Kalmar DCF360CSG, DCF450CSG Service Manual

Kalmar DCF360-450CSG
Toplift container handlers
36 – 45 tonnes

Technical information

Introduction

Welcome

Let us introduce to you the details about the
new ultimate top-lift handler – the Kalmar
DCF-series.

These heavy-duty container handlers have
been developed exclusively for ports and ter­minals with strong demands on productivity
and high quality operation. This is a machine,
which has long been asked for among de­manding terminal operators all over the world.

So what about the special benefits?

The Two basic elements
in container handling.

The decision to develop a “brand new” ma­chine came after getting input from terminal
operators for a basic type of machine, but
with superior performance characteristics. We
then decided to build a family of integrated
top-lift handlers that would surpass all exist­ing machines.

Drawing on our global experience we know
that there are two basic elements in container
handling that ensures success in the working
day on every port and terminal. Two ele­ments in the mind of operations, financial and
purchasing managers, but also in the mind of
drivers and maintenance staff.

These two elements were our top priority in
the design and development of the Kalmar
DCF.

Technical solutions are only the tool.
Not the goal.

There is new leveraging technology under the
skin of the DCF in order to provide the best
everyday performance and availability.

PERFORMANCE

PERFORMANCE

ERGONOMICS

ERGONOMICS

DRIVING

DRIVING

LIFTING

LIFTING

CAPACITY AND

CAPACITY AND

DIMENSIONS

DIMENSIONS

We have examined and evaluated every nut,
bolt and component to ensure we provided a
machine with the highest possible specifica­tion.

When appropriate simple technical solutions
were available we have applied them, and
when the need was for more sophisticated
systems we have installed them to boost your
uptime and productivity.

AVAILABILITY

AVAILABILITY

RELIABILITY

RELIABILITY

MAINTENANCE

MAINTENANCE

INTELLIGENCE

INTELLIGENCE

SIMPLICITY

SIMPLICITY

The technical optimisation of the Kalmar DCF
means that you will get the best technology
available but still have the feeling of hav­ing a reliable, simple, safe and hard working
machine.

Providing the highest possible
throughput.

This is what it’s all about. But of course you
have to add “at the lowest lifetime cost pos­sible”. To reach such a goal you need to focus
on specific critical targets.

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Ergonomics

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The heart of top performance in top-lift handling

To obtain the maximum out of your invest­ment, you can never underestimate the
importance of the drivers’ working environ­ment. High throughput demands full driver
concentration and efficiency to keep up the
container moves, but also to avoid injuries
and costly damages.

This is what ergonomics is all about. Being
comfortable and aware.

The driver environment in Kalmar DCF is the
comfortable Spirit Delta high visibility cabin;
appreciated by professional drivers, proven
on thousands of Kalmar container handlers all
over the world.

We focus on four important
ergonomic areas:

• Operation

• Visibility

• Sound and vibrations

• Climate
The result is a cabin where everything is opti­mised to improve driver performance.

Consider this:

• Individually adjustable controls, steering
wheel and seat.

• Intuitively positioned instruments.

• Switches and buttons with lights.

• Comfort pedals.

• Electronic accelerator.

• Central operation/warning display.

• Separately suspended and isolated cabin.

• Shock absorption to minimise vibrations.

• Maximum sound level inside is 70 dB (A).

• Generous interior dimensions and floor
space.

• Optimised visibility – 360˚ all around.

• Electronically controlled heating/
ventilation.

• Filters for fresh air and recirculation.

• High performance air conditioning system,
optional.

• Pollen filter, optional.

Left ins trumen t panel

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Gear sel ector and m ulti-fun ction lev er

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Steerin g wheel pan el

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Direct ion indica tors

Prepare d for termi nal and
dashbo ard atta chment

Hydraul ic control s

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Panel for h ydraulic fu nctions

Emergen cy switch

Parking b rake

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Capacity and dimensions

Matching your handling and throughput needs

When we designed the Kalmar DCF top-lift
we already knew the detailed status of all the
main alternatives on the market. Hence, we
designed a machine which meets or exceeds
the specifications of the others – on the spec
sheet and in reality.

You can choose between three basic models,
each optimised according to lifting capacity
– stability – overall dimensions – weight – top­lift speed and driving performance.

Three models cover container handling
between 36 – 45 tonnes capacity, 20’-40’
containers and up to five high stacking at full
capacity. This means that you may easily find
the right machine or combination of machines
to suit your operational requirements.

The design of the chassis, mast, carriage and
spreader has resulted in machines with very
good dimensional-, stability- and operational
characteristics.

41000 kg

In spite of its size and capacity the Kalmar
DCF has a short turning radius. Together with
the optimised visibility and good manoeuvra­bility it saves terminal space and makes the
machine a smooth operator in confined aisles.
The counterweight and lifting height require­ments have been matched with a modern
chassis to keep down the overall weight but
with no sacrifice in stability.

45000 k g

DCF360CSG DCF410CSG DCF450CSG

Capacity and weight

Lifting capacity Classification

Load cen tre attachment retracted

Weight Service weight

Weight front axle unloaded

Weight rear axle unloaded

36000 k g

36000 k g

36000 k g

36000 k g

attachment extended

at rated load

at rated load

41000 kg

41000 kg

41000 kg

41000 kg

DCF360CSG DCF410CSG DCF4 50CSG

kg 3600 0 41000 450 00

L4 mm 1750 1750 1750

L7 mm 1955 1955 1955

kg 6640 0 69750 75000

kg 41300 42290 44000

kg 94800 101450 110500

kg 25100 27460 31000

kg 7600 9300 9500

45000 k g

45000 k g

45000 k g

45000 k g

4

The mast and carriage are computer designed
and optimised (FEM and Catia V5) which al­lowed for a decrease in the front axle weight.
Together with Kalmar’s integrated high capac-

A1
A2

ity spreader it allows you to fully utilise the
capabilities of mast tilt, slewing, extension,
sideshift at full lifting height and full capacity.
No compromises.

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Additionally, we have ensured that every
single detail, component and system have
been selected and manufactured to provide
the highest possible reliability.

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H4

H3

H10

R1

100

Dimensions

Truck Truck leng th, with at tachm ent

Standa rd duplex mast
(5 high 8’6, 5 high 9’6)

Attachment Width, min – max

Truck width

Truck height

Seat heig ht

Distance between fron t axle cen ter – front side of mast

Wheelb ase

Track (c-c ), front – rear

Turning radius, outer

Ground cl earance min. unde r truck

Min. track with for 90º
stacking

Height under tw istlocks 4-high – 5 -high ma st

Mast height, min.

Mast tilting, for wards – b ackwards

Hydraulic slewing

Side shif t, ± eithe r side center

Levelling

R2

inner

with 20’ container

with 40’ c ontain er

min.

max

L3

100

DCF360CSG DCF410CSG DCF4 50CSG

L mm 10970 10970 11020

B mm 4450 4450 4450

H6 mm 4650 4720 4720

H8 mm 3560 3630 3630

L2 mm 900 900 950

L3 mm 6000 600 0 600 0

S mm 3020 – 2820 3020 – 2820 3020 – 2820

R1 mm 8 660 8 660 8 660

R2 mm 1090 1090 10 90

mm 280 280 280

A1 mm 11990 11990 11990

A2 mm 14680 14680 14680

H4 mm 12090 15160 15160

H10 mm 2080 2160 2160

H3 mm 7700 9190 9190

H5 mm 15170 17170 17170

α – β º 5 – 10 5 – 10 5 – 10

V mm 12170 – 6070 12170 – 6070 12170 – 6070

º ±3 ±3 ±3

V1 mm 400 400 400

º ±5 ±5 ±5

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L4

L7L2

5