 Load handling.

Operator’s manual DCG 180-330 IDCG02.03GB

40 4 Instruments and controls – Warning and indicator lights

4.1 Warning and indicator lights

General
This section describes the warning lamps and indicator lights in the
cab. They indicate the status of subsystems/systems. An illuminated
warning lamp should be attended to immediately. An illuminated
indicator light informs of imminent action.
Warning lamps and indicator lights are grouped in the steering wheel
panel. The brightness of the lamps is adjusted according to the
ambient lighting conditions. All lamps light up briefly when the ignition
is switched on .
Numbers in brackets refer to the positions in Cab overview, page 35.

Indicator light, parking brake (16)

The light (red) is activated when the parking brake is applied.
If the indicator light flashes, the parking brake has been applied
000311

automatically (not by the operator) when the machine has stopped,

or released by the operator without the service brake pedal being
depressed.
The service brake pedal must be pressed down and the lever moved to
the released position to release the parking brake, provided that the
brake system is adequately pressurised.
To activate the parking brake it is sufficient to move the lever to the
position for applying the parking brake.
The service brake must be activated when the parking brake is
released otherwise the indicator light for the parking brake flashes
(position 16) and the event menu is displayed, see Event menu release
the parking brake, description, page 91.

Indicator light, high beams (17)

The light (blue) is activated when the high beams are on.
000309

Indicator light for active error codes (18)

The indicator light (orange) shows that the control system has one or
more active error codes.
000299

Indicator light, direction indicators (19)

The lamp (green) flashes when the direction indicators or hazard lights
are on.
000310

Warning lamp, by-pass of safety system (20)

The warning light (orange) shows the by-pass of safety functions.

NOTE
000300

By-pass takes place as long as the switch for by-pass of safety

system (position 47) is activated.

IDCG02.03GB Operator’s manual DCG 180-330

4 Instruments and controls – Warning and indicator lights 41

Travel direction indicator, Forward Neutral

Reverse (33)
Travel direction indicator for F (Forward), N (Neutral) or R (Reverse)
is activated to indicate the selected direction.

000403
Indicator light for locked twistlocks (80)

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

000312
and thereby lock the load.

Indicator light for contact (81)

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

012697

contact with the load.

Indicator light for unlocked twistlocks (82)

The indicator light (red) is illuminated when the twistlocks are unlocked
000314

and thereby release the load.

Indicator light for extra function (83)

016670

Indicator light (green) for extra function.

Indicator light for clamp 1 (indicator light for extra

function (84))
016671

The indicator light (red) shows the status for clamping pressure on
clamp 1.

Status for clamping pressure on clamp 1 is shown according to:

• The light flashes. Clamping pressure is being adjusted.
• The light comes on with a constant light. Clamping pressure
reached
• The light has gone out. No clamping pressure.

Operator’s manual DCG 180-330 IDCG02.03GB

42 4 Instruments and controls – Warning and indicator lights

Indicator light for tilt control (indicator light for

extra function (85))

016672
The indicator light (yellow) shows the status of the tilt control (automatic
tilt system). Tilt control is activated/deactivated with the switch on the
linear lever for the tilt function.

Tilt control status is shown in accordance with:

• The light flashes. The mast's vertical position is being adjusted.
• The light comes on with a constant light. The mast is in the vertical
position.
• The light has gone out. Tilt control is not active.

Indicator light for clamp 2 (indicator light for extra

function (86))
016671

The indicator light (red) shows the status for clamping pressure on
clamp 2.

Status for clamping pressure on clamp 2 is shown according to:

• The light flashes. Clamping pressure is being adjusted.
• The light comes on with a constant light. Clamping pressure
reached
• The light has gone out. No clamping pressure.

IDCG02.03GB Operator’s manual DCG 180-330

 4 Instruments and controls – Ignition key lock and start and stop button for the engine 43

4.2 Ignition key lock and start and

stop button for the engine
General
This section describes starting and stopping the engine.

Numbers in brackets refer to the positions in Cab overview, page 35.

Ignition key lock function

0 Ignition voltage and drivetrain are switched off, the key can
be removed.
Voltage to certain functions such as interior lighting, pause
heater, alcolock and standby voltage control units.
I Ignition voltage switched on and drivetrain activated for
starting.
016968

14. Ignition

Start and stop button's function

The start button is used to engage the starter and is held down until
the engine starts. The ignition must be in the I position in order for
the start button to work. The engine can also be stopped by holding
the button down for one second.

NOTE
The machine is equipped with an electric restart interlock, which
prevents engagement of the starter motor when the engine is
rotating.
Conditions for the starter motor to engage are that the transmission
is in neutral position and that the engine is not already running.
012816

15
15. Start button

Operator’s manual DCG 180-330 IDCG02.03GB

44 4 Instruments and controls – Ignition key lock and start and stop button for the engine

Alcolock function

The machine may be equipped with an alcolock. In order to start the

machine the operator must blow into the alcolock, which then measures
the alcohol content in the breath. A successful breath test permits
the machine to be started.

For information about handling, statistics, maintenance, etc., see the

manufacturer's instructions.

016631

Alcolock

IDCG02.03GB Operator’s manual DCG 180-330

4 Instruments and controls – Switches 45

4.3 Switches
General
This section describes the switches in the cab. Each switch controls
a function.

The switches on the panels have white pilot lights that change to
a green or red function light when the function is activated. The
brightness of the switches is adjusted according to the ambient lighting
conditions. All function lights in the switches light up briefly when the
ignition is switched on. Only the functions that are available on the
machine will display a white pilot light followed by a function light.

A white light in a switch indicates a function that can be activated.

The switch changes colour when a function is activated. When the
colour has changed to green, this indicates that the function has been
switched on.

Numbers in brackets refer to the positions in Cab overview, page 35.

Switch for combined windscreen wiper,

windscreen/roof window, continuous (21)
Switch (green) for combined windscreen wiper on the front
windscreen/roof window. Continuous wiping. Wiping stops when the
operator leaves the seat. Reactivated when the operator sits in the
012705

driver's seat.

Wiping windscreen/roof window activated/deactivated with the press

of a button.

The switch is connected in parallel with the Switch, windscreen wiper

roof, continuous (position 25).

NOTE
Do not use the wipers on dry or dirty windscreens without first
activating the windscreen washers. The roof window is especially
sensitive to scratching and can be damaged by dry wiping.

Switch for windscreen wiper, windscreen,

continuous (21)

Switch (green) for the windscreen wiper on the front windscreen.

Continuous wiping. Wiping stops when the operator leaves the seat.
Reactivated when the operator sits in the driver's seat.
012705

Wiping windscreen is activated/deactivated with the press of a button.

NOTE
Do not use the wipers on dry or dirty windscreens without first
activating the windscreen washers. The roof window is especially
sensitive to scratching and can be damaged by dry wiping.

Operator’s manual DCG 180-330 IDCG02.03GB

46 4 Instruments and controls – Switches

Switch for combined windscreen wiper,

windscreen/roof window, intermittent (22)
Switch (green) for combined windscreen wiper on the front
windscreen/roof window. Intermittent wiping. Wiping stops when the
operator leaves the seat. Reactivated when the operator sits in the

012706
driver's seat.

Intermittent wiping windscreen/roof window activated/deactivated with

the press of a button.

The event menu appears when intermittent wiper mode is activated,

see Event menu intermittent wiper, description, page 94.

Two time intervals can be selected:

• Short interval - one press of the button.
• Long interval - a further press of the button.
• Switch off - a further press of the button.

The switch is connected in parallel with the Switch, windscreen wiper

roof, intermittent (position 24).

NOTE
Do not use the wipers on dry or dirty windscreens without first
activating the windscreen washers. The roof window is especially
sensitive to scratching and can be damaged by dry wiping.

Switch for windscreen wiper, windscreen,

intermittent (22)

Switch (green) for the windscreen wiper on the front windscreen.

Intermittent wiping. Wiping stops when the operator leaves the seat.
Reactivated when the operator sits in the driver's seat.
012706

Intermittent wiping windscreen is activated/deactivated with the press

of a button.

The event menu appears when intermittent wiper mode is activated,

see Event menu intermittent wiper, description, page 94.

Two time intervals can be selected:

• Short interval - one press of the button.
• Long interval - a further press of the button.
• Switch off - a further press of the button.

NOTE
Do not use the wipers on dry or dirty windscreens without first
activating the windscreen washers. The roof window is especially
sensitive to scratching and can be damaged by dry wiping.

IDCG02.03GB Operator’s manual DCG 180-330

4 Instruments and controls – Switches 47

Switch for windscreen flusher (23)

Switch (green) for washing the screens. Washing occurs in the screens
where the wiper is activated.

012707
Pressing the button when no wipers are activated activates the front
wipers or the combined wipers on the front windscreen/roof window
and washing on each screen.

If the machine is equipped with a turnable operator's station then the

wiper on the rear window is activated when the driver's seat is in the
reversed position .

Wiping temporarily changes over to continuous wiping with window

flushing.

Windscreen washing is active as long as the button is pressed down.

Event menu appears with a low washer fluid level, see Event menu low
washer fluid level, description, page 91.

NOTE
Do not use the wipers on dry or dirty windscreens without first
activating the windscreen washers. The roof window is especially
sensitive to scratching and can be damaged by dry wiping.

Switch, windscreen wiper roof, interval (24)

Switch (green) for windscreen wiper on roof window. Intermittent

wiping. Wiping stops when the operator leaves the seat. Reactivated
when the operator sits in the driver's seat.
012715

Intermittent wiping is activated/deactivated with the press of a button.

The event menu appears when intermittent wiper mode is activated,

see Event menu intermittent wiper, description, page 94.

Two time intervals can be selected:

• Short interval - one press of the button.
• Long interval - a further press of the button.
• Switch off - a further press of the button.

The switch is connected in parallel with the Switch for combined

windscreen wipers front windscreen/roof window, intermittent (22).

NOTE
Do not use the wipers on dry or dirty windscreens without first
activating the windscreen washers. The roof window is especially
sensitive to scratching and can be damaged by dry wiping.

Operator’s manual DCG 180-330 IDCG02.03GB

48 4 Instruments and controls – Switches

Switch, windscreen wiper roof, continuous (25)

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

wiping. Wiping stops when the operator leaves the seat. Reactivated
when the operator sits in the driver's seat.

012714
Wiping is activated/deactivated with the press of a button.
The switch is connected in parallel with the Switch for combined
windscreen wipers front windscreen/roof window, continuous (21).

NOTE
Do not use the wipers on dry or dirty windscreens without first
activating the windscreen washers. The roof window is especially
sensitive to scratching and can be damaged by dry wiping.

Switch, windscreen wiper rear, continuous (26)

Switch (green) for windscreen wiper on rear window. Continuous
wiping. Wiping stops when the operator leaves the seat. Reactivated
when the operator sits in the driver's seat.
012713

Wiping is activated/deactivated with the press of a button.

NOTE
Do not use the wipers on dry or dirty windscreens without first
activating the windscreen washers. The roof window is especially
sensitive to scratching and can be damaged by dry wiping.

Switch, windscreen wiper rear, interval (27)

Switch (green) for windscreen wiper on rear window. Intermittent
wiping. Wiping stops when the operator leaves the seat. Reactivated
when the operator sits in the driver's seat.
012712

Intermittent wiping is activated/deactivated with the press of a button.

Two time intervals can be selected:
• Short interval - one press of the button.
• Long interval - a further press of the button.
• Switch off - a further press of the button.

NOTE
Do not use the wipers on dry or dirty windscreens without first
activating the windscreen washers. The roof window is especially
sensitive to scratching and can be damaged by dry wiping.

Switch for inching (29)

Switch (green) for activating inching.
Inching is activated/deactivated with the press of a button.
012711

Switch for manual shifting up (30)

Switch (green) to shift up one gear. Shifting up takes place from
the current gear. If automatic shifting is selected, it is automatically
switched off if the switch for manual shifting up or down is activated.
012708

At the same time the switch colour for manual shifting up and down
goes from white to green.
The current gear is shown in the operating menu.

IDCG02.03GB Operator’s manual DCG 180-330

4 Instruments and controls – Switches 49

Switch for manual shifting down (31)

Switch (green) to choose to shift down one gear. Shifting down takes
place from the current gear. If automatic shifting is selected, it is
automatically switched off if the switch for manual shifting up or down

012709
is activated. At the same time the switch colour for manual shifting up
and down goes from white to green.

Downshift is activated with the press of a button. Manual shifting is

activated.
The current gear is shown in the operating menu.

Switch for automatic shifting (32)

Switch (green) for selecting automatic shifting.

Automatic shifting is activated by pressing a button. The automatic

012710 shifting function is disabled if the switch for manual shifting up or down
is activated.

Switch for pause heater (35)

Switch (green) for pause heater. The cab fan emits heat from the
012716

engine's cooling system during short-term parking of the machine.

Instructions for use:

a. Park the machine. Let the engine idle.
b. Set desired temperature (position 41, 42).
c. Press in the switch for pause heater (position 35).
d. Switch off the ignition with the ignition key lock.
The pause heater is now activated and strives to maintain preset
temperature for the cab.
If the cab temperature drops down to the set temperature, or pause
heater has been running for the preset time, the pause heater
stops running when the engine's cooling system can no longer
deliver the heat needed.

NOTE
The higher the preset cab temperature, the shorter the operating
time for the pause heater.

Recirculation switch (36)

Recirculation switch (green) If this function is activated, air circulates
inside the compartment without fresh air being taken from outside and
is used to prevent bad air, or unpleasant odours from entering the cab.
012717

Recirculation is activated/deactivated with the press of a button.

Switch for defroster (37)

The switch (green) for the defroster can be used to quickly demist the
windscreens. When the defroster is activated the function controls fan,
temperature and damper position.
012718

The defroster is activated/deactivated by pressing a button or with any

of the other switches for the system. The defroster function switches
off automatically.

Operator’s manual DCG 180-330 IDCG02.03GB

50 4 Instruments and controls – Switches

Switch for reduced fan speed (38)

Switch (green) to lower fan speed in the cab. When the fan speed
is controlled with the switch the automatic fan control is disengaged.
The automatic function is reactivated with the switch for automatic
regulation of air conditioning (position 39).

012719
Reduced fan speed is activated with the press of a button.

The fan speed is displayed in the operating menu.

The event menu appears when the fan speed drops, see Event menu
raise/lower fan speed, description, page 92.

Switch for automatic regulation of air conditioning

(39)
Switch (green) for automatic fan speed control, temperature control
and air distribution in the cab. With AUTO mode enabled, the control
system attempts to maintain the temperature set on the display. Fan
012720

speed, temperature control and air distribution in the cab take place
automatically.

Automatic regulation is reactivated with the press of a button if manual

control is selected with the buttons for air distribution or fan speed.

Temperature setting and fan speed are shown in the operating menu.

Switch for increased fan speed (40)

Switch (green) to increase the fan speed in the cab. When the
fan speed is controlled with the switch the automatic fan control is
disengaged. The automatic function is reactivated with the switch for
automatic regulation of air conditioning (position 39).
012721

Increased fan speed is activated with the press of a button.

The fan speed is displayed in the operating menu.

The event menu appears when the fan speed increases, see Event
menu raise/lower fan speed, description, page 92.

Switch for increased temperature (41)

Switch (red) to increase the cab temperature. Setting takes place in
steps of 0.5 °C.
012723

Temperature increase is activated with the press of a button.

The temperature range is 16 °C to 28 °C. Setting of max. temperature

switches off automatic climate control (control of fan, heat and air
distribution) and sets the heat valve in the max. position.

If necessary, cab air is cooled or heated to the set temperature.

Desired cab temperature is displayed in the operating menu.

The event menu appears when the cab temperature is increased,

Event menu raise/lower cab temperature, description, page 92.

IDCG02.03GB Operator’s manual DCG 180-330

4 Instruments and controls – Switches 51

Switch for reduced temperature (42)

Switch (blue) to decrease the cab temperature. Setting takes place in
steps of 0.5 °C.

012722
Temperature decrease is activated with the press of a button.

The temperature range is 16 °C to 28 °C. Setting of min. temperature

switches off automatic climate control (control of fan, heat and air
distribution) and sets the heat valve in the min. position.

If necessary, cab air is cooled or heated to the set temperature.

Desired cab temperature is displayed in the operating menu.

The event menu appears when the cab temperature is decreased,

Event menu raise/lower cab temperature, description, page 92.

Switch for cooling (43)

Cooling function switch (green).

012727

Cooling is activated/deactivated with the press of a button.

The system's cooling function does not start if the fan is switched off or
if the doors are open. The fan stops after a short period if the doors are
opened. If the doors are not closed after a further short period then the
cooling compressor will also be switched off.

Switch for air distribution, to the floor (44)

Switch (green) for air distribution, to the floor. When the air distribution
is controlled with the switch the automatic air distribution is disengaged.
The automatic function is reactivated with the switch for automatic
012724

regulation of air conditioning (position 39).

Air distribution toward the floor is activated/deactivated by pressing a

button. The air distribution can be combined toward the floor, operator
and roof.

Switch for air distribution to the operator (45)

Switch (green) for air distribution to the operator. When the air
distribution is controlled with the switch the automatic air distribution is
disengaged. The automatic function is reactivated with the switch for
012725

automatic regulation of air conditioning (position 39).

Air distribution to the operator is activated/deactivated with a press

of the button. The air distribution can be combined toward the floor,
operator and roof.

Switch for air distribution to the roof (46)

Switch (green) for air distribution to the roof. When the air distribution is
controlled with the switch the automatic air distribution is disengaged.
The automatic function is reactivated with the switch for automatic
012726

regulation of air conditioning (position 39).

Air distribution toward the roof is activated/deactivated by pressing a

button. The air distribution can be combined toward the floor, operator
and roof.

Operator’s manual DCG 180-330 IDCG02.03GB

52 4 Instruments and controls – Switches

Switch for by-pass of safety system (47)

Bypassing the machine's safety features. Rocker switch.

The operator may, if the situation so requires, disconnect all safety

012733
features on the machine.
0 1
Position 0 provides normal function.

Position 1 provides the option to:

• to lock or open twistlocks without contact.
• adjust the length of the attachment with locked twistlocks.
• lift, without indication of locked or open twistlocks.
• Selection of travel direction without the sensor in the driver’s seat
indicating that someone is sitting in the seat, speed is limited to
10 km/h.
(The machine adopts neutral position when no one is sitting in
the driver’s seat.)
• Engage gear without seat belt fastened, applies to machines with
seat belt requirement while driving.
• Release of the parking brake in the event of a fault in the parking
brake or without the sensor in the driver’s seat indicating that
someone is sitting in the seat.
• Use of load handling functions at reduced speed without the sensor
in the driver’s seat indicating that someone is sitting in the seat.
• rotate the operator's station without all conditions being met.
• use load handling functions when the turnable operator's station
is not in the permitted position.
• drive the machine with the speed limitation 5 km/h when the
turnable operator's station e.g. is not in the permitted position.

Warning lamp for by-pass (position 20), shows when the by-pass of
safety features is activated.

WARNING
Safety features are blocked.
No safety system is engaged!
Only use bypass in emergency situations!

WARNING
By-pass of load handling functions must not be used
during normal load handling.
Extreme hazard to personal health and risk of property
damage.
Only use the bypass in emergency situations.

IDCG02.03GB Operator’s manual DCG 180-330

 4 Instruments and controls – Switches 53

Switch for electrically heated rear view mirrors

(48)

Switch (green) for electrically heated rear view mirrors. Rocker switch.

012792
0 1 Position 0 – Function for electrically heated rear view mirrors
deactivated.

Position 1 - The function electrically-heated rear view mirrors is

activated for a preset time.

If both the machine and cab are equipped with electrically heated
mirrors all of these are activated with the same switches.

If the cab is equipped with electrically heated mirrors and screens the
functions are activated with the same switches.

The event menu appears when the electrically heated mirrors

are activated and deactivated, see Event menu heating rear view
mirrors/rear windscreen, description, page 93.

Switch for electrically heated rear windscreen (48)

Switch (green) for electrically heated rear windscreen. Rocker switch.

012792

0 1 Position 0 – The function for rear windscreen heating is deactivated.

Position 1 - The function electrically-heated rear windscreen is

activated for a preset time.

If the cab is equipped with electrically heated mirrors and screens the
functions are activated with the same switches.

The event menu appears when the electrically heated rear windscreen
is activated and deactivated, see Event menu heating rear view
mirrors/rear windscreen, description, page 93.

Control lever for electrically-operated mirrors (49)

Control lever for setting the machine's mirrors.

Select left (L) or right (R) mirrors using the control lever.

Set the mirror with the help of the control lever.

Set the control lever in the centre position again to avoid unwanted
adjustment of the rear view mirrors.
015219

Switch for mirrors cab/machine (50)

Switch (green) to select if the mirrors on the cab or the machine should
be controlled by the control lever for electrically-operated mirrors.
013656

Position 0 – Control of mirrors on the cab.

0 1
Position 1 – Control of mirrors on the machine.

Operator’s manual DCG 180-330 IDCG02.03GB

54 4 Instruments and controls – Switches

Switch for preventing regeneration of the engine's

after-treatment system (51)
Applies to Cummins QSB6.7 Stage 4/Tier 4f.

The switch (green) prevents regeneration of the engine's after-treatment

system.

015210
Position 0 – The regeneration function for the engine's after-treatment
0 1 system is activated with automatic control via the engine control unit.

Position 1 – The regeneration function for the engine's after-treatment

system is deactivated. If regeneration is in progress, the engine control
unit will stop the process, and it is started once all conditions are again
fulfilled and the switch is in position 0.

The event menu is shown when regeneration of the engine's

after-treatment system is deactivated, see Deactivated regeneration of
the engine's after-treatment system, description, page 92.

NOTE
"Prevent regeneration of the engine's after-treatment system"
should be used by the operator when the machine operates in a
flammable environment where high exhaust gas temperature may
cause fire or other damage.

Switch for audio off (audio system) (52)

Switch (green) for audio off in the cab, e.g. dampening of the audio
012731

system's volume.
0 1
Position 0 – Function audio off is deactivated.

Position 1 – Function audio off is activated.

Switch for twistlocks, automatic/manual locking

(54)

See Switch for twistlocks, automatic/manual locking (58), page 54.

Switch for twistlocks, automatic/manual locking

(58)

Switch (green) for locking the twistlocks. The switch is spring-loaded in

position 2.

Position 1 - Twistlocks are locked automatically when there is contact

with the load. The parking brake must be OFF, see position 1 and
indicator light for parking brake, position 16.

Position 0 - Locking of twistlocks not activated.

Position 2 - Twistlocks are locked manually. Button spring-returns.

See Instructions for top lift attachment, page 240.

IDCG02.03GB Operator’s manual DCG 180-330

 4 Instruments and controls – Switches 55

Switch for hydraulic lateral sliding cab (59)

Switch (green) for cab movement.

012793
1 0 2 Position 0 - Rest position.

Position 1 – Cab to right.

Position 2 – Cab to left.

Switch to rotate the operator's station (60)

Switch (green) to rotate the operator's station Rocker switch.

Position 0 - Rest position.

012788
1 0 2 Position 1 - Rotate to the right (forward).

Position 2 – Rotate to the left (backward).

Switch for horn (62)

012790

Switch for horn. Rocker switch.

Switch for horn in right-hand dashboard panel

Switch for horn in joystick

Switch for work lights on cab (63)

Switch (green) for work lights on cab.

Work lights on the cab are activated/deactivated with the press of a

012760

button.

Switch for work lights on mast (64)

Switch (green) for work lights on mast.

Work lights on the mast are activated/deactivated with the press of a

012762

button.

For machines with revolving operator's station :

If the work light on the mast is activated when the operator's station is
in forward position, the rear lights are activated automatically when the
operator's station is turned backwards. The work light on the mast
is switched off automatically when the operator's station is turned
backwards. The reversing light is activated/deactivated with the press
of a button on the switch for the work light on the mast.

Operator’s manual DCG 180-330 IDCG02.03GB

56 4 Instruments and controls – Switches

Switch for extra work lights (65)

Switch (green) for extra work lights on the fender or between the masts.

012763
Extra work lights are activated/deactivated with the press of a button.

Switch for extra work lights on cab (66)

Switch (green) for extra work lights on cab.

012764
Extra work lights on the cab are activated/deactivated with the press
of a button.

Switch for back-up light (67)

Switch (green) for back-up light.

Back-up light is activated/deactivated by pressing the button when

012765

travel direction reverse is selected. The function of the back-up lights

is reset after ignition off/on to be switched on when travel direction
reverse is selected.

Switch for length adjustment of the right-hand

control panel (68)
Switch (white) for length adjustment of the right-hand control panel.

Length adjustment is activated with the press of a button.

When you are logged into the control system's menus, the switch for
navigating up and down in the menus acts as a complement to the
function keys on the display.
012766

Switch for height adjustment of steering wheel

(69)
Switch (white) for height adjustment of steering wheel.

Height adjustment is activated with the press of a button.

012768

Switch for height adjustment of the right-hand

control panel (70)
Switch (white) for height adjustment of the right-hand control panel.

Height adjustment is activated with the press of a button.

When you are logged into the control system's menus, the switch for
navigating right and left in the menus acts as a complement to the
function keys on the display.
012767

IDCG02.03GB Operator’s manual DCG 180-330

4 Instruments and controls – Switches 57

Function keys and navigation wheel for control

system (71)
Function keys and navigation wheel for control system, see 4.11
Control system, page 78.

Switch for headlights (72)

Switch (green) for headlights. Also activates the tail lights.

012771 The headlights are activated/deactivated with the press of a button.

Switch, interior lighting (73)

Switch (green) for interior lighting in cab.

The lighting is activated/deactivated with the press of a button.

012772

Switch for revolving beacon (74)

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

012773

connection with hazards.

The revolving beacon is activated/deactivated with the press of a

button.

Switch for flashing hazard lights (75)

Switch (red) for flashing hazard lights used to attract attention in
connection with parking hazard.
012774

The warning beacon is activated/deactivated with the press of a button.

Operator’s manual DCG 180-330 IDCG02.03GB

58 4 Instruments and controls – Travel direction selector and parking brake

4.4 Travel direction selector and

parking brake
General
This section describes the travel direction selector (position 1) that is
used to choose the direction and for the parking brake.

Numbers in brackets refer to the positions in Cab overview, page 35.

1
015215

1. Travel direction selector on steering column

Selecting direction of travel

Travel direction is selected with the travel direction selector on:
F P • steering column
• control lever, see Linear levers (up to 5 levers), page 63
• mini-wheel, see Mini-wheel, page 69
• joystick control, see Joystick control, page 70
N The lever is spring-loaded and the selected direction of travel is shown
on the steering wheel panel.

The current gear is shown on the display.

Selecting direction of travel:

• F - Forward. Move the lever forward for forward drive.
015430

R • N - Neutral. Neutral. Move the lever up or down for neutral.

• R - Reverse. Move the lever backward for reverse drive. (Acoustic
Travel direction selector on steering column warning signal )

Manual shifting up and down is performed using the switch for manual
shifting up (position 30) and the switch for manual shifting down
(position 31). Selection of automatic shifting is done with the switch for
automatic shifting (position 32).

IDCG02.03GB Operator’s manual DCG 180-330

 4 Instruments and controls – Travel direction selector and parking brake 59

Parking brake
Activation of the parking brake is performed with the travel direction
F P selector. Lift the control upward toward the steering wheel and then
move it forward to the parking braking position. The parking brake
indicator light shows when the parking brake is activated, see Indicator
light, parking brake (16), page 40.

Deactivate the parking brake by pressing down the service brake pedal
N and then move the travel direction selector from the parking position
to neutral/gear position. The event menu appears when you try to
release the parking brake without the service brake being pressed
down or when the brake pressure is too low, see Event menu release
the parking brake, description, page 91.

015430
R DANGER
The parking brake should never be applied when the
machine is moving, unless an emergency requires it.
Very heavy braking. Risk of machine tipping, load
tipping over, being dropped or damage to property
or extreme danger!
Stop the machine before applying the parking brake.

Operator’s manual DCG 180-330 IDCG02.03GB

60 4 Instruments and controls – Multi-function lever

4.5 Multi-function lever

General
This section describes the functions of the multi-function lever (position
2 2).

Numbers in brackets refer to the positions in Cab overview, page 35.

015221

Light control
With headlights on: On machines with LED type headlights, the control
has no effect on the headlights.

With headlights off: The multi-function lever is used as a headlamp

015433

flasher. Move the control upward for light signal, return is automatic.

On machines with high and low beam, the multi-function lever is

used for changing between high and low beam. Move the control
upward to switch between full and low beam.

Horn
Move the lever inwards towards the steering wheel for horn.
015431

Direction indicators
Move the lever backward or forward to indicate left and right travel
indication respectively.
015432

IDCG02.03GB Operator’s manual DCG 180-330

 4 Instruments and controls – Load handling 61

4.6 Load handling

General
This section describes the functions of the control for load handling
(position 53). The control governs functions for handling the forks
and other attachments. Some hydraulic functions are controlled by
switches, see 4.3 Switches, page 45.

It is possible to vary the speed of the different hydraulic functions, i.e.

lift, tilt, etc., by varying the extent of the lever deflection. It is also
possible to vary the speed of the hydraulic functions with the engine
speed (rpm).

34
WARNING
In an emergency! In the event of undesired
activation/movement of a function.
Risk of personal injury and/or property damage!
IMMEDIATELY TURN OFF all working hydraulics by
pressing the CONTROL BREAKER for hydraulics.

NOTE
The operator must sit in the driver's seat in order for the load
handling functions to work.

NOTE
019613

Position of a control is need-adapted and may thus differ from this

section. See the plates on the machine.
34. Control breaker for hydraulics
Numbers in brackets refer to the positions in Cab overview, page 35.

Operator’s manual DCG 180-330 IDCG02.03GB

62 4 Instruments and controls – Load handling

Right-hand control panel

The control panel to the right of the operator is adjustable in several
ways for optimum ergonomics.
1. Panel position is longitudinal.
Adjust the control panel to the desired position, see Switch for
length adjustment of the right-hand control panel (68), page 56.
2. Panel position is vertical.
Adjust the control panel to the desired position, see Switch for
height adjustment of the right-hand control panel (70), page 56.
3. The angle of the rear section.
Pull the control (position A) upwards and adjust the panel manually
A. Control for adjusting the rear section to the desired position.
B. Control for adjusting the centre section 4. The angle of the centre section.
Pull the control (position B) upwards and adjust the panel manually
to the desired position.
5. The angle of the control lever's grip .
Contact service for adjustment of the control lever's angle.

IDCG02.03GB Operator’s manual DCG 180-330

 4 Instruments and controls – Control for load handling 63

4.6.1 Control for load handling

Linear levers (up to 5 levers)
Fingertip-operated linear levers.
a. Lifting/lowering
LIFT - pull the lever backwards.
LOWER - push the lever forwards.
The lowering speed can be varied only with the lever angle - the
engine speed has no influence.
b. Tilt
REVERSE - pull the lever backwards.
FORWARD - push the lever forwards.
Function for tilt control is deactivated in the event of lever
movement.
c. Side shift
34 a b c d e LEFT - push the lever forwards.
RIGHT - pull the lever backwards.
The forks cannot be side-shifted if fork spreading is at maximum.
d. Spreading (positioning)
OUTWARDS - push the lever forwards.
INWARDS - pull the lever backwards.
Positioning locks when one of the forks reaches the end position.
Side shift to the centre and spread again.
f k
j Fork spreading left fork
i
h FORK TO LEFT – push the lever forwards.
g FORK TO RIGHT - pull the lever backwards.
Spreading side-lift attachment
INCREASE SPREADING – push the lever forwards.
DECREASE SPREADING – pull the lever backwards.
For attachments that clamp in the load (e.g. paper handling
attachment)
OPEN ATTACHMENT - depress the switch fitted on the lever and
move the lever forward.
CLOSE ATTACHMENT - pull the lever backwards.
The function may be located on another lever.
018607

e. Levelling
FORK UP - pull the lever backwards.
FORK DOWN - push the lever forwards.
Levelling acts on the right or left fork.
Central levelling
CENTRAL LEVELLING ANTICLOCKWISE – push the lever
forward.
CENTRAL LEVELLING CLOCKWISE – pull the lever backward.
Fork spreading right fork
FORK TO LEFT - pull the lever backwards.
FORK TO RIGHT – push the lever forwards.

Operator’s manual DCG 180-330 IDCG02.03GB

64 4 Instruments and controls – Control for load handling

f. Selecting direction of travel . The switch is spring-loaded, the

current gear is shown in the display and the selected direction of
travel is shown on the steering wheel panel.
Travel direction FORWARD – move the switch forward.
Travel direction NEUTRAL – move the switch up and down.
Travel direction REVERSE – move the switch backward.
g. Switch to open the twistlocks
Lower the attachment so that contact is obtained, and depress
the button to open twistlocks.
h. Switch for tilt control
Switch activates/deactivates tilt control.
i. Spare
j. Spare
k. Spare

34. Control breaker for hydraulics

Control lever

34

53
015960

34. Control breaker for hydraulics

53. Control lever

IDCG02.03GB Operator’s manual DCG 180-330

 4 Instruments and controls – Control for load handling 65

53 Lift, lower / Tilt in, tilt out [Levelling ] SPREADING OUT - move the upper thumb control
forward.
LIFT - pull the whole control lever backward.
SPREADING IN - move the upper thumb control
LOWER - move the whole control lever forward. backward.
The lowering speed can be varied only with the lever b. Selecting direction of travel .
angle - the engine speed has no influence.
The control is spring-loaded, the current gear is shown in
TILT OUT - move the whole control lever to the right. the display and the selected direction of travel is shown
on the steering wheel panel.
TILT IN - move the whole control lever to the left.
Travel direction FORWARD - move the lower thumb
LEVELLING, FORKS UPWARD - press in the control forward.
shift-button (position f) and move the whole control Travel direction NEUTRAL – move the lower thumb
lever to the right. control up or down.
LEVELLING, FORKS DOWNWARD - press in the Travel direction REVERSE - move the lower thumb control
shift-button (position f) and move the whole control backward.
lever to the left.
c. Spare
CENTRAL LEVELLING ANTICLOCKWISE - press d. Switch for tilt control
in the shift-button (position f) and move the whole
control lever to the left. Switch activates/deactivates tilt control.

CENTRAL LEVELLING CLOCKWISE - press e. Opening the twistlocks .

in the shift-button (position f) and move the whole Lower the attachment so that contact is obtained, and
control lever to the right. depress the button to open twistlocks.

a. Side shift / Spreading f. Switch for alternative function "shift key" . The switch
changes the function of the other controls on the control
SIDE SHIFT LEFT - move the upper thumb control lever.
downward.
62. Switch for horn .
SIDE SHIFT RIGHT - move the upper thumb control
upward.

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66 4 Instruments and controls – Pedals

4.7 Pedals
General
This section describes the machine's foot-operated functions.

Numbers in brackets refer to the positions in Cab overview, page 35.

NOTE
The default pedal height setting can be changed by adjusting the
angle of their console. The adjustment must be performed by a
service technician.

11
12 015214

11. Accelerator
12. Brake pedal

Accelerator (11)
The accelerator pedal (position 11) is electronic and controls the engine
speed via the CAN bus and the machine's control system.

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4 Instruments and controls – Pedals 67

Brake pedals (12)

The brake pedals (position 12) are hydraulic and connected to the
machine's hydraulic system. The brake pedals are used for service
brake.

The accumulator stores energy so that there is brake pressure even if

the engine stops. The event menu appears if the accumulator pressure
drops too low, see Event menu low accumulator pressure, description,
page 84.

The brake function is available in different versions:

• Brake without inching
The service brake is combined with declutching and at a specific
brake pressure and a minimum engine speed the drive is
declutched completely. The brake pressure level and engine speed
are adjustable within specific maximum and minimum values and
adjustability is dependent on machine model, contact Cargotec
service if values need to be adjusted.
If the brake pedal is pressed down without declutching occurring,
the engine helps to slow down the machine provided that the
throttle is released.
• Brake with inching .
Switch (position 29) for inching.
012711

Inching is activated/deactivated with the press of a button.

Inching is not activated.
The brakes are activated by the brake pedal. Declutching occurs
when the pedal is pressed down and a specific brake pressure and
minimum engine speed are reached. The pressure and speed are
dependent on machine model. The function can be adjusted and
declutching can be disabled via the display and settings.
Inching enabled.
Inching and braking are controlled with the brake pedal. When you
depress the pedal the drive starts to slip, i.e. inching. The system
is disengaged if overloaded. Ideally inching can be used when you
want a higher engine speed available during load handling.
If the brake pedal is pressed down more than half of the pedal
range the drive is completely declutched. This can vary depending
on the drivetrain.

Operator’s manual DCG 180-330 IDCG02.03GB

68 4 Instruments and controls – Steering wheel

4.8 Steering wheel

General
This section describes controls for steering. The following alternatives
are available for steering the machine:
• adjustable steering wheel (position 3)
• joystick (position 13)
• mini steering wheel (position 13)

Numbers in brackets refer to the positions in Cab overview, page 35.

Steering wheel
Clockwise rotation of the steering wheel steers the machine to the
right, and vice versa.

The steering wheel's (position 3) inclination and height can be set to

the desired operating position.
1. Steering wheel angle in the longitudinal direction.
To adjust: Move the control on the steering column upward, angle
the steering wheel in the longitudinal direction and lock the control
when the steering wheel is in the desired position.
015216

2. Steering wheel angle in the lateral direction.

To adjust: To adjust: move the steering wheel's right-hand side
upward, angle the steering wheel sideways and lock the control
when the steering wheel is in the desired position.
3. Steering wheel's height.
To adjust: set the desired height with the Switch for height
adjustment of the steering wheel, see Switch for height adjustment
of steering wheel (69), page 56.
015217

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 4 Instruments and controls – Steering wheel 69

Mini-wheel

3 Mini-steering wheel control is an electro-hydraulic system, mounted in

the left arm rest, to steer the machine with an ergonomically designed
2 rotating plate. Clockwise rotation of the steering wheel steers the
machine to the right, and vice versa. The wheels always follow the
1 position of the mini-wheel. If the steering wheel is released, both the
4
mini-wheel and the wheels remain in the set position.

5 The standard steering wheel is equipped with sensors that detect any
steering wheel movement in an emergency situation. If the operator
starts to steer using the standard steering wheel, the mini steering
wheel is disengaged.
1. Direction indicators.
2. Mini-wheel.
The steering wheel's position on the arm rest is adjustable.
3. Switch for engaging the mini steering wheel.
Conditions: The speed must be below 3 km/h. If the speed
exceeds 3 km/h mini-wheel cannot be engaged.

6 NOTE
A sensor in the armrest mount on the driver's seat detects the
armrest angle. If the arm rest is angled upward, the mini steering
wheel function is deactivated at a certain angle and must be
activated again with the switch for engaging the mini steering wheel.

4. Travel direction selector F/N/R. The switch is spring-loaded, the

current gear is shown in the display and the selected direction of
travel is shown on the steering wheel panel.
Travel direction FORWARD – move the switch forward.
Travel direction NEUTRAL – move the switch up and down.
015422

Travel direction REVERSE – move the switch backward.

5. With headlights switched off: The switch is used for the headlamp
flasher.
If the switch is held depressed for more than 2 seconds then the
windscreen and roof wipers are activated and make one sweep.
Machines with high and low beam and headlights switched on: The
switch is used to change between high and low beam.
6. Arm rest. Can be folded up to easily enter and leave the driver's
seat.

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70 4 Instruments and controls – Steering wheel

Joystick control

Joystick control functions as the mini steering wheel, with the difference
that the mini steering wheel is replaced by a lever that is moved
left/right in order to steer the machine.

The standard steering wheel is equipped with sensors that detect any
steering wheel movement in an emergency situation. If the operator
starts to steer using the standard steering wheel, joystick steering is
disengaged.
1. Joystick.
2. Direction indicators.
3. Travel direction selector F/N/R. The switch is spring-loaded, the
current gear is shown in the display and the selected direction of
travel is shown on the steering wheel panel.
Travel direction FORWARD – move the switch forward.
Travel direction NEUTRAL - move the switch right or left.
Travel direction REVERSE – move the switch backward.
4. With headlights switched off: The switch is used for the headlamp
flasher.
If the switch is held depressed for more than 2 seconds then the
windscreen and roof wipers are activated and make one sweep.
Machines with high and low beam and headlights switched on: The
switch is used to change between high and low beam.
5. Switch for engaging the mini steering wheel.
Conditions: The speed must be below 3 km/h. If the speed
exceeds 3 km/h mini-wheel cannot be engaged.

NOTE
A sensor in the armrest mount on the driver's seat detects the
armrest angle. If the arm rest is angled upward, the mini steering
wheel function is deactivated at a certain angle and must be
activated again with the switch for engaging the mini steering wheel.

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 4 Instruments and controls – Steering wheel 71

Adjustment of the mini steering wheel/joystick

control
1. Adjusting the mini steering wheel longitudinally.
Adjust the mini steering wheel (position 1) to the desired position.
1
2. Adjusting the arm rest longitudinally.
To adjust: Loosen the knob (position 2) and adjust the arm rest to
the desired position. Lock the arm rest with the knob when the arm
rest is in the desired position.

015423

3. Height of the mini steering wheel/joystick control.

To adjust: Loosen the knob (position 3) and adjust the arm rest
to the desired position. Tighten the knob when the arm rest is in
the desired position.
4. Longitudinal angle of the mini steering wheel/joystick control.
To adjust: Loosen the Allen screw (position 4) and angle the
bracket for mini steering wheel/joystick control to the desired
position. Tighten the Allen screw when the bracket is in the desired
015424

position.
4
3

5. Sideways position of the mini steering wheel/joystick control.

To adjust: Loosen the Allen screw (position 5) and turn the arm
rest and bracket for the mini steering wheel/joystick control to the
desired position. Tighten the Allen screws when the armrest and
bracket are in the desired position.
015425

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72 4 Instruments and controls – Driver's seat

4.9 Driver's seat

General
This section describes the driver's seat (position 10) in the cab.

Numbers in brackets refer to the positions in Cab overview, page 35.

Driver's seat
Standard seat

Standard seat
The driver's seat is equipped with several controls for adjustment as
11 follows (adjustment is easier when nobody is sitting in the seat):
1. Seat belt, 2-point.
Seat belt, 3-point .
2. Seat tilt.
3. Horizontal suspension (forward/backward) .
4. Seat length.
10 5. Height of seat.
Mechanical elevation of seat height:
1
9 Turn the knob clockwise or anticlockwise until desired height is
obtained.
Air suspension elevation of seat height:
2
Lift the control up to increase seat height or alternatively press
8 the control down to reduce seat height. The suspension adapts
automatically to the bodyweight of the operator.
3 An indicator shows green when the correct height is reached. The
7 indicator turns red when the seat's suspension is set outside the
comfort mode.

4 6. Longitudinal adjustment.
Release the seat using the lever and move the seat forwards or
5 6 backwards.
7. Back rest angle.
Release the lock with the lever, set the desired tilt angle and
release the lever to lock in the desired position.
8. Adjusting arm rest, left .
9. Lower back (lumbar) support.
Turn knob until desired firmness in lumbar support is obtained.
10. Seat heating .
017255

11. Adjusting the head rest .

Driver's seat with adjustment possibilities

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4 Instruments and controls – Driver's seat 73

Optional seat Grammer

Optional seat Grammer

The driver's seat is equipped with several setting controls, they have
the following functions:
1. Seat heating.
2. Upper lumbar support.
Press + or - until the required firmness in the lumbar support is
reached.
3. Lower lumbar support.
Press + or - until the required firmness in the lumbar support is
reached.
4. Back rest angle.
Release the lock with the lever, set the desired tilt angle and
release the lever to lock in the desired position.
5. Horizontal suspension (forward/backward).
Control forward = locked.
Control backward = suspension.
To lock the suspension, move the control forward and then press
the seat backward until a click is heard when the suspension locks.
6. Longitudinal adjustment.
Release the seat with the lever, set the desired distance and
release the lever to lock in the desired position.
7. Height and angle of the seat
Angle setting: Set the vertical dampening (position 8) to the softest
position, sit on the seat, pull the control upward and release
directly. The suspension adapts automatically to the bodyweight.
Height control: Move the control upward to increase the seat
height or downward to lower the seat height.
8. Vertical dampening (up/down).
Control to the left = soft.
Control straight up = medium.
Control to the right = hard.
9. Seat length.
Release the length with the control, set the desired length and
release the control to lock in the desired position.
10. Seat tilt.
Release the tilt with the control, set the desired tilt and release the
control to lock in the desired position.
11. Seat belt, 2-point (not shown in the figure).
Seat belt, 3-point (not shown in the figure).

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74 4 Instruments and controls – Driver's seat

Optional seat Isringhausen

Optional seat Isringhausen

15
The driver's seat is equipped with several setting controls, they have
the following functions:
1. Seat belt, 2-point.
Seat belt, 3-point .
2. Seat tilt.
Release the tilt with the control, set the desired tilt and release the
control to lock in the desired position.
1 3. Seat length.
14
Release the length with the control, set the desired length and
release the control to lock in the desired position.
13 4. Longitudinal adjustment.
2 Release the seat with the bar, set the desired distance and release
12 the bar to lock in the desired position.
5. Height adjustment
11
3 Adjust the height of the seat using the control.
6. Vertical dampening (up/down).
7. Horizontal suspension (forward/backward).
022056

4 5 6 7 8 9 10 8. Lower lumbar support.

Press + or - until the required firmness in the lumbar support is
reached.
Driver's seat with adjustment possibilities 9. Upper lumbar support.
Press + or - until the required firmness in the lumbar support is
reached.
10. Side support.
Steplessly adjustable support for the back.
Press + or - to adjust the side support.
11. Ventilation seat.
12. Seat heating.
13. Setting for ventilation seat and seat heating.
14. Back rest angle.
Release the lock with the lever, set the desired tilt angle and
release the lever to lock in the desired position.
15. Adjusting the head rest .

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 4 Instruments and controls – Driver's seat 75

Optional seat BeGe

Optional seat BeGe

12
The driver's seat is equipped with several setting controls, they have
the following functions:
1. Seat belt, 2-point.
Seat belt, 3-point .
2. Seat length.
Release the length with the control, set the desired length and
1 release the control to lock in the desired position.
3. Side support.
Steplessly adjustable support for the back.
2 Press + or - to adjust the side support.
11 4. Lower back (lumbar) support.
Press + or - until the required firmness in the lumbar support is
3 reached.
5. Vertical dampening (up/down).
Stepless adjustment of the seat's damping. Move the control
4 sideways for harder/softer damping.
6. Height adjustment
Move the control up to raise the seat.
5
6 7 8 9 10 Move the control down to lower the seat.
7. Longitudinal adjustment.
022055

Release the seat with the bar, set the desired distance and release
Driver's seat with adjustment possibilities the bar to lock in the desired position.
8. Seat heating.
9. Seat tilt.
a Adjust by lifting the control. Use bodyweight to help. Release
the control when the inclination feels right.
b Adjust by pressing the control to the left. Use bodyweight to
help to tilt. Release the control when the inclination feels right.
10. Adjusting arm rest, left .
11. Back rest angle.
Release the lock with the lever, set the desired tilt angle and
release the lever to lock in the desired position.
12. Adjusting the head rest .
Passenger seat

Passenger seat

As an option, the machine can be equipped with a folding passenger

seat with two-point belt on the left of the driver's seat.
020552

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76 4 Instruments and controls – Heating / Air conditioning

4.10 Heating / Air conditioning

General information on air conditioning
This section describes function of:
38 39 40 43
• The heating system, EHC. EHC automatically regulates the fresh
air flow and air distribution in the cab and constantly strives toward
regulating the temperature to a selected temperature level. It
37 cannot cool the fresh air, but warms it if necessary to achieve the
selected temperature.
36 • Air conditioning, ECC. The ECC automatically regulates air flow
and air distribution in the cab and it constantly strives to regulate
35 the temperature to a selected comfort level by heating or cooling
the air in the cab to the selected temperature.

The heating/air conditioning system receives heat from the engine's

cooling system and provides heat when the engine is warm. Cooling
012820

41 42 44 45 46 performance is generated by the cooling compressor (for ECC).

Panel for heating and air conditioning (position 6) The system is controlled by fan, heat and air distribution as well as
function for recirculation and defroster:
• Automatic control of the fan speed, temperature control and air
distribution in the cab is activated by switch (position 39). With
AUTO mode enabled, the control system attempts to maintain
the temperature selected on the display. Both fan speed and
temperature control are automatic.
• Heat (and cooling performance for ECC) is controlled
with temperature switches (position 41, 42). Cooling is
activated/deactivated with the switch for cooling (position 43).
When adjusting the temperature the event menu appears on the
display, Event menu raise/lower cab temperature, description,
page 92.
• If necessary, the airflow can be adjusted manually with the switch
for the fan (position 38, 40). When adjusting the fan speed the
event menu appears on the display, Event menu raise/lower fan
speed, description, page 92.
• If necessary, the air distribution can be adjusted manually with the
switch for the air distribution (position 44, 45, 46). The fresh air
intake is equipped with a fine filter. Filter replacement is indicated
on the display by a filter monitor.

NOTE
015218

Filter replacement is first indicated in the event of high fan capacity

use.

• If necessary, the recirculation of cab air can be activated/deactivated

with the switch for recirculation (position 36).
Air distribution in the cab • Defroster for fast demisting of windows is activated/deactivated
with the switch for defroster (position 37). As there is no cooling
function on machines with EHC the dehumidification function may
be less effective.
• The pause heater is activated/deactivated with the pause heater
switch (position 35) .

NOTE
Operator's door and windows shall be closed for satisfactory
function of the system.
With ECC: A short while after one of the doors is opened, the fan
shuts off. After an additional period the air conditioning system's
cooling compressor shuts off (cooling function and air- drying
stops). Close the door and the cooling compressor and fan are
activated again. The function can be turned off via the machine's
settings in the service menus.

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 4 Instruments and controls – Heating / Air conditioning 77

The current settings for the heating/air conditioning system are shown
in the display.

For information on the switches, see 4.3 Switches, page 45.

For information on the display, see 4.11 Control system, page 78.

Diesel heater

As an option the machine can be equipped with diesel heater for

heating the cab and the engine without the engine being started. The
diesel heater heats and circulates the engine's coolant. The diesel
heater is controlled by a separate timer, with the display mounted on
the panel below the rear window on the left-hand side of the cab.

When the coolant has reached the required temperature, the cab fan is
activated in order to heat the cab. If the battery voltage becomes too
low then the heater is switched off automatically.

A. Menu bar For setting the diesel heater's timer, see Setting the diesel heater, page
228.
B. Status field (Main menu)
Input field (Submenu)
C. Selection front / rear
D. Button 1
E. Button 2

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78 4 Instruments and controls – Control system

4.11 Control system

General
This section describes the control system (position 71) and the
information that can be obtained from the operating menus (position 5).

The machine is equipped with an electronic system for control and

monitoring of the machine's different functions.

The system gives the operator information in the form of:

• Error code information
Three levels of error code information can be shown. In the event
of a new error code, error code information is shown over the
entire display. See 5.3 Error codes, page 107.
• Operating information
Operating information includes, for example, machine speed,
engine rpm, fuel level, etc.
• Event-controlled information
Event-controlled information is, e.g. contact and overload.

Information is presented on the display (position a). The function keys

(position c-e) are used to navigate the display menus and confirm
selections. Figures are stated with example data.

The information in the display can be selected to show values with

metric (SI) or imperial (US) units, see Setting of display units, page 255.

a. Display
b. Pop-up for button function
c. Enter/YES/Save
d. Navigate through menus/adjust values with the
wheel or buttons , , or
e. Exit/NO

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 4 Instruments and controls – Control system 79

Description
The loop for the operating menus is described in this section.

Example of operating menus 4. Transmission and hydraulics operating menu

1. Operating menu 5. Operating menu electrical system
2. Operating menu trip computer work shift 6. Operating menu extra functions, e.g. scales
3. Engine operating menu 7. Operating menu customer settings

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80 4 Instruments and controls – Operating menus

4.11.1 Operating menus

Description
After starting the machine the operating menu is displayed with engine
speed, speed, time, fuel level and information on the current setting for
the heating or air conditioning system.
a. Time.
b. Field for the four event menus with the highest priority and which
have status indicators. When there are only up to two event menus
with status indicators, status for heating or air conditioning is
shown in the lower part of the field.
c. Fuel economy. The green field indicates economical driving while
the red field indicates uneconomical driving that consumes a lot
of fuel.
d. Speed in km/h.
e. Eco Drive Mode setting. Eco Drive Mode, page 217. Selected
mode has white text, the row is only shown on machines with Eco
Drive Mode.
f. Fuel level.
g. Current gear.
h. Engine speed.
i. Utilised load capacity, the bar shows load 0-100%.
j. Operating time in hours (h).
k. AdBlue level (only applies to certain engine options).
l. Scales, current weight in tonnes or lbs (pounds).

4.11.1.1 Operating menu trip computer work shift

Operating menu trip computer work shift, description
Trip computer for work shift shows current work shift machine statistics
since last reset to zero.
a. Instantaneous fuel consumption in litres per hour.
b. Average fuel consumption, in litres per hour.
c. Estimated operating hours to empty tank in hours and minutes.
d. Current engine speed in revolutions per minute.
e. Current speed in km/h.
f. Average speed in km/h.
g. Driving distance in kilometres.
h. Number of lifts.

Trip computer work shift is reset automatically if the machine has been
switched off for longer than two hours or manually with .

4.11.1.2 Engine operating menu

Engine operating menu, description
a. Shows current engine coolant temperature in °C or °F.
b. Shows current engine oil pressure in bar or psi.
a b
014519

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 4 Instruments and controls – Operating menus 81

4.11.1.3 Transmission and hydraulics operating menu

Transmission and hydraulics operating menu,

description
a. Shows the current transmission oil temperature in °C or °F.
b. Shows the current hydraulic system oil temperature in °C or °F.
a

014520

4.11.1.4 Operating menu electrical system

Operating menu electrical system, description

a. Shows the current battery voltage in volts.

4.11.1.5 Operating menu scales

Operating menu scale, description

a. Displays the tare in tonnes or lbs (pounds).

Tare weight is the change in weight in relation to the last reset to
zero of the tare weight. This can be used to weigh the load in a
container. If the tare weight is reset to zero with an empty container
then the tare weight shows the weight of the load in the container.
b. Current weight in tonnes or lbs (pounds) (net weight).
c. Total weight in tonnes or lbs (pounds) (gross weight).

To operate the scales, see Scales, page 247.

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82 4 Instruments and controls – Operating menus

4.11.1.6 Operating menu tyre pressure monitoring

Operating menu tyre pressure, description

Operating menu tyre pressure shows the current pressure in the tyres
and, together with the event menus, warns of low tyre pressure in two
stages with a coloured frame around the tyre in question.
a. Shows the air pressure in the left-hand steering wheel in bar or psi.
b. Shows the air pressure in the right-hand steering wheel in bar or
psi.
c. Shows the air pressure in the left-hand outer drive wheel in bar
or psi.
d. Shows the air pressure in the left-hand inner drive wheel in bar
or psi.
e. Shows the air pressure in the right-hand inner drive wheel in bar
or psi.
f. Shows the air pressure in the right-hand outer drive wheel in bar
or psi.

Green frame indicates that the tyre pressure is approved.

Yellow frame indicates that the tyre pressure is high or low and activates
the event menu, see Event menu tyre pressure, description, page 88.

Red frame indicates that the tyre pressure is incorrect (too high or low)
and activates the event menu, see Event menu incorrect tyre pressure,
description, page 84.

4.11.1.7 Operating menu customer settings

Operating menu system, description

a. Number of active error codes with error code level stop.
b. Number of active error codes with error code level warning.
c. Number of active error codes with error code level information.
d. Menu for customer settings such as date and time, SI/US units,
Eco Drive Mode and Automatic Start and Stop function .
e. Menu for statistics, history and operating hours.
f. Menu for services and settings.
g. Menu for machine check.
h. Menu for active error codes.
i. Menu for inactive error codes.

For a more detailed description of the different submenus, see 5.6

Customer settings via display, page 253.

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 4 Instruments and controls – Event menus 83

4.11.2 Event menus

General
Event menu categories

The control system attracts the operator's attention to important

information by showing the event menus on the control system display.
a The event menus are divided into the categories: STOP, WARNING,
INFO and NOTICE. Each menu is displayed with an icon with a border
b around it. The severity of the menu is indicated by the colour of the
border around the function symbol.

Some event menus give an audio signal to attract the operator's

attention.

014952
Table Event menu categories
Example figure STOP Red border.
a. The colour of the border indicates the category
of the event menu. WARNING Yellow border.

b. Symbol for the current function. INFO Grey border.

NOTICE No border.

Event menus with the level STOP, WARNING and INFO menus can
be acknowledged with otherwise they automatically disappear
when the state that generated the event ends. Event menus with
the level NOTICE automatically disappear. Menus that have been
acknowledged can be displayed with the current symbols in the status
field to the left. The event menus are ranked according to a priority
order in which those with the highest priority are displayed in the status
field. Not all event menus have status indicators and no icon will appear
in the status field for these. If there are more than four active event
menus, those with the highest priority are displayed, yet all menus
with status indicators are placed in a queue and are displayed when
there is space in the status field. If there is space in the status field,
information for the heating or air conditioning system will be shown in
the lower part of the field.

How each event menu affects the machine's different functions is

described under each event menu.

4.11.2.1 Event menu brake temperature

Event menu brake temperature, description

The figure is shown if:
• the temperature of the brakes is too high.
The machine's speed is limited for safety reasons when the
temperature is too high.

If the figure is shown, let the machine idle until the brake temperature
has reached the normal level. The display then disappears. The
display can be removed with the function key .
014984

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84 4 Instruments and controls – Event menus

4.11.2.2 Event menu low accumulator pressure

Event menu low accumulator pressure, description
The figure is shown if:
• The hydraulic oil pressure in the brake system is too low. The red
border is not displayed for a specific time during startup when the
pressure is being built up. The current pressure is shown in the
menu.

The event menu disappears when the hydraulic oil pressure has
reached the right level. The display can be removed with the function

015440
key .

4.11.2.3 Event menu incorrect tyre pressure

Event menu incorrect tyre pressure, description

The figure is shown if:

• The tyre pressure becomes too low. Current tyre pressure for all
tyres is shown in the menu, a tyre with pressure too low has a
red frame in the menu.
• The tyre pressure becomes too high. Current tyre pressure for all
tyres is shown in the menu, a tyre with pressure too high has a
red frame in the menu.

If the figure is shown (and speed limitation occurs):

• Set down the load in a safe manner and immediately call a service
technician to check the tyre pressures.

WARNING
Incorrect tyre pressure means that the stability of the
machine is reduced and that the tyres and rims are
subjected to abnormal loads.
Risk of roll-over and tipping over!
Do not use a machine with incorrect tyre pressure.

The event menu disappears when the tyre pressure has reached the
correct level. The display can be removed with the function key .

4.11.2.4 The event menu parking brake not activated

and no operator in the driver's seat
The event menu parking brake not activated and no
operator in the driver's seat, description
The figure is shown if:
• The parking brake is not activated and the operator is not sitting
in the driver's seat.

The event menu disappears when the operator sits in the driver's seat,
or when the parking brake is activated. The display can be removed
with the function key .
015441

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4 Instruments and controls – Event menus 85

4.11.2.5 High exhaust temperature in the engine

exhaust filter

High exhaust gas temperature in the engine's

after-treatment system, description
Applies to Cummins QSB6.7 Stage 4/Tier 4f.

The figure is shown if:

• The exhaust gas temperature in the engine's after-treatment
system is high.
• A manual regeneration of the after-treatment system is performed.

The display can be removed with the function key .

014985

4.11.2.6 After-treatment system, regeneration

After-treatment system regeneration, description

Applies to Cummins QSB6.7 Stage 4/Tier 4f.

The figure only shows if the function for regeneration of the engine's
after-treatment system is deactivated and the after-treatment system
needs to be regenerated.

NOTE
Perform a regeneration as soon as possible in order to maintain
engine performance and service life.
014986

There are a number of levels indicating the severity of the clogging in

the after-treatment system. The levels are:
1. Event menu appears with a fixed light. This is the first warning
level when the system starts to become clogged, there are then
two options:
a Operate as normal and allow regeneration of the
after-treatment system. Check that the regeneration function
is not shut off with the switch, see Switch for preventing
regeneration of the engine's after-treatment system (51), page
54. The engine runs with an increased load. The event menu
switches off when regeneration has been performed.
b Perform a manual regeneration, see Manual regeneration of
the engine's after-treatment system, description, page 232.
2. The border around the event menu flashes. Perform a manual
regeneration when possible, see Manual regeneration of the
engine's after-treatment system, description, page 232.
3. The border around the event menu flashes and error code 5631
is shown. Perform a manual regeneration as soon as possible,
see Manual regeneration of the engine's after-treatment system,
description, page 232
4. Error code 3714, 2777 or 3753 is shown. Contact Service for
regeneration.

After regeneration, the display disappears. The display can be

removed with the function key .

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86 4 Instruments and controls – Event menus

4.11.2.7 Event menu AdBlue end

Event menu AdBlue end, description
Only applies to machines with Volvo TAD871VE and Cummins QSB6.7
Stage 4/Tier 4f

The figure is shown if:

• There is a fault in the supply of AdBlue.
• The engine indicates low AdBlue level.

Emission is control not working and engine power is limited.

016679
If the figure is shown, top up the AdBlue. The display then disappears.
The display can be removed with the function key .

NOTE
Fuel and AdBlue must be filled at the same time.

4.11.2.8 Event menu engine coolant temperature

Event menu engine coolant temperature, description
The figure is shown if:
• The coolant temperature is high.

If the figure is shown, check that the engine's cooling fan has been
activated and allow the machine to run at idle until the coolant
temperature has reached normal level. The display then disappears.
The display can be removed with the function key .
014987

4.11.2.9 Event menu oil temperature transmission

Event menu oil temperature transmission, description
The figure is shown if:
• Transmission oil temperature is high.

If the figure is shown, check that the engine's cooling fan has been
activated and allow the machine to remain at idle until the transmission
oil has reached normal temperature. The display then disappears. The
display can be removed with the function key .
014988

4.11.2.10 Event menu oil temperature hydraulics

Event menu oil temperature hydraulics, description
The figure is shown if:
• The hydraulic system's oil temperature is high.

If the figure is shown, let the machine stand and idle until the hydraulic
oil has reached the normal temperature. The display then disappears.
The display can be removed with the function key .
015479

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4 Instruments and controls – Event menus 87

4.11.2.11 Event menu height warning

Event menu height warning, description

The figure is shown when:

• set lifting height is reached.
See Height warning, page 249.

The display can be removed with the function key .

016677
4.11.2.12 Event menu height limitation

Event menu height limitation, description

The figure is shown when:

• set lifting height is reached. Lift movement is stopped.

If the figure is shown, lower the load. The display then disappears. The
function can be bypassed, see Height limitation, page 249.

The display can be removed with the function key .

016678

4.11.2.13 Event menu overload lift

Event menu overload lift, description

The figure is shown if:

• the lifting equipment is overloaded. The overload system stops
lift and tilt.

The event menu disappears when the overload ceases. In the event
of overload the load can always be lowered and tilted out to withdraw
016682

from the overload situation. The display can be removed with the
function key .

4.11.2.14 Event menu overload tilt

Event menu overload tilt, description

The figure is shown if:

• the lifting equipment is overloaded. The overload system stops
lift and tilt.

The event menu disappears when the overload ceases. In the event
of overload the load can always be lowered and tilted out to withdraw
016683

from the overload situation. The display can be removed with the
function key .

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88 4 Instruments and controls – Event menus

4.11.2.15 Event menu overload lift and tilt

Event menu overload lift and tilt, description

The figure is shown if:

• the lifting equipment is overloaded. The overload system stops
lift and tilt.

The event menu disappears when the overload ceases. In the event
of overload the load can always be lowered and tilted out to withdraw

016684
from the overload situation. The display can be removed with the
function key .

4.11.2.16 Event menu tyre pressure

Event menu tyre pressure, description

The figure is shown if:

• The tyre pressure becomes low. Current tyre pressure for all tyres
is shown in the menu, a tyre with low pressure has a yellow frame
in the menu.
• The tyre pressure becomes high. Current tyre pressure for all
tyres is shown in the menu, a tyre with high pressure has a yellow
frame in the menu.

In case the figure is shown:

• Finish the work shift and call a service technician as soon as
possible to check the tyre pressures.

WARNING
Incorrect tyre pressure means that the stability of the
machine is reduced and that the tyres and rims are
subjected to abnormal loads.
Risk of roll-over and tipping over!
Do not use a machine with incorrect tyre pressure.

The event menu disappears when the tyre pressure has reached the
correct level. The display can be removed with the function key .

4.11.2.17 Event menu seat belt

Event menu seat belt, description

The figure is shown if:
• The belt is not fastened and the speed exceeds 3 km/h

If the figure is shown, fasten the seat belt. The display then disappears.
The display can be removed with the function key .

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4 Instruments and controls – Event menus 89

4.11.2.18 Event menu low accumulator pressure

Event menu low accumulator pressure, description
The figure is shown if:
• Try to release the parking brake when the accumulator pressure
is low.

If the figure is shown, wait until the pressure is built up in the

accumulators and release the parking brake. The display then
disappears. The display can be removed with the function key .

4.11.2.19 Event menu parking brake

Event menu parking brake, description
The figure is shown when:
• The parking brake is activated and you try to engage a gear.
• The parking brake is activated and you try to activate the automatic
functions that require the parking brake to be released.

Release the parking brake and the display disappears. The display can
be removed with the function key .
014990

4.11.2.20 Event menu low AdBlue level

Event menu low AdBlue level, description
Only applies to machines with Volvo TAD871VE and Cummins QSB6.7
Stage 4/Tier 4f

The figure is shown if:

• The level in the AdBlue tank is low.

If the figure is shown, top up the AdBlue. The display then disappears.
The display can be removed with the function key .
014991

NOTE
Fuel and AdBlue must be filled at the same time.

4.11.2.21 Event menu AdBlue

Event menu AdBlue, description
Only applies to machines with Volvo TAD871VE and Cummins QSB6.7
Stage 4/Tier 4f

The figure is shown if:

• There is a fault in the supply of AdBlue.
• The engine indicates low AdBlue level.

If the figure is shown, top up the AdBlue. The display then disappears.
016680

The display can be removed with the function key .

NOTE
Fuel and AdBlue must be filled at the same time.

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90 4 Instruments and controls – Event menus

4.11.2.22 Event menu low fuel level

Event menu low fuel level, description
The figure is shown if:
• The level in the fuel tank is low.

If the figure is shown, top up the fuel. The display then disappears. The
display can be removed with the function key .

For machines with Volvo TAD871VE and Cummins QSB6.7 Stage

4/Tier 4f:

014992
NOTE
Fuel and AdBlue must be filled at the same time.

4.11.2.23 Event menu battery capacity

Event menu battery capacity, description
The figure is shown if:
• The battery capacity is becoming low.

If the figure is shown, check battery voltage and charge or replace the
batteries. The display then disappears. The display can be removed
with the function key .
014993

4.11.2.24 Event menu no operator in seat

Event menu no operator in seat, description
The figure is shown with:
• Attempt to engage a gear without anyone sitting in the driver's
seat. The transmission then goes to neutral and the gear must be
engaged again once the operator sits in the seat again.
• The working hydraulics are activated without anyone sitting in the
driver's seat.
• Attempt to rotate the operator's station without someone sitting in
the driver's seat .
014994

If the figure is shown, sit down in the driver's seat and select the gear
again, try to rotate the operator's station once more or activate the
working hydraulics. The display then disappears. The display can be
removed with the function key .

4.11.2.25 Event menu open door

Event menu open door, description
The figure is shown if:
• A function is limited because the door(s) is/are not closed.

In the event that the display is shown, close the door(s). The display
then disappears. The display can be removed with the function key .
015206

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4 Instruments and controls – Event menus 91

4.11.2.26 Event menu low washer fluid level

Event menu low washer fluid level, description

The figure is shown if:
• The level in the washer fluid reservoir is low.

If the figure is shown, top up the washer fluid. The display then
disappears. The display can be removed with the function key .

015205
4.11.2.27 Event menu air filter air conditioning system

Event menu air filter air conditioning system,

description
The figure is shown if:
• The air filter in the air-conditioning system is clogged.

If the figure is shown, replace the air filter. The display then disappears.
The display can be removed with the function key .
015442

4.11.2.28 Event menu release the parking brake

Event menu release the parking brake, description

The figure is shown if:
• Attempt to release the parking brake is made without the service
brake pedal being pressed down.
• Attempts to rotate the operator's station are performed without the
service brake pedal being depressed sufficiently or the parking
brake is not activated .

In case the figure is shown:

014995

• Depress the service brake pedal and release the parking brake.
• Depress the service brake pedal or activate the parking brake and
try to rotate the operator's station once again.

The display then disappears. The display can be removed with the
function key .

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92 4 Instruments and controls – Event menus

4.11.2.29 Deactivated regeneration of the engine's

after-treatment system, description
Deactivated regeneration of the engine's
after-treatment system, description
Applies to Cummins QSB6.7 Stage 4/Tier 4f.
The figure is shown if:
• the after-treatment system's regeneration is prevented.
This is done by activating the Switch preventing regeneration of
the engine's after-treatment system, see Switch for preventing
regeneration of the engine's after-treatment system (51), page 54.
In the event that the figure is shown, regeneration is prevented.
014996 If the after-treatment system needs to be regenerated clean,
After-treatment system regeneration, description, page 85 is shown.
The display can be removed with the function key .

4.11.2.30 Event menu preheating

Event menu preheating, description
The figure is shown if:
• Preheating is activated.
The engine's control system activates the preheating during a time
period as necessary.
The event menu disappears when preheating is complete. The display
can be removed with the function key .
014997

4.11.2.31 Event menu raise/lower cab temperature

Event menu raise/lower cab temperature, description
The figure is shown if:
• The cab temperature is raised or lowered. Desired temperature is
displayed in the menu.
The event menu disappears a short time after the most recent
temperature change with the cab temperature switches. The display
can be removed with the function key .

4.11.2.32 Event menu raise/lower fan speed

Event menu raise/lower fan speed, description
The figure is shown if:
• The fan speed is raised or lowered.
The event menu disappears a short time after the last fan change
with the switches for fan speed. The display can be removed with the
function key .
014999

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4 Instruments and controls – Event menus 93

4.11.2.33 Event menu start interlock

Event menu start interlock, description

The figure is shown when:
• The start interlock (Immobiliser) function prevents the operator
from staring the engine, e.g. with the alcolock.
• The starter motor has run too long. The engine's control unit stops
the starting attempt. A new attempt to start the engine can be
made when the starter motor has rested for a while. Applies to
Cummins QSB6.7.
• Engine or hydraulic oil heater is engaged.

015200
The event menu disappears when the conditions for starting the
machine are met. The display can be removed with the function key .

4.11.2.34 Event menu heating rear view mirrors/rear

windscreen

Event menu heating rear view mirrors/rear windscreen,

description

The figure is shown if:

• Heating in rear window is activated.
• Heating rear view mirrors/rear windscreen activated.

The event menu disappears a short time after activation. The display
can be removed with the function key .
015201

The figure is shown if:

• Heating in rear window is deactivated.
• Heating rear view mirrors/rear windscreen deactivated.

The event menu disappears a short time after the function is

deactivated. The display can be removed with the function key .
015202

4.11.2.35 Event menu service

Event menu service, description

The figure is shown when:
• Time to next service is approaching. The remaining time to service
in hours is shown in the menu.

Ensure that the machine is serviced according to the prescribed

intervals. The display can be removed with the function key .

Operator’s manual DCG 180-330 IDCG02.03GB

94 4 Instruments and controls – Event menus

4.11.2.36 Event menu control breaker

Event menu control breaker, description

The figure is shown if:
• The control breaker is pressed in when specific functions are
activated.
• The control breaker is activated.

Reset the control breaker by turning it clockwise. The display can be

removed with the function key .

015444
4.11.2.37 Event menu intermittent wiper

Event menu intermittent wiper, description

The figure is shown when:
• Slow intermittent wipers are activated.

The display can be removed with the function key .

015445

The figure is shown when:

• Fast intermittent wipers are activated.

The display can be removed with the function key .

015446

4.11.2.38 Event menu speed limitation

Event menu speed limitation, description

The figure is shown when:
• Functions in the machine are prevented because the speed is too
high.

If the figure is shown, reduce speed. The display then disappears.

The display can be removed with the function key .

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4 Instruments and controls – Event menus 95

4.11.2.39 Event menu battery charging

Event menu battery charging, description

The figure is shown if:
• The engine's alternator does not charge the battery for a few
seconds.

If the figure is shown, increase the engine speed in order to increase

alternator output. The display disappears after 2 seconds when the
alternator is charging the battery. If the display does not disappear,
release the load safely, park the machine and contact service.

The display can be removed with the function key .

4.11.2.40 Event menu low coolant level engine

Event menu low coolant level engine, description

The figure is shown if:
• The coolant level in the engine's expansion tank becomes too low.

If the figure is shown, release the load safely, park the machine and
check the coolant level, see Cooling system, general, page 284.

The display can be removed with the function key .

4.11.2.41 Event menu rotate the operator's station

Event menu rotate the operator's station, description

The figure is shown if:

• The travel direction selector is activated when the operator's
station is in zone C.
• Load handling functions are activated when the operator's station
is in zone C, D or E.
• The operator's station rotates without the operator activating the
016608

switch to rotate the operator's station.

• The switch to rotate the operator's station is activated but the
turning torque is too high.

Operator’s manual DCG 180-330 IDCG02.03GB

96 4 Instruments and controls – Event menus

If the figure is shown, do not activate the travel direction selector or load
handling functions in zones where they stop the function. The display
then disappears. The display can be removed with the function key .

180°
E
D

B
A
0°
016607

4.11.2.42 Event menu mini-wheel/joystick control,

description

Event menu mini-wheel/joystick control, description

The figure shows when the switch to rotate the operator's station is
activated at the same time as mini-wheel/joystick control.

If the figure is shown, do not use the mini-wheel/joystick control when

rotating the operator's station. The display then disappears. The
display can be removed with the function key .
016609

4.11.2.43 Event menu arm rest

Event menu arm rest, description

The figure shows when the switch to rotate the operator's station is
activated and the right-hand arm rest is not in the permitted range.

The figure also shows whether the left-hand arm rest by the
mini-wheel/joystick control is in the lowered position .

If the figure is shown, adjust the right-hand arm rest to the permitted
position and lower the arm rest by the mini-wheel/joystick control
and try to rotate the operator's station once again. The display then
016610

disappears. The display can be removed with the function key .

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4 Instruments and controls – Event menus 97

4.11.2.44 Event menu automatic stop function

Event menu automatic stop function, description

The image is shown before:
• The engine is stopped by automatic engine shutdown, see
Automatic stop function, page 215.
• The engine is stopped by the automatic start and stop function, see
Automatic start and stop function, page 216.

The bar indicates remaining time until shutdown as a % of set time for
automatic shutdown.

4.11.2.45 Event menu automatic start function

Event menu automatic start function, description

The figure is shown when:

• The engine is ready to be started automatically by the automatic
start/stop function, see Automatic start and stop function, page 216.

To start the engine, activate any hydraulic function, depress the

accelerator pedal or depress the brake pedal.
017365

4.11.2.46 Event menu, clamped load

Event menu, clamped load, description

The figure is shown if:

• Open attachment is activated without the switch on the lever being
activated.

If the figure is shown, activate the switch and select open attachment
with the lever. The display then disappears. The display can be
016681

removed with the function key .

Operator’s manual DCG 180-330 IDCG02.03GB

98 4 Instruments and controls – Optional equipment

4.12 Optional equipment

Back-up camera and distance warning
General

As an option, the machine can be equipped with back-up camera.

There are two different systems with back-up camera.
• Back-up camera.
• Back-up camera with distance warning.

Back-up camera

The back-up camera is fitted in a recess in the counterweight and the

image is shown on a monitor in the cab.

The monitor is fitted on a hinged bracket to the right, in front of the door
in the cab. The back-up camera has a microphone, the audio is played
back using a loudspeaker in the monitor. Volume is adjusted using
the Right and Left buttons on the monitor (position A). The monitor
brightness is adapted automatically to the light in the cab by the light
sensor (position F). Lines are shown over the camera image that help
to judge the distance to the object in the picture.

Monitor back-up camera The monitor can also be mounted on the left-hand side, in front of the
door .
A. Right / Left (volume)
B. Up / Down The machine can be equipped with several cameras. Selection of
camera display is made via the Confirm selection button on the monitor
C. Off / On (position D), the back-up camera is automatically selected when
D. Confirm selection (change camera) reverse gear is activated.
E. Show menu
More settings are available via the monitor's built-in menu system that
F. Light sensor is shown with the Show menu button (position E). To navigate in the
menus, use the arrow keys (position A and B) and the button Confirm
selection (position D).

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 4 Instruments and controls – Back-up camera and distance warning 99

Back-up camera with distance warning

The back-up camera with distance warning uses the camera to show
the area behind the machine and ultrasonic sensors to warn of objects
in the area behind the machine. The distance warning system is only
active when reverse gear is selected.

The back-up camera is fitted in a recess in the counterweight and the

image is shown on a monitor in the cab.

The monitor is fitted on a hinged bracket to the right, in front of the

door in the cab. The camera has a microphone, the audio is played
back using a loudspeaker in the monitor. The monitor has four
programmable shortcut buttons (position D), the function of the buttons
can be set using the menu system in the monitor.

The sensors for distance warning are located on each side of the rear
A. Screen display off / on
counterweight. When objects are detected by the sensors the operator
B. Indicator light, power is warned by coloured bars on the right-hand side of the monitor as well
C. Light sensor as by acoustic warnings (see below).
D. Shortcuts 1 - 4 The monitor can also be mounted on the left-hand side, in front of the
E. Cancel door .
F. Menu navigation The machine can be equipped with several cameras. Selection of
G. Confirm selection camera display is made via the Confirm selection button on the monitor
(position D), the back-up camera is automatically selected when
reverse gear is activated.

More settings are available via the monitor's built-in menu system that
is shown when the Menu navigation button (position F) is pressed up
or down. To navigate in the menus, use the Menu navigation button
(position F) and confirm a selection by pressing the Confirm selection
button (position G), undo a selection or exit the menus by pressing the
Cancel button (position E).

Operator’s manual DCG 180-330 IDCG02.03GB

100 4 Instruments and controls – Fire extinguishing system

Distance warning

Distance warning

Back-up camera with distance warning works in the same way as

the normal back-up camera but with the addition that it also warns of
objects behind the machine.

NOTE
The distance warning system should be seen as an aid when
driving at low speed. Always have a clear view of the area behind
the machine; personnel or other vehicles may enter the area behind
the machine.

Distance warning takes place in four stages with audio and visual
indication on the monitor.

A. Distance warning stage 1 and 2

Stage 1
• No objects within 3 metres behind the machine.
B. Distance warning stage 3
• Green constant indicator to the right of the monitor (position A).
C. Distance warning stage 4
D. Distance warning stage 4 Stage 2
• Object within 3.0 - 1.7 metres behind the machine.
• Yellow flashing indicator to the right of the monitor (position A) and
warning sound twice per second.
Stage 3
• Object within 1.7 - 0.7 metres behind the machine.
• Red flashing indicator to the right of the monitor (position B) and
warning sound, four times per second.
Stage 4
• Object within 0.7 metres behind the machine or at the sides.
• Red constant indicator to the right of the monitor (position C), stop
symbol above image and constant warning sound.

Fire extinguishing system

General

As an option, the machine can be equipped with a fire extinguishing

system, see Emergency equipment, page 103.

This system is permanently mounted with both a manual and an

automatic trigger and a display.

For more information, contact the supplier of the system.

IDCG02.03GB Operator’s manual DCG 180-330

 4 Instruments and controls – Vehicle Data Interface (VDI) 101

Vehicle Data Interface (VDI)

General

As an option, the machine can be prepared for connecting external

systems for reading operating data from the machine (e.g.Insight).

On machines with VDI there is an extra connector (X039), the 9-pin

Universal mate-n-lock type, in the electronic box in the cab. The
connector contains the following connections:
1. CAN bus option (R+)
2. CAN bus option (R-)
3. Ignition voltage, 24 V 10 A
4. Battery voltage, 24 V 10 A
5. Ground
6. Not connected
7. Not connected
8. Not connected
9. Battery voltage before battery disconnector, 24 V 10 A (may
require extra installation on the machine)

For more information, contact Cargotec.

Insight
General
Operator identification

Insight is an option for process automation. Insight reads operational

data from the machine through VDI. The information is sent wirelessly
to a en central server for further processing and display on a website at
the customer. For more information, contact Cargotec.
Operator identification
As an option for Insight, the machine can be equipped with driver
identification. Operator identification uses identification tags and a tag
reader at the rear of the cab by the door.

Using operator identification, operator-dependent functions can be

selected in Insight, such as start interlock and speed limitation, for
example. For more information, contact Cargotec

Tag and tag reader for driver identification

Operator’s manual DCG 180-330 IDCG02.03GB

102 5 Handling

5 Handling
General
The machine is intended to be used in the way that is described in
the operator's manual. If the machine is used in any other way or in
potentially dangerous environments, e.g. an explosive environment,
then special safety rules must be followed and the machine must be
equipped for such an environment.

NOTE
It is the operator who is responsible for ensuring that the machine
comes in for service according to prescribed service intervals.
Procedures are described in the maintenance manual.

The information in the chapter for handling the machine does not
relieve the operator of the responsibility of following laws or other
national regulations for road safety and work safety.

Awareness, alertness, good judgement and respect for governing

safety regulations are prerequisites for avoiding accident risks.

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

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Handling 103

Emergency equipment
The following emergency equipment is available on the machine:
• Emergency exit from cab, right-hand door.
In an emergency:
1. Open the emergency exit right-hand door with handle on inside.

34 • Control breaker for load handling.

In an emergency:
1. Press down the control breaker (position 34) immediately.
All load handling functions stop and the transmission is set into
neutral.
2. Restore control breaker (turn clockwise).
• Fire extinguisher
Fire extinguishers are located on the left-hand front wing but can
also be located on the right-hand front wing behind the right or
left-hand footsteps (or in these locations simultaneously).
012702

In case of engine fire, press in the fire extinguisher's nozzle

through the perforation on the plate for fire extinguisher on the
sides of the engine hood.

WARNING
By-pass of load handling functions must not be used
during normal load handling.
Extreme hazard to personal health and risk of property
damage.
Only use the bypass in emergency situations.

• Display fire extinguishing system

If the fire extinguishing system fails to trigger automatically in
the event of fire, depress the switch for manual triggering (a) to
activate the fire extinguishing system.
a Switch for manual triggering.
b Warning lamp, fire.
c Warning lamp, fault in trigger coil.
d Warning lamp, fault in detector coil.
e Indicator light, manual mode.
f Indicator light, fire monitoring active.
If the indicator light is extinguished, this means there is a fault
in the voltage feed to the fire extinguishing system.
g Alarm test and reset.

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104 5 Handling – Handling

• External activation control, fire extinguishing system

Visible external position on the chassis!
If the fire extinguishing system fails to trigger automatically in the
event of fire, depress the control to activate the fire extinguishing
system.

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 5 Handling – Running-in 105

5.1 Running-in
General
The machine should be operated with great care during the running-in
period. The intention is to considerably increase the service life of
the machine.

Recommended running-in period is 10 hours of operating time. This

results in fewer malfunctions.

Engine
The oil and filter must be changed according to intervals described in
the maintenance manual.

Transmission
The oil and filter must be changed according to intervals described in
the maintenance manual.

Tyres and rims

For a new machine it is extremely important that the wheel nuts
are check-tightened during the first week of operation until they are
properly set in. This should 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 described in the maintenance
manual.

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106 5 Handling – Daily inspection

5.2 Daily inspection

General
Daily inspection of the machine is extremely important in order to
ensure that it is safe both for the operator and its surroundings.

Every operator should perform checks before a new work shift. In this
way, operators can avoid running defective machines with malfunctions
that have been generated or caused during an earlier work shift.

WARNING
Never use a machine without first performing the daily
inspection.
Risk of personal injury and property damage!
For work instructions, see 6.1 Daily inspection, page
266. Report to the foreman/supervisor if defects are
found on the machine during daily inspection!

For work instructions, see 6.1 Daily inspection, page 266.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error codes 107

5.3 Error codes

Error codes, general
Error codes indicate that there is a defect on the machine. Errors are
d indicated by an Indicator light for active errors (position 18) on the
a steering wheel panel. The number of active errors is totalled on the
display (position a-c). Some error codes are displayed via pop-up
e menus to attract the operator's attention. The error codes should be
b used by operators and service technicians to identify faults and to
implement suitable action.

c 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.

015223
All error code information for active and inactive error codes is collected
a. Number of active error codes with error code on the operating menu Customer settings and the sub-menus Active
level stop. Errors (position d) and Error history (position e).
b. Number of active error codes with error code Select Active Errors or Error history with or and press to
level warning. activate the desired menu.
c. Number of active error codes with error code
level information.
d. Menu for active error codes, Active errors.
e. Menu for inactive error codes, Error history.

Error code information via pop-up menu

Error code information via pop-up menu

Error codes are automatically shown via pop-up menus on the display.
Some information about the error code can be read out directly by
the symbols in the pop-up menu. The menus Active errors and Error
history show detailed information about the error codes.

Press to show specific detailed information via the Active errors

menu.

Press to confirm the error and the display returns to show the menu
that was active before the pop-up men was activated. If there are more
015224

active errors, the next pop-up menu is shown.

Example figure

Error code information Active errors

Error code information Active errors

Detailed information about the error codes are presented under Active
errors where, among others, the error code level, action with error code
and the device that generated the error code are presented.

For information about how the error code should be interpreted, see
Field d: Error code number, page 114.

Scroll through active error codes with and . Leave the error code
list by pressing the function key .
015225

Example figure Active errors

Operator’s manual DCG 180-330 IDCG02.03GB

108 5 Handling – Error codes

Error code information in Error history

Error code information in Error history

Detailed information about the last 50 inactive error codes is presented
under Error history where, amongst other things, the error code level,
the unit that generated the error code and the date and time are
presented.

For information about how the error code should be interpreted, see
Field d: Error code number, page 114.

Scroll through inactive error codes with and . Leave the error code
list by pressing the function key .

Example figure Error history 014945

Action in the event of error code

CAUTION
STOP indicates a malfunction in the machine which
may affect the safety of the operator and others in the
vicinity or may cause a breakdown. Read the error
code. Switch off the engine and perform action in
accordance with the error code table.
WARNING and INFORMATION alarms indicate
malfunctions of such character that work does not
have to be stopped immediately. The capacity of the
machine may be reduced and specific functions may
stop working. - Perform the measures according to the
error code table immediately.

1 Errors are indicated through the pop-up menus, and by an indicator

light for active errors (position 18) being lit.
Stop the machine and let the engine run at idle speed.
2 Identify error code level, see Field a: Error code level, page 111.

NOTE
If several error codes come from the engine or transmission, the
error code level is shown for the most serious error code.
015224

3 Note all error codes. For explanation, see Display figure for error
code information, page 111.
4 Perform the action depending on the action symbol shown in the
Example figure
middle field, see Field b: Operator action, page 111.
5 Check: Start the engine and check under Active errors that the
error code has disappeared.

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 5 Handling – Error code indication 109

5.3.1 Error code indication

General
Error codes are indicated with an activated indicator light for active
error codes (position 18) and a pop-up menu. The error codes are
divided into three error code levels depending on their severity.

The error code levels are shown as follows:

a b c d • STOP is indicated by:
1. Lit indicator light for active fault codes (position 18).
2. STOP symbol in the pop-up menu.
3. Red border around the pop-up menu.
• WARNING indicated by:
1. Lit indicator light for active fault codes (position 18).
2. Warning triangle in the pop-up menu.
3. Yellow border around the pop-up menu.
• INFORMATION indicated by.
1. Lit indicator light for active fault codes (position 18).
2. Information symbol in the pop-up menu.
3. Grey border around the pop-up menu.
015226

a Symbol for the error code level

STOP, WARNING or INFORMATION
b Symbol for action
c Symbol for component
d Border indicates error code level
Red = STOP
Yellow = WARNING
Grey = INFORMATION

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110 5 Handling – Error code information on display

5.3.2 Error code information on display

Error code display
Error code information is shown with display figures in two ways:
• Automatically in display.
The error code is confirmed by . When the error code is
confirmed the display returns to the previous selected menu. If the
error code is active then it is stored in the error code list under the
operating menu Active errors.
If the error code remains active, the figure returns in the display
within 3-5 minutes. Level STOP error codes are shown five times,
WARNING three times and INFORMATION once or not at all.

014954

Example of automatic figure in display

• In error code list Active errors.

Active error codes are stored in the error code list. Navigate to
the operating menu Customer settings with or , select Active
errors and confirm with . Navigate the error code list with the
function keys and . Leave the error code list by pressing the
function key .

NOTE
If error code isn't included in the error code list, it may be due to
015225

the following:
– condition for error detection no longer exists, e.g., control
Example of the error code list Active errors
lever is released or engine is off.
– loose connection/poor contact.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code information on display 111

Display figure for error code information

The menus are divided into fields where the information is displayed.
• Field a: Error code level. Shown with a symbol.
• Field b: Operator action. Shown with a symbol.
• Field c: Component that generated the error code. Shown with
a b c a symbol.
• Field d: Error code.
• Field e: Number of errors. For Error history the number of errors
is limited to the last 50 errors.

015228
• Field f: Number of errors on each error code level.
h
• Field g: Date and time.
Pop-up menu for error codes • Field h: Number of unconfirmed pop-up menus.

Field a: Error code level

e
f The control and monitoring system gives error code information in three
d levels which are indicated with a symbol in the display unit.

Symbol Action
a b c STOP
Indicates a serious malfunction that may jeopardise
the operator's safety or cause machine failure. The
015229

error code must be attended to immediately.

WARNING
Active error codes shown in Active errors
Indicates malfunction in machine that should be
taken care of as soon as possible.
e
f
d INFORMATION
a g c
Information to the operator that something should
be rectified, e.g. broken bulb. Rectify the cause
at a suitable opportunity. Instructions for action
are normally found in chapter 6 Inspection and
maintenance.
015230

Field b: Operator action

The control system provides information about what action the operator
Inactive error codes are shown in Error history
should carry out. The information is indicated with a symbol on the
display unit.

Symbol Action
Carry out action according to the daily inspection,
see Instructions, page 266.

Error requires action by trained personnel.

One of the functions of the machine is not working
fully.

Critical error.
Errors that may jeopardise the machine or safety,
such as low oil pressure or overload. Stop the
machine and safeguard the error.
Read the operator's manual.

Operator’s manual DCG 180-330 IDCG02.03GB

112 5 Handling – Error code information on display

Field c: Affected function

For an explanation of the display fields, see Display figure for error
code information, page 111.

Symbol Function Symbol Function Symbol Function

Engine Fuel level AdBlue level

Temperature electric Temperature electric Particulate filters

motor hydraulics motor drive

After-treatment system Exhaust temperature Air filter

Engine coolant level Coolant temperature Engine oil level

engine

Preheating engine Transmission Oil temperature torque

converter

Lock-up, torque converter Differential locks Transmission oil level

Oil pressure, transmission Transmission oil Power transmission

temperature

Tyre pressure Regulator (inverter) Brakes

Brake pressure Parking brake Oil temperature brake

system

Steering Suspension Load handling

Control levers Lift/lower Lift/lower

Extension Side shift Side shift

Spreading (positioning) Spreading (positioning) Rotation

Tilt Tilt lock Tilt

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code information on display 113

Symbol Function Symbol Function Symbol Function

Levelling Levelling lock Levelling

Contact twistlocks Locked twistlocks Unlocked twistlocks

Contact top lift attachment Contact side-lift Bottom lift attachment

attachment

Support jacks Control system Boom angle

Boom length Scales Overload system

Overload system Height limit Frame, body, cab and

accessories

Hour meter (operating Seat Revolving driver's seat

hours)

Air conditioning ECH, ECC Fresh air filter

Pause heater Temperature water heater Recirculation

Washer fluid Wipers Revolving or flashing

beacon

Lighting Horn Heating rear

windscreen/rear view
mirrors

Cab sliding length Vertically adjustable cab Tiltable cab

Central lubrication Hydraulic oil filter Hydraulic oil temperature

Battery charging CAN bus CAN bus drivetrain

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114 5 Handling – Error code information on display

Field d: Error code number

Field d: Error code number

The control system gives error codes from the machine's sub-systems:
1 2 3
For an explanation of the display fields, see Display figure for error
code information, page 111.

Node (AAA)
The first part of the error code specifies the control unit (Node) that
generated the error. The following control units can generate error
codes:

Node Control unit

015233
1–99 Control units in the RedCAN system
100 Engine
Example figure error codes
111 Transmission ZF
1. Node (control unit) (AAA)
210 Exhaust system
2. SPN (component) (BCCCC-DD)
3. FMI (type of error) (E) Type (B)
Type is indicated with a letter before the digits in the component
number, which specifies the type of component concerned.

The following component types are used:

Type Component type

A Unit
B Sensor
D Control unit
E White light
F Fuse
G Battery or alternator
H Signal unit for audio or light
K Relay
M Electric motor
P Meter
R Resistor, potentiometer
S Switch, contact
X Connector
Y Solenoid valve

SPN (CCCC)
SPN is a unique number (component number) to locate the faulty
component.

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 5 Handling – Error code information on display 115

Location (DD)
In the cases where several components have the same component
number, there is a number for location that makes the error code
unique, either a serial number (1 – 9) or a number equivalent to a
position (10 – 220).

The following locations are used:

Location Explanation (abbreviation)

10 Left (LE)
20 Right (RI)
30 Upper (UP)
40 Lower (LO)
100 Front (LE)
110 Left front (LF)
120 Right front (RF)
200 Rear (RE)
210 Left rear (LR)
220 Right rear (RR)

FMI (EE)
FMI indicates type of error.

The following error types are used:

Table Specifications FMI

FMI Description SAE text

0 Value too high. Data valid, but higher than normal operating range.
1 Value too low. 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 Value too high. Data valid but higher than normal operating range: The least serious
level.
16 Value too high. Data valid but higher than normal operating range: Moderately
serious level.
17 Value too low. Data valid but under normal operating range: The least serious level.

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116 5 Handling – Error code information on display

FMI Description SAE text

18 Value too low. Data valid but under normal operating range: Moderately serious
level.
19 Communication error. Received network data incorrect.
20 Data too high. Data valid but higher than normal value.
21 Data too low. Data valid but lower than normal value.
22-30 Reserved for SAE allocation.
31 FMI not available or the condition Not available or the condition exists.
indicated by SPN exists.
32 Electrical problem. Abnormally high resistance or short-circuit to higher voltage.
33 Electrical problem. Abnormally low resistance or short-circuit to lower voltage.
34 Time exceeded. Time exceeded.
35 Communication error. CAN bus error.
36 Communication error. Driver error.
37 Communication error. Over flow.
38 Communication error. Error passive stat.
39 Communication error. Baud rate.
40 Communication error. Control unit disappears (stop sending messages) after start up.
41 Communication error. Control unit missing on start up.
42 Communication error. CAN-bus segment after the control unit is faulty. Normal side.
43 Communication error. CAN-bus segment after the control unit is faulty. RedCAN side.
44 Communication error. Control unit incorrectly positioned RedCAN circuit.
45 Communication error. Checksum error in the control unit.

Field e: Number of error codes

Specifies the number of menu pages with active fault codes in Active
errors and the number of menu pages with inactive error codes Error
history.

For an explanation of the display fields, see Display figure for error
code information, page 111.

Field f: Number of errors on each error code level

Specifies the number of active error codes on each error code level.

For an explanation of the display fields, see Display figure for error
code information, page 111.

Field g: Date and time

Specifies the date and time when the error code was confirmed.

For an explanation of the display fields, see Display figure for error
code information, page 111.

Field h: Number of unconfirmed pop-up menus

Specifies the number of unconfirmed pop-up menus.

For an explanation of the display fields, see Display figure for error
code information, page 111.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 117

5.3.3 Error code tables

Error codes machine
General

General
Error codes for the machine are sorted in numerical order. The table
contains the following information:
• Type - Denotes the type of component, see Type (B), page 114.
• SPN - Denotes the component concerned, see SPN (CCCC),
page 114.
• FMI - Denotes the type of error, see FMI (EE), page 115.
• Node - Denotes which unit has generated the error, see Node
(AAA), page 114.
• Location - denotes the component's location in the machine,
Location (DD), page 115.
• Description - Indicates description of the error code as well as any
limitation that can occur in the machine in case of the error code
in question.
• Action - Indicates STOP/WARNING/INFORMATION for action
according to error code level, with or without detailed information.

If the error code number isn't included in the error code table, contact
service.

Table Error codes machine

Type SPN FMI Node Location Description Action

114 1 1 Overcurrent will cause BMS STOP
to switch off and open the
contactor.
The battery is switched off after
timeout and error code.
114 2 1 Fault in current sensor, battery INFORMATION
cell.
114 6 1 The current is above the WARNING
configured alarm level for a
configured time.
168 3 1 Warning of overvoltage. INFORMATION
168 3 1 Cell voltage is above configured WARNING
alarm level 4.0V.
H 1037 6 11 2 Indicator light, levelling lock, in WARNING
control lever.
S 1310 7 11 Travel direction selector, logical STOP
error.
S 1500 31 1 0 No ignition at speeds above 3 WARNING
km/h.
Switch off and restart the
machine to reset the error code.
H 1753 6 1 2 Indicator light wide twistlocks INFORMATION
(WTP), outer position.
H 1753 6 7 1 Indicator light wide twistlocks INFORMATION
(WTP), outer position.
1800 0 1 Battery temperature is above INFORMATION
configured warning level 55 °C.
Allow the battery to cool down.

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118 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

1800 0 1 Battery temperature is above WARNING
configured alarm level 65 °C.
Allow the battery to cool down.
1800 1 1 Battery temperature is below INFORMATION
configured warning level -6 °C.
Warm up the battery by driving
or park the machine in a warm
building.
1800 1 1 Battery temperature is below WARNING
configured alarm level -11 °C.
Warm up the battery by driving
or park the machine in a warm
building.
1800 1 1 Temperature in battery too low STOP
and BMS contactor open.
The battery is switched off after
timeout and error code.
Park the machine in a warm
building.
1800 2 1 The temperature sensor in INFORMATION
the battery module registers
temperature above 250 °C or
lower than -100 °C.
B 2070 3 2 Contact differential lock, WARNING
position signal.
B 2190 2 1 Sensor, cab filter. INFORMATION
B 2460 2 1 Low pressure, air conditioning. WARNING
K 3150 6 1 Relay, ignition, grounded STOP
circuit.
K 3312 6 2 Driving forward relay, signal STOP
status.
K 3312 6 1 Driving forward relay, signal INFORMATION
status.
K 3312 6 2 Driving forward relay, signal INFORMATION
status.
K 3320 6 2 Driving reverse relay, signal STOP
status.
K 3320 6 1 Driving reverse relay, signal INFORMATION
status.
K 3320 6 2 Driving reverse relay, signal INFORMATION
status.
3509 2 1 Voltage sensor battery cell INFORMATION
detects an incorrect voltage
due to poor connection of the
sensor's cables.
Contact Cargotec support.
K 3600 6 2 Relay, starter motor. WARNING
Only engine option Cummins.
E 4000 5 2 10 Low beam, left. Check the INFORMATION
lamp.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 119

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

E 4000 5 3 210 Low beam left rear, at turnable INFORMATION
operator's station. Check the
lamp.
E 4000 6 2 10 Low beam, left. INFORMATION
E 4000 6 3 210 Low beam left rear, at turnable INFORMATION
operator's station.
E 4000 5 2 20 Low beam, right. Check the INFORMATION
lamp.
E 4000 5 3 220 Low beam right rear, at turnable INFORMATION
operator's station. Check the
lamp.
E 4000 6 2 20 Low beam, right. INFORMATION
E 4000 6 3 220 Low beam right rear, at turnable INFORMATION
operator's station.
E 4020 5 2 10 High beam, left. Check the INFORMATION
lamp.
E 4020 5 3 210 High beam left rear, at turnable INFORMATION
operator's station. Check the
lamp.
E 4020 6 2 10 High beam, left. INFORMATION
E 4020 6 3 210 High beam left rear, at turnable INFORMATION
operator's station.
E 4020 5 2 20 High beam, right. Check the INFORMATION
lamp.
E 4020 5 3 220 High beam right rear, at INFORMATION
turnable operator's station.
Check the lamp.
E 4020 6 2 20 High beam, right. INFORMATION
E 4041 5 2 1 Working lighting load centre. INFORMATION
Check the lamp.
Extra work lights, frame left.
Check the lamp.
E 4041 6 2 1 Working lighting load centre. INFORMATION
Check the lamp.
Extra work lights, frame left.
Check the lamp.
E 4041 5 2 2 Work lights option. INFORMATION
Extra work lights, frame right.
E 4041 6 2 2 Work lights option. INFORMATION
Extra work lights, frame right.
E 4042 5 1 10 Extra work lights, cab left. INFORMATION
Check the lamp.
E 4042 6 1 10 Extra work lights, cab left. INFORMATION
E 4042 5 1 20 Extra work lights, cab right. INFORMATION
Check the lamp.
E 4042 6 1 20 Extra work lights, cab right. INFORMATION
E 4042 5 1 1 Extra work lights left. Check INFORMATION
the lamp.

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120 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

E 4042 6 1 1 Extra work lights left. INFORMATION
E 4042 5 1 2 Extra work lights right. Check INFORMATION
the lamp.
E 4042 6 1 2 Extra work lights right. INFORMATION
E 4043 5 2 10 Work lights, mast left. Check INFORMATION
the lamp.
E 4043 6 2 10 Work lights, mast left. Check INFORMATION
the lamp.
E 4043 5 2 20 Work lights, mast right. Check INFORMATION
the lamp.
E 4043 6 2 20 Work lights, mast right. Check INFORMATION
the lamp.
E 4044 5 7 10 Work lights, attachment left. WARNING
Check the lamp.
E 4044 6 7 10 Work lights, attachment left. WARNING
E 4044 5 7 110 Extra work lights, attachment WARNING
left. Check the lamp.
E 4044 6 7 110 Extra work lights, attachment WARNING
left.
E 4044 5 7 20 Work lights, attachment right. WARNING
Check the lamp.
E 4044 6 7 20 Work lights, attachment right. WARNING
E 4044 5 7 120 Extra work lights, attachment WARNING
right. Check the lamp.
E 4044 6 7 120 Extra work lights, attachment WARNING
right.
E 4045 5 6 110 Extra work lights, attachment lift WARNING
leg left front. Check the lamp.
E 4045 6 6 110 Extra work lights, attachment WARNING
lift leg left front.
E 4045 5 6 120 Extra work lights, attachment lift WARNING
leg right front. Check the lamp.
E 4045 6 6 120 Extra work lights, attachment WARNING
lift leg right front.
E 4045 5 6 210 Extra work lights, attachment WARNING
lift leg left rear. Check the lamp.
E 4045 6 6 210 Extra work lights, attachment WARNING
lift leg left rear.
E 4045 5 6 220 Extra work lights, attachment lift WARNING
leg right rear. Check the lamp.
E 4045 6 6 220 Extra work lights, attachment WARNING
lift leg right rear.
E 4050 5 1 10 Work lights, backward left. WARNING
Check the lamp.
E 4050 6 1 10 Work lights, backward left. WARNING
Check the lamp.
E 4050 5 1 20 Work lights, backward right. WARNING
Check the lamp.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 121

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

E 4050 6 1 20 Work lights, backward right. WARNING
Check the lamp.
E 4050 6 2 Work lights, steering. Check INFORMATION
the lamp.
H 4110 6 2 Brake light. INFORMATION
H 4110 6 3 100 Brake lights front, at turnable INFORMATION
operator's station.
H 4120 6 2 1 Tail lights. INFORMATION
H 4120 6 3 100 Tail lights front, at turnable INFORMATION
operator's station.
H 4160 6 2 Position light. INFORMATION
H 4220 6 2 10 Direction indicators left. INFORMATION
H 4220 6 2 20 Direction indicators right. INFORMATION
H 4281 6 2 Revolving beacon, WARNING
counterweight.
H 4282 6 1 Revolving beacon, cab. WARNING
H 4284 6 7 Revolving beacon, attachment. WARNING
E 4340 6 1 Interior lighting. WARNING
H 5001 6 7 30 Indicator light, overheight legs WARNING
up.
H 5004 6 7 Indicator light, scale position WARNING
load receipt,
H 5620 6 1 2 Indicator light, unlocked WARNING
twistlocks (roof panel cab).
H 5620 6 7 1 Indicator light, unlocked WARNING
twistlocks
H 5630 6 1 2 Indicator light, locked twistlocks WARNING
(roof panel cab).
H 5630 6 7 1 Indicator light, locked WARNING
twistlocks.
H 5640 6 1 2 Indicator light tilt control, WARNING
grounded circuit.
Indicator light, contact (roof
panel cab).
H 5640 6 7 1 Indicator light, contact WARNING
twistlocks.
H 5640 6 7 30 Indicator light, contact upper WARNING
container.
H 5640 6 7 40 Indicator light, contact lower WARNING
container.
H 5720 6 7 Indicator light, height limitation. WARNING
H 5740 6 1 Indicator light, support jacks WARNING
down (roof panel cab).
H 5760 6 6 110 Indicator light, contact lift leg WARNING
left front.
H 5760 6 6 120 Indicator light, contact lift leg WARNING
right front.

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122 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

H 5760 6 6 210 Indicator light, contact lift leg WARNING
left rear.
H 5760 6 6 220 Indicator light, contact lift leg WARNING
right rear.
H 5780 6 6 100 Indicator light, lift legs clamping WARNING
position front.
H 5780 6 6 200 Indicator light, lift legs clamping WARNING
position rear.
H 5800 6 6 30 Indicator light, lift legs front up. WARNING
H 5800 6 6 40 Indicator light, lift legs front WARNING
down.
5981 1 1 Warning of critical state of INFORMATION
charge, SoC.
5981 2 1 State of charge, SoC does not INFORMATION
correspond.
5981 4 1 Cell voltage is below configured WARNING
alarm level 2.3V.
Charge the battery.
5983 12 1 Control unit BMS cannot INFORMATION
communicate with at least one
battery cell at the moment.
Contact Cargotec support.
H 5991 6 1 Indicator light, buckled seat WARNING
belt.
H 5992 6 1 Indicator light, Mini steering WARNING
wheel/joystick control.
H 5993 6 11 3 Indicator light, tilt lock, control WARNING
lever.
Y 6002 5 2 Servo valve, load signal WARNING
attachment.
Y 6003 5 2 Solenoid valve, engagement of WARNING
hydraulic top lift.
Y 6003 6 2 Solenoid valve, engagement of WARNING
hydraulic top lift.
Y 6004 5 2 Solenoid valve lower. WARNING
Y 6004 6 2 Solenoid valve lower. WARNING
Y 6004 5 2 2 Solenoid valve lower 2. WARNING
Y 6004 6 2 2 Solenoid valve lower 2. WARNING
Y 6005 5 2 Solenoid valve lift. WARNING
Y 6005 6 2 Solenoid valve lift. WARNING
Y 6005 5 2 2 Solenoid valve lift 2. WARNING
Y 6005 6 2 2 Solenoid valve lift 2. WARNING
Y 6006 5 2 Solenoid valve, boom out. WARNING
Y 6006 6 2 Solenoid valve, boom out. WARNING
Y 6007 5 2 Solenoid valve, boom in. WARNING
Y 6007 6 2 Solenoid valve, boom in. WARNING

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 123

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

Y 6008 5 2 Rotation clockwise. WARNING
Y 6008 6 2 Rotation clockwise. WARNING
Y 6008 5 7 Solenoid valve, rotation WARNING
clockwise.
Y 6008 6 7 Solenoid valve, rotation WARNING
clockwise.
Y 6009 5 2 Rotation anticlockwise. WARNING
Y 6009 6 2 Rotation anticlockwise. WARNING
Y 6009 5 7 Solenoid valve, rotation WARNING
anticlockwise.
Y 6009 6 7 Solenoid valve, rotation WARNING
anticlockwise.
Y 6010 5 2 Solenoid valve tilt out. WARNING
Y 6010 6 2 Solenoid valve tilt out. WARNING
Y 6010 5 7 Solenoid valve tilt out WARNING
Y 6010 6 7 Solenoid valve tilt out WARNING
Y 6011 5 2 Solenoid valve tilt in. WARNING
Y 6011 6 2 Solenoid valve tilt in. WARNING
Y 6011 5 7 Solenoid valve tilt in WARNING
Y 6011 6 7 Solenoid valve tilt in WARNING
Y 6012 5 7 1 Solenoid valve tilt lock. WARNING
Y 6012 6 7 1 Solenoid valve tilt lock. WARNING
Y 6012 5 7 2 Solenoid valve tilt lock. WARNING
Y 6012 6 7 2 Solenoid valve tilt lock. WARNING
Y 6014 5 2 Solenoid valve differential lock. WARNING
Y 6014 6 2 Solenoid valve differential lock. WARNING
Y 6016 5 2 Solenoid valve, cab sliding out WARNING
(forward/up).
Y 6016 6 2 Solenoid valve, cab sliding out WARNING
(forward/up).
Y 6016 5 3 Cab sliding up. WARNING
Y 6016 6 3 Cab sliding up. WARNING
Y 6017 5 2 Solenoid valve, cab sliding in WARNING
(backward/lower).
Y 6017 6 2 Solenoid valve, cab sliding in WARNING
(backward/lower).
Y 6017 5 3 Cab sliding lower. WARNING
Y 6017 6 3 Cab sliding lower. WARNING
Y 6018 5 2 Solenoid valve spreading out. WARNING
Y 6018 6 2 Solenoid valve spreading out. WARNING
Y 6018 5 2 10 Solenoid valve spreading out WARNING
left fork.
Y 6018 6 2 10 Solenoid valve spreading out WARNING
left fork.

Operator’s manual DCG 180-330 IDCG02.03GB

124 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

Y 6018 5 2 20 Solenoid valve spreading out WARNING
right fork.
Y 6018 6 2 20 Solenoid valve spreading out WARNING
right fork.
Y 6018 5 7 Solenoid valve spreading out. WARNING
Y 6018 6 7 Solenoid valve spreading out. WARNING
Solenoid valve function lifting
tool, tool changer open/out.
Y 6018 5 7 10 Solenoid valve spreading out WARNING
left.
Y 6018 6 7 10 Solenoid valve spreading out WARNING
right.
Y 6018 5 7 20 Solenoid valve spreading out WARNING
right.
Y 6018 6 7 20 Solenoid valve spreading out WARNING
right.
Y 6019 5 2 Solenoid valve spreading in. WARNING
Y 6019 6 2 Solenoid valve spreading in. WARNING
Y 6019 5 2 10 Solenoid valve spreading in left WARNING
fork.
Y 6019 6 2 10 Solenoid valve spreading in left WARNING
fork.
Y 6019 5 2 20 Solenoid valve spreading in WARNING
right fork.
Y 6019 6 2 20 Solenoid valve spreading in WARNING
right fork.
Y 6019 5 7 Solenoid valve spreading in. WARNING
Alternative solenoid valve
function lifting tool, tool changer
close/in.
Y 6019 6 7 Solenoid valve spreading in. WARNING
Alternative solenoid valve
function lifting tool, tool changer
close/in.
Y 6019 5 7 10 Solenoid valve spreading in left. WARNING
Y 6019 6 7 10 Solenoid valve spreading in left. WARNING
Y 6019 5 7 20 Solenoid valve spreading in WARNING
right.
Y 6019 6 7 20 Solenoid valve spreading in WARNING
right.
Y 6020 5 2 Solenoid valve side shift left. WARNING
Y 6020 6 2 Solenoid valve side shift left. WARNING
Y 6020 5 7 Solenoid valve side shift left. WARNING
Y 6020 6 7 Solenoid valve side shift left. WARNING
Y 6021 5 2 Solenoid valve side shift right. WARNING
Y 6021 6 2 Solenoid valve side shift right. WARNING
Y 6021 5 7 Solenoid valve side shift right. WARNING

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 125

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

Y 6021 6 7 Solenoid valve side shift right. WARNING
Y 6022 5 2 Solenoid valve extra hydraulic WARNING
function out.
Y 6022 6 2 Solenoid valve extra hydraulic WARNING
function out.
Y 6022 5 7 Open container door. WARNING
Y 6022 6 7 Open container door. WARNING
Y 6023 5 2 Solenoid valve extra hydraulic WARNING
function in.
Y 6023 6 2 Solenoid valve extra hydraulic WARNING
function in.
Y 6023 5 7 Close container door. WARNING
Y 6023 6 7 Close container door. WARNING
Y 6034 5 7 1 Solenoid valve levelling lock. WARNING
Y 6034 6 7 1 Solenoid valve levelling lock. WARNING
Y 6034 5 7 2 Solenoid valve levelling lock. WARNING
Y 6034 6 7 2 Solenoid valve levelling lock. WARNING
Y 6035 5 2 Solenoid valve levelling right WARNING
up/anticlockwise.
Y 6035 6 2 Solenoid valve levelling right WARNING
up/anticlockwise.
Y 6035 5 7 Solenoid valve levelling WARNING
anticlockwise.
Y 6035 6 7 Solenoid valve levelling WARNING
anticlockwise.
Y 6036 5 2 Solenoid valve levelling left WARNING
up/clockwise.
Y 6036 6 2 Solenoid valve levelling left WARNING
up/clockwise.
Y 6036 5 7 Solenoid valve levelling left WARNING
up/clockwise.
Y 6036 6 7 Solenoid valve levelling left WARNING
up/clockwise.
Y 6039 5 7 Solenoid valve open twistlocks. WARNING
Y 6039 6 7 Solenoid valve open twistlocks. WARNING
Y 6040 5 7 Solenoid valve lock twistlocks. WARNING
Y 6040 6 7 Solenoid valve lock twistlocks. WARNING
Y 6045 5 2 10 Solenoid valve, blocking lower WARNING
left.
Y 6045 6 2 10 Solenoid valve, blocking lower WARNING
left.
Y 6045 5 2 20 Solenoid valve, blocking lower WARNING
right.
Y 6045 6 2 20 Solenoid valve, blocking lower WARNING
right.
Y 6046 5 7 1 Twistlocks out to WTP position. STOP
Y 6046 6 7 1 Twistlocks out to WTP position. STOP

Operator’s manual DCG 180-330 IDCG02.03GB

126 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

Y 6046 5 7 2 Twistlocks in to standard STOP
position.
Y 6046 6 7 2 Twistlocks in to standard STOP
position.
Y 6047 5 2 Solenoid valve, cab tilt up. WARNING
Y 6047 6 2 Solenoid valve, cab tilt up. WARNING
Y 6048 5 2 Solenoid valve, cab tilt down. WARNING
Y 6048 6 2 Solenoid valve, cab tilt down. WARNING
Y 6050 5 2 Solenoid valve, blocking boom WARNING
in.
Y 6050 6 2 Solenoid valve, blocking boom WARNING
in.
Y 6051 5 2 1 Solenoid valve, regeneration WARNING
boom out.
Y 6051 6 2 1 Solenoid valve, regeneration WARNING
boom out.
Y 6051 5 2 10 Solenoid valve, regeneration lift WARNING
left.
Y 6051 6 2 10 Solenoid valve, regeneration lift WARNING
left.
Y 6051 5 2 20 Solenoid valve, regeneration lift WARNING
right.
Y 6051 6 2 20 Solenoid valve, regeneration lift WARNING
right.
Y 6053 5 6 10 Solenoid valve, operating WARNING
position left.
Y 6053 6 6 10 Solenoid valve, operating WARNING
position left.
Y 6053 5 6 20 Solenoid valve, operating WARNING
position right.
Y 6053 6 6 20 Solenoid valve, operating WARNING
position right.
Y 6054 5 2 Clamp close not working. WARNING
Y 6054 6 2 Clamp close not working. WARNING
Y 6054 5 2 10 Clamp close left not working. WARNING
Y 6054 6 2 10 Clamp close left not working. WARNING
Y 6054 5 2 20 Clamp close right not working. WARNING
Y 6054 6 2 20 Clamp close right not working. WARNING
Y 6054 5 3 10 Clamp close not working. WARNING
Y 6054 6 3 10 Clamp close not working. WARNING
Y 6054 5 3 20 Clamp close right not working. WARNING
Y 6054 6 3 20 Clamp close right not working. WARNING
Y 6054 5 6 10 Solenoid valve clamp close left. WARNING
Y 6054 6 6 10 Solenoid valve clamp close left. WARNING
Y 6054 5 6 20 Solenoid valve clamp close WARNING
right.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 127

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

Y 6054 6 6 20 Solenoid valve clamp close WARNING
right.
Y 6054 6 7 Solenoid valve clamp close WARNING
ELME.
Y 6055 5 2 Clamp open not working. WARNING
Y 6055 6 2 Clamp open not working. WARNING
Y 6055 5 2 10 Clamp open left not working. WARNING
Y 6055 6 2 10 Clamp open left not working. WARNING
Y 6055 5 2 20 Clamp open right not working. WARNING
Y 6055 6 2 20 Clamp open right not working. WARNING
Y 6055 5 3 10 Clamp open not working. WARNING
Y 6055 6 3 10 Clamp open not working. WARNING
Y 6055 5 3 20 Clamp open right not working. WARNING
Y 6055 6 3 20 Clamp open right not working. WARNING
Y 6055 5 6 10 Solenoid valve clamp release WARNING
left.
Y 6055 6 6 10 Solenoid valve clamp release WARNING
left.
Y 6055 5 6 20 Solenoid valve clamp release WARNING
right.
Y 6055 6 6 20 Solenoid valve clamp release WARNING
right.
Y 6055 6 7 Solenoid valve clamp release WARNING
ELME.
Y 6056 5 6 110 Solenoid valve knee in left front. WARNING
Y 6056 6 6 110 Solenoid valve knee in left front. WARNING
Y 6056 5 6 120 Solenoid valve knee in right WARNING
front.
Y 6056 6 6 120 Solenoid valve knee in right WARNING
front.
Y 6056 5 6 210 Solenoid valve knee in left rear. WARNING
Y 6056 6 6 210 Solenoid valve knee in left rear. WARNING
Y 6056 5 6 220 Solenoid valve knee in right WARNING
rear.
Y 6056 6 6 220 Solenoid valve knee in right WARNING
rear.
Y 6057 5 6 110 Solenoid valve knee out left WARNING
front.
Y 6057 6 6 110 Solenoid valve knee out left WARNING
front.
Y 6057 5 6 120 Solenoid valve knee out right WARNING
front.
Y 6057 6 6 120 Solenoid valve knee out right WARNING
front.
Y 6057 5 6 210 Solenoid valve knee out left WARNING
rear.

Operator’s manual DCG 180-330 IDCG02.03GB

128 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

Y 6057 6 6 210 Solenoid valve knee out left WARNING
rear.
Y 6057 5 6 220 Solenoid valve knee out right WARNING
rear.
Y 6057 6 6 220 Solenoid valve knee out right WARNING
rear.
Y 6058 5 6 110 Solenoid valve leg up left front. WARNING
Y 6058 6 6 110 Solenoid valve leg up left front. WARNING
Y 6058 5 6 120 Solenoid valve leg up right WARNING
front.
Y 6058 6 6 120 Solenoid valve leg up right WARNING
front.
Y 6058 5 6 210 Solenoid valve leg up left rear. WARNING
Y 6058 6 6 210 Solenoid valve leg up left rear. WARNING
Y 6058 6 7 100 Solenoid valve leg up front WARNING
ELME.
Y 6058 6 7 200 Solenoid valve leg up rear WARNING
ELME.
Y 6058 5 7 220 Solenoid valve leg up right rear. WARNING
Y 6058 6 7 220 Solenoid valve leg up right rear. WARNING
Y 6059 5 6 110 Solenoid valve leg down left WARNING
front.
Y 6059 6 6 110 Solenoid valve leg down left WARNING
front.
Y 6059 5 6 120 Solenoid valve leg down right WARNING
front.
Y 6059 6 6 120 Solenoid valve leg down right WARNING
front.
Y 6059 5 6 210 Solenoid valve leg down left WARNING
rear.
Y 6059 6 6 210 Solenoid valve leg down left WARNING
rear.
Y 6059 6 7 100 Solenoid valve leg down front WARNING
ELME.
Y 6059 6 7 200 Solenoid valve leg down rear WARNING
ELME.
Y 6059 5 7 220 Solenoid valve leg down right WARNING
rear.
Y 6059 6 7 220 Solenoid valve leg down right WARNING
rear.
Y 6062 5 2 Solenoid valve, disengagement WARNING
hydraulic oil pump 2.
Y 6062 6 2 Solenoid valve, disengagement WARNING
hydraulic oil pump 2.
Y 6063 5 3 Solenoid valve support jacks WARNING
up.
Y 6063 6 3 Solenoid valve support jacks WARNING
up.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 129

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

Y 6064 5 3 Solenoid valve support jacks WARNING
down.
Y 6064 6 3 Solenoid valve support jacks WARNING
down.
Y 6065 5 7 Solenoid valve, disengage WARNING
rotation.
Y 6065 6 7 Solenoid valve, disengage WARNING
rotation.
Y 6070 5 7 Solenoid valve overheight legs WARNING
up.
Y 6070 6 7 Solenoid valve overheight legs WARNING
up.
Y 6071 5 7 Solenoid valve overheight legs WARNING
down.
Y 6071 6 7 Solenoid valve overheight legs WARNING
down.
Y 6072 5 3 1 Solenoid valve clamping WARNING
pressure.
Y 6072 6 3 1 Solenoid valve clamping WARNING
pressure.
Y 6072 5 3 2 Solenoid valve clamping WARNING
pressure.
Y 6072 6 3 2 Solenoid valve clamping WARNING
pressure.
Y 6078 5 3 1 Solenoid valve, paper WARNING
attachment closing upper
clamping arm.
Y 6078 6 3 1 Solenoid valve, paper WARNING
attachment closing upper
clamping arm.
Y 6078 5 3 2 Solenoid valve, paper WARNING
attachment closing upper
clamping arm.
Y 6078 6 3 2 Solenoid valve, paper WARNING
attachment closing upper
clamping arm.
Y 6080 5 2 Solenoid valve activation cab WARNING
movement.
Y 6080 6 2 Solenoid valve activation cab WARNING
movement.
Y 6085 5 2 Solenoid valve share hydraulic WARNING
function 1.
Y 6085 6 2 Solenoid valve share hydraulic WARNING
function 1.
Y 6085 5 7 Select door opener. WARNING
Y 6085 6 7 Select door opener. WARNING
Y 6087 5 2 Solenoid valve share hydraulic WARNING
function 2.
Y 6087 6 2 Solenoid valve share hydraulic WARNING
function 2.

Operator’s manual DCG 180-330 IDCG02.03GB

130 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

Y 6088 5 2 Solenoid valve accumulator WARNING
shut off.
Y 6088 6 2 Solenoid valve accumulator WARNING
shut off.
Y 6089 5 2 Solenoid valve, activate extra WARNING
hydraulic oil pump lift.
Y 6089 6 2 Solenoid valve, activate extra WARNING
hydraulic oil pump lift.
Y 6091 5 2 Solenoid valve fan speed WARNING
engine cooling fan.
Y 6091 6 2 Solenoid valve fan speed WARNING
engine cooling fan.
Y 6092 5 2 Solenoid valve fan speed INFORMATION
direction, engine cooling fan.
Y 6092 6 2 Solenoid valve fan speed INFORMATION
direction, engine cooling fan.
Y 6093 5 2 Solenoid valve, pump WARNING
unloading boom in.
Y 6093 6 2 Solenoid valve, pump WARNING
unloading boom in.
Y 6094 5 2 Solenoid valve, disengagement WARNING
hydraulic pump attachment.
Y 6094 6 2 Solenoid valve, disengagement WARNING
hydraulic pump attachment.
Y 6095 5 2 Solenoid valve split function WARNING
mast.
Y 6095 6 2 Solenoid valve split function WARNING
mast.
Y 6100 5 7 Wide body in. WARNING
Y 6100 6 7 Wide body in. WARNING
Y 6101 5 7 Wide body out. WARNING
Y 6101 6 7 Wide body out. WARNING
Y 6104 6 7 Solenoid valve beam lock WARNING
locked.
Y 6105 6 7 Solenoid valve beam lock WARNING
unlocked.
Y 6120 5 1 1 Damper motor, recirculation. INFORMATION
Y 6120 6 1 1 Damper motor, recirculation. INFORMATION
Y 6120 5 1 2 Damper motor, recirculation. INFORMATION
Y 6120 6 1 2 Damper motor, recirculation. INFORMATION
Y 6150 5 2 1 Voltage feed to electronic STOP
control module for joystick
control/mini steering wheel.
Y 6150 6 2 1 Voltage feed to electric control STOP
module for joystick control/mini
steering wheel.
Y 6150 6 2 2 Voltage feed to electric control STOP
module for joystick control/mini
steering wheel.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 131

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

Y 6150 2 2 3 Electric control module for STOP
joystick control/mini steering
wheel.
Y 6150 31 2 Control unit control valve STOP
feedback seat position and
Control unit mini-wheel or
joystick control (Y6150) are
missing.
Y 6301 5 3 210 Solenoid valve drive left rear WARNING
wheel forward (Y6301-LE),
open circuit.
4WD is disengaged.
Y 6301 6 3 210 Solenoid valve drive left rear WARNING
wheel forward (Y6301-LE),
short circuit to ground.
4WD is disengaged.
Y 6301 5 3 220 Solenoid valve drive right rear WARNING
wheel forward (Y6301-RI),
open circuit.
4WD is disengaged.
Y 6301 6 3 220 Solenoid valve drive right rear WARNING
wheel forward (Y6301-RI),
short circuit to ground
4WD is disengaged.
Y 6311 5 3 210 Solenoid valve drive left rear WARNING
wheel backward (Y6311-LE),
open circuit.
4WD is disengaged.
Y 6311 6 3 210 Solenoid valve drive left rear WARNING
wheel backward (Y6311-LE),
short circuit to ground.
4WD is disengaged.
Y 6311 5 3 220 Solenoid valve drive right rear WARNING
wheel backward (Y6311-RI),
open circuit
4WD is disengaged.
Y 6311 6 3 220 Solenoid valve drive right rear WARNING
wheel backward (Y6311-RI),
short circuit to ground.
4WD is disengaged.
Y 6360 5 3 100 Directional control valve STOP
steering, forward. At revolving
driver's seat.
Y 6360 6 3 100 Directional control valve STOP
steering, forward. At revolving
driver's seat.
Y 6360 5 3 200 Directional control valve STOP
steering, backward. At
revolving driver's seat.
Y 6360 6 3 200 Directional control valve STOP
steering, backward. At
revolving driver's seat.

Operator’s manual DCG 180-330 IDCG02.03GB

132 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

Y 6420 2 2 Solenoid valve parking brake. STOP
Y 6420 5 2 Solenoid valve parking brake. STOP
Y 6420 6 2 Solenoid valve parking brake. STOP
Y 6450 5 2 Electromagnetic clutch cooling INFORMATION
compressor.
Y 6450 6 2 Electromagnetic clutch cooling INFORMATION
compressor.
K 6501 6 1 10 Windscreen wiper left, relay. INFORMATION
K 6501 6 1 20 Windscreen wiper right, relay. INFORMATION
M 6501 7 1 10 Windscreen wiper left, position INFORMATION
signal.
M 6501 7 1 20 Windscreen wiper right, position INFORMATION
signal.
M 6502 5 1 Rear windscreen wipers. INFORMATION
M 6502 6 1 Rear windscreen wipers. INFORMATION
M 6502 7 1 Wiper rear window, position INFORMATION
signal.
M 6503 5 1 Combined wipers, windscreen INFORMATION
and roof window, position
signal.
Wiper roof window, position
signal.
M 6503 6 1 Combined wipers, windscreen INFORMATION
and roof window, position
signal.
Wiper roof window, position
signal.
M 6503 7 1 Combined wipers, windscreen INFORMATION
and roof window, position
signal.
Wiper roof window, position
signal.
M 6511 6 1 Washing, front windscreen. INFORMATION
M 6512 5 1 Washing, rear windscreen. INFORMATION
M 6512 6 1 Washing, rear windscreen. INFORMATION
M 6513 5 1 Washing, combined wipers, INFORMATION
windscreen and roof window.
Motor washing, roof window.
M 6513 6 1 Washing, combined wipers, INFORMATION
windscreen and roof window.
Motor washing, roof window.
M 6570 5 1 Cabin fan. INFORMATION
M 6570 6 1 Cabin fan. INFORMATION
M 6570 7 1 10 Cooling fan, transmission. WARNING
M 6570 7 1 20 Cooling fan, transmission. WARNING
M 6580 6 2 Electromagnetic clutch, engine WARNING
cooling fan.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 133

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

M 6580 7 2 Electromagnetic clutch, engine WARNING
cooling fan.
M 6590 6 2 Cooling fan, intercooler. WARNING
M 6590 7 2 10 Cooling fan, intercooler. WARNING
M 6590 7 2 20 Cooling fan, intercooler. WARNING
M 6670 5 1 Circulation pump pause heater. INFORMATION
M 6670 6 1 Circulation pump pause heater. INFORMATION
M 6680 5 2 Cooling fan, hydraulic oil cooler. WARNING
M 6680 6 2 Cooling fan, hydraulic oil cooler. WARNING
Y 6720 3 1 Damper motor air distribution, INFORMATION
position signal.
Y 6720 4 1 Damper motor air distribution, INFORMATION
position signal.
Y 6720 5 1 1 Damper motor air distribution. INFORMATION
Y 6720 6 1 1 Damper motor air distribution. INFORMATION
Y 6720 5 1 2 Damper motor air distribution. INFORMATION
Y 6720 6 1 2 Damper motor air distribution. INFORMATION
Y 6730 3 1 Heating valve, position signal. INFORMATION
Y 6730 4 1 Heating valve, position signal. INFORMATION
Y 6730 5 1 1 Heating valve. INFORMATION
Y 6730 6 1 1 Heating valve. INFORMATION
Y 6730 5 1 2 Heating valve. INFORMATION
Y 6730 6 1 2 Heating valve. INFORMATION
M 6740 5 2 Cooling fan, oil cooler brake WARNING
system.
M 6740 6 2 Cooling fan, oil cooler brake WARNING
system.
M 6750 5 3 20 Motor, revolving driver's seat. WARNING
M 6750 6 3 20 Motor, revolving driver's seat. WARNING
M 6750 5 3 10 Motor, revolving driver's seat. WARNING
M 6750 6 3 10 Motor, revolving driver's seat. WARNING
Y 6760 5 1 Solenoid valve, swivel driver's WARNING
seat.
Y 6760 6 1 Solenoid valve, swivel driver's WARNING
seat.
Y 6760 5 3 20 Solenoid valve, brake revolving WARNING
driver's seat.
Y 6760 6 3 20 Solenoid valve, brake revolving WARNING
driver's seat.
Y 6760 5 3 10 Solenoid valve, brake revolving WARNING
driver's seat.
Y 6760 6 3 10 Solenoid valve, brake revolving WARNING
driver's seat.
Y 6820 5 2 Extension out. WARNING
Y 6820 6 2 Extension out. WARNING

Operator’s manual DCG 180-330 IDCG02.03GB

134 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

Y 6821 5 2 Extension in. WARNING
Y 6821 6 2 Extension in. WARNING
Y 6840 5 3 Solenoid valve torque control, WARNING
hydrostatic transmission
(Y6840), open circuit.
4WD is disengaged.
Y 6840 6 3 Solenoid valve torque control, WARNING
hydrostatic transmission
(Y6840), short circuit to ground.
4WD is disengaged.
Y 6841 5 3 Solenoid valve drain hydrostatic WARNING
transmission (Y6841), open
circuit.
4WD is disengaged.
Y 6841 6 3 Solenoid valve drain hydrostatic WARNING
transmission (Y6841), short
circuit to ground.
4WD is disengaged.
Y 6842 5 3 Solenoid valve back pressure WARNING
hydrostatic transmission
(Y6842), open circuit.
4WD is disengaged.
Y 6842 6 3 Solenoid valve back pressure WARNING
hydrostatic transmission
(Y6842), short circuit to ground.
4WD is disengaged.
R 6900 3 11 1 Accelerator pedal, signal A. WARNING
R 6900 4 11 1 Accelerator pedal, signal A. WARNING
R 6900 13 11 1 Accelerator pedal, signal A. WARNING
R 6900 3 11 2 Accelerator pedal, signal B. WARNING
R 6900 4 11 2 Accelerator pedal, signal B. WARNING
R 6900 13 11 2 Accelerator pedal, signal B. WARNING
R 6900 3 11 3 Accelerator pedal 2, signal A. WARNING
R 6900 4 11 3 Accelerator pedal 2, signal A. WARNING
R 6900 13 11 3 Accelerator pedal 2, signal A. WARNING
R 6900 3 11 4 Accelerator pedal 2, signal B. WARNING
R 6900 4 11 4 Accelerator pedal 2, signal B. WARNING
R 6900 13 11 4 Accelerator pedal 2, signal B. WARNING
R 6900 2 11 40 Accelerator. STOP
M 6930 5 2 1 Pump central lubrication frame. INFORMATION
M 6930 6 2 1 Pump central lubrication frame. INFORMATION
M 6930 5 7 2 Pump central lubrication INFORMATION
attachment.
M 6930 6 7 2 Pump central lubrication INFORMATION
attachment.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 135

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

B 6941 3 11 Engine right dashboard panel INFORMATION
forward/backward position
signal.
B 6941 4 11 Engine right dashboard panel INFORMATION
forward/backward position
signal.
B 6941 7 11 Engine right dashboard panel INFORMATION
forward/backward position
signal.
M 6941 5 11 1 Engine right dashboard panel INFORMATION
forward/backward.
M 6941 6 11 1 Engine right dashboard panel INFORMATION
forward/backward.
M 6941 5 11 2 Engine right dashboard panel INFORMATION
forward/backward.
M 6941 6 11 2 Engine right dashboard panel INFORMATION
forward/backward.
B 6942 3 11 Engine right dashboard panel INFORMATION
up/down position signal.
B 6942 4 11 Engine right dashboard panel INFORMATION
up/down position signal.
B 6942 7 11 Engine right dashboard panel INFORMATION
up/down position signal.
M 6942 6 11 1 Engine right dashboard panel INFORMATION
up/down.
M 6942 6 11 1 Engine right dashboard panel INFORMATION
up/down.
M 6942 5 11 2 Engine right dashboard panel INFORMATION
up/down.
M 6942 6 11 2 Engine right dashboard panel INFORMATION
up/down.
B 6943 3 11 Engine steering wheel panel INFORMATION
up/down position signal.
B 6943 4 11 Engine steering wheel panel INFORMATION
up/down position signal.
B 6943 7 11 Engine steering wheel panel INFORMATION
up/down position signal.
M 6943 5 11 1 Engine steering wheel panel INFORMATION
up/down.
M 6943 6 11 1 Engine steering wheel panel INFORMATION
up/down.
M 6943 5 11 2 Engine steering wheel panel INFORMATION
up/down.
M 6943 6 11 2 Engine steering wheel panel INFORMATION
up/down.
P 7080 14 1 Operating hours do not WARNING
correspond to reference Control
2 unit frame KFU (D7971).
3
11
12

Operator’s manual DCG 180-330 IDCG02.03GB

136 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

D 7090 31 1 Control unit BMS is missing. STOP
Speed limitation
B 7202 2 7 Sensor, contact jammed. WARNING
Check that the indicator pin is
not binding and that the sensor
is clean.
B 7205 3 7 10 Sensor, twistlocks. WARNING
B 7205 4 7 10 Sensor, twistlocks. WARNING
B 7205 13 7 10 Sensor, twistlocks. WARNING
B 7205 3 7 20 Sensor, twistlocks. WARNING
B 7205 4 7 20 Sensor, twistlocks. WARNING
B 7205 13 7 20 Sensor, twistlocks. WARNING
B 7205 3 7 110 Sensor, twistlocks. WARNING
B 7205 4 7 110 Sensor, twistlocks. WARNING
B 7205 13 7 110 Sensor, twistlocks. WARNING
B 7205 3 7 120 Sensor, twistlocks. WARNING
B 7205 4 7 120 Sensor, twistlocks. WARNING
B 7205 13 7 120 Sensor, twistlocks. WARNING
B 7205 3 7 210 Sensor, twistlocks. WARNING
B 7205 4 7 210 Sensor, twistlocks. WARNING
B 7205 13 7 210 Sensor, twistlocks. WARNING
B 7205 3 7 220 Sensor, twistlocks. WARNING
B 7205 4 7 220 Sensor, twistlocks. WARNING
B 7205 13 7 220 Sensor, twistlocks. WARNING
B 7205 7 7 10 Sensor, twistlocks locked and WARNING
open simultaneously.
Check that the sensor is clean.
B 7205 7 7 20 Sensor, twistlocks locked and WARNING
open simultaneously
Check that the sensor is clean.
B 7216 2 7 Sensor, float position lifting WARNING
head.
B 7226 3 2 1 Sensor, hydraulic pressure lift WARNING
cylinder.
B 7226 4 2 1 Sensor, hydraulic pressure lift WARNING
cylinder.
B 7226 13 2 1 Sensor, hydraulic pressure lift WARNING
cylinder.
B 7226 3 2 2 Sensor, hydraulic pressure, lift WARNING
cylinder piston side right.
B 7226 4 2 2 Sensor, hydraulic pressure, lift WARNING
cylinder piston side right.
B 7226 3 2 3 WARNING
B 7226 4 2 3 WARNING

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 137

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

B 7226 3 2 4 Sensor, hydraulic pressure, lift WARNING
cylinder rod side right.
B 7226 4 2 4 Sensor, hydraulic pressure, lift WARNING
cylinder rod side right.
B 7228 3 2 Height sensor, lift. WARNING
B 7228 4 2 Height sensor, lift. WARNING
B 7228 3 7 Height sensor, lift. WARNING
B 7228 4 7 Height sensor, lift. WARNING
B 7229 3 2 Sensor, tilt angle. WARNING
B 7229 4 2 Sensor, tilt angle. WARNING
B 7229 13 2 Sensor, tilt angle. WARNING
B 7230 3 7 Sensor, damping attachment. INFORMATION
B 7230 4 7 Sensor, damping attachment. INFORMATION
B 7235 3 2 10 Sensor, power cell left. WARNING
B 7235 4 2 10 Sensor, power cell left. WARNING
B 7235 13 2 10 Sensor, power cell left. WARNING
B 7235 3 2 20 Sensor, power cell right. WARNING
B 7235 4 2 20 Sensor, power cell right. WARNING
B 7235 13 2 20 Sensor, power cell right. WARNING
B 7235 3 7 110 Sensor, load attachment, left STOP
front.
B 7235 4 7 110 Sensor, load attachment, left STOP
front.
B 7235 3 7 120 Sensor, load attachment, right STOP
front.
B 7235 4 7 120 Sensor, load attachment, right STOP
front.
B 7235 3 7 210 Sensor, load attachment, left STOP
rear.
B 7235 4 7 210 Sensor, load attachment, left STOP
rear.
B 7235 3 7 220 Sensor, load attachment, right STOP
rear.
B 7235 4 7 220 Sensor, load attachment, right STOP
rear.
B 7236 3 2 Sensor, power cell tilt. WARNING
B 7236 4 2 Sensor, power cell tilt. WARNING
B 7237 2 7 Sensor, upper container has WARNING
jammed.
Check that the indicator pin is
not binding and that the sensor
is clean.
B 7238 3 2 Sensor, pressure tilt cylinder. WARNING
B 7238 4 2 Sensor, pressure tilt cylinder. WARNING
B 7241 3 2 WARNING

Operator’s manual DCG 180-330 IDCG02.03GB

138 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

B 7241 4 2 WARNING
B 7241 7 2 WARNING
B 7242 7 2 Central lubrication frame. INFORMATION
B 7242 7 7 Central lubrication attachment. INFORMATION
B 7243 3 2 Sensor, electronic dipstick WARNING
engine oil.
B 7243 4 2 Sensor, electronic dipstick WARNING
engine oil.
B 7244 3 2 Electric dipstick transmission WARNING
sensor.
B 7244 4 2 Electric dipstick transmission WARNING
sensor.
B 7245 3 2 10 Sensor, feedback steering, WARNING
channel 1.
B 7245 4 2 10 Sensor, feedback steering, WARNING
channel 1.
B 7245 3 2 20 Sensor, feedback steering, WARNING
channel 2.
B 7245 4 2 20 Sensor, feedback steering, WARNING
channel 2.
B 7252 3 11 Ambient light intensity sensor. WARNING
B 7252 4 11 Ambient light intensity sensor. WARNING
B 7253 3 7 Tilt or levelling angle WARNING
attachment.
B 7253 4 7 Tilt or levelling angle WARNING
attachment.
B 7254 3 1 Sensor, cab position. WARNING
B 7254 4 1 Sensor, cab position. WARNING
B 7255 3 1 Sensor, tilt angle, cab. WARNING
B 7255 4 1 Sensor, tilt angle, cab. WARNING
B 7258 2 7 Sensor, lock wedge position WARNING
locked has jammed.
Check that the indicator pin is
not binding and that the sensor
is clean.
B 7570 3 2 Sensor fuel level. INFORMATION
B 7570 4 2 Sensor fuel level. INFORMATION
B 7572 3 2 Sensor back pressure, exhaust WARNING
system.
B 7572 4 2 Sensor back pressure, exhaust WARNING
system.
B 7572 15 2 Sensor back pressure, exhaust WARNING
system.
B 7572 16 2 Sensor back pressure, exhaust WARNING
system.
B 7600 0 2 0 Speed sensor. WARNING
B 7600 8 2 0 Speed sensor. WARNING

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 139

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

B 7601 8 3 210 Speed sensor left rear wheel WARNING
(B7601-LE).
B 7601 8 3 220 Speed sensor right rear wheel WARNING
(B7601-RI).
B 7680 3 3 1 Sensor, clamping pressure WARNING
single/left clamp.
B 7680 4 3 1 Sensor, clamping pressure WARNING
single/left clamp.
B 7680 3 3 2 Sensor, clamping pressure WARNING
single/left clamp.
B 7680 4 3 2 Sensor, clamping pressure WARNING
single/left clamp.
B 7680 3 3 3 Sensor, clamping pressure right WARNING
clamp.
B 7680 4 3 3 Sensor, clamping pressure right WARNING
clamp.
B 7680 3 3 4 Sensor, clamping pressure right WARNING
clamp.
B 7680 4 3 4 Sensor, clamping pressure right WARNING
clamp.
B 7680 3 7 10 Sensor, function lifting tool, tool WARNING
changer left.
B 7680 4 7 10 Sensor, function lifting tool, tool WARNING
changer left.
B 7680 3 7 20 Sensor, function lifting tool, tool WARNING
changer right.
B 7680 4 7 20 Sensor, function lifting tool, tool WARNING
changer right.
B 7681 3 2 Brake pressure sensor. WARNING
B 7681 4 2 Brake pressure sensor. WARNING
B 7682 3 2 Sensor parking brake WARNING
B 7682 4 2 Sensor parking brake WARNING
B 7682 15 2 Sensor parking brake WARNING
B 7683 3 2 Accumulator pressure sensor. WARNING
B 7683 4 2 Accumulator pressure sensor. WARNING
B 7686 3 2 Sensor, boom length. WARNING
B 7686 4 2 Sensor, boom length. WARNING
B 7686 7 2 Sensor, boom length. WARNING
B 7688 3 7 LS-pressure attachment WARNING
(K-motion).
B 7688 4 7 LS-pressure attachment WARNING
(K-motion).
B 7701 2 3 Revolving driver's seat, STOP
incorrect or no feedback.
B 7720 0 2 High temperature oil brake STOP
system.
B 7720 32 2 Sensor, oil temperature brake WARNING
system.

Operator’s manual DCG 180-330 IDCG02.03GB

140 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

B 7720 33 2 Sensor, oil temperature brake WARNING
system.
B 7740 32 1 Ambient temperature sensor. INFORMATION
B 7740 33 1 Ambient temperature sensor. INFORMATION
B 7751 32 1 Inner temperature sensor. INFORMATION
B 7751 33 1 Inner temperature sensor. INFORMATION
B 7752 32 1 Fan temperature sensor. INFORMATION
B 7752 33 1 Fan temperature sensor. INFORMATION
B 7753 32 1 Temperature display sensor. INFORMATION
B 7753 33 1 Temperature display sensor. INFORMATION
B 7755 1 2 Water heater, air conditioning INFORMATION
water level low.
B 7760 32 2 Hydraulic oil temperature WARNING
sensor.
B 7760 33 2 Hydraulic oil temperature WARNING
sensor.
B 7770 3 3 Turnable operator's station, STOP
position operator's station.
B 7770 4 3 Turnable operator's station, STOP
position operator's station.
B 7770 2 3 Turnable operator's station, no STOP
change of angle when turning
is requested.
B 7770 3 7 Position sensor side shift. STOP
B 7770 4 7 Position sensor side shift. STOP
D 7801 31 2 20 Motor regulator propulsion right STOP
is missing (D7801).
D 7802 31 2 10 Motor regulator propulsion left STOP
is missing (D7802).
D 7811 31 2 Motor regulator pump load STOP
handling and steering is
missing (D7811).
D 7812 31 2 Motor regulator pump brake STOP
system and A/C is missing
(D7812).
A 7870 2 2 Sensor fault, overload system. STOP
D 7901 31 12 Control unit missing. STOP
D 7902 31 12 Control unit missing. STOP
D 7930 31 2 1 Control unit missing. STOP
D 7940 31 2 1 Control unit missing. STOP
D 7940 31 2 2 Control unit missing. STOP
D 7950 31 12 Control unit missing. STOP
D 7971 31 2 Control unit missing. STOP
D 7972 31 2 Control unit missing. STOP
D 7911 31 2 Control unit missing. STOP
D 7912 31 2 Control unit missing. STOP

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 141

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

A 7991 31 1 Control unit missing. STOP
A 7992 31 7 Control unit missing. STOP
A 7993 31 7 Control unit missing. STOP
E 8020 5 2 Electrically-heated rear view INFORMATION
mirror.
E 8020 6 2 Electrically-heated rear view INFORMATION
mirror.
E 8050 11 2 Water heater, air conditioning INFORMATION
not working.
R 8070 3 11 1 Control lever lift/lower. WARNING
R 8070 4 11 1 Control lever lift/lower. WARNING
R 8070 3 11 2 Control lever tilt out/in. WARNING
R 8070 4 11 2 Control lever tilt out/in. WARNING
R 8070 3 11 3 Control lever side shift. WARNING
R 8070 4 11 3 Control lever side shift. WARNING
R 8070 3 11 4 Control lever spreading/spread- WARNING
ing left/extension left.
R 8070 4 11 4 Control lever spreading/spread- WARNING
ing left/extension left.
R 8070 3 11 5 Control lever 5th function. WARNING
R 8070 4 11 5 Control lever 5th function. WARNING
R 8070 3 11 6 Levelling, spreading right-hand WARNING
side.
R 8070 4 11 6 Levelling, spreading right-hand WARNING
side.
R 8092 3 11 1 Brake position A. WARNING
R 8092 4 11 1 Brake position A. WARNING
R 8092 13 11 1 Brake position A. WARNING
R 8092 3 11 2 Brake position B. WARNING
R 8092 4 11 2 Brake position B. WARNING
R 8092 13 11 2 Brake position B. WARNING
M 8100 5 1 Condenser roof. INFORMATION
M 8100 6 1 Condenser roof. INFORMATION
R 8250 3 1 1 Potentiometer joystick STOP
control/mini-wheel, channel 1.
R 8250 4 1 1 Potentiometer joystick STOP
control/mini-wheel, channel 1.
R 8250 3 1 2 Potentiometer mini-steering STOP
wheel, channel 2.
R 8250 4 1 2 Potentiometer mini-steering STOP
wheel, channel 2.
H 8500 6 1 Horn. WARNING
K 8881 6 1 Relay rear windscreen heating. INFORMATION
D 9001 31 1 VDI. WARNING

Operator’s manual DCG 180-330 IDCG02.03GB

142 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

H 9003 5 7 Buzzer automatic spreading WARNING
20'–40'.
H 9003 6 7 Buzzer automatic spreading WARNING
20'–40'.
D 9130 13 2 Tyre pressure monitoring INFORMATION
system.
D 9130 14 2 1 Sensor, tyre pressure, left front INFORMATION
outer wheel.
D 9130 14 2 2 Sensor, tyre pressure, left front INFORMATION
inner wheel.
D 9130 14 2 3 Sensor, tyre pressure, right INFORMATION
front inner wheel.
D 9130 14 2 4 Sensor, tyre pressure, right INFORMATION
front outer wheel.
D 9130 14 2 5 Sensor, tyre pressure, right INFORMATION
rear.
D 9130 14 2 6 Sensor, tyre pressure, left rear. INFORMATION
D 9130 31 2 Tyre pressure monitoring WARNING
system.
A 9150 31 1 Kalmar MTU (Machine WARNING
Telematic Unit).
A 9170 11 1 External scales. WARNING
A 9170 31 1 External scales. WARNING
A 9170 2 1 100 External scales, scales unit WARNING
attachment.
A 9170 2 1 110 External scales, scales unit WARNING
attachment.
A 9170 2 1 120 External scales, scales unit WARNING
attachment.
A 9630 5 2 Fire extinguishing system. WARNING
A 9630 6 2 Fire extinguishing system. WARNING
H 9650 6 2 1 Reverse alarm. WARNING
H 9650 6 3 2 Reverse alarm front, at WARNING
revolving driver's seat
10001 54 1 System error. INFORMATION
10001 55 1 System error. INFORMATION
10001 56 1 System error. INFORMATION
10002 14 1 Configuration number does STOP
not correspond for Control unit
KCU (D7901).
10002 14 2 Configuration number does not STOP
correspond for Control unit KFU
(D7971).
10002 14 3 Configuration number does STOP
not correspond for Control unit
KFU-2 (D7972).
10002 14 6 Configuration number does STOP
not correspond for Control unit
KAU-2 (D7912).

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 143

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

10002 14 7 Configuration number does STOP
not correspond for Control unit
KAU (D7911).
10002 14 11 Configuration number does STOP
not correspond for Control unit
KPU (D7902).
10002 14 12 Configuration number does not STOP
correspond for Control unit KID
(D7950).
10002 14 99 Configuration number in STOP
a control unit does not
correspond, but Control unit
KCU (D7901) does not know
which control unit contains the
error.
10003 14 1 Program version does not WARNING
correspond for Control unit
KCU (D7901).
10003 14 2 Program version does not WARNING
correspond for Control unit KFU
(D7971).
10003 14 3 Program version does not WARNING
correspond for Control unit
KFU-2 (D7972).
10003 14 6 Program version does not WARNING
correspond for Control unit
KAU-2 (D7912).
10003 14 7 Program version does not WARNING
correspond for Control unit
KAU (D7911).
10003 14 11 Program version does not WARNING
correspond for Control unit
KPU (D7902).
10003 14 12 Program version does not WARNING
correspond for Control unit KID
(D7950).
10004 14 1 No Setup file for Control unit STOP
KCU (D7901).
10004 14 2 No Setup file for Control unit STOP
KFU (D7971).
10004 14 3 No Setup file for Control unit STOP
KFU-2 (D7972).
10004 14 6 No Setup file for Control unit STOP
KAU-2 (D7912).
10004 14 7 No Setup file for Control unit STOP
KAU (D7911).
10004 14 11 No Setup file for Control unit STOP
KPU (D7902).
10004 14 12 No Setup file for Control unit STOP
KID (D7950).
10005 14 1 1 No drivetrain parameter file, STOP
Control unit KCU (D7901).
10005 14 2 1 No drivetrain parameter file, STOP
Control unit KCU KFU (D7971).

Operator’s manual DCG 180-330 IDCG02.03GB

144 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

10005 14 2 2 No load sensor parameter file, STOP
Control unit KCU KFU (D7971).
10005 14 2 3 No fuel tank parameter file, STOP
Control unit KCU KFU (D7971).
10005 14 2 4 No central lubrication STOP
parameter file, Control unit
KFU (D7971).
10005 14 2 5 No front tyre parameter file, STOP
Control unit KFU (D7971).
10005 14 2 6 No overload system (OLS) STOP
parameter file, Control unit KFU
(D7971).
10005 14 2 7 No parameter file Eco Drive STOP
Mode, Control unit KFU
(D7971).
10005 14 3 1 No drivetrain parameter file, STOP
Control unit KFU-2 (D7972).
10005 14 7 4 No parameter file central STOP
lubrication attachment, Control
unit KAU (D7911).
10005 14 11 1 No drivetrain parameter file, STOP
Control unit KPU (D7902).
10005 14 11 7 No control lever parameter file, STOP
Control unit KPU (D7902).
10005 14 12 1 No drivetrain parameter file, STOP
Control unit KID (D7950).
10101 3 1 Battery voltage Control unit WARNING
KCU (D7901).
10101 4 1 Battery voltage Control unit STOP
KCU (D7901). Check the fuses.
10102 3 1 Ignition voltage Control unit WARNING
KCU (D7901).
10102 4 1 Ignition voltage Control unit STOP
KCU (D7901). Check the fuses.
10102 4 1 1 Ignition voltage Control unit WARNING
KEM (A7991). Check the fuses.
10102 3 2 Ignition voltage Control unit WARNING
KFU (D7971).
10102 4 2 Ignition voltage Control unit STOP
KFU (D7971). Check the fuses.
10102 6 2 2 Ignition voltage Control unit WARNING
engine (D7940).
10102 3 3 Ignition voltage Control unit WARNING
KFU-2 (D7972).
10102 4 3 Ignition voltage Control unit STOP
KFU-2 (D7972). Check the
fuses.
10102 3 6 Ignition voltage Control unit STOP
KAU-2 (D7912).
10102 4 6 Ignition voltage Control unit STOP
KAU-2 (D7912). Check the
fuses.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 145

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

10102 3 7 Ignition voltage Control unit WARNING
KAU (D7911).
10102 4 7 Ignition voltage Control unit STOP
KAU (D7911). Check the fuses.
10102 4 7 1 Ignition voltage Control unit STOP
KEM-2 (A7992). Check the
fuses.
10102 4 7 2 Ignition voltage Control unit STOP
KEM-3 (A7993). Check the
fuses.
10102 3 11 Ignition voltage Control unit WARNING
KPU (D7902).
10102 4 11 Ignition voltage Control unit STOP
KPU (D7902). Check the fuses.
10102 3 12 Ignition voltage Control unit KID WARNING
(D7950).
10102 4 12 Ignition voltage Control unit KID STOP
(D7950). Check the fuses.
10103 6 1 Redundant voltage feed Control STOP
unit KCU (D7901).
10103 3 2 Redundant voltage feed Control STOP
unit KFU (D7971).
10103 4 2 Redundant voltage feed Control STOP
unit KFU (D7971).
10103 3 3 Redundant voltage feed Control STOP
unit KFU-2 (D7972).
10103 4 3 Redundant voltage feed Control STOP
unit KFU-2 (D7972).
10103 3 6 Redundant voltage feed Control STOP
unit KAU-2 (D7912).
10103 4 6 Redundant voltage feed Control STOP
unit KAU-2 (D7912).
10103 3 7 Redundant voltage feed Control STOP
unit KAU (D7911).
10103 4 7 Redundant voltage feed Control STOP
unit KAU (D7911).
10103 4 11 Redundant voltage feed Control STOP
unit KPU (D7902).
10103 3 12 Redundant voltage feed Control STOP
unit KID (D7950).
10103 4 12 Redundant voltage feed Control STOP
unit KID (D7950).
10104 3 1 5V reference voltage Control WARNING
unit KCU (D7901).
10104 4 1 5V reference voltage Control WARNING
unit KCU (D7901).
10104 3 1 1 5V reference voltage Control STOP
unit KEM (A7991).
10104 4 1 1 5V reference voltage Control STOP
unit KEM (A7991).

Operator’s manual DCG 180-330 IDCG02.03GB

146 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

10104 3 2 5V reference voltage Control WARNING
unit KFU (D7971).
10104 4 2 5V reference voltage Control WARNING
unit KFU (D7971).
10104 3 3 5V reference voltage Control WARNING
unit KFU-2 (D7972).
10104 4 3 5V reference voltage Control WARNING
unit KFU-2 (D7972).
10104 3 6 5V reference voltage Control WARNING
unit KAU-2 (D7912).
10104 4 6 5V reference voltage Control WARNING
unit KAU-2 (D7912).
10104 3 7 5V reference voltage Control WARNING
unit KAU (D7911).
10104 3 7 1 5V reference voltage Control STOP
unit KEM-2 (A7992).
10104 3 7 2 5V reference voltage Control STOP
unit KEM-3 (A7993).
10104 4 7 5V reference voltage Control WARNING
unit KAU (D7911).
10104 4 7 1 5V reference voltage Control STOP
unit KEM-2 (A7992).
10104 4 7 2 5V reference voltage Control STOP
unit KEM-3 (A7993).
10104 3 11 5V reference voltage Control WARNING
unit KPU (D7902).
10104 4 11 5V reference voltage Control WARNING
unit KPU (D7902).
10104 3 11 1 5V voltage feed to steering WARNING
wheel panel.
10104 4 11 1 5V voltage feed to steering WARNING
wheel panel.
10104 6 11 2 Background lighting, steering WARNING
wheel panel.
10104 6 11 3 Function lighting, steering WARNING
wheel panel.
10104 3 12 5V reference voltage Control WARNING
unit KID (D7950).
10104 4 12 5V reference voltage Control WARNING
unit KID (D7950).
10105 2 2 1 Reference ground Control unit WARNING
KFU (D7971).
10105 6 2 1 Reference ground Control unit WARNING
KFU (D7971).
10105 2 2 2 Reference ground Control unit WARNING
KFU (D7971).
10105 6 2 2 Reference ground Control unit WARNING
KFU (D7971).
10105 2 3 1 Reference ground Control unit WARNING
KFU-2 (D7972).

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 147

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

10105 6 3 1 Reference ground Control unit WARNING
KFU-2 (D7972).
10105 2 3 2 Reference ground Control unit WARNING
KFU-2 (D7972).
10105 6 3 2 Reference ground Control unit WARNING
KFU-2 (D7972).
10105 2 6 Reference ground Control unit WARNING
KAU-2 (D7912) indicator lights.
10105 6 6 Reference ground Control unit WARNING
KAU-2 (D7912) indicator lights.
10105 2 6 1 Reference ground Control unit WARNING
KAU-2 (D7912).
10105 6 6 1 Reference ground Control unit WARNING
KAU-2 (D7912).
10105 2 6 2 Reference ground Control unit WARNING
KAU-2 (D7912).
10105 6 6 2 Reference ground Control unit WARNING
KAU-2 (D7912).
10105 2 6 3 Reference ground Control unit WARNING
KAU-2 (D7912).
10105 6 6 3 Reference ground Control unit WARNING
KAU-2 (D7912).
10105 2 7 1 Reference ground Control unit WARNING
KAU (D7911).
10105 6 7 1 Reference ground Control unit WARNING
KAU (D7911).
10105 2 7 2 Reference ground Control unit WARNING
KAU (D7911).
10105 6 7 2 Reference ground Control unit WARNING
KAU (D7911).
10105 2 7 3 Reference ground Control unit WARNING
KAU (D7911).
10105 6 7 3 Reference ground Control unit WARNING
KAU (D7911).
10105 5 7 2 Reference ground Control unit STOP
KEM-3 (A7993).
10105 6 7 2 Reference ground Control unit STOP
KEM-3 (A7993).
10106 6 1 24V voltage feed left-hand STOP
arm rest (mini steering
wheel/joystick control).
10106 6 2 1 24V voltage feed sensor frame. WARNING
10106 6 2 2 24 V voltage feed sensor mast. WARNING
10106 6 6 LF 24V voltage feed sensor lift leg, WARNING
front left.
10106 6 6 RF 24V voltage feed sensor lift leg, WARNING
front right.
10106 6 6 LR 24V voltage feed sensor lift leg, WARNING
rear left.

Operator’s manual DCG 180-330 IDCG02.03GB

148 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

10106 6 6 RR 24V voltage feed sensor lift leg, WARNING
rear right.
10106 6 7 2 24V voltage feed sensor WTP. STOP
10106 6 7 10 24V voltage feed sensor WARNING
attachment, left.
10106 6 7 20 24V voltage feed sensor WARNING
attachment, right.
10106 6 7 1 24V voltage feed sensor WARNING
attachment, ELME.
10106 6 11 1 24V voltage feed switch cab. WARNING
10106 6 11 2 24V voltage feed switch cab. WARNING
10106 6 11 3 24V voltage feed components WARNING
cab.
10106 6 11 4 24V voltage feed control WARNING
breaker.
10107 6 11 1 Guide lights dashboard panel. WARNING
10201 35 1 RedCAN, CAN error. STOP
10201 35 2 RedCAN, CAN error. STOP
10201 35 3 RedCAN, CAN error. STOP
10201 35 6 RedCAN, CAN error. STOP
10201 35 7 RedCAN, CAN error. STOP
10201 35 11 RedCAN, CAN error. STOP
10201 35 12 RedCAN, CAN error. STOP
10201 40 12 CAN bus, control unit STOP
disappeared after start-up,
Control unit KID (D7950).
10201 41 12 CAN bus, control unit not found STOP
at start-up, Control unit KID
(D7950).
10201 42 1 CAN bus, segment error normal WARNING
side, Control unit KID (D7950).
10201 42 2 CAN bus, segment error normal WARNING
side, Control unit KID (D7950).
10201 42 3 CAN bus, segment error normal WARNING
side, Control unit KID (D7950).
10201 42 6 CAN bus, segment error normal WARNING
side, Control unit KID (D7950).
10201 42 7 CAN bus, segment error normal WARNING
side, Control unit KID (D7950).
10201 42 11 CAN bus, segment error normal WARNING
side, Control unit KID (D7950).
10201 42 12 CAN bus, segment error normal WARNING
side, Control unit KID (D7950).
10201 43 1 CAN bus, segment error WARNING
RedCAN side, Control unit KID
(D7950).
10201 43 2 CAN bus, segment error WARNING
RedCAN side, Control unit KID
(D7950).

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 149

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

10201 43 3 CAN bus, segment error WARNING
RedCAN side, Control unit KID
(D7950).
10201 43 6 CAN bus, segment error WARNING
RedCAN side, Control unit KID
(D7950).
10201 43 7 CAN bus, segment error WARNING
RedCAN side, Control unit KID
(D7950).
10201 43 11 CAN bus, segment error WARNING
RedCAN side, Control unit KID
(D7950).
10201 43 12 CAN bus, segment error WARNING
RedCAN side, Control unit KID
(D7950).
10201 44 12 CAN bus, control unit STOP
misplaced, Control unit KID
(D7950).
10202 31 2 CAN bus drivetrain STOP
communication error.
10202 35 2 CAN bus drivetrain open circuit. STOP
10202 36 2 CAN bus drivetrain STOP
communication error.
10202 37 2 CAN bus drivetrain STOP
communication error.
10202 38 2 CAN bus drivetrain STOP
communication error.
10204 35 1 CAN bus option cab, open STOP
circuit.
10204 36 1 CAN bus option cab, STOP
communication error.
10204 37 1 CAN bus option cab, STOP
communication error.
10204 38 1 CAN bus option cab, STOP
communication error.
10301 2 1 Non-volatile memory Control STOP
unit KCU (D7901).
10301 2 2 Non-volatile memory Control STOP
unit KFU (D7971).
10301 2 3 Non-volatile memory Control STOP
unit KFU-2 (D7972).
10301 2 6 Non-volatile memory Control STOP
unit KAU-2 (D7912).
10301 2 7 Non-volatile memory Control STOP
unit KAU (D7911).
10301 2 11 Non-volatile memory Control STOP
unit KPU (D7902).
10301 2 12 Non-volatile memory Control STOP
unit KID (D7950).
10302 2 1 Application log Control unit STOP
KCU (D7901).

Operator’s manual DCG 180-330 IDCG02.03GB

150 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

10302 2 2 Application log Control unit STOP
KFU (D7971).
10302 2 3 Application log Control unit STOP
KFU-2 (D7972).
10302 2 6 Application log Control unit STOP
KAU-2 (D7912).
10302 2 7 Application log Control unit STOP
KAU (D7911).
10302 2 11 Application log Control unit STOP
KPU (D7902).
10302 2 12 Application log Control unit KID STOP
(D7950).
10303 0 1 High temperature circuit board, STOP
Control unit KCU (D7901).
10303 0 2 High temperature circuit board, STOP
Control unit KFU (D7971).
10303 0 3 High temperature circuit board, STOP
Control unit KFU-2 (D7972).
10303 0 6 High temperature circuit board, STOP
Control unit KAU-2 (D7912).
10303 0 7 High temperature circuit board, STOP
Control unit KAU (D7911).
10303 0 11 High temperature circuit board, STOP
Control unit KPU (D7902).
10303 0 12 High temperature circuit board, STOP
Control unit KID (D7950).
10304 2 1 Processing time for software in STOP
Control unit KCU (D7901).
10304 2 2 Processing time for software in STOP
Control unit KFU (D7971).
10304 2 3 Processing time for software in STOP
Control unit KFU-2 (D7972).
10304 2 11 Processing time for software in STOP
Control unit KPU (D7902).
10304 2 12 Processing time for software in STOP
Control unit KID (D7950).
10305 6 1 High power consumption WARNING
Control unit KCU (D7901).
10305 6 2 High power consumption WARNING
Control unit KFU (D7971).
10305 6 3 High power consumption WARNING
Control unit KFU-2 (D7972).
10305 6 6 High power consumption WARNING
Control unit KAU-2 (D7912).
10305 6 7 High power consumption WARNING
Control unit KAU (D7911).
10305 6 11 High power consumption WARNING
Control unit KPU (D7902).
10305 6 12 High power consumption WARNING
Control unit KID (D7950).

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 151

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

10306 3 2 1 Control breaker voltage Control WARNING
unit KFU (D7971).
10306 4 2 1 Control breaker voltage Control STOP
unit KFU (D7971).
10306 3 2 2 Control breaker voltage Control STOP
unit KFU (D7971).
10306 4 2 2 Control breaker voltage Control STOP
unit KFU (D7971).
10306 3 2 3 Control breaker voltage Control STOP
unit KFU (D7971).
10306 4 2 3 Control breaker voltage Control STOP
unit KFU (D7971).
10306 3 3 1 Control breaker voltage Control STOP
unit KFU-2 (D7972).
10306 4 3 1 Control breaker voltage Control STOP
unit KFU-2 (D7972).
10306 3 3 2 Control breaker voltage Control STOP
unit KFU-2 (D7972).
10306 4 3 2 Control breaker voltage Control STOP
unit KFU-2 (D7972).
10306 3 3 3 Control breaker voltage Control STOP
unit KFU-2 (D7972).
10306 4 3 3 Control breaker voltage Control STOP
unit KFU-2 (D7972).
10306 3 6 1 Control breaker voltage Control STOP
unit KFU-2 (D7972).
10306 4 6 1 Control breaker voltage Control STOP
unit KAU-2 (D7912).
10306 3 6 2 Control breaker voltage Control STOP
unit KAU-2 (D7912).
10306 4 6 2 Control breaker voltage Control STOP
unit KAU-2 (D7912).
10306 3 6 3 Control breaker voltage Control STOP
unit KAU-2 (D7912).
10306 4 6 3 Control breaker voltage Control STOP
unit KAU-2 (D7912).
10306 3 7 1 Control breaker voltage Control STOP
unit KAU (D7911).
10306 4 7 1 Control breaker voltage Control STOP
unit KAU (D7911).
10306 3 7 2 Control breaker voltage Control STOP
unit KAU (D7911).
10306 4 7 2 Control breaker voltage Control STOP
unit KAU (D7911).
10306 3 7 3 Control breaker voltage Control STOP
unit KAU (D7911).
10306 4 7 3 Control breaker voltage Control STOP
unit KAU (D7911).
10307 2 1 Memory error Control unit KCU STOP
(D7901).

Operator’s manual DCG 180-330 IDCG02.03GB

152 5 Handling – Error code tables

Table Error codes machine (continued)

Type SPN FMI Node Location Description Action

10307 2 2 Memory error Control unit KFU STOP
(D7971).
10307 2 3 Memory error Control unit STOP
KFU-2 (D7972).
10307 2 6 Memory error Control unit STOP
KAU-2 (D7912).
10307 2 7 Memory error Control unit KAU STOP
(D7911).
10307 2 11 Memory error Control unit KPU STOP
(D7902).
10307 2 12 Memory error Control unit KID STOP
(D7950).
10308 2 1 Memory error Control unit KCU STOP
(D7901).
10308 2 2 Memory error Control unit KFU STOP
(D7971).
10308 2 3 Memory error Control unit STOP
KFU-2 (D7972).
10308 2 6 Memory error Control unit STOP
KAU-2 (D7912).
10308 2 7 Memory error Control unit KAU STOP
(D7911).
10308 2 11 Memory error Control unit KPU STOP
(D7902).
10308 2 12 Memory error Control unit KID STOP
(D7950).
10309 2 1 Memory error Control unit KCU STOP
(D7901).
10309 2 2 Memory error Control unit KFU STOP
(D7971).
10309 2 3 Memory error Control unit STOP
KFU-2 (D7972).
10309 2 6 Memory error Control unit STOP
KAU-2 (D7912).
10309 2 7 Memory error Control unit KAU STOP
(D7911).
10309 2 11 Memory error Control unit KPU STOP
(D7902).
10309 2 12 Memory error Control unit KID STOP
(D7950).

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 153

Error codes Volvo TAD871VE

General

General
Error codes for the engine are sorted in numerical order. The table
contains the following information:
• SPN - Specifies component, SPN is the error code that is shown in
the machine, in accordance with SAE J1939
• FMI - Denotes the type of error, see FMI (EE), page 115.
• Supplier-code indicates the error code in accordance with the
supplier's specification.
• Description - Indicates description of the error code as well as any
limitation that can occur in the machine in case of the error code
in question.
• Action - Indicates STOP/WARNING/INFORMATION for action
according to error code level, with or without detailed information.

Table Error codes, engine (engine option Volvo TAD871VE)

SPN FMI Supplier code Description Action

28 2 - + switches. WARNING
29 2 - Accelerator. WARNING
29 3 - Accelerator. WARNING
29 4 - Accelerator. WARNING
29 5 - Accelerator. WARNING
51 3 P02E612 Sensor throttle position. Engine speed WARNING
limited to idling speed.
51 5 P02E613 Sensor throttle position. Engine speed WARNING
limited to idling speed.
51 7 P02E699 Sensor throttle position. Engine speed WARNING
limited to idling speed.
51 12 P02E601 Sensor throttle position. Engine speed WARNING
limited to idling speed.
51 13 P02E697 Sensor throttle position. Engine speed WARNING
limited to idling speed. Engine difficult to
start or does not start at all.
91 0 P012085 Accelerator. Speed limitation. WARNING
91 2 - Accelerator. WARNING
91 3 - Accelerator. WARNING
91 4 - Accelerator. WARNING
91 5 - Accelerator. WARNING
91 9 P012082 Accelerator. WARNING
91 19 P012083 Accelerator. Speed limitation. WARNING
94 0 P008B97 High fuel pressure. WARNING
94 3 P253912 Fuel pressure sensor. WARNING
94 5 P253913 Fuel pressure sensor. WARNING
94 12 P253901 Fuel pressure sensor. WARNING
94 18 P008A00 Low fuel pressure. Reduced output and WARNING
torque.
97 0 P226985 Water in fuel. WARNING
Drain the fuel pre-filter, see 6.2.2
Fuel system.

Operator’s manual DCG 180-330 IDCG02.03GB

154 5 Handling – Error code tables

Table Error codes, engine (engine option Volvo TAD871VE) (continued)

SPN FMI Supplier code Description Action

97 4 P226411 Sensor, water-in-fuel. WARNING
97 12 P226401 Sensor, water-in-fuel. WARNING
98 1 P250F00 Low oil level engine. WARNING
Check the oil level in the engine.
See 6.2.7 Engine oil.
98 4 P250A11 Sensor oil level engine. WARNING
Check the oil level in the engine.
See 6.2.7 Engine oil.
98 5 P250A13 Sensor oil level engine. WARNING
Check the oil level in the engine.
See 6.2.7 Engine oil.
98 18 P108600 Low oil level engine. WARNING
Check the oil level in the engine.
See 6.2.7 Engine oil.
100 1 P052400 Oil pressure too low. Reduced engine WARNING
power or engine is turned off.
Check the oil level in the engine.
See 6.2.7 Engine oil.
100 3 P052012 Oil pressure sensor. STOP
100 5 P052013 Oil pressure sensor. STOP
100 18 P109300 Low oil pressure in engine. Reduced WARNING
engine power or engine is turned off.
Check the oil level in the engine.
See 6.2.7 Engine oil.
102 0 P111800 Boost pressure too high. Reduced STOP
engine power.
102 3 P010512 Sensor, boost pressure. Reduced STOP
engine power.
102 5 P010513 Sensor, boost pressure. Reduced STOP
engine power.
102 16 P111600 High charge-air pressure. STOP
105 0 P111A00 Boost temperature too high. Reduced STOP
engine power.
105 4 P011011 Sensor, boost temperature. STOP
105 5 P011013 Sensor, boost temperature. STOP
105 16 P111900 High boost temperature. STOP
107 0 P10F800 Low pressure between air filter and WARNING
turbo.
107 3 P100712 Sensor air pressure intake. WARNING
107 4 P100711 Sensor air pressure intake. WARNING
107 5 P100713 Sensor air pressure intake. WARNING
107 12 P100701 Pressure sensor air filter. WARNING
108 5 P222613 Sensor air pressure. WARNING
110 0 P021700 Coolant temperature too high. Reduced STOP
engine power.
Check the coolant level. See 6.2.6
Cooling system.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 155

Table Error codes, engine (engine option Volvo TAD871VE) (continued)

SPN FMI Supplier code Description Action

110 4 P011511 Sensor, coolant temperature. Engine STOP
hard to start.
110 5 P011513 Sensor, coolant temperature. Engine STOP
hard to start.
110 16 P111E00 High coolant temperature. STOP
Check the coolant level. See 6.2.6
Cooling system.
111 1 P256000 Low coolant level. STOP
Check the coolant level. See 6.2.6
Cooling system.
111 3 P255612 Sensor, coolant level. STOP
111 4 P255611 Sensor, coolant level. STOP
111 5 P255613 Sensor, coolant level. STOP
111 18 P111D00 Low coolant level. STOP
Check the coolant level. See 6.2.6
Cooling system.
131 3 P047012 Pressure sensor exhaust gases. Engine WARNING
brake, low performance.
131 5 P047013 Pressure sensor exhaust gases. Engine WARNING
brake, low performance.
131 12 P047001 Pressure sensor exhaust gases. WARNING
157 0 P008800 Fuel pressure, too high. Reduced WARNING
engine power.
157 1 P008700 Fuel pressure, too low. The engine can WARNING
be switched off.
157 4 P019011 Pressure sensor fuel. Reduced engine WARNING
power.
157 5 P019013 Pressure sensor fuel. Reduced engine WARNING
power.
157 7 P019062 Pressure sensor fuel. Reduced engine WARNING
power.
157 12 P019001 Pressure sensor fuel. Reduced engine WARNING
power.
157 14 P00C600 Pressure sensor fuel. The engine turns WARNING
over but does not start.
157 16 P114700 Fuel pressure, high. Reduced engine WARNING
power.
158 2 P05611F Voltage feed Control unit engine WARNING
(D7940). Uneven torque.
158 3 - Voltage feed Control unit engine WARNING
(D7940).
158 4 - Voltage feed Control unit engine WARNING
(D7940).
172 4 P00D911 Ambient temperature sensor. Engine WARNING
difficult to start at low temperatures.
172 5 P00D913 Ambient temperature sensor. Engine WARNING
difficult to start at low temperatures.

Operator’s manual DCG 180-330 IDCG02.03GB

156 5 Handling – Error code tables

Table Error codes, engine (engine option Volvo TAD871VE) (continued)

SPN FMI Supplier code Description Action

173 0 P242800 Exhaust temperature too high. Reduced WARNING
engine power.
173 16 P112E00 High exhaust temperature. WARNING
175 0 P029800 Oil temperature too high. Reduced STOP
engine power.
175 4 P019511 Sensor, oil temperature. Speed STOP
limitation.
175 5 P019513 Sensor, oil temperature. STOP
175 16 P112500 High oil temperature. STOP
190 0 P021900 Engine speed too high. Engine speed WARNING
is limited.
190 16 P119D00 Engine speed too high. WARNING
411 3 P040912 Pressure sensor exhaust gas WARNING
recirculation (EGR).
411 5 P040913 Pressure sensor exhaust gas WARNING
recirculation (EGR).
411 12 P040901 Pressure sensor exhaust gas WARNING
recirculation (EGR).
412 0 P112100 EGR temperature too high. Reduced WARNING
engine power.
412 4 P040A11 Temperature sensor exhaust gas WARNING
recirculation (EGR).
412 5 P040A13 Temperature sensor exhaust gas WARNING
recirculation (EGR).
412 12 P040A01 Temperature sensor exhaust gas WARNING
recirculation (EGR).
412 16 P112200 EGR temperature higher than normal. WARNING
Reduced engine power.
626 2 - Start button WARNING
626 3 P100212 Relay, preheating. Engine difficult to WARNING
start at low temperatures.
626 4 P100211 Relay, preheating. Engine difficult to WARNING
start at low temperatures.
626 5 P100213 Relay, preheating. Engine difficult to WARNING
start at low temperatures.
628 2 P060741 Memory error in Control unit engine WARNING
(D7940). Engine does not start.
628 2 - Memory error in Control unit engine WARNING
(D7940). Engine does not start.
628 12 - Memory error in Control unit engine WARNING
(D7940). Engine does not start.
629 12 - Memory error in Control unit engine WARNING
(D7940). Engine does not start.
630 2 - Memory error in Control unit engine WARNING
(D7940). Engine does not start.
630 12 - Memory error in Control unit engine WARNING
(D7940). Engine does not start.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 157

Table Error codes, engine (engine option Volvo TAD871VE) (continued)

SPN FMI Supplier code Description Action

636 7 P001676 Camshaft speed sensor. The engine WARNING
takes longer to start than normal or does
not start at all.
636 8 P034038 Speed sensor camshaft. The engine WARNING
takes longer to start than normal.
636 9 P034031 Speed sensor camshaft. The engine WARNING
takes longer to start than normal.
637 2 P03351F Crankshaft speed sensor. The engine WARNING
takes longer to start than normal.
Reduced torque.
637 8 P033538 Crankshaft speed sensor. The engine WARNING
takes longer to start than normal.
Reduced torque.
637 9 P033531 Crankshaft speed sensor. The engine WARNING
takes longer to start than normal.
Reduced torque.
639 2 U001088 Control unit engine (D7940), WARNING
communication error CAN bus
drivetrain (J1939).
Engine shut-off: the engine cannot be
started.
Engine running: the engine can only be
stopped by using the emergency stop.
639 2 - Control unit engine (D7940), WARNING
communication error CAN bus
drivetrain (J1939).
Engine shut-off: the engine cannot be
started.
Engine running: the engine can only be
stopped by using the emergency stop.
639 9 - Control unit engine (D7940), WARNING
communication error CAN bus
drivetrain (J1939).
Engine shut-off: the engine cannot be
started.
Engine running: the engine can only be
stopped by using the emergency stop.
641 0 P004577 Variable turbo geometry too high value. WARNING
Reduced engine power.
641 2 P256214 Actuator variable turbo geometry. WARNING
Reduced engine power.
641 3 P006E17 Actuator variable turbo geometry. WARNING
Reduced engine power.
641 5 P004513 Actuator variable turbo geometry. WARNING
Reduced engine power.
641 6 P004519 Actuator variable turbo geometry. WARNING
Reduced engine power.
641 9 U010C00 Actuator variable turbo geometry. WARNING
Reduced engine power.
641 11 P004592 Actuator variable turbo geometry. WARNING
Reduced engine power.

Operator’s manual DCG 180-330 IDCG02.03GB

158 5 Handling – Error code tables

Table Error codes, engine (engine option Volvo TAD871VE) (continued)

SPN FMI Supplier code Description Action

641 17 P112B00 Variable turbo geometry temperature WARNING
higher than normal. Reduced engine
power.
647 3 P048012 Electromagnetic clutch cooling fan. WARNING
Cooling fan drive locked at 100%.
647 4 P048011 Electromagnetic clutch cooling fan. WARNING
Cooling fan drive not working, risk of
overheating.
647 5 P048013 Electromagnetic clutch cooling fan. WARNING
Cooling fan drive locked at 100%.
651 3 P020112 Injector cylinder 1. The engine has WARNING
reduced power output.
651 4 P020111 Injector cylinder 1. The engine has WARNING
reduced power output.
651 5 P020113 Injector cylinder 1. The engine has WARNING
reduced power output.
652 3 P020212 Injector cylinder 2. The engine has WARNING
reduced power output.
652 4 P020211 Injector cylinder 2. The engine has WARNING
reduced power output.
652 5 P020213 Injector cylinder 2. The engine has WARNING
reduced power output.
653 3 P020312 Injector cylinder 3. The engine has WARNING
reduced power output.
653 4 P020311 Injector cylinder 3. The engine has WARNING
reduced power output.
653 5 P020313 Injector cylinder 3. The engine has WARNING
reduced power output.
654 3 P020412 Injector cylinder 4. The engine has WARNING
reduced power output.
654 4 P020411 Injector cylinder 4. The engine has WARNING
reduced power output.
654 5 P020413 Injector cylinder 4. The engine has WARNING
reduced power output.
655 3 P020512 Injector cylinder 5. The engine has WARNING
reduced power output.
655 4 P020511 Injector cylinder 5. The engine has WARNING
reduced power output.
655 5 P020513 Injector cylinder 5. The engine has WARNING
reduced power output.
656 3 P020612 Injector cylinder 6. The engine has WARNING
reduced power output.
656 4 P020611 Injector cylinder 6. The engine has WARNING
reduced power output.
656 5 P020613 Injector cylinder 6. The engine has WARNING
reduced power output.
677 3 P061512 Start relay on the starter motor. Engine WARNING
does not start.
677 4 P061511 Start relay on the starter motor. Engine WARNING
does not start.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 159

Table Error codes, engine (engine option Volvo TAD871VE) (continued)

SPN FMI Supplier code Description Action

677 5 P061513 Start relay on the starter motor. Engine WARNING
does not start.
677 6 P061519 Start relay on the starter motor. Engine WARNING
does not start.
679 3 P009012 Fuel pressure regulator (MPROP). WARNING
Reduced engine power.
679 4 P009011 Fuel pressure regulator (MPROP). WARNING
Reduced engine power.
679 5 P009013 Fuel pressure regulator (MPROP). WARNING
Reduced engine power.
679 7 P228D72 Fuel pressure regulator (MPROP). WARNING
Reduced engine power.
729 5 P054013 Preheating element. Engine difficult to WARNING
start at low temperatures.
729 6 P054070 Relay, preheating. Engine difficult to WARNING
start at low temperatures.
729 7 P05407F Relay, preheating. Engine difficult to WARNING
start at low temperatures.
729 12 P054001 Preheating element. Engine difficult to WARNING
start at low temperatures.
970 3 P100112 Stop-button on engine. The engine is WARNING
switched off and cannot be started.
970 4 P100111 Stop-button on engine. The engine is WARNING
switched off and cannot be started.
970 5 P100113 Stop-button on engine. The engine is WARNING
switched off and cannot be started.
970 11 P100192 Stop-button on engine. Engine cannot WARNING
be started.
970 14 P100190 Stop-button on engine. Engine cannot WARNING
be started.
1188 3 P024312 Actuator intercooler pressure control. WARNING
1188 4 P024311 Actuator intercooler pressure control. WARNING
1188 5 P024313 Actuator intercooler pressure control. WARNING
1239 14 P009400 Fuel leakage, minor. WARNING
1347 7 P06279C Fuel pressure pump. Reduced engine WARNING
power.
1485 7 P068573 Voltage feed Control unit engine WARNING
(D7940).
1639 3 P052612 Sensor fan speed. The cooling fan does WARNING
not disengage.
1668 2 U008088 Engine control unit (D7940) WARNING
communication error.
1761 3 P203A12 Level sensor AdBlue tank. WARNING
P203A86
1761 5 P203A13 Level sensor AdBlue tank. WARNING
1761 12 P203A01 Level sensor AdBlue tank. WARNING
P203A86
1761 17 P114500 AdBlue level, below normal level. WARNING

Operator’s manual DCG 180-330 IDCG02.03GB

160 5 Handling – Error code tables

Table Error codes, engine (engine option Volvo TAD871VE) (continued)

SPN FMI Supplier code Description Action

1761 18 P203F00 AdBlue-level, low. Reduced engine WARNING
power.
2000 9 U010000 Control unit engine (D7940) WARNING
communication error CAN bus
drivetrain (J1939).
2017 9 U014100 Control unit engine (D7940) WARNING
communication error CAN bus
drivetrain (J1939).
2036 9 U117100 Communication error with machine. WARNING
2659 10 P04007C EGR system. WARNING
2659 18 P04009C EGR system, low flow. WARNING
2791 2 P048613 EGR position sensor. Reduced engine WARNING
power.
2791 3 P041A12 EGR unit. Reduced engine power. WARNING
2791 4 P041A11 EGR unit. Reduced engine power. WARNING
2791 5 P040313 EGR unit. Reduced engine power. WARNING
2791 6 P040312 EGR unit. Reduced engine power. WARNING
2791 7 P040371 EGR unit. Reduced engine power. WARNING
2791 9 U010A00 Communication error between EGR WARNING
unit and Control unit engine (D7940).
Reduced engine power.
2791 11 P040392 EGR valve. Reduced engine power. WARNING
2791 12 P040341 EGR valve. Reduced engine power. WARNING
2791 17 P114E00 EGR valve, temperature higher than WARNING
normal. Reduced engine power.
3031 0 P24FF00 AdBlue-temperature too high. WARNING
3031 4 P205A11 Temperature sensor AdBlue tank. WARNING
3031 5 P205A13 Temperature sensor AdBlue tank. WARNING
3031 12 P205A86 Temperature sensor AdBlue tank. WARNING
Reduced engine power.
P205A01
3216 2 P220064 NOx sensor inlet catalytic converter WARNING
3216 3 P220012 NOx sensor inlet catalytic converter WARNING
3216 5 P220013 NOx sensor inlet catalytic converter WARNING
3216 9 U029D00 NOx sensor inlet catalytic converter WARNING
Reduced engine power.
3216 11 P225D00 NOx sensor inlet catalytic converter WARNING
Reduced engine power.
3216 12 P22FB92 NOx sensor inlet catalytic converter WARNING
3216 13 P220093 NOx sensor inlet catalytic converter WARNING
3216 14 P22001C NOx sensor inlet catalytic converter WARNING
3226 2 P229E64 NOx sensor outlet catalytic converter. WARNING
3226 3 P229E12 NOx sensor outlet catalytic converter. WARNING
Reduced engine power.
3226 5 P229E13 NOx sensor outlet catalytic converter. WARNING
Reduced engine power.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 161

Table Error codes, engine (engine option Volvo TAD871VE) (continued)

SPN FMI Supplier code Description Action

3226 7 P225F00 NOx sensor outlet catalytic converter. WARNING
Reduced engine power.
3226 9 U029E00 NOx sensor outlet catalytic converter. WARNING
Reduced engine power.
3226 12 P22FE00 NOx sensor outlet catalytic converter. WARNING
3226 13 P229E93 NOx sensor outlet catalytic converter. WARNING
3226 14 P229E1C NOx sensor outlet catalytic converter. WARNING
3241 4 P054411 Sensor exhaust temperature 1. WARNING
3241 5 P054415 Sensor exhaust temperature 1. WARNING
3241 12 P054401 Sensor exhaust temperature 1 WARNING
3241 19 P054486 Sensor exhaust temperature 1. WARNING
3361 12 P204F93 Metering valve AdBlue. Reduced engine WARNING
power.
3361 12 P208A86 AdBlue pump. Reduced engine power. WARNING
3363 3 P20B112 Heating valve AdBlue tank. Risk that WARNING
AdBlue freezes in the tank.
3363 4 P20B111 Heating valve AdBlue tank. Risk that WARNING
AdBlue freezes in the tank.
3363 5 P20B113 Heating valve AdBlue tank. Risk that WARNING
AdBlue freezes in the tank.
3364 17 P207F9A Incorrect AdBlue quality. WARNING
3464 3 P02E012 Actuator motor throttle. WARNING
3464 4 P02E011 Actuator motor throttle. WARNING
3464 5 P02E013 Actuator motor throttle. WARNING
3464 7 P02E09C Actuator motor throttle. WARNING
3464 10 P02E07C Actuator motor throttle. WARNING
3464 12 P02E09B Actuator motor throttle. WARNING
3468 2 P018564 Fuel temperature manifold. WARNING
3468 4 P018511 Fuel temperature sensor. WARNING
3468 5 P018513 Fuel temperature sensor. WARNING
3468 12 P018501 Fuel temperature sensor. WARNING
3468 16 P016800 Fuel temperature too high. Reduced WARNING
engine power.
3509 3 P06B017 Voltage feed sensor A. WARNING
3509 4 P06B016 Voltage feed sensor A. WARNING
3510 3 P06B317 Voltage feed sensor B. WARNING
3510 3 P06B317 Voltage feed sensor B. WARNING
3510 4 P06B316 Voltage feed sensor B. WARNING
3510 4 P06B316 Voltage feed sensor B. WARNING
3511 3 P06E617 Voltage feed sensor C. WARNING
3511 4 P06E616 Voltage feed sensor C. WARNING
3597 3 P065712 AdBlue pump unit voltage feed A. No WARNING
AdBlue additive.

Operator’s manual DCG 180-330 IDCG02.03GB

162 5 Handling – Error code tables

Table Error codes, engine (engine option Volvo TAD871VE) (continued)

SPN FMI Supplier code Description Action

3597 4 P065711 AdBlue pump unit voltage feed A. No WARNING
AdBlue additive.
3598 3 P266912 AdBlue pump unit voltage feed B. Risk WARNING
that AdBlue freezes.
3598 4 P266911 AdBlue pump unit voltage feed B. Risk WARNING
that AdBlue freezes.
4334 4 P204A11 Pressure sensor AdBlue. Reduced WARNING
engine power.
4334 5 P204A13 Pressure sensor AdBlue. Reduced WARNING
engine power.
4354 3 P20B912 Hose heater A AdBlue. Risk that AdBlue WARNING
freezes in the hose.
4354 4 P20B911 Hose heater A AdBlue. Risk that AdBlue WARNING
freezes in the hose.
4354 5 P20B913 Hose heater A AdBlue. Risk that AdBlue WARNING
freezes in the hose.
4355 3 P20BD12 Hose heater B AdBlue. Risk that AdBlue WARNING
freezes in the hose.
4355 4 P20BD11 Hose heater B AdBlue. Risk that AdBlue WARNING
freezes in the hose.
4355 5 P20BD13 Hose heater B AdBlue. Risk that AdBlue WARNING
freezes in the hose.
4356 3 P20C112 Hose heater C AdBlue. Risk that AdBlue WARNING
freezes in the hose.
4356 4 P20C111 Hose heater C AdBlue. Risk that AdBlue WARNING
freezes in the hose.
4356 5 P20C113 Hose heater C AdBlue. Risk that AdBlue WARNING
freezes in the hose.
4366 14 P20B992 Hose heater A AdBlue. Risk that AdBlue WARNING
freezes in the hose.
4374 0 P202D7A AdBlue system, pressure leakage. WARNING
4374 1 P208A92 AdBlue pump unit, motor speed too low. WARNING
No AdBlue additive.
4375 0 P10AD12 Motor AdBlue pump unit. WARNING
4375 1 P10AD11 Motor AdBlue pump unit. WARNING
4375 3 P208A12 Motor AdBlue pump unit. WARNING
4375 4 P208A11 Motor AdBlue pump unit. WARNING
4375 5 P208A13 Motor AdBlue pump unit. WARNING
4375 12 P10AD13 Motor AdBlue pump unit. WARNING
4375 14 P21CAA1 Motor AdBlue pump unit. WARNING
4376 3 P20A012 Directional control valve AdBlue pump WARNING
unit. AdBlue is not pumped back to the
tank when the engine is switched off.
4376 4 P20A011 Directional control valve AdBlue pump WARNING
unit. AdBlue is not pumped back to the
tank when the engine is switched off.
4376 5 P20A013 Directional control valve AdBlue pump WARNING
unit. AdBlue is not pumped back to the
tank when the engine is switched off.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 163

Table Error codes, engine (engine option Volvo TAD871VE) (continued)

SPN FMI Supplier code Description Action

4376 7 P20A007 Directional control valve AdBlue pump WARNING
unit. AdBlue is not pumped back to the
tank when the engine is switched off.
4752 7 P245700 EGR cooler, temperature deviation. WARNING
5016 4 P26E711 AdBlue pump unit voltage feed D. WARNING
5392 31 P20E892 AdBlue pressure. Reduced engine WARNING
power.
5394 3 P204712 AdBlue injection unit. No AdBlue WARNING
additive.
5394 4 P204711 AdBlue injection unit. No AdBlue WARNING
additive.
5394 5 P204713 AdBlue injection unit. No AdBlue WARNING
additive.
5394 12 P204786 AdBlue injection unit. WARNING
5394 14 P204773 AdBlue injection unit. No AdBlue WARNING
additive.
5435 14 P204F94 AdBlue system. WARNING
5485 14 P10CE97 AdBlue pump unit, no return flow. WARNING
5765 10 P041A2A EGR temperature sensor. Reduced WARNING
engine power.
520244 3 P009B12 Fuel pressure relief valve. Reduced WARNING
engine power.
520244 4 P009B11 Fuel pressure relief valve. Reduced WARNING
engine power.
520244 5 P009B13 Fuel pressure relief valve. Reduced WARNING
engine power.
520244 7 P009B73 Fuel pressure relief valve. Reduced WARNING
engine power.
520244 12 P018F00 Fuel pressure relief valve. Reduced WARNING
engine power.
520245 0 P016E00 Fuel pressure, too high. Reduced WARNING
engine power.
520245 1 P016F00 Fuel pressure, too low. Reduced engine WARNING
power.
520245 16 P228F00 Fuel pressure above normal level. WARNING
Reduced engine power.
520245 18 P228E00 Fuel pressure below normal level. WARNING
520335 5 U300001 Control unit engine (D7940). Engine WARNING
does not start.
520416 9 U116F00 Communication error Control unit WARNING
after-treatment system (UDS). No
AdBlue additive.
520688 0 P11A600 Exhaust temperature too high. WARNING
520688 3 P11A412 Sensor exhaust temperature. WARNING
520688 4 P11A411 Sensor exhaust temperature. WARNING
520688 5 P11A413 Sensor exhaust temperature. WARNING
520688 16 P11A500 Exhaust temperature higher than WARNING
normal.

Operator’s manual DCG 180-330 IDCG02.03GB

164 5 Handling – Error code tables

Error codes engine Cummins QSB6.7 Stage 3A/Tier 3

General

General
Error codes for the engine are sorted in numerical order. The table
contains the following information:
• SPN - Specifies component, SPN is the error code that is shown in
the machine, in accordance with SAE J1939
• FMI - Denotes the type of error, see FMI (EE), page 115.
• Supplier-code indicates the error code in accordance with the
supplier's specification.
• Description - Indicates description of the error code as well as any
limitation that can occur in the machine in case of the error code
in question.
• Action - Indicates STOP/WARNING/INFORMATION for action
according to error code level, with or without detailed information.

Table Error codes engine (engine option Cummins QSB6.7 Stage 3A/Tier 3)

SPN FMI Supplier code Description Action

91 3 131 Accelerator pedal or lever position WARNING
sensor circuit. Major decrease in engine
power. Only emergency operation
power.
91 4 132 Accelerator pedal or lever position WARNING
sensor circuit. Major decrease in engine
power. Only emergency operation
power.
91 9 3326 SAE J1939 multiplexing, system error WARNING
accelerator pedal sensor. Engine speed
limited to idling speed.
94 3 546 Sensor, injection pressure. WARNING
94 4 547 Sensor, injection pressure. WARNING
94 15 2261 Fuel pressure. Least serious level. WARNING
Decrease in engine power.
94 17 2262 Fuel pressure. Least serious level. WARNING
Engine difficult to start. Decrease in
engine power.
94 18 559 Fuel pump feed pressure. Moderately WARNING
serious level. The engine control unit
2215 has detected fuel pressure in the fuel
rail, which is higher than the requested
pressure. Engine power decreases
97 3 428 Sensor circuit for water in fuel indicator. WARNING
No performance loss. No water in fuel
1845 warning available.
97 4 429 Sensor circuit for water in fuel indicator. WARNING
No performance loss. No water in fuel
1846 warning available.
97 15 418 Water in fuel indicator. The least serious WARNING
level. Water has been detected in the
fuel filter. Possible white smoke, power
reduction or difficult to start.
97 16 1852 Water in fuel indicator. Moderately WARNING
serious level. Possible white smoke,
power reduction or difficult to start.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 165

Table Error codes engine (engine option Cummins QSB6.7 Stage 3A/Tier 3) (continued)

SPN FMI Supplier code Description Action

100 1 415 Engine oil duct pressure. The most STOP
serious level. Progressive power
reduction that increases with time after
the warning. If the Engine protection
shutdown function is activated, the
engine is switched off 30 seconds after
the red STOP light starts to flash.
100 2 435 Oil pressure switch sensor circuit. No WARNING
performance loss.
100 3 135 Oil pressure sensor circuit. No WARNING
performance loss.
100 4 141 Oil pressure sensor circuit. No WARNING
performance loss.
100 18 143 Engine oil duct pressure. Moderately WARNING
serious level. No performance loss.
101 0 556 Crankcase pressure. The engine is WARNING
switched off.
101 2 1942 Crankcase pressure. WARNING
101 3 1843 Crankcase pressure. WARNING
101 4 1844 Crankcase pressure. WARNING
101 16 555 Crankcase pressure. No performance WARNING
loss.
1974
102 2 2973 Intake manifold pressure sensor circuit. WARNING
Engine power decreases.
102 3 122 Intake manifold pressure sensor circuit. WARNING
Engine power decreases.
102 4 123 Intake manifold pressure sensor circuit. WARNING
Engine power decreases.
105 0 155 Temperature intake manifold 1. The STOP
most serious level. Progressive power
reduction that increases with time after
the warning. If the Engine protection
shutdown function is activated, the
engine is switched off 30 seconds after
the red STOP light starts to flash.
105 3 153 Intake manifold air temperature sensor WARNING
circuit. Possible white smoke. The
fan remains switched on if controlled
by the engine control unit. No engine
protection for the intake manifold air
temperature.
105 4 154 Intake manifold air temperature sensor WARNING
circuit. Possible white smoke. The
fan remains switched on if controlled
by the engine control unit. No engine
protection for the intake manifold air
temperature.
105 10 783 Temperature inlet manifold. The engine WARNING
is switched off.
105 16 488 Circuit, temperature sensor inlet WARNING
manifold.
108 2 295 Barometric pressure. WARNING

Operator’s manual DCG 180-330 IDCG02.03GB

166 5 Handling – Error code tables

Table Error codes engine (engine option Cummins QSB6.7 Stage 3A/Tier 3) (continued)

SPN FMI Supplier code Description Action

108 3 221 Barometric pressure sensor circuit. WARNING
Engine power decreases.
108 4 222 Barometric pressure sensor circuit. WARNING
Engine power decreases.
109 1 228 Sensor coolant pressure. Most serious WARNING
level.
109 3 231 Sensor coolant pressure. No limitation. WARNING
109 4 232 Sensor coolant pressure. No limitation. WARNING
110 0 151 Engine coolant temperature. The STOP
most serious level. Progressive power
reduction that increases with time after
the warning. If the Engine protection
shutdown function is activated, the
engine is switched off 30 seconds after
the red STOP light starts to flash.
110 3 144 Engine coolant temperature sensor WARNING
circuit 1. Possible white smoke. The fan
remains switched on if controlled by the
engine control unit. No engine protection
for the engine coolant temperature.
110 4 145 Engine coolant temperature sensor WARNING
circuit 1. Possible white smoke. The fan
remains switched on if controlled by the
engine control unit. No engine protection
for the engine coolant temperature.
110 14 1847 Engine coolant temperature high. The WARNING
engine is switched off.
110 16 146 Engine coolant temperature. Moderately WARNING
serious level. Progressive power
reduction that increases with time after
the warning.
111 1 235 Coolant level. The most serious level. STOP
Progressive power reduction that
increases with time after the warning. If
the Engine protection shutdown function
is activated, the engine is switched off
for 30 seconds after the red STOP light
starts to flash.
111 2 422 Coolant level. The engine is switched WARNING
off.
111 3 195 Coolant level sensor circuit. No WARNING
performance loss.
111 4 196 Coolant level sensor circuit. No WARNING
performance loss.
111 18 197 Coolant level. The most serious level. WARNING
Progressive power reduction that
increases with time after the warning. If
the Engine protection shutdown function
is activated, the engine is switched off
for 30 seconds after the red STOP light
starts to flash.
157 0 449 Injector measurement, pressure channel WARNING
number 1. Moderately serious level.
1911 No noise or possible noise from the
engine associated with higher injection
pressure (particularly while idling or with
a high load). Engine power decreases.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 167

Table Error codes engine (engine option Cummins QSB6.7 Stage 3A/Tier 3) (continued)

SPN FMI Supplier code Description Action

157 1 2249 Injector measurement, pressure channel WARNING
number 1. The most serious level.
No noise or possible noise from the
engine associated with higher injection
pressure (particularly while idling or with
a high load). Engine power decreases.
157 2 554 Injector measurement, pressure channel WARNING
number 1. The engine control unit
estimates the fuel pressure and the
power output is reduced.
157 3 451 Injector measurement, channel number WARNING
1, pressure sensor circuit. Power and/or
speed reduction.
157 4 452 Injector measurement, channel number WARNING
1, pressure sensor circuit. Power and/or
speed reduction.
157 16 553 Injector measurement, channel number WARNING
1, pressure. Moderately serious level.
No noise or possible noise from the
engine associated with higher injection
pressure (particularly while idling or with
a high load). Engine power decreases.
166 2 951 Imbalance between cylinders. WARNING
168 16 442 Voltage battery 1. Moderately serious WARNING
level.
168 18 441 Voltage battery 1. Moderately serious WARNING
level.
173 0 2737 Exhaust temperature sensor. WARNING
173 16 248 Exhaust temperature sensor. WARNING
175 0 214 High engine oil temperature. Power WARNING
and/or speed reduction.
175 3 212 Sensor, oil temperature. No limitation. WARNING
175 4 213 Sensor, oil temperature. No limitation. WARNING
175 16 421 High engine oil temperature. The engine WARNING
is switched off.
190 0 234 Engine crankshaft speed/position. The STOP
most serious level.
190 2 689 Engine's crankshaft speed/position. WARNING
Engine may run rough. May be difficult
2321 to start. The engine is run with backup
speed sensor. Engine power is reduced.
190 16 1992 Engine crankshaft speed/position. WARNING
Moderately serious level. Engine speed
signal indicates engine speed above
engine protection limit. Fuel injection
disabled until engine speed fails below
the overspeed limit.
441 3 293 Auxiliary temperature sensor input WARNING
signal 1. No performance loss.
441 4 294 Auxiliary temperature sensor input WARNING
signal 1. No performance loss.
441 14 292 Ambient temperature 1. Possible WARNING
reduced engine power.

Operator’s manual DCG 180-330 IDCG02.03GB

168 5 Handling – Error code tables

Table Error codes engine (engine option Cummins QSB6.7 Stage 3A/Tier 3) (continued)

SPN FMI Supplier code Description Action

611 4 238 Voltage feed no. 3, sensor. WARNING
611 16 2292 Measuring device fuel inlet. Moderately WARNING
serious level. Engine may be difficult to
start. Engine power is reduced.
611 18 2293 Fuel injection unit. Moderately serious WARNING
level. The engine has lower power
output.
611 31 757 Control unit engine (D7940). Engine WARNING
may be difficult to start.
612 2 115 The engine's magnetic crankshaft WARNING
speed/position sensor has lost both
425 signals. The fuel to the injectors is
shut-off and the engine cannot be
started.
627 2 1117 No power supply with the ignition on. WARNING
Possibly no noticeable performance
decreases or the engine stalls or is
difficult to start.
627 12 351 Voltage feed to injectors. D7940 WARNING
measured that injector boost voltage is
low. Possible smoke, low power output,
engine misfiring, and/or engine will not
start.
629 12 111 Engine control unit internal error. Engine WARNING
might not start.
1597
630 12 3697 Engine control unit memory error. WARNING
Engine may not be able to start.
633 31 2311 Circuit error in fuel actuator no. 1. WARNING
Possible low power output.
639 2 426 SAE J1939. Link error between Control WARNING
unit engine (D7940) and other units in
SAE J1939.
639 9 285 Timeout error for SAE J1939 multiplexer WARNING
PNG.
639 13 286 Configuration error for SAE J1939 WARNING
multiplexer.
644 2 237 Input signal from external speed request. WARNING
651 5 322 Circuit for injector solenoid coil drive WARNING
cylinder 1. The engine may misfire or
run rough.
651 7 1139 Injector solenoid coil drive cylinder 1. WARNING
The engine is switched off.
652 5 331 Injector solenoid cylinder #2 circuit. The WARNING
engine may misfire or run rough.
652 7 1141 Circuit for injector solenoid coil drive WARNING
cylinder 2. The engine is switched off.
653 5 324 Circuit for injector solenoid coil drive WARNING
cylinder 3. The engine may misfire or
run rough.
653 7 1142 Injector solenoid coil drive cylinder 3. WARNING
The engine is switched off.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 169

Table Error codes engine (engine option Cummins QSB6.7 Stage 3A/Tier 3) (continued)

SPN FMI Supplier code Description Action

654 5 332 Circuit for injector solenoid coil drive WARNING
cylinder 4. The engine may misfire or
run rough.
654 7 1143 Injector solenoid coil drive cylinder 4. WARNING
The engine is switched off.
655 5 323 Circuit for injector solenoid coil drive WARNING
cylinder 5. The engine may misfire or
run rough.
655 7 1144 Injector solenoid coil drive cylinder 5. WARNING
The engine is switched off.
656 5 325 Circuit for injector solenoid coil drive WARNING
cylinder 6. The engine may misfire or
run rough.
656 7 1145 Injector solenoid coil drive cylinder 6. WARNING
The engine is switched off.
697 3 2557 External PWM drive circuit 1. WARNING
697 4 2558 External PWM drive circuit 1. WARNING
723 2 778 Engine reserve crankshaft WARNING
speed/position sensor no. 2. Possible
2322 low power output.
723 2 1376 Engine speed sensor error (camshaft). WARNING
Possibly difficult to start. Engine power
decreases.
723 7 731 Engine speed/position sensor camshaft WARNING
and crankshaft. Engine runs at low
power output.
974 3 133 Circuit for remote accelerator pedal or WARNING
lever position sensor 1.
974 4 134 Circuit for remote accelerator pedal or WARNING
lever position sensor 1.
1075 3 2265 Electric lift pump for the engine's fuel WARNING
feed circuit. The engine may be difficult
to start.
1075 4 2266 Electric lift pump for the engine's fuel WARNING
feed circuit. The engine may be difficult
to start.
1079 3 386 Voltage feed no. 1, sensor. Engine WARNING
power decreases.
1079 4 352 Voltage feed no. 1, sensor. Engine WARNING
power decreases.
1080 3 227 Voltage feed no. 2, sensor circuit. WARNING
Engine power decreases.
1080 4 227 Voltage feed no. 2, sensor circuit. WARNING
Engine power decreases.
1172 3 691 Intake temperature sensor circuit for WARNING
compressor turbocharger no. 1. Engine
power is reduced.
1172 4 1172 Intake temperature sensor circuit for WARNING
compressor turbocharger no. 1. Engine
power is reduced.
1347 3 272 Circuit for fuel high pressure solenoid WARNING
valve. Engine runs poorly and with
reduced power

Operator’s manual DCG 180-330 IDCG02.03GB

170 5 Handling – Error code tables

Table Error codes engine (engine option Cummins QSB6.7 Stage 3A/Tier 3) (continued)

SPN FMI Supplier code Description Action

1347 4 271 Circuit for fuel high pressure solenoid WARNING
valve. Engine runs poorly at idle and
has low power output
1347 7 281 Fuel pumping element no. 1. Engine WARNING
not running or has low power output.
1388 14 296a Circuit for auxiliary pressure sensor. WARNING
Possible reduced engine power.
3510 4 187 Voltage feed no. 2, sensor circuit. WARNING
Engine power decreases.
3511 3 239 Voltage feed no. 3, sensor circuit. WARNING
Possibly difficult to start the engine and
rough running.
3512 3 2185 Voltage feed no. 4, sensor circuit. WARNING
Engine power decreases.
3512 4 2186 Voltage feed no. 4, sensor circuit. WARNING
Engine power decreases.
3513 3 1695 Voltage feed no. 5, sensor. Engine WARNING
power decreases.
3513 4 1696 Voltage feed no. 5, sensor. Engine WARNING
power decreases.
3514 3 515 Voltage feed no. 6, sensor. Engine WARNING
power decreases.
3514 4 516 Voltage feed no. 6, sensor. Engine WARNING
power decreases.
3938 3 1978 Speed/load. WARNING
3938 4 1979 Speed/load. WARNING
4182 3 1411 Frequency potentiometer. WARNING
4182 4 3695 Frequency potentiometer. WARNING
4183 3 1412 Potentiometer (Droop Adjust WARNING
Potentiometer).
4183 4 3696 Potentiometer (Droop Adjust WARNING
Potentiometer).
5571 0 3741 Common rail relief valve. Most serious WARNING
level. Engine coughing / stops / does
not start / difficult to start.
5571 7 3727 Common rail relief valve. Reduced WARNING
performance.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 171

Error codes engineCummins QSB6.7 Stage 4/Tier 4f

Error codes for the engine are sorted in numerical order. The table
contains the following information:
• SPN - Specifies component, SPN is the error code that is shown in
the machine, in accordance with SAE J1939
• FMI - Denotes the type of error, see FMI (EE), page 115.
• Supplier-code indicates the error code in accordance with the
supplier's specification.
• Description - Indicates description of the error code as well as any
limitation that can occur in the machine in case of the error code
in question.
• Action - Indicates STOP/WARNING/INFORMATION for action
according to error code level, with or without detailed information.

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f)

SPN FMI Supplier code Description Action

27 4 2272 EGR valve position. WARNING
Engine power decreases.
51 3 6497 Position sensor accelerator pedal. WARNING
Engine power decreases.
51 4 6498 Position sensor accelerator pedal. WARNING
Engine power decreases.
81 16 2754 Particulate trap inlet pressure. WARNING
84 2 241 Engine speed sensor circuit. WARNING
Engine speed is limited.
84 10 242 Engine speed sensor circuit. WARNING
Engine speed is limited.
84 19 3525 Engine speed sensor circuit. WARNING
Engine speed is limited.
91 0 148 Position sensor accelerator pedal WARNING
Engine power decreases.
91 1 147 Position sensor accelerator pedal WARNING
Engine power decreases.
91 2 1242 Position sensor accelerator pedal. WARNING
91 3 1358 Position sensor accelerator pedal. WARNING
Engine power decreases.
91 4 1359 Position sensor accelerator pedal. WARNING
Engine power decreases.
91 9 3326 SAE J1939 multiplexing, system WARNING
error accelerator pedal sensor.
Engine speed limited to idling
speed.
91 19 1515 SAE J1939 multiplexing, system WARNING
error accelerator pedal sensor -
CAN-bus data error.
Engine speed limited to idling
speed.
94 3 546 Fuel pressure sensor. WARNING

Operator’s manual DCG 180-330 IDCG02.03GB

172 5 Handling – Error code tables

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

94 4 547 Fuel pressure sensor. WARNING
95 16 2372 Differential pressure, fuel filter. WARNING
97 3 428 Water-in-fuel sensor circuit. WARNING
No water in fuel warning available.
97 4 429 Water-in-fuel sensor circuit. WARNING
No water in fuel warning available.
97 15 418 Water-in-fuel indicator high. Least WARNING
serious level.
Possible power reduction or
difficult to start.
97 16 1852 Water-in-fuel indicator high. WARNING
Moderately serious level.
Possible power reduction or
difficult to start.
100 1 415 Engine oil pressure low. STOP
Engine power decreases. Check the oil level in the engine,
fill when necessary.
100 2 435 Engine oil pressure sensor. WARNING
100 3 135 Engine oil pressure sensor. WARNING
100 4 141 Engine oil pressure sensor. WARNING
100 18 143 Engine oil pressure low. WARNING
Engine power decreases. Check the oil level in the engine,
fill when necessary.
101 0 556 Crankcase pressure. WARNING
101 2 1942 Crankcase pressure. WARNING
101 3 1843 Crankcase pressure. WARNING
101 4 1844 Crankcase pressure. WARNING
101 15 1974 Crankcase pressure. Least WARNING
serious level.
101 16 555 Crankcase pressure. WARNING
102 2 2973 Inlet manifold pressure sensor WARNING
circuit.
Engine power decreases.
102 3 122 Inlet manifold pressure sensor. WARNING
Engine power decreases.
102 4 123 Inlet manifold pressure sensor. WARNING
Engine power decreases.
102 16 124 Inlet manifold pressure sensor. WARNING
Pressure below permitted limit
value. Moderately serious level.
Engine power decreases.
103 15 2288 Turbo #1 high speed. WARNING
Engine power decreases.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 173

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

103 16 595 Turbo #1 high speed. Moderately WARNING
serious level.
Engine power decreases.
103 18 687 Turbo #1 low speed. Moderately WARNING
serious level.
Engine power decreases.
105 0 155 Circuit, temperature sensor inlet STOP
manifold.
Engine power decreases.
Very serious.
105 3 153 Inlet manifold temperature sensor. WARNING
105 4 154 Inlet manifold temperature sensor. WARNING
105 15 2964 Inlet manifold temperature high. WARNING
Moderately serious level.
Engine power decreases.
105 16 488 Inlet manifold temperature high. WARNING
Moderately serious level. Engine
power decreases.
107 15 5576 Engine air filter pressure. Least WARNING
serious level.
107 16 3341 Engine air filter pressure. WARNING
Moderately serious level.
Engine power decreases.
108 3 221 Sensor air pressure. WARNING
Engine power decreases.
108 4 222 Sensor air pressure. WARNING
Engine power decreases.
110 0 151 Engine coolant temperature. STOP
The most serious level. The
engine's coolant temperature Check coolant level.
signal indicates that the coolant
temperature is higher than the
critical limit for engine protection.
Engine power decreases.
110 2 334 Sensor engine coolant. The WARNING
coolant temperature sensor reads
an incorrect value during starting.
110 3 144 Sensor engine coolant. WARNING
110 4 145 Sensor engine coolant. WARNING
110 16 146 Engine coolant temperature. WARNING
Moderately serious level. The
engine's coolant temperature Check coolant level.
signal indicates that the coolant
temperature is higher than the
warning limit for engine protection.
Engine power decreases.

Operator’s manual DCG 180-330 IDCG02.03GB

174 5 Handling – Error code tables

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

110 31 2646 Coolant temperature engine. The WARNING
EGR valve has closed in order to
reduce the coolant temperature.
Engine power decreases.
111 1 235 Engine coolant level. Moderately WARNING
serious level. Low coolant level
detected. Check the coolant level, fill if
necessary.
Engine power decreases.
111 3 195 Engine coolant level. WARNING
6522
111 4 196 Engine coolant level. WARNING
6523
111 9 3613 Coolant level sensor loss of WARNING
communication.
Engine power decreases.
111 17 2448 Engine coolant level. Least WARNING
serious level.
Check the coolant level, fill if
necessary.
111 18 197 Engine coolant level. Moderately WARNING
serious level.
Check the coolant level, fill if
Engine power decreases. necessary.
111 19 3614 Engine coolant level. WARNING
Engine power decreases.
157 0 449 Fuel pressure high. WARNING
Engine power decreases.
157 3 451 Injection pressure measurement WARNING
bank 1.
Power and/or speed reduction.
157 4 452 Injection pressure measurement WARNING
bank 1.
Power and/or speed reduction.
157 16 553 Fuel pressure high. WARNING
Engine power decreases.
157 18 559 Fuel pressure low. Moderately WARNING
serious level.
Engine coughing / stops / does
not start / difficult to start.
168 16 442 High Battery #1 voltage. WARNING
Moderately serious level.
6256
168 17 3724 Low Battery #1 voltage. Least WARNING
serious level.
Reduced performance.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 175

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

168 18 441 Low Battery #1 voltage. WARNING
Moderately serious level.
6257
The engine may stop or be difficult
to start.
171 3 249 Sensor for ambient air WARNING
temperature.
171 4 256 Sensor for ambient air WARNING
temperature.
171 9 3531 Sensor for ambient air WARNING
temperature.
175 3 6524 Sensor for engine oil temperature. WARNING
175 4 6525 Sensor for engine oil temperature. WARNING
190 0 234 Engine over-revving. STOP
190 2 689 Main speed sensor error. WARNING
2321 Engine power decreases.
190 2 Rotation speed/position sensor. WARNING
Engine power decreases.
190 16 2468 Engine crankshaft speed/position STOP
- Data above normal level. Speed
above critical level. Moderately
serious level!
The engine is switched off.
191 9 3328 Transmission speed sensor WARNING
output.
191 16 349 Transmission speed sensor WARNING
output.
191 18 489 Transmission speed sensor WARNING
output.
191 19 3418 Transmission speed sensor WARNING
output.
237 13 4517 Vehicle identification number has WARNING
not been programmed.
411 2 1866 EGR-valve delta pressure. WARNING
Engine power decreases.
411 3 2273 EGR-valve delta pressure. WARNING
Engine power decreases.
411 4 2274 EGR-valve delta pressure. WARNING
Engine power decreases.
412 3 2375 EGR temperature sensor. WARNING
Engine power decreases.
412 4 2376 EGR temperature sensor. WARNING
Engine power decreases.
412 15 2961 EGR temperature. The least WARNING
serious level.
Engine power decreases.

Operator’s manual DCG 180-330 IDCG02.03GB

176 5 Handling – Error code tables

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

412 16 2962 EGR temperature. Moderately WARNING
serious level.
Engine power decreases.
441 3 293 Extra temperature sensor # 1 WARNING
circuit.
441 4 294 Extra temperature sensor # 1 WARNING
circuit.
441 14 292 Extra temperature sensor # 1 - STOP
Special instructions. Temperature
limit exceeded.
Engine power decreases.
442 3 3765 Extra temperature sensor # 1 WARNING
circuit.
Engine power decreases.
442 4 3766 Extra temperature sensor # 1 WARNING
circuit.
Engine power decreases.
558 2 431 Accelerator pedal idling validation WARNING
circuit.
Engine only running at idling
speed.
558 13 432 Accelerator pedal idling validation WARNING
circuit.
Engine only running at idling
speed.
558 19 3527 Accelerator pedal idling validation WARNING
circuit.
Engine only running at idling
speed.
563 9 3488 Anti-lock braking system (ABS). WARNING
563 31 4215 Anti-lock braking system (ABS) WARNING
Active. Error message from ABS
control unit.
Cruise control not working.
611 2 523 Speed sensor. WARNING
6563 Reduced performance.
612 2 115 Engine speed and position sensor WARNING
circuit has lost the input from the
magnetic sensor.
The engine stops and cannot be
started.
625 9 291 Data link error (OEM / Vehicle STOP
Data Link) - Abnormal degree of
change.
Engine may not be able to start.
629 12 111 Engine control unit internal error. WARNING
343 Engine may not be able to start.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 177

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

630 12 3697 Engine control unit memory error. STOP
Engine may not be able to start.
633 31 2311 Circuit, fuel injection valve. WARNING
Reduced performance.
639 9 285 SAE J1939 multiplexing PGN time WARNING
limit exceeded.
4677
639 13 286 SAE J1939 multiplexing, WARNING
configuration error.
640 14 599 Fuel injection valve. STOP
Reduced performance.
641 7 2387 Variable Turbo Geometry valve WARNING
circuit.
Reduced performance.
641 9 2636 Variable Turbo Geometry valve WARNING
circuit.
Reduced performance.
641 11 2198 Variable Turbo Geometry valve. WARNING
Reduced performance.
641 12 2634 Variable Turbo Geometry valve. WARNING
Reduced performance.
641 13 1898 VGT (Variable Geometry Turbo). WARNING
2449 Reduced performance.
641 15 1962 VGT (Variable Geometry Turbo). WARNING
1976 Reduced performance.
641 31 2635 Variable Turbo Geometry valve. WARNING
Reduced performance.
647 3 2377 Fan, control circuit. WARNING
6263 The fan may remain on
continuously or be totally
inoperable.
647 4 245 Fan, control circuit. WARNING
6264 The fan may remain on
continuously or be totally
inoperable.
651 5 322 Injector solenoid cylinder #1. WARNING
The engine may misfire or run
rough.
652 5 331 Injector solenoid cylinder #2. WARNING
The engine may misfire or run
rough.
652 7 1141 Injector solenoid cylinder #2. WARNING
The engine is switched off.

Operator’s manual DCG 180-330 IDCG02.03GB

178 5 Handling – Error code tables

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

653 5 324 Injector solenoid cylinder #3. WARNING
The engine may misfire or run
rough.
653 7 1142 Injector solenoid cylinder #3. WARNING
The engine is switched off.
654 5 332 Injector solenoid cylinder #4. WARNING
The engine may misfire or run
rough.
654 7 1143 Injector solenoid cylinder #4. WARNING
The engine is switched off.
655 5 323 Injector solenoid cylinder #5. WARNING
The engine may misfire or run
rough.
655 7 1144 Injector solenoid cylinder #5. WARNING
The engine is switched off.
656 5 325 Injector solenoid cylinder #6. WARNING
The engine may misfire or run
rough.
656 7 1145 Injector solenoid cylinder #6. WARNING
The engine is switched off.
677 3 584 Circuit, start relay. WARNING
Either the engine does not start
or, in addition, the engine has no
start interlock.
677 4 585 Circuit, start relay. WARNING
The engine has no start interlock.
697 3 2557 Extra PWM Driver 1. WARNING
697 4 2558 Extra PWM Driver 1. WARNING
701 14 4734 Extra input/output #1. No data STOP
messages between Control unit,
engine (D7940) and machine.
Reduced engine power.
702 3 527 Extra input/output #2. WARNING
703 3 529 Extra input/output #3. WARNING
723 2 778 Engine speed sensor #2. WARNING
2322
723 7 731 Engine speed sensor/position WARNING
sensor #2 mechanically
misaligned between the camshaft
and crankshaft.
Engine power decreases.
729 3 2555 Air preheating element. WARNING
6556 The intake air heaters can be ON
or OFF the whole time.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 179

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

729 4 2556 Air preheating element. WARNING
6557 The intake air heaters can be ON
or OFF the whole time.
748 9 3641 Transmission output retarder. WARNING
862 3 6336 Crankcase ventilation heater. WARNING
862 4 6337 Crankcase ventilation heater. WARNING
974 3 133 Remote accelerator pedal or lever WARNING
to position sensor 1.
Remote accelerator pedal not
working.
974 4 134 Remote accelerator pedal or lever WARNING
to position sensor 1.
Remote accelerator pedal not
working.
974 19 288 SAE J1939 multiplexing, value STOP
error, remote accelerator sensor.
Engine running only at idling
speed.
1072 3 6418 Engine brake (compression) WARNING
actuator 1.
1072 4 6419 Engine brake (compression) WARNING
actuator 1.
1073 3 2367 Engine brake (compression) WARNING
actuator 2.
6421
1073 4 2363 Engine brake (compression) WARNING
actuator 2.
6422
1075 3 6258 Electric lift pump for the engine's WARNING
fuel feed.
1075 4 6259 Electric lift pump for the engine's WARNING
fuel feed.
1081 9 3555 Engine - Wait for start lamp. WARNING
1172 3 691 Turbocharger pressure WARNING
temperature sensor.
Engine power decreases.
1172 4 692 Turbocharger pressure WARNING
temperature sensor.
Engine power decreases.
1176 2 743 Turbo #1 Compressor Inlet WARNING
pressure.
Engine power decreases.
1176 3 741 Turbo #1 Compressor Inlet WARNING
pressure.
Engine power decreases.
1176 4 742 Turbo #1 Compressor Inlet WARNING
pressure.
Engine power decreases.

Operator’s manual DCG 180-330 IDCG02.03GB

180 5 Handling – Error code tables

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

1194 13 3298 Anti-theft encryption cores. WARNING
1209 2 2554 Exhaust pressure sensor. WARNING
Engine power decreases.
1209 3 2373 Exhaust pressure sensor. WARNING
1209 4 2374 Exhaust pressure sensor. WARNING
1231 2 3329 J1939 network 2. WARNING
1235 2 3331 J1939 network 2. WARNING
1267 3 338 Circuit idle shutdown vehicle WARNING
accessory relay.
1267 4 339 Circuit idle shutdown vehicle WARNING
accessory relay.
1323 31 1654 Engine misfiring cylinder 1. WARNING
1324 31 1655 Engine misfiring cylinder 2. WARNING
1325 31 1656 Engine misfiring cylinder 3. WARNING
1326 31 1657 Engine misfiring cylinder 4. WARNING
1327 31 1658 Engine misfiring cylinder 5. WARNING
1328 31 1659 Engine misfiring cylinder 6. WARNING
1347 3 272 Fuel valve high pressure. WARNING
Engine power decreases.
1347 4 271 Fuel valve high pressure. WARNING
Engine power decreases.
1347 7 281 Fuel valve high pressure. WARNING
1349 3 483 Fuel pressure sensor. WARNING
Engine power decreases.
1349 4 484 Fuel pressure sensor. WARNING
Engine power decreases.
1377 2 497 Switch circuit. WARNING
Engine power decreases.
1378 31 649 Interval for changing engine oil WARNING
reached.
1387 3 1539 Extra pressure sensor circuit #1. WARNING
1387 4 1621 Extra pressure sensor #1. WARNING
1388 3 297 Extra pressure sensor #2. WARNING
1388 4 298 Extra pressure sensor #2. WARNING
1388 14 296 Extra pressure sensor #2. WARNING
Engine power decreases.
1569 31 3714 Engine protection - Torque WARNING
reduction - Critical error codes
related to engine operation.
Engine power decreases.
1623 9 3186 Tachograph output axle speed. WARNING

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 181

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

1623 13 5248 Tachograph output axle speed. WARNING
1623 19 3213 Tachograph output axle speed. WARNING
1632 14 2998 Torque limitation. WARNING
1639 0 4789 Fan speed. WARNING
6467 Most serious level!
1639 1 4791 Fan speed. WARNING
6468 Most serious level!
1639 2 Fan speed. WARNING
1668 2 4437 J1939 network 4. WARNING
1675 31 3737 Starter motor overheat protection. STOP
The starter motor has been
switched off to avoid damage.
The start function is prevented
until the starter motor has cooled
down.
1761 1 1673 AdBlue tank, level. Data below STOP
normal level. Most serious level!
Engine power decreases.
1761 3 1669 AdBlue tank, level sensor circuit. WARNING
Engine power decreases.
1761 4 1668 AdBlue tank, level sensor circuit. WARNING
Reduced performance.
1761 10 4769 AdBlue tank level. WARNING
Reduced performance.
1761 11 4739 AdBlue tank, level sensor. WARNING
Unknown malfunction.
6562
Reduced performance.
1761 13 4732 AdBlue tank, level sensor. WARNING
6526
1761 17 3497 AdBlue tank level. Least serious WARNING
level!
1761 18 3498 AdBlue tank level. Moderately WARNING
serious level!
2623 3 1239 Position sensor accelerator pedal. WARNING
Engine power decreases.
2623 4 1241 Position sensor accelerator pedal. WARNING
Engine speed limited to idling
speed.
2630 3 2571 Outlet temperature intercooler. WARNING
2630 4 2572 Outlet temperature intercooler. WARNING
2789 15 2346 Temperature inlet turbine turbo. WARNING
Decrease in engine power.

Operator’s manual DCG 180-330 IDCG02.03GB

182 5 Handling – Error code tables

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

2791 5 2349 EGR-valve control unit. WARNING
Reduced performance.
2791 6 2353 EGR-valve control unit. WARNING
Reduced performance.
2791 7 2357 EGR-valve control unit. WARNING
Reduced performance.
2791 13 1896 EGR-valve control unit. WARNING
Engine power decreases.
2791 15 1961 EGR-valve control unit, WARNING
temperature.
Engine power decreases.
3031 2 1679 AdBlue tank temperature. WARNING
Temperature not in phase with
surrounding environment.
Reduced performance.
3031 3 1678 AdBlue tank, temperature sensor. WARNING
Reduced performance.
3031 4 1677 AdBlue tank, temperature sensor. WARNING
6559 Reduced performance.
3031 9 4572 AdBlue tank temperature. WARNING
Reduced performance.
3031 11 4737 AdBlue tank temperature. WARNING
Engine power decreases.
3031 13 4731 AdBlue tank, temperature sensor. WARNING
Reduced performance.
3216 2 3228 NOx sensor inlet. WARNING
Reduced performance.
3216 4 1885 NOx sensor inlet. WARNING
Reduced performance.
3216 9 3232 NOx sensor inlet. WARNING
Reduced performance.
3216 10 3725 NOx sensor inlet. WARNING
3216 13 3718 NOx sensor inlet. WARNING
3216 20 3748 NOx sensor inlet. WARNING
6458
6459
3218 2 3682 NOx sensor power supply. WARNING
3226 2 1694 After-treatment outlet NOx sensor. WARNING
The value from the NOx sensor is
too high or too low.
Reduced performance.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 183

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

3226 4 1887 NOx sensor outlet. WARNING
6521 Reduced performance.
3226 9 2771 NOx sensor outlet. WARNING
Reduced performance.
3226 10 3545 NOx sensor outlet. WARNING
6565
3226 13 3717 NOx sensor outlet. WARNING
3226 20 3749 NOx sensor outlet. WARNING
6462 Reduced performance.
6463
6464
3228 2 3681 NOx sensor power supply. WARNING
3246 3 3319 After-treatment 1 exhaust filter WARNING
outlet temperature.
3361 2 2976 AdBlue temperature in metering WARNING
unit.
Engine power decreases.
3361 3 3558 AdBlue temperature in metering WARNING
unit.
Reduced performance.
3361 4 3559 AdBlue temperature in metering WARNING
unit.
Reduced performance.
3362 31 1682 AdBlue metering unit inlet pipe. WARNING
Reduced performance.
3363 3 1683 AdBlue tank heater. WARNING
6479 Reduced performance.
3363 4 1684 AdBlue tank heater. WARNING
6481 Reduced performance.
3363 7 3242 AdBlue tank heater. WARNING
6475 Reduced performance.
3363 16 1713 AdBlue tank heater. Moderate WARNING
serious level.
3363 18 1712 AdBlue tank heater. Moderate WARNING
serious level. Cannot thaw the
6476 fluid.
Reduced performance.
3364 2 3878 AdBlue pressure sensor. WARNING
Engine power decreases.
3364 3 1686 AdBlue quality sensor. WARNING
Reduced performance.

Operator’s manual DCG 180-330 IDCG02.03GB

184 5 Handling – Error code tables

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

3364 4 1685 After-treatment AdBlue quality WARNING
sensor.
Reduced performance.
3364 5 4741 After-treatment AdBlue quality WARNING
sensor.
Reduced performance.
3364 6 4742 After-treatment AdBlue quality WARNING
sensor.
Reduced performance.
3364 7 3876 After-treatment AdBlue pressure WARNING
sensor.
Engine power decreases.
3364 9 3868 After-treatment AdBlue quality. WARNING
Engine power decreases.
3364 10 4277 After-treatment AdBlue quality. WARNING
Engine power decreases.
3364 11 1715 After-treatment AdBlue quality. WARNING
Engine power decreases.
3364 12 3877 After-treatment AdBlue quality WARNING
sensor.
Engine power decreases.
3364 13 3364 AdBlue quality. WARNING
Engine power decreases.
3364 15 4842 AdBlue quality. WARNING
Engine power decreases.
3364 18 3867 AdBlue quality. Moderately WARNING
serious level.
Reduced performance.
3364 19 4241 AdBlue quality. WARNING
Reduced performance.
3464 3 6493 Electronic accelerator pedal. WARNING
6496 Engine power decreases.
3464 4 6494 Electronic accelerator pedal. WARNING
Engine power decreases.
3464 7 5882 Electronic accelerator pedal. WARNING
Engine power decreases.
3509 3 386 Voltage feed no. 1, sensor. WARNING
Engine power decreases.
3509 4 352 Voltage feed no. 1, sensor. WARNING
Engine power decreases.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 185

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

3510 3 227 Voltage feed no. 2, sensor circuit. WARNING
Engine power decreases.
3510 4 187 Voltage feed no. 2, sensor. WARNING
Engine power decreases.
3511 3 239 Voltage feed no. 3, sensor. WARNING
Possibly difficult to start the engine
and rough running.
3511 4 238 Voltage feed no. 3, sensor. WARNING
Possibly difficult to start the engine
and rough running.
3512 3 2185 Voltage feed no. 4, sensor. WARNING
Engine only running at idling
speed.
3512 4 2186 Voltage feed no. 4, sensor. WARNING
Engine only running at idling
speed.
3513 3 1695 Voltage feed no. 5, sensor. WARNING
Engine power decreases.
3513 4 1696 Voltage feed no. 5, sensor. WARNING
Engine power decreases.
3514 3 515 Voltage feed no. 6, sensor. WARNING
Engine power decreases.
3514 4 516 Voltage feed no. 6, sensor. WARNING
Engine power decreases.
3515 5 4743 Sensor AdBlue temperature 2. WARNING
3515 6 4744 Sensor AdBlue temperature 2. WARNING
3515 11 4745 AdBlue temperature 2. WARNING
Reduced performance.
3521 11 4768 AdBlue properties. Unknown fluid WARNING
in tank.
Engine power decreases.
3597 2 1117 Voltage feed 1. Low voltage WARNING
to actuator on VGT (Variable
Geometry Turbo).
Engine power decreases.
3597 12 351 Voltage feed injector. WARNING
Engine power decreases.
3597 18 1938 Voltage feed 1. Low voltage WARNING
to actuator on VGT (Variable
6499 Geometry Turbo).
Engine power decreases.
3610 2 6553 Particulate filter after-treatment WARNING
system outlet pressure.

Operator’s manual DCG 180-330 IDCG02.03GB

186 5 Handling – Error code tables

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

3610 3 6552 Particulate filter after-treatment WARNING
system pressure sensor outlet.
3610 4 6551 Particulate filter after-treatment WARNING
system pressure sensor outlet.
3667 3 3139 Engine air shutdown circuit. WARNING
3667 4 3141 Engine air shutdown circuit. WARNING
3667 7 4484 Engine air shutdown circuit. WARNING
3695 2 4213 Switch for regeneration, but in WARNING
OFF position. Regeneration
6568 required.
Possible frequent need for
regeneration.
3936 7 6265 Particulate filter after-treatment WARNING
system.
4094 31 3543 NOx limits exceeded. Poor WARNING
AdBlue quality.
Reduced performance.
4096 31 3547 AdBlue tank empty. WARNING
Reduced performance.
4185 31 1427 Relay for shutdown in the event WARNING
of over-revving.
4186 31 1428 Relay for shutdown in the event of WARNING
low oil pressure.
4187 31 1429 Relay for shutdown in the event of WARNING
high engine temperature.
4188 31 1431 Relay for indication of low oil WARNING
pressure.
4223 31 1432 Relay for indication of high engine WARNING
temperature.
4334 2 3596 AdBlue pressure sensor. WARNING
Reduced performance.
4334 3 3571 AdBlue pressure sensor. WARNING
Reduced performance.
4334 4 3572 AdBlue pressure sensor. WARNING
Reduced performance.
4334 16 3575 AdBlue pressure sensor. WARNING
Moderate serious level.
Reduced performance.
4334 18 3574 AdBlue pressure sensor. WARNING
Moderate serious level!
Reduced performance.
4337 10 4249 AdBlue metering temperature. WARNING
4340 3 3237 AdBlue line heater 1. WARNING
6531 Reduced performance.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 187

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

4340 4 3238 AdBlue line heater 1. WARNING
6532 Reduced performance.
4340 5 3258 AdBlue line heater 1. WARNING
6482 Reduced performance.
4342 3 3239 AdBlue line heater 2. WARNING
6533 Reduced performance.
4342 4 3241 AdBlue line heater 2. WARNING
6534 Reduced performance.
4342 5 3261 AdBlue line heater 2. WARNING
6483 Reduced performance.
4344 3 3422 AdBlue line heater 3. WARNING
6535 Reduced performance.
4344 4 3423 AdBlue line heater 3. WARNING
6536 Reduced performance.
4344 5 3425 AdBlue line heater 3. WARNING
6484 Reduced performance.
4360 0 3229 SCR temperature inlet. Exceeded WARNING
maximum engine protection
temperature limit. Most serious
level!
Reduced performance.
4360 2 3144 SCR temperature inlet. WARNING
Reduced performance.
4360 3 3142 SCR temperature inlet. WARNING
Reduced performance.
4360 4 3143 SCR temperature inlet. WARNING
Reduced performance.
4360 15 3164 SCR temperature inlet. Least WARNING
serious level!
Reduced performance.
4360 16 3231 SCR temperature inlet. Exceeded WARNING
maximum temperature limit.
Moderate serious level!
Reduced performance.
4363 0 3165 SCR temperature outlet. Most STOP
serious level!
Reduced performance.
4363 2 3148 SCR temperature outlet. WARNING
Reduced performance.
4363 3 3146 SCR temperature outlet. WARNING
6569 Reduced performance.

Operator’s manual DCG 180-330 IDCG02.03GB

188 5 Handling – Error code tables

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

4363 4 3147 SCR temperature outlet. WARNING
6571 Reduced performance.
4363 16 3235 SCR temperature outlet. Most STOP
serious level!
Reduced performance.
4364 18 3582 SCR conversion of catalyst output. WARNING
Moderate serious level.
6517
Reduced performance.
4376 2 3577 AdBlue return valve. WARNING
Reduced performance.
4376 3 3578 AdBlue return valve. WARNING
Reduced performance.
4376 7 4157 AdBlue return valve. WARNING
6527 Reduced performance.
4765 2 3315 Catalyst (DOC) temperature inlet. WARNING
6539 Reduced performance.
4765 3 3314 Catalyst (DOC) temperature inlet. WARNING
Reduced performance.
4765 4 3313 Catalyst (DOC) temperature inlet. WARNING
Reduced performance.
4765 16 3251 Catalyst (DOC) temperature inlet. STOP
Reduced performance.
4766 0 5387 Catalyst (DOC) temperature STOP
outlet. Most serious level.
The engine is switched off.
4766 2 5386 Catalyst (DOC) temperature WARNING
outlet.
Reduced performance.
4766 3 4533 Catalyst (DOC) temperature WARNING
outlet.
Reduced performance.
4766 4 4534 Catalyst (DOC) temperature WARNING
outlet.
Reduced performance.
4766 15 5389 Catalyst (DOC) temperature WARNING
outlet. Least serious level.
Reduced performance.
4766 16 5388 Catalyst (DOC) temperature WARNING
outlet. Moderate serious level.
The engine is switched off.
4792 7 3751 SCR catalyst. WARNING

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 189

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

4792 14 4585 SCR catalyst. Wrong system has STOP
been installed.
The engine is switched off.
4794 31 3151 SCR catalyst, system missing. WARNING
Reduced performance.
4796 31 1664 Catalyst (DOC) missing. WARNING
Reduced performance.
5018 11 2637 Catalyst (DOC) WARNING
Reduced performance.
5018 14 5617 Catalyst (DOC). WARNING
Reduced performance.
5024 10 3649 NOx sensor outlet. Abnormal rate WARNING
of change.
5031 10 3583 NOx sensor outlet. Abnormal rate WARNING
of change.
6581
5125 3 3419 Voltage feed no. 7, sensor. WARNING
5125 4 3421 Voltage feed no. 7, sensor. WARNING
5245 31 4863 Critical SCR-related error codes WARNING
active.
Reduced performance.
5246 0 3712 Critical SCR-related error codes STOP
active. Most serious level!
Reduced engine power.
5298 18 1691 Catalyst (DOC). Moderate serious WARNING
level.
2638
Possible frequent need for
regeneration of the after-treatment
system.
5394 2 3755 Metering valve AdBlue. WARNING
Reduced performance.
5394 5 3567 Metering valve AdBlue. WARNING
Reduced performance.
5394 7 3568 Metering valve AdBlue. WARNING
Reduced performance.
5484 3 3633 Engine fan clutch 2. WARNING
6456
5484 4 3634 Engine fan clutch 2. WARNING
6457
5491 3 3562 AdBlue relay line heater. WARNING
6477 Reduced performance.
5491 4 3563 AdBlue line heater relay. WARNING
6478 Reduced performance.

Operator’s manual DCG 180-330 IDCG02.03GB

190 5 Handling – Error code tables

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

5491 7 6537 AdBlue line heater relay. WARNING
5571 0 3741 Common rail relief valve. Most WARNING
serious level.
Engine coughing / stops / does
not start / difficult to start.
5571 3 4262 Common rail relief valve. WARNING
Engine coughing / stops / does
not start / difficult to start.
5571 4 4263 Common rail relief valve. WARNING
Engine coughing / stops / does
not start / difficult to start.
5571 7 3727 Common rail relief valve. WARNING
Reduced performance.
5571 11 4265 Common rail relief valve. WARNING
5571 15 5585 Common rail relief valve. Least WARNING
serious level.
Reduced performance.
5571 31 4867 Common rail relief valve. WARNING
Engine coughing / stops / does
not start / difficult to start.
5742 3 4161 Temperature sensor particle filter WARNING
after-treatment system.
5742 4 4162 Temperature sensor particle filter WARNING
after-treatment system.
5742 9 4151 Temperature sensor particle filter WARNING
after-treatment system.
5742 12 4158 Temperature sensor particle filter WARNING
after-treatment system.
5742 16 4163 Temperature sensor particle filter WARNING
after-treatment system.
5743 3 4164 SCR temperature sensor. WARNING
Reduced performance.
5743 4 4165 SCR temperature sensor. WARNING
Reduced performance.
5743 9 4152 SCR temperature sensor. WARNING
Reduced performance.
5743 11 4261 SCR temperature sensor. WARNING
Reduced performance.
5743 12 4159 SCR temperature sensor. WARNING
Reduced performance.
5743 16 4166 SCR temperature sensor. WARNING
Moderate serious level.
Reduced performance.
5745 3 4168 AdBlue heater metering unit. WARNING

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 191

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

5745 4 4169 AdBlue heater metering unit. WARNING
Reduced performance.
5745 18 4171 AdBlue heater metering unit. WARNING
Moderately serious level.
6513
Reduced performance.
5746 3 4155 AdBlue relay heater metering unit. WARNING
6529 Reduced performance.
5746 4 4156 AdBlue relay heater metering unit. WARNING
Reduced performance.
5798 10 4251 AdBlue heater metering unit, WARNING
temperature.
6303 3 4865 Coolant level sensor. WARNING
6303 4 4866 Coolant level sensor. WARNING
6713 9 5177 VGT (Variable Geometry Turbo), WARNING
software.
Reduced performance.
6713 13 4956 VGT (Variable Geometry Turbo), STOP
not calibrated.
Reduced performance.
6713 31 4957 VGT (Variable Geometry Turbo), WARNING
software without calibration.
Reduced performance.
6802 31 5278 AdBlue metering system frozen. WARNING
6881 9 5653 Switch for preventing regeneration WARNING
of the engine's after-treatment
system.
6881 13 5654 Switch for preventing regeneration WARNING
of the engine's after-treatment
system.
6882 3 5393 Catalyst (DOC) temperature WARNING
module.
Reduced performance.
6882 4 5394 Catalyst (DOC) temperature WARNING
module.
Reduced performance.
6882 9 5391 Catalyst (DOC) temperature WARNING
module.
Reduced performance.
6882 11 5395 Catalyst (DOC) temperature WARNING
module.
Reduced performance.
6882 12 5392 Catalyst (DOC) temperature WARNING
module.
Reduced performance.

Operator’s manual DCG 180-330 IDCG02.03GB

192 5 Handling – Error code tables

Table Error codes engine (engine option Cummins QSB6.7 Stage 4/Tier 4f) (continued)

SPN FMI Supplier code Description Action

6882 16 5396 Catalyst (DOC) temperature WARNING
module.
Reduced performance.
6918 31 5632 Regeneration SCR system is WARNING
prevented due to disconnected
switch.
6928 31 5631 Regeneration SCR system WARNING
prevented due to time limit.
6597
SCR system cannot perform
cleaning.
520968 9 5939 Limited operation. WARNING
Reduced performance.
520968 19 5941 Limited operation. WARNING
Reduced performance.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 193

Error codes transmission Dana Spicer Off-Highway

TE17000FF
General

General
Error codes from the transmission generally have error code level
"WARNING", but error codes from the transmission can specify another
error code level in accordance with the action column in the table below.

Error codes for the transmission are sorted in numerical order. The
table contains the following information:
• SPN - Specifies component, SPN is the error code that is shown in
the machine, in accordance with SAE J1939.
• FMI - Denotes the type of error, see FMI (EE), page 115.
• Supplier-code indicates the error code in accordance with the
supplier's specification in decimal form.
• Supplier-code2 indicates the error code in accordance with the
supplier's specification in hexadecimal form.
• Description - Indicates description of the error code as well as any
limitation that can occur in the machine in case of the error code
in question.
• Action - Indicates STOP/WARNING/INFORMATION for action
according to error code level, with or without detailed information.

Table Error codes transmission Dana TE17000FF

SPN FMI Supplier Supplier code 2 Description Action

code
520349 12 00.50 7F09D Memory error in control STOP
unit transmission.
Transmission in
locked neutral position
(Shutdown).
520349 12 00.51 7F09D Memory error in control STOP
unit transmission.
Transmission in
locked neutral position
(Shutdown).
520349 12 00.52 7F09D Memory error in control STOP
unit transmission.
Transmission in
locked neutral position
(Shutdown).
520349 12 00.53 7F09D Memory error in control STOP
unit transmission.
Transmission in
locked neutral position
(Shutdown).
520293 1 20.60 7F065 Logical error Pressure STOP
sensor gear 1/3
(B7651). Transmission
in locked neutral position
(Shutdown).
520293 0 20.61 7F065 Logical error Pressure STOP
sensor gear 1/3
(B7651). Transmission
in locked neutral position
(Shutdown).
520297 1 21.00 7F069 Oil pressure sensor. STOP
Transmission in
locked neutral position
(Shutdown).

Operator’s manual DCG 180-330 IDCG02.03GB

194 5 Handling – Error code tables

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520297 0 21.01 7F069 Oil pressure sensor. STOP
Transmission in
locked neutral position
(Shutdown).
520298 1 22.00 7F06A Oil pressure sensor. STOP
Transmission in
locked neutral position
(Shutdown).
520298 0 22.01 7F06A Oil pressure sensor. STOP
Transmission in
locked neutral position
(Shutdown).
520299 1 23.00 7F06B Oil pressure sensor. STOP
Transmission in
locked neutral position
(Shutdown).
520299 0 23.01 7F06B Oil pressure sensor. STOP
Transmission in
locked neutral position
(Shutdown).
520300 1 24.00 7F06C Oil pressure sensor. STOP
Transmission in
locked neutral position
(Shutdown).
520300 0 24.01 7F06C Oil pressure sensor. STOP
Transmission in
locked neutral position
(Shutdown).
520336 1 30.04 7F090 Low battery voltage. STOP
520336 0 30.05 7F090 High battery voltage. WARNING
520339 1 31.00 7F093 Reference voltage to WARNING
sensor is too low.
520339 0 31.01 7F093 Reference voltage to WARNING
sensor is too high.
520379 31 34.00 7F0BB Sensor fault in a speed WARNING
sensor. Transmission in
neutral position.
520380 1 34.01 7F0BC Measured turbine rpm WARNING
at start-up is too low.
Transmission in neutral
position.
520381 0 34.02 7F0BD Measured drum rpm WARNING
at start-up is too
high. Transmission in
locked neutral position
(Shutdown).
520382 1 34.03 7F0BE Internal rotation speeds WARNING
indicate that there is
no system pressure
when there should
be. Transmission in
locked neutral position
(Shutdown).

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 195

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520382 0 34.04 7F0BE Internal rotation speeds WARNING
indicate that there
is system pressure
when there should not
be. Transmission in
locked neutral position
(Shutdown).
520371 0 38.00 7F0B3 Disengaged 4WD/2WD- INFORMATION
selector has jammed
in engaged position or
the feedback signal is
incorrect.
520371 1 38.01 7F0B3 Engaged 4WD/2WD- INFORMATION
selector has jammed
in disengaged position
or the return signal is
incorrect.
520371 7 38.07 7F0B3 4WD/2WD selector is in INFORMATION
changeover mode (tooth
against tooth).
520372 0 39.00 7F0B4 Disengaged Low/High- INFORMATION
selector has jammed
in engaged position or
the feedback signal is
incorrect.
520372 1 39.01 7F0B4 Engaged Low/High- INFORMATION
selector has jammed
in disengaged position
or the return signal is
incorrect.
520286 2 40.06 7F05E Wrong direction from WARNING
the gear selector.
Transmission in neutral
position.
520257 31 40.08 7F041 The seat direction INFORMATION
changed during
operations. Transmission Stop the machine and
in neutral position. select neutral. Check
seat direction or show
the driver how the seat is
turned as per the correct
procedure.
520287 2 41.06 7F05F Incorrect gear selection WARNING
from the gear selector.
Control unit does not
allow change of gear
range, however, operation
of machine is possible.
520320 1 42.04 7F080 Actual gear ratio too low. STOP or WARNING
One or several clutches
slipping. Transmission
in locked neutral position
(Shutdown).
520320 0 42.05 7F080 Actual gear ratio too high. STOP or WARNING
One or several clutches
slipping. Transmission
in locked neutral position
(Shutdown).

Operator’s manual DCG 180-330 IDCG02.03GB

196 5 Handling – Error code tables

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520291 4 43.03 7F063 Sensor temperature WARNING
torque converter.
520291 16 43.07 7F063 Torque converter's WARNING
temperature exceeds
100 °C. Note the error and try
to reduce temperature
in torque converter by
operating calmly.
520291 0 43.08 7F063 Torque converter's WARNING
temperature exceeds
120 °C. Stop the machine, select
neutral and apply full
The control unit protects throttle (limited to 50%) to
the transmission and does cool the transmission oil
not allow the temperature so that temperature drops
in the torque converter below 100 °C (error code
to exceed the maximum 43/03 disappears).
limit. Transmission in
locked neutral position When temperature in
(Shutdown). The engine torque converter is below
is limited to 50 % of the 100 °C, resume work with
maximum speed. machine.

520390 9 44.10 7F0C6 Position accelerator pedal WARNING

no message from engine's
control unit.
520264 2 45.06 7F048 Invalid combination for INFORMATION
redundant digital speed
inputs. The speed is
limited
520246 15 46.05 7F036 Max. torque at inching WARNING
has been exceeded.
Stop the machine, select
neutral. Reselect the
gear.
520315 0 47.01 7F07B Transmission has INFORMATION
exceeded the limit value
for upper rpm. Release the accelerator
pedal and slow down the
machine.
520208 4 50.00 7F010 Pressure sensor gear STOP
1/3. Transmission in
locked neutral position
(Shutdown).
520208 3 50.01 7F010 Pressure sensor gear STOP
1/3. Transmission in
locked neutral position
(Shutdown).
520208 17 50.04 7F010 Pressure sensor gear 1/3. WARNING
520208 15 50.05 7F010 Pressure sensor gear 1/3. WARNING
520209 4 51.00 7F011 Sensor transmission oil WARNING
temperature.
520209 3 51.01 7F011 Sensor transmission oil WARNING
temperature.
520209 17 51.04 7F011 Sensor transmission oil INFORMATION
temperature, value error.
520209 15 51.05 7F011 Sensor transmission oil INFORMATION
temperature, value error.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 197

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520210 4 52.00 7F012 Temperature monitor INFORMATION
torque converter.
520210 3 52.01 7F012 Temperature monitor INFORMATION
torque converter.
520210 17 52.04 7F012 Temperature monitor INFORMATION
torque converter, value
error.
520210 15 52.05 7F012 Temperature monitor INFORMATION
torque converter, value
error.
520211 4 53.00 7F013 Analogue input signal. INFORMATION
520211 3 53.01 7F013 Analogue input signal. INFORMATION
520211 17 53.04 7F013 Analogue input signal, INFORMATION
value error.
520211 15 53.05 7F013 Analogue input signal, INFORMATION
value error.
520212 4 54.00 7F014 Reference voltage sensor WARNING
5 V.
520212 3 54.01 7F014 Reference voltage sensor WARNING
5 V.
520213 4 55.00 7F015 Analogue input signal. INFORMATION
520213 3 55.01 7F015 Analogue input signal. INFORMATION
520213 17 55.04 7F015 Analogue input signal, INFORMATION
value error.
520213 15 55.05 7F015 Analogue input signal, INFORMATION
value error.
520214 4 56.00 7F016 Pressure sensor gear INFORMATION
2. Transmission in
locked neutral position
(Shutdown).
520214 3 56.01 7F016 Pressure sensor gear INFORMATION
2. Transmission in
locked neutral position
(Shutdown).
520214 17 56.04 7F016 Pressure sensor gear 2, INFORMATION
value error.
520214 15 56.05 7F016 Pressure sensor gear 2, INFORMATION
value error.
520215 4 57.00 7F017 Analogue input signal. INFORMATION
520215 3 57.01 7F017 Analogue input signal. INFORMATION
520215 17 57.04 7F017 Analogue input signal, INFORMATION
value error.
520215 15 57.05 7F017 Analogue input signal, INFORMATION
value error.
520216 4 58.00 7F018 Analogue input signal. INFORMATION
520216 3 58.01 7F018 Analogue input signal. INFORMATION
520216 17 58.04 7F018 Analogue input signal, INFORMATION
value error.

Operator’s manual DCG 180-330 IDCG02.03GB

198 5 Handling – Error code tables

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520216 15 58.05 7F018 Analogue input signal, INFORMATION
value error.
520218 6 60.00 7F01A Sensor rpm drum. STOP or WARNING
If several rpm signals or
the engine rpm signal
are incorrect, control unit
transmission activates
Limp-home.
520218 5 60.01 7F01A Sensor rpm drum. STOP or WARNING
If several rpm signals or
the engine rpm signal
are incorrect, control unit
transmission activates
Limp-home.
520218 10 60.03 7F01A Sensor rpm drum, value STOP or WARNING
error.
520218 1 60.04 7F01A Sensor rpm drum, value STOP or WARNING
error.
520218 0 60.05 7F01A Sensor rpm drum, value STOP or WARNING
error.
520219 6 61.00 7F01B Sensor rpm output shaft. STOP or WARNING
If several rpm signals or
the engine rpm signal
are incorrect, control unit
transmission activates
Limp-home.
520219 5 61.01 7F01B Sensor rpm output shaft. STOP or WARNING
If several rpm signals or
the engine rpm signal
are incorrect, control unit
transmission activates
Limp-home.
520219 10 61.03 7F01B Sensor rpm output shaft, STOP or WARNING
value outside limit values.
520219 1 61.04 7F01B Sensor rpm output shaft, STOP or WARNING
value error.
520219 0 61.05 7F01B Sensor rpm output shaft, STOP or WARNING
value error.
520220 6 62.00 7F01C Sensor engine rpm. STOP or WARNING
If several rpm signals or
the engine rpm signal
are incorrect, control unit
transmission activates
Limp-home.
520220 5 62.01 7F01C Sensor engine rpm. STOP or WARNING
If several rpm signals or
the engine rpm signal
are incorrect, control unit
transmission activates
Limp-home.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 199

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520220 10 62.03 7F01C Engine speed STOP or WARNING
information not available.
Transmission locked to
gear 1 and 2 (Limp-home).
520220 1 62.04 7F01C Sensor engine rpm, value STOP or WARNING
error.
520220 0 62.05 7F01C Sensor engine rpm, value STOP or WARNING
error.
520314 1 62.06 7F07A Faulty engine speed STOP or WARNING
information when
the turbine speed is
calculated. Transmission
locked to gear 1 and 2
(Limp-home).
520221 6 63.00 7F01D Sensor rpm turbine. STOP or WARNING
If several rpm signals or
the engine rpm signal
are incorrect, control unit
transmission activates
Limp-home.
520221 5 63.01 7F01D Sensor rpm turbine. STOP or WARNING
If several rpm signals or
the engine rpm signal
are incorrect, control unit
transmission activates
Limp-home.
520221 10 63.03 7F01D Sensor rpm turbine value STOP or WARNING
error.
520221 1 63.04 7F01D Sensor rpm turbine value STOP or WARNING
error.
520221 0 63.05 7F01D Sensor rpm turbine value STOP or WARNING
error.
520224 4 70.00 7F020 Servo valve gear STOP
forward/reverse.
Transmission locked to Stop the machine and
gear 1 and 2 (Limp-home). change to neutral. Select
reverse gear.
520224 3 70.01 7F020 Servo valve gear STOP
forward/reverse.
Transmission locked to Stop the machine and
gear 1 and 2 (Limp-home). change to neutral. Select
reverse gear.
520224 6 70.02 7F020 Servo valve gear STOP
forward/reverse.
Transmission in
locked neutral position
(Shutdown).
520224 8 70.03 7F020 Servo valve gear STOP
forward/reverse.
Transmission in
locked neutral position
(Shutdown).

Operator’s manual DCG 180-330 IDCG02.03GB

200 5 Handling – Error code tables

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520224 5 70.09 7F020 Servo valve gear STOP
forward/reverse.
Transmission locked to Stop the machine and
gear 1 and 2 (Limp-home). change to neutral. Select
reverse gear.
520225 4 71.00 7F021 Servo valve gear 1/3. STOP
Transmission locked to
gear 1 and 2 (Limp-home). Stop the machine and
change to neutral. Select
reverse gear.
520225 3 71.01 7F021 Servo valve gear 1/3. STOP
Transmission locked to
gear 1 and 2 (Limp-home). Stop the machine and
change to neutral. Select
reverse gear.
520225 6 71.02 7F021 Servo valve gear STOP
1/3. Transmission in
locked neutral position
(Shutdown).
520225 8 71.03 7F021 Servo valve gear 1/3. STOP
Transmission locked to
gear 1 and 2 (Limp-home). Stop the machine and
change to neutral. Select
reverse gear.
520225 5 71.09 7F021 Servo valve gear 1/3. STOP
Transmission locked to
gear 1 and 2 (Limp-home). Stop the machine and
change to neutral. Select
reverse gear.
520226 4 72.00 7F022 Servo valve gear 2. STOP
Transmission locked to
gear 1 and 2 (Limp-home). Stop the machine and
change to neutral. Select
reverse gear.
520226 3 72.01 7F022 Servo valve gear 2. STOP
Transmission locked to
gear 1 and 2 (Limp-home). Stop the machine and
change to neutral. Select
reverse gear.
520226 6 72.02 7F022 Servo valve gear STOP
2. Transmission in
locked neutral position
(Shutdown).
520226 8 72.03 7F022 Servo valve gear 2. STOP
Transmission locked to
gear 1 and 2 (Limp-home). Stop the machine and
change to neutral. Select
reverse gear.
520226 5 72.09 7F022 Servo valve gear 2. STOP
Transmission locked to
gear 1 and 2 (Limp-home). Stop the machine and
change to neutral. Select
reverse gear.
520227 4 73.00 7F023 Analogue output signal. STOP
Transmission locked to
gear 1 and 2 (Limp-home). Stop the machine and
change to neutral. Select
reverse gear.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 201

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520227 3 73.01 7F023 Analogue output signal. STOP
Transmission locked to
gear 1 and 2 (Limp-home). Stop the machine and
change to neutral. Select
reverse gear.
520227 6 73.02 7F023 Analogue output STOP
signal. Transmission
in locked neutral position
(Shutdown).
520227 8 73.03 7F023 Analogue output signal. STOP
Transmission locked to
gear 1 and 2 (Limp-home). Stop the machine and
change to neutral. Select
reverse gear.
520227 5 73.09 7F023 Analogue output signal. STOP
Transmission locked to
gear 1 and 2 (Limp-home). Stop the machine and
change to neutral. Select
reverse gear.
520228 4 74.00 7F024 Analogue output signal. STOP
520228 3 74.01 7F024 Analogue output signal. STOP
520228 5 74.09 7F024 Analogue output signal. STOP
520229 4 75.00 7F025 Analogue output signal. STOP
520229 3 75.01 7F025 Analogue output signal. STOP
520229 5 75.09 7F025 Analogue output signal. STOP
520230 4 76.00 7F026 Analogue output signal. STOP
520230 3 76.01 7F026 Analogue output signal. STOP
520230 6 76.02 7F026 Analogue output signal. STOP
520230 8 76.03 7F026 Analogue output signal. STOP
520230 5 76.09 7F026 Analogue output signal. STOP
520239 31 77.02 7F02F All gear packages STOP
disengaged.
Transmission in
locked neutral position
(Shutdown).
520231 4 80.00 7F027 Solenoid valve driving STOP
forward. Transmission
locked to gear 1 and 2 Stop the machine and
(Limp-home). change to neutral. Select
reverse gear.
520231 3 80.01 7F027 Solenoid valve driving STOP
forward. Transmission
locked to gear 1 and 2 Stop the machine and
(Limp-home). change to neutral. Select
reverse gear.
520231 5 80.09 7F027 Solenoid valve driving STOP
forward. Transmission
locked to gear 1 and 2 Stop the machine and
(Limp-home). change to neutral. Select
reverse gear.

Operator’s manual DCG 180-330 IDCG02.03GB

202 5 Handling – Error code tables

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520232 4 81.00 7F028 Solenoid valve driving STOP
reverse. Transmission
locked to gear 1 and 2 Stop the machine and
(Limp-home). change to neutral. Select
reverse gear.
520231 3 81.01 7F028 Solenoid valve driving STOP
reverse. Transmission
locked to gear 1 and 2 Stop the machine and
(Limp-home). change to neutral. Select
reverse gear.
520231 5 81.09 7F028 Solenoid valve driving STOP
reverse. Transmission
locked to gear 1 and 2 Stop the machine and
(Limp-home). change to neutral. Select
reverse gear.
520233 4 82.00 7F029 Solenoid valve STOP
gear selection 1/3.
Transmission locked to Stop the machine and
gear 1 and 2 (Limp-home). change to neutral. Select
reverse gear.
520233 3 82.01 7F029 Solenoid valve STOP
gear selection 1/3.
Transmission locked to Stop the machine and
gear 1 and 2 (Limp-home). change to neutral. Select
reverse gear.
520233 5 82.09 7F029 Solenoid valve STOP
gear selection 1/3.
Transmission locked to Stop the machine and
gear 1 and 2 (Limp-home). change to neutral. Select
reverse gear.
520234 3 83.00 7F02A Digital output signal. STOP
Transmission locked to
gear 1 and 2 (Limp-home). Stop the machine and
change to neutral. Select
reverse gear.
520234 4 83.01 7F02A Digital output signal. STOP
Transmission locked to
gear 1 and 2 (Limp-home). Stop the machine and
change to neutral. Select
reverse gear.
520236 31 85.01 7F02C Towing detected. STOP
520388 9 C4.99 7F0C4 Abnormal update rate. WARNING
520352 520352 90.90 31 Software error, STOP
Transmission control
unit. Transmission
locked in neutral position
(Shutdown).
520352 31 90.xx - 7F0A0 Transmission fault STOP or INFORMATION
99.xx Transmission in
locked neutral position
(Shutdown).
520192 0 90.xx 7F000 Communication error STOP
CAN bus drivetrain.
One error code per
message. Transmission
in locked neutral position
(Shutdown).

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 203

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520433 xx 91.xx 7F0F1 Communication error STOP
CAN bus drivetrain.
One error code per
message. Transmission
in locked neutral position
(Shutdown).
520434 0 92.00 7F0F2 Software error, -
Transmission control
unit.
520434 1 92.01 7F0F2 Shifting has no direction. STOP
Transmission locked
in neutral position
(Shutdown).
520434 2 92.02 7F0F2 Doubled direction. STOP
Transmission locked
in neutral position
(Shutdown).
520434 3 92.03 7F0F2 Doubled shifting. STOP
Transmission locked
in neutral position
(Shutdown).
520434 4 92.04 7F0F2 Doubled pulse pattern. STOP
Transmission locked
in neutral position
(Shutdown).
520434 6 92.06 7F0F2 Signal error. STOP
Transmission locked
in neutral position
(Shutdown).
520434 7 92.07 7F0F2 Gear control position. STOP
Transmission locked
in neutral position
(Shutdown).
520434 8 92.08 7F0F2 Signal error. STOP
Transmission locked
in neutral position
(Shutdown).
520434 9 92.09 7F0F2 Signal error. STOP
Transmission locked
in neutral position
(Shutdown).
520434 10 92.10 7F0F2 Signal error. STOP
Transmission locked
in neutral position
(Shutdown).
520434 11 92.11 7F0F2 Signal error. STOP
Transmission locked
in neutral position
(Shutdown).
520434 12 92.12 7F0F2 Signal error. STOP
Transmission locked
in neutral position
(Shutdown).
520434 13 92.13 7F0F2 Signal error. STOP
Transmission locked
in neutral position
(Shutdown).

Operator’s manual DCG 180-330 IDCG02.03GB

204 5 Handling – Error code tables

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520434 14 92.14 7F0F2 Signal error speed STOP
sensor 1-2. Transmission
locked in neutral position
(Shutdown).
520434 15 92.15 7F0F2 Signal error speed STOP
sensor 3. Transmission
locked in neutral position
(Shutdown).
520434 16 92.16 7F0F2 Signal error speed STOP
sensor. Transmission
locked in neutral position
(Shutdown).
520434 17 92.17 7F0F2 Faulty supply voltage. STOP
Transmission locked
in neutral position
(Shutdown).
520434 18 92.18 7F0F2 Signal error sensor. STOP
Transmission locked
in neutral position
(Shutdown).
520434 19 92.19 7F0F2 Signal error pressure STOP
sensor. Transmission
locked in neutral position
(Shutdown).
520434 20 92.20 7F0F2 Incorrect configuration. STOP
Transmission locked
in neutral position
(Shutdown).
520434 21 92.21 7F0F2 Incorrect configuration. STOP
Transmission locked
in neutral position
(Shutdown).
520434 30 92.30 7F0F2 Incorrect configuration. STOP
Transmission locked
in neutral position
(Shutdown).
520435 0 93.00 7F0F3 Memory error, STOP
Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

520435 1 93.01 7F0F3 Memory error, STOP

Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

520435 2 93.02 7F0F3 Memory error, STOP

Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

520435 3 93.03 7F0F3 Memory error, STOP

Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 205

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520435 4 93.04 7F0F3 Memory error, STOP
Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

520435 5 93.05 7F0F3 Memory error, STOP

Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

520435 9 93.09 7F0F3 Memory error, STOP

Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

520435 10 93.10 7F0F3 Memory error, STOP

Transmission control
unit. Switch off the machine
and the main electrical
power.
520435 11 93.11 7F0F3 Memory error, STOP
Transmission control
unit. Switch off the machine
and the main electrical
power.
520436 0 94.00 7F0F4 Memory error, STOP
Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

520436 1 94.01 7F0F4 Memory error, STOP

Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

520436 2 94.02 7F0F4 Memory error, STOP

Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

520436 3 94.03 7F0F4 Memory error, STOP

Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

520436 4 94.04 7F0F4 Memory error, STOP

Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

520436 5 94.05 7F0F4 Memory error, STOP

Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

Operator’s manual DCG 180-330 IDCG02.03GB

206 5 Handling – Error code tables

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520436 9 94.09 7F0F4 Memory error, STOP
Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

520437 0 95.00 7F0F5 Memory error, STOP

Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

520437 20 95.70 7F0F5 Memory error, STOP

Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

520347 31 95.71 7F09B Control unit cannot STOP

interpret input data.
Transmission locked
in neutral position
(Shutdown).
520436 22 95.72 7F09B Memory error, STOP
Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

520436 23 95.73 7F09B Memory error, STOP

Transmission control
unit. Transmission Switch off the machine
locked in neutral position and the main electrical
(Shutdown). power.

520438 0 99.90 7F0F6 Hardware fault. STOP

Transmission locked
in neutral position Switch off the machine
(Shutdown). and the main electrical
power.
520438 1 99.91 7F0F6 CPU overload. STOP
Transmission in
locked neutral position Switch off the machine
(Shutdown). and the main electrical
power.
520438 2 99.92 7F0F6 CPU overload. STOP
Transmission in
locked neutral position Switch off the machine
(Shutdown). and the main electrical
power.
520438 3 99.93 7F0F6 CPU overload. STOP
Transmission in
locked neutral position Switch off the machine
(Shutdown). and the main electrical
power.
520394 31 99.95 7F0CA Communication error, STOP
Transmission control unit.
520438 9 9999 7F0F6 Calibration error STOP
hardware. Transmission
locked in neutral position
(Shutdown).
520417 15 E0.01 7F0E1 Machine's speed is too INFORMATION
high to enable downshift.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 207

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520418 15 E1.01 7F0E2 Machine speed is too high INFORMATION
to enable change of travel
direction.
520419 15 E2.01 7F0E3 Engine rpm is too high to INFORMATION
enable change of travel
direction or select same
travel direction again.
520420 14 E3.00 7F0E4 Machine's speed INFORMATION
limitation is activated.
520420 15 E3.01 7F0E4 Machine's speed INFORMATION
limitation is activated
regardless of if speed is
above the limit value.
520420 16 E3.02 7F0E4 Machine's speed is higher INFORMATION
than the upper limit value.
520421 17 E4.00 7F0E5 Abnormal speed INFORMATION
reduction. The
transmission disconnects
automatic gearing for a
time.
520421 15 E4.01 7F0E5 Abnormal acceleration. INFORMATION
The transmission
disconnects automatic
gearing for a time.
520416 13 E5.01 7F0E0 Time for calibration INFORMATION
reached.
Calibrate the
transmission.
520422 31 E6.00 7F0E6 The operator is not sitting INFORMATION
in the operator's seat and
the gear selector is not in
neutral and/or the parking
brake is not activated.
520423 15 E7.01 7F0E7 Turbine speed exceed the INFORMATION
limit value. Transmission
control unit forces engine
to idle.
520424 15 E8.01 7F0E8 Conditions to switch INFORMATION
between 2WD and
4WD not satisfied.
The machine must be
stationary.
520425 15 E9.01 7F0E9 Conditions to switch INFORMATION
between High and Low not
satisfied. The machine
must be stationary.
520442 1 E.1.01-05 7F0FA - 7F0FD INFORMATION
520443 2
520444 3
520445 4
5

Operator’s manual DCG 180-330 IDCG02.03GB

208 5 Handling – Error code tables

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520442 6 E.1.06 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 9 E.1.07-09 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 10 E.1.10 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 11 E.1.11-13 7F0FA - 7F0FD Calibration error. INFORMATION
520443 12
520444 13
520445
520442 14 E.1.14 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 15 E.1.15 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 16 E.1.16 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 17 E.1.17-24 7F0FA - 7F0FD Calibration error. INFORMATION
520443 18
520444 19
520445 20
21
22
23
24

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 209

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520442 25 E.1.25 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 26 E.1.26 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 28 E.1.28 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 29 E.1.29 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 1 E.2.01-05 7F0FA - 7F0FD Calibration error. INFORMATION
520443 2
520444 3
520445 4
5
520442 6 E.2.06 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 9 E.2.07-09 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 10 E.2.10 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 11 E.2.11-13 7F0FA - 7F0FD Calibration error. INFORMATION
520443 12
520444 13
520445

Operator’s manual DCG 180-330 IDCG02.03GB

210 5 Handling – Error code tables

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520442 14 E.2.14 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 15 E.2.15 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 16 E.2.16 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 17 E.2.17-24 7F0FA - 7F0FD Calibration error. INFORMATION
520443 18
520444 19
520445 20
21
22
23
24
520442 25 E.2.25 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 26 E.2.26 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 28 E.2.28 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 29 E.2.29 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Error code tables 211

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520442 1 E.3.01-05 7F0FA - 7F0FD Calibration error. INFORMATION
520443 2
520444 3
520445 4
5
520442 6 E.3.06 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 9 E.3.07-09 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 10 E.3.10 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 11 E.3.11-13 7F0FA - 7F0FD Calibration error. INFORMATION
520443 12
520444 13
520445
520442 14 E.3.14 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 15 E.3.15 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 16 E.3.16 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445

Operator’s manual DCG 180-330 IDCG02.03GB

212 5 Handling – Error code tables

Table Error codes transmission Dana TE17000FF (continued)

SPN FMI Supplier Supplier code 2 Description Action

code
520442 17 E.3.17-24 7F0FA - 7F0FD Calibration error. INFORMATION
520443 18
520444 19
520445 20
21
22
23
24
520442 25 E.3.25 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 26 E.3.26 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 28 E.3.28 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
520442 29 E.3.29 7F0FA - 7F0FD Calibration error. INFORMATION
520443
520444
520445
- - xx.49 - Undefined failure. STOP

Control unit transmission can generate two states with reduced

functionality to protect the transmission in the event of serious
malfunctions:
• "Limp-home"
In this condition only gear 1-2 in each direction can be used. When
the error occurs the transmission shifts to neutral position. To
continue, set the travel direction selector to neutral position and
select the travel direction again.
• "Shutdown"
In this mode the transmission is permanently in neutral to protect
the transmission.

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 5 Handling – Operating 213

5.4 Operating
5.4.1 While operating
General

DANGER
The machine's work area is large and visibility from
the operator's cab is restricted.
Extreme hazard to personal health and risk of property
damage!
Keep in mind:
• Always check that no persons are in the way of the
machine or its equipment. Also check that the area
upwards is free. If there are unauthorised persons
or vehicles within the work area then the machine
must be stopped.
• The operator must always face in the travel
direction and should operate with special care
where persons or vehicles may appear.
• The operator must adapt the speed to the load and
ground conditions, visibility, and wind conditions,
etc.
• The operator must pay extra attention and operate
with special care near electric power lines,
viaducts, docksides, ramps, doorways, etc.
• Always operate carefully so that the attachment
does not collide with posts, power lines, etc.
• Use available visibility-enhancing equipment such
as rear view mirrors and camera ( ).

WARNING
Never use a machine without first performing the daily
inspection.
Risk of personal injury and property damage!
For work instructions, see 6.1 Daily inspection, page
266. Report to the foreman/supervisor if defects are
found on the machine during daily inspection!

WARNING
Never operate the machine without wearing the
seatbelt.
Extreme danger!
Always use the seatbelt when operating the machine,
even when you expect a short shift. The seatbelt must
not be modified.

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214 5 Handling – While operating

WARNING
The operator must exercise additional caution when
the reverse alarm is switched off.
Extreme danger!
Always check that no persons are in the way of the
machine or its equipment.

WARNING
Don't let the engine idle for a long time.
Risk of engine damage!
Turn off the engine during breaks in operation and
load handling.

Instructions
Make a habit of checking the following at regular intervals while
operating:
• that all gauges are within normal range, optimum operating value is
when the indicator needle is in the centre of the normal operating
range (straight up).
• that fuel indicator on the display shows that there is fuel in the tank.

NOTE
The fuel level should never go down to empty tank.

• that the AdBlue indicator on the display shows that there is AdBlue
in the tank.
Applies to machines with Volvo TAD871VE and Cummins QSB6.7
Stage 4/Tier 4f.
• that all warning lights are off.
• that horn, lighting, brake lights and direction indicators function
correctly.
• that all hydraulic functions function correctly.
• that no error codes have been generated (shown on operator's
display with error code indication and symbol). See 5.3 Error
codes, page 107.

When necessary, the control system can set speed limitations for the
machine. This happens in the event of the following:
• high hydraulic oil temperature.
• pressed down control breaker.
• operator's station not in position straight ahead or straight back,
see Use the revolving operator's station, page 231.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – While operating 215

Automatic stop function

The automatic stop function means that the engine is switched off
automatically when certain conditions are met.

The automatic function monitors special conditions (see below), and

when all are met it starts a countdown before the engine is stopped.
During the countdown, the event menu for the automatic stop function
is shown in the display. The bar in the menu shows the remaining time
to stop as a percentage of the delay time. When the bar is filled the
engine is stopped. The countdown can be interrupted by breaking any
of the conditions for auto-stop. The delay time can be changed by a
Event menu automatic stop function service technician.

Conditions for auto-stopping the engine:

• Machine has reached operating temperature.
• Battery charging status is OK.
• Machine stationary in neutral position at idling speed.
• Load handling functions inactive.
• Parking brake is activated.

When the engine has been stopped automatically, the engine must be
started in the normal way, see 5.4.2 Starting engine, page 217.

This function is always active in ECO mode and cannot be deactivated.

A service technician can activate/deactivate the automatic stop function
for Normal and Power operating modes.

The function for automatic shutdown of the ignition is available

as an option. When the engine is stopped by this function, and the
operator does not activate any functions, the ignition is also shut down
automatically after a certain predetermined time. The time before
shutdown can be set by a service technician.

If the machine is equipped with the automatic start and stop function
then the function will apply ahead of the automatic stop function, see
Automatic start and stop function, page 216.

Operator’s manual DCG 180-330 IDCG02.03GB

216 5 Handling – While operating

Automatic start and stop function

The automatic start and stop function means that the engine is stopped
when the machine is considered to be inactive and the engine is started
automatically when work is resumed.

The automatic function monitors special conditions (see below), and

when all are met it starts a countdown before the engine is stopped.
During the countdown, the event menu for the automatic stop function
is shown in the display. The bar in the menu shows the remaining time
Event menu automatic stop function to stop as a percentage of the delay time. When the bar is fully filled,
the engine is stopped. The countdown can be interrupted by breaking
any of the conditions for auto-stop. The delay time can be set by a
service technician.

Conditions for auto-stopping the engine:

• The machine has operating temperature.
• Battery charging status is OK.
• The operator is sitting in the seat.
• The machine is stationary at idling speed in neutral position
• Load handling functions inactive.

If the parking brake is activated manually (with the control) the bar in
the display is filled immediately, and the engine is stopped immediately.

When the engine is auto-stopped the parking brake is activated

automatically (without the need to move the control). If the engine is
auto-started by depressing the brake pedal then the parking brake
is released.

When the engine has been auto-stopped and is in standby for

automatic start then event menu automatic start function is shown.

If one of the doors is opened then the automatic start function is

temporarily disengaged (the event menu is switched off) until the door
is closed (the event menu is shown again).

NOTE
017365

The automatic start function is disengaged if the operator leaves

the seat. When this takes place, the event menu for the automatic
Event menu automatic start function start function disappears and the engine must be started with the
start button.

When the event menu for the automatic start function is shown, the
engine starts automatically if:
• The accelerator pedal is depressed.
• The brake pedal is depressed.
If the gear selector is in neutral position then the parking brake is
released when the engine is started by means of depressing the
brake pedal.
• Load handling function is activated.
• The start button is depressed.

The machine has a timer for how long the ignition can be activated
after the engine has been auto-stopped. If this time expires then the
ignition is switched off in the same way as during in normal shutdown,
see 5.4.2 Starting engine, page 217. The time for automatic shutdown
of the ignition can be changed by a service technician.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Starting engine 217

Eco Drive Mode

Eco Drive Mode consists of functions for reducing fuel consumption
and thereby environmental impact.
Eco Drive Mode contains three operating modes for how the machine's
fuel-saving functions should operate.
Depending on options, the operating mode can be set via customer
settings, see Setting of Eco Drive Mode, page 256.
Power
• No limitations activated.
• Automatic stop function, see Automatic stop function, page
215. Can be changed by a service technician.
Normal
• Operator guidance, stage 1.
• Performance loss, stage 1.
• Engine limited to idling speed in neutral position and passive
machine.
• Automatic stop function, see Automatic stop function, page
215. Can be changed by a service technician.
ECO
• Operator guidance, stage 2.
• Performance loss, stage 2.
• Engine limited to idling speed in neutral position and passive
machine.
• Automatic stop function, see Automatic stop function, page 215.
If the machine is equipped with the automatic start and stop function
the automatic start and stop functions will apply throughout the Eco
Drive Mode, see Automatic start and stop function, page 216.

5.4.2 Starting engine

General

WARNING
If it's difficult to start the engine, do not use start spray.
Risk of explosion!
In case of start problems, contact service.

Instructions
1. If the machine is equipped with an electric auxiliary heater,
disconnect the electrical cable from the machine .
2. Set the travel direction selector in neutral position or in the position
for activated parking brake.
The travel direction selector must be in neutral position or in the
position for activated parking brake, otherwise it is not possible
to start the engine.
3. Turn the ignition key lock to operating position, position I.
Current is now supplied to all electrical functions.
4. If the machine is equipped with an alcolock, blow in the alcolock .
The alcolock calculates the amount of alcohol in the breath.
In the event of a successful breath test, proceed as follows:
5. Press the start button and hold depressed until the starter motor
starts, release the start button when the engine starts.

Operator’s manual DCG 180-330 IDCG02.03GB

218 5 Handling – Warming up

When needed, the engine's control unit activates preheating during

a time period. The event menu for preheating indicates whether
preheating is activated, see Event menu preheating, description,
page 92.
Engine option Cummins QSB6.7 has automatic preheating without
an indicator for the operator.

NOTE
The starter motor can be activated 20-30 seconds then the circuit
cuts 1.5 to 2 minutes so the starter motor has time to cool. This
is to protect the starter motor.

5.4.3 Warming up
General

CAUTION
Never rev a cold engine at high engine speeds.
Risk of engine damage!
Run the engine at 1400-1500 rpm until it starts to get
warm.

WARNING
Don't let the engine idle for a long time.
Risk of engine damage!
Turn off the engine during breaks in operation and
load handling.

Instructions
Engine
In cold temperatures the machine may not be used for tough work until
the engine and hydraulics are at operating temperature.

If the machine needs to be cold started below 0 °C then an engine

heater and hydraulic oil heater should be used. If the machine is
started below -10 °C without hydraulic oil heater, the pumps may be
damaged in a way that is not covered by warranty.

Start the engine and run it at approx. 1400-1500 rpm until it starts to
get warm. It is very important that the engine is warmed up and the oil
circulates well before the turbocharger starts to operate at high revs.
Never rev a cold engine as this can cause engine damage.

Start working with the machine when the coolant has reached normal
operating temperature, approx. 85 °C, see Engine operating menu,
description, page 80.

Transmission
A cold transmission will not shift at temperatures below -12 °C. The
transmission must be warmed up. Follow the instructions for warming
up the engine.

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 5 Handling – Gearshifting 219

Hydraulic system
Never operate a hydraulic function in the cold until the hydraulic oil is
warm, since there is a risk of damage and leakage in the hydraulic
system.

When the engine has reached its working temperature, warm run the
hydraulic oil by running the mast slowly up and down. Full actuation of
the hydraulic function may not be performed until the tank temperature
is +1 °C.

After this, all other hydraulic functions should be run slowly so that
warm oil circulates through the whole system, and this should be
repeated at least ten times.

NOTE
Hydraulic functions and the steering may feel sticky when the oil
is cold.

5.4.4 Gearshifting
General
The machine is equipped with an automatic transmission. The system
shifts to a lower/higher gear under certain conditions, such as torque,
30
engine speed, travel speed, etc.

A cold transmission will not shift at temperatures below -12 °C. The
transmission must be warmed up, see warming up 5.4.3 Warming
up, page 218.

General about the automatic transmission:

• The transmission is locked in neutral position when the operator is
not sitting in the seat, see Transmission assumes neutral position,
page 222.
• Has a built-in control system, providing optimised operation.
013489

32 31 33 • Shows current gear on the control system display.

• The reversing lock prevents the travel direction being changed too
30. Switch for upshift
quickly, i.e. prevents possible damage to the transmission. The
31. Switch for downshift reversing lock is automatic and is dependent on engine speed
and travel speed.
32. Switch for automatic shifting • Shifting is variable (modulated) and gives smoother operation.
33. Travel direction indicator, Forward Neutral Normally start-up takes place in first gear. Use of first gear is
Reverse governed by engine speed, amongst other things.

Operator’s manual DCG 180-330 IDCG02.03GB

220 5 Handling – Gearshifting

Instructions, seat belt requirement while driving

The machine may be equipped with "Seat belt requirement while

driving" in accordance with the requirement in SIS-ISO/TS 3691–8:2012
4.1.10.

If the machine is equipped with seat belt requirement while driving, the
seat belt must be fastened before a gear can be selected.
1 Ignition on/start the machine to activate the switch in the seat, see
5.4.2 Starting engine, page 217.
2 Activate the seat switch.
3 Fasten the seat belt. Now a gear can be selected, see Instructions,
gearshifting, page 220.

Seat belt requirement can be bypassed, see Switch for by-pass of

safety system (47), page 52. Activate the by-pass switch, select travel
direction and drive the machine to the workshop. Speed is limited to
5 km/h.

WARNING
Safety features are blocked.
B No safety system is engaged! Risk of roll-over and
tipping over!
Only use bypass in emergency situations!
017353

A
A. Switch in driver's seat.
B. Switch in seat belt buckle.

Instructions, gearshifting
1 Deactivate the parking brake by first depressing the service brake
pedal and then move the travel direction selector from the parking
brake position to neutral/gear position.
2 Let the engine run at idle speed. Select travel direction.
a) Travel direction selector
Move the lever (position a):
• forward (F) for travel direction forward.
• reverse (R) for travel direction reverse.
• downwards or upwards (N) for neutral.

a
015234

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 5 Handling – Gearshifting 221

015235
b

Travel direction selector on control lever lift/lower

b) Travel direction selector on control for load handling
Move the switch (position b):
• forward (F) for travel direction forward.
• reverse (R) for travel direction reverse.
• downwards or upwards (N) for neutral.

Travel direction selector on control lever EGO

(joystick)

c) Travel direction selector on mini steering wheel or joystick

Move the switch (position c):
• forward (F) for travel direction forward.
• reverse (R) for travel direction reverse.
• downwards or upwards (N) for neutral.
c
3 Select automatic or manual shifting:
015435

Automatic shifting
1 Activate automatic shifting with the switch for automatic shifting A
(position 32). The system automatically shifts between all gears.
2 Automatic shifting is disengaged if the switch for upshift or
downshift (position 30, 31) is activated.
Manual shifting
1 Machine gearshifting takes place manually with the switch for
upshift or downshift (position 30, 31). The current gear is shown
on the display.

NOTE
In certain circumstances, the transmission may be forced to
reduce speed due to a problem. The control unit may then set
the transmission in "limp home" mode.

Operator’s manual DCG 180-330 IDCG02.03GB

222 5 Handling – Steering

CAUTION
Changing the travel direction must be done with care.
The machine has a reversing lock as standard but
transmission service life is increased if change of
travel direction takes place at a lower travel speed and
engine speed.
Risk of machine damage! Axles may fail!
Change of travel direction must take place within the
limitations set by the reversing lock.

Transmission assumes neutral position

A control breaker senses when the operator leaves the operator's
station. The signal from the control breaker means that the transmission
automatically assumes neutral position. It is not possible to select any
travel direction.

NOTE
If the buzzer sounds when the operator sits in the seat and releases
the parking brake then the control breaker in the seat may be
malfunctioning. It is not possible to select any travel direction. The
function of the switch in the driver's seat must be checked.

The event menu appears if the driver's seat is left without the parking
brake being activated, see The event menu parking brake not activated
and no operator in the driver's seat, description, page 84.

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

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.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Service brake 223

5.4.6 Service brake

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

Use the brakes in a smooth but firm way. Brake pressure remains for
a time after the engine has been switched off, accumulated during
operation. If the accumulator pressure drops below a certain level then
the event menu shows low accumulator pressure. When the event
menu is shown the capacity of the service brake is limited. The buzzer
sounds and speed is limited. Finally, the parking brake is applied
automatically by a forceful spring in the brake cylinder. Check the
11 accumulators' sealing integrity if the pressure does not build up and is
not maintained, see chapter 6 Inspection and maintenance.

015214
12

11. Accelerator
12. Brake pedal

Service brake without inching

The service brake is combined with the declutching pedal. The drive is
declutched completely at a certain brake pressure.

If the brake pedal is applied without declutching taking place then the
engine can assist with braking the machine if the accelerator pedal
is released.

Service brake with inching

Switch for inching (position 29)

Switch for inching (position 29)

Inching is activated/deactivated with the press of a button.

Inching is not activated.

012711

The brake is activated with the brake pedal and declutch takes place
when the pedal is depressed more than half of the pedal range.

Inching enabled.

Inching and braking are controlled with the brake pedal. When you
depress the pedal, the drive starts to slip, so-called inching. If the brake
pedal is pressed down more than half of the pedal range the drive
is completely declutched.

Operator’s manual DCG 180-330 IDCG02.03GB

224 5 Handling – Parking brake

5.4.7 Parking brake

General

DANGER
The parking brake should never be applied when the
machine is moving, unless an emergency requires it.
Very heavy braking. Risk of machine tipping, load
tipping over, being dropped or damage to property
or extreme danger!
Stop the machine before applying the parking brake.

WARNING
Never leave the operator's station 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 travel direction selector (position
1) adjacent to the steering wheel. Activate the parking brake by lifting
the control upward toward the steering wheel and then forward to
the parking brake position. The indicator light for the parking brake
(position 16) is lit red when the parking brake is applied and the event
menu appears, see Event menu parking brake, description, page 89.

To be able to deactivate the parking brake there must be an

accumulated brake pressure or the engine is started in order to reach
the brake pressure required when depressing the brake pedal.

Instructions
The parking brake is applied when:
• When the travel direction selector is moved to the position for the
parking brake (parking brake indicator light is lit red) and the event
menu for parking brake applied is shown, see Event menu parking
brake, description, page 89.
• The ignition is switched off (ignition key lock to 0 position).
When the machine is started again the parking brake is applied
without the travel direction selector being in the position for
activated parking brake. The indicator light for the parking brake
flashes to indicate that the parking brake must be activated and
deactivated with the travel direction selector to release the parking
brake. The light flashes even if the service brake is not activated at
the same time as you try to release the parking brake, even the
event menu is shown, see Event menu release the parking brake,
1 description, page 91.
015215

Check the sealing integrity of the accumulators if pressure is not

built up and maintained, see 6 Inspection and maintenance, page
1. Travel direction selector on steering column 265.

An audible signal is activated if the operator gets up from the driver's

seat without first applying the parking brake and the event menu is
shown, The event menu parking brake not activated and no operator in
the driver's seat, description, page 84.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Parking brake 225

If the accumulator pressure drops below a certain level an error code is

shown in the display. The capacity of the service brake is restricted with
a low accumulator pressure error code. If the accumulator pressure
drops further, the parking brake is applied automatically by a strong
spring in the brake cylinder.

If the machine needs to be moved, see 7 Transporting the machine,

page 308.

Emergency brake
The parking brake can be used as emergency brake in emergency
situations.

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

DANGER
The parking brake should never be applied when the
machine is moving, unless an emergency requires it.
Very heavy braking. Risk of machine tipping, load
tipping over, being dropped or damage to property
or extreme danger!
Stop the machine before applying the parking brake.

Operator’s manual DCG 180-330 IDCG02.03GB

226 5 Handling – Heating / Air conditioning

5.4.8 Heating / Air conditioning

General
The heating (EHC) /air conditioning system (ECC) receives heat
38 39 40 43 from the engine's cooling system and provides heat when the engine
is warm. For ECC the cooling function is generated by the cooling
compressor.
37
If necessary, the air conditioning can be controlled manually with the
36 switches for the fan, heating and air distribution. In addition to this there
are functions for recirculation and defroster.
35 With ECC: In the event of an open door, the air conditioning's cooling
compressor is switched off (cooling function and air drying stop). Close
the door and the cooling function is activated again.
012820
41 42 44 45 46 NOTE
Open windows disrupt air conditioning function and capacity.
Panel for heating and air conditioning system

NOTE
Paper and similar located on the inner front panel can significantly
reduce air conditioning function and performance.

Setting the heating/air conditioning system

1 Activate automatic regulation of the air conditioning (position 39)
to achieve optimal function of the system.
Fan speed, temperature control and air distribution in the cab take
place automatically.
2 Set desired temperature (position 41, 42).
Set the temperature within temperature range 16 °C to 28 °C. See
temperature in 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. (LO) and max. (HI) position respectively.
Cooling is activated/deactivated with the switch for cooling
(position 43) .
3 Align the panel nozzles as follows:
• in cold weather, aim the panel nozzles against the windows,
• in hot weather, aim the panel nozzles upwards.
4 Manual setting the fan's capacity is made with the switch for the
fan (position 38, 40). Return to automatic control with the switch
(position 39).
Manual control is possible in five steps from Off to Max. Fan speed
is indicated by a bar in the operating menu.

NOTE
When the fan is switched off all functions for heating/air
conditioning are stopped.

NOTE
When setting the fan capacity manually, automatic control of the
fan is stopped.

5 Manual setting of air distribution is performed using the switch for

air distribution (position 44, 45, 46).

NOTE
When setting the air distribution manually, automatic control of
the air distribution is stopped.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Heating / Air conditioning 227

6 Normally, recirculation (position 36) and defroster (position 37)

do not have to be used.

NOTE
With EHC it is inappropriate to operate with recirculation unless it
is to avoid temporary exhaust gases or odours from outside.

Mist on windows

WARNING
Misting on the windscreens can lead to limited visibility
from the cab.
Extreme hazard to personal health and risk of property
damage!
Make sure the windscreens are free of mist before
using the machine.

1 Set a warm temperature (position 41). Ideally use the defroster

function.
2 Set a fan speed to a faster position (position 40).
3 Direct air distribution (position 46) and panel nozzles to the
windscreen for good visibility through the windows.
4 Check that recirculation (position 36) is not engaged. Recirculation
may impair effective demisting.
5 Activate defroster (position 37).
The defroster controls the function fan, temperature and damper
015236

position to optimally heat and more quickly dry the air at the
windscreen for faster demisting. The function is active for 6
A minutes.

A NOTE
A. Panel nozzles The defroster function is active for 6 minutes. Check that
temperature control returns to the set value when the defroster
is switched off.

6 If there is a lot of mist, direct the panel nozzles to the windscreen

for optimal demisting.
With ECC: The cooling function will be active and help to
dehumidify the air .

Operator’s manual DCG 180-330 IDCG02.03GB

228 5 Handling – Heating / Air conditioning

Setting the diesel heater

Direct start of heater

The diesel heater is controlled by a separate timer with display, fitted

in the cab. Running time and up to three activation times can be set
using the timer.

If the timer display is in standby mode, it can be activated by means

of a short press on one of the buttons. A short press is less than 2
seconds and a long press is more than 2 seconds.
Direct start of heater
1. The heater is activated directly by means of a long press on button
A. Menu bar 2 (E).
B. Status field/Input field (The exception is if the timer is programmed or if it is in setting
mode.)
C. Selection front / rear
D. Button 1 Shutdown of heater
E. Button 2 1. If the heater is operating, it is shut down by means of a long press
on button 1 (D).
Quick start of heater, with setting of time or temperature
1. By means of a short press on button 2 (E), when the display is
illuminated, there is the option to set target temperature (only
air heater) or the time at which the heater should be running.
The setting is made using the buttons for option (C) and is then
confirmed using button 2 (E).
Activating/deactivating programs (P1, P2, P3)
1. Activate the display.
2. Press front / rear (C) until the P-symbol flashes in the menu bar
(A). Confirm the selection with a short press on button 2 (E).
3. Select program memory (P1, P2, P3) using the buttons for option
(C), confirm with button 2 (E).
4. Set whether the selected program should be active or inactive
using the buttons for option (C). Confirm with button 2 (E)

Change in programs
1. Activate the display.
2. Select program memory (P1, P2, P3) using the buttons for option
(C), confirm with button 2 (E).
3. Select, using the buttons for option (C), the position for settings.
Confirm with button 2 (E).
4. Select, using the buttons for option (C), the desired day or group of
days. Confirm with button 2 (E).
5. Set the start time (hours) using the buttons for option (C). Confirm
with button 2 (E).
6. Set the start time (minutes) using the buttons for option (C).
Confirm with button 2 (E).
7. Set the desired operating mode, heating or ventilation. Use the
buttons for option (C). Confirm with button 2 (E).
8. Set the temperature (only air heating) or for how long the heater
should be activated. Use the buttons for option (C) and confirm
with button 2 (E).

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5 Handling – Heating / Air conditioning 229

Setting the clock

1. Activate the display.
2. Select Settings in the menu bar (A). Use the buttons for option (C)
and confirm with button 2 (E).
3. Select Set time in the input field (B). Use the buttons for option (C)
and confirm with button 2 (E).
4. Set hours using the buttons for option (C) and confirm with button
2 (E).
5. Set minutes using the buttons for option (C) and confirm with
button 2 (E).
6. Press button 1 (D) to return to Settings.
Setting the day of the week
1. Activate the display.
2. Select Settings in the menu bar (A). Use the buttons for option (C)
and confirm with button 2 (E).
3. Select Day of the week in the input field (B). Use the buttons for
option (C) and confirm with button 2 (E).
4. Select the correct day using the buttons for option (C) and confirm
with button 2 (E).
5. Press button 1 (D) to return to Settings.

Operator’s manual DCG 180-330 IDCG02.03GB

230 5 Handling – Stopping the engine - parking

5.4.9 Stopping the engine - parking

General

NOTE
Never disconnect the system voltage with the battery disconnector
when the engine is running! The voltage regulator may be
damaged.

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.

Instructions
1. Stop the machine and set the travel direction selector in the
position for parking brake.
2. Tilt the mast slightly forward so that the underside of the forks can
rest on the ground. Lower the forks to the ground.
3. Let the engine run 1 minute at idle speed before stopping the
engine so that the engine cools down slightly and the turbo
bearings are lubricated.
4. Stop the engine by turning the ignition key lock to position 0.
If the start button (position 15) is pressed for more than one second
when the engine is already running then just the engine is stopped.
If the machine is going to be parked for a long time, e.g. after a
work shift is over, then the battery disconnector should be turned
to the OFF (0) position.
For machines with Volvo TAD871VE and Cummins QSB6.7 Stage
4/Tier 4f:

NOTE
Wait for two minutes before the system voltage is disconnected
with the battery disconnector so that the SCR system has time to
be drained of AdBlue, this is particularly important in cold weather.

Certain machines are equipped with automatic engine stop:

• In case the operator leaves the machine for some time without
stopping the engine, normally 5 minutes.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Turnable operator's station 231

5.4.10 Turnable operator's station

General

Turning the operator's station is primarily used to facilitate operations.

Use the revolving operator's station

The operator's station can, by using the rotate operator's station switch,
be rotated and locked in any position from 0-180 degrees.

Conditions to rotate the operator's station are:

• Control breaker must be inactivated.
• The operator must sit in the driver's seat.
180°
E • The machine speed must be lower than 5 km/h except when the
D operator's station is in zone C where the speed must be below
0.5 km/h.
C • The brake pressure must be above a certain pressure or the
parking brake activated.

B
• Right-hand arm rest in permitted position.
A • For mini-wheel/joystick control, the left-hand arm rest must be
0° lowered .
• Mini-wheel/joystick control disabled when rotating the operator's
station in zone C .

If any of the conditions are not fulfilled, event menus to guide you
through what needs to be changed are displayed, see Event menu
rotate the operator's station, description, page 95.
016607

NOTE
Remember that the angle/position of the back rest may limit the
options for turning the operator's station.

Shift between forward/reverse occurs at the transition from zone C to

either zone B or D. This means that the steering angle is changed
automatically. The function of the travel direction selector is also
adapted to the position of the operator's station.

Lighting such as headlights, brake lights, back-up lights and tail lights
are on both ends of the machine and are automatically switched on
correctly in relation to the direction the operator's station is facing.

Windscreen/window washing is also adapted according to the position

of the operator's station.

Operator’s manual DCG 180-330 IDCG02.03GB

232 5 Handling – Manual regeneration of the engine's after-treatment system

Restrictions in machine functions

The machine's functions have different restrictions depending on which
zone the operator's station is located.

Table Restrictions in machine functions

Zone Limitations
180°
E A No restrictions.
D
B Speed limitation can occur.
C Drive stopped.
C
Load handling functions inactivated.

B D Speed limitation when reversing (direction of forks) and

A driving forward. Speed limitations may be different when
0° driving forward and reversing.
Load handling functions inactivated.
E No speed limitation.
Load handling functions inactivated.
016607

5.4.11 Manual regeneration of the engine's

after-treatment system
Manual regeneration of the engine's after-treatment
system, description
Applies to Cummins QSB6.7 Stage 4/Tier 4f.

Manual regeneration of the after-treatment system can only be

performed if the event menu for regeneration of the engine's
after-treatment system is shown.
014986

Event menu for regeneration of the after-treatment

system

1 Read through the safety section, see Operator’s manual.

2 Make sure that a fire extinguisher is close at hand.
3 Park the machine outside and not in the vicinity of any buildings.
Check that there is no flammable material in the vicinity of the
exhaust system's outlet.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Manual regeneration of the engine's after-treatment system 233

4 Lower the lifting carriage and tilt the mast forward.

5 Select neutral gear position and activate the parking brake.
6 Let the engine run at idle speed.

018177
Machine with forks and lifting carriage in fully lowered
position

7 Select the menu for MACHINE CHECK with or and confirm

with .

8 Select the menu for regeneration of the after-treatment system

with or .
Activate regeneration of the engine's after-treatment system using
. The tick in the box indicates that regeneration is activated.

DANGER
Pay attention to the risk of fire during regeneration of
the after-treatment system.
Fire hazard!
Check that there is nothing flammable in the vicinity
of hot components.

WARNING
Hot exhaust system!
Risk of burn injuries!
Never touch hot components, e.g. turbo, exhaust pipe,
silencer or catalysts!

9 Leave the menu with .

Operator’s manual DCG 180-330 IDCG02.03GB

234 5 Handling – Load handling

5.5 Load handling

General
During all lifting work, make sure that the max. lift capacity is not
exceeded, see machine plate or load diagram.

The forklift's capacity is indicated by three parameters:

018139
• position of load's centre of gravity
• lifting height

300 mm
• weight of the load

The capacity varies between models and versions, see the machine
Transport position and type plates, section 3.2 Plates.

NOTE
The operator must sit in the driver's seat in order for the load
handling functions to work.

It is important to estimate the position of the centre of gravity. If the

machine appears to be side-heavy, the load should be lowered and
adjusted with side shift so that the load's centre of gravity is moved to a
position along the machine's centre line.

The function load handling refers to, e.g., to lift, lower, rotate, angle or
hold loads. Load handling also includes lifting devices for handling
018152

different types of load, e.g. sidelift attachment.

Load handling subfunctions:

Transport position

• Lift/lower
018140

Lift and lower

• Tilt
018141

Tilt

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Load handling 235

• Side shift

018142
Side shift

• Spreading (positioning)

018143

Spreading (positioning)

• Levelling
018144

Levelling

• Rotation, only for top lift

018157

Rotation

Operator’s manual DCG 180-330 IDCG02.03GB

236 5 Handling – Load handling

Overload system

The machine can be equipped with an overload warning system.

Warning systems must ALWAYS be functional! The system is used for
stationary load handling, so that the machine's strength and forward
stability are not jeopardised.

When the machine approaches the stability limit, the following takes
place:
• buzzer in the cab sounds (indication to operator)
See 2.1 Safety and emergency equipment, page 8.
• warning figure is shown on the display (indication to operator)
See:
Event menu overload lift, description, page 87
Event menu overload tilt, description, page 87
Event menu overload lift and tilt, description, page 88
• load handling movement is stopped.
In this mode, the mast, and with that the load, can only be lowered
and then tilted out so that the buzzer stops and the display figure
is cleared.

The overload system is not intended for controlling lateral stability or

stability during operation. In addition, it does not take sloping ground
conditions into consideration.

For advice on the handling of the machine, see section 2.4 Keep in
mind, page 11.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Lifting load 237

5.5.1 Lifting load

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

There are three types of top lift attachment

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

This manual describes lifting using forks, and lifting using the top lift
attachment fitted on inverted forks.

DANGER
Respect the lifting capacity of the machine and
exercise the greatest caution during load handling:
• Never handle unstable or loosely loaded goods.
Take great care when handling long, high or wide
goods to prevent the load from sliding off, being
damaged or tipping the machine.
• Remember not to exceed the maximum load
capacity, see the type plate. If necessary, estimate
the centre of gravity and determine the maximum
load capacity with the help of load diagram located
in the cab.
• Never tilt the mast forward with a load on it.
• No personnel may encroach or stand under a
raised load.
Risk of load tipping over, being dropped or damage to
property or extreme danger!
Make sure that the load is positioned securely before
lifting.

Operator’s manual DCG 180-330 IDCG02.03GB

238 5 Handling – Lifting load

DANGER
Make sure that the lifting equipment is marked with the
capacity data. There must always be a type plate from
Cargotec or other manufacturers with the capacity
data for all attachments.
Extreme hazard to personal health and risk of property
damage!
Make sure that nothing other than approved lifting
equipment or attachments are used.

WARNING
Do not use a machine where the indicator lights are
out of order.
Danger of reduced safety during load handling!
If the indicator lights don't work, stop work with the
machine and repair.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Lifting load 239

Instructions for forks

1 Move forward towards the load, as close as possible.
• Aim to have the machine's centre line towards the load's
centre of gravity.
• The approach angle to the load should be as straight as
possible.
• Tilt the mast forwards slightly.

018145
• Lower the forks as low as possible and adjust the fork
spreading and insert them under the load.
• Tilt the mast backwards so that the forks are horizontal.

NOTE
When handling drums, strive to keep the forks as close together
as possible.

2 Keep the machine at a standstill with the service brake.

Alternatively, apply the parking brake if required and/or shift to
neutral. If necessary, use wheel chocks on the drive wheels.

DANGER
The operator must exercise extra caution during
load handling near electric power lines, by viaducts,
docksides, ramps, doorways, etc.
Extreme danger!
Use the parking brake and stop blocks!

3 Lift the load and tilt the mast backwards.

If the machine seems side heavy - lower the load and change the
lifting point using side shift so that the load's centre of gravity is
along the machine's centre line.

WARNING
018146

Forks (with or without load) are easily manoeuvrable

work tools with great strength.
Extreme hazard to personal health and risk of property
damage!
Make sure that no person stands under a raised
attachment, whether it is loaded or not. Take great
care when driving.

Operator’s manual DCG 180-330 IDCG02.03GB

240 5 Handling – Lifting load

Instructions for top lift attachment

1 Run towards the stack of containers, as close as possible. Strive
to line up the machine's centre line with the centre of the container.
2 Keep the machine at a standstill with the service brake.
Alternatively, apply the parking brake if required and/or shift to
neutral.
3 For adjustable attachment, adjust with spreading to relevant
container length.
Right light, C — Twistlocks unlocked, red light illuminates, indicates
that load is not secured.
4 Position the attachment slightly above the container. Adjust with
rotation, side shift and tilting.
5 Lower the attachment on the container.
The display shows the event menu for contact and indicates when
one to three twistlocks have contact.
018147

6 Middle light, B – Contact, orange light activated, indicates when

all four corner boxes have correct contact against the container,
event menu contact is switched off.
7 Lock twistlocks with the switch for twistlocks, see Switch for
twistlocks, automatic/manual locking (58), page 54.
If automatic locking of twistlocks is used, locking is automatic when
the attachment is in contact with the load.
Locking alternative is selected with the switch for automatic or
manual locking, see Switch for twistlocks, automatic/manual
locking (58), page 54.
018148

NOTE
For automatic locking of twistlocks, the parking brake must be
released.

8 Right light, C - Twistlocks unlocked, off.

Left light, A - Twistlocks locked, illuminates with green light and
indicates that load is secured and ready for lifting.
The lift function is disengaged when both right light, C - Twistlocks
unlocked, and left light, A - Twistlocks locked, are off. Left light, A -
Twistlocks locked, is activated with green light when the locking
process has been completed.

CAUTION
018149

Do not start to lift if light C "Twistlocks unlocked" is

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

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Lifting load 241

9 Ready for lifting.

When the container is lifted, the light for contact (position B)
should go out. Use side shift to centre the load so that its lateral
point-of-gravity is along the machine's centre line.

018150

Operator’s manual DCG 180-330 IDCG02.03GB

242 5 Handling – Transporting load

5.5.2 Transporting load

General

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

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Transporting load 243

Instructions for forks

1 Lift the load slightly. Back away from the loading site.
2 Adjust the mast and load height to transport position.
Correct transport position is with the load as far down and in as
possible without obstructing visibility, see Transport position, page
243. The load's centre of gravity must be centred laterally.

018146
Instructions for top lift
1 Lift the load slightly. Back away from the stack.
When the load is lifted, the middle light, B - Contact, (orange), is
off. The function for twistlocks is then disengaged.
2 Adjust load height and tilt angle to transport position. See
Transport position, page 243.
018150

Transport position
Instructions for forks

Instructions for forks

When the machine is to be operated with or without a load, adopt
the transport position to minimise the risk of roll-over and imbalance
while operating.
018139

If the load blocks visibility ahead then the machine must be reversed.

NOTE
300 mm

When handling special loads local regulations may apply. Learn

what they are and follow them.
Transport position

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

maximise operator visibility.

When in transport position without a load, the mast must be vertical

and the forks raised slightly above the ground, approx. 300 mm. (See
figure to the left). The forks should, if possible, be spread so that both
300 mm

fork tips are visible, this means the machine's total length including
forks is visible.
018151

Transport position without load

Operator’s manual DCG 180-330 IDCG02.03GB

244 5 Handling – Transporting load

Instructions for top lift

Instructions for top lift

When in transport position, the mast is tilted back and the load lifted for
good forward visibility, see the figure to the left. The load's centre of
gravity must be centred laterally.

018152

Transport position with load

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

maximise operator visibility.

When in transport position without a load, the mast must be vertical and
the attachment raised for good forward visibility, see figure to the left.
018153

Transport position without load

Operating on grades
It is important to operate with extreme care on grades since there's
an increased risk of tipping and rolling over. Remember the angle of
the ramp.
• Operating with a load.
Adjust load height and tilt angle to transport position, see Transport
position, page 243.
Always drive with the lifting attachment upwards in the grade,
regardless of travel direction, i.e. the truck must be reversed down
a grade.
• Operating without a load.
Lower the lifting attachment and tilt back the mast as far as
possible.
018154

Always drive with the lifting attachment upwards in the grade,

regardless of travel direction, i.e. the truck must be reversed down
Operating with a load on grades a grade.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Unloading 245

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 lifting mast and load.

DANGER
If the machine comes into contact with overhead high
voltage power lines. Remain seated and call for help!
Extreme danger!
Remain in the cab. Wait for assistance.

5.5.3 Unloading
General
There are different types of lifting attachments for load handling,
e.g. forks, coil rams and sidelift attachment or top lift attachment for
container handling.

Instructions for forks

1 Move forward and stop in front of the unloading location.
• If necessary, lift the load sufficiently for unloading, but no
higher.
• The approach angle to the unloading location should be as
straight as possible.
• Tilt the mast to vertical position.
018155

2 Move forward slowly until the load is in position above the

unloading surface.
3 Apply the parking brake if desired, or hold the machine stationary
with the service brake. Alternatively, shift to neutral.
4 Lower the load slowly and make sure that it is standing firmly on the
unloading surface, e.g. level ground or the stack of another load.
5 Reverse away slowly from the unloading location and raise/lower
the forks to transport position.

NOTE
For attachments that clamp, e.g. attachment for rolls of paper,
the switch and lever must be activated simultaneously in order for
the attachment to open.

Operator’s manual DCG 180-330 IDCG02.03GB

246 5 Handling – Unloading

Instructions for top lift attachment

1 Run towards the stack of containers, as close as possible.
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. Alternatively, shift to neutral.
4 Position the load over the stack. Adjust with rotation, side shift
and tilting.

018156
5 Lower the load.
When contact is obtained, the middle light, B - Contact, is activated.
6 Open twistlocks. Left light, A - Twistlocks locked, goes out (green)
when release of twistlocks is initiated. Right light, C - Twistlocks
unlocked, illuminates (red) when the twistlocks are completely
open.
When releasing twistlocks with activated automatic locking of
twistlocks you must:
a. Activate the switch to open locked twistlocks until the red light
is on.
018149

b. Lift until the yellow light goes out before releasing the switch
to open the twistlock.
Never lift when twistlocks are in the process of being released.

NOTE
Automatically locked twistlocks are also opened manually.

IDCG02.03GB Operator’s manual DCG 180-330

 5 Handling – Functions for load handling 247

5.5.4 Functions for load handling

Scales

The weight of the load is approximated with the operating menu for
scales, see Operating menu scale, description, page 81.

NOTE
The scales must be calibrated regularly with a known weight for
accurate weighing. The weight should be large for the greatest
accuracy.

NOTE
For calibration, contact service personnel.

1 Set the mast vertically.

2 Position the load at the same centre of gravity distance as for
calibration.
3 Perform the lifting movement and then lower the load slowly about
30 cm.
4 Select the operating menu for the scales with or and confirm
with . A border around the row for the current weight (position
b) indicates that the function is activated.
5 The different rows have different functions:
Select row with or . Confirm the selection with .
Undo the selection with .
a. Shows tare weight in tonnes or pounds (lbs).
The value shown in row (a) can be reset to zero (tared) using
the function keys.
Select taring with or .
a. Shows tare weight in tonnes. Switch between taring (current tare weight is displayed) or to
b. Actual weight in tonnes (net weight). no tare (0 shown). Confirm with .

c. Total weight in tonnes (gross weight). b. Current weight in tonnes or pounds (lbs), (net weight).
The value in row (b) can be added to row (c).
Select row (b) with or .
Add the value in row (b) to row (c) with .
c. Total weight in tonnes or pounds (lbs) (gross weight).
The value in the row (c) can be reset.
Select row (c) with or .
The value on row (c) can be reset with .

Leave the menu with .

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248 5 Handling – Functions for load handling

Tilt control

Tilt control always strives to hold the mast and the load vertically. The
system is load compensating and also takes into account the machine's
displacement when the load is picked up/put down. Compensation
for loading takes place after the lifting/lowering function has been
completed.

The function for tilt control is activated with the switch (position A).
1 Perform load handling, e.g. lifting/lowering the load.
2 Activate the function for tilt control with the switch (position A).
Indicator light (orange) in the roof panel gives the status:
• The light flashes: The mast's vertical position is being
adjusted.
• The light comes on with a constant light: The mast is in the
vertical position.
• The light has gone out: Tilt control is not active.
3 Continue with load handling.
Tilt control works continuously until the function is deactivated
Tilt control is deactivated:
• If the tilt control switch (position A) is depressed.
• If the tilt function is activated with the linear lever for tilt or the
control lever.
• If the operator moves from the driver's seat. Tilt control stops
after 2 seconds.
A. Switch for tilt control
• If the hydraulic control breaker is depressed.
• In the event the lift or tilt function is overloaded.

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 5 Handling – Functions for load handling 249

Height warning

A Height warning warns when the set lifting height is reached. Height
warning is adjustable according to customer requirements.

When the mast reaches a certain preset height (position A), the
machine warns and the event menu is shown.

The event menu on the display is always shown when the lifting
height exceeds the set lifting height, see Event menu height warning,
description, page 87.

018159

Height limitation

Height limitation restricts how high the mast can be operated. Height
limitation is adjustable according to the customer needs.

When the mast reaches a certain preset height (position A), the
A machine stops the lift movement and the height limitation event menu
is shown. Lower the mast for continued load handling.

If it is necessary to lift above the height limitation, the function can

be bypassed. Activate the switch for bypassing the safety system
(position 47) and use the lift function. After a few seconds the switch
for bypassing the safety system (position 47) can be deactivated,
lifting/lowering can then be performed without bypassing.

Event menu in the display is always shown when the lift height exceeds
the height limitation, see Event menu height limitation, description,
018160

page 87.

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250 5 Handling – Functions for load handling

Side-lift attachment
General

Max General
Points to consider when handling side-lift attachments with empty
container:

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.

• Before work begins, check the function of the side-lift attachment's

indicator lights.
It is forbidden to use the attachment if the lights give incorrect
018161

indication or do not work.

Using the attachment without functioning indicator lights is a major
Transport position with side-lift attachment
safety hazard.
• The brakes must always be operated smoothly and with great care
according to the prevailing conditions.
• When operating without a load, the side-lift attachment must be
lowered to the lowest position.
• When operating with a load, the machine must be in transport
position, see the figure.
• It is forbidden to drive the machine with a load in a higher position
than that shown in the figure. The side-lift attachment, with or
without load, may only be lifted higher than that shown in the figure
when stacking.
• After stacking, the side-lift attachment must always return to the
transport position (with load) or the lowest position (without load)
before the machine can be operated again.
• During all operation, the mast must be at maximum tilt backwards,
see the figure.
• If forward visibility is obscured by the load, the operator must
always reverse.

WARNING
Side-lift attachments (with or without load) are easily
manoeuvrable work tools with great strength.
Extreme hazard to personal health and risk of property
damage!
Make sure that no person stands under a raised
attachment, whether it is loaded or not. Take great
care when driving.

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 5 Handling – Functions for load handling 251

Hoisting technique
1 Set spreading to the container length in question (position d).
A B C Right light, C — Twistlocks unlocked, red light illuminates, indicates
that load is not secured.
2 Drive slowly toward the container, adjust with side shift (position c).
3 Tilt the mast forward slightly (position b), lower the side-lift
attachment (position a) to the container and fit the two twistlocks
into the locking holes in the container so that both sides of the
attachment are resting on the container. Check that the indicator
light B switches on.
4 Locked twistlocks (position 54).
If automatic locking of twistlocks is used, locking is automatic when
the attachment is in contact with the load.
53 e
d
c NOTE
b For automatic locking of twistlocks, the parking brake must be
a
released.

5 Right light C — Twistlocks unlocked, off.

Left light A — Twistlocks locked, illuminates with green light and
indicates that the load is secured and ready for lifting.

CAUTION
g
015237

54
Do not start to lift if light C "Twistlocks unlocked" is
on, or if any of the lights A "Twistlocks locked" or B
"Contact" are off.
Light panel on attachment.
A. Indicator light for locked twistlocks
The load is not secured!
B. Indicator light for contact Try to lock twistlocks once again.
C. Indicator light for unlocked twistlocks
6 Tilt the mast backward and lift. Check that indicator light B for
53. Control for load handling contact switches off when the container is lifted.
a. Control lever for lifting/lowering 7 Transport the container in transport position. Reverse if the
b. Control lever for tilt container blocks the view.
c. Control lever for side shift 8 Releasing the container: Set the container down on the surface
below. Check that the indicator light B switches on. Release the
d. Control lever for spreading twistlocks. Check that the indicator light C switches on.
e. Control lever for levelling
g. Switch to open the twistlocks NOTE
54. Switch for twistlock, automatic/manual locking. For load handling with the control lever, see the plates on the
machine.

Load counter
The number of lifts is recorded in the operating menu for load counter.
The different counters can be reset to zero separately.
Instructions
1 Select the operating menu for load counter with or and
confirm with . A frame around the row shows the selected
counter.
Undo selection with .
2 Select counter with or . A frame around the row shows the
selected counter.
Undo selection with .
a. Counter 1.
b. Counter 2.
3 Reset the counter to zero with .

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252 5 Handling – Extra hydraulic function

5.5.5 Extra hydraulic function

General

The machine may be prepared for connection of an extra hydraulic

function. On these machines, there are two hydraulic connections on
the lifting carriage for connection to customer-unique equipment. The
hydraulic connections are controlled by their own control lever.

Connection of customer-unique equipment

1 Lift the customer-unique equipment in the intended way with the
machine.
2 Switch off the machine.
3 Connect the equipment's hydraulic couplings to the machine's
hydraulic connections.
4 Start the machine and check the equipment's functions using its
current instructions.
5 Check that the hydraulic connections are sealed tightly.

Example of location of hydraulic connections

5A. Extra function, lever forward.
5B. Extra function, lever backward.

Disconnection of customer-unique equipment

1 Drive the machine to the location where the customer-unique
equipment shall be unloaded.
2 Lower the equipment into its storage area.
3 Switch off the machine.
4 Disconnect the equipment's hydraulic connections from the
machine's hydraulic connections. Refit any protection on couplings
and connections.
5 Start the machine and drive away from the equipment.
6 Check that the hydraulic connections on the machine are sealed.

Example of location of hydraulic connections

5A. Extra function, lever forward.
5B. Extra function, lever backward.

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5 Handling – Customer settings via display 253

5.6 Customer settings via display

5.6.1 Menu for date and time
Description
Setting the time
1 Select menu for customer settings with or and confirm with
.

2 Select SET TIME/DATE with or and confirm with .

a. Setting the date and time
b. Setting units
c. Setting of Eco Drive Mode
d. Setting of automatic start and stop function

3 Select SET TIME with or and confirm with .

014935

4 Adjust the hours with and , confirm with . Continue in this

way with the minutes and seconds. Leave the menu with .
014941

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254 5 Handling – Menu for date and time

Setting the date

1 Select menu for customer settings with or and confirm with
.

2 Select SET TIME/DATE with or and confirm with .

a. Setting the date and time
b. Setting units
c. Setting of Eco Drive Mode
d. Setting of automatic start and stop function

3 Select SET DATE with or and confirm with .

015322

4 Adjust the year with and , confirm with . Continue in this

way with the month and day. Leave the menu with .
014942

Setting the time format

1 Select menu for customer settings with or and confirm with
.

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5 Handling – Menu for date and time 255

2 Select SET TIME/DATE with or and confirm with .

a. Setting the date and time
b. Setting units
c. Setting of Eco Drive Mode
d. Setting of automatic start and stop function

3 Select SET TIME STYLE with or and confirm with .

015323

4 Select the time format 24h or 12h am/pm with or . Leave

the menu with .
014943

Setting of display units

1 Select menu for customer settings with or and confirm with
.

2 Select SET SI/US UNITS with or and confirm with .

a. Setting the date and time
b. Setting units
c. Setting of Eco Drive Mode
d. Setting of automatic start and stop function

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256 5 Handling – Menu for date and time

3 Select SI UNITS or US UNITS with or . Leave the menu

with .

014936
Setting of Eco Drive Mode

The menu is only available if the machine is set for Eco Drive Mode
to be selectable by the operator.
1 Select menu for customer settings with or and confirm with
.

2 Select SET ECO DRIVE MODE with or and confirm with .

a. Setting the date and time
b. Setting units
c. Setting of Eco Drive Mode
d. Setting of automatic start and stop function

3 Select POWER, NORMAL or ECO with or . Leave the menu

with .
For a more detailed description, see Eco Drive Mode, page 217.
017376

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5 Handling – Menu for date and time 257

Setting of automatic start and stop function

1 Select menu for customer settings with or and confirm with

.

2 Select SET AUTO START AND STOP with or and confirm

with .
a. Setting the date and time
b. Setting units
c. Setting of Eco Drive Mode
d. Setting of automatic start and stop function

3 Select off or on with or . Leave the menu with .

For a more detailed description, see Automatic start and stop
function, page 216.

Setting of increased engine speed for load handling.

1 Select menu for customer settings with or and confirm with
.

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258 5 Handling – Menu for date and time

2 Select AUTO RPM FOR LOAD HANDLING with or and

confirm with .

020230
3 Change the setting for increased engine speed for load handling
(lift, tilt in, other functions) with or and confirm with . Leave
the menu with .
020229

Setting of sensitivity for joystick control or mini-wheel

1 Select menu for customer settings with or and confirm with
.

2 Select SET COMFORT STEERING with or and confirm

with .
020231

3 Set the sensitivity of the joystick with or and store the value
with .
The sensitivity is set in stages where 0 = no deflection and 10
= max valve deflection.

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 5 Handling – Menu for active error codes 259

5.6.2 Menu for active error codes

Description
1 Select the menu for ACTIVE ERRORS with or and confirm
with .

a b c 2 The menu shows the active error codes.

Scroll through the error codes with or . Leave the menu
with .
d
a. Device that generated the error code.

k e b. Component error code concerns (SPN code).

c. Type of error (FMI code).
d. Number of active error codes. The first digit shows the error
j being displayed, the second digit the number of active error
codes.

i e. Information can be found in the operator's manual.

f. Symbol for the device that generated the error code.
014944

h g f g. Symbol for operator action.

h. Symbol for the error code level.
i. Number of error codes with the level INFORMATION.
j. Number of error codes with the level WARNING.
k. Number of error codes with the level STOP.
For more information, see Error codes, general, page 107.

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260 5 Handling – Menu for inactive error codes

5.6.3 Menu for inactive error codes

Description
1 Select the menu for INACTIVE ERRORS with or and confirm
with .

2 The menu shows the inactive error codes.

Scroll through the error codes with or . Leave the menu
with .

For more information, see Error codes, general, page 107.

014945

5.6.4 Menu for statistics and history

Description

1 Select the menu for running times with or and confirm with .

2 The menu shows the cumulative operating time for the machine's
components. This counter cannot be reset.
a. Operating time engine in hours.
b. Operating hours for transmission, with gear activated, in hours.
c. Operating hours for hydraulic functions activated, in hours.
d. Proportion of engine operating hours at idling speed, in
percent.
Select the next statistics and history menu with or go back with
. Leave the menu with .

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5 Handling – Menu for statistics and history 261

3 The menu shows resettable operating time, since the last reset
for the machine's components.
a. Operating time engine in hours.
b. Operating hours for transmission, with gear activated, in hours.
c. Operating hours for hydraulic functions activated, in hours.
d. Proportion of engine operating hours at idling speed, in
percent.
Select which row should be reset by pressing momentarily.
Select row with or . Reset the row with .
Reset all rows by pressing for more than 2 seconds.
Select the next statistics and history menu with or go back with
. Leave the menu with .
4 The menu shows driving distances.
a. Cumulative driving distance in km or miles. This counter
cannot be reset.
b. Driving distance odometer 1 since last reset to zero in km or
miles.
c. Driving distance odometer 2 since last reset to zero in km or
miles.
Select which row should be reset by pressing momentarily.
Select row with or . Reset the row with .
Reset all rows by pressing for more than 2 seconds.
Select the next statistics and history menu with or go back with
. Leave the menu with .
5 The menu shows accumulated fuel statistics. This counter cannot
be reset.
a. Total fuel consumption in litres or gallons.
b. Average fuel consumption in litres/hour or gallons/hour.
c. Average fuel consumption in litres/100 km or gallons/100
miles.
d. Average fuel consumption in litres/lift or gallons/lift.
Select the next statistics and history menu with or go back with
. Leave the menu with .

6 The menu shows resettable fuel statistics since the last reset.
a. Fuel usage in litres or gallons.
b. Average fuel consumption in litres/hour or gallons/hour.
c. Average fuel consumption in litres/100 km or gallons/100
miles.
d. Average fuel consumption in litres/lift or gallons/lift.
Select which row should be reset by pressing momentarily.
Select row with or . Reset the row with .
Reset all rows by pressing for more than 2 seconds.
Select the next statistics and history menu with or go back with
. Leave the menu with .
7 The menu shows accumulated load statistics. This counter cannot
be reset.
a. Total number of lifts.
b. Average lift rate in number of lifts/hour.
Select the next statistics and history menu with or go back with
. Leave the menu with .

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262 5 Handling – Menu for statistics and history

8 The menu shows resettable load statistics.

a. Number of lifts counter 1.
b. Number of lifts counter 2.
c. Average lift rate in number of lifts/hour.
Select which row should be reset by pressing momentarily.
Select row with or . Reset the row with .
Reset all rows by pressing for more than 2 seconds.
Select the next statistics and history menu with or go back with
. Leave the menu with .

9 The menu shows resettable load statistics.

a. Cumulative lifting load of 1000s of tonnes. This counter
cannot be reset.
b. Total lifting load since last reset to zero in tonnes.
c. Average load per lift since last reset to zero in tonnes/lift or
pounds/lift.
Select which row should be reset by pressing momentarily.
Select row with or . Reset the row with .
Reset all rows by pressing for more than 2 seconds.
Select the next statistics and history menu with or go back with
. Leave the menu with .
10 The menu shows resettable load and fuel statistics.
a. Average lifting load since last reset to zero in tonnes/hour or
pounds/hour.
b. Average fuel consumption since last reset to zero in litres/hour
or gallons/hour.
c. Average fuel consumption since last reset to zero in litres/100
tonnes or gallons/100 tonnes.
Select which row should be reset by pressing momentarily.
Select row with or . Reset the row with .
Reset all rows by pressing for more than 2 seconds.
Select the next statistics and history menu with or go back with
. Leave the menu with .
11
The menu shows the cumulative statistics for the automatic start
and stop function.
a. Average fuel consumption in litres/hour or gallons/hour,
including the time that the engine has been auto-stopped.
b. The time that the engine has been switched off by the
automatic start and stop function in hours, including the time
that the engine has been auto-stopped.
c. Number of automatic engine stops.
Select the next statistics and history menu with or go back with
. Leave the menu with .

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5 Handling – Menu for services and settings 263

12
The menu shows the resettable statistics for the automatic start
and stop function.
a. Average fuel consumption in litres/hour or gallons/hour,
including the time that the engine has been auto-stopped.
b. The time that the engine has been switched off by the
automatic start and stop function in minutes, including the time
that the engine has been auto-stopped.
c. Number of automatic engine stops.
Select which row should be reset by pressing momentarily.
Select row with or . Reset the row with .
Reset all rows by pressing for more than 2 seconds.
Select the next statistics and history menu with or go back with
. Leave the menu with .

5.6.5 Menu for services and settings

Description
Used for diagnostics, calibration and settings on the machine by
authorised personnel. Access code required.
014981

5.6.6 Menu for machine check

Menu for machine check, description
1 Select the menu for MACHINE CHECK with or and confirm
with .

2 The menu shows lamp checking. This function switches on all the
lights on the machine in order to facilitate daily inspection.
Switch on all the lights on the machine with . The tick in the box
indicates that the lights are switched on.

NOTE
Run the engine at idle in order to prevent discharge of the
batteries.

Select the next menu with or go back with . Leave the menu
with .

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264 5 Handling – Menu for machine check

3
The menu shows central lubrication. This menu activates the
central lubrication for extra lubrication or function check of the
central lubrication.
Activate the central lubrication's main units with . The tick in the
box indicates that a lubrication cycle is activated.
Select the next menu with or go back with . Leave the menu
with .

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6 Inspection and maintenance 265

6 Inspection and
maintenance
General
This chapter describes:
• DAILY INSPECTION - performed by the operator.
Daily inspection describes the running inspection that significantly
contributes to making the machine a safe and reliable workplace.
• MAINTENANCE - performed by the operator.
Maintenance describes some simple maintenance actions.
• SERVICE - performed by trained service technician.
Service is performed according to a service schedule and by
service technicians. Service is described in the maintenance
manual.
It is the operator who is responsible for ensuring that the machine
comes in for service according to prescribed service intervals.
Procedures are described in the maintenance manual.
• ERROR CODE INFORMATION - read off by the operator.
Error code information is read off by the operator from the control
system's display in the cab. Depending on the type of error code, it
is handled by the operator or a service technician.

NOTE
All time information refers to operating time, that is, the time shown
by the hour meter on the panel.

CAUTION
Only spare parts approved by Cargotec may be used.
This is to maintain the machine's safety as well as to
meet warranty and service agreements!
Only use spare parts and fluids approved by Cargotec
to fulfil warranty terms.

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266 6 Inspection and maintenance – Daily inspection

6.1 Daily inspection

General
Daily inspection of the machine is extremely important in order to
ensure that it is safe both for the operator and its surroundings.

Every operator should perform checks before a new work shift. In this
way, operators can avoid running defective machines with malfunctions
that have been generated or caused during an earlier work shift.

WARNING
Never use a machine without first performing the daily
inspection.
Risk of personal injury and property damage!
For work instructions, see 6.1 Daily inspection, page
266. Report to the foreman/supervisor if defects are
found on the machine during daily inspection!

Instructions
Perform the following checks:
1. Visual inspection of the machine's exterior and engine
compartment. Pay attention to odours from fuel or electronic
equipment. Walk around the machine and check the following:
• Leakage from engine, fuel and AdBlue systems, transmission,
drive axle, steering cylinder, hydraulic hoses and hydraulic
cylinders.

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

• Loose wheel nuts.

Following a wheel replacement, check-tightening of the bolted
joints is very important (after approx. 4-5 operating hours).
• Damage to rims.
• Uneven tyre wear - remove any objects that may penetrate the
tyres, e.g. glass, metal filings, etc.
• Any blisters or damage to the tyres - contact service
immediately to replace tyres that are blistered or damaged.
• Tyre pressure.

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6 Inspection and maintenance – Daily inspection 267

• Damage or cracks in vital components and their mountings

such as lifting chains, fork mountings, mast and tilt cylinders.

DANGER
Cracks in materials or welds in load bearing structures
can reduce the machine's strength.
Extreme hazard to personal health and risk of property
damage!
If there are cracks in materials or welds in
load-carrying structures/structural elements, the
machine shall be taken out of use immediately
and taken for repair. Contact Cargotec for repair
instructions.

• that pins and bolts for the lifting equipment and other vital
parts are firmly affixed.
• If the machine is equipped with sidelift attachment or top lift
attachment, check that sensors for twistlocks and contact are
clean and free from grease.
• Cab with regards to damage and dirty windows, rear view
mirrors.
Also check that the cab is locked to the chassis.
• If the machine is equipped with hydraulic oil cooler, check that
it is in working order.
2. In cold weather:
• Check that wiper blades have not frozen to the windscreen.

WARNING
Attempting to manually move the wiper armswill
damage the wiper motor's gear or shaft.
Damage to the wiper motor's gear or shafts.
Never try to manually move the wiper arms.

• Remove snow and ice from air inlets and radiator grill.
• Antifreeze in washer fluid.
• Disconnect the electric auxiliary heater for the cab and engine
. The auxiliary heater for the engine does not heat the
AdBlue tank and AdBlue hoses.
3. Check fluid levels for the following fluids in accordance with the
description, see 6.2 Maintenance, page 271. Top up, if necessary,
with the correct fluid:
• Hydraulic oil.
• Oil for brake system .
• Coolant.
• Washer fluid - windows.
• Engine oil, see Engine oil, general, page 285.
• Transmission oil.
4. Check the engine:
• Check the engine's air filter indicator, also check and drain
the water separator under the fuel prefilter if required (Volvo
engine) and the fuel filter (Cummins engine). For a description,
see Air filter engine, general, page 283 and Fuel system,
general, page 276.

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268 6 Inspection and maintenance – Daily inspection

5. Cab, internally:
• Check that everything is in order in the cab.
• Check that everything is clean in the cab.
• Check that the operator's manual for the machine is in the cab.
6. Start the machine according to instructions and check:
• Instruments - warning lamps, indicators, any error codes.
• Fuel level - the gauge must not show empty tank.
• AdBlue– level - the gauge must not show empty tank.
Only applies to certain engine options.
Operating the machine without AdBlue leads to restricted
engine power output. In serious cases, a service technician
may need to reset the engine in order to regain full
performance.
• Lighting, direction indicators, signal, brake lights, warning
lights and reflectors, check function and rectify any damage.
All the lights on the machine can be switched on simultaneously
with the menu for machine check, see Menu for machine
check, description, page 263.
• Windscreen wipers.
• Check that mirrors are intact, clean and well-adjusted for
visibility all around the machine.
• Cooling function in the ECC .
7. 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.
8. Run all functions with hydraulic cylinders (lift, tilt, side shift and
spreading) to their end positions for lubrication of the cylinder
barrels and piston rods.

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 6 Inspection and maintenance – Daily inspection 269

2 9. If the machine is equipped with sidelift attachment or top lift

attachment, check the lift attachment and that:
• Indicator lights for twistlocks and contact are working.

WARNING
1 Make sure that the engine is off when working with
twistlocks.
Twistlocks can be locked automatically if all sensors
for contact are activated manually at the same time.

• The contact pins for the twistlocks can be moved up and down
easily. Note that a contact pin that binds in the upper position
can indicate contact despite the frame not being positioned
against the container.
• Check the function of the twistlocks. This is done by lifting an
empty container until the light "Contact" goes out. It should not
now be possible to open the twistlocks.

5
007007

1. Sensor twistlock
2. Sensor contact
3. Lock guide
4. Lift pin
5. Contact pin

10. For central lubrication :

Make sure grease has not seeped out from the safety valve
(position A). This is a sign that the central lubrication is not working
properly.
11. Check the machine's operating hours - notify the
foreman/supervisor if the machine is close to a service interval.
12. Notify the foreman/supervisor immediately if any defects are
detected on the machine.

WARNING
A Safety valve
B Filler nipple Do not use the machine if the system for locking
containers does not work.
Extreme hazard to personal health and risk of property
damage!
Use of the machine must be discontinued, and it has to
be taken to a service workshop for needed actions.

13. Check if any error codes are active.

See 5.3 Error codes, page 107.

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270 6 Inspection and maintenance – Daily inspection

14. Make sure that AdBlue is drained from the hoses when the
machine is turned off. The AdBlue– pump can still be heard for
short time after the engine has been switched off.
The system voltage must not be cut with the battery disconnector
before the pump has stopped.
Only applies to certain engine options.

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6 Inspection and maintenance – Maintenance 271

6.2 Maintenance
General
The following maintenance actions are described in this chapter:
– Cleanliness, general, page 274
– Fuel system, general, page 276
– Windscreen washer, general, page 281
– Wiper blades, general, page 282
– Air filter engine, general, page 283
– Cooling system, general, page 284
– Engine oil, general, page 285
– Transmission oil, general, page 287
– Hydraulic system, general, page 288
– Oil, brake system, general, page 289
– Tyres and rims, general, page 290
– Checking the accumulator, page 293
– Central lubrication, general, page 294
– Battery and battery disconnector, general, page 295
– Fuses for electrical system, general, page 297
– Lighting, general, page 305

Safety during maintenance

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

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272 6 Inspection and maintenance – Maintenance

Tilting the cab

WARNING
Never work under a cab that is not tilted over its
balance position or secured by other means.
Risk of crushing injury.
Always tilt the cab as far as possible. At the maximum
A,B,D C tilt angle (on a horizontal surface), the centre of gravity
of the cab means that it cannot tip back.

C The cab must always be tilted over its balance position. If the lateral
space is insufficient, the cab must always be secured against accidental
lowering by means of a stay.

A B Preparations:
• Park the machine on a horizontal surface.
• Set the gear and travel direction selector to neutral.
• Tilt the mast forward and lower the forks.
• Apply the parking brake.
• Check that there are no loose items in the cab.
• Close the doors.

Manual tilting
1. Turn both lock handles (position C) so that they are located in their
outer position to loosen the cab from the frame.
2. Turn the pump valve (position B) clockwise.
3. Fit the pump rod in its bracket (position A).
4. Pump until the cab has reached the end position.

NOTE
018185

D
Stop pumping/raising when the cab is at the end position, otherwise
the pump valve will be difficult to turn.
A. Pump rod bracket
B. Pump valve
Manual lowering
C. Lock handle (figure shows the open position)
1. Turn the pump valve (position B) anticlockwise.
D. Control buttons
2. Fit the pump rod in its bracket (position A).
3. Pump all the way until the cab makes contact with the frame.
4. Turn both lock handles (position C) so that they are located in their
inner position in order to lock the cab to the frame.

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6 Inspection and maintenance – Maintenance 273

Electric tilting

1. Turn both lock handles (position C) so that they are located in their
outer position to loosen the cab from the frame.
2. Turn the pump valve (position B) clockwise.
3. Use the control buttons (position D) to raise the cab to the end
position. Depress both buttons simultaneously.

NOTE
Stop pumping/raising when the cab is at the end position, otherwise
the pump valve will be difficult to turn.

Electric lowering

1. Turn the pump valve (position B) anticlockwise.

2. Use the control buttons (position D) to lower the cab until it makes
contact with the frame. Depress both buttons simultaneously.
3. Turn both lock handles (position C) so that they are located in their
inner position in order to lock the cab to the frame.

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274 6 Inspection and maintenance – Cleanliness

6.2.1 Cleanliness
Cleanliness, general
Dirt has a negative impact on performance. Experience shows that
clean machines have fewer malfunctions.

The machine should be washed regularly for optimal functionality.

Keep the following in mind when washing:
• Run the hydraulic cylinders to the inner positions.
• Use mild cleaning agents.
Use a degreaser if necessary. Scrub if necessary.
• Use a high-pressure washer, wide water jet.

CAUTION
High-pressure washing of sensitive
components may lead to short-circuiting and
cause malfunction.
Product damage!
Do not use a high-pressure washer on the
cab, radiator, battery compartment, electric
components, control units, connectors, cable
joints, cylinder seals, stub axles, axle seals and
chains.

NOTE
After washing with de-greaser, the hydraulic cylinders should be run
in and out a few times to obtain satisfactory lubrication once again.

WARNING
The strength of the roof window may be significantly
reduced in case of exposure to substances containing
aromatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the surface layer of the roof window and
clean only with washer fluid or mild detergent. Rinse
thoroughly with lukewarm water afterwards. Replace a
damaged roof window that shows cracks or scratches
immediately!

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6 Inspection and maintenance – Cleanliness 275

CAUTION
Cleaning agents contain different solvents.
Health-hazardous and highly flammable.
Ensure good ventilation when cleaning the machine.
Avoid skin contact, use protective gloves. If you
get dizzy when using cleaning agents, get fresh air
immediately and contact a doctor. If the cleaning agent
has found its way into your eyes, rinse immediately
with lots of water and contact a doctor immediately.

CAUTION
Objects may shoot off when using compressed air for
cleaning.
Risk of injury.
Use protective goggles and protective gloves. Exercise
caution to avoid injury to yourself or those nearby.

For optimum functionality the machine should also be kept clean inside
the cab.
• Plastic material: Vacuum clean, brush/wipe with lightly moistened
rag. Use mild cleaning agent and always wipe down with a lightly
moistened rag and clean water.
• Textile material: Vacuum clean, brush/clean with e.g. furniture or
carpet cleaning agent in accordance with the instructions on the
packaging.

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276 6 Inspection and maintenance – Fuel system

6.2.2 Fuel system

Fuel system, general
Fuel filling is located on the left-hand side of the machine.

NOTE
In order to prevent fuel and AdBlue being filled in the wrong tank,
the filler cap for fuel is black and for AdBlue it is blue.

NOTE
Make sure that the area around the tank cap is clean when
refuelling.
B A
The filler pipe for the AdBlue tank is equipped with an integrated
strainer. The inner diameter of the filler pipe makes it impossible to
fill with an automatic nozzle for diesel. The filler pipe also has an
integrated magnet which can be used for opening the special automatic
018186

nozzle for filling AdBlue.

A. Fuel filler orifice

B. Filling AdBlue. WARNING
Fuel is highly flammable and health hazardous.
Fire hazard! Health hazard!
Handle with great care and avoid all possible ignition
sources, for example, cigarettes, sparks. Avoid skin
contact, use protective gloves. In the event of skin
contact and spills on clothes, wash the skin and
change clothes.

CAUTION
The quality of the diesel affects the service life of the
engine.
Make sure that correct diesel quality is used.
Incorrect diesel quality will lead to after-treatment
system failure resulting in high repair costs.

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6 Inspection and maintenance – Fuel system 277

IMPORTANT
If AdBlue is accidentally poured into the fuel tank this
can lead to the following:
• The engine will not run at full power or not at all.
• Injectors can be damaged.
• Corrosion may arise in the exhaust system between
the turbo and the after-treatment system.
• Expensive repairs.
If fuel is accidentally poured into the AdBlue tank this
can lead to the following:
• The after-treatment system can be seriously
damaged.
• The engine no longer satisfies emission
requirements.
• Expensive repairs.

Fuel
• Always refuel with diesel. For tank volume and fuel quality, see 9
Specifications, page 344.
• Never use additives in the diesel.
• In wintertime, try to fill up immediately after finished operation.
This prevents condensation in the fuel tank. Do not use
anti-condensation agents, for example, alcohol, in the fuel.
• Do not refuel when the engine is running.
• Make sure that the fuel nozzle is connected securely in the filler
pipe (to prevent spills and generation of static electricity).
• Clean around the filler pipe after refuelling and handle used rags,
wiped up fuel, etc. in an environmentally sound manner.

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278 6 Inspection and maintenance – Fuel system

CAUTION
AdBlue can irritate with skin and eye contact and if
inhaled.
Health hazard!
Handle carefully and avoid skin contact, wear
protective gloves. In the event of any contact with
the skin and spillage on clothing, wash the skin with
large quantities of water and change contaminated
clothing and gloves. In the event of eye contact, rinse
thoroughly with water for several minutes and seek
medical advice if necessary. If inhaled, breathe fresh
air and seek medical advice if necessary.

CAUTION
AdBlue spilt on hot components evaporates quickly.
Irritating to the eyes and respiratory system.
Turn your face away. Vaporized AdBlue can act
corrosive to eyes and mucous membranes in the
throat. In the event of eye contact, rinse thoroughly
with water for several minutes and seek medical advice
if necessary. If inhaled, breathe fresh air and seek
medical advice if necessary.

IMPORTANT
Avoid spilling AdBlue on the ground and in
watercourses.
Spillage on the ground must be absorbed with sand or
other absorbent, non-combustible materials.

IMPORTANT
Never fill another AdBlue other than that specified in 9
Specifications.
Risk of damage to the after-treatment system!
Never start the engine if anything other than pure
AdBlue has been filled in the AdBlue– tank.

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6 Inspection and maintenance – Fuel system 279

IMPORTANT
Avoid spilling AdBlue on the machine.
AdBlue is highly corrosive and harmful primarily to
wiring and electrical components.
Clean AdBlue from electrical wiring and components
immediately. If a connector has been exposed to
AdBlue solution then it must be replaced immediately
so that the AdBlue solution does not creep further into
the wiring. AdBlue creeps at a speed of 0.6 m/h in the
wiring. Cleaning with water and compressed air is not
sufficient due to AdBlue oxidising the metal itself.

AdBlue
• Always fill with pure AdBlue. For tank volume and AdBlue quality,
see 9 Specifications, page 344.
• Never use additives in the AdBlue.
• In wintertime, try to fill up immediately after finished operation. This
prevents condensation in the AdBlue tank.
• Do not refuel when the engine is running.
Switch off the engine and wait 2 minutes before refilling AdBlue.
When the engine is switched off AdBlue is pumped back into the
tank. If the engine is not switched off before refilling then there
is a risk of overfilling and leakage, with damage to the machine
and the environment as a result when the engine is switched off
the next time.
• Make sure the nozzle for AdBlue is correctly fitted to the filler pipe.
We recommend that filling equipment with automatic shut-off is
always used in order to avoid overfilling.
• Clean around the filler pipe after refuelling and handle used rags,
wiped up fuel, etc. in an environmentally sound manner.

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280 6 Inspection and maintenance – Fuel system

Fuel prefilter (Volvo engine) and fuel filter (Cummins

engine), instructions

NOTE
The water separator should be drained of water when necessary
or at least every 50 operating hours.

DANGER
The fuel is highly flammable.
Fire hazard! Extreme danger!
Make sure that open flames, sparks, or red-hot/glowing
objects have been extinguished before starting work
on or near the fuel system. Do not smoke near the
machine during work on the fuel system.

1 Turn off the engine and the main system voltage with the battery
disconnector.
2 Position a receptacle under the filter.

019491
018187

Cummins QSB6.7 Volvo TAD817VE

3 Drain the water from the filter.
Use manual force to open the drain valve. Turn until the valve
opens and draining starts, drain until clear fuel is visible. Close the
valve and tighten the cock with manual force.

CAUTION
When closing, do not turn too hard. Overtightening
may damage the threads.

IDCG02.03GB Operator’s manual DCG 180-330

 6 Inspection and maintenance – Windscreen washer 281

WARNING
Fuel on hands.
Rash and irritation.
Avoid skin contact with the fuel, use gloves.

4 Remove the collection container. Handle the fuel as

environmentally hazardous and fire hazardous waste.

6.2.3 Windscreen washer

Windscreen washer, general

CAUTION
The strength of the roof window may be significantly
reduced in case of exposure to substances containing
aromatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
The strength of the roof window may be affected!
Only use clean water with an antifreeze agent, e.g.
antifreeze fluid.

The washer fluid reservoir (position A) is located to the left of the cab's
front edge.

Low washer fluid level is indicated with the event menu, see Event
menu low washer fluid level, description, page 91.
Instructions
018162

1. Check the level in the reservoir. Top up with washer fluid as

required. For volume, see 9 Specifications, page 344.
A. Washer fluid reservoir 2. Add anti-freeze. Select a suitable concentration (dilution
water/anti-freeze fluid) according to the prevailing outdoor
temperatures.

Operator’s manual DCG 180-330 IDCG02.03GB

282 6 Inspection and maintenance – Wiper blades

6.2.4 Wiper blades

Wiper blades, general
Instructions

WARNING
Attempting to manually move the wiper armswill
damage the wiper motor's gear or shaft.
Damage to the wiper motor's gear or shafts.
Never try to manually move the wiper arms.

NOTE
Do not use the wipers on dry or dirty windscreens without first
activating the windscreen washers. The roof window is especially
sensitive to scratching and can be damaged by dry wiping.

Check the condition of the wiper blades; replace damaged wiper blades
in order to reduce the risk of damage to the windows.
Wiper blades, combined windscreen and roof wipers
Instructions
• Roof wiper: Carefully lift the wiper blade's locking arm and detach
the washer hose from the blade's nozzle. Replace the wiper blade,
lock in the wiper blade and refit the washer hose.

NOTE
If the wiper arm is lifted too much then it may be damaged and
wiper blade contact may be affected.

• Rear wiper: Lift the wiper arm, press in the wiper blade's locking
catch (position B) and replace the wiper blade. Check that the
wiper blade is locked in the correct position.
• Windscreen wipers: Undo the wiper blade's attaching bolt (position
C). Carefully lift the wiper arm and replace the wiper blade. Fit
the attaching bolt (position C).

Wiper blades, separate windscreen and roof wipers NOTE

If the wiper arm is lifted too much then it may be damaged and
wiper blade contact may be affected.

IDCG02.03GB Operator’s manual DCG 180-330

 6 Inspection and maintenance – Air filter, engine 283

6.2.5 Air filter, engine

Air filter engine, general
Instructions

NOTE
Poorly filtered induction air can very quickly result in serious engine
damage.

The filter is changed by the service technician during scheduled

inspection and service. When the machine is used in very dusty air, the
filter may be clogged after a relatively short time.

In the induction system, between the engine and air filter (A), there's an
A
indicator (B) which shows red when the air filter is clogged.

The air filter has a dust reservoir (position C) which is normally emptied
during operation by vibration in the induction system. It can also be
emptied manually by shaking it.
Instructions
• Check the indicator regularly and contact service as soon as the
indicator shows a red signal.
• The indicator can be reset to zero.

C
018188

B
A. Position for air filter reservoir
B. Indicator for change
C. Dust reservoir

Operator’s manual DCG 180-330 IDCG02.03GB

284 6 Inspection and maintenance – Cooling system

6.2.6 Cooling system

Cooling system, general
Coolant is filled in the system's expansion tank (position B). The coolant
level with a cold engine must be visible in the sight glass (position C)
on the expansion tank.

Low coolant level is indicated via the event menu, see Event menu low
coolant level engine, description, page 95.

WARNING
A Low coolant level may result in serious engine damage.
B Risk of engine damage!
Never operate an engine with low coolant level.
C

D High coolant temperature is indicated via the event menu, see Event
menu engine coolant temperature, description, page 86.
Instructions
018189

WARNING
A. Position of the coolant container (expansion
tank) The cooling system is pressurised when the coolant is
B. Filling point hot. Steam or hot coolant may spray out.
C. Sight glass Risk of scalding and burn injuries and incorrect
coolant level.
D. Sensor, coolant level
Never open the filler cap when the coolant temperature
is higher than the ambient temperature. Always wait
until the coolant has fully cooled down before checking
the level. Incorrect coolant level may cause engine
damage.

WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
Handle with care. Avoid skin contact. Wear protective
glasses and protective gloves. In the event of skin
contact, wash the skin.

CAUTION
Use approved coolant.
Risk of engine damage and invalidated warranty if
unapproved coolant is used.
Only use coolant approved by the engine supplier
when changing and topping up the coolant.

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 6 Inspection and maintenance – Engine oil 285

IMPORTANT
On machines with ECC or AC it is of the utmost
importance that the engine's cooling system is
refilled with coolant containing the correct mixture of
anti-freeze fluid, otherwise there is a risk that the air
conditioning could freeze and breakdown when used.

• Allow the coolant to cool to the ambient temperature, use the

operating menus to check the coolant level.
• Check the coolant level in the expansion tank. Fill with coolant
approved by the engine supplier as required. For volume, see 9
Specifications, page 344.

6.2.7 Engine oil

Engine oil, general

WARNING
The machine uses oils and lubricants.
Health hazard in the event of protracted skin contact!
Avoid skin contact with oils and lubricants. Use
protective gloves.

A B
The engine's oil filler pipe (position B) and oil dipstick (position C) are
located under the hood.
C To check the oil level, the vehicle must be on level ground and in
service position.
• Check the oil level.
Check the oil level when the engine is warm. Switch off the engine
and wait approx. 5 minutes (wait at least 15 minutes for Cummins
QSB6.7 Stage 4/Tier 4f) before checking the oil level.
018190

Wipe off the oil dipstick before checking.

The oil dipstick has two markings, MAX and MIN, the oil level
should be between these markings.
Cummins QSB6.7 Stage 4/Tier 4f
A. Placement filling and oil dipstick engine oil NOTE
B. Oil filling
The oil dipstick is long on certain machines. Wear gloves.
C. Oil dipstick
• Top up as required with new engine oil (position B). For volume
and quality, see 9 Specifications, page 344.
Fill - wait a moment - check the oil dipstick.

NOTE
Work carefully when filling engine oil to prevent other fluids or
particles from contaminating the oil. Other fluids or particles in the
engine oil means a risk of engine damage.

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286 6 Inspection and maintenance – Engine oil

A B A C B

019492

019493
Cummins QSB6.7 Stage 3A/Tier 3 Volvo TAD871VE Stage 4/Tier 4f
A. Placement filling and oil dipstick engine oil A. Placement filling and oil dipstick engine oil
B. Oil filling B. Oil filling
C. Oil dipstick C. Oil dipstick

IDCG02.03GB Operator’s manual DCG 180-330

 6 Inspection and maintenance – Transmission oil 287

6.2.8 Transmission oil

Transmission oil, general
Instructions

WARNING
The machine uses oils and lubricants.
Health hazard in the event of protracted skin contact!
Avoid skin contact with oils and lubricants. Use
protective gloves.
B A
The transmission's oil filler pipe and dipstick are located under the hood
on the left-hand side of the machine.
Instructions
• Check the oil level.
Check the oil level with the engine idling and the transmission in
neutral position and at operating temperature (60-70 °C).
There are two holes in the oil dipstick that show MIN and MAX. The
bottom hole is MIN and the top one is MAX. The oil level should
be between the two holes when the transmission is warm and at
idling speed in neutral position.
• Wipe off the oil dipstick before checking.

MIN MAX
NOTE
018191

The oil dipstick is long. Wear gloves.

• Top up as required with new transmission oil (position B). For

A. Position for filling point and level checking volume and quality, see 9 Specifications, page 344).
B. Oil dipstick and filling point transmission oil It is recommended to fill the oil when the transmission is at
operating temperature. Top up – wait awhile – check on the
dipstick.

NOTE
Work carefully when filling transmission oil to prevent other fluids or
particles from contaminating the oil. Other fluids or particles in the
transmission oil means a risk of transmission damage.

Operator’s manual DCG 180-330 IDCG02.03GB

288 6 Inspection and maintenance – Hydraulic system

6.2.9 Hydraulic system

Hydraulic system, general
Instructions

WARNING
The machine uses oils and lubricants.
Health hazard in the event of protracted skin contact!
Avoid skin contact with oils and lubricants. Use
protective gloves.
C E A
The hydraulic oil tank is located on the machine's right-hand side.
D Instructions
• Check the oil level (position B) when the oil reaches the working
temperature. All hydraulic pistons should be in retracted position
(pushed in).
The level should be in the middle of the sight glass.
• Top up as required with new oil (position D). For volume and
quality, see 9 Specifications, page 344.
• Check that the oil cooler isn't clogged.
Clean as needed.

B NOTE
Work carefully when filling engine oil to prevent other fluids or
particles from contaminating the oil. Other fluids or particles in the
engine oil involve a risk of damage to the brake system or working
hydraulics.
018197

A. Position for hydraulic oil tank

B. Sight glass
C. Breather filter
D. Filler hole in cover plate for oil filter
E. Oil cooler

IDCG02.03GB Operator’s manual DCG 180-330

 6 Inspection and maintenance – Oil, brake system 289

6.2.10 Oil, brake system

Oil, brake system, general
Instructions

WARNING
The machine uses oils and lubricants.
Health hazard in the event of protracted skin contact!
B D A C E Avoid skin contact with oils and lubricants. Use
protective gloves.

The tank for the brake system is located on the machine's right-hand
side.
Instructions
• Check the oil level (position E).
The level should be in the middle of the sight glass.
• Top up as required with new oil (position C). For volume and
quality, see 9 Specifications, page 344).
• Check that the oil cooler (position B) is not clogged. Clean as
needed.

NOTE
Work carefully when filling brake oil to prevent other fluids or
018196

particles from contaminating the oil. Other fluids or particles in the

brake oil means a risk of damage to the brake system.
A. Oil tank for brake system
B. Oil cooler
C. Filling point
D. Breather filter
E. Sight glass oil tank

Operator’s manual DCG 180-330 IDCG02.03GB

290 6 Inspection and maintenance – Tyres and rims

6.2.11 Tyres and rims

Tyres and rims, general

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

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.
Extreme hazard to personal health and risk of property
damage!
Tighten bolted joints crosswise. Contact a service
technician as required.

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

IMPORTANT
Wheels, tyres and rims are dimensioned and selected
for each machine type so that maximum wheel loads
and travel speeds are not exceeded. For this reason it
is not permitted to change tyre dimension, tyre make,
tyre type, rim type, or rim make without approval from
Cargotec.

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6 Inspection and maintenance – Tyres and rims 291

Changing wheel:
Changing wheels, see Maintenance manual.

DANGER
When changing tyres, deflate first.
Risk of tyre explosion! Extreme danger!
Deflate tyres by loosening and removing the valve.

DANGER
Rim damage makes wheel handling extremely
dangerous!
Risk of tyre explosion! Extreme danger!
Let service personnel change tyres, they have the
competence and authority to handle tyres!

CAUTION
Remove the sensors for tyre pressure monitoring
before the wheels are removed.
Risk of product damage.
The sensors for tyre pressure monitoring are fitted on
the valves and may be damaged when the tyres are
handled.

Inflating tyres
Care of compressor for inflating tyres:
• An air filter with water separator should be installed in the line from
the compressor used for inflating tyres. The water filter minimises
the risk of corrosion on wheel rims.
• Drain the water separator regularly.

DANGER
Never stand in front of a tyre when inflating! Do
not exceed prescribed air pressure, which must be
checked at ambient temperature. When changing
tyre or rim version, another tyre pressure may apply,
contact Cargotec. The plate for tyre air pressure
must be replaced with a plate with the applicable tyre
pressure!
Extreme danger!
Always follow instructions for inflating tyres to avoid
serious accidents.
018163

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292 6 Inspection and maintenance – Tyres and rims

Instructions

Instructions
1 2 3
1. Before inflating, make sure that the rim's lock ring is in the correct
position.

NOTE
If the tyre has been completely deflated, the rim must be dismantled
and checked for damage. Let service personnel change tyres, they

002202
have the competence and authority to handle tyres!

1. Lock ring 2. On machines with tyre pressure monitoring.

2. Rim edge Only remove one sensor at a time in order to avoid mixing them
up. Sensor locations are programmed into the monitoring system;
3. Tapered rim contact a service technician for reprogramming.
3. Connect the compressor with a locking air-chuck to the nipple on
the tyre.
4. Stand at an angle behind the tyre and remain there until inflating
has been completed. This is to avoid being hit by rim parts in the
event of an explosion.
5. Inflate the tyre to the prescribed pressure, see chapter 9
Specifications. When changing tyre or rim version, another tyre
pressure may apply, contact Cargotec.
6. On machines with tyre pressure monitoring.
Refit the sensor for tyre pressure monitoring.

IDCG02.03GB Operator’s manual DCG 180-330

 6 Inspection and maintenance – Checking the accumulator 293

6.2.12 Checking the accumulator

Checking the accumulator
The function of the accumulator (position A) is to maintain even brake
pressure and to maintain brake pressure, and thus braking action, a
short time after eventual loss of hydraulic pressure.

The accumulator is precharged with nitrogen gas.

Instructions

Check the sealing integrity in accordance with the following points if

the event menu for low accumulator pressure, see Event menu low
accumulator pressure, description, page 84, appears in the control
A system display:
1. Start the engine and let it run until the accumulator is filled.
018164 2. Stop the engine.
3. Press down the brake pedal with long pumping brake strokes, with
A. Accumulator a slight delay between each braking action. Count the number of
brake applications until the accumulator is empty, i.e. when the
resistance to depressing the pedal disappears.
It must be possible to brake six times before the accumulator is
drained.
4. Start the engine, let the accumulator charge and repeat the test
a couple of times.

If you cannot make at least six brake applications before the

accumulator is drained, there is something wrong with the accumulator
circuit. Contact service as soon as possible for troubleshooting and
suitable action.

WARNING
The machine's hydraulic system includes accumulators
with high pressure.
Risk of personal injury!
Always exercise extreme caution when working
with the hydraulic system and avoid unnecessarily
remaining close to hydraulic components or hoses.
The accumulators must be drained prior to work in the
hydraulic system (see Maintenance manual).

Operator’s manual DCG 180-330 IDCG02.03GB

294 6 Inspection and maintenance – Central lubrication

6.2.13 Central lubrication

Central lubrication, general

Central lubrication (which replaces the majority of manual lubrication)

consists of a pump unit located in the right-hand cab step that lubricates
selected lubrication points. The lubricant quantity can be adjusted
according to requirements, contact Cargotec Service.

NOTE
Cleanliness when performing work on the central lubrication system
is extremely important. Dirt and debris can cause disturbances
in the system. Naphtha or light petroleum can be used to clean
the system. Do not use e.g. Tri or other organic solvents such as
alcohol, methanol, acetone or the like.
A. Safety valve
B. Filler nipple Instructions
• Maintenance for central lubrication is the filling of lubricant and
checking that all connected lubrication points receive sufficient
lubricant.
• Fill the reservoir up to the "Max" mark through the filler nipple
(position B).
For type of grease, see Oils and lubricants, recommendation,
page 349.
Lubricating grease must be clean from contaminants and must not
change consistency as it ages.
• If the reservoir has become completely empty and is then filled, the
pump may need to be operated for longer in order to provide all the
lubrication points with a sufficient amount of lubricant.
Operate the pump manually with the menu for machine check, see
Menu for machine check, description, page 263.
• The quantity of grease supplied to the lubrication points can be set
via the machine's menus, see the Workshop manual.

IDCG02.03GB Operator’s manual DCG 180-330

 6 Inspection and maintenance – Battery and battery disconnector 295

6.2.14 Battery and battery disconnector

Battery and battery disconnector, general

WARNING
Short-circuiting of battery.
Risk of explosion! Fire hazard! Risk of personal injury!
The battery's terminals must not be connected to each
other or to common grounding point (frame).
B

CAUTION
Always turn off the system voltage at the end of your
shift, when working on the electrical system and when
welding on the machine.
Danger!
Turn off the system voltage with the battery
disconnector. After the engine is turned off, wait a
A while before switching off the system voltage. The
018212

control system for the diesel engine and transmission

performs actions, depending on the model, up to two
A. Battery disconnector minutes after the engine is turned off.
B. Battery cover
The electrical system works with a system voltage of 24 Volt (DC). The
power source consists of two series-connected 12 Volt (DC) batteries
which are charged by an AC alternator with rectifier. The negative
terminal is connected to the body.
The plus terminal is connected to a battery disconnector (position A).
The batteries are located inside of a cover (position B) behind the steps
on the machine's left-hand side.
Starting with booster battery

WARNING
Handle batteries and connectors with great care during
charging and boosting (jump starting). Do not mix
up the battery terminals! Follow the instructions for
starting with a booster battery!
Danger of short circuit! Warning - risk of hydrogen gas
forming! Danger of sparks and fire! Hydrogen gas is
very explosive!
Batteries must always be equipped with covers over
terminals and connections. Connect positive terminals
first. Then connect the negative terminals in order to
avoid sparks that could ignite the hydrogen gas.

1 Switch off the system voltage with the battery disconnector

(position A).
2 Open the battery cover on the machine's left-hand side.
3 Check that the engine on the machine with booster batteries is
switched off.

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296 6 Inspection and maintenance – Battery and battery disconnector

4 Check that the booster batteries are connected in series so that

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

IDCG02.03GB Operator’s manual DCG 180-330

 6 Inspection and maintenance – Fuses for electrical system 297

6.2.15 Fuses for electrical system

Fuses for electrical system, general

D The machine's electrical system is fuse-protected in three levels:

A
• Main fuses
• Distribution fuses
• Fuses

The machine's electrical system is also divided into two electrical

power circuits:
• Battery voltage, i.e. the voltage output in the machine when the
battery disconnector is in position I.
• Ignition voltage, i.e. the voltage output in the machine when the
ignition key lock is in position I provided the battery disconnector
is in position I.

CAUTION
Never use fuses with too high ampere rating.
Risk of cable damage or cable fire!
Follow instructions on the fuse plate for fuse type and
ampere rating.

C B
018205

Fuses on frame
A. Main fuses, F9952-1
B. Distribution fuses, F9952-2, F9954-1
C. Fuses in electronic box frame, F9958
D. Fuses in electronic box cab, F9968

Operator’s manual DCG 180-330 IDCG02.03GB

298 6 Inspection and maintenance – Fuses for electrical system

019477

Fuse plate for the cab electronic box

018225

Fuse plate for the frame electronic box

See also:
• Main fuses, page 299.
• Distribution fuses, page 300.
• Fuses, page 301.

IDCG02.03GB Operator’s manual DCG 180-330

 6 Inspection and maintenance – Fuses for electrical system 299

Main fuses

Main fuses
The machine's main fuses are located inside the battery cover for the
batteries on the left-hand side of the machine.

Table Main fuses F9951

Fuse number / Size Functions

1 / 100 A Fuses everything that is disconnected
with the main switch
2 / 50 A Fuses everything that is not
disconnected with the main switch

018213

1 2

Main fuse in the battery compartment on the frame

Instructions
When checking and changing main fuses:
1 Turn off the system voltage with the battery disconnector.
The engine must be switched off.
See Battery and battery disconnector, general, page 295.
2 Open the battery cover.
3 Remove the plastic cover.
4 Check and change main fuses when necessary.
Fuse plate on the inside of the cover provides information about
each fuse.

Operator’s manual DCG 180-330 IDCG02.03GB

300 6 Inspection and maintenance – Fuses for electrical system

Distribution fuses

Distribution fuses
The machine's distribution fuses are located in the electronic box on
the left-hand side of the machine.

Table Distribution fuses, battery voltage F9952-2

Fuse number /
Size Functions
1 / 50A Frame
2 / 50A Cab

F9952-2
1 Table Distribution fuses, ignition voltage F9954-1
2 Fuse number /
F9954-1 Size Functions
1 1 / 50A Frame
2
2 / 50A Cab
3
3 / 50A Control unit KFU (D7971) and Control unit
KFU (D7972)
4/- -
018214

Distribution fuses in electronic box frame

Instructions
When checking and changing distribution fuses:
1 Turn off the system voltage with the battery disconnector.
The engine must be switched off.
See Battery and battery disconnector, general, page 295.
2 Remove the cover for the electronic box on the frame.
3 Remove the plate with fuses fitted in front of the distribution fuses.
4 Remove the plastic cover.
5 Check and change distribution fuses when necessary.
Fuse plate on the inside of the cover provides information about
each fuse.

IDCG02.03GB Operator’s manual DCG 180-330

 6 Inspection and maintenance – Fuses for electrical system 301

Fuses

Fuses
The machine's fuses are located in the electronic box in the cab (F9968)
and in the electronic box on the left-hand side of the machine (F9958).

Table Fuses battery voltage frame F9958-RD

Fuse number /
Size Functions
RD1 / 15A/30A Control unit engine (D7940) for Volvo
TAD871VE (15A)
Control unit engine (D7940) for Cummins
QSB6.7 Stage 4/Tier 4f (30A).
RD2 / 30A Control unit engine (D7940) for TAD871VE
Control unit engine (D7940) for Cummins
QSB6.7
RD3 / 15A After-treatment system AdBlue pump,
Cummins QSB6.7 Stage 4/Tier 4f
RD4 / 15A After-treatment system heating AdBlue,
Cummins QSB6.7 Stage 4/Tier 4f
RD5 / 5A Courtesy lighting
RD6 / 5A Control unit, transmission (D7930)
RD7 / 5A Tyre pressure monitoring
RD8 / 30A Electric cab tilting

Table Fuses ignition voltage frame F9958-BK

RD1 BK1 GN1

Fuse number /
Size Functions
RD2 BK2 GN2
BK1 / 10A Power supply after-treatment system
RD3 BK3 GN3
Cummins QSB6.7 Stage 4/Tier 4f (10A).
RD4 BK4 GN4
BK2 / - -
RD5 BK5 GN5
BK3 / 5A Start interlock
RD6 BK6 GN6

RD7 BK7 GN7 BK4 / - -

RD8 BK8 GN8 BK5 / 20A Expansion module KEM (Kalmar

Expansion Module)
BK6 / 5A Control unit (D7930) for transmission
-
018215

BK7 / -
BK8 / 5/15A Horn 5A
Fuses in electronic box frame, F9958 Loud air horn 15A

Operator’s manual DCG 180-330 IDCG02.03GB

302 6 Inspection and maintenance – Fuses for electrical system

Table Fuses options frame F9958-GN

Fuse number /
Size Functions
GN1 / - -

GN2 / - -

GN3 / - -

GN4 / - -

GN5 / 10A Constant-loading functions, timer diesel

heater
GN6 / 20A Constant-loading functions, Eberspächer
(diesel heater)
GN7 / 10A Fire extinguishing system
GN8 / 5A Engine compartment lighting

IDCG02.03GB Operator’s manual DCG 180-330

 6 Inspection and maintenance – Fuses for electrical system 303

Fuses battery voltage cab F9968 RD

Table Fuses battery voltage cab F9968 RD

Fuse number /
Size Functions
RD1 / 5A Start up, alcolock, start interlock
RD2 / 15A Control unit KCU (D7901)
RD3 / - -

RD4 / 5A Radio
RD5 / 10A Service, RMI
RD6 / 10A Customer-specific equipment
RD7 / - -

RD8 / 10A Loud horn

Table Fuses ignition voltage cab F9968 BK

Fuse number /
Size Functions
BK1 / 10A Control unit KPU (D7902)
BK2 / 10A Service, RMI , distance warning system
back-up camera
BK3 / 10A Monitor, back-up camera

RD1 BK1 GN1

BK4 / 5A Radio

RD2 BK2 GN2 BK5 / 25A Seat heating, seat belt, ventilation control
driver's seat
RD3 BK3 GN3

RD4 BK4 GN4

BK6 / 10A 24 V socket cab, electrically operated
mirrors , customer-specific equipment
RD5 BK5 GN5

RD6 BK6 GN6

BK7 / 15A Work lights

RD7 BK7 GN7 BK8 / 10A Searchlight

RD8 BK8 GN8

Table Fuses options cab F9968 GN

Fuse number /
018216

Size Functions
GN1 / 25A Heated rear window
Fuses in electronic box cab, F9968 GN2 / 10A Double windscreen wipers front
GN3 / 10A Voltage converter 12/24 VDC
GN4 / - -

GN5 / 5A Revolving operator's station

GN6 / - Motor, left-hand arm rest
GN7 / - -

Compressor, air suspension driver's seat

GN8 / 10A , ventilation feed driver's seat

Operator’s manual DCG 180-330 IDCG02.03GB

304 6 Inspection and maintenance – Fuses for electrical system

Instructions
When checking and changing fuses:
1 Turn off the system voltage with the battery disconnector.
The engine must be switched off.
See Battery and battery disconnector, general, page 295.
2 Remove the cover for the electronic box.
3 Check and change fuses when needed.
Fuse plate on the inside of the cover provides information about
each fuse.
Fuse engine option Cummins QSB6.7

Fuse engine option Cummins QSB6.7

The engine fuse for preheating is located on the right-hand side of
the machine.

Table Fuse engine option Cummins QSB6.7 Stage 4/Tier 4f

Fuse number /
Size Functions
1 / 150A Preheating
1
018217

Fuse engine option Cummins B6.7

Instructions
When checking and changing fuses:
1 Turn off the system voltage with the battery disconnector.
The engine must be switched off.
See Battery and battery disconnector, general, page 295.
2 Check and change fuses when needed.

IDCG02.03GB Operator’s manual DCG 180-330

6 Inspection and maintenance – Lighting 305

6.2.16 Lighting
Lighting, general
It is important to use the right type of bulb for each respective lighting
point, see section 9 Specifications.

Light bulbs can be changed for the following:

• Interior lighting
• Position light
• Headlights, (with high/low beam)
• Back-up light, white
• Work light, glow lights
• Revolving beacon

Direction indicators front replaced complete.

Taillights, brake lights and direction indicators rear are in a single fitting
and are replaced complete.

Operator’s manual DCG 180-330 IDCG02.03GB

306 6 Inspection and maintenance – Service

6.3 Service
General
It's very important that inspections and service are performed at the
recommended intervals.

Service is performed by Cargotec, or by service technicians authorised

by Cargotec.

CAUTION
Service interval must be followed.
This is to maintain the machine's safety as well as to
meet warranty and service agreements!
Use spare parts and fluids approved by Cargotec to
fulfil warranty terms.

Service intervals and actions are described in the maintenance manual.

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

IDCG02.03GB Operator’s manual DCG 180-330

6 Inspection and maintenance – Service 307

WARNING
For safety reasons, the following spare parts may only
be replaced with genuine spare parts:
• Drive axle
• Brake valve
• Accumulator charging valve
• Accumulator
• Steering valve (Orbitrol)
• Control valve steering incl. priority valve
• Steering axle
• Steering cylinder
• Steering spindle
• Hub
• Rim
• Mast, carriage
• Lift cylinder incl. load control valve
• Separate load control valve
• Lifting chains
• Chain tightener and shaft
• Forks, fork carrier
• Main valve load handling
• Tilt cylinder
• Tilt valve
• Twistlocks
• Attachment assembly
• Lifting ears
• Control breaker (for hydraulic function)
• Cab
• Hydraulic cylinder, cab tilt
• Frame
• All control units

Operator’s manual DCG 180-330 IDCG02.03GB

308 7 Transporting the machine

7 Transporting the machine

Safety

DANGER
The machine must be firmly secured for transport! The
machine is heavy and can cause extensive damage in
the event of a fall and similar.
Extreme hazard to personal health and risk of 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.

IDCG02.03GB Operator’s manual DCG 180-330

7 Transporting the machine – Towing 309

7.1 Towing
General

DANGER
The machine cannot be operated or braked if the
hydraulic pressure is lost, e.g., if the engine is off.
Rolling machine! Extreme danger!
If possible, tow with maintained hydraulic pressure.
If it's not possible to have the engine running when
towing, a tow bar must be used! Only tow for short
distances!

CAUTION
Do not try to start the machine by towing.
Causes serious damage to the transmission!
Start the engine according to instructions in the
operator's manual.

Before taking actions and after finished towing, the parking brake
must be applied and the wheels blocked to prevent the machine from
starting to roll.

Extreme care must be observed during towing work to avoid personal

injuries.

When towing, keep in mind:

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

Operator’s manual DCG 180-330 IDCG02.03GB

310 7 Transporting the machine – Mechanical release of parking brake

7.1.1 Mechanical release of parking brake

Description
The parking brake is applied automatically by a forceful spring in the
brake cylinder if the pressure in the hydraulic accumulator(s) should
drop below a certain level.

If the machine has to be moved (towed) without sufficient pressure

in the hydraulic accumulator(s), 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.
Risk of personal injury!
Follow the instructions.

The parking brake is a disc brake on the drive axle's input shaft.
1 Remove protective cover from caliper (position A).
2 Note the nut's position on the bolt and remove the split pin that
A B C
secures the nut.
3 Screw in the nut, this compresses the brake spring. Screw until
the brake pads release from the brake disc.
4 Restore the parking brake function by screwing out the nut to the
same position acc. to item 2. Install new split pin.
5 Refit protective cover on the caliper.

NOTE
The parking brake may have to be adjusted again.
See Maintenance manual.
000835

NOTE
A. Protective cover If the parking brake has been released mechanically, the parking
brake must always be restored in order to give the machine
B. Brake disc for parking brake parking brake function.
C. Connection propeller shaft

IDCG02.03GB Operator’s manual DCG 180-330

7 Transporting the machine – Lifting and transporting the machine 311

7.2 Lifting and transporting the

machine
General
When lifting and transporting the machine, follow the governing safety
regulations.

DANGER
High demands are made of the lifting and transport
equipment, e.g. lifting chains, hooks, etc.
Extreme danger!
Check the equipment and its capacity, lifting slings on
the machine as well as lashing points on the transport
vehicle and machine.

DANGER
Overload of load equipment.
Extreme danger!
Lifting equipment must be dimensioned for the load.
Never walk under hanging loads.

The following actions are recommended when the machine is to be

transported:
• Apply parking brake.
• Turn off the system voltage with the battery disconnector.
• Remove any fragile equipment, e.g. rear view mirrors.
• Secure the machine for transport on e.g. a truck with chains. See
the sign for the machine's weight.
Front: Attach the chains in the eyes on frame left and right-hand
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.
• 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.

Operator’s manual DCG 180-330 IDCG02.03GB

312 7 Transporting the machine – Lifting machine

7.2.1 Lifting machine

Instructions
The machine must be lifted as follows:
1 Fit two lifting slings in the two lifting eyes of the counterweight.
2 Fit two lifting slings in the two lifting eyes of the lifting mast.
Mast with low lifting height does not have lifting eyes. Lifting straps
must be guided round the cut-out for the lift cylinder or in some
other way so that the straps are secured to the mast.
3 The lifting device must be adapted so that the lifting point runs
through the machine's centre of gravity.

018175

7.2.2 Transporting the machine

General
For machines with high lifting height, the mast must be removed to
follow the regulations in force.

Lashing down for transport

The machine must be transported on a trailer that is wide enough to
support the drive axle's inner wheel.
1. Reverse the machine up on the trailer.
2. Run the lifting carriage down completely and tilt the mast forwards
as far as possible.
3. Apply the parking brake and switch off the engine.
4. Turn off the system voltage with the battery disconnector.
5. Anchor the machine's front section with chains fitted with hooks
and a tensioning unit. Attach the chains securely at the anchor
points on the chassis marked with the sign for transport locking
and at the designated anchor points on the trailer.
018176

6. Anchor the machine's rear section with chains fitted with hooks
and a tensioning unit. Attach the chains at the anchor points on the
wheel housings marked with the sign for transport locking and at
the designated anchor points on the trailer.
7. Fold in the rear view mirrors and remove protruding parts, such as
the revolving beacon, to prevent damage during transport.

IDCG02.03GB Operator’s manual DCG 180-330

7 Transporting the machine – Service position 313

7.3 Service position

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

Service position entails:

• The machine is parked, i.e. parking brake applied.
• Lifting carriage lowered and mast tilted forward.
• Engine off.
• System voltage switched off (with battery disconnector).
• If necessary: Lift up the machine on axle stands or back up the
machine on ramps. Axle stands and ramps must be dimensioned

018177
for the machine's weight.

Operator’s manual DCG 180-330 IDCG02.03GB

314 7 Transporting the machine – Attachment of lifting equipment

7.4 Attachment of lifting equipment

General
This section describes how the attachment of lifting equipment should
be performed. It covers both mechanical and hydraulic attachment.

Hydraulic system, depressurising

WARNING
The accumulator is pressurized with gas.
The gas charge pressure is not drained when the
accumulator drain valve is opened. Risk of personal
injury!
Exercise care when working with the accumulator.

Before the hydraulic system is opened

1 Machine in service position see 7.3 Service position, page 313.
2 Depressurise the hydraulic system by opening the accumulator
drain valve on the accumulator charging valve.

DANGER
Extreme danger!
Extreme danger exists when working with hydraulics
when the hydraulic system is pressurised.
Depressurise the hydraulic system. Open the
accumulator drain valve.

3 Check that the accumulator pressure has been released.

Connect the pressure gauge to the measuring outlet for
accumulator pressure on the accumulator drain valve and check
that the pressure is 0 MPa.

NOTE
Keep the accumulator drain valve open for as long as work is in
progress.
018810

Measuring outlet, accumulator pressure

IDCG02.03GB Operator’s manual DCG 180-330

7 Transporting the machine – Assembly of mechanics to mast and carriage 315

After work is completed

4 Close the accumulator drain valve on the accumulator charging
valve and tighten the lock nut.

NOTE
Check that the accumulator drain valve is fully closed and tighten
the lock ring.

5 Switch on the battery voltage.

6 Start the engine and activate the hydraulic functions.
7 Turn off engine.
8 Check the hydraulic connections.

7.4.1 Assembly of mechanics to mast and carriage

General
Ensure that the lifting equipment is firmly attached before operating
the machine.

The hydraulic hoses must be depressurised before assembly.

Depressurise the hydraulic system by opening the accumulator drain
valve. See Hydraulic system, depressurising, page 314.

WARNING
The lifting equipment is classified as a tool.
Extreme hazard to personal health and risk of property
damage!
Make sure that nobody is under the lifting equipment
during the assembly work.

DANGER
Lifting equipment classified as an attachment (for
example, coil ram and paper clamp) must be marked
with a type plate. Machine capacity with the current
attachment must be shown on the capacity plate.
Machine capacity with standard lifting equipment
(mast, carriage and forks) is stated on the machine
plate.
Extreme hazard to personal health and risk of property
damage!
Make sure that nothing other than approved lifting
equipment is used.

Operator’s manual DCG 180-330 IDCG02.03GB

316 7 Transporting the machine – Assembly of mechanics to mast and carriage

Mast

NOTE
Read the safety instructions for the oil before starting work, see
section B Safety.

CAUTION
Do not overfill!
Leakage and environmental damage!
Check the hydraulic oil level with all hydraulic
cylinders fully retracted.

1 Turn off engine.

2 Turn the start key to position 0 and switch off the main electric
power.
3 Connect lifting equipment to the lifting eyes on the mast in a
secure manner so that the mast does not tilt when lifted. Lift the
mast from the ground.
4 The shafts and bearing surfaces must be checked before the mast
is refitted for deep grooves/scratches, fibres must not protrude
above the bearing surface. If there are signs of damage, then the
shaft, bearings and seals must be replaced.
007791

5 Lift the mast so that it is hanging vertically, lift the mast into position.

NOTE
The mast is secured into the frame of the truck with robust shafts
that run in maintenance-free bearings.
It is of the utmost importance that the bearing surfaces are
completely clean during mast installation.
The shafts and bearing surfaces mentioned above must NEVER
be lubricated with oil or grease.

6 Align the mast and position the shafts in their mast mountings.
Then fasten the shafts, fit circlips.
007786

IDCG02.03GB Operator’s manual DCG 180-330

7 Transporting the machine – Assembly of mechanics to mast and carriage 317

7 Use suitable lifting equipment and align one tilt cylinder in position
against the bracket in the mast.
8 Start the engine and activate the tilt function, extend the tilt
cylinder's piston rod until it aligns against the bracket in the mast.
9 Turn off engine.

10 Connect the tilt cylinder to the mast, align the tilt cylinder in position
and fit spacers. Fit circlips.
11 Repeat points 7 to 10 for the other tilt cylinder.
12 Remove the lifting equipment from the mast.

13 Grease connectors with contact grease and connect them together.

Operator’s manual DCG 180-330 IDCG02.03GB

318 7 Transporting the machine – Assembly of mechanics to mast and carriage

14 Remove the plugs and connect the mast's hydraulic hoses in

accordance with the marking.

1
2
3
4
018977

1. Connections for fork spreading

2. Connections for side shift

15 Remove the plugs and connect the hydraulic hoses to the lifting
cylinders in accordance with the marking.
16 Switch on the main electric power and start the engine.
17 Check the sealing integrity of the hydraulic connections.
18 Install the lifting carriage, see Lifting carriage, page 319.
19 Check the mast's functions.
018978

IDCG02.03GB Operator’s manual DCG 180-330

7 Transporting the machine – Assembly of mechanics to mast and carriage 319

Lifting carriage

NOTE
Read the safety instructions for the oil before starting work, see
section B Safety.

1 Start the machine and set the mast vertically.

2 Lift the mast high enough so that there is space for the lifting
carriage.
3 Connect the lifting equipment to the lifting carriage in a secure
manner and drive the machine towards the mast, or position the
lifting carriage in the mast with the lifting equipment.
4 Lower the mast.
5 Machine in service position see 7.3 Service position, page 313.
6 Depressurise the hydraulic system, see Hydraulic system,
depressurising, page 314.
018981

7 Fasten the lifting chain tensioners in the lifting carriage.

018979

Operator’s manual DCG 180-330 IDCG02.03GB

320 7 Transporting the machine – Assembly of hydraulics to mast and carriage

8 Tension the chain with the chain tensioner. Check that the chains
are tensioned equally.
9 Adjust the lifting carriage's lower position so that the carriage
sides cannot run against the bottom plate of the outer mast. Then
measure the ground clearance of the lifting carriage. The distance
must be equal on the right and left-hand sides, with a tolerance of
5 mm. Adjust further with the chain tensioner if necessary.

018980

10 Connect the hydraulic hoses to the lifting carriage in accordance

with the marking.

NOTE
Replace the O-rings. Check that the O-rings are in the correct
position.

11 Detach the lifting equipment.

12 Switch on the main electric power and start the engine.
13 Activate the load handling functions. Check the sealing integrity of
the hydraulic connections.
14 Check the oil level in the hydraulic system with all cylinders in
007718

retracted position. Top up if necessary.

7.4.2 Assembly of hydraulics to mast and carriage

General
The hydraulic hoses must be depressurised before connection.
Depressurise the hydraulic system by opening the accumulator drain
valve. See Hydraulic system, depressurising, page 314.

Carriage
Connect the hydraulic hoses in accordance with the marking and the
following information about the mast.

IDCG02.03GB Operator’s manual DCG 180-330

 7 Transporting the machine – Assembly of hydraulics to mast and carriage 321

Mast FKLD
18–25 tonnes

18–25 tonnes
1. Side shift right
2. Side shift left
3. Spreading in
4. Spreading out
5. Extra function in
6. Extra function out
1 7. Electrical cable
2
3
4 8. Central lubrication
5
6
7

018973
8

28–33 tonnes

28–33 tonnes
1. Side shift right
2. Side shift left
3. Spreading in
4. Spreading out
5. Extra function in
1 6. Extra function out
2
3 7. Electrical cable, central lubrication
4
5
6
018974

Mast FFKD
18–25 tonnes

18–25 tonnes
1. Electrical cable, central lubrication
2. Spreading out
3. Spreading in
4. Side shift left

1 3 5 7 5. Side shift right

6. Extra function out
7. Extra function in
018975

2 4 6
28–33 tonnes

28–33 tonnes
1. Electrical cable, central lubrication
2. Spreading out
3. Spreading in
4. Side shift left

1 3 5 7 5. Side shift right

6. Extra function out, cable for indicator
7. Extra function in
018976

8. Cable for indicator

2 4 6 8

Operator’s manual DCG 180-330 IDCG02.03GB

322 7 Transporting the machine – Forks

7.4.3 Forks
Forks, general
The forks are very heavy. Make sure that they are handled in a safe
manner.

CAUTION
The forks may tip over during fitting and removal.
Product damage! Personal injury!
Handle the fitting and removal of forks in a safe and
cautious manner.

WARNING
Exercise caution when changing forks.
Risk of crushing!

Fitting the roller forks

1 Start the machine and set the mast vertically.
2 Raise the lifting carriage slightly so that it is at just the right height
for fitting the fork.
3 Machine in service position see 7.3 Service position, page 313.
4 Check that the fork to be fitted is firmly anchored with tensioning
straps or similar in e.g. a loading pallet before being fitted to the
lifting carriage. This is in order to prevent the fork from tipping over.
Move the lifting equipment in from the side of the carriage.

CAUTION
The forks may tip over during fitting and removal.
Product damage! Personal injury!
Handle the fitting and removal of forks in a safe and
cautious manner.

5 Connect the axle mounting to the fork using the four screws.

B
017279

A. Screw
B. Axle mounting

IDCG02.03GB Operator’s manual DCG 180-330

 7 Transporting the machine – Forks 323

Removing the roller forks

1 Start the machine and set the mast vertically.
2 Raise the lifting carriage slightly and position a hand truck with
a loading pallet under the fork being removed. Lower the lifting
carriage so that the fork is in contact with the loading pallet. Anchor
the fork with tensioning straps or similar so that it does not tip over
when it is detached from the lifting carriage.
3 Machine in service position see 7.3 Service position, page 313.
4 Fasten the side shift cylinder with tensioning straps or similar.
5 Undo the screws that secure the side shift cylinder to the fork.
6 Remove the fork from the carriage by pulling it sideways.

CAUTION
A
The forks may tip over during fitting and removal.
Product damage! Personal injury!
Handle the fitting and removal of forks in a safe and
B cautious manner.
017279

A. Screw
B. Axle mounting

Operator’s manual DCG 180-330 IDCG02.03GB

324 7 Transporting the machine – Forks

Fitting the roller fork with levelling function

1 Start the machine and set the mast vertically.
2 Raise the lifting carriage slightly so that it is at just the right height
for fitting the fork.
3 Machine in service position see 7.3 Service position, page 313.
4 Check that the fork to be fitted is firmly anchored with tensioning
straps or similar in e.g. a loading pallet before being fitted to the
lifting carriage. This is in order to prevent the fork from tipping over.
Move the lifting equipment in from the side of the carriage.

CAUTION
The forks may tip over during fitting and removal.
Product damage! Personal injury!
Handle the fitting and removal of forks in a safe and
cautious manner.
017284

WARNING
The cylinders for the levelling forks can be retracted or
extended for assembly and removal.
Risk of crushing!
Handle the fitting and removal of levelling forks in a
safe and cautious manner.

5 Connect the axle mounting to the fork using the four screws.

B
017279

A. Screw
B. Axle mounting

IDCG02.03GB Operator’s manual DCG 180-330

 7 Transporting the machine – Forks 325

Removing the roller fork with levelling function

1 Start the machine and set the mast vertically.
2 Raise the lifting carriage slightly and position a hand truck with
a loading pallet under the fork being removed. Lower the fork
completely so that the cylinder is fully retracted and then lower the
lifting carriage so that the fork is in contact with the loading pallet.
Anchor the fork with tensioning straps or similar so that it does not
tip over when it is detached from the lifting carriage.
3 Machine in service position see 7.3 Service position, page 313.
4 Fasten the side shift cylinder with tensioning straps or similar.
5 Undo the screws that secure the side shift cylinder to the fork.

B
017279

A. Screw
B. Axle mounting

6 Remove the fork from the carriage by pulling it sideways.

CAUTION
The forks may tip over during fitting and removal.
Product damage! Personal injury!
Handle the fitting and removal of forks in a safe and
cautious manner.
017284

WARNING
The cylinders for the levelling forks can be retracted or
extended for assembly and removal.
Risk of crushing!
Handle the fitting and removal of levelling forks in a
safe and cautious manner.

Operator’s manual DCG 180-330 IDCG02.03GB

326 7 Transporting the machine – Forks

Attachment of fork for fork carrier system (hook type)

1 Check that the fork to be fitted is firmly anchored with tensioning
straps or similar in e.g. a loading pallet before being fitted to the
lifting carriage. This is in order to prevent the fork from tipping over.

CAUTION
The forks may tip over during fitting and removal.
Product damage! Personal injury!
Handle the fitting and removal of forks in a safe and
cautious manner.

2 Tilt the mast forwards and drive the machine towards the forks.
1 3 Correct with fork spreading and side shift so that the fork bracket
fits against the fork's upper attachment hook.
4
3 Lift slightly and tilt backwards, check that the fork bracket fully
5 grips into the upper attachment hook.
4 4 Lift until the fork is in full contact with the fork bracket.
5 Fit the shaft and secure with bolt and pins.

2
015643

Lifting fork for fork carrier systems (hook type)

1. Fork bracket
2. Lifting fork
3. Bolt
4. Pin
5. Shaft

IDCG02.03GB Operator’s manual DCG 180-330

 7 Transporting the machine – Forks 327

Removal of fork for fork carrier system (hook type)

1 Raise the lifting carriage slightly and position a hand truck with
a loading pallet under the fork being removed. Lower the lifting
carriage so that the fork is in contact with the loading pallet. Anchor
the fork with tensioning straps or similar so that it does not tip over
when it is detached from the lifting carriage.

CAUTION
The forks may tip over during fitting and removal.
Product damage! Personal injury!
Handle the fitting and removal of forks in a safe and
cautious manner.

2 Pull the pin out from the bolt.

1 3
3 Pull the bolt out from the shaft that secures the forks.
4 4 Pull or tap out the shaft so that the fork loosens from the fork
bracket.
5
5 Lower/tilt forward and move away from the fork.
4

2
015643

Lifting fork for fork carrier systems (hook type)

1. Fork bracket
2. Lifting fork
3. Bolt
4. Pin
5. Shaft

Operator’s manual DCG 180-330 IDCG02.03GB

328 7 Transporting the machine – Forks

Attachment of fork for fork carrier system (pin type)

1 Check that the fork to be fitted is firmly anchored with tensioning
straps or similar in e.g. a loading pallet before being fitted to the
lifting carriage. This is in order to prevent the fork from tipping over.

CAUTION
The forks may tip over during fitting and removal.
Product damage! Personal injury!
Handle the fitting and removal of forks in a safe and
cautious manner.

2 Tilt the mast forwards and drive the machine towards the forks.
Correct with fork spreading and side shift so that the fork carriers
fit against the forks' bracket.
3 Fit the shaft and secure with bolt and pins.

Lifting fork for fork carrier systems (pin type)

1. Bolt
2. Pin
3. Ring pin
4. Shaft
5. Lifting fork
6. Fork bracket

IDCG02.03GB Operator’s manual DCG 180-330

 7 Transporting the machine – Forks 329

Removal of fork for fork carrier system (pin type)

1 Raise the lifting carriage slightly and position a hand truck with
a loading pallet under the fork being removed. Lower the lifting
carriage so that the fork is in contact with the loading pallet. Anchor
the fork with tensioning straps or similar so that it does not tip over
when it is detached from the lifting carriage.

CAUTION
The forks may tip over during fitting and removal.
Product damage! Personal injury!
Handle the fitting and removal of forks in a safe and
cautious manner.

2 Pull the pin out from the bolt.

3 Pull the bolt out from the shaft that secures the forks.
4 Pull or tap out the shaft so that the fork loosens from the fork
bracket.
5 Tilt the mast backwards and back the machine away from the forks.

Lifting fork for fork carrier systems (pin type)

1. Bolt
2. Pin
3. Ring pin
4. Shaft
5. Lifting fork
6. Fork bracket

Operator’s manual DCG 180-330 IDCG02.03GB

330 7 Transporting the machine – Forks

Attachment of inverted forks/coil ram for fork carrier

system
1 Operate side shift and fork spreading so that the fork bracket
reaches the right position for forks/coil ram.

1. Upper attachment hook

2. Lock pin
3. Moving locking catch
4. Lower attachment hook
2 Fold out the moving locking catches down onto the forks/coil ram.
3 Tilt the mast forwards and move the machine forwards towards the
forks/coil ram. Correct with fork spreading and side shift so that
the fork bracket aligns against the upper attachment hooks for
the forks/coil ram.
4 Lift slightly and tilt backwards, check that the fork bracket fully
grips into the upper attachment hooks.
5 Lift until the forks/coil ram are in full contact with the fork bracket.
Check that the lower attachment hooks are gripping the lifting
carriage's lower beam.
6 Fold in the moving locking catches and lock with the pins.

Coil ram.
1. Upper attachment hook
2. Lock pin
3. Moving locking catch
4. Lower attachment hook

IDCG02.03GB Operator’s manual DCG 180-330

 7 Transporting the machine – Forks 331

Removal of inverted forks/coil ram for fork carrier

system
1 Position the forks/coil ram in a safe stowage location, e.g. in a
stand.

1. Upper attachment hook

2. Lock pin
3. Moving locking catch
4. Lower attachment hook
2 Fold out the moving locking catches down onto the forks/coil ram.
3 Tilt the mast forwards so that the lower attachment hooks release.
4 Lower slightly so that the upper attachment hooks release and
reverse away from the forks/coil ram.

Coil ram.
1. Upper attachment hook
2. Lock pin
3. Moving locking catch
4. Lower attachment hook

Operator’s manual DCG 180-330 IDCG02.03GB

332 7 Transporting the machine – Forks

Attachment of kissing forks

1 Operate side shift and fork spreading so that the fork carriers reach
the correct position for the forks.
2 Tilt the mast forwards and drive the machine towards the forks.
Correct with fork spreading and side shift so that the fork carriers
fit against the forks' attachment hook.
3 Lift slightly and tilt backwards, check that the fork carrier bracket
fully grips into the attachment hooks.
4 Lift until the forks are in full contact with the fork carriers.
5 Install the pins and insert the bolts.
6 Lock using the pins.

4
3

2
012550

Kissing forks.
1. Attachment hook
2. Shaft
3. Bolt
4. Pin

IDCG02.03GB Operator’s manual DCG 180-330

 7 Transporting the machine – Forks 333

Removal of kissing forks

1 Lower the forks so that they are resting against the surface below,
e.g. in a stand, or anchor them in a loading pallet
2 Pull out the pins from the bolt.
3 Pull out the bolts and pins.
4 Tilt the mast forward and lower slightly so that the attachment
hooks release, and reverse away from the forks.

4
3

2
012550

Kissing forks.
1. Attachment hook
2. Shaft
3. Bolt
4. Pin

Operator’s manual DCG 180-330 IDCG02.03GB

334 7 Transporting the machine – Forks

Attachment of fork carrier

1 Start the machine and set the mast vertically.
2 Raise the lifting carriage so that it is at just the right height for
fitting the fork carrier.
3 Machine in service position see 7.3 Service position, page 313.
4 Check that the fork carrier to be fitted is firmly anchored with
tensioning straps or similar in e.g. a loading pallet before being
fitted to the lifting carriage. This is in order to prevent it from
tipping over.
Move in the fork carrier from the side of the carriage.

CAUTION
The fork carrier may tip over during fitting and removal.
Product damage! Personal injury!
Handle the fitting and removal of fork carriers in a safe
and cautious manner.

5 Connect the axle mounting to the fork carrier using the four screws.

B
017279

A. Screw
B. Axle mounting

IDCG02.03GB Operator’s manual DCG 180-330

 7 Transporting the machine – Forks 335

Removal of fork carrier

1 Start the machine and set the mast vertically.
2 Raise the lifting carriage slightly and position a hand truck with a
loading pallet under the fork carrier being removed. Anchor the
fork carrier with tensioning straps or similar so that it does not tip
over when it is detached from the lifting carriage.
3 Machine in service position see 7.3 Service position, page 313.
4 Check that the fork carrier to be fitted is firmly anchored with
tensioning straps or similar in e.g. a loading pallet before being
fitted to the lifting carriage. This is in order to prevent it from
tipping over.

CAUTION
The fork carrier may tip over during fitting and removal.
Product damage! Personal injury!
Handle the fitting and removal of fork carriers in a safe
and cautious manner.

5 Fasten the side shift cylinder with tensioning straps or similar.

6 Undo the screws that secure the side shift cylinder to the fork
carrier.
7 Remove the fork carrier from the carriage by pulling it sideways.

A
CAUTION
The fork carrier may tip over during fitting and removal.
Product damage! Personal injury!
B Handle the fitting and removal of fork carriers in a safe
017279

and cautious manner.

A. Screw
B. Axle mounting

Operator’s manual DCG 180-330 IDCG02.03GB

336 7 Transporting the machine – Attachment

7.4.4 Attachment
Removal of fork-mounted top lift

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

WARNING
Always make sure that forks, inverted forks or coil ram
are always stored in a safe place.

1 Start the machine and set the mast vertically.

2 Set the length setting at 20'' (adjustable top lift).
3 Set the top lift in a safe stowage location, on an empty container,
for example.
4 Set the rotation in centre position (or extension to min.) so that the
hydraulic pressure is equalised and it becomes easier to detach
the quick couplings. This also prevents unnecessary oil spillage.
5 Machine in service position see 7.3 Service position, page 313.
6 Connect the hydraulic hoses and electrical cable from the top lift to
the quick couplings on the lifting carriage. Check that hoses and
cables are routed so that they cannot be damaged.
7 Unlock the braces behind the forks, set the mast vertical and
reverse away from the top lift.

Attachment of fork-mounted top lift

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

WARNING
Always make sure that forks, inverted forks or coil ram
are always stored in a safe place.

1 Set fork spreading so that the forks fit the fork pockets.
2 Insert the forks into the fork pockets.
3 Machine in service position see 7.3 Service position, page 313.
4 Lock the forks to the top lift with the braces behind the forks.
5 Connect the hydraulic hoses and electrical cable from the top lift to
the quick couplings on the lifting carriage. Check that hoses and
cables are routed so that they cannot be damaged.
6 Check the different functions of the top lift.

IDCG02.03GB Operator’s manual DCG 180-330

 7 Transporting the machine – Attachment 337

Connecting the top lift attachment

1 Operate the side shift and fork spreading so that the forks reach
the correct position for the fork pockets.
2 Insert the forks into the fork pockets.
1 3 Machine in service position see 7.3 Service position, page 313.
2
4 Secure the forks to the top lift attachment with the braces behind
the forks. Lock using bolts and pins.
5 Connect the hydraulic hoses and electrical cable from the top lift

002061
attachment to the quick couplings on the lifting carriage. Check that
hoses and cables have been routed so that they are not damaged.

Top lift attachment, locking braces. 6 Check the different functions of the top lift attachment.

1. Bolt
2. Pin

Uncoupling the top lift attachment

1 For adjustable attachment, set the length setting at 20'.
2 Position the top lift attachment in a safe stowage location. For
example, on a container or in a stand.
3 Set the rotation in centre position so that the hydraulic pressure is
equalised and it becomes easier to detach the quick couplings. In
1 this way, oil spillage is avoided.
4 Machine in service position see 7.3 Service position, page 313.
5 Detach the quick couplings.
6 Unlock the braces behind the forks, set the mast vertical and
reverse away from the top lift attachment.
2
002060

Top lift attachment, connection of quick couplings.

1. Electrical cable
2. Hydraulic hoses

Operator’s manual DCG 180-330 IDCG02.03GB

338 7 Transporting the machine – Long-term storage

7.5 Long-term storage

General
Short-term storage is storage up to 4 weeks.

Long-term storage is storage for more than 4 weeks.

Short-term storage
Prepare for short-term storage
1 Wash the outside of the machine.
2 Perform the daily inspection, see 6.1 Daily inspection, page 266.
3 Park the machine in service position, see .
4 Depressurise the brake and hydraulic systems, see Maintenance
manual.
5 Check the coolant level and the coolant's freezing point, see
Maintenance manual.
6 Close the cab windows and doors.
7 Turn off the system voltage with the battery disconnector, see
Battery and battery disconnector, general, page 295.
8 Disconnect the cables from the battery and trickle charge the
battery during the entire storage period.

NOTE
Since Insight draws a little current even when the battery voltage
is switched off using the battery disconnector, the battery cables
should be disconnected.

If very low temperatures are expected during the storage period,

remove the batteries and store them in a warmer location.
Reset after short-term storage
1 Connect the battery cables to the battery.
2 Close the valves that were opened to drain the pressure in the
hydraulic system, see Maintenance manual.
3 Perform the daily inspection, see 6.1 Daily inspection, page 266.
4 Start the engine and allow it to idle for 3 to 5 minutes.

IDCG02.03GB Operator’s manual DCG 180-330

7 Transporting the machine – Long-term storage 339

Long-term storage
General

NOTE
Kalmar recommends storing the machine in a dry and protected
area, preferably indoors.

Prepare for long-term storage

NOTE
If the machine is stored in long-term storage without being
prepared for it, there is a great risk of extensive damage to
machine and engine.
Always complete all measures for long-term storage in
accordance with the instructions from Kalmar and the engine
supplier.

1 Wash the machine externally and clean inside the cab.

2 Park the machine in service position, see .
3 Perform the daily inspection, see 6.1 Daily inspection, page 266.
4 Fill the fuel tank to full in order to avoid condensation, see Fuel
system, general, page 276.
5 Drain the AdBlue tank.
6 Depressurise the brake and hydraulic systems, see Maintenance
manual.
7 Clean the piston rod surfaces that are exposed. Treat with oil or
grease.
Inject oil into the free-lift cylinders in accordance with the supplier's
recommendations.
8 Repair any damage from leaks, see Maintenance manual.
9 Check the coolant level and the coolant's freezing point, see
Maintenance manual.
10 Cover the exhaust outlet and air intake.
11 Close the cab windows and doors.
12 Turn off the system voltage with the battery disconnector, see
Battery and battery disconnector, general, page 295.
13 Prepare the engine for long-term storage, adapted according
to the intended storage time, in accordance with the engine
manufacturer's instructions.

NOTE
Follow the engine manufacturer's instructions carefully. In the
event of any doubt, contact Kalmar.

14 Drain and fill with new oil in the transmission and axles, see
Maintenance manual.

NOTE
If the machine has only operated for a short time since the last
scheduled oil change for the transmission and axles, skip this
step.

Operator’s manual DCG 180-330 IDCG02.03GB

340 7 Transporting the machine – Long-term storage

15 Support the wheel axles on jack stands to avoid load on the tyres.
16 Disconnect the cables from the battery and trickle charge the
battery during the entire storage period.

NOTE
Since Insight draws a little current even when the battery voltage
is switched off using the battery disconnector, the battery cables
should be disconnected.

If very low temperatures are expected during the storage period,

remove the batteries and store them in a warmer location.
Reset after long-term storage

NOTE
If the machine is started without previously being reset after
long-term storage, there is a great risk of extensive damage to
machine and engine.
Always complete all measures for resetting the machine in
accordance with the instructions from Kalmar and the engine
supplier.

1 Check that there are no visible signs of leakage on or around the

machine.
2 Check that the tyre pressure is correct.
3 Remove the jack stands from under the wheel axles.
4 Connect the battery cables to the battery.
5 Remove covers over exhaust outlet and air inlet.
6 Wipe oil/grease from the piston rod surfaces
7 Fill the AdBlue tank, AdBlue, page 279.
8 Close the valves that were opened to drain the pressure in the
hydraulic system, see Maintenance manual.
9 Reset the engine in accordance with the engine manufacturer's
instructions for resetting an engine after long-term storage.

NOTE
Follow the engine manufacturer's instructions carefully. In the
event of any doubt, contact Kalmar.

10 Perform the daily inspection, see 6.1 Daily inspection, page 266.
11 Start the engine and allow it to idle for 3 to 5 minutes.
12 Calibrate the transmission, see Maintenance manual.

IDCG02.03GB Operator’s manual DCG 180-330

 8 Environment and standards 341

8 Environment and
standards
General
The ever-increasing industrialisation of our world is having a significant
impact on our global environment. Nature, animals and people are
subjected daily to risks in connection with various forms of chemical
handling.

There are still no fully environmentally safe chemicals, such as oils and
coolants, available on the market. Therefore, all who handle, perform
service on or repair machines must use the tools, assisting devices and
methods necessary to protect the environment in an environmentally
sound manner.

By following the simple rules below, you will contribute to protecting

our environment.

Recycling
Conscientious recycling of the machine is the starting point for the life
cycle to come full circle, and for being able to recycle and make use of
material in new products. According to calculations by Cargotec, the
machine is more than 90% recyclable by weight.

Environmentally hazardous waste

Components such as batteries, oils, and various chemicals and other
items that may constitute environmentally hazardous waste must be
handled and taken care of in an environmentally safe and sound
manner.

Discarded batteries contain substances hazardous to personal health

and the environment. Therefore, handle batteries in an environmentally
safe manner and according to national regulations.

Oils and fluids

Oils freely discharged cause environmental damage and can also be a
fire hazard. Therefore, when emptying and draining oils or fuel, take
appropriate action to prevent unnecessary spills.

Waste oils and fluids should always be taken care of by an authorised

disposal company.

Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal the leaks.

Air conditioning
The refrigerant in the air conditioning for the cab adds to the
"greenhouse 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.

Working in a contaminated area

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

Operator’s manual DCG 180-330 IDCG02.03GB

342 8 Environment and standards – Environment and standards

Declarations
The machine does not contain asbestos.
The machines contains lead in batteries and in electric cabling. In
certain models, there are lead castings as counterweight.
If the machine is equipped with air conditioning then refrigerant of type
R134a is used.

Standards
Noise, vibration, stability and visibility, etc.
This machine conforms to the harmonised standard EN-ISO 3691-1
Industrial trucks. Safety requirements and verification - Part 1:
Propelled trucks and the harmonised standard EN 16307-1 Industrial
trucks. Safety requirements and verification - Part 1: Additional
requirements for propelled industrial trucks. This machine also
complies with the North American standard ANSI/ITSDF B56.1 "Safety
Standard for Low Lift and High Lift Trucks".
CE marking
Machines for the EU/EEA market are CE marked. This means that
upon delivery the machine fulfils the applicable "Essential Health
and Safety Requirements" specified in the EU Machine Directive,
2006/42/EC, as well as other EU directives relevant to this machine
type. For more information, see section 2.2 CE marking.
ANSI/ITSDF marking
Versions of this machine for North America are ANSI/ITSDF marked.
This means that, when delivered, the machine fulfils the basic safety
requirements specified in ANSI/ITSDF B56.1. For more information,
see section 2.3 ANSI/ITSDF marking.
EMC, electromagnetic interference
The EU's EMC directive regarding "Electromagnetic compatibility",
2014/30/EU, gives a general description of the standards that may be
required of a machine from a safety aspect, where the limit values have
been established in international standards. A machine or device that
meets these standards should be CE marked.
Cargotec machines are especially tested with regards to
electromagnetic interference in accordance with harmonised standard
EN12895. The machine's CE-marking and declaration of conformity
also cover the EMC directive. If other electronic equipment is installed
on the machine, it must be CE-marked and tested on the machine
with regards to electromagnetic interference. It must also be approved
by Cargotec.
Exhaust emissions
Machines for the EU/EEA market fulfil the EU Exhaust Directives
97/68/EC and 2004/26/EC, which means that the engine's exhaust
emissions have been limited in accordance with the requirements.
Machines for the North American market fulfil the EPA and CARB
exhaust regulations, which means that engine exhaust emissions have
been limited in accordance with the requirements.
Noise emissions
The machine for the EU/EEA market fulfils EU Noise Directives
2000/14/EC and 2005/88/EC, which means that the machine is marked
with guaranteed sound power level, which is also limited in accordance
with the requirements for trucks with lift capacity over 10 000 kg. See
section 3.2 Plates.

IDCG02.03GB Operator’s manual DCG 180-330

8 Environment and standards – Environment and standards 343

Vibration standard
Vibration emitted by the machine is measured according to harmonised
standard EN 13059, where the level of vibration varies depending on
with which type of tyres and driver's seat the machine is equipped. See
section 9 Specifications.

Operator’s manual DCG 180-330 IDCG02.03GB

344 9 Specifications

9 Specifications
Data
The machine's weights and dimensions vary depending on how the
machine is equipped. Detailed information regarding this is given in the
product specification and data sheet for the machine in question.

DCG 180-250 DCG 280-330

0 Complete machine Volvo Cummins Cummins Volvo Cummins Cummins
TAD871VE QSB6.7 QSB6.7 TAD871VE QSB6.7 QSB6.7
Stage Stage Stage Stage Stage Stage
4/Tier 4f 3A/Tier 3 4/Tier 4f 4/Tier 4f 3A/Tier 3 4/Tier 4f
Guaranteed sound power level in LWA 110 LWA 109 LWA 109 LWA 110 LWA 110 LWA 110
accordance with 2000/14/EC and dB(A) dB(A) dB(A) dB(A) dB(A) dB(A)
2005/88/EC including measurement
uncertainty 1.5 dB.

DCG 180-250 DCG 280-330

1 Engine Volvo Cummins Cummins Volvo Cummins Cummins
TAD871VE QSB6.7 QSB6.7 TAD871VE QSB6.7 QSB6.7
Stage Stage Stage Stage Stage Stage
4/Tier 4f 3A/Tier 3 4/Tier 4f 4/Tier 4f 3A/Tier 3 4/Tier 4f
Output in accordance with ISO 3046 185 kW 164 kW at 168 kW at 185 kW 194 kW at 194 kW at
(marked output) between 2200 rpm 2200 rpm between 2200 rpm 2200 rpm
1500 – 22 1500 – 22
00 rpm 00 rpm
Torque ISO 3046 1160 Nm at 949 Nm at 949 Nm at 1160 Nm at 987 Nm at 990 Nm at
1100 – 15 1500 rpm 1500 rpm 1100 – 15 1500 rpm 1500 rpm
00 rpm 00 rpm
Max. rotation speed 2200 rpm
Number of cylinders 6
Alternator, output 3080 W 1680 W 1680 W 3080 W 1680 W 1680 W
System voltage, voltage – capacity 24 V (2x12 V / 145 Ah)

2 Transmission DANA TE17

No. of gears, forward - reverse 3 - 3

3.3 Power transmission, drive

DCG 180-250 DCG 280-330
axle
Drive axle, type Kessler D91 AxleTech PRC3806W4H

4 Brakes
Footbrake system – wheel affected Wet Disc Brake – drive wheel
Parking brake system – wheel affected Spring brake - drive wheel

5 Steering
Steering system Hydraulic servo

IDCG02.03GB Operator’s manual DCG 180-330

 9 Specifications – Specifications 345

6 Wheels DCG 180-250 DCG 280-330

Dimension, front and rear 14.00x24 16.00x25
Tyre pressure, also see pressure plate 1.0 MPa 1.0 MPa
Tyre type, front and rear Inflated with air. Spare and replacement tyres must be of brand
names approved by Cargotec.

9 Cab Cab Protection bar

Equivalent sound pressure level LpAZ 72 dB(A) LpAZ 73 dB(A)
in cab according to EN12053 with
measurement uncertainty σR=2.5 dB.
Measurement value with standard
engine.
Whole-body vibrations according 0.4 - 0.7 m/s2
to EN13059 with measurement
uncertainty k=0.3 x measured value.

Lamp Output (W) Socket

Direction indicator, front - LEDs are replaced complete
Tail lights, brake lights & direction indicators rear - LEDs are replaced complete
Position lamps - LEDs are replaced complete
Headlights, (with high and low beam) 75/70 P43t-38 (H4)
Back-up light 70 PK22s (H3)
Back-up light LED - LEDs are replaced complete
Work lights glow lights 70 PK22s (H3)
Work lights, LED - LEDs are replaced complete

Revolving beacon LED - LEDs are replaced complete

Flashing beacon 15 Xenon tube. Insert replaced
complete.
Flashing beacon LED - LEDs are replaced complete
Adjustable search light 70 PK22s (H1)
Interior lighting - Replaced complete

Operator’s manual DCG 180-330 IDCG02.03GB

346 9 Specifications – Specifications

Volumes
For oil types see Oils and lubricants, recommendation, page 349.

DCG 180 DCG 200 DCG 220 DCG 250 DCG 280 DCG 300 DCG 330
1.2 Engine, fuel system -12LB -12LB -12LB -12LB -12LB -12LB -12LB
Fuel tank, volume 300 l 300 l 300 l 375 l 450 l 450 l 450 l
Fuel quality Recommendation for Stage 3A/Tier 3 engines
Diesel according to:
EN590,
ASTM D 975 No 1-D,
ASTM D 975 No 2-D.

CAUTION
Use only the fuel of approved quality.
Risk of engine damage, warranty invalidated.
Only fuel of a quality that is approved by the engine supplier
may be used.

WARNING
If fuel with a sulphur content higher than 0.3% (3000 ppm) is
used then the engine oil and oil filter must be changed at more
frequent intervals.
Risk of engine damage!
Change the engine oil and oil filter in accordance with the
prescribed intervals.

Requirements for Stage 4/Tier 4f engines

Diesel according to:
EN590,
ASTM D 975 No 1-D,
ASTM D 975 No 2-D.

CAUTION
Use only the fuel of approved quality.
Risk of engine damage, warranty invalidated.
Only fuel of a quality that is approved by the engine supplier
may be used.

AdBlue tank, volume 35 l

AdBlue quality AdBlue, according to ISO standard 22241.

IDCG02.03GB Operator’s manual DCG 180-330

 9 Specifications – Specifications 347

1.7 Engine, cooling system Volvo TAD871VE Cummins QSB6.7 Cummins QSB6.7
Stage 4/Tier 4f Stage 3A/Tier 3 Stage 4/Tier 4f
Coolant volume 35 l 33 l 33 l
Coolant filling point Volvo Penta Coolant ES Compleat, Premix ES Compleat, Premix
VCS, ready-mixed

CAUTION
Use approved coolant.
Risk of engine damage and invalidated warranty if unapproved
coolant is used.
Only use coolant approved by the engine supplier when
changing and topping up the coolant.

1.8 Engine, lubrication system Volvo TAD871VE Cummins QSB6.7 Cummins QSB6.7
Stage 4/Tier 4f Stage 3A/Tier 3 Stage 4/Tier 4f
Oil type, quality See Oils and lubricants, recommendation, page 349.
Oil volume incl. filter 27 l 23 l 23 l

2.6 Transmission, lubrication DANA TE17

system
Oil type See Oils and lubricants, recommendation, page 349
Oil volume 39 l

DCG 180-250 DCG 280-330

3.3 Power transmission, drive Kessler D91 AxleTech PRC3806W4H
axle
Oil quality See Oils and lubricants, recommendation, page 349.
Oil volume, differential 29.9 l 34 l
Oil volume, hub reduction 2x3.8 l 2x12.5 l

4.8 Brake system, separate oil

tank
Oil quality See Oils and lubricants, recommendation, page 349
Oil tank brake system, volume 90 l

7 Load handling
Oil quality See Oils and lubricants, recommendation, page 349
Oil volume, planetary gear, hydraulic 1.6 l
motor

Operator’s manual DCG 180-330 IDCG02.03GB

348 9 Specifications – Specifications

9 Frame, body, cab and

accessories
Refrigerant air conditioning R134a

Volume refrigerant 2000 g (unless otherwise indicated on the air conditioning sign)

Lubricant air conditioning ZXL100PG

Lubricant quantity air conditioning 0.3 l (depending on compressor)

Volume, washer fluid Max. 6 l

10 Common hydraulics
Oil quality See Oils and lubricants, recommendation, page 349.
Oil additive Lubrizol 3%
Volume hydraulic oil tank 360 l
Volume hydraulic oil tank, machine 270 l
with separate oil tank for brake
system

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 9 Specifications – Specifications 349

Oils and lubricants, recommendation

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

Any deviation from this table must be approved in writing by Cargotec,

and may mean changed service intervals.

°C -30 -20 -10 0 +10 +20 +30 +40 +50

Oil type, quality °F -22 -4 +14 +32 +50 +68 +86 +104 +122
1.8 Engine, lubrication system
Cummins QSB6.7 Stage 3A/Tier SAE 15W40 (engine oil)
3:
SAE 10W30 (engine oil)
API: CH-4/SJ, CI-4/SK
ACEA: E5, E7 SAE 5W30 (engine oil)
Cummins: CES-20071,
CES-20072, CES-20076,
CES-20077, CES-20078
1.8 Engine, lubrication system
Cummins QSB6.7 Stage 4/Tier SAE 5W/40 or 15W/40 (engine oil)
4f:
SAE 10W/30 (engine oil)
API: CJ-4
ACEA: E9-08 SAE 5W/30 (engine oil)
Cummins: CES 20081
Volvo: VDS-4
SAE 15W40 (engine oil)
SAE 10W30 (engine oil)
SAE 5W301 (engine oil)

2.6 Transmission, lubrication

system DEXRON® III
ATF Dexron III
3.3 Power transmission, drive
axle SAE 80W140
Kessler SAE 80W90
Hypoid oil, API GL-5 and
MIL-L-2105B SAE 90
SAE 85W140

AxleTech
Hypoid oil, API GL-5 SAE 80W140
SAE 75W90

1 Only applies to synthetic or semi-synthetic engine oil.

Operator’s manual DCG 180-330 IDCG02.03GB

350 9 Specifications – Specifications

°C -30 -20 -10 0 +10 +20 +30 +40 +50

Oil type, quality °F -22 -4 +14 +32 +50 +68 +86 +104 +122
4 Brakes (UTTO oil 2)
GM Allison C-4 SAE 5W30 (transmission oil)
John Deere J20 C, D
Caterpillar TO-4
10 Common hydraulics
Hydraulic oil AV 32
SS 155434 BBV AV 46

Hydraulic oil HVLP 46

DIN 51524 HLP 68

Hydraulic oil ISO - LHV 46

ISO 6743/4 ISO - LHM 68

NOTE
Oil filters must be changed in connection with oil change.

2 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

CES = Cummins Engine Standard

VDS = Volvo Drain Specification

Engine oil

NOTE
Oil filters must be changed in connection with oil change.

Stage 3A/Tier 3 engines

WARNING
Change intervals for engine oil and oil filter depend on
the sulphur content in the fuel.
Risk of engine damage!
Change the engine oil and oil filter in accordance with
the prescribed intervals.

IDCG02.03GB Operator’s manual DCG 180-330

9 Specifications – Specifications 351

Lubricating grease
Use a universal grease type EP in accordance with NLGI Grade 2
(EP2) for all lubrication points except for slide plates.

NLGI Grade 1 (EP1) can ideally be used in areas with low ambient
temperatures.

NLGI Grade 3 (EP3) can ideally be used in areas with high ambient
temperatures.

For slide plates use a lubricant approved by Cargotec. Obtained from

Cargotec Spare Parts Department. 0.65 kg cartridge for grease gun
part. no 923110.0360 and 5 kg tin part. no 923595.0003.

NOTE
Select lubricant class according to the prevailing climate.

Contact grease
Use contact grease part no. 923836.0552. Applies for sealed
connectors.

Sealant silicone
Use silicone part. no. 923107.0308.

Adhesive system for window panes

Only use PU polymer recommended by Cargotec.

Coolant
Use ready-mixed recommended coolant. Choose the mixture of
coolant that is adapted for the right temperature.

CAUTION
Use approved coolant.
Risk of engine damage and invalidated warranty if
unapproved coolant is used.
Only use coolant approved by the engine supplier
when changing and topping up the coolant.

Operator’s manual DCG 180-330 IDCG02.03GB

352 9 Specifications – Specifications

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

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 9 Specifications – Specifications 353

Conversion SI-units
Recalculation Recalculation
SI-unit factor Non-SI factor SI
Torque
Nm x 10.2 = kg·cm x 0.8664 = lb·in
Nm x 0.74 = lbf·ft x 1.36 = Nm
Nm x 0.102 = kg·m x 7.22 = lb·ft
Pressure (Pa = N/m2)
kPa x 4.0 = in.H2O x 0.249 = kPa
kPa x 0.30 = in.Hg x 3.38 = kPa
kPa x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
kp/cm 2 x 14.22 = psi x 0.070 = kp/cm2
N/mm 2 x 145.04 = psi x 0.069 = bar
MPa x 145 = psi x 0.00689 = MPa
Power (W = J/s)
kW x 1.36 = hp (cv) x 0.736 = kW
kW x 1.34 = bhp x 0.746 = kW
kW x 0.948 = Btu/s x 1.055 = kW
W x 0.74 = ft·lb/s x 1.36 = W
Energy (J = Nm)
kJ x 0.948 = Btu x 1.055 = kJ
J x 0.239 = calorie x 4.19 = J
Speed and acceleration
m/s2 x 3.28 = ft/s2 x 0.305 = m/s2
m/s x 3.28 = ft/s x 0.305 = m/s
km/h x 0.62 = mph x 1.61 = km/h
Horsepower/torque
Bhp x 5252 rpm= TQ (lb·ft) TQ x rpm 5252 = bhp
Temperature
°C = (°F – 32)/1.8 °F = (°C x 1.8) + 32
Flow factor
l/min (dm3 /min) x 0.264 = US gal/min x 3.785 = litre/min

Operator’s manual DCG 180-330 IDCG02.03GB

354 9 Specifications – Specifications

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)

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 9 Specifications – Specifications 355

Conversion table pressure

Unit kp/cm 2 bar Pa = N/m2 kPa lbf/in2 lbf/ft2
kp/cm 2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa = N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kg/cm2 = 735.56 Torr (mmHg) = 0.96784 atm

Operator’s manual DCG 180-330 IDCG02.03GB

356 10 Terminology

10 Terminology
Explanations

Term Description
Accumulator Reservoir that stores (accumulates) pressure for, i.e. hydraulic functions.
AdBlue AdBlue (DEF) contains deionised water mixed with 32.5% urea.
Attachment Part of the machine that grips the load when lifting.
Anti-corrosion agent Prevents oxidation, in simple terms, rustproofing.
Working hydraulics All load handling functions, e.g. lifting/lowering, tilt, side shift, positioning and levelling.
Wheelbase Distance between drive axle and steering axle.
Bar Unit to express pressure.
Battery disconnector Cuts off power supply from battery.
CAN Controller Area Network - Network for communication between the control units.
CAN bus The network between the control units in the machine.
CECS Common Electrical and Control System. An electronic control system that monitors and
regulates certain systems in the machine that require CECS, such as certain engine
and transmission alternatives.
Central lubrication An automatic system for lubrication of a preset number of lubrication points.
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.
DEF Diesel Exhaust Fluid, see AdBlue.
Displacement The oil volume that the pump can supply per pump revolution.
Display "Window" showing digital information, i.e. on steering wheel panel in the cab.
DOC Diesel Oxidation Catalyst. DOC is a catalytic converter that removes carbon monoxide
(CO) and hydrocarbons (HC) from the exhaust gases, and even a certain amount of
particles, soot, etc.
Operating time Number of hours machine has been in operation, shown on hour meter in cab.
Drive axle Driving axle that receives the torque from the drivetrain.
Drivetrain Parts in the machine involved in power transmission; engine, torque converter,
transmission, propeller shaft and drive axle with differential and hub reduction.
ECC Electric Climate Control. Air conditioning with thermostat-controlled cooling,
dehumidification and heating.
EHC Electric Heat Control. Heating system with thermostat-controlled heating.
Electrolyte level Fluid level in battery cells.
Electric servo Load handling's hydraulic components receive control signals from electro-mechanical
controls.
Expansion tank Tank for coolant.
Fixed displacement Non-adjustable volume (capacity) in a pump.
FMI Fault Message Identifier. The part of the error code indicating the type of error.
Forks Lifting device that lifts the load.
Fork bracket Bracket for forks, fitted on the lifting carriage.
Main fuse Located by battery. Breaks the current to all systems in the whole machine.
Hydraulic oil Oil for hydraulic system. See specifications in operator's manual.
Hydraulic oil pump Pump in hydraulic system.

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 10 Terminology – Terminology 357

Term Description
Hydraulic servo Load handling's hydraulic components receive control signals from mechanical controls.
Hydraulic system System that uses oil pressure to transfer power to different functions.
Cab Enclosed type of cab.
Hanging load Lifted load.
Indicator Manual "sensor", for example, shows that a filter is clogged and needs to be changed.
Inverted forks Forks turned upside down, for lifting and fitting top lift.
KCU Kalmar Cab Unit - Control Unit KCU (D7901) is fitted in the cab and is the control unit
that controls the start-up and shutdown of the machine's electrical system.
KFU Kalmar Frame Unit – Control unit KFU (D7971) is fitted in the electronic box on the
left-hand side. The control unit operates components in the frame and on the mast.
KID Kalmar Information Display - Control unit KID (D7950), the display in the cab.
KPU Kalmar Panel Unit - Control unit KPU (D7902) is fitted in the right-hand switch panel in
the cab and operates switches and controls in the cab.
KST Kalmar Service Tool - Computer program for service, calibration, setting and
programming of the machine's control units.
Piston rod Rod that is pushed into the piston's cylinder barrel and is acted upon by the hydraulic
pressure.
Refrigerant Fluid/gas in air conditioning. Must only be handled by authorised trained personnel.
LC Load centre.
Lift capacity Indicates machine's maximum lift capacity.
Lifting point Attaching point for lift device when lifting an object.
Lifting carriage Lifts the load, located on the mast.
Low-emission engine Engine with low emissions of hazardous substances. Manufactured in accordance
with regulations.
Solenoid valve An electro-magnetically controlled valve. See also proportional valve.
Control valve Valves that can be used to control something, for example, to release pressure and thus
lower a mast or a fork.
Machine model Machine type. Specified, for example: DCG 180-330. See also type designation.
Environmental waste Used oils, filters, etc., must be handled in accordance with national laws and regulations
in force.
Torque converter Hydraulic, variable clutch.
Counterweight Weights adapted to the machine's lift capacity to constitute an opposing load when lifting.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases torque
from the drivetrain.
Pilot oil pressure A low control pressure to, for example, a valve.
Planetary gear Type of transmission with gears in constant engagement.
Product alternative One of several alternatives is selected for a machine, e.g. engine option.
Progressive steering Quick steering wheel movements give greater steering angles.
Proportional valve An electro-magnetically controlled valve. If a voltage is applied, the valve is activated
in proportion to the voltage amplitude. In simple terms, infinitely variable valve, as
opposed to on/off valve. For example, found on transmission's valve housing.
Frame member Structural members in the frame.
Recirculation Circulation in a closed system.

Operator’s manual DCG 180-330 IDCG02.03GB

358 10 Terminology – Terminology

Term Description
SCR Selective Catalytic Reduction. Exhaust technology which means that AdBlue is added
to the exhaust gases to reduce nitrogen oxides (NOx). The urea in AdBlue breaks down
into ammonia, which in the SCR catalytic converter, reacts with nitrogen oxide (NOx) as
harmless nitrogen and water vapour is formed.
Available for Volvo Stage 4/Tier 4f engines.
Serial number Unique machine designation. On the machine plate.
Service position How machine should be safely positioned before service may be started.
Servo A small movement by the user results in a large angle, i.e. servo steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side shift Parallel sideways movement of forks.
Levelling Forks are tilted, e.g. if load stands on uneven ground.
SPN Suspect Parameter Number. Is a unique number for machine components. Used in
circuit diagrams and error codes.
Spreading (positioning) Spreading of the forks, e.g. change to relative distance between the forks.
Mast Carrier of attachment and load.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, which is emptied
automatically during operation.
Steering axle Wheel axle with steering.
Protection bar Protective cage with protective heavy-duty frame construction. Open.
Buzzer Acoustic alarm to catch the operator's attention.
Option Extra equipment for machine.
Tilt The mast is tilted forward or backward.
Top lift Attachment. See attachment.
Transmission oil Oil for transmission and torque converter. See specifications in operator's manual.
Securing machine for transport Actions before transporting machine.
Twistlocks Two or four locking pins, one in each corner of the attachment, pushed down in
corresponding holes in container and twisted to lock the container when lifting.
Type designation Indicates machine type and capacity. See also machine model.
Maintenance Periodic maintenance actions so that machine functions safely and for a long service life.
Variable pump Pump with adjustable flow rate.
Variable displacement Adjustable volume (capacity) of a pump.
Valve slide Moveable part in valve. Determines oil's path.
Wet brakes Brake discs in oil bath.
Recyclable Used equipment must be handled according to national laws and regulations.

IDCG02.03GB Operator’s manual DCG 180-330

 11 Index – Index 359

Index Event menu mini-wheel/joystick control, description

Event menu no operator in seat. . . . . . . . .
.
.
.
.
.
.
96
90
Event menu oil temperature hydraulics . . . . . . . . 86
Event menu oil temperature transmission . . . . . . . 86
A Event menu open door . . . . . . . . . . . . . . . 90
Event menu overload lift . . . . . . . . . . . . . . . 87
About the documentation kit . . . . . . . . . . . . . . 4 Event menu overload lift and tilt. . . . . . . . . . . . 88
About the operator's manual . . . . . . . . . . . . . . 1 Event menu overload tilt . . . . . . . . . . . . . . . 87
After-treatment system, regeneration . . . . . . . . . 85 Event menu parking brake . . . . . . . . . . . . . . 89
Air filter, engine . . . . . . . . . . . . . . . . . . . 283 Event menu preheating . . . . . . . . . . . . . . . 92
ANSI/ITSDF marking . . . . . . . . . . . . . . . . 10 Event menu raise/lower cab temperature . . . . . . . 92
Assembly of hydraulics to mast and carriage . . . . . . 320 Event menu raise/lower fan speed . . . . . . . . . . 92
Assembly of mechanics to mast and carriage . . . . . . 315 Event menu release the parking brake . . . . . . . . . 91
Attachment . . . . . . . . . . . . . . . . . . . . 336 Event menu rotate the operator's station . . . . . . . . 95
Attachment of lifting equipment . . . . . . . . . . . . 314 Event menu seat belt . . . . . . . . . . . . . . . . 88
Event menu service . . . . . . . . . . . . . . . . . 93
Event menu speed limitation . . . . . . . . . . . . . 94
B Event menu start interlock . . . . . . . . . . . . . . 93
Back-up camera and distance warning . . . . . . . . 98 Event menu tyre pressure . . . . . . . . . . . . . . 88
Battery and battery disconnector . . . . . . . . . . . 295 Event menu, clamped load . . . . . . . . . . . . . . 97
Event menus . . . . . . . . . . . . . . . . . . . . 83
Extra hydraulic function . . . . . . . . . . . . . . . 252
C
CE-marking . . . . . . . . . . . . . . . . . . . . . 9 F
Central lubrication . . . . . . . . . . . . . . . . . 294
Fire . . . . . . . . . . . . . . . . . . . . . . . . 18
Checking the accumulator . . . . . . . . . . . . . . 293
Fire extinguishing system . . . . . . . . . . . . . . 100
Cleanliness . . . . . . . . . . . . . . . . . . . . 274
Foreword . . . . . . . . . . . . . . . . . . . . . . 1
Control for load handling . . . . . . . . . . . . . . . 63
Forks . . . . . . . . . . . . . . . . . . . . . . . 322
Control system . . . . . . . . . . . . . . . . . . . 78
Fuel system . . . . . . . . . . . . . . . . . . . . 276
Cooling system . . . . . . . . . . . . . . . . . . . 284
Functions for load handling . . . . . . . . . . . . . 247
Customer settings via display . . . . . . . . . . . . 253
Fuses for electrical system . . . . . . . . . . . . . . 297

D G
Daily inspection . . . . . . . . . . . . . . . 106, 266 Gearshifting . . . . . . . . . . . . . . . . . . . . 219
Deactivated regeneration of the engine's after-
treatment system, description . . . . . . . . . . . . 92
Description . . . . . . . . .
Driver's seat . . . . . . . . .
. . . .
. . . .
. . .
. . .
. . . .
. . . .
20
72
H
Handling. . . . . . . . . . . . . . . . . . . . . . 102
Heating / Air conditioning . . . . . . . . . . . . 76, 226
High exhaust temperature in the engine exhaust filter . . 85
E Hydraulic system . . . . . . . . . . . . . . . . . . 288
Engine oil . . . . . . . . . . . . . . . . . . . . . 285
Engine operating menu . . . . . . . . . . . . . . . 80
Environment and standards . . . . . . . . . . . . . 341 I
Error code indication . . . . . . . . . . . . . . . . 109
Identification of the machine . . . . . . . . . . . . . 20
Error code information on display . . . . . . . . . . . 110
Ignition key lock and start and stop button for the
Error code tables . . . . . . . . . . . . . . . . . . 117
engine . . . . . . . . . . . . . . . . . . . . . . 43
Error codes . . . . . . . . . . . . . . . . . . . . 107
Insight. . . . . . . . . . . . . . . . . . . . . . . 101
Event menu AdBlue . . . . . . . . . . . . . . . . . 89
Inspection and maintenance . . . . . . . . . . . 5, 265
Event menu AdBlue end . . . . . . . . . . . . . . . 86
Instruments and controls. . . . . . . . . . . . . . . 34
Event menu air filter air conditioning system . . . . . . 91
Event menu arm rest . . . . . . . . . . . . . . . . 96
Event menu automatic start function. . . . . . . . . . 97
Event menu automatic stop function . . . . . . . . . . 97 K
Event menu battery capacity . . . . . . . . . . . . . 90 Keep in mind . . . . . . . . . . . . . . . . . . . . 11
Event menu battery charging . . . . . . . . . . . . . 95
Event menu brake temperature . . . . . . . . . . . . 83
Event menu control breaker . . . . . . . . . . . . . 94 L
Event menu engine coolant temperature . . . . . . . . 86
Lifting and transporting the machine . . . . . . . . . . 311
Event menu heating rear view mirrors/rear windscreen . . 93
Lifting load . . . . . . . . . . . . . . . . . . . . . 237
Event menu height limitation . . . . . . . . . . . . . 87
Lifting machine . . . . . . . . . . . . . . . . . . . 312
Event menu height warning . . . . . . . . . . . . . 87
Lighting . . . . . . . . . . . . . . . . . . . . . . 305
Event menu incorrect tyre pressure . . . . . . . . . . 84
Load handling . . . . . . . . . . . . . . . . . 61, 234
Event menu intermittent wiper . . . . . . . . . . . . 94
Long-term storage . . . . . . . . . . . . . . . . . 338
Event menu low accumulator pressure . . . . . . 84, 89
Event menu low AdBlue level. . . . . . . . . . . . . 89
Event menu low coolant level engine . . . . . . . . . 95
Event menu low fuel level . . . . . . . . . . . . . . 90 M
Event menu low washer fluid level . . . . . . . . . . 91 Maintenance . . . . . . . . . . . . . . . . . . . . 271

Operator’s manual DCG 180-330 IDCG02.03GB

360 11 Index – Index

Manual regeneration of the engine's after- Service . . . . . . . . . . . . . . . . . . . . . . 306

treatment system . . . . . . . . . . . . . . . . . 232 Service brake . . . . . . . . . . . . . . . . . . . 223
Mechanical release of parking brake . . . . . . . . . 310 Service position . . . . . . . . . . . . . . . . . . 313
Menu for active error codes . . . . . . . . . . . . . 259 Specifications . . . . . . . . . . . . . . . . . . . 344
Menu for date and time . . . . . . . . . . . . . . . 253 Starting engine . . . . . . . . . . . . . . . . . . . 217
Menu for inactive error codes. . . . . . . . . . . . . 260 Steering . . . . . . . . . . . . . . . . . . . . . . 222
Menu for machine check . . . . . . . . . . . . . . . 263 Steering wheel . . . . . . . . . . . . . . . . . . . 68
Menu for services and settings . . . . . . . . . . . . 263 Stopping the engine - parking . . . . . . . . . . . . 230
Menu for statistics and history . . . . . . . . . . . . 260 Switches . . . . . . . . . . . . . . . . . . . . . 45
Multi-function lever . . . . . . . . . . . . . . . . . 60

T
O
Terminology . . . . . . . . . . . . . . . . . . . . 356
Oil, brake system . . . . . . . . . . . . . . . . . . 289 The event menu parking brake not activated and no
Operating . . . . . . . . . . . . . . . . . . . . . 213 operator in the driver's seat . . . . . . . . . . . . . 84
Operating menu customer settings . . . . . . . . . . 82 Towing . . . . . . . . . . . . . . . . . . . . . . 309
Operating menu electrical system . . . . . . . . . . . 81 Transmission and hydraulics operating menu . . . . . . 81
Operating menu scales . . . . . . . . . . . . . . . 81 Transmission oil . . . . . . . . . . . . . . . . . . 287
Operating menu trip computer work shift . . . . . . . . 80 Transporting load . . . . . . . . . . . . . . . . . . 242
Operating menu tyre pressure monitoring . . . . . . . 82 Transporting the machine . . . . . . . . . . . 308, 312
Operating menus . . . . . . . . . . . . . . . . . . 80 Travel direction selector and parking brake . . . . . . . 58
Optional equipment . . . . . . . . . . . . . . . . . 98 Turnable operator's station . . . . . . . . . . . . . . 231
Overview . . . . . . . . . . . . . . . . . . . . . 20 Tyres and rims . . . . . . . . . . . . . . . . . . . 290
Overview description . . . . . . . . . . . . . . . . 21

P U
Unloading . . . . . . . . . . . . . . . . . . . . . 245
Parking brake . . . . . . . . . . . . . . . . . . . 224
Pedals . . . . . . . . . . . . . . . . . . . . . . 66
Plates . . . . . . . . . . . . . . . . . . . . . . . 26
V
Vehicle Data Interface (VDI) . . . . . . . . . . . . . 101
R
Reading instructions . . . . . . . . . . . . . . . . . 2
Running-in . . . . . . . . . . . . . . . . . . . . . 105 W
Warming up . . . . . . . . . . . . . . . . . . . . 218
Warning and indicator lights . . . . . . . . . . . . . 40
S While operating. . . . . . . . . . . . . . . . . . . 213
Safety . . . . . . . . . . . . . . . . . . . . . . . . 6 Windscreen washer . . . . . . . . . . . . . . . . . 281
Safety and emergency equipment. . . . . . . . . . . . 8 Wiper blades . . . . . . . . . . . . . . . . . . . . 282

IDCG02.03GB Operator’s manual DCG 180-330

 Declaration of Conformity
We, Cargotec Sweden AB, SE-341 32 Ljungby, Sweden, (Registration No. 556014-5418)
herewith declare that the machine,

Type Forklift truck

Commercial name KALMAR

Model DCG250-12LB

Serial No B20700124

is manufactured in conformity with the requirements in

- The Machinery Directive 2006/42/EC

- The Electro Magnetic Compatibility Directive 2014/30/EU

- the harmonised standard EN-ISO 3691-1 Industrial trucks - Safety requirements and verification
- Part 1: Self-propelled industrial trucks.

- the harmonised standard EN 16307-1 Industrial trucks - Safety requirements and verification -
Part 1: Supplementary requirements for self-propelled industrial trucks.

- the Outdoor Noise Directive 2000/14/EC, with use of annex VI, procedure 1 as amended by the
Directive 2005/88/EC, internal control of production with assessment of technical documentation
and periodical checking, under supervision of the Notified Body 0404:

0404 RISE, SMP - Svensk Maskinprovning AB

Box 7035
SE-750 07 Uppsala

Noise related value 185 / 2200 kW/rpm

Measured sound power level LWA 108 dB
Guaranteed sound power level LWA 110 dB

Authorized to compile the technical file

Torbjörn Lövdahl
InfoString: 2A / KIS / O / 16055 / G / GB / 20181127 / 095532

Cargotec Sweden AB, SE-341 32 Ljungby, Sweden

Name Dan Pettersson

Position SVP Kalmar Mobile Equipment

Ljungby 2018-11-19
Place, Date of Issue Signature
361 11 Index – Index

IDCG02.03GB Operator’s manual DCG 180-330

last page

Kalmar offers the widest range of cargo handling solutions and services Cargotec Sweden AB
to ports, terminals, distribution centres and heavy industry. Kalmar is Movägen 1
the industry forerunner in terminal automation and in energy-efficient SE-341 32, Ljungby, Sweden
container handling, with one in four container moves around the globe
tel. +46 372 260 00
being handled by a Kalmar solution.
Through our extensive product portfolio, global service network and ability www.kalmarglobal.com
to enable a seamless integration of different terminal processes, Kalmar
improves the efficiency of every move.