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CONTMASTER 45 TONNES
TECHNICAL INFORMATION CONTAINER HANDLER
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a lowered lifting boom, means high acces- models will be found in the technical data Lifting capacity in decitonnes (1st row)
Spreader
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Capacity (tonnes)
Container 8’6’’ Container 9’6’’ Lifting height toplift attachment
Model
1:st row 2:nd row 3:rd row 1:st row 2:nd row 3:rd row H4 (mm) H5 (mm)
DRS4527-S5 42*/45 27 13 40*/45 27 13 14900 17900
DRS4531-S5 42*/45 31 15 40*/45 31 15 14900 17900
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Rotator The attachment can easily be adapted Each function has it’s own set of valves to
The rotator is fixed in the inner boom and to different container standards by two ensure that each function gets the right oil
enables the container to be rotated. The hydraulic cylinders pushing the T-beams volume and pressure.
rotator consists of an upper and a lower back and forth within the mainframe of the
yoke joined with a powerful bearing. Rota- spreader. Chassis
tion is enabled by two hydraulic motors, The frame forms the basis of the machine’s
which drive a gear-ring. Two cylinders The container can also be moved sidewise lifting and manoeuvring characteristics.
help prevent the container from swinging to facilitate loading and unloading or to The frame’s beam construction, along with
lengthways and can also be utilised to tilt compensate unbalanced containers. Two its width, makes the reachstacker stable,
the load. hydraulic cylinders perform the side-shift torsion resistant and service-friendly. The
movement. basic principles of this chassis design have
The attachment been tested for a long time in different
On the attachment, four twistlocks firmly Attachment and rotator hydraulics locations in previous reachstacker models.
locks the container to it by rotating thereby A fixed vane pump feed the spreader func-
securely gripping the container’s corner tions. The spreader functions are prioritised The chassis comes in one length optimised
fittings. The mechanical levelling ensures but when handling light loaded container according to the relationship between
that the twistlocks reach the corners, even the lifting- and extension functions pick capacity and manoeuvrability.
if the container is leaning. 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.
Dimensions
Aisle width (mm) Turning radius (mm) Main dimesions (mm) Service
Model weight
A1 - 20 ft A2 - 40 ft R1 - 20 ft R3 - 40 ft B V L H3 Clearance Wheels (kg)
DRS4527-S5 9900 12600 8350 9400 4160 6050-12185 11700 4500 400 18.00x25/40 65000
DRS4531-S5 9900 12600 8350 9400 4160 6050-12185 11700 4500 400 18.00x25/40 68500
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Driver environment
Drivers best friend The vertical grip type joystick has a precise Climate
Kalmar’s goal while developing the cab has feeling and all main hydraulic controls are An efficient heating and ventilation system
been to assure the driver the best conceiv- placed on the lever as push buttons. On the comes as standard. An air cooling system is
able safety, ergonomics and visibility. side panel on right hand contains the rest available as an optional extra. The cooling
of the hydraulic function buttons direct in system provides comfort, even in extremely
Sound and vibration reach of hand. high temperatures.
The cab is fitted with insulation material
both inside and out. The maximum noise From the drivers position the visibility is
level inside the cab is 72 dB (A). high in all directions. To further increase
the visibility the cabin can be hydraulically
Ergonomics moved lengthwise. Tinted windows are
Entering the cabin is safe and easy by the standard equipment.
newly developed angled instep. Well inside
controls and instruments are well placed
and have a precise feeling making them Left instrument panel
efficient to use. Control system, display and
keyboard
Gear selector
Steering wheel panel
Multi function lever
Joystick
Panel for hydraulic
functions
Parking brake
Emergency switch
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Performance
The ultimate workhorse Transmission
Container handling is not just about lifting The proven 4 by 4 transmission transfers
container fast and high. All functions must power from the engine to the hydraulic
work smoothly together even under heavy- pumps and drive line.
duty operations. An efficient machine is a
machine that can handle all moments of The transmission system consists of a
the working cycle in a simple and precise torque converter and a gearbox. The
way at lowest possible cost, just like the same gearbox is used whichever engine
ContMaster. is chosen. The gearbox is automatic, but
can partly be shifted manually. The torque
Over the years the ContMaster has shown converter is a hydraulic coupling positioned
a remarkable availability which is the basic between the engine and gearbox. The gear-
for this further development. All perfor- box and torque converter work together
mace boosts have been made with no via a joint hydraulic system. This gearbox is
compromise to the quality of the reach- one of the most used in the heavy range of
stacker, keeping and enhancing the virtual Kalmar due to its high reliability.
availablity.
Standard
drive train
Brakes Drive line
A fixed pump feed the brake circuit. It is The propeller-shaft and drive axle trans-
separated from the hydraulic system and fers the power from the transmission to
has its own tank, cooler and filter. The the driving wheels. The drive axle shifts
brakes are of wet disc brake type. When gear down in two stages, differential and
the accumulators are set at required value hub reduction. The engine only achieves
the priority valve lead oil through the wet maximum torque at the drive wheels, which
brakes to cool them. spares the transmission.
Drive train
Standard Optional
Engine Manufacturer Cummins QSM11 with
Scania DI12 54A
Model air cooled intercooler
Power 243 kW at 2100 rpm 246 kW at 2100 rpm
Peak torque 1589 Nm at 1400 rpm 1674 Nm at 1100-1400 rpm
Transmission Spicer off Highways 36431 Spicer off Highways 36431
Driving axle Meritor PRC7534W4H140512 Meritor PRC7534W4H140512
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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
Lifting speed (m/s) Lowering speed (m/s) Driving speed (km/h) Grade ability (%) Draw pull(kN)
Model at 70% of unloaded at rated load at 2 km/h, at 2 km/h,
unloaded unloaded at rated load max
rated load (F/R) (F/R) unloaded, max loaded, max
DRS4527-S5 0,37 0,29 0,40 0,30 25/25 22/22 50 29 330
DRS4531-S5 0,37 0,29 0,40 0,30 25/25 22/22 47 28 330
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CAN-bus communication The CAN-bus system consists of five nodes Power supply
The system consists of electrical compo- (control units) and one display mounted on The power supply starts from the distri-
nents and a microcomputer based system the top of the dashboard. Each node has its bution boxes that are connected to the
for controlling and monitoring the reach- own field of responsibility and is connected batteries charged by the alternator. One of
stacker’s functions. to the other nodes in the system. the boxes is located in the locker on right
hand side, the other one will be found in the
The most important components of the The control system consists of six nodes cabin together with two of the nodes.
control system are the nodes. Each node linked together. Two nodes, A82 and A84,
has its own processor. The nodes integrate and the display A80 are found in the cabin. Most of the reachstacker functions are
with each other and all communication; The control system display A80 is logically dependent of the electrical- or the CAN-bus
control signals and signal information are located on the left side of the dashboard. system. In a traditional system a function
sent via data buses. CAN-bus is a two-wire A84 is the only module not containing any is fed directly from one of the distribution
transfer of data and a defined of a bus type. program and is purely an input node for the boxes via a switch or lever. Power feed of
CAN-bus provides reliable and robust trans- cabin switches. A82 monitors critical values a CAN-bus driven function is always trans-
fer of data and is difficult to disrupt. of the engine, stability, execute cabin trans- ferred via one or several nodes of the nodes
fer and spreader indication lights. in the CAN-bus network.
The greatest benefit of using CAN-bus
technology are that the amount of wiring A96 deals with the management of the All nodes are fed with power from one of
can be reduced. All that is needed to estab- engine and is located on the right hand side the two distribution boxes. In this case the
lish communication are two data-bearing locker together with the frame node (A81). electrical power dedicated to a specific
leads and two leads for feeding the nodes’ A81 control boom functions. Node A83 is function is transferred though the node.
processors. positioned on the boom and controls the The node transmits the power according
spreader functions. to the message received on the CAN-bus
system, initiated of the operator, and the
function is executed.
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A80 display
A80 keyboard
Reliability
The machine structure
The chassis and boom are of a heavy-duty
design. Well-known mechanical compo-
nents 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.
Hydraulics
The load sensing pumps feeding the main
hydraulics generates less heat than fixed
pumps and provide higher efficiency. There
are extremely reliable, well sealed ORFS-
couplings (O-ring face seals) in all hydraulic
connections. Well known hydraulic compo-
nents 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 filter clogging
warning indicator on the right hand dash-
board tells the operator when to replace and along with that the potential sources of prevented in an early stage. The machine is
the return filters of the hydraulic system to errors. The display A80 continuously gives also equipped with a forced motion switch,
maintain a high cleanliness. the driver information about the machines a portable control positioned on the back
performance. It also provides the driver of the cabin rear wall, making it possible
Electrical- and control system with alarms and error messages if any to move the machine without using the ac-
The system combines electric and CAN-bus of the controlled functions suffers from celerator, ignition key and gear lever in case
functions in a reliable way. The amount of malfunctions. This increases the reliability of emergency.
wiring needed is reduced by this solution because expected breakdowns can be
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Standard equipment
Chassis Instrumentation Electrics
• Angled entrance • Gauges • Electrical system 24 V
• Lifting eyes front/rear - Hour • Main power switch electrical
• Towing pin - Fuel • 2 working lights on attachment
- Transmission oil temperature • 4 working lights on boom
Body • 2 working lights on front edge cabin
• Steps with anti slip protection • Warning/Indication lamps • 2 rear lights on fenders activated
• Rear view mirrors on each side - charging in reverse
- direction • 2 head lights on front fenders
Steeringaxle - high beam • 2 position lights on each side
• Rear axle: Kalmar - parking brake • Lights high/low beam front
• Double acting steering cylinder - failure indicator • Tail lights, brake lights
- low brake pressure • Directional indicators front and rear
Drive train - low transmission oil pressure • Rotating beacon
• Engine: Scania DI12 - high transmission oil temperature
• Transmission: Spicer off Highways 15.5HR36431 - indication locked twistlock Attachment
• Engine protection system - Indication alignment • Top lift 20’-40’ (cap. 45 ton)
• Transmission protection system - indication opened twistlock - Sideshift ±800 mm
• Parking brake connected with main brake - warning hydraulic oil return filter - Slewing mechanical ±5°
• Front axle : Meritor - warning brake hydraulic oil filter - Oscillation +200°/-100°
• Filter/Water separator - Controlled tilt ±2°
• Display - Hooks on corners (4 pcs) for sling
Cabin - stability control bar (%)
• Heating - actual gear and driving direction Signs and documentation
• Instep handle - travelling speed (km/h) • Load chart diagram in cabin
• Fixed drivers seat BEGE - transmission slip ratio (%) • Machine data plate chassi incl. load chart
• Armrest right hand side - engine rpm • Warning stickers
• Wipers/washers on front, - gear rpm • Information stickers
rear and roof pane - engine coolant temperature • Fuse diagram
• Interval wipers on front pane - engine oil pressure • Instruction manual
• Sliding window on left side - operating hours/effective • Maintenance manual
• Emergency exit operating hours • Spare parts catalogue
• Lockable doors (key) - automatic gripping on/off • Instruction manual engine
• Inside rear view mirror - alternative languages • Instruction/service manual transmission
• Joystick for boom and attachment
functions incl. tilt Wheels
• Control panel in cabin for top lift • Tyres : 18.00 x 25
(std incl. 3 buttons)
• Steering wheel knob Lifting boom
• Horn • Lifting boom std 5 high
• Electric accelerator pedal
• 24 V outlet Hydraulics
• Brake pedal incl. transmission • Return filters hydr. oil (10 micron)
disconnection (declutch) • Pressure filter brakes (10 micron)
• Button for electronic hand brake • Load sensing pumps (3 pcs)
• Warning buzzer for not activated hand • Fixed pumps (2 pcs)
brake, leaving seat • Visual level glass hydraulic
• Hydraulically movable cabin (horizontal) tank/brake tank
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Service friendly
Service The air intake is located on the left fender
This is a machine built to run. Therefore by the instep. On the same side, behind the
Kalmar has tried to minimise the time service hatch, you will find the hydraulic fil-
for stoppages by extending the service ters, cooler for the main hydraulics and the
intervals, reducing the service points and pressure accumulators. Measuring points of
making maintenance work as easy as pos- the hydraulic system is also located here.
sible to perform.
When the top covers of the frame above the
Service accessibility engine compartment are removed engine,
Hatches on the side of the machine transmission and main hydraulic compo-
together with a small inspection hatch on nents are easy accessible. The cabin can be
the engine hood gives easy access for daily Easy accessable air intake mounted on left fender. moved back and forth which also increases
inspections. The top covers don’t need to the accessibility.
be removed. With this solution most of the
daily inspection work can be done from
ground level. The transmission filters are
located outside the frame on the backside
of the right fender.
Fault identification
The maintenance displays of control unit
A80 are only intended for professional
maintenance personnel, so they can cor-
rect error situations and make necessary
calibrations.
Easy access for inspections- and maintainance work when top covers are removed.
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Contact information:
We reserve the right to change the design and technical data without prior notice.
Our products are manufactured in Sweden,
Finland, the USA and the Netherlands.
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