Kalmar CONTMASTER 45 Service Manual

CONTMASTER 45 TONNES

TECHNICAL INFORMATION CONTAINER HANDLER

3

Dedicated for Container Handling

A renewed workhorse dedicated for

laden containers.

The Contmaster is improved in several
ways, which is reected in higher efciency
and longer service intervals. In other words
the machine now gives you a higher output
per hour.

A reachstacker is one of the most exible
handling solutions weather to operate a
smaller one-unit terminal or a medium
sized port. The ContMaster can handle
loaded containers quickly and efciently in
narrow spaces, while still ensuring that the
driver has optimum visibility. The machine
comes in one wheel base optimised for lift­ing capacity in relation to manoeuvrability.

The extensive freedom allowed by the lift­ing equipment means that the machine’s
position in relation to the container and
its drop-off is of little signicance. The
rotational and side-shift function means
that the machine does not usually need to
be placed at right angles to the container
during loading and unloading. The distance
between the container and the machine
can also be varied, as the boom can be
extended and withdrawn.

Compared to a conventional forklift, a larg­er proportion of the lifting manoeuvre can
be performed while the truck is stationary.

Containers can also be lifted and trans­ported lengthwise, making it possible to
pass through narrow gaps such as gates.
The low overall height of the machine, with
a lowered lifting boom, means high acces­sibility in low spaces.

2

Any driver with the ability to take advan­tage of the machine’s capacity and techni­cal benets will nd this reachstacker a
powerful, exible tool for handling contain­ers and this to lowest possible cost.

More detailed information about the DRS
models will be found in the technical data
sheets.

Clarication of model
designation

e.g. DRS4531-S5

Diesel

Reachs tacker

Generation

Lifting capa city in d ecitonnes (1st row )

Lifting capa city in d ecitonnes (2nd row)

Spread er

Five cont ainer s high in r st sta cking row

Capacity and dimensions

Adapted for toplift handling

The chassis and lifting equipment have
gone through major improvements to
ensure the best possible performance,
strength and user-friendliness. The nature
of the working cycle and capacity require­ments in second and third row determine
which of the three basic models that is the
most suitable.

Lifting boom

The lifting boom bears the weight. The
container-handling device consists of a
telescopic boom to which a spreader has
been attached. The booms durable and
robust design is welded on the neutral axle
for maximum strength. The boom consists
of two sections, one section moving within
the other. Rollers are tted in the rear part
of the inner-boom, which together with

the oating wear pads in front of the outer
boom facilitate the sliding motion. The
boom’s xture in the frame and the lifting
cylinders are tted with spherical plane
thrust bearings.

Lifting boom hydraulics

Hydraulic cylinders carry out the lifting
and extension functions of the boom. Load
sensing pumps feed the lifting cylinders via
main valves. The pump pressure is deter­mined by drive pressure (load).

For maximum lifting- and extension speeds
hydraulics works in three steps depend­ing on the weight of the load. Movement
speed in lifting and telescope are adjusted
after start up phase by changing the pumps
output angle and by altering the engine
running speed.

In the rst step, up to 12 tonnes load, all
load-sensing pumps feed the cylinders of
the boom. One of the load sensing pumps
priorities the steering function. If steering­and the spreader functions not are in use
at the same time as lifting three variable
pumps and the xed pump serving the
spreader functions will feed to the boom
functions.

In second step the function of the new
hydraulic- and control system optimises the
function of the load sensing pumps to pump
a maximum oil volume at a required oil
pressure. This increases lifting speed with
15% for loads between 12 and 33 tonnes,
most containers weigh somewhere within
this span. In third step, above 33 tonnes
load, the system will not use the variable
pump that priorities the steering function.

The boom’s extension function is damped
in the end positions for reduced wear and
greater comfort.

Container 8’6’’ Container 9’6’’

Capacity (tonnes)

Model

DRS4527-S5
DRS4531-S5

1:st r ow 2:nd row 3:rd row 1:st r ow 2:nd row 3:rd row H4 (mm) H5 (mm)

42*/45 27 13 40*/45 27 13 14900 17900
42*/45 31 15 40*/45 31 15 14900 17900

Container 8’6’’ Container 9’6’’

Lifting height toplif t attachment

3

5

Rotator

The rotator is xed in the inner boom and
enables the container to be rotated. The
rotator consists of an upper and a lower
yoke joined with a powerful bearing. Rota­tion is enabled by two hydraulic motors,
which drive a gear-ring. Two cylinders
help prevent the container from swinging
lengthways and can also be utilised to tilt
the load.

The attachment

On the attachment, four twistlocks rmly
locks the container to it by rotating thereby
securely gripping the container’s corner
ttings. The mechanical levelling ensures
that the twistlocks reach the corners, even
if the container is leaning.

The attachment can easily be adapted
to different container standards by two
hydraulic cylinders pushing the T-beams
back and forth within the mainframe of the
spreader.

The container can also be moved sidewise
to facilitate loading and unloading or to
compensate unbalanced containers. Two
hydraulic cylinders perform the side-shift
movement.

Attachment and rotator hydraulics

A xed vane pump feed the spreader func­tions. The spreader functions are prioritised
but when handling light loaded container
the lifting- and extension functions pick
oil fed from this pump to enhance lifting
speed. When no load handling functions
are used the pump will lead the oil through
the cleaning and cooling system of the
hydraulics.

Each function has it’s own set of valves to
ensure that each function gets the right oil
volume and pressure.

Chassis

The frame forms the basis of the machine’s
lifting and manoeuvring characteristics.
The frame’s beam construction, along with
its width, makes the reachstacker stable,
torsion resistant and service-friendly. The
basic principles of this chassis design have
been tested for a long time in different
locations in previous reachstacker models.

The chassis comes in one length optimised
according to the relationship between
capacity and manoeuvrability.

Dimensions

Model

DRS4527-S5
DRS4531-S5

4

Aisle width (mm) Turning radius ( mm) Main dimesions ( mm)

A1 - 20 ft A2 - 40 ft R1 - 20 ft R3 - 40 ft B V L H3 Clearance

9900 12600 8350 9400 4160 6050-12185 11700 4500 400 18.00x25/40 65000
9900 12600 8350 9400 4160 6050-12185 11700 4500 400 18.00x25/40 68500

Wheels

Service
weight

(kg)

Driver environment

Drivers best friend

Kalmar’s goal while developing the cab has
been to assure the driver the best conceiv­able safety, ergonomics and visibility.

Sound and vibration

The cab is tted with insulation material
both inside and out. The maximum noise
level inside the cab is 72 dB (A).

Ergonomics

Entering the cabin is safe and easy by the
newly developed angled instep. Well inside
controls and instruments are well placed
and have a precise feeling making them
efcient to use.

The vertical grip type joystick has a precise
feeling and all main hydraulic controls are
placed on the lever as push buttons. On the
side panel on right hand contains the rest
of the hydraulic function buttons direct in
reach of hand.

From the drivers position the visibility is
high in all directions. To further increase
the visibility the cabin can be hydraulically
moved lengthwise. Tinted windows are
standard equipment.

Climate

An efcient heating and ventilation system
comes as standard. An air cooling system is
available as an optional extra. The cooling
system provides comfort, even in extremely
high temperatures.

Left in strum ent pane l
Control system, display and

keyboard
Gear selector
Steering wheel panel
Multi function lever
Joystick
Panel fo r hydraulic

funct ions
Parking brake
Emergency swit ch

5

7

Performance

The ultimate workhorse

Container handling is not just about lifting
container fast and high. All functions must
work smoothly together even under heavy­duty operations. An efcient machine is a
machine that can handle all moments of
the working cycle in a simple and precise
way at lowest possible cost, just like the
ContMaster.

Over the years the ContMaster has shown
a remarkable availability which is the basic
for this further development. All perfor­mace boosts have been made with no
compromise to the quality of the reach­stacker, keeping and enhancing the virtual
availablity.

Brakes

A xed pump feed the brake circuit. It is
separated from the hydraulic system and
has its own tank, cooler and lter. The
brakes are of wet disc brake type. When
the accumulators are set at required value
the priority valve lead oil through the wet
brakes to cool them.

Transmission

The proven 4 by 4 transmission transfers
power from the engine to the hydraulic
pumps and drive line.

The transmission system consists of a
torque converter and a gearbox. The
same gearbox is used whichever engine
is chosen. The gearbox is automatic, but
can partly be shifted manually. The torque
converter is a hydraulic coupling positioned
between the engine and gearbox. The gear­box and torque converter work together
via a joint hydraulic system. This gearbox is
one of the most used in the heavy range of
Kalmar due to its high reliability.

Standard

drive tr ain

Drive line

The propeller-shaft and drive axle trans­fers the power from the transmission to
the driving wheels. The drive axle shifts
gear down in two stages, differential and
hub reduction. The engine only achieves
maximum torque at the drive wheels, which
spares the transmission.

Pushing a button on the side panel activates
the parking brake and the main brakes.

Drive train

Standard Optional

Engine

Transmission Spicer off Highways 364 31 Spicer off Highways 364 31
Driving axle Meritor PRC7534W4H140512 Meritor PRC7534W4H140512

Manufacturer
Model

Power 243 kW at 2100 rpm 246 kW at 2100 rpm
Peak torque 1589 Nm at 1400 rpm 1674 Nm at 1100-1400 rpm

Scania DI12 54A

Cummins QSM11 with
air cooled intercooler

6

Engine

Scania engine is standard. Cummins is
available as optional extra. The engine
provides power for driving and the working
hydraulics. The engines are low-emis­sion turbo diesels with unit injectors and
intercoolers.

The design of the combustion vessels in
these engines, along with the precise fuel
injection control, ensures more efcient
combustion. Emissions decrease, while

power and torque increase. The engines
full the requirements of 97/68 EC stage
2, US EPA Tier 2, and sound and vibration
standards PREN 13059.

The engines are specially adapted for the
working principle of a reachstacker ma­chine type with high torque at low revs.

Cummins QSM11 with air co oled int ercoo ler

can be t ted as op tional extra.

Steering system

A variable pump via a priority valve and the
orbitrol feeds the double action steering
cylinder. The priority valve secures that the
steering cylinder gets oil whenever it needs
it. The steering function operates smooth,
fast and precise. Lifting speeds will be
increased by leading oil from the steering
function when it´s not used.

Performance

Model

DRS4527-S5
DRS4531-S5

The steering axle is of a heavy-dut y
sandwich-type. Mechanical stops limit the
axle oscillation, which improves the lateral
stability. The axle are mounted onto the
frame with spherical plane bearings on the
pivot points.

Lifting speed (m/s) Lowering speed ( m/s ) D riving s peed (km/h ) G rade ab ility ( %)

unloaded

0,37 0, 29 0,40 0,3 0 25/25 22/22 50 29 330
0,37 0, 29 0,40 0,3 0 25/25 22/22 47 28 330

at 70% of

rated load

unloaded at rated load

unloaded

(F/R)

at rated load

(F/R)

at 2 km/h,

unloaded, max

at 2 km/h,

loaded , max

Draw pul l(kN)

max

7

9

Electrical- and control system

A system designed for maximum reli-

ability and performance.

The system is a mix of a traditional electri­cal system and an advanced CAN-bus
system. Basic functions in the cabin and

The communication network layout (standard drive train) .

on the chassis are operated without any
involvement of the CAN-bus system. Func­tions that require a more advanced control
system are CAN-bus driven. For example
the boom functions, the spreader move-

ments, engine management or monitoring
functions. In other words CAN-bus technol­ogy is only used when it is necessary to
achieve high performance with retained
reliability.

Display and Keyboard
Frame No de
Control Node
Boom Node
Cabin input Node
Engine No de

CAN-bus communication

The system consists of electrical compo­nents and a microcomputer based system
for controlling and monitoring the reach­stacker’s functions.

The most important components of the
control system are the nodes. Each node
has its own processor. The nodes integrate
with each other and all communication;
control signals and signal information are
sent via data buses. CAN-bus is a two-wire
transfer of data and a dened of a bus type.
CAN-bus provides reliable and robust trans­fer of data and is difcult to disrupt.

The greatest benet of using CAN-bus
technology are that the amount of wiring
can be reduced. All that is needed to estab­lish communication are two data-bearing
leads and two leads for feeding the nodes’
processors.

The CAN-bus system consists of ve nodes
(control units) and one display mounted on
the top of the dashboard. Each node has its
own eld of responsibility and is connected
to the other nodes in the system.

The control system consists of six nodes
linked together. Two nodes, A82 and A84,
and the display A80 are found in the cabin.
The control system display A80 is logically
located on the left side of the dashboard.
A84 is the only module not containing any
program and is purely an input node for the
cabin switches. A82 monitors critical values
of the engine, stability, execute cabin trans­fer and spreader indication lights.

A96 deals with the management of the
engine and is located on the right hand side
locker together with the frame node (A81).
A81 control boom functions. Node A83 is
positioned on the boom and controls the
spreader functions.

Power supply

The power supply starts from the distri­bution boxes that are connected to the
batteries charged by the alternator. One of
the boxes is located in the locker on right
hand side, the other one will be found in the
cabin together with two of the nodes.

Most of the reachstacker functions are
dependent of the electrical- or the CAN-bus
system. In a traditional system a function
is fed directly from one of the distribution
boxes via a switch or lever. Power feed of
a CAN-bus driven function is always trans­ferred via one or several nodes of the nodes
in the CAN-bus network.

All nodes are fed with power from one of
the two distribution boxes. In this case the
electrical power dedicated to a specic
function is transferred though the node.
The node transmits the power according
to the message received on the CAN-bus
system, initiated of the operator, and the
function is executed.

8

Control functions

Functions are displayed in the multi-func­tion display A80. During normal operation
the display shows a basic menu that pro­vides the driver with basic data. The display
also shows alarms reporting errors on the
engine, communication buses and sensors.

Reliability

The machine structure

The chassis and boom are of a heav y-duty
design. Well-known mechanical compo­nents have been chosen and are carefully
tested together under heavy conditions
in various climates. The ContMaster is
the sum of long experience of operating
reachstackers.

In addition to the drivers interface there is
also interfaces for maintenance and calibra­tion. These menus are accessible by turning
the service key in the electrical box locker
on the right frame side. The node also has a
plug-in contact for a PC used for calibra­tions or error detecting.

A80 display
A80 keyboa rd

Hydraulics

The load sensing pumps feeding the main
hydraulics generates less heat than xed
pumps and provide higher efciency. There
are extremely reliable, well sealed ORFS­couplings (O-ring face seals) in all hydraulic
connections. Well known hydraulic compo­nents put together in a balanced system.
The temperature and cleanliness are kept
under control in two separate systems,
main hydraulic circuit and brake circuit.
The brake circuit has a separate tank with
its one cleaning system. A lter clogging
warning indicator on the right hand dash­board tells the operator when to replace
the return lters of the hydraulic system to
maintain a high cleanliness.

Electrical- and control system

The system combines electric and CAN-bus
functions in a reliable way. The amount of
wiring needed is reduced by this solution

and along with that the potential sources of
errors. The display A80 continuously gives
the driver information about the machines
performance. It also provides the driver
with alarms and error messages if any
of the controlled functions suffers from
malfunctions. This increases the reliability
because expected breakdowns can be

prevented in an early stage. The machine is
also equipped with a forced motion switch,
a portable control positioned on the back
of the cabin rear wall, making it possible
to move the machine without using the ac­celerator, ignition key and gear lever in case
of emergency.

9

11

Standard equipment

Chassis

• Angled entrance

• Lifting eyes front/rear

• Towing pin

Body

• Steps with anti slip protection

• Rear view mirrors on each side

Steeringaxle

• Rear axle: Kalmar

• Double acting steering cylinder

Drive train

• Engine: Scania DI12

• Transmission:

• Engine protection system

• Transmission protection system

• Parking brake connected with main brake

• Front axle : Meritor

• Filter/Water separator

Cabin

• Heating

• Instep handle

• Fixed drivers seat BEGE

• Armrest right hand side

• Wipers/washers on front,
rear and roof pane

• Interval wipers on front pane

• Sliding window on left side

• Emergency exit

• Lockable doors (key)

• Inside rear view mirror

• Joystick for boom and attachment
functions incl. tilt

• Control panel in cabin for top lift
(std incl. 3 buttons)

• Steering wheel knob

• Horn

• Electric accelerator pedal

• 24 V outlet

• Brake pedal incl. transmission
disconnection (declutch)

• Button for electronic hand brake

• Warning buzzer for not activated hand
brake, leaving seat

• Hydraulically movable cabin (horizontal)

Spicer off Highways 15.5HR36431

Instrumentation

• Gauges

- Hour

- Fuel

- Transmission oil temperature

• Warning/Indication lamps

- charging

- direction

- high beam

- parking brake

- failure indicator

- low brake pressure

- low transmission oil pressure

- high transmission oil temperature

- indication locked twistlock

- Indication alignment

- indication opened twistlock

- warning hydraulic oil return lter

- warning brake hydraulic oil lter

• Display

- stability control bar (%)

- actual gear and driving direction

- travelling speed (km/h)

- transmission slip ratio (%)

- engine rpm

- gear rpm

- engine coolant temperature

- engine oil pressure

- operating hours/effective
operating hours

- automatic gripping on/off

- alternative languages

Wheels

• Tyres : 18.00 x 25

Lifting boom

• Lifting boom std 5 high

Hydraulics

• Return lters hydr. oil (10 micron)

• Pressure lter brakes (10 micron)

• Load sensing pumps (3 pcs)

• Fixed pumps (2 pcs)

• Visual level glass hydraulic

tank/brake tank

Electrics

• Electrical system 24 V

• Main power switch electrical

• 2 working lights on attachment

• 4 working lights on boom

• 2 working lights on front edge cabin

• 2 rear lights on fenders activated
in reverse

• 2 head lights on front fenders

• 2 position lights on each side

• Lights high/low beam front

• Tail lights, brake lights

• Directional indicators front and rear

• Rotating beacon

Attachment

• Top lift 20’-40’ (cap. 45 ton)

- Sideshift ±800 mm

- Slewing mechanical ±5°

- Oscillation +200°/-100°

- Controlled tilt ±2°

- Hooks on corners (4 pcs) for sling

Signs and documentation

• Load chart diagram in cabin

• Machine data plate chassi incl. load chart

• Warning stickers

• Information stickers

• Fuse diagram

• Instruction manual

• Maintenance manual

• Spare parts catalogue

• Instruction manual engine

• Instruction/service manual transmission

10

Service friendly

Service

This is a machine built to run. Therefore
Kalmar has tried to minimise the time
for stoppages by extending the service
intervals, reducing the ser vice points and
making maintenance work as easy as pos­sible to perform.

Service accessibility

Hatches on the side of the machine
together with a small inspection hatch on
the engine hood gives easy access for daily
inspections. The top covers don’t need to
be removed. With this solution most of the
daily inspection work can be done from
ground level. The transmission lters are
located outside the frame on the backside
of the right fender.

On the right hand side behind the service
hatch the batteries are located on a roll out
device providing excellent access during
inspections or service. Behind the same
hatch the main battery relay, contactors
and fuses are located together the frame
node of the control system. The cabin
transfer unit will also be found here. All
components are in easy reach and have
great accessibility.

Easy acc essable air int ake mounted on lef t fender.

Service hatc h on right h and side. The batteries

can be ro lled out.

The air intake is located on the left fender
by the instep. On the same side, behind the
service hatch, you will nd the hydraulic l­ters, cooler for the main hydraulics and the
pressure accumulators. Measuring points of
the hydraulic system is also located here.

When the top covers of the frame above the
engine compartment are removed engine,
transmission and main hydraulic compo­nents are easy accessible. The cabin can be
moved back and forth which also increases
the accessibility.

Service hatc h for hydraulic on left hand side.

Fault identication

The maintenance displays of control unit
A80 are only intended for professional
maintenance personnel, so they can cor­rect error situations and make necessary
calibrations.

The service switch of the control system is
located behind the seat on the back wall of
the cabin. By turning this switch and there­by pushing the M-button on the display
keyboard gives access to the maintenance
displays. In this mode all nodes and related
functions can be gone through in order to
locate the error.

Easy acc ess for inspec tions - and maintainance work w hen top covers are removed.

11

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3

4

1

2

9

3

Contact information:

Kalmar global partner

Local presence, globally

Kalmar is a global supplier of heavy materials
handling equipment and services for ports,
terminals, industry and intermodal handling.

Local presence means that we can support
our customers throughout the product’s life
cycle, wherever they are.

Our products are manufactured in Sweden,
Finland, the USA and the Netherlands.

Other reachstacker models

Container Handler ContChamp Intermodal ContChamp Empty Container Handler ContChamp

921524-0741/04- 01 KST Råd & Resultat

We reser ve the rig ht to change the desi gn and tec hnical data with out prior notice.

Kalmar Industries Sverige

Torggatan 3 SE-340 10 Lidhult, Sweden
Tel: [phone]. Fax: [phone].

www.kalmarind.com