Kalmar CONTMASTER 45 Service Manual

4 (2)
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 The distance between the container and the machine can also be varied, as the boom can be extended and withdrawn.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.
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
Reachs tacker
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)
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
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.
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.
DRS4527-S5 DRS4531-S5
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
Service weight
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