Container handling with a reachstacker is
one of the most flexible handling solutions whether to operate a smaller oneunit terminal or a medium sized port. A
reachstacker can handle loaded containers
quickly and efficiently in narrow spaces,
while still ensuring the driver has optimum
visibility.
The extensive freedom allowed by the
lifting equipment, boom and attachment,
and its rotation possibilities, gives that
the driver can improve the work efficiency
of the unit, by not needing to approach
the container from a 90 degrees position.
Contai ners c an be lif ted lengthwi se making it possible to d eliver
the container into and tr ough workshop doors, p ort sh ed gates, etc
in then low, longitu dinal position.
Instead, the container can be picked or
dropped-off by the unit approaching from
any angle <90 degree. And by rotating the
spreader and reaching the boom to suitable
length, the driver can handle the container
from any position. As an additional advantage, the aisle width - driving space depth,
needed - can be squeezed, as well.
Wear on the machine and the working
surface can be reduced if the reachstacker
is used in the right way. Compared to a conventional forklift, a larger proportion of the
lifting manoeuvre can be performed while
the unit is stationary.
Containers can also be lifted and transported lengthwise, making it possible to deliver
the container into and through workshop
doors, port shed gates, etc in then low, longitudinal position. This can be a vital ability
for the possibility of container stripping and
stuffing inside the sheds.
2
The fac t of not ne eding to p ick
a container, right- angled, means
a lot of in te rms of work efficiency
and handling speed, duri ng loading and
unloading.
The goals in developing a reachstacker are
clear: high performance throughout the
operating cycle, high user-friendliness, and
low running costs. Together with a high
level of environmental awareness, this has
resulted in new technical solutions and
systems.
Any driver with the ability to take advantage of the machine’s capacity and technical benefits will find this reachstacker a
powerful, flexible tool for handling containers with the lowest possible operating and
maintenance costs.
The technical information in this material
primarily refers to the DRF. Specific information about the DRD’s technical systems
is available on request.
Clarification of model
designation
e.g DRF450-65S5XS
Diesel
Reachs tacker
Generation
First row capacity in decitonnes
Wheel ba se in decimetr es
Spread er
Five cont ainer s tacking
Extended cap acity
Suppor t jacks
Page 3
Capacity and dimensions
Maximum lifting capacity
in confined spaces.
with spherical plane thrust bearings. The
width of the rear fixture (boom suspension)
increases the overall rigidity and the good
The chassis and lifting equipment have
rearward visibility.
been developed to ensure the best possible
performance, strength and user-friendliness. The nature of the working environment and capacity requirements at different load centres determine which model is
the most suitable.
The boom has two sections, the inner and
outer boom. The sliding plates between the
inner and outer boom require no lubrication. The cable-chain which leads hydraulic
hoses and cabling to the attachment is
made of maintenance-free plastic.
Lifting boom
The lifting boom carries the load. The
design has been optimised using computer simulations and extensive field tests.
The powerful execution in high-tensile
steel has a minimal number of welds for
maximum strength. The boom’s fixture in
the frame and the lifting cylinders are fitted
Contai ner 8’6’’Contai ner 9’6’’
Lifting boom hydraulics
Oil is fed to the boom functions by load
sensing pumps. To reduce pressure drops,
wide hydraulic hoses have been used for
the boom functions. A wider hose produces
a lower flow rate with the same volume,
thereby reducing friction and heat development.
The blocking valves on the lifting and
extension cylinders block the oil flow when
the boom functions are not in use, which
secures the boom position. The base of
the lifting cylinders has a new design that
produces smooth stopping and starting
movements.
The boom’s lifting and extension function
is damped in the end positions for reduced
wear and greater comfort.
Rotator
The rotator is fixed 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 hydraulic dampers
help prevent the container from swinging
lengthwise.
The primary function of the attachment is
to firmly attach the container during lifting.
This is done with four twistlocks which
rotate, thereby securely gripping the
container’s corner fittings.
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. A hydraulic
motor drives the function via chains. The
container can also be moved sideways
to facilitate loading and unloading, or to
compensate for unbalanced loads. Two
hydraulic cylinders perform the side-shift
movement.
Attachment and rotator hydraulics
The functions are fed with a constant pressure, which means there is no pumping of
hydraulic oil when the functions are not in
use. One valve serves all the hydraulic functions in the attachment. The valve ensures
that each hydraulic function is fed the exact
amount of oil needed to optimise the speed
of the functions’ movements. The attachment functions are damped in the end
positions.
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.
Firstly, a large number of computer simulations have been run in order to eliminate
critical tensions under various kinds of
strain. The simulations were characterised
by uncompromising demands on the fundamental principles of stability, manoeuvrability and visibility. Secondly, the machine has
then undergone extensive field-testing to
fully ensure its dynamic strength.
The reachstacker is available with a variety
of wheelbases to fulfil demands on lifting
capacity in relation to manoeuvrability and
operating economy in the best way.
Increased capacity
In some cases, high capacit y requirements
in the second and third rows of containers,
or on the far rail track, call for the benefit of
support legs. In other cases, it may be the
restricted handling space that determines
the most suitable model.
Kalmar’s goal while developing the cabin
has been to assure the driver the best conceivable safety, ergonomics and visibility.
Sound and vibration
The cabin is separately suspended and
isolated from the frame with powerful rubber dampers. Effective shock absorption
minimises vibration. The cabin is fitted with
insulation material both inside and out. The
maximum noise level inside the cabin is 72
dB (A).
Ergonomics
Controls and instruments are intuitively
positioned and work the way a driver would
expect. Search lights in the buttons and
switches make them easy to identify and
use, even in darkness.
In the centre above the steering wheel is
a display showing operating information,
warning messages, error codes etc. To the
left of the display is the panel for warning
and indication lamps.
The driver’s seat and control lever for the
lifting functions can be adjusted to the
optimum individual driving position.
The pedals are designed for high comfort,
with a hanging accelerator. The internal dimensions are otherwise generous, offering
an open floor space.
Climate
An electronic controlled heating and ventilation system comes as standard, as do
filters for fresh air and recirculation. An air
cooling system is available as an optional
extra. The cooling system provides a good
cooling effect, even in extremely high
temperatures. A pollen filter is available as
an optional extra.
Left in strument panel
Gear selector and
multi-function lever
Steering wheel p anel
Direc tion indicators
Prepar ed for terminal a nd
dashbo ard attachment
Hydraulic cont rols
Panel fo r hydraulic
funct ions
Emergency switch
Parking brake
5
Page 6
Performance
Performance is the result of how well
the machine’s functions work together.
The efficacy of the lifting equipment is determined by a combination of lifting speed,
capacity, visibility and user-friendliness.
Lifting places heavy demands on the engine
and working hydraulics, but lifting is only
part of the operating cycle. Before the
machine is in position to load or unload,
the demands are instead on precise control
with tight turning radius, effective brakes
and high pulling power. And of course, all
the functions must still perform optimally
even after heavy use.
Brakes
The brake circuit is separated from the hydraulic system and has its own tank, cooler
and high-pressure filter. A temperature
transmitter in the separate tank regulates
the cooler fan.
Transmission
The transmission transfers power from
the engine to the hydraulic pumps and
drive line. The engine and gearbox control
systems work together to find the optimum
balance between power and fuel economy
at any given point.
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.
Standard
drive tr ain
Drive line
The propeller shaft and drive axle transfer
the power from the transmission to the
driving wheels. The mountings on the propeller shaft are fitted with cross-flanges for
optimum strength.
The foot-brake valve, which controls the
oil feed to the brakes, is sensitive enough
so that the driver can brake optimally yet
still gently. The parking brake is activated
automatically when the ignition
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.
Power247 kW at 1900 rpm261 kW at 2000 rpm
Peak torque1760 Nm at 1400 rpm1830 Nm at 1100-1400 rpm
Volvo TAD 1250VE with
air cooled intercooler
* Stage 2 and T ier 2 outs ide US and EU
Cummins QSM11 with
air cooled intercooler
6
Page 7
Engine
A Volvo 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,
along with the precise fuel injection control,
ensures more efficient combustion. Emissions decrease, while power and torque increase. The engines fulfil the requirements
of 97/68*2004/26 EC stage 3, US EPA Tier 3.
The engine and transmission cooler is a single unit that uses the same fan. The engine
cooler’s separate expansion vessels are
fitted with a level transmitter that indicates
low coolant level.
When the engine temperature is too high or
the coolant level or oil pressure too low, the
engine’s power output is actively reduced.
Should the oil pressure fall below a certain
level, the fuel feed to the engine is cut off
automatically.
Steering system
The steering axle has been cut from a single
piece of robust steel, which means as few
maintenance-requiring parts as possible and
high structural strength.
Cummins QSM11 with air co oled intercooler
can be fit ted as optional extra.
The hydraulics that feed oil to the steering
cylinder is optimised for enhanced driving
sensation. Orbitrol and the priority valve
jointly provide gentle yet precise steering
movements.
Two things are needed for a command initiated by the driver to result in a particular
function, or for several functions to work
together: power-feed and communication.
The power-feed supplies the machine’s
electrical and electrohydraulic functions
with voltage, while the communication system controls and checks that the functions
have been activated, waits in standby mode
or indicates a fault.
Kalmar Cabin Uni t
Kalmar Information Terminal
Kalmar Information Display
Elect ronic Diesel Control
Transmission Contr ol Unit
Kalmar Distri buted Unit
Communication
The distributed power-feed and communication network consists of electrical
components and a microcomputer-based
system for controlling and monitoring the
reachstacker’s functions.
The most important components in the
network are the control units (nodes). They
distribute control of the machine’s functions. 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.
The nodes transmit their signals in messages on the network. Each message
contains several signals and has its own
address. Any units that need to know the
status of a signal listen out for the address
of the signal’s message. All the nodes in the
network listen to each other.
CAN-bus is a two-wire transfer of data and
a definition of a bus type. CAN-bus technology has been chosen because it provides a
reliable, robust transfer of data and is difficult to disrupt. CAN-bus loops have been
used in Kalmar machines since 1995.
The greatest benefit of using CAN-bus
technology is that the amount of cabinling
can be reduced. All that is needed to establish communication are two data-bearing
leads and two leads for feeding the nodes’
processors. The network loop for both the
CAN-bus and the nodes’ processor feed are
redundant.
The Kalmar Cabin Unit (KCU) is the control
node for the entire network. There are several nodes, called KDUs (Kalmar Distribution
Units), in the network. Each node is positioned near to the functions it is designed
to deal with. With certain optional equipment, further nodes (KDUs) are connected
to the existing network near to where the
specific functions are located.
The Transmission Control Unit (TCU),
which is the gearbox node, deals with
the gearbox. The unit is connected in a
separate CAN-bus loop with the EDC engine
node (Engine Diesel Control) and KCU. The
engine node controls the fuel injection and
receives its control signals from its own
transmitters on the engine.
Power supply
Power-feed for the functions differ from the
feed required for communication and feeding of the nodes’ processors.
Each distribution unit (node) in the distributed network is fed voltage from one of the
power distribution boxes. The distribution
boxes are located inside the cabin and on
one side of the frame. The distribution units
(nodes) guide power from the distribution
box to the required functions based on the
instructions in the messages from the communication network.
8
Page 9
Control functions
The driver and machine communicate
via the Kalmar Information Terminal (KIT)
and the Kalmar Information Display (KID).
Control signals initiated by the driver are
transferred to the KCU, which handles all
incoming signals from the controls in the
cabin, and sends messages out into the
communication network.
Reliability
High reliability is achieved by reducing
the number of components and ensur-
ing each individual component main-
tains a consistent high quality.
The system also distributes information to
the driver such as alarm warnings, operating details and action-guided information.
In these cases, messages are sent from one
of the nodes in the network, captured by
the KCU, and then presented in the KID or
the panel for warning and indication lamps.
The KID shows information from the control
units in the form of messages, status, fault
indication etc.
Keyboard (KIT)
Warning and indic ation lamps ( KIT)
Display (KID )
Alarm in dicat or
One of our guiding principles in designing the reachstacker was to minimise
the number of potential sources of error.
Therefore, the machine consists of as few
components and moving parts as possible.
The functionalit y and operational reliability
of each component is assured by extensive
testing.
The machine’s structure
Kalmar has been making reachstackers
since the mid-1980s. There are a lot of
Kalmar machines around the world, used
in all kinds of climates. Overall, this has
helped build our completely unique experience of this machine type. The machine’s
lifting equipment, frame and structure
has been fine-tuned over the years, and
today we can offer the best balance of
performance and operational reliability in
the machine’s mechanical components and
structure.
Hydraulic components and couplings
The number of hydraulic components and
hydraulic couplings has been minimised.
The main valve has an integrated servo,
which helps increase control of the oil flow
and keep the number of components to a
minimum.
The boom’s lifting and extension cylinders
are fitted with double gaskets. Moreover,
the machine is fitted with extremely reliable, well-sealed ORFS (O-Ring Face Seal)
couplings in all the hydraulic hoses as
standard.
Temperature control
and hydraulic cleanliness
In order to maintain optimum functionality
in the hydraulic system even under extreme
operating conditions, cleaning and cooling
of the hydraulic oil is highly efficient. The
brake circuit is separated from the rest of
the hydraulic system and is fitted with its
own cleaning process and cooling system.
Redundant communication network
A network of distributed control units
(nodes) using limited cabling and fewer
couplings, meaning fewer sources of error.
The power-feed for each node is independent of the other nodes, which help prevent
other nodes from being disrupted, should
one stop working. The same applies to
the transfer of control signals. Both the
power-feed and control signal transfer are
redundant, so that power or signals always
have two paths to choose for maintaining
communication, thus offering extra safety
and reliability.
9
Page 10
Standard equipment
Chassis
• Safe angled entrance
• Lifting eyes front/rear
• Towing pin (incasted)
Body
• Steps with anti slip protection
• Rear view mirrors on each side
Steeringaxle
• Rear axle: Kalmar
• Double acting steering cylinder
Drive train
• Engine: Volvo or Cummins
• Transmission: Dana
• Engine protection system
• Transmission protection system
• Preheating engine
• Front axle: Axletech
Cabin
• ECH, electronic controlled heater
• Fresh air and recirculation filter
• Step for roof access
• Instep handle
• Fixed drivers seat BEGE
• Armrest right hand side
• Wipers/washers on front, rear
and roof pane
• Interval wipers on front, rear
and roof pane
• Tinted windows
• Sliding window on left side
• Lockable doors (key)
• Door with air damper
• Inside rear view mirror
• Interior light with fade away
• Background button light
• Joystick for boom and
attachment functions
• Automatic gas at lifting/extension
• Control panel in cabin for top lift
(std incl. 3 button)
• Warning buzzer for not activated
hand brake, leaving seat
• Automatic gear shifting
• Only first gear activated
• Only second gear activated
Instrumentation
• Graphic display with automatic
fault analyses
- Alignment indicator spreader
- Twistlock indicator
- System voltage
- Actual gear
- Engine rpm
- Travelling speed
- Fuel bar
- Hydraulic oil temperature
- Transmission oil temperature
- Engine oil pressure
- Engine coolant temperature
- Overload warning
- Overload warning steering axle
- Clock
• Hour meter
• Charging
• Low brake pressure
• Failure indicator
• Safety system disconnected
• High engine coolant temperature
• Low engine oil pressure
• Preheating engine
• Low engine coolant level
(not on Cummins)
• Transmission oil temperature
• Low fuel level
• Hydraulic oil temperature
• High beam
• Direction indicator
• Parking brake
• Indication locked twistlock
• Indication alignment
• Indication opened twistlock
Wheels
• Tyres: 18.00 × 25
• Wheel nut protection
Lifting boom
• Lifting boom std 5 high(6-7m wheel base)
Hydraulics
• Return filters hydr. Oil (10 micron)
• Pressure filter brakes (10 micron)
• Load sensing pumps (4 pcs)
• Vane pumps (2 pcs for brakes and cooling)
• Visual level glass hydraulic tank/brake tank
• Regeneration system (lift and
extension boom)
• Environmental air filter hydraulic tank
Electrics
• Electrical system 24 V
• Main power switch
• 2 working lights on attachment
• 2 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
• Blinkers front and rear
• Rotating beacon
• Flashing brake lights when reversing
• Acousting signal when reversing
Attachment
• Top lift 20’-40’ (cap. 45 ton)
- Sideshift ±800 mm
- Mechanical levelling ±5°
- Rotation +195°/-105°
- Hook on corners for slings
• Floating ISO twistlocks
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
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Page 11
Service friendly
Few, short stoppages for ser vice
and maintenance minimise loss of
production time.
In the longer term, the reachstacker´s reliability is a crucial parameter in the overall
handling economy. At the same time, each
machine must be service-friendly so it can
be maintained and repaired quickly and
easily, thereby maintaining high reliability.
Kalmar’s products have always been very
service friendly as we continuously strive:
• to minimise the number of components
• to choose the highest quality
components throughout
• to use lubrication-free options
wherever possible
• to optimise accessibility for service
and maintenance
Service accessibility
The top covers on the frame can be removed quickly and easily. Most of the main
components are easily accessible from
above in the broad frame when inspection
and maintenance need to be carried out.
The cabin can also be moved lengthwise
thus further increasing ease of access.
High availability and grouped service points makes
daily inspect ions and maintenance work easy.
Fault identification
The control and monitoring system offers
completely new opportunities for fault identification. There are over 400 fault codes
and 140 diagnostics menus built into the
system.
The overall aim is to make stoppages as few
and as short as possible. With this machine,
Kalmar has created the best possible balance between performance and operating
economy - in other words, a low cost over
the entire life cycle of the reachstacker.
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Contact information:
Kalmar global partner
Local presence
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 located.
There are 17 Kalmar sales companies that
support dealers and agents in 140 countries
around the world.
Other reachstacker models
Intermodal HandlerEmpty Co ntainer Handl er
921524-0711/06 -03 KST Råd & Resultat
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