Operator s manual DRT450

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Reachstackers 45 tonnes

Publ no IDRT02.01GB

DRT 450

1 Foreword 1

1.1 About the operator's manual 1

1.2 About the documentation kit 3

1.3 Inspection and maintenance 4

2 Safety 5

2.1 Safety and emergency equipment 7

2.2 CE-marking 8

2.3 ANSI/ITSDF marking 9

2.4 Keep in mind 10

2.5 Fire 17

3 Overview 19

3.1 Description DRT 450 19

3.2 Plates 23

4 Instruments and controls 30

4.1 Warning and indicator lights 34

4.2 Instruments 37

4.3 Ignition key lock 38

4.4 Switches 39

4.5 Gear selector and multi-function lever 43

4.6 Control lever 45

4.7 Pedals 47

4.8 Steering wheel 48

4.9 Operator's seat 49

4.10 Heating / Air conditioning 51

4.11 Control system 54

5 Handling 60

5.1 Running-in 62

5.2 Daily inspection 63

5.3 Error codes 64

5.4 Operating 107

5.5 Load handling 118

6 Inspection and maintenance 126

6.1 Daily inspection 127

6.2 Maintenance 130

6.3 Service 156

7 Transporting the machine 158

7.1 Towing 159

7.2 Lifting and transporting the machine 162

7.3 Service position 173

7.4 Long-term storage 174

8 Environment and standards 175

9 Technical data 178

10 Terminology 187

Index 189

Operator's manual, purpose

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

Cargotec will not accept any responsibility for machine modificationswithout permission from Cargotec Further, Cargotec will not acceptany responsibility if other lifting devices, tools or work methods areused 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'sdesign and appearance on delivery from Cargotec Deviations mayarise due to customer adaptations

Cargotec reserves the right to make changes to specifications andequipment without prior notice Information provided in the manualapplies at the date of issue

Copyright

Cargotec Sweden AB

Duplication of the content in this manual, in whole or in part, is strictlyprohibited without written permission from Cargotec Sweden AB.All duplication by any means, such as copying, printing, etc., isprohibited

Manufacturer

This machine is manufactured by Cargotec Industries Co., Ltd, 201306Shanghai P.R.C., China

2 1 Foreword – Reading instructions

1.1.1 Reading instructions

Warning information

This manual contains descriptions of warnings that apply to yoursafety Warnings provide information about potential dangers that, ifthe warnings are not followed, could result in injury or product damage

NOTE

Important information not related to safety.

Read the operator's manual

Read the operator's manual

The symbol to the left is used in certain cases on the machine andrefers to important information in the Operator's manual

Read the Maintenance manual

Read the Maintenance manual

The symbol to the left is used in certain cases on the machine andrefers to important information in the Maintenance manual

1 Foreword – About the documentation kit 3

1.2 About the documentation kit

Documentation kit

The following documentation is supplied with the machine:

• Operator's manual (in cab with machine)

• Maintenance manual

• Spare parts catalogue with machine card

There is supplementary documentation that can be ordered for themachine:

• Workshop manual

• Supplier documentation for engine, transmission, and drive axle

Ordering documentation

The documentation is ordered from the dealer for Cargotec

Always indicate publication number when ordering

4 1 Foreword – Inspection and maintenance

1.3 Inspection and maintenance

General

Maintenance must be managed properly in order for the machine tooperate satisfactorily and at the lowest cost Intervals for inspectionand maintenance refer to operation under normal environmental andworking 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 thatthe operator should carry out when starting a shift

Maintenance

For other maintenance not included in this operator's manual (serviceand repairs), contact an authorised workshop

2 Safety 5

2 Safety

General

Safety rules are intended to reduce the risk of personal injuries as well

as damage to the load or other property

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

The safety information in this operator's manual are intended for yourinformation and safety It cannot, and is not intended to, cover allpossible events during operation Responsible operators with the righttraining is the only way to ensure the safe and prolonged use of themachine

The machine was thoroughly tested and adjusted before it left thefactory This does not preclude the possibility that it has been damagedduring delivery The machine must undergo a thorough inspection inorder to ensure correct function before being put into service

Important to read the operator's manual

inspection In addition, you will obtain a lot of valuable informationthat makes it easier for you at work

The operator's manual should always remain in the machine If it islost 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 donot understand or if you feel information is missing in any area

Intended use

• The machine must only be used for what it is designed andmanufactured for, i.e to lift and transport goods (whose weightdoes not exceed the machine's maximum permitted load

capacity) If it is used in any other way or in potentially dangerousenvironments (e.g an explosive environment, an area withasbestos dust) then special safety rules must be followed and themachine must be equipped for such operations

• The machine must not be modified or changed without permissionfrom Cargotec In the event of modifications approved by Cargotecthe signs on the machine and documentation affected must beadapted to apply to the modification

In the event of modification or conversion without Cargotec'spermission Cargotec's product liability ceases to apply

Modification and conversion may only be made if the knowledgeexists to verify and test the modifications and conversions.Modifications and conversions must be documented (date andaction) and the organisation responsible must be stated with nameand address Signs and stickers must be updated in accordancewith the machine's new design

• The machine is designed for use in outdoor temperatures -20 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

• 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 warningand information plates as well as understand and be able to usethe 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'swork area

• If the machine has been repaired, modified or adjusted without thesupervisor's/work management's permission

• If the machine is equipped with tyres not approved by Cargotec

• Overload system (OP) for load handling is not working

2 Safety – Safety and emergency equipment 7

2.1 Safety and emergency equipment

1 Back-up alarm

2 Revolving beacon

3 Horn

4 Fire extinguisher

A fire extinguisher may also be located externally

If the machine is supplied with a fire extinguisher, it should be ofthe type ABE according to EN3 pt 1, 2, 4, and 5 With such afire extinguisher, it is possible to put out fires in both solid organicmaterials and fluids Adapted fire extinguishing equipment can beordered from Cargotec

8 Back-up light

9 External rear view mirrorsUsed to provide improved visibility while manoeuvring and loadhandling A rear view mirror on each side

10 Control breaker for hydraulicsCuts off all power supply and control signals to hydraulics

11 Emergency exit from cab, right-hand door(Not located in illustration)

Machine plates for CE-marking, machine and attachment

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

This machine is CE-marked This means that upon delivery it fulfilsthe applicable "Essential Health and Safety Requirements" specified

in the EU Machine Directive, 2006/42/EC, as well as other EUdirectives relevant to this machine type

As proof that the requirements are fulfilled, the machine is providedwith an EC Declaration of Conformity, issued by Cargotec for everymachine The EC declaration also includes tools and optionsproduced by the Cargotec The documentation is a valuabledocument that must be properly preserved and saved for at least

10 years The documentation must always follow with the machinewhen it is sold

See example of EC Declaration after 11 Index.

Anyone making modifications that affect the safety of the machinealso assumes responsibility for them If the machine is used forother purposes or with other tools than what is specified in theseinstructions, safety must be ensured in each individual case Themachine owner is responsible that the machine is used in accordancewith the instructions in the operator's manual In some cases theapplication area may require a new CE marking and issue of new ECdeclaration of conformity

For additional information, see standards under chapter 8

Environment and standards.

2 Safety – ANSI/ITSDF marking 9

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 machinealso 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 eachindividual case The machine owner is responsible that the machine

is used in accordance with the instructions in the operator's manual

For additional information, see standards under chapter 8

Environment and standards.

10 2 Safety – Keep in mind

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

During work shifts

DANGER

The attachment is a tool that handles heavy loads Extreme hazard to personal health and risk of property damage!

Never walk under hanging loads Make sure that no persons stand or walk under a raised work attachment, regardless of whether it is loaded or not.

2 Safety – Keep in mind 11

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.

direction and should operate with special care where persons or vehicles may appear.

ground conditions, visibility, and wind conditions, etc.

with special care near electric power lines, viaducts, docksides, ramps, doorways, etc.

does not collide with posts, power lines, etc.

12 2 Safety – Keep in mind

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 lift capacity of the machine and exercise the greatest caution during load handling:

surfaces, intended for the machine's total weight and ground pressure.

position Exercise caution when operating, think about the width and height so that the boom or attachment does not collide with poles, cables, etc.

may cause the machine to roll or tip over.

uphill or downhill grade, never operate or turn across a grade.

load obscures visibility to the front.

load.

heavy braking in order to prevent risk of tipping and roll-over.

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 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!

2 Safety – Keep in mind 13

WARNING

Lifting loads in very windy conditions is associated with great difficulties.

Risk of roll-over and tipping over!

Avoid lifting loads at wind speeds higher than 12.2 m/s.

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!

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.

14 2 Safety – Keep in mind

WARNING

The cab has the manual sliding cab function The cab must ALWAYS be in the rear position while operating the machine.

Warning - risk of crushing!

Always make sure that the cab locks on both sides are locked in their rear position before operating, and that the locks are secured with the lock pins.

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).

Batteries must always be equipped with covers over terminals and connections Connect positive terminals first Then connect the negative terminals in order to avoid sparks that could ignite the hydrogen gas.

WARNING

The machine uses oils and lubricants.

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

2 Safety – Keep in mind 15

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.

If the parking brake has been released mechanically then it must always be reset to restore the machine's parking brake function.

16 2 Safety – Keep in mind

NOTE

When persons with active or non-active medical products are not nearby, telephone and two-way radio may be used in the cab Equipment should not be used during operation or load handling as this takes away from the operator's concentration.

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

2 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.

Make it a habit to make a visual inspection of the engine and enginecompartment before starting the engine and after operation, when theengine has been stopped This helps to quickly detect if anythingabnormal has happened or is about to happen Look particularlyclosely for oil, fuel or coolant leakage, loose bolts, worn or badlytensioned drive belts, loose connections, damaged hoses and electricalcables The inspection only takes a few minutes and can preventserious faults and costly repairs.

Action after fire

When handling a machine damaged by fire, or exposed to excessiveheat, the following safety regulations must always be followed:

• Check that the fire has been fully extinguished Re-extinguish ifnecessary

• Make sure that system voltage is switched off with the batterydisconnector

• Make sure that the machine is in a secure location, service position

• Check for that there are no leaks which could cause damage tothe surrounding environment

• Never touch the burned components with bare hands in order to

3 Overview 19

3 Overview

3.1 Description DRT 450

General

The DRT 450 machine is a reachstacker for handling containers It has

a maximum lift capacity of 45 tonnes and a lifting height of 5 containers(9' 6" container)

3.1.1 Identification of the machine

Type designation of reachstacker

Each machine from Cargotec has a type designation Example: Typedesignation DRT450 indicates the following:

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'sproduct alternatives and optional equipment

The machine card must be updated when the machine is modifiedand Cargotec must be informed

20 3 Overview – Overview description

The machine is equipped with one of the following engine alternatives:

Drive axle

The machine is equipped with Merritor PRC7534 drive axle The driveaxle (front axle) is equipped with a differential and hub reductions ofthe planetary gear type

Brakes

3 Overview – Overview description 21

Steering

The machine is steered with the rear axle A double-acting hydrauliccylinder acts on the wheel pair The steering is linear, that is, thesteering angle is dependent on the number of steering wheel turns

Electrical system

The electrical system consists of electrical and electromagneticcomponents such as battery, switches, cable harnesses, solenoidvalves, fuses and relays

Control system

The machine has a computer-based control and monitoring system formonitoring and controlling the machine's functions as well as handlingall functions in the machine, such as power electronics, drivetrainand hydraulic system The control and monitoring system facilitatesmaintenance

Cab

The cab is available in one version Instrumentation and equipment(steering wheel, operator's seat, fresh air system) are customisablefor customers and models

• Cab Spirit Delta

Spirit Delta is an enclosed operator's station built of a supportingframe to withstand falling objects in accordance with the standards

in force It is equipped with filtered inlet, recirculation as well asair conditioning

The roof window is made of high-strength material and withstandsheavy blows, e.g from falling objects

The cab can be moved longitudinally, manually

The brake system is separated from the working hydraulics with its owntank, fixed gear-pump, high-pressure filter, accumulators and cooler

22 3 Overview – Overview description

9

6 15,16

1 Interior rear view mirror

2 External rear view mirrors

3 Horn

Located under cab

4 Back-up alarm

5 Tinted windows (Not positioned in figure)

6 Openable window, left door

7 Openable window, right door

8 Camera with monitor

For improved rearward visibility The camera is

located on the counterweight and the monitor is

located inside the cab

9 Socket 24 VDC

The socket is located on the right side behind the

operator's seat and is routed across a fuse

10 Slip-protection on steps (Not positioned in figure)

11 Steps with rail by cab steps

12 Steps to cab roof

13 Work lights cab roof, 2 lights

14 Headlights front wing, 2 lamps

15 Work lights boom, 2 lights

16 Extra work lights boom, 2 lights

17 Work lights attachment, 2 lights

18 Extra work lights attachment, 2 lights

19 Back-up lights, 2 lights

20 Brake lights, 2 lights

21 Running lights, 2 lights

22 Direction indicators, 4 lights

23 Lockable tank cap

Machine outside the EU/EEA

1 Machine plate, A32653.5700

M = Machine model

S/N= Serial number/Year of manufacture

W = Machine's operating weight (without load)

Q = Machine's classed lift capacity acc to EN1459

L = Distance between leading edge of wheels and load's centre

of gravity

H = Classed lifting height

Field H and L indicate how big a load the machine can handle at aspecified attachment height (H) and distance from the machine'sleading edge (L)

Machine plate can only be ordered with complete engraving.Machine for the EU/EEA

Machine for the EU/EEA

1 Machine plate, A32653.0700

T = Machine type

M = Machine model

S/N= Serial number/Year of manufacture

Q = Classed lift capacity acc to EN1459

W = Machine's operating weight (without load)

P = Engine power

L = Distance between leading edge of wheels and load's centre

of gravity

H = Classed lifting height

Field H and L indicate how big a load the machine can handle at aspecified attachment height (H) and distance from the machine'sleading edge (L)

Machine plate can only be ordered with complete engraving

24 3 Overview – Plates

2 Type plate for attachment, A45809.6100

A = Identification number for attachmentS/N = serial number/Year of manufacture Right field, states theyear of manufacture

H = Hydraulic pressure

Q = Classed lift capacity acc to EN1459, at centre of gravitydistance (D)

D = Centre of gravity distance for load

COG = Centre of gravity distance for attachment

LLC = Front mounting dimensions

W = The attachment's weight

Type plate can only be ordered with complete engraving

Warning and information plates

The following figures show the warning texts and information textsthat are located on the machine The operator must be aware of thewarnings and should also follow the instructions and information given

on the plates

Make sure warning and information symbols on the machine and itscomponents are always easy to see and are legible Plates that havebeen damaged, illegible or painted over must be replaced immediately

4 8 3

For lifting the machine (1a):

• front part of frame

• rear part of frame by boom mountingFor lifting boom (1b):

• front part of boom

• rear part of boom

4 Warning! A30536.0300

No passengers allowed Passengers may only travel in the cab if

it is equipped with a permanently mounted passenger seat

5 Warning! A30770.0100Air conditioning Filling of refrigerant requires special competenceand authorisation (follow national legislation and local rules)

6 Warning! A30770.0200Air conditioning Located on right frame member

Filling of refrigerant requires special competence andauthorisation (follow national legislation and local rules)

7 Warning! A54527.0200Air conditioning Filling of refrigerant requires special competenceand authorisation (follow national legislation and local rules).

11 Battery disconnector, A30537.0300

In position 0, the battery's plus terminal is disconnected

12 Plate battery voltage, A30534.0200

15 Warning! A30532.0100Hot surfaces.

Power transmission, wheels

18 Air pressure tyres 1.0 MPa, A32049.0100

22 Warning! A30529.0100

Never walk under hanging loads Make sure that

no persons stand or walk under a raised work attachment, regardless of whether it is loaded or not.

30 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 areused!

This chapter gives general information about instruments, switches,controls and other equipment in the machine's cab

1 Left instrument panel

2 Gear selector and multi-function lever

3 Steering wheel panel

4 Steering wheel

5 Direction indicators

6 Panel for hydraulic functions

7 Control breaker for hydraulics

8 Switch for parking brake

4 Instruments and controls – Instruments and controls 31

16 Switch for fan

17 Switch for heat

18 Switch for air distribution

19 Switch, work lights cab roof

20 Switch, work lights attachment

21 Switch, work lights boom

22 Switch, revolving beacon

23 Switch for flashing hazard lights

24 Switch for headlights

25 Switch for seat heating

32 4 Instruments and controls – Instruments and controls

Steering wheel panel

59 58 57 60

Steering wheel panel

32 Warning lamp, low battery charging

33 Warning lamp for low brake pressure

34 Indicator light for active error codes

35 Warning lamp for by-pass

36 Not used

37 Warning lamp, high coolant temperature

38 Warning lamp, low oil pressure in engine

39 Indicator light for preheating

40 Warning lamp for low coolant level engine

41 Warning lamp, high oil temperature in transmission

42 Warning lamp, low fuel level

43 Warning lamp, high temperature hydraulic oil

44 Indicator light, high beams

45 Indicator light for direction indicators

46 Indicator light, parking brake

47 Indicator light, locked twistlocks (secured load)

48 Indicator light, alignment (attachment/load)

49 Indicator light, unlocked twistlocks (load released)

50 Panel, warning and indicator lights

51 Control system display

52 Control system indicator

53 Ignition key lock

54 Switch for defroster

55 Switch, windscreen wiper roof, interval

56 Switch, windscreen wiper roof, continuous

57 Switch, interior lighting

58 Switch, windscreen wiper rear, interval

59 Switch, windscreen wiper rear, continuous

60 Control system function keys

61 Travel direction indicator, Forward Neutral Reverse

62 Switch, shifting program A, Automatic shifting

63 Switch, shifting program 1, locked to 1st gear

64 Switch, shifting program 2, locked to 2nd gear

4 Instruments and controls – Instruments and controls 33

Panel for hydraulic functions

Panel for hydraulic functions

Panel for hydraulic functions

34 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 thecab They indicate the status of subsystems/systems An illuminatedwarning lamp should be attended to immediately An illuminatedindicator light informs of imminent action

All lights in the panel are activated briefly when starting Warningand indicator lights are concentrated in a panel on the steering wheelpanel (position 50)

Numbers in brackets refer to the positions in Overview, page 30.

Warning lamp, low battery charging (32)

If the warning lamp remains lit, switch off the engine and contactservice

NOTE

Do not operate with an activated light for low battery charging.

Warning lamp, low brake pressure (33)

The light (red) is activated when the pressure in the accumulator, that

is, the brake pressure is too low After the light has been activated,the service brake's capacity is limited

Check the accumulators' sealing integrity if the pressure does not build

up and is not maintained, see chapter 6 Inspection and maintenance.

Indicator light for active error codes (34)

The indicator light (orange) shows that the control system has one

or more error codes, active or passive For detailed information, see

Section 5.3 Error codes.

The indicator light is activated for as long as there are active errorcodes (STOP, WARNING or INFORMATION)

Warning lamp, by-pass (35)

By-pass can only continue for 60 seconds at a time.

Warning lamp, high coolant temperature (37)

The light (red) is activated if the engine coolant temperature is too

4 Instruments and controls – Warning and indicator lights 35

Warning lamp, low oil pressure in engine (38)

For engine alternative Cummins QSM11 :Engine power output is restricted at low oil pressure

Indicator light, preheating (39)

For engine alternative Yuchai YC6M360-30:

The light (orange) is activated during the engine's preheating phase.Preheating heats the engine's induction air, if necessary, to a suitabletemperature with the heating coil when the ignition key lock is inposition II

When needed, the engine's control unit activated preheating during

If the light (red) is activated during operation the coolant level is too

low Check and fill if necessary For action, see chapter 6 Inspection

Warning lamp, low fuel level (42)

6 Inspection and maintenance.

Approx 10% of the fuel remains, which corresponds to approx 3hours operating time, when the light is first activated

Warning lamp, high temperature hydraulic oil (43)

Indicator light, high beams (44)

36 4 Instruments and controls – Warning and indicator lights

Indicator light, direction indicators (45)

The light (red) is activated when the parking brake is applied

If the indicator light flashes, the parking brake has been appliedautomatically (not by the operator) when the machine has stopped

To release the parking brake, activate and deactivate the parkingbrake with the switch for parking brake (position 8)

Indicator light for locked twistlocks (47)

See section 4.11 Control system for detailed information.

Travel direction indicator, Forward Neutral Reverse (61)