Kalmar CONTMASTER 45 Service Manual
CONTMASTER 45 TONNES
TECHNICAL INFORMATION CONTAINER HANDLER
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Dedicated for Container Handling
A renewed workhorse dedicated for
laden containers.
The Contmaster is improved in several
ways, which is reected in higher efciency
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 efciently 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 signicance. 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extended and withdrawn.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.
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Any driver with the ability to take advantage of the machine’s capacity and technical benets 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.
Clarication 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
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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)
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