A Foreword

B Safety

C Preventive maintenance

0 Complete machine

1 Engine

2 Transmission
DRT 450
3 Driveline/axle

4 Brakes

5 Steering

6 Suspension

7 Load handling

8 Control system

9 Frame, body, cab and accessories

10 Common hydraulics

11 Common electrics

12 Common pneumatics

D Error codes

E Schematics

F Technical data

G Terminology and index

 A:1

A Foreword

Contents A Foreword
Foreword ............................................................................................................ A:3
About the maintenance manual ...................................................................... A:3
General ...................................................................................................... A:3
Conditions .................................................................................................. A:3
Storage....................................................................................................... A:3
About the machine version......................................................................... A:3
Copyright .................................................................................................... A:3
Reading instructions ....................................................................................... A:4
Warning information ................................................................................... A:4
Important information ................................................................................. A:4
Read operator's manual ............................................................................. A:4
Read maintenance manual ........................................................................ A:4
Maintenance manual's content................................................................... A:5
Function group structure ............................................................................ A:6
Product alternatives and optional equipment ............................................. A:6
Machine card.............................................................................................. A:8
Function descriptions ................................................................................. A:8
About the documentation ...............................................................................A:11
The documentation's parts ........................................................................A:11
Ordering of documentation........................................................................A:11
Feedback ...................................................................................................... A:12
Form for copying ...................................................................................... A:12

Maintenance Manual DRT 450 UDRT02.02GB

A:2

UDRT02.02GB Maintenance Manual DRT 450

 A Foreword – Foreword A:3

A Foreword
About the maintenance manual
General
Thank you for selecting Cargotec as your machine supplier. We hope
that we will meet your expectations.

The maintenance manual contains information about how the machine

should be maintained for maximal operating reliability and service
life as well as troubleshooting information for fast correction of any
malfunctions.

Conditions
The instructions are based on use of general tools available in stores.
All lifting devices, e.g., straps, slings, ratchet blocks, etc., must meet
governing national regulations for lifting devices.

Cargotec will not accept any responsibility for modi�cations performed

without permission from Cargotec or in the event of the use of lifting
devices, tools or work methods other than those described in this
manual.

Storage

NOTE
The maintenance manual shall be accessible to service personnel.

About the machine version

The information in this publication corresponds to the machine's
design and appearance when delivered from Cargotec. There may be
differences due to customization of the machine.

Cargotec reserves the right to change speci�cations and equipment

without prior noti�cation. The information in the manual is valid at the
time of publication.

DANGER
External equipment may only be used if it is approved
by Cargotec.
Risk of fatal accidents and property damage!
Only used equipment approved by Cargotec.

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.

Duplication by any means such as copying, printing, etc., is prohibited.

Maintenance Manual DRT 450 UDRT02.02GB

A:4 A Foreword – Reading instructions

Reading instructions
Warning information
Warnings inform of potential hazards that, if warnings are not heeded,
may result in personal injury or product damage.

DANGER
Situation that may lead to severe personal injury or
fatality if the rule is not followed.

WARNING
Situation that may lead to personal injury if the rule is
not followed.

CAUTION
Situation that may lead to product damage if the rule
is not followed.

Important information
Important information is indicated by NOTE, and is provided to
facilitate the work process, handling or increase understanding of the
information.

NOTE
Information that is important without being related to safety.

Read 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.

Read the operator's manual

Read maintenance manual

The symbol to the left is used in certain cases on the machine and
refers to important information in the maintenance manual.

Read the maintenance manual

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 A Foreword – Reading instructions A:5

Maintenance manual's content

The information in the maintenance manual is divided into function
groups (0-12) to facilitate searching for information. The manual is
divided in 20 sections A-C, 0-12, D-G. The sections with letters contain
speci�c information that applies to several function groups and is not
bound to a function, e.g., section "F Technical data". This is described
in greater detail in the table below.

For more information about function groups, see Function group

structure, page A:6.

A Foreword General information about the maintenance manual's purpose, content and
reading instructions as well as survey for feedback of views and eventual
inaccuracies.
B Safety Keep in mind for your safety.
C Preventive maintenance General information about preventive maintenance of the machine.
0 Complete machine
1 Engine
2 Transmission
3 Driveline/Axle
4 Brakes
Technical description, description of the machine's functions with schematic
5 Steering drawings and explanatory texts for the included components.
6 Suspension Overviews with the components' position on the machine.
7 Load handling Work instructions for preventive maintenance.
8 Control system Work instructions for checking and adjusting.
9 Frame, body, cab and
accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes Error code information is found in the Workshop manual and Operator's manual.
E Diagrams Wiring diagrams and hydraulic diagrams are found in the Workshop manual.
F Technical data Technical data, conversion tables, information for conversion of units.
G Terminology and index General terminology and abbreviations, explanations of terms and abbreviations
that may appear in the manual, index for headings in the manual.

Maintenance Manual DRT 450 UDRT02.02GB

A:6 A Foreword – Reading instructions

Function group structure

The information in the manual is divided in a structure of functions
at different levels, based on the machine's design and use, called
function groups.

The upper level (called main group) determines group, e.g., group 7
Load handling. The second level (called two-digit) determines function,
e.g., 7.2 Lifting/lowering. The third and fourth levels are used to break
down functions into smaller parts (components).

The function groups' structure for main group and two-digit group level
are common for all machines from Cargotec, e.g., 4.3 Power-assisted
brake system. Machine-unique adaptations of function groups are
done at the third and fourth group level, e.g., 4.3.9 Wheel brake and
4.3.9.1 Disc pack. This means that some function groups (headings)
will be left out of the documentation for certain machines since the
machine does not have that particular function or component. In turn,
this means that the function groups' numbering may 'skip', e.g., the
three-digit heading level 4.8.7 Oil cooler may be included for some
machines but not for others.

The idea is that the function groups are intended to work as a search
term to �nd different types of information between different sections and
manuals. The information under a function group is divided into smaller
sections according to the type of content, e.g., description or change.

The maintenance manual and workshop manual contain different

information. The maintenance manual only includes information
needed for preventive maintenance as well as simpler troubleshooting.
The workshop manual includes more in-depth information and repair
instructions.

References between sections in the same manual are indicated with

section and group number, e.g., "see section 4 Brakes, group 4.3.9
Wheel brake". References within a section are indicated with a page
number, e.g., "see Sensor fuel level, description page 24".

References are not given between Maintenance manual and Workshop

manual. If more information is desired for a function group, the primary
recommendation is to search under the same function group in the
other manual.

Product alternatives and optional equipment

The information in the manual is divided in modules. For product
alternatives and optional equipment, handling of the modules differs
depending on if it is the one or the other that is described, see below.

Special equipment is not described in the manual. If you're uncertain

about what equipment the machine should have, use the machine card
to decide which information applies, see Machine card, page A:8.
Product alternatives
Product alternatives

Product alternatives are such options that exclude certain standard

Symbol indicating optional equipment equipment (e.g., engine alternative).

Equivalent information for different product alternatives is described

in separate sections following each other under the same function
group. To indicate that there are different alternatives, the supplement
"Product alternative" is used in the heading together with a simple
description of which alternative is described, e.g., "(Product alternative
Climate control unit ECC)". In addition, alternatives that are optional
are marked with the symbol for optional equipment.

UDRT02.02GB Maintenance Manual DRT 450

A Foreword – Reading instructions A:7

Optional equipment

Optional equipment are options that can be added to the standard

equipment to obtain additional or improved functions.

Information for optional equipment is described in separate sections

with the standard equipment as starting point. Description of the
optional equipment describes how the standard function is affected by
the option as well as which additional components are added.

Maintenance Manual DRT 450 UDRT02.02GB

A:8 A Foreword – Reading instructions

Machine card

NOTE
If the machine has been modi�ed after delivery the information on
the machine card may be lacking or incorrect.

IMPORTANT
Changes done on the machine shall be reported to
Cargotec so that the machine card can be updated. A
new updated machine card is sent on the request of
the customer.

The machine card indicates of which drawings the machine consists,

in many cases these can be associated to options and product
alternatives. For more information on handling product alternatives and
optional equipment, see Product alternatives and optional equipment,
page A:6. The machine card is supplied with the spare parts catalogue
and should be in the cab.

The machine card is divided in the same function groups as the spare
parts catalogue, maintenance manual, and workshop manual. For
practical reasons, the machine card only uses the �rst and second
level of the function group index. The function groups are written in
groups of four characters, e.g., group 0107 corresponds to group 1.7
Cooling system in the manual.

For more information about how the machine card is used for ordering
spare parts, see the parts catalogue's foreword.

If the information on the machine card does not help, contact Cargotec.

NOTE
All documents that accompany the machine are non-registered
documents and there will be no noti�cation of changes.

Function descriptions
Function descriptions are schematic overviews that describe how a
function works as well as which components and signals work together.

The function descriptions describe the function in a logical ow from

input signal to desired output signal. Most functions require that
pre-determined conditions are ful�lled for that function to be activated.
In these cases the conditions are listed above the �gure.

Function descriptions use symbols to illustrate components such as

valves, sensors, etc.

UDRT02.02GB Maintenance Manual DRT 450

 A Foreword – Reading instructions A:9

Example of function description

1. Hydraulic force (solid double line) 4. Illustration of function, (applied brake)
2. Flag pressure check connection (Check point), 5. Component list
indicates that there is pressure check connection for
6. Position number in illustration, reference to
checking pressure signal
component list
3. Flag diagnostic test, indicates that the signal can be
7. Electric power (solid single line)
checked with diagnostic test, see section 8 Control
system, group 8.4 Diagnostics

Maintenance Manual DRT 450 UDRT02.02GB

A:10 A Foreword – Reading instructions

Symbol explanation function descriptions

Symbol explanation function descriptions

The following symbols are used in function descriptions, the symbols

are based on standard symbols used in wiring and hydraulic diagrams.
1. Electric control signal
2. Electric force
3. Hydraulic control signal
4. Hydraulic force
5. Hydraulic motor
6. Hydraulic oil pump with variable displacement
7. Hydraulic oil pump with �xed displacement
8. Electric motor
9. Accumulator
10. Disc brake
11. Filter
12. Radiator
13. Bulb
14. Control system, two control units with CAN-bus
15. Restriction
16. Adjustable restriction
17. Inductive position sensor
18. Electrically controlled servo valve
19. Thermal bypass valve
20. Temperature-controlled switch
21. Temperature sensor
22. Pressure sensor
23. Pressure-controlled switch
24. Hydraulic cylinder
25. Double-acting hydraulic cylinder
26. Spring brake cylinder
27. Valve block
28. Shuttle valve
29. Non-return valve

UDRT02.02GB Maintenance Manual DRT 450

A Foreword – About the documentation A:11

About the documentation

The documentation's parts
The documentation for the machine consists of the following parts:
Operator's manual
The operator's manual is delivered with the machine in the cab.
Documentation kit
Maintenance manual and spare parts catalogue with machine card are
delivered to the machine as a separate documentation kit.
Supplementary documentation
Supplementary documentation can be ordered for the machine.
• Workshop manual
• Supplier documentation for engine, transmission and drive axle.

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

Always specify publication number when ordering.

For publication number, see the machine card.

Maintenance Manual DRT 450 UDRT02.02GB

A:12 A Foreword – Feedback

Feedback
Form for copying
Cargotec's ambition is that you who work with maintenance of Kalmar
machines shall have access to correct information.

Your feedback is important to be able to improve the information.

Copy this form, write down your views and send it to us. Thanks for
your help!

To: Cargotec Sweden AB

Technical Documentation
Torggatan 3
SE-340 10 Lidhult
SWEDEN
Fax: +46 372 263 93
From:
Company / Sender: ..........................................................................................................................................

Telephone: ..........................................................................................................................................................

E-mail: .................................................................................................................................................................

Date: .................................... - .................. - ..................

Manual in-
formation
Name / Publication number: .............................................................................................................................

Section / page number: ......................................................................................................................................

Sugges-
tions,
.............................................................................................................................................................................
views, re-
marks,
etc.
.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

UDRT02.02GB Maintenance Manual DRT 450

 B:1

B Saf ety

Contents B Safety
Safety.................................................................................................................. B:3
General safety information.............................................................................. B:3
Safety concerns everyone!......................................................................... B:3
A near accident is a warning! ..................................................................... B:3
Safety instructions........................................................................................... B:4
General ...................................................................................................... B:4
Service position .......................................................................................... B:4
Hydraulic and brake systems, depressurising............................................ B:5
Oils ............................................................................................................. B:6
Fuel system................................................................................................ B:7
Clothing, etc. .............................................................................................. B:8
Several mechanics on the same machine.................................................. B:8
Working under machine ............................................................................. B:9
Lifting heavy components .......................................................................... B:9
Vibrations ................................................................................................. B:10
Noise ........................................................................................................ B:10
Solvents ....................................................................................................B:11
Fire and explosion risks............................................................................ B:12
Fluid or gas under pressure ..................................................................... B:14
Coolant ..................................................................................................... B:14
Refrigerant ............................................................................................... B:15
Air pollution .............................................................................................. B:15
Tensioned springs .................................................................................... B:16
Electric motors ......................................................................................... B:16
Rotating components and tools................................................................ B:17
Tyres and rims.......................................................................................... B:17
Lifting equipment ...................................................................................... B:18
Spare parts............................................................................................... B:18
Non-ionised radiation ............................................................................... B:19
Environment.................................................................................................. B:20
General .................................................................................................... B:20

Maintenance Manual DRT 450 UDRT02.02GB

B:2

UDRT02.02GB Maintenance Manual DRT 450

 B Safety – Safety B:3

B Safety
General safety information
Safety concerns everyone!
The safety information concerns everyone who works with the machine!
Persons who do not follow the safety instructions in this manual must
make absolutely sure that the work is performed without risks of
personal injury, without risks of machine damage, or property damage!

Remember to:
• follow the instructions in this manual
• be trained for the work in question
• follow local laws, safety rules and regulations
• use the correct equipment and tools for the job
• wear the correct clothes
• use common sense and be careful. Do not take any risks!

Cargotec has in this publication documented and warned for situations

and risks that may occur in connection with using as well as service or
repairs of the machine during normal circumstances.

Therefore, it is very important that all who work with the machine, or
carry out repairs or service work, acquaint themselves with and act
according to the information in the Maintenance Manual and Operator's
Manual.

A near accident is a warning!

An incident is an unforeseen event where neither a person, the
machine, nor property is damaged. However, incidents indicate that
there is a risk of injury and actions must be taken to avoid injury risks.

Maintenance Manual DRT 450 UDRT02.02GB

B:4 B Safety – Safety instructions

Safety instructions
General
Read, consider and follow the safety instructions below before starting
to work in the machine:
• Service position, page B:4
• Hydraulic and brake systems, depressurising, page B:5
• Oils, page B:6
• Fuel system, page B:7
• Clothing, etc., page B:8
• Several mechanics on the same machine, page B:8
• Working under machine, page B:9
• Lifting heavy components, page B:9
• Vibrations, page B:10
• Noise, page B:10
• Solvents, page B:11
• Fire and explosion risks, page B:12
• Fluid or gas under pressure, page B:14
• Coolant, page B:14
• Refrigerant, page B:15
• Air pollution, page B:15
• Tensioned springs, page B:16
• Electric motors, page B:16
• Rotating components and tools, page B:17
• Tyres and rims, page B:17
• Lifting equipment, page B:18
• Spare parts, page B:18
• Non-ionised radiation, page B:19

Service position
General
General

Service position is used for service, maintenance and other situations

when the machine needs to be secured.

Service position means:

• Machine parked, that is, applied parking brake.
• Boom fully retracted and lowered to horizontal position.
• Engine off.
Machine with fully retracted and lowered boom
• System voltage off (with battery disconnector).

UDRT02.02GB Maintenance Manual DRT 450

 B Safety – Safety instructions B:5

Hydraulic and brake systems, depressurising

1 Machine in service position.

2 Depressurise the hydraulic system.

Turn the start key to position I and activate extension out, a loud
hissing sound is heard if there is pressure in the hydraulic system.
Activate lift, extension, and side shift several times.
3 Turn the start key to position 0 and turn off the system voltage.

4 Depressurize the attachment.

Open relief valve top lift.

CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to �ne �lter hydraulic oil.
Check that relief valve top lift is closed before the
engine is started.

The �gure above shows open valve.

5 Depressurise the brake system by opening the drain valve on the

accumulator charging valve.

NOTE
Keep the drain valve open as long as work is in progress.

NOTE
After the work has been �nished, close the drain valve and
tighten the lock ring.

Maintenance Manual DRT 450 UDRT02.02GB

B:6 B Safety – Safety instructions

Oils
The following safety instructions shall be followed for work when
handling oils.

WARNING
Warm and pressurised oil.
Always completely depressurize the hydraulic and
brake systems before starting to work in these systems.
Hydraulic and brake systems are pressurized and the
oil can cause personal injuries.
Avoid skin contact with the oil, use protective gloves.
Hot oil may cause burns, rashes and irritation! Oil may
also be corrosive to mucous membranes in, e.g., eyes,
skin, and throat.

IMPORTANT
Always clean the area around components and
connections before loosening them. Dirt in oil systems
causes increased wear, which results in material
damage.
Always take actions to avoid spills. Where a container
cannot be used for draining, use a pump or hose for
safe handling.
Always check that plugs seal tight before collection
containers are moved.
Handle all oil as environmentally hazardous waste.
Oils freely released cause damage to the environment
and may also start �res. Waste oils/ uids shall always
be handled and taken care of by companies that are
authorized for this work.

UDRT02.02GB Maintenance Manual DRT 450

B Safety – Safety instructions B:7

Fuel system
The following safety instructions shall be followed for work when
handling fuel.

DANGER
Pay attention to the risk of �re when working on the
fuel system.
Work on the fuel system shall be avoided when the
engine is warm since fuel can spill on hot surfaces and
may ignite.
Ensure that naked ames, sparks or red-hot/glowing
objects have been extinguished before starting work
on or in the vicinity of the fuel system.
Do not smoke in the vicinity of the machine when work
on the fuel system is in progress.

WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can
damage the skin, which results in serious injuries.
Risk of personal injury.
Use protective gloves and protective safety goggles,
avoid skin contact with fuel. If a component is to be
loosened, hold a rag over the coupling as protection
and collect the fuel. Fuel may be corrosive to mucous
membranes in, e.g., eyes, skin, and throat.

CAUTION
Always clean the area around components and
connections before loosening them. Dirt in the fuel
system can cause malfunctions and engine stops in
unwanted situations, as well as increased wear and
material damages.

Maintenance Manual DRT 450 UDRT02.02GB

B:8 B Safety – Safety instructions

IMPORTANT
Always take actions to avoid spills. Where a container
cannot be used for draining, use a pump or hose for
safe handling.
Always check that plugs and connections seal tight
before moving collection containers.
Handle the fuel as environmentally hazardous waste.
Fuel freely released causes damage to the environment
and may also start �res. Fuel shall always be handled
and taken care of by companies that are authorized for
this work.

Clothing, etc.
Clothes should be in good repair. Remove loose, hanging items (e.g.,
tie, scarf). Do not wear clothes with wide sleeves, pant legs, etc.

Remove jewellery as it may conduct electricity and get caught in

moving parts.

Long hair should be put up securely since it may otherwise get caught
in moving parts. Be careful when working with a welder or open ame
since hair is ammable.

Several mechanics on the same machine

WARNING
If several mechanics are working on the same vehicle,
be extra careful so that accidental movements do not
injure another person. Communicate so that everyone
knows where everyone is and what they are doing.

Risks
Work with wheels or axle suspension, mountings, etc., may result in
components on the other side moving and causing damage or injury.

Movements performed from the operator's station, e.g., all movement

of lifting equipment, may cause severe personal injuries.

Safety actions
• Make sure that the machine's lifting equipment is completely
lowered or secured in another way.
• Move the battery disconnector to position zero and remove the key.
• Be aware of the risks when several persons work around the
vehicle.
• Make your co-workers aware of what you're working with.
• Do not work with drive wheels on the machine's both sides at the
same time.

UDRT02.02GB Maintenance Manual DRT 450

B Safety – Safety instructions B:9

Working under machine

Working under frame

A raised vehicle may not, for any reason, be supported or lifted in parts
that belong to the wheel suspension or steering. Always support under
the frame or wheel axle.
Risks
Mechanical or hydraulic tools and lifting devices can fall over or
accidentally be lowered due to malfunctions or incorrect use.
Safety actions
• Use axle stands and supports that stand securely.
• Lifting tools should be inspected and type approved for use.

Lifting heavy components

WARNING
Careless handling of heavy components may lead to
serious personal injury and material damage.
Use type approved lifting tools or other devices to
move heavy components. Make sure that the device
is sturdy and intact.

Risks

Unsuitable lift slings, straps, etc. may break or glide.

The centre of gravity of the component can change during the course of
the work, and the component may then make unexpected movements
which may cause severe personal injuries and material damage.

A component lifted with lifting equipment can start to turn if the centre
of gravity changes.

A component lifted using an overhead crane may start to swing

back and forth, which can cause severe crushing injuries or material
damage.

Safety actions

Lift with lifting device.Use lifting tools or other devices, especially

when such items are available for certain jobs. See the workshop
manual for methods.

If lifting must be performed without lifting device:

• Lift near the body.
• Keep your back vertical. Raise and lower with your legs and arms,
do not bend your back. Do not twist your body while lifting. Ask for
assistance - before lifting.
• Wear gloves. They're often good protection to reduce crushing
and cutting injuries to �ngers.
• Always use protective shoes.

Maintenance Manual DRT 450 UDRT02.02GB

B:10 B Safety – Safety instructions

Vibrations
Use of vibrating tools, e.g. impact nut runner or grinder, for an extended
period of time may cause injuries as vibration is transmitted from tool
to hands. Most of all when �ngers are cold.

Safety actions
• Use heavy gloves to protect against the cold and transfer of
vibrations.
• Switch between work duties to give the body time to rest.
• Vary work position and grip so that the body is not stressed in only
one position by the vibrations.

Noise
Noise louder than 85 dB (A) lasting for longer than 8 hours is deemed to
damage hearing. (Limit values may differ between different countries.)
High tones (high frequency) is more damaging than low tones at the
same sound level. Noise in the form of impulse sounds may also be
damaging, e.g., hammer blows.

Risks

Hearing damage may occur at noise levels higher than the limit value.
In severe cases, damage may be permanent.

Safety actions
• Use hearing protection. Make sure that it's tested and protects
against the right noise level.
• Limit noise with noise-absorbing dividers, for example,
noise-absorbing materials in roof and on walls.

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B Safety – Safety instructions B:11

Solvents
Fluids that (unlike water) dissolve grease, paint, lacquer, wax, oil,
glue, rubber, etc., are called organic solvents. Examples:Naphtha,
gasoline, thinner, alcohols, diesel, xylene, trichloroethylene, toluene.
Many solvents are ammable.

Risks

Products with solvents give off vapours that may cause dizziness,
headache, and nausea. They may also cause irritation of mucous
membranes in the throat and respiratory tracts.

If dissolvent comes into direct contact with the skin it can dry and crack.
Higher risk of skin allergies. Solvents may also cause injuries if they
penetrate the skin and are absorbed by the blood.

If the body is continuously exposed to solvents, the central nervous

system may be injured. This manifests itself as trouble sleeping,
depressions, nervousness, poor memory, and general tiredness.
Continuous inhalation of gasoline and diesel vapours is suspected
of causing cancer.

Safety actions
• Avoid inhaling solvent fumes by providing good ventilation, or
wearing a fresh-air mask or respiratory device with a suitable �lter
for the toxic gases.
• Never leave a solvent container without tight-sealing lid.
• Use solvents with a low content of aromatic compounds. This
reduces the risk of injuries.
• Avoid skin contact.
• Use protective gloves.
• Make sure that work clothes are solvent-resistant.

Maintenance Manual DRT 450 UDRT02.02GB

B:12 B Safety – Safety instructions

Fire and explosion risks

DANGER
The operator's safety may not be jeopardized in case
of �re.
If possible, take the following actions at the slightest
sign of �re:
1. Stop the machine and turn the start key to stop
position.
2. Leave the cab.
3. Turn off the system voltage with the battery
disconnector.
4. Call the �re department.
5. Try to put out the �re.
If this is not possible, leave the machine and the
danger area.

DANGER
Smoke from a �re may be very toxic.
Smoke anesthetizes, suffocates, and kills! Smoke from
�res, even small amounts, can damage lungs and
respiratory organs.
Avoid inhaling smoke gases, do not stand in the
smoke. Use breathing protection when putting out a
�re and working with burnt materials.

Examples of ammable and explosive substances are oils, gasoline,

diesel fuel oil, organic solvents (lacquer, plastics, cleaning agents),
rustproo�ng agents, welding gas, gas for heating (acetylene), high
concentration of dust particles consisting of combustible materials.
Rubber tyres are ammable and cause explosive �res.

Risks

Examples of causes of ignition are welding, cutting with a welding

torch, smoking, sparks from grinding machines, contact between
hot machine parts and ammable materials, heat generation in rag
drenched with oil or paint (linseed oil), and oxygen. Oxygen cylinders,
lines, and valves shall be kept free from oil and grease.

Fumes from, e.g., fuel are heavier than air and may "run" down into a
sloping plane, or down in a grease pit, where welding ames, grinding
sparks or cigarette glow may cause an explosion. Evaporated gasoline
explodes very forcefully.

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B Safety – Safety instructions B:13

Special cases

Gas oil with added gasoline has a reduced ash point. Risk of
explosion already at room temperature. Explosion risk for heated gas
oil is higher than for gasoline.

When changing oil in the engine, hydraulic system and transmission,

keep in mind that the oil may be hot and can cause burn injuries.

Welding on or near machine. If diesel and or other oils have leaked out
and been absorbed by rags, absorbent agents, paper or other porous
material, glowing welding sparks can cause ignition and explosive �res.

When a battery is being charged, the battery electrolyte's water is

divided into oxygen and hydrogen gas. This mixture is very explosive.
The risk of explosion is especially high when a booster battery or a
rapid-charge device is used since this increases the risk of sparks.

In today's machines there are a lot of electronics. When welding,

all control units must be unplugged and the electric power must be
turned off with the battery disconnector. Powerful welding currents may
otherwise short-circuit the electronics, destroy expensive equipment,
and may cause an explosion or �re.

Never weld on painted surfaces (remove paint, preferably by blasting at

least 10 cm around the welding or cutting point). Use gloves, breathing
protection, and protective safety glasses. Also, never weld near plastic
or rubber materials without �rst protecting them from the heat. Paint,
plastic, and rubber generate many substances when heated, and these
may be hazardous to health. Be careful with machines that have been
exposed to intense heat or �re.

Safety actions

DANGER
Remains of fuel, oils, grease, and other ammable
materials on the engine or in the engine compartment
are �re hazards.
Risk of �re!
Remove remains of ammable materials from the
engine compartment as soon as they are discovered,
be extra thorough with hot surfaces such as the
exhaust system, manifold, or turbo. If leaks of oil, fuel,
or coolant are detected, �nd the cause and solve the
problem before starting the engine.

• Make a habit of performing a visual check of the engine and engine

compartment before starting the engine and after operation, when
the engine has been stopped. This ensures fast detection if
anything abnormal has happened or is about to occur. Pay special
attention to oil, fuel, or coolant leaks, loose bolts, worn or poorly
tensioned drive belts, loose connections, damaged hoses, and
electrical cables. The inspection only takes a few minutes and may
prevent serious problems and expensive repairs.
• Store hazardous substance in approved and sealed container.
• Make sure that there is no ignition source near ammable or
explosive substances.
• Make sure that ventilation is adequate or there is an air extraction
unit when handling ammable substances.

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B:14 B Safety – Safety instructions

Fluid or gas under pressure

Lines with high pressure may be damaged during work and uid or
gas may jet out.
There may be high pressure in a line even if the pump has stopped,
therefore gas or uid may leak out when the connection for the hose
is loosened.
A gas cylinder exposed to outside forces may explode, e.g., if it falls on
a hard surface. Gas may ow out from damaged valves.

Risks
Risk of damage/injuries in connection with work on:
• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Changing tyres.
• Climate control unit (air conditioning).

Safety actions
• Use protective goggles and protective gloves.
• Never work in a pressurised system.
• Never adjust a pressure limiting valve to a higher pressure than
the manufacturer's recommendations.
• A hydraulic hose that swells, e.g., at a connection, shows that it
is about to rupture. Replace it as soon as possible! Check the
connections thoroughly.
• Use uid when checking for leaks.
• Never blow clothes clean with compressed air.
• Failed pressure accumulators shall �rst be drained of pressure
and then punctured before being discarded (to avoid risk of
explosion). Carefully drill a hole with 3 mm diameter after draining
the pressure.
• Never feel with your hands to check for any leaks. A �ne jet from
a hydraulic hose may have such high pressure that it easily cuts
through, e.g., a hand, causing very severe injuries.

Coolant
The coolant in the machine’s cooling system consists of water,
anti-corrosion compound and anti-freeze uid, for example, ethylene
glycol.
Coolant must not be drained into the sewer system or directly onto
the ground.

Risks
The cooling system is at high pressure when the engine is warm. Hot
coolant may jet out and cause scalding in case of leaks or when the
cap on the expansion tank (�lling point) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous
and hazardous to health.

Safety actions
• Use protective gloves and safety glasses if there is a risk of
splashing or spraying.
• First open the cap for the �lling point, to release the high pressure.
Be careful. Hot steam and coolant may jet out.
• If possible, avoid working on the cooling system when the coolant
is hot.

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B Safety – Safety instructions B:15

Refrigerant
Refrigerant is used in the machine’s air conditioning system.

Work on the air conditioning system must be performed by

accredited/authorised and trained personnel according to national
legislation and local regulations.

Risks

The air conditioning operates at high pressure. Escaping refrigerant

can cause frostbite injuries.

Refrigerant that is heated (e.g., when repairing leaking climate/AC

system), generates gases that are very dangerous to inhale.

Safety actions
• Follow special instructions and equipment for refrigerant according
to the manual when working on the air conditioning unit. Any
person doing the work must have special accreditation. (Note
national legislation and local regulations!)
• Use protective gloves and safety glasses if there’s a risk of leaks.
• Make sure that heat-producing sources or objects are not close by
(cigarette glow, welding ame).

Air pollution
Air pollution is the pollution in the air around us and that are regarded
as hazardous to health. Certain pollutants are more prevalent in some
environments.

The following health-hazardous air pollution is especially prominent in

workshops:
• Carbon monoxide (fumes) is found in exhaust gases. Odourless
and therefore extremely dangerous.
• Nitrogen oxides (nitrous gases) are present in exhaust fumes.
• Welding smoke especially hazardous to health when welding on
oily surfaces, galvanised or lacquered materials.
• Oil mist for example, when applying anti-corrosion agent.
• Grinding dust and gases generated when grinding and heating
plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.
• Isocyanates are present in certain paints, �llers, adhesives and
foam plastics used on machines.

Risks

Sulphuric acid mist is corrosive and injures the respiratory tracts.

(Generated when heating certain plastics and paints.)

Isocyanates may be released in the form of vapour, dust (or may

be found in aerosol) when cutting, grinding, or welding. May cause
irritation of mucous membranes with asthma-like symptoms as well as
impaired lung function. Even brief exposure to high levels may give
problems with permanent oversensitive.

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B:16 B Safety – Safety instructions

Safety actions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are
generated.
• Use suitable protective gloves and breathing protection when there
is risk of oil mist. Make sure that the protection is oil-resistant.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eyewash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine inside the workshop.
Connect air extraction to the exhaust pipe so that exhausts are led
out from the workshop.

Tensioned springs
Examples of tensioned springs:
1. Torque springs in, e.g., pedals.
2. Return spring (cup springs) in parking brake cylinder.
3. Lock rings
4. Gas springs

Risks

If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.

Small springs can cause eye injuries.

Parking brake springs are tensioned with high force and can cause very
severe accidents if they are accidentally released in an uncontrolled
manner.

Gas springs and gas-charged shock absorbers are tensioned with high
force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.

Safety actions
• Use safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manual when performing
maintenance and changing parts and components.
• Always use recommended tools.

Electric motors
Safety actions
Always turn off the battery disconnector when working on electric
motors.

Always block the machine’s wheels, make sure that the parking brake
is activated and that the gear selector is in neutral position before
starting any work on the machine.

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B Safety – Safety instructions B:17

Rotating components and tools

Examples of rotating components and tools:
• Cooling fan
• Drive belts
• Propeller shafts
• Drills
• Grinding machines

Risks

Rotating components, e.g., fans or shafts, can cause severe injuries

if touched.

Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothes or hair get caught and are wound up in
the machine.

Safety actions
• Do not use gloves when working with a drill.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or pant legs.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair-net or similar.
• Remove large or loose hanging jewellery from hands, arms and
neck.

Tyres and rims

DANGER
Tyres are to be considered as pressurized containers.
Handling incorrectly, they are a fatal hazard.
Parts can be thrown with explosive force and may
cause severe injuries.
Never repair damaged tyres, rims, or lock rings. Tyre
changes shall be performed by authorized personnel.

Risks

Dismantling wheels:Tyres, rims, and lock rings may be ejected.

In ating tyres:Tyres, rims, or lock rings may be ejected.

Safety actions
• Always de ate the tyre before starting to work on the wheel.
• Check that tyres, rims, and lock rings are free from damage. Never
repair damaged rims or lock rings.
• Wheels shall be in ated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.
• Use protective screen and safety glasses.

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B:18 B Safety – Safety instructions

Lifting equipment
When working on the machine in general, and with the machine's lifting
equipment in particular, the greatest care must be taken with regards
to securing the boom and attachment.

Therefore, always make a habit of having the boom fully lowered and
completely retracted when working on the machine.

Risks

If the machine's lifting equipment is not lowered or secured, there is a

risk of crushing.

Risk of crushing is extra high when depressurising the hydraulic

system, see Hydraulic and brake systems, depressurising, page B:5.

Safety actions
• If possible, do not start to work before the boom is completely
lowered and fully retracted.

Spare parts

WARNING
For safety reasons, the following spare parts may only
be replaced by genuine spare parts:
• Brake valve
• Drive axle
• Steering valve (Orbitrol)
• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Rim
• Lift cylinder
• Tilt cylinder
• Twistlock
• Control breaker (for hydraulic function)
• Emergency stop
• Accumulator
• Main valve load handling
• Accumulator charging valve
• All control units

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B Safety – Safety instructions B:19

Non-ionised radiation

WARNING
Extra equipment such as two-way radio, telephone, etc.,
may emit non-ionized radiation.
Risk of interference with active or non-active medical
products.
Use two-way radio, telephone, etc., when no persons
with active or non-active medical products are nearby.

NOTE
When persons with active or non-active medical products are not
nearby, then telephone and two-way radio may be used in the cab.
Equipment should not be used when operating or load handling
since this reduces your concentration as operator.
Cargotec does not assume any responsibility for extra equipment
not installed by Cargotec or according to installation instructions
approved by Cargotec.

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B:20 B Safety – Environment

Environment
General
Our global environment is signi�cantly affected by the world's
ever-increasing industrialization. Nature, animals, and humans are
exposed daily to great risks in connection with handling of chemicals in
various forms.

Still there are no environmentally safe chemicals, e.g., oils and

coolants, on the market. Therefore, all who handle, perform service, or
repair machines must use the tools and methods that are necessary to
protect the environment in an environmentally correct way.

By following the simple rules below, you will contribute to protecting

our environment.

Recycling

Well-planned recycling of the machine is the starting point for �nishing

the life cycle and making use of materials for re-use in new products.
According to calculations by Cargotec, the machine can be recycled to
more than 90% by weight.

Environmentally hazardous waste

Components such as batteries, oils and other chemicals, and other

materials 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 uids

Oils freely released cause damage to the environment and may also
start �res. When emptying and draining oils or fuel, take actions to
prevent unnecessary spills.

Waste oils and uids must always be taken care of by an authorised

disposal company.

Pay close attention to oil leaks and other uid leaks! Take immediate
action to seal any leaks.

Air conditioning system

The refrigerant in the air conditioning unit for the cab contributes to
the greenhouse effect if it escapes into the open air. Special training
is required for all service work on the air conditioning unit. Many
countries also require certi�cation by an authority for such work. When
scrapping an air conditioning unit, the refrigerant shall be taken care
of by a certi�ed company.

Working in a contaminated area

The machine shall be equipped for work within a contaminated area

(polluted environment or health-hazardous area) before starting the
work. Also, special local instructions apply for handling and service
work on such a machine.

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 B Safety – Environment B:21

Declarations

The machine does not contain asbestos.

The machine contains lead in batteries and electrical wiring. Some

models have cast lead counterweights.

If the machine is equipped with air conditioning, refrigerant of the type

R134a and an amount between 1-3 kg is used.

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B:22

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 C:1

C Preventive maintenance

Contents C Preventive maintenance

Preventive maintenance ................................................................................... C:3
Preventive maintenance, general ................................................................... C:3
Wheel nuts, check-tightening.......................................................................... C:3
Preventive maintenance, work instructions..................................................... C:3
Check and service log..................................................................................... C:4
50h-check ....................................................................................................... C:5
Service schedule............................................................................................. C:7
Washing ........................................................................................................ C:14
Lubrication 500 hours ................................................................................... C:15
Lubrication 1000 hours ................................................................................. C:16
Checking for cracks ...................................................................................... C:19

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C:2

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C Preventive maintenance – Preventive maintenance C:3

C Preventive maintenance
Preventive maintenance, general
It’s very important that preventive maintenance is performed according
to recommended intervals.

Preventive maintenance should be performed by Cargotec or by a

service organisation authorised by Cargotec.

CAUTION
Service intervals shall be followed.
This is to maintain the machine's safety and to ful�ll
warranty and service agreements!
Use spare parts and uids approved by Cargotec to
ful�ll the warranty.

Wheel nuts, check-tightening

1 For a new machine it is very important to check-tighten the wheel

nuts during the �rst work week until they are seated properly.
This should be done at an interval of 4–5 operating hours (up to
approx. 40–50 operating hours).

Preventive maintenance, work instructions

1 For a new machine, perform check actions after 50 operating

hours, see 50h-check, page C:5.
Note completed 50h-check in the service log, see Check and
service log, page C:4.

2 Regular service shall be performed according to service schedule,

see Service schedule, page C:7. The service schedule shall be
followed to ensure high machine reliability and safety.
Note completed service in the service log, see Check and service
log, page C:4.

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C:4 C Preventive maintenance – Preventive maintenance

Check and service log

Model:
Serial number:

Completed maintenance
Oper-
ating Operating
hours Actions hours Date Signature
50h 50h-check
500h 500h service
1000h 1000 service
1500h 500h service
2000h 2000h service
2500h 500h service
3000h 1000 service
3500h 500h service
4000h 2000h service
4500h 500h service
5000h 1000 service
5500h 500h service
6000h 2000h service
6500h 500h service
7000h 1000 service
7500h 500h service
8000h 2000h service
8500h 500h service
9000h 1000 service
9500h 500h service
10000h 2000h service

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 C Preventive maintenance – Preventive maintenance C:5

50h-check
On a new machine, the following checks shall be performed after 50
operating hours. The checks are performed to increase reliability and
safety.

1 Engine Reference
Performance and exhaust smoke, check (engine
alternative Yuchai YC6M360-30)
Leakage check oil, coolant, exhaust system
Fuel pre-�lter, drain water Section 1 Engine, group 1.2.3 Fuel pre-�lter
Air �lter main cartridge, inspection Section 1 Engine, group 1.6.1 Air cleaning system
Air �lter safety cartridge, inspection Section 1 Engine, group 1.6.1 Air cleaning system
Drive belt tension, checking Section 1 Engine, group 1.7.5 Cooling fan
Coolant level, check Section 1 Engine, group 1.7.7 Coolant
Oil and oil �lter, change Section 1 Engine, group 1.8 Lubrication system
Bolted joints, attachments, mountings, hose clamps,
wear and cha�ng of hoses, cable harnesses, etc.
2 Transmission
Leakage check
Oil level, check Section 2 Transmission, group 2.6 Lubrication system
Transmission oil �lter, changing Section 2 Transmission, group 2.6 Lubrication system
3 Driveline/Axle
Mounting propeller shaft, check-tightening Section 3 Power transmission, group 3.2 Propeller shaft
Mounting drive axle, inspection Section 3 Power transmission, group 3.3 Drive axle
4 Brakes
Power-assisted brake, function check Section 4 Brakes, group 4.3.4 Accumulator
Parking brake, function check
Leakage check
5 Steering
No action
6 Suspension
Tyres and rims, check Section 6 Wheel suspension, group 6.3 Tyre system
Wheel nuts, check-tightening Section 6 Wheel suspension, group 6.3 Tyre system
7 Load handling
Hose connections, check-tightening
Chain tension spreading, checking and adjusting Section 7 Load handling, group 7.5.7 Spreader chains
Lower slide surfaces inner boom The lower glide surfaces of the inner boom should be lubricated
every 250 operating hours up to 1,000 operating hours, thereafter
Slide surfaces main beam attachment according to lubrication chart.
8 Control system
Check that there are no active error codes Section 8 Control and monitoring system, group 8.3 Error codes
9 Frame, body, cab and accessories
Locking of the cab (mechanically movable), checking Section 9 Frame, body, cab and accessories, group 9.10.4
Sliding cab
10 Common hydraulics
Leakage check, retightening as required

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C:6 C Preventive maintenance – Preventive maintenance

Oil level, check Section 10 Common hydraulics, group 10.6.8 Hydraulic oil
Fine �lter hydraulic oil, changing Section 10 Common hydraulics, group 10.6.9 Fine �lter hydraulic
oil
11 Common electrics
Batteries, check Section 11 Common electrical, group 11.3.1 Start battery

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 C Preventive maintenance – Preventive maintenance C:7

Service schedule
Service shall be performed every 500 operating hours. The actions are
divided into 500 h, 1,000 h, and 2,000 h service.

Actions for 250h service are performed between 500h and 1000h
service, which means at 250h, 750h, 1250h, etc.

Actions for 500h service are performed between 1000h and 2000h
service, which means at 500h, 1500h, 2500h, etc.

Actions for 1000h service are performed at odd thousands of operating

hours: 1000h, 3000h, 5000h, etc.

Actions for 2000h service are performed at even thousands of

operating hours: 2000h, 4000h, 6000h, etc.

After service is performed, make a note in the check and service log,
see Check and service log, page C:4.

In the column for service below, the following abbreviations are used:

R = replace

C = check or inspection

L = lubrication

Service
250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Object, action h, etc.. etc. etc. etc. Comment Reference
0 complete machine
Checking cleanliness and C C C Check and remove Section B Safety
leakage remains of ammable
materials in the engine
compartment, pay extra
attention to hot surfaces
such as exhaust system,
manifold, or turbo. If leaks
of oil, fuel, or coolant are
detected, �nd the cause
and solve the problem.
Attachments (stub axles) C C Visual check in connection
with greasing.
Checking for cracks C* C* * Check every 1000h or Checking for cracks,
every year. page C:19
Lubrication 500 hours L L L NOTE: only: Lubrication 500 hours,
page C:15
Brake pedal
Link arms
Wheel hub steering axle
Wheel spindle steering
axle
Lubrication 1000 hours L L Lubrication 1000 hours,
page C:16
1 Engine

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C:8 C Preventive maintenance – Preventive maintenance

Service
250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Object, action h, etc.. etc. etc. etc. Comment Reference
Engine oil (engine R R R R For volume and quality, Section 1 Engine, group
alternative Yuchai see section F F Technical 1.8 Lubrication system
YC6M360-30) data.
Engine oil (engine option R R R
Cummins QSM11 )
Engine oil �lter (engine R R R R
alternative Yuchai
YC6M360-30)
Engine oil �lter (engine R R R
option Cummins QSM11
)
Performance and exhaust C C C C
smoke, check (engine
alternative Yuchai
YC6M360-30)
Fuel tank C Clean if necessary.
Fuel pre-�lter (engine R* R* R* R* Incl. draining of Section 1 Engine, group
alternative Yuchai condensation water. 1.2.3 Fuel pre-�lter
YC6M360-30) Shall be done every 50
hours.
Fuel pre-�lter (engine R* R* R*
option Cummins QSM11 * Change �lter earlier if
error code is displayed.
)
Fuel �lter (engine R* R* R* R* * Change �lter earlier if Section 1 Engine, group
alternative Yuchai error code is displayed. 1.2.4 Fuel �lter
YC6M360-30)
Fuel �lter (engine option R* R* R*
Cummins QSM11 )
Valves and injectors C C C Section 1 Engine, group
(engine alternative 1.5.4 Valve mechanism
Cummins QSM11 )
Vibration damper (engine C* * Check every 6,000 h or Section 1 Engine, group
option Cummins QSM11 every 2 years. 1.5.6 Crank mechanism
)
Air �lter main cartridge C/R C/R C/R Checking indicators, Section 1 Engine,
change when indicated. group 1.6.1 Air cleaning
system
Air �lter safety cartridge C C /R C/R Changed every other time Section 1 Engine,
main cartridge is changed. group 1.6.1 Air cleaning
system
Turbo (engine alternative C C C Section 1 Engine, group
Yuchai YC6M360-30) 1.6.2 Turbo
Turbo (engine option C* * Check every 6,000 h or Section 1 Engine, group
Cummins QSM11 ) every 2 years. 1.6.2 Turbo

Exhaust system C C Check sealing and Section 1 Engine, group

suspension. 1.6.3 Exhaust system
Intercooler C C Check sealing and Section 1 Engine, group
suspension. 1.6.4 Intercooler

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 C Preventive maintenance – Preventive maintenance C:9

Service
250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Object, action h, etc.. etc. etc. etc. Comment Reference
Radiator C C C External cleaning.

NOTE
Do not use high
pressure wash.

Coolant �lter (engine R R R Section 1 Engine, group

option Cummins QSM11 1.7.2 Coolant �lter
)
Fan belt (engine C/R C/R C/R C/R Change when needed. Section 1 Engine, group
alternative Yuchai 1.7.5 Cooling fan
YC6M360-30)
Fan belt (engine option C/R C/R C/R
Cummins QSM11 )
Fan hub (engine option C C Check after 1000 h or Section 1 Engine, group
Cummins QSM11 ) every year. 1.7.5 Cooling fan

Coolant, level (engine C C R R For volume and quality, Section 1 Engine, group
alternative Yuchai see section F F Technical 1.7.7 Coolant
YC6M360-30) data.
Coolant, level (engine C C C / R* * Change after 5 000 h or
alternative Cummins once every two years.
QSM11 ) For volume and quality,
see section F F Technical
data.
Coolant, freezing point C C C For volume and quality, Section 1 Engine, group
see section F F Technical 1.7.7 Coolant
data.
Coolant quality, checking C C Check after 1000 h or Section 1 Engine, group
(engine option Cummins every year. 1.7.7 Coolant
QSM11 )
Bolted joints, C C C Checks and
attachments, mountings, check-tightening
etc.
Connectors (engine C C C C Visual check for damage
alternative Yuchai or corrosion.
YC6M360-30)
Connectors (engine C C C
option Cummins QSM11
)
2 Transmission
Breather �lter, torque C C Clean, when needed. Section 2 Transmission,
converter group 2.2 Torque
converter/clutch
Transmission oil �lter R R Section 2 Transmission,
group 2.6 Lubrication
Transmission oil R R For volume and quality, system
see section F F Technical
data.
3 Driveline/Axle

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C:10 C Preventive maintenance – Preventive maintenance

Service
250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Object, action h, etc.. etc. etc. etc. Comment Reference
Propeller shaft C C C Bolted joints and universal Section 3 Power
joint. transmission, group
3.2 Propeller shaft
Drive axle oil R R For volume and quality, Section 3 Power
see section F F Technical transmission, group
data. 3.3 Drive axle
Mounting drive axle C C Section 3 Power
transmission, group
3.3 Drive axle
4 Brakes
Brake pedal C C Section 4 Brakes, group
4.1.1 Brake pedal
Brake oil pump C C C Section 4 Brakes, group
4.3.1 Brake oil pump
Accumulator C C C Section 4 Brakes group,
4.3.4 Accumulator
Parking brake C/R C/R C/R Check pad thickness, Section 4 Brakes group,
change when needed. 4.5.4 Parking brake unit
Oil cooler C C C Clean when needed.

NOTE
Do not use high
pressure wash.

Breather �lter R Section 4 Brakes group,

4.8.11 Breather �lter
Brake oil �lter R R R Section 4 Brakes group,
4.8.12 Brake oil �lter
Oil brake system R For volume and quality, Section 4 Brakes group,
see section F F Technical 4.8.14 Oil for brake
data. system
5 Steering
Link arms C/L C/L C/L Check bearings. Lubrication 500 hours,
page C:15
6 Suspension
Steering axle suspension C C Section 6 Wheel
suspension, group
6.2.1 Steering axle
cradle
Wheel spindle, check C C Clearance in wheel Section 6 Wheel
suspension shall be suspension, group
checked. Max. 1.5 mm. 6.2.2 Wheel spindle
Wheel hub steering axle, C Check bearing pre-load. Section 6 Wheel
check suspension, group
6.2.3 Wheel hub
Tyres and rims C C C Damage, wear and Section 6 Wheel
pressure, change as suspension, group
needed. 6.3 Tyre system
Wheel nuts C C Check-tightening. Section 6 Wheel
suspension, group
6.3 Tyre system

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 C Preventive maintenance – Preventive maintenance C:11

Service
250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Object, action h, etc.. etc. etc. etc. Comment Reference
Rim C* * Checking for cracks, Section 6 Wheel
every 2,000 hours and suspension, group
in connection with tyre 6.3.2 Rim
changes.
7 Load handling
Servo �lter R R R Section 7 Load
handling, group 7.2.2
Servo �lter
Servo pressure C C C Section 7 Load
handling, group 7.2.3
Pressure reducer
Cable racks boom and C C Hose and cable damage.
attachment
Boom and attachment C C Damage.
Slide plates boom C C Check wear, change as Section 7 Load
needed. handling, group 7.3.10
Lift boom
Slide plates side shift C C Check wear, change as Section 7 Load
frame needed. handling, group 7.4.6
Sideshift frame
Slide plates main beam C C Check wear, change as Section 7 Load
attachment needed. handling, group 7.4.7
Main beam attachment
Chain spreading C C Tension chain when Section 7 Load
needed. handling, group 7.5.7
Spreader chains
Slide plates spreader C C Check wear, change as Section 7 Load
beam needed. handling, group 7.5.8
Spreader beam
Oil spreading motor unit R R For volume and quality, Section 7 Load
see section F F Technical handling, group 7.5.6
data. Spreader motor
Oil rotation motor unit R R For volume and quality, Section 7 Load
see section F F Technical handling, group 7.6.6
data. Rotation motor unit
Twistlocks C C C/R Checking that the parts Section 7 Load
are properly tightened handling, group 7.9.1.7
every 500 hours. Twistlocks
Check of oat position
every 500 hours.
Check of vertical
movement every 2000
hours.
Check for cracks every
other year or every 4000
operating hours.
Replace every 10,000
operating hours. Reset
time counter for twistlocks
after replacement.
Sensor contact C C Checking and adjustment. Section 7 Load
handling, group 7.9.1.8
Sensor alignment

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C:12 C Preventive maintenance – Preventive maintenance

Service
250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Object, action h, etc.. etc. etc. etc. Comment Reference
Sensor twistlocks C C Checking and adjustment. Section 7 Load
handling, group 7.9.1.9
Sensor twistlocks
C Check that deviation Section 7 Load
Weight indicator without load is max. 0.5 handling, group 7.10.2
ton. Weight indicator
8 Control system
Overload system C C C Section 8 Control
system, group 8.2.1
Overload system
9 Frame, body, cab and accessories
Instruments and controls C C C Checking function.
Fresh air �lter R R R Dependent on external Section 9 Frame, body,
environment, at latest cab, and accessories,
every 500 operating group 9.4.1 Fresh air
hours. �lter
C C C Clean when needed. Section 9 Frame, body,
Condenser cab, and accessories,
group 9.4.8 Condenser
NOTE
Do not use high
pressure wash.

C/R C/R C/R Checking, change if Section 9 Frame, body,

Moisture �lter indication is grey. cab and accessories,
group 9.4.9 Moisture
�lter
Windshield wipers C C C Incl. washer, top up when
needed.
Roof window C C Check damage, change Section 9 Frame, body,
when needed. cab, and accessories,
group 9.9.3 Roof
window
Lighting and audible C C C
signals
Cab undercarriage C C Check mountings,
isolators and bolted
joints.
Sliding cab C C Check locking. Section 9 Frame, body,
cab and accessories,
group 9.10.4 Sliding
cab
Doors C C Check doors' mounting
points.
Paint/coatings C Check the machine's Section 9 Frame,
painted surfaces for stone body, cab and
chips and scratches. accessories, group
9.15 Paint/coatings
Repair damage
immediately to avoid
corrosion.
Handles and hand rails C C Checking the mountings.

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 C Preventive maintenance – Preventive maintenance C:13

Service
250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Object, action h, etc.. etc. etc. etc. Comment Reference
Safety decals C C C Check that safety decals See Operator's manual
are legible, securely DRT450, section 3.2
fastened, and not Plates
damaged. Clean dirty
decals and replace decals
as needed.
10 Common hydraulics
Breather �lter C/R R R Change at indication. Section 10 Common
hydraulics, group
10.6.6 Breather �lter
hydraulic oil tank
Hydraulic oil �lter R R Section 10 Common
hydraulics, group
10.6.7 Hydraulic oil
�lter
Oil cooler C C Clean when needed.

NOTE
Do not use high
pressure wash.

Hydraulic oil R For volume and quality, Section 10 Common

see section F F Technical hydraulics, group
data. 10.6.8 Hydraulic oil
Fine �lter hydraulic oil R R R Section 10 Common
hydraulics, group
10.6.9 Fine �lter
hydraulic oil
11 Common electrics
Batteries C C C Section 11 Common
electrical, group 11.3.1
Start battery
Battery cable C C C Section 11 Common
electrical, group 11.3.1
Start battery
Fuses C C C Check that fuses are Section 11 Common
intact, change if needed. electrical, group 11.2.2
Fuses
Position sensors C C C Should be free from
grease and dirt, clean as
needed.
• Attachment
Test-run

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C:14 C Preventive maintenance – Preventive maintenance

Service
250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Object, action h, etc.. etc. etc. etc. Comment Reference
Test-run the machine and check:
• Instruments
• Brakes
• Gearshifting
• All load handling functions
• Steering
• Any noise

WARNING
The cab has manual sliding cab. The cab shall ALWAYS be in its rear position during operation.
Warning, risk of crushing!
Always make sure that the cab locks on both sides are locked in their rear positions before
operating, and that the locks are secured with the lock pins.

After test-run
Check the following after test-run:
• Sealing (no leakage)
• Fluid levels

Washing

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

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 C Preventive maintenance – Preventive maintenance C:15

Lubrication 500 hours

1 Clean the area around each grease cup before greasing.

2 Lubricate all points with grease, see section F Technical data.

Wheel hub and wheel spindle

3 Lift the right steering wheel with a jack (40 ton) so that wheel
bearing and wheel spindle are unloaded, do not lift so high that
the wheel hangs freely.
4 Grease the wheel hub until grease comes out at the seal on the
hub's inside.
Lift the seal ring's lip with a small screwdriver to facilitate pressing
out of air. Grease until grease comes out by the seal.

NOTE
Be careful so that the seal is not damaged.

Grease point wheel hub

5 Grease the wheel spindle's upper and lower bearings.

NOTE
It is important that both upper and lower bearings are greased
separately since grease is not pressed between the bearings.

6 Lower the wheel.

7 Repeat steps 3 - 7 on the left steering wheel.

Lubrication points wheel spindle

1. Upper lubrication point
2. Lower lubrication point

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C:16 C Preventive maintenance – Preventive maintenance

Link arms
8 Lubricate both link arms' outer and inner bearings with grease.

Lubrication points link arm

1. Outer bearing
2. Inner bearing

Brake pedal
9 Lubricate the brake pedal's hinge with grease.
10 Wipe off excess grease.

Grease points brake pedal

Lubrication 1000 hours

1 Lower and run out the boom completely and run out spreading
completely.

2 Turn off the engine and turn off the system voltage.

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 C Preventive maintenance – Preventive maintenance C:17

3 Lubricate the machine's grease points with Lubricating grease

as shown on the diagrams below, see section F Technical data.
Also do a visual check of all lubricated mounts.

IMPORTANT
Visually inspect all stub axles in connection with
lubrication. Damaged stub axles must be changed.

Grease points, lubricating grease

1. Mounting lift boom (2 pcs.) 1. Brake pedal inside cab (2 pcs)

2. Mounting attachment (2 pcs.) 2. Wheel spindles (4 pc)
3. Bearing rotation yoke (4 pcs., two per side) 3. Wheel hubs (2 pc)
brushing of ring gear
4. Slide beam mounting side shift frame
4. Chain and chain wheel spreading
5. Link arms (4 pc)
5. Twistlocks (4 pc)
6. Joint steering axle
6. Universal joints (2 pc)

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C:18 C Preventive maintenance – Preventive maintenance

4 Brush slide surfaces on the boom and attachment with white

lubrication paste as shown on the diagrams below, see section
F Technical data.

NOTE
The upper slide surfaces in the outer boom should be lubricated
at the same time as the other slide surfaces.

5 Operate the boom and spreading in and out, and side shift
attachment max. right - left, a few times without a load.

IMPORTANT
Wipe off excess lubrication paste.

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C Preventive maintenance – Preventive maintenance C:19

Checking for cracks

DANGER
Risk of dropped load.
FATAL DANGER!
Never use a machine with structural damage to the
boom and attachment.

DANGER
All of the machine's welds shall be checked according
to recommended interval. The interval is calculated
according to the machine being used for normal
handling and on a level, smooth ground surface. For
other handling or, e.g., rough surface, the interval
should be shortened.
If the welds show signs of cracking, the machine
should be taken out of operation immediately and
contact Cargotec Support.

1 Turn off the engine and turn off the system voltage.

2 Clean every weld carefully before inspection.

3 Check for damage and cracks in the areas with high stress
concentration, see Checkpoints, page C:20. Check the whole
length of every weld.
When uncertain, welds can be tested with magnetic powder and
even penetrating uid as follows:
a. The magnetic powder method is used to determine if there's a
crack or not, and where it is. See Magnetic powder method,
page C:19.
b. Con�rmed cracks are investigated further with penetrating
uid. See Checking cracks with penetrating uid, page C:20.

Magnetic powder method

1 Blast the applicable area clean so that it is completely free of
paint residue.

2 Test using magnetic powder and the following equipment:

• Equipment:Yoke Tiede
• Method:
a Alternating current AC
b Contrast colour
• Checking medium:
a Wet
b Colour (for example, Tiede Ferrolux)
If no cracks are detected with the magnetic powder method,
checking is �nished and the applicable area is approved.
If cracks are indicated, the crack should be investigated further
with penetrating uid.

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C:20 C Preventive maintenance – Preventive maintenance

Checking cracks with penetrating uid

1 Clean the area with cleaning uid part no. 923626.0668.

2 Spray penetrating uid part no. 923626.0669 on the cleaned area

and let dry 10 min.

3 Wash off penetrating uid with cleaning uid part no. 923626.0668.
Thoroughly wipe off the cleaning uid with a drying cloth and let
any remaining cleaning uid evaporate.

4 Spray detection uid part no. 923626.0670 on the area.

5 Let the sprayed area dry 1-2 hours.

6 Visually inspect the area.

If the tested area does not show signs of linear or point-shaped
cracks, it is approved.
If the crack check indicates linear or point-shaped cracks, contact
Cargotec Support.

Examples of cracks
1. Linear crack
2. Pointed crack

Checkpoints
1 Park the machine with attachment lowered as far down as possible
and spreading in the 40-foot position.

Steering axle mounts

2 Check the welding joints at the steering axle's mountings to the
frame for damage and signs of cracking.

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C Preventive maintenance – Preventive maintenance C:21

Lift boom
3 Check the lift boom's surfaces and welding joints for damage and
signs of cracking.
Pay particular attention to the grey-marked areas in accordance
with the illustration.
4 Check the mountings to the frame and the lift cylinders with regard
to wear.

Attachment
5 Check the attachment's surfaces and welding joints for damage
and signs of cracking.
Pay particular attention to the grey-marked areas in accordance
with the illustration.

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C:22 C Preventive maintenance – Preventive maintenance

Frame
6 Check the frame's surfaces and welding joints for damage and
signs of cracking.
Pay particular attention to the grey-marked areas in accordance
with the illustration.
7 Check the mountings to the boom and the lift cylinders with regard
to wear.
8 If the event of signs of damage, please contact Cargotec Support
for further instructions.

DANGER
Risk of reduced strength.
FATAL DANGER!
Damage to frame, boom, and attachment must be
repaired in the correct way. Incorrect repairs reduce
the strength.

UDRT02.02GB Maintenance Manual DRT 450

 0:1

0 Complete machine

Contents 0 Complete machine

Complete machine..............................................................................................0:3

Maintenance Manual DRT 450 UDRT02.02GB

0:2

UDRT02.02GB Maintenance Manual DRT 450

0 Complete machine – Complete machine 0:3

0 Complete machine
Complete machine, description
Kalmar DRT 450 is a "Reachstacker" for container handling. The
machine has a lift capacity of 45 tons.

It is powered by a six-cylinder, four-stroke diesel engine with direct

injection.

The transmission is hydromechanical with gears in constant mesh. It

has four forward gears and four reverse gears. The engine's power is
transmitted using a torque converter.

The power transmission consists of a propeller shaft and a rigid drive

axle with hub reduction. The machine has front-wheel drive.

The service brake is of the type disc brake in oil, which is integrated
with the driving wheels' wheel hubs. The parking brake is of the type
disc brake and acts on the drive axle's input shaft.

The machine is steered with the rear wheels using a double-acting

hydraulic cylinder. The steering axle is oscillation-mounted in the frame.

The wheels are fastened on the hubs using clamps. The drive axle has
twin wheels, the steering axle has single wheels.

Load handling consists of components and functions for handling loads.

Load is lifted with an attachment mounted on a telescopic boom with
lift function. Load handling is divided into the functions lift and lower,
extension, side shift, spreading, rotation, tilt, levelling, and load carrier.
• Lifting/lowering is the function for lifting and lowering the boom.
• Extension is the function to extend the boom in and out.
• Side shift is moving the lift attachment laterally in relation to the
machine.
• Spreading is used to adjust the width between the attachment's
lifting points.
• Rotation is rotating the load in relation to the machine.
• The load carriers are designed to hold a load securely.

The control system includes functions to warn the operator of

dangerous situations and machine problems. The control system has
diagnostic possibilities that facilitate troubleshooting.

The frame supports the machine. The engine, transmission, drive axle,
and steering axle are installed in the frame. On the sides of the frame
there are tanks for fuel, hydraulic oil, and oil for the brake system. The
cab has a central location and can be moved fore-aft.

Maintenance Manual DRT 450 UDRT02.02GB

0:4

UDRT02.02GB Maintenance Manual DRT 450

 1:1

1 Engine

Contents 1 Engine
1 Engine..................................................................................................................1:3
1.2 Fuel system....................................................................................................1:10
1.2.3 Fuel pre-�lter ............................................................................................. 1:11
1.2.4 Fuel �lter ...................................................................................................1:13
1.5 Engine's mechanical parts .............................................................................1:15
1.5.4 Valve mechanism ......................................................................................1:15
1.5.6 Crank mechanism .....................................................................................1:19
1.6 Air intake and exhaust outlet..........................................................................1:20
1.6.1 Air cleaning system ...................................................................................1:20
1.6.2 Turbo .........................................................................................................1:21
1.6.3 Exhaust system.........................................................................................1:23
1.6.4 Intercooler .................................................................................................1:23
1.7 Cooling system ..............................................................................................1:25
1.7.2 Coolant �lter ..............................................................................................1:25
1.7.5 Cooling fan ................................................................................................1:27
1.7.7 Coolant ......................................................................................................1:29
1.8 Lubrication system .........................................................................................1:36
1.9 Control system engine ...................................................................................1:39
1.10 Ignition/heating...............................................................................................1:40
1.11 Start/stop........................................................................................................1:41

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1:2

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 1 Engine – Engine 1:3

1 Engine
Engine, description
The engine provides power for propulsion and the working hydraulics.

The engines are low-emission engines and meet governing emission

standards. The new engines provide considerable improvement, not
only for exhaust emissions but also for the power and torque curve.

The following engine alternatives are available:

• Yuchai YC6M360-30
• Cummins QSM11

Engine alternative Yuchai YC6M360-30,

function description
Yuchai YC6M360-30 is a straight 6-cylinder, 4-stroke turbocharged
low-emission diesel engine with unit injectors and air-to-air intercooler.

1. Ignition (S150) 8. Accelerator pedal (B690)

2. Control unit cab (D790-1) 9. Make-contact (closing switch), coolant level (B759)
3. Control unit KIT (D790-2) 10. Make-contact (closing switch), water in fuel (B760)
4. Control unit engine (D794) 11. Sensor fuel level (B757)
5. Relay, starter motor (K360) 12. Control unit frame rear (D797-R)
6. Starter motor (M654) 13. Control unit KID (D795)
7. Electric components engine 14. Control unit, frame front (D797-F)

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1:4 1 Engine – Engine

Engine alternative Cummins QSM11,

function description
Cummins QSM11 is a straight 6-cylinder, 4-stroke turbocharged
low-emission diesel engine with unit injectors and air-to-air intercooler.

1. Ignition (S150) 7. Accelerator pedal (B690)

2. Control unit cab (D790-1) 8. Make-contact (closing switch) coolant level (B759)
3. Control unit KIT (D790-2) 9. Sensor fuel level (B757)
4. Control unit engine (D794) 10. Control unit frame (D797-1)
5. Starter motor (M654) 11. Control unit KID (D795)
6. Electric components engine 12. Relay coolant level (K322)

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 1 Engine – Engine 1:5

Engine alternative Yuchai YC6M360-30,

component position

Engine right side (in machine's direction of travel)

1. Connection exhaust system 6. Connection radiator
2. Turbo 7. Transmission oil cooler
3. Connection air cleaner 8. Radiator
4. Oil �lter 9. Intercooler
5. Connection intercooler

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1:6 1 Engine – Engine

Engine left side (in machine's direction of travel)

1. Preheating coil (E8000) 8. Alternator
2. Relay, preheating (K312) 9. Coolant pump
3. Thermostat housing 10. Connection radiator outlet
4. Make-contact (closing switch), low coolant level 11. Control unit engine (D794)
(B759) 12. Fuel �lter
5. Expansion tank 13. Fuel pump
6. Connection cab heat 14. Starter motor (M654)
7. Connection intercooler 15. Relay, starter motor (K360)

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 1 Engine – Engine 1:7

Engine alternative Cummins QSM11,

component position

Engine alternative Cummins, right side (in the machine's direction of travel)
1. Expansion tank 11. Fuel �lter
2. Connection intercooler (intake) 12. Drainage condensation water fuel �lter and sensor
water in fuel
3. Place for compressor air conditioning unit
13. Fuel pump
4. Connection intercooler (outlet)
14. Sensor oil pressure and oil temperature
5. Fuel connection (intake)
15. Sensor crankshaft position
6. Fuel connection (outlet)
16. Transmission oil cooler
7. Control unit engine (D794)
17. Water cooler
8. Starter motor
18. Intercooler
9. Drain plug engine oil
10. Sensor fuel pressure

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1:8 1 Engine – Engine

Engine alternative Cummins, left side (in the machine's direction of travel)
1. Connection air cleaner 10. Connection intercooler (intake)
2. Turbo 11. Thermostat housing
3. Sensor induction air temperature 12. Intake, intercooler
4. Connection intercooler (outlet) 13. Alternator
5. Connection radiator (outlet) 14. Sensor coolant temperature
6. Expansion tank 15. Coolant pump
7. Make-contact (closing switch), low coolant level 16. Connection exhaust system
(B759) 17. Oil �lter
8. Sensor boost pressure 18. Coolant �lter
9. Connection cab heat 19. Shut-off valve coolant

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 1 Engine – Engine 1:9

Components on the machine, component

location

1. Accelerator pedal (B690) 9. Sensor fuel level (B757)

2. Ignition (S150) 10. Fuel tank
3. Control unit KIT (D790-2) 11. Control unit, frame front (D797-F)
4. Control unit KID (D795) 12. Sensor water in fuel (B760) (engine alternative
Yuchai YC6M360-30)
5. Control unit cab (D790-1)
13. Fuel pre-�lter (engine alternative Yuchai
6. Control unit frame rear (D797-R)
YC6M360-30)
7. Diagnostic socket drivetrain
8. Diagnostic socket engine (X281) (engine alternative
Yuchai YC6M360-30)

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1:10 1 Engine – Fuel system

1.2 Fuel system

Fuel system, description
For position of components see Engine alternative Yuchai
YC6M360-30, component position, page 1:5.

1. Fuel �ller ori�ce

2. Fuel tank
3. Sensor, fuel level (behind air �lter)

Fuel system, bleeding air (engine alternative

Yuchai YC6M360-30)

NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.

The fuel system must be bled, e.g., if the fuel tank has been run dry
or after long periods of operation.
1 Machine in service position, see section B Safety.
2 Place a container under the fuel pre-�lter.
3 Open the air bleeder screw on the fuel �lter.
4 Pump with the hand pump until the owing fuel is free from air.

NOTE
If only the fuel �lter is changed, no further bleeding is
neccessary.

5 Close the screw when clean (air-free) fuel ows out.

6 Wipe off the fuel pre-�lter and remove the collection container.

1. Hand pump
2. Air bleeder screw

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 1 Engine – Fuel pre-�lter 1:11

Fuel system, bleeding air (engine alternative

Cummins QSM11 )
The fuel system must be bled after fuel �lter replacement, if the fuel
tank has been run dry or after long periods of operation for example.

NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.

1 Machine in service position, see section B Safety.

2 Make sure that the fuel �lter is �lled with fuel.

3 Bleed the fuel system by running the starter motor until the engine
starts.

4 Check sealing integrity.

1.2.3 Fuel pre-�lter

Fuel pre-�lter, draining condensation water (engine
alternative Yuchai YC6M360-30)

NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.

NOTE
The fuel pre-�lter should be drained of water every 50 operating
hours.

1 Machine in service position, see section B Safety.

2 Place a container under the fuel pre-�lter.
3 Drain the fuel pre-�lter of water.
Open the drain valve on the underside, close the valve when
clean fuel ows out.
4 Wipe off the fuel pre-�lter and remove the collection container.

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1:12 1 Engine – Fuel pre-�lter

Fuel pre-�lter, changing (engine alternative Yuchai

YC6M360-30)

NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.

1 Machine in service position, see section B Safety.

2 Place a container under the fuel pre-�lter.
3 Drain the fuel pre-�lter of fuel and water.
Open the drain valve on the underside, close the valve when the
�lter is empty.
4 Disconnect the wiring from Sensor water in fuel (B760).
5 Remove Sensor water in fuel (B760) from the �lter insert.
6 Remove the fuel �lter with the �lter removal tool.
7 Install Sensor water in fuel (B760) on the new fuel pre-�lter.
8 Fill the fuel pre-�lter with clean fuel.

CAUTION
The fuel system is sensitive to impurities.
Risk of product damage.
Only use new fuel from a clean container to reduce the
risk of impurities in the fuel system.

9 Lubricate the O-ring on the new fuel �lter with engine oil.
10 Install the new fuel pre-�lter.
Tighten to contact and then an additional one-half to three-quarter
turn.
11 Connect the line supply to the sensor water in fuel.
12 Wipe off the fuel pre-�lter and remove the collection container.
13 Turn on the system voltage and start the engine. Check that the
�lter seals tight.

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 1 Engine – Fuel �lter 1:13

1.2.4 Fuel �lter

Fuel �lter, changing (engine alternative Yuchai
YC6M360-30)

NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.

1 Machine in service position, see section B Safety.

2 Place a container under the fuel �lter.

3 Remove the fuel �lter with the �lter removal tool.

4 Lubricate the O-ring on the new fuel �lter with engine oil.
5 Fill the fuel pre-�lter with clean fuel.

CAUTION
The fuel system is sensitive to impurities.
Risk of product damage.
Only use new fuel from a clean container to reduce the
risk of impurities in the fuel system.

6 Install the new fuel �lter.

Tighten to contact and then an additional one-half to three-quarter
turn.
7 Wipe off the fuel �lter and remove the collection container.
8 Turn on the system voltage and start the engine. Check that the
fuel �lter seals tight.

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1:14 1 Engine – Fuel �lter

Fuel �lter, changing (engine alternative Cummins

QSM11 )

NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.

1 Machine in service position, see section B Safety.

2 Disconnect the wiring from the sensor for water in fuel.
3 Remove the fuel �lter with the �lter removal tool.
4 Change the seal at the �lter's thread connection on the �lter
bracket and lubricate it with engine oil.
5 Fill the new fuel �lter with clean fuel.
6 Lubricate the seal on the new fuel �lter with engine oil.
7 Install the new fuel �lter.
Tighten the fuel �lter to contact and then an additional one-half to
three-quarter turn.
8 Turn on the system voltage and start the engine. Check that the
fuel �lter seals tight.

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1 Engine – Engine's mechanical parts 1:15

1.5 Engine's mechanical parts

1.5.4 Valve mechanism
Adjusting valves and injectors, preparations (engine
alternative Cummins QSM11 )
Valves and injectors must be adjusted when the engine is cold (coolant
temperature under 60 ºC).
1 Machine in service position, see section B Safety.
2 Place the cab in the front position.

3 Disconnect the crankcase ventilation hose from the crankcase

ventilation outlet on the valve cover.
4 Remove the 16 bolts with washers that attach the valve cover in
the cylinder head.
5 Remove the valve cover and the valve cover gasket.

6 Rotate the engine on the auxiliary shaft so that the setting mark
on the belt pulley stands in line with one of the markings on the
casing behind the belt pulley.

WARNING
Do not pull on or bend the fan blades to rotate the
crankshaft.
The fan blades may be damaged which may lead to fan
failure, which in turn may result in personal injuries
or product damage.
Use the accessory drive axle to pull the crankshaft
around.

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1:16 1 Engine – Valve mechanism

7 The crankshaft rotates clockwise, if viewing the engine from the

front.
The �ring order is cylinder no. 1-5-3-6-2-4.

NOTE
Cylinder number 1 is the cylinder nearest the cooling fan.

8 Every cylinder has three valve lifters:

• Valve lifter (position E) is for the outlet valves.
• The centre valve lifters are for the injectors.
• The short valve lifters (position I) are for the intake valves.
See adjoining diagram for position of valve lifters for intake and
outlet valves.

9 One valve pair and one injector are adjusted at each adjustment
mark. The pulley is then rotated to the next adjustment mark.
Two full turns on the crankshaft are required to adjust all valves
and injectors.

NOTE
Valves and injectors for the respective cylinders are adjusted at
the same mark on the pulley.

NOTE
Carefully read the example in the text before beginning the
adjustment procedure.

10
Adjustment position for adjustment of valves and injectors
Turn the engine Position of Adjust valves / injectors
around in the the pulley on cylinder no.
direction of rotation.
Start A 1 1
Move ahead to B 5 5
Move ahead to C 3 3
Move ahead to A 6 6
Move ahead to B 2 2
Move ahead to C 4 4
The �ring order cylinder no.: 1-5-3-6-2-4.

Adjustment can be started at any of the settings marks for

adjusting valves/ injectors. In the following example, adjustment
is started at setting mark A with the valves on cylinder 1 closed
and ready for adjustment.

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1 Engine – Valve mechanism 1:17

11 Turn the engine around clockwise until the adjustment mark A for
the adjustment of valves / injectors on the pulley are aligned in
front of the mark on the cover behind the pulley.

12 When setting mark A stands directly opposite the marking on the

casing behind the belt pulley, the inlet and exhaust valves for
cylinder 1 must be closed (if the valves are not closed the engine
has been rotated a whole revolution too much and instead the inlet
and exhaust valves for cylinder no. 6 are ready for adjustment).
Adjust injectors and valves on the cylinder so that rocker arms for
both inlet and exhaust valves are unloaded and can be moved
from side to side.

Injectors, adjusting (engine alternative Cummins

QSM11 )
1 Work through preparations for adjusting injectors, see Adjusting
valves and injectors, preparations (engine alternative Cummins
QSM11 ), page 1:15.

2 Loosen the lock nut for the injector's adjustment.

3 Use a screwdriver and the adjuster bolt and push the injector
plunger in the bottom position three or four times to remove all
fuel in the injector.
4 Unscrew the adjuster bolt 1/3 turn (two of the at sides of the nut
or 120 degrees).
Secure the adjuster bolt and tighten the lock nut, tightening
torque 61 Nm (45 ft-lb).
5 If valves do not have to be adjusted, install the valve cover. See
Valve cover, installing (engine alternative Cummins QSM11 ),
page 1:19.

NOTE
Only screw in the adjuster bolt until you feel that the injector plunger
has just pushed down in its bottom position.

NOTE
Do not use excessive force when pushing the injector plunger in
the bottom.

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1:18 1 Engine – Valve mechanism

Valves, adjusting (engine alternative Cummins QSM11

)
1 Work through preparations for adjusting valves, see Adjusting
valves and injectors, preparations (engine alternative Cummins
QSM11 ), page 1:15.

2 With adjustment mark A positioned aligned in front of the mark on

the cover behind the pulley and both valves closed for the cylinder
to be adjusted, loosen the adjuster bolt's lock nut for both the
intake and outlet valve.

3 Choose a feeler gauge with a thickness that corresponds with the

valve clearance to be adjusted.

Valve clearance tolerance

mm in
Intake valves 0,36 mm 0,014
Outlet valves 0,69 mm 0,027

4 Place the thickness gauge between the top side of the push
rod the valve lifter's seat. Use a torque wrench and tighten the
adjuster bolt. Tightening torque 0.7 Nm (6 in-lb).

5 After the lock nut has been tightened with the correct tightening
torque, check that that feeler gauge can be moved back and forth
between the top side of the push rod and the valve lifter's seat
with only a slight resistance.
6 If injectors do not have to be adjusted, install the valve cover. See
Valve cover, installing (engine alternative Cummins QSM11 ),
page 1:19.

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1 Engine – Crank mechanism 1:19

Valve cover, installing (engine alternative Cummins

QSM11 )
1
NOTE
If the valve cover gasket is not damaged when removing, it
can be re-used after it has been cleaned. If the valve cover
gasket was damaged when removing, it must be replaced with
a new gasket.

Reinstall the valve cover gasket.

2 Mount the valve cover with the 16 insulators, the washers and
the bolts.
Tighten the bolts according to the numbering on the diagram.
Tighten the bolts with 9 Nm.
3 Connect the crankcase ventilation hose to the crankcase
ventilation's outlet on the valve cover.
4 After �nished adjustment, return the cab to the rear position and
secure both sides of the cab with the lock devices.

DANGER
The cab is heavy and the machine may never be moved
without secured cab.
Fatal danger! Risk of crushing!
Secure both sides of the cab with lock devices and
pins before starting to operate.

1.5.6 Crank mechanism

Viscous vibration damper, checking (engine
alternative Cummins QSM11 )

CAUTION
The silicone uid in the vibration damper hardens after
a long period of use, which means that the vibration
damper stops working. A non-functioning vibration
damper can cause serious damage to the engine or
drive.

The vibration damper is located on the crankshaft's belt pulley.

Viscous vibration dampers have a limited service life.

Check the vibration damper for uid loss, dents/damage, and that it
rotates without run-out. Check the vibration damper's thickness for
deformations or that the damper's cover plate has lifted.

If any of the above defects exist, contact your local authorised

Cummins workshop to replace the vibration damper.

Maintenance Manual DRT 450 UDRT02.02GB

1:20 1 Engine – Air intake and exhaust outlet

1.6 Air intake and exhaust outlet

1.6.1 Air cleaning system

Air �lter, changing

1 Machine in service position, see section B Safety.

2 Clean the outside of the air �lter housing.

3 Remove the cap from the air �lter housing.
4 Remove the �lter cartridge.

1. Intake hose
2. Filter indicator
3. Air cleaner
4. Inlet
5. Dust reservoir

5 Clean the dust reservoir.

6 Check the safety insert, change as needed. (The safety insert
should be changed every other time the �lter insert is changed).
7 Fit a new �lter insert.

NOTE
The �lter cartridge should be changed, not cleaned.

8 Fit the cover to the air cleaner casing.

9 Check that the hoses from the air �lter housing (and other parts)
are intact and sealed.
10 Reset the indicator.

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 1 Engine – Turbo 1:21

1.6.2 Turbo
Turbo, checking (engine alternative Yuchai
YC6M360-30)
1 Machine in service position, see section B Safety.

2 Place the cab in the front position.

3 Disconnect the inlet pipe from the turbo.

4 Check that the impeller rotates freely and that the axial clearance
is max. 1 mm.
In case of deviations, replace or overhaul the turbocharger.

5 Connect the inlet pipe to the turbo.

6 Return the cab to the rear position and secure both sides of the
cab with the lock devices.

DANGER
The cab is heavy and the machine may never be moved
without secured cab.
Fatal danger! Risk of crushing!
Secure both sides of the cab with lock devices and
pins before starting to operate.

Maintenance Manual DRT 450 UDRT02.02GB

1:22 1 Engine – Turbo

Turbo, checking (engine option Cummins QSM11 )

1 Machine in service position, see section B Safety.

2 Place the cab in the front position.

3 Check tightening torque for the turbo's mounting bolts. Tighten

the bolts to 61 Nm.

4 Check the turbo housing's sealing face on the exhaust side. If

leakage is discovered, tighten the bolt on the clamp (V-band).
Tighten the bolt with 9 Nm.

5 Check the turbo housing's sealing face on the inlet side. If leakage
is discovered, tighten the bolt on the clamp (V-band). Tighten
the bolt with 9 Nm.
6 Return the cab to the rear position and secure both sides of the
cab with the lock devices.

DANGER
The cab is heavy and the machine may never be moved
without secured cab.
Fatal danger! Risk of crushing!
Secure both sides of the cab with lock devices and
pins before starting to operate.

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1 Engine – Exhaust system 1:23

1.6.3 Exhaust system

Exhaust system, checking

WARNING
Hot exhaust system!
Risk of burn injuries.
Never touch the turbo, exhaust pipe, or muf er when the
machine is in operation or has recently been turned off!

1 Machine in service position, see section B Safety.

2 Check the exhaust system's sealing and other wear.

3 Check that the exhaust system suspension is intact.

1.6.4 Intercooler
Intercooler, checking
1 Machine in service position, see section B Safety.

2 Place the cab in the front position.

3 Clean the intercooler with compressed air.

NOTE
Do not use high pressure wash.

4 Check that the intercooler suspension is intact.

5 Check the sealing and check that the intercooler's hoses and
clamps are in good condition.

6 Return the cab to the rear position and secure both sides of the
cab with the lock devices.

DANGER
The cab is heavy and the machine may never be moved
without secured cab.
Fatal danger! Risk of crushing!
Secure both sides of the cab with lock devices and
pins before starting to operate.

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1:24 1 Engine – Intercooler

Charge-air pipe, checking (engine option Cummins

QSM11 )
1 Machine in service position, see section B Safety.
2 Check the charge-air pipes, hose connections, and the condition
of the clamps for visible cracks and external damage. If the pipes
are damaged or if connections leak, the boost pressure will be too
low and engine power is reduced.
3 Check that there is no oil in the charge-air pipes. If the pipes have
oil on the inside, this indicates leakage by the turbo's turbine shaft
seal. Then replace the whole turbocharger.

NOTE
If there is oil in the intercooler hoses, very carefully clean the
intercooler and all pipes and hoses in the intercooler system on
the inside before the engine is started.

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 1 Engine – Cooling system 1:25

1.7 Cooling system

Cooling system, description
The engine radiator is located together with the intercooler and the
transmission oil cooler in one unit, a cooling unit.

For position of components see:

• Engine alternative Yuchai YC6M360-30, component position,
page 1:5

• Engine alternative Cummins QSM11, component position ,

page 1:7

1.7.2 Coolant �lter

Coolant �lter, changing (engine alternative Cummins
QSM11 )

NOTE
Close the shut-off valve before loosening the �lter. Coolant may run
out and cause environmental damage.

1 Machine in service position, see section B Safety.

2 Place the cab in the front position.
3 Close the shut-off valve on the �lter holder.
4 Clean the area around the coolant �lter.
5 Place a receptacle under the coolant �lter.
6 Remove the coolant �lter with the �lter removal tool.
7 Lubricate the O-ring on the �lter insert with engine oil.
8 Install the new �lter.
Tighten to contact and then an additional one-half to three-quarter
turn.
9 Open the shut-off valve on the �lter holder.

NOTE
Do not forget to open the valve after replacement. The coolant
does not pass through the �lter and therefore it is not cleaned.

10 Turn on the system voltage and start the engine.

11 Check that the coolant �lter seals tightly.
Filter left side, engine alternative Cummins
12 Remove the container. Handle the coolant as environmentally
1. Shut-off valve coolant hazardous waste.

2. Coolant �lter 13 Place the cab in the front position.

3. Oil �lter

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1:26 1 Engine – Coolant �lter

14 Check the coolant level in the expansion tank, �ll if necessary.

15 Return the cab to the rear position and secure both sides of the
cab with the lock devices.

DANGER
The cab is heavy and the machine may never be moved
without secured cab.
Fatal danger! Risk of crushing!
Secure both sides of the cab with lock devices and
pins before starting to operate.

1. Sight glass, checking level

2. Filling point
3. Coolant reservoir (expansion tank)

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 1 Engine – Cooling fan 1:27

1.7.5 Cooling fan

Drive belt, checking (engine alternative Yuchai
YC6M360-30)
1 Warm up the machine. Check after operating when the belts are
warm.
2 Machine in service position, see section B Safety.
3 Place the cab in the front position.
4 Check the belts' condition and tension. Change when needed.

IMPORTANT
Always change a drive belt that looks to be worn or
has cracks.

Check that the belts do not have any intersecting cracks.

Transverse cracks are acceptable, longitudinal cracks that are
intersected by transverse cracks are not acceptable.
It should be possible to press down the belts approx. 3-4 mm
between the belt pulleys.

NOTE
The belt tensioners are automatic.

5 Return the cab to the rear position and secure both sides of the
cab with the lock devices.

DANGER
The cab is heavy and the machine may never be moved
without secured cab.
Fatal danger! Risk of crushing!
Secure both sides of the cab with lock devices and
pins before starting to operate.

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1:28 1 Engine – Cooling fan

Drive belt, checking (engine alternative Cummins

QSM11 )
1 Warm up the machine. Check after operating when the belts are
warm.
2 Machine in service position, see section B Safety.
3 Place the cab in the front position.
4 Check the belts' condition and tension. Change when needed.

IMPORTANT
Always change a drive belt that looks to be worn or
has cracks.

Check that the belts do not have any intersecting cracks.

Transverse cracks are acceptable, longitudinal cracks that are
intersected by transverse cracks are not acceptable.
It should be possible to press down the belts approx. 3-4 mm
between the belt pulleys.

NOTE
The belt tensioners are automatic.

5 Return the cab to the rear position and secure both sides of the
cab with the lock devices.

DANGER
The cab is heavy and the machine may never be moved
without secured cab.
Fatal danger! Risk of crushing!
Secure both sides of the cab with lock devices and
pins before starting to operate.

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 1 Engine – Coolant 1:29

Fan hub, checking (engine alternative Cummins

QSM11 )
1 Machine in service position, see section B Safety.
2 Place the cab in the front position.
3 Remove drive belt, see Drive belt, checking (engine alternative
Cummins QSM11 ), page 1:28. Check the fan hub, replace if
necessary.

NOTE
The fan hub must rotate without wobbling or excessive length
clearance.

4 Return the cab to the rear position and secure both sides of the
cab with the lock devices.

DANGER
The cab is heavy and the machine may never be moved
without secured cab.
Fatal danger! Risk of crushing!
Secure both sides of the cab with lock devices and
pins before starting to operate.

1.7.7 Coolant
Coolant level, check

WARNING
The cooling system is pressurized. Steam or hot uid
may jet out.
Risk of scalding and burn injuries!
Open the �ller cap very carefully when the engine is
warm. Wait until the coolant has cooled before topping
up.

Coolant should be �lled in the system's expansion tank (position 3).

The uid level should be over the sight glass (position 1) on the
expansion tank.

NOTE
Open very carefully as hot coolant may jet up.

If the coolant level becomes too low, the warning lamp for low coolant
level lights up on the instrument panel.

NOTE
A low coolant level may cause engine damage or may cause the
engine to stop.

1 Machine in service position, see section B Safety.

2 Place the cab in the front position.

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1:30 1 Engine – Coolant

3 If needed, top up with ready-mixed recommended coolant. For

volume and quality, see section F F Technical data.

CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, only use
coolant of the same type that was used before.

4 Return the cab to the rear position and secure both sides of the
cab with the lock devices.

DANGER
The cab is heavy and the machine may never be moved
without secured cab.
1. Sight glass, checking level Fatal danger! Risk of crushing!
2. Filling point Secure both sides of the cab with lock devices and
3. Coolant reservoir (expansion tank) pins before starting to operate.

Coolant quality, checking (engine alternative

Cummins QSM11 )

WARNING
The cooling system is pressurized. Steam or hot uid
may jet out.
Risk of scalding and burn injuries!
Open the �ller cap very carefully when the engine is
warm. Wait until the coolant has cooled before topping
up.

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 1 Engine – Coolant 1:31

1 Machine in service position, see section B Safety.

2 Place the cab in the front position.
3 Check the coolant's quality with test equipment for coolant,
"Quick-Check Coolant Quality Test Strips".

IMPORTANT
Only use testing equipment that is appropriate for the
type of coolant used in the machine. Coolant type
differs depending on engine alternative.

4 Change the coolant if the test equipment indicates poor coolant

quality, see Coolant, changing (engine alternative Cummins
QSM11 ), page 1:34.
5 Return the cab to the rear position and secure both sides of the
cab with the lock devices.

DANGER
1. Sight glass, checking level
2. Filling point The cab is heavy and the machine may never be moved
3. Coolant reservoir (expansion tank) without secured cab.
Fatal danger! Risk of crushing!
Secure both sides of the cab with lock devices and
pins before starting to operate.

Coolant, changing (engine alternative Yuchai

YC6M360-30)

NOTE
Read safety instructions for coolant before starting work, see section
B Safety.

1 Machine in service position, see section B Safety.

2 Place the cab in the front position.

3 Remove the cap on the expansion tank.

4 Place a container under the radiator and engine. (The cooling

system holds approx. 40 l.)

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1:32 1 Engine – Coolant

5 Drain the cooling system.

Open the drain valve on the lower part of the radiator. Collect the
coolant in the container.

6 Open the drain valve on the engine.

7 When all the coolant has run out, close the drain taps.

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 1 Engine – Coolant 1:33

8 Fill with new ready-mixed coolant of correct type in the expansion

tank. For volume and quality, see section F F Technical data.

CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, only use
coolant of the same type that was used before.

9 Turn on the system voltage and start the engine.

10 Set the cab heat to max.
11 Run the engine warm so that the thermostat opens and coolant is
pumped through the whole system. Do not operate the machine.

DANGER
1. Sight glass, checking level
The cab is heavy and the machine may never be moved
2. Filling point
without secured cab.
3. Coolant reservoir (expansion tank)
Fatal danger! Risk of crushing!
Secure both sides of the cab with lock devices and
pins before starting to operate.

12 Check the level in the expansion tank, �ll if necessary.

13 Return the cab to the rear position and secure both sides of the
cab with the lock devices.

DANGER
The cab is heavy and the machine may never be moved
without secured cab.
Fatal danger! Risk of crushing!
Secure both sides of the cab with lock devices and
pins before starting to operate.

14 Check the coolant level again after 10 operating hours.

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1:34 1 Engine – Coolant

Coolant, changing (engine alternative Cummins

QSM11 )

NOTE
Read safety instructions for coolant before starting work, see section
B Safety.

1 Machine in service position, see section B Safety.

2 Place the cab in the front position.

3 Remove the cap on the expansion tank.

4 Place a container under the radiator and engine. (The cooling

system holds approx. 40 l.)

5 Drain the cooling system.

Open the drain valve on the lower part of the radiator. Collect the
coolant in the container.

6 Open the drain valve on the engine.

7 When all the coolant has run out, close the drain taps.

1. Shut-off valve coolant

2. Coolant �lter
3. Oil �lter

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 1 Engine – Coolant 1:35

8 Fill with new ready-mixed coolant of correct type in the expansion

tank. For volume and grade, see section F Technical data.

CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, only use
coolant of the same type that was used before.

9 Turn on the system voltage and start the engine.

10 Turn on max. heat in the cab.
11 Run the engine warm so that the thermostat opens and coolant is
pumped through the whole system.
12 Check the level in the expansion tank, �ll if necessary.
13 Return the cab to the rear position and secure both sides of the
cab with the lock devices.
1. Sight glass, checking level
2. Filling point
DANGER
3. Coolant reservoir (expansion tank)

The cab is heavy and the machine may never be moved

without secured cab.
Fatal danger! Risk of crushing!
Secure both sides of the cab with lock devices and
pins before starting to operate.

14 Check the coolant level again after 10 operating hours.

Maintenance Manual DRT 450 UDRT02.02GB

1:36 1 Engine – Lubrication system

1.8 Lubrication system

Lubrication system, description
The engine's lubrication system is completely closed and has no
connections to the machine.

For position of components see:

• Engine alternative Yuchai YC6M360-30, component position,
page 1:5

• Engine alternative Cummins QSM11, component position ,

page 1:7

Oil and oil �lters, changing (engine alternative

Yuchai YC6M360-30)

NOTE
Read safety instructions for oil before starting work, see section B
Safety.

1 Run the engine until warm.

2 Machine in service position, see section B Safety.

3 Remove the drain plug from the engine and drain the engine of oil.

4 Remove the oil �lters.

5 Install new oil �lters.
Lube the O-rings on the �lters with engine oil and install according
to instructions on the �lter.
6 Fit the drain plug when the oil has drained. Tighten with torque
of 27-34 Nm.

NOTE
Do not tighten the oil plug with higher tightening torque, the
threads will be damaged.

7 Fill engine oil. For volume and quality, see section F Technical
data.
8 Start the engine, let it idle.
9 Turn off the engine and check the oil level, see Oil level, check,
page 1:38. Top up as needed.

UDRT02.02GB Maintenance Manual DRT 450