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Lift trucks

37-52 tonnes
Kalmar DCF370-520
Technical information
Welcome to a new world of heavy-duty handling Made for top performance
The Kalmar F generation heavy-duty To obtain the maximum out of your We focus on four important Electronic accelerator pedal.
lift trucks are based on long experience investment, you can never underestimate ergonomic areas: Central operation/warning display.
and smart utilisation of the lastest tech- the importance of the drivers working Operation
Separately suspended and isolated
nology. A machine loaded with customer environment. High productivity requires Visibility cabin.
value. full driver concentration and efficiency to
Sound and vibrations Shock absorption to minimise
keep up handling speed, but also to avoid
The heavy-duty lift trucks have been accidents causing injuries and costly Climate vibrations.
developed for a broad spectrum of heavy damages. Maximum sound level inside is 70 dB (A).
handling applications. Very strong The result is a cabin where everything
Generous interior dimensions and
emphasis has been put on providing our This is what ergonomics is all about. Be- is optimised to improve driver perform-
floor space.
customers, not only a machine, but pro- ing comfortable and aware. ance.
Optimised visibility 360 all around.
ductivity and cost efficiency.
Consider this: Electronically controlled heating/
The driver environment in Kalmar Heavy
Individually adjustable controls, ventilation.
This is a machine generation which re- Lift Trucks is the efficient Spirit Delta
flects the overall increased demands and high visibility cabin; appreciated by pro- steering wheel and seat. Filters for fresh air and recirculation.
requirements among our customers all fessional drivers, proven on thousands Intuitively positioned instruments. High performance air conditioning
over the world. of Kalmar medium heavy lift trucks and Switches and buttons with lights. system, optional.
container handlers all over the world. Comfort pedals. Pollen filter, optional.

A A
A Left instrument panel
A B A
B
B Gear selector and multi-function lever
A
B
A B C C
C Steering wheel panel
B
C
A B C D D
D Direction indicators
C
D
A B C D E E
E Prepared for terminal
D
E and dashboard attachment
B C D E F F
PRODUCTIVITY COST EFFICIENCY C D E F G
F
E
F
G
G Panel for hydraulic functions
DIMENSIONING RUNNING COST F
G Hydraulic controls
A
D E F G H H
H
GENERAL PERFORMANCE AVAILABILITY G (levers for electrical servo) A B
E F G H I H
I
APPLICATION FLEXIBILITY RELIABILITY H Control switch A B C
F G H I I
OPERATIONAL PERFORMANCE INTELLIGENCE I Parking brake B C D
G H I
ERGONOMICS MAINTENANCE C D E
H I
D E F
I
E F G

F G H

G H I

H I
The Two basic elements When appropriate simple technical solu- Finally, the technical optimisation of the
in heavy-duty handling tions were available we applied them, and Kalmar F-series means that you will get I

Based on our experience from more than when the need was for more sophisticat- the best technology available but still
10.000 predecessors operating world- ed systems we installed them to increase have the feeling of having a reliable, sim-
wide, the F-generation has gone through your productivity and cost efficiency. ple, safe and hard working machine.
an aggressive product development,
where we have scrutinised and improved And there is of course, exciting new lever- This is what its all about. But of course
every detail, component and system. aging technology under the skin in order you have to add at the lowest operational A

to provide the best everyday performance cost possible. B

We have learnt that demanding custom- and availability. C

ers have two main priorities when it D


comes to machine choice and decision E
productivity and cost efficiency. All other F
aspects are there to fulfil these priorities G
and add even more customer value. H

2 3
Match your specific handling requirements
55
When we designed the Kalmar F-series a
DCF520-12
b
we already knew the detailed status of 50
DCF500-12

all the main alternatives on the market.


Hence, we designed a machine which 45
DCF450-12 / CS

meets or exceeds the specifications of the DCF370-12


DCF420-12 / CS
DCF450-12CS
40
others on the spec sheet and in reality. DCF370-12 / CS
H5
35
You can choose between several basic H4
H3
models, each optimised according to lift- H6 30

Lifting capacity, in tonne


H8
ing capacity stability overall dimen- a
H2

25
sions weight and driving performance.
S L3 L2 L4
20
L L1
Ten models covering loads between
28 52 tonnes, specified for a compre- 15
600 900 1200 1400 1600 1800 2000
hensive range of lifting heights at 1200 A1
100 100 Load centre, mm
mm load centre, including the side-shift/
DCF280-330 (1) / DCF370-520 (2) models: Full lifting capacity up to
fork positioning carriage. This means that 7.000 (1) / 10.000 (2) mm lift height with duplex/duplex freelift masts
b and integrated sideshift/fork positioning carriage.
you may easily find the right machine or V1 V B

combination of machines to suit your


operational requirements.
R2
R1
The design of the chassis, mast and car-
riage has resulted in machines with very
good dimensional-, stability- and opera-
DCF370-12 DCF420-12 DCF450-12 DCF500-12 DCF520-12
tional characteristics. Dimensions CS CS CS

Lifting capacity Rated (kg) 37000 42000 45000 50000 52000


In spite of its size and capacity the Load centre (mm) L4 1200 1200 1200 1200 1200

machines have short turning radius. Truck Truck length (mm) L 7345 7845 7950 8550 8550
Truck width (mm) B 4150 4150 4150 4150 4150
Together with the optimised visibility Height, basic machine, Spirit Delta (mm) H6 3725 4550 3725 4620 3825 4720 3825 3825
and good manoeuvrability, it saves site Seat height, Spirit Delta (mm) H8 2350 3460 2350 3530 2450 3630 2450 2450

space and makes the machine a smooth Distance between centre of front axle front face of fork arm (mm) L2 1295 1295 1400 1420 1420
Wheelbase (mm) L3 5000 5500 5500 6000 6000
operator in confined spaces. The coun- Track (c-c) front rear (mm) S 3030 2625 3030 2625 3030 2815 3030 2815 3030 2815

terweight and lifting height requirements Turning radius, outer inner (mm) R1 R2 6900 1000 7400 1100 8150 1100 8650 1200 8650 1200
Ground clearance, min. (mm) 300 300 300 300 300
have been matched with a modern chassis Min. ailse width for 90 stacking with forks (mm) A1 10795 11295 12100 12600 12600
to keep down the overall weight but with Standard duplex mast Lifting height (mm) H4 5000 5000 5000 5000 5000

no sacrifice in stability. Mast height, min. (mm) H3 5050 5050 5050 5600 5600
Mast height, max (mm) H5 7550 7550 7550 8100 8100
Mast tilting, forward backward* () 5 10 5 10 5 10 5 10 5 10

Additionally, we have ensured that every Ground clearance, min.


Forks Width (mm) b 300 300 300 300 300
single detail, component and system have Thickness (mm) a 135 135 135 145 145
been selected and manufactured to pro- Length of fork arm (mm) l 2400 2400 2400 2400 2400

vide the highest possible reliability. Width across fork arms, max. min. (mm) V 2750 1950 2750 1950 2750 1950 2700 1900 2700 1900
Sideshift at width across fork arms (mm) V1 V 200 2350 200 2350 200 2350 200 2300 200 2300
Weight Service weight (kg) 50100 51900 56000 61500 63000
Axle load front, unloaded (kg) 26400 27400 28800 33000 34000
Axle load front, at rated load (kg) 81800 88400 95100 105300 108800
Axle load back, unloaded (kg) 23700 24500 27200 28500 29000
Axle load back, at rated load (kg) 5300 5500 5900 6200 6200
Wheels / tyres Type, front rear Pneumatic Pneumatic
Dimensions, front rear (inch) 18.0025 18.0025 18.0033 18.0033
Number of wheels, front rear (*driven) 4* 2 4* 2 4* 2 4* 2 4* 2
Pressure (Mpa) 1,0 1,0 1,0 1,0 1,0
Steering system Type manoeuvring Hydraulic servo Steering wheel
Service brake system Type affected wheels Oil cooled disc brakes (Wet disc brakes) drive wheels
Parking brake system Type affected wheels Dry, spring activated disc brake drive wheels
Hydraulic pressure Max. (Mpa) 15,0 17,0 18,0 20,0 20,0
Hydraulic fluid volume (l) 600 600 600 600 600
Fuel volume (l) 400 400 400 400 400
AdBlue volume (l) 20 20 20 20 20

4 5
Versatility provides productivity
1

The standard lifting equipment of Kalmar 1 Duplex standard mast 1 Standard carriage 1 2

is an integrated assembly consisting of a The


2 Duplex mast is a well proven design Sideshift/fork
2 positioning carriage 2 3
free visibility duplex mast, side-shift/fork which minimises the concealed angles for hydraulic operated of free visibility type.
3 3 3 4
positioning carriage and forks, hydraulics the driver. The functions includes sideshift and fork
and control system. This is to ensure you 4 positioning.
4 4 5

get a reliable and good running machine 5 5 5 6


1
with high availability even after long
6 2 6
1 6 7
shifts and high load stresses in general
3
cargo handling. 7 7
2 Carriage for steel application 7
4
This
3 carriage of free visibility type in-
5
A major objective in the development cludes sideshift and fork positioning. The
6 4
process has been to combine optimum forks could be positioned againts each
7
functionality for the driver together with other
5 to become a sort of flexible coil ram.
high performance in lifting and load Full visual contact with the load and attachement,
6
is provided by the Spirit Delta cabin and the open
handling.
design of the mast and carriage. 7

The mast and carriage are computer


designed and optimised (FEM and Catia
V5) which allowed for a decrease in the 1

front axle weight. Together with Kalmars Due to the wide range of optional equip- 1 Fork shaft system 1 2
integrated high capacity carriage it allows ment the machines can be equipped with A2smooth way to improve handling flex-
2 3
you to fully utilise the capabilities of mast a lifting equipment adapted to almost ibility is to use the fork shaft system. The
3 3 4
tilt, side-shift at full lifting height and full every application. system enables the driver to quick and
capacity. No compromises. easy
4 change between different carriers 4 5
or
5 attachments like extra long forks, coil 5 6
1
ram, inverted forks etc. The carriage
6 6 7
2 Duplex free-lift mast is equipped with a separate shaft
The
3 Duplex mast is also available in a holder.
7 The fork shaft system could 7
Duplex standard, clear view
Free-lift version for certain lifting heights be of pin-type or hook-on type.
DCF370-450 / CS DCF500 DCF520 4
Lift
height, Mast height Free lift, Mast height Free lift, Mast height Free lift,
and models, providing full free-lift as well 1
H4 H3 min. H5 max. H2 H3 min. H5 max. H2 H3 min. H5 max. H2
as
5 exceptionally good through visibility.
1 2
4000 4550 6550 5100 7100 5100 7100
4500 4800 7050 5350 7600 5350 7600 6
1 2 3
5000 5050 7550 5600 8100 5600 8100 1
5500 5300 8050 7
2 2 Coil ram 3 Top-lift attachment 4 Inverted forks
6000 5550 8550 6100 9100
6500 5800 9050 3 The
3 coil ram is made for intensive han-
The
4
container top-lift attachment is The
5
inverted forks are easily mounted on
7000 6600 10100 4 dling of heavy coils. The coil ram is used available in two fixed sizes 20 and 40. the fork shaft system. They are used as
7500 6300 10050 6850 10600 4 5 6
10000 7550 12550
5 together with fork shaft system and sup- It is used together with either standard carrier for the top lift attachments. The
6 ported
5 with side-shift function. forks
6 or inverted forks. The hydraulics inversion
7 also means that the basic lifting
7
6 for
7 the twist-locks is connected through height is maintained.
1
Duplex free-lift, clear view* quick couplings.
DCF370-450 / CS DCF500 DCF520 7
Lift 2
height, Mast height Free lift, Mast height Free lift, Mast height Free lift,
H4 H3 min. H5 max. H2 H3 min. H5 max. H2 H3 min. H5 max. H2
3
4000 4550 6550 2000
4500 4800 7050 2250
4
5000 5050 7550 2500 5050 7550 2500 5050 7550 2500
5500 5300 8050 2750 5
1
6000 5550 8550 3000
6
* Duplex freelift and triplex mast requires el-hydr. servo incl minilevers. 2

7
3

Triplex free-lift, clear view* 4


DCF370-450 / CS DCF500 DCF520
Lift
height, Mast height Free lift, Mast height Free lift, Mast height Free lift, 5
H4 H3 min. H5 max. H2 H3 min. H5 max. H2 H3 min. H5 max. H2
5900 6
6000 4310** 8210** 2000
7
* Duplex freelift and triplex mast requires el-hydr. servo incl minilevers.
** Might be slightly reduced if the smallest available tyres are choosed.

6 7
The basic set up 1

A key factor for heavy duty handling We have put highest priority on over- 1 Engine 2 Transmission
productivity is the basic machine set up. all technical reliability. Looking at the Kalmar products are fitted with the lat- The transmission transfers power from
2 3
Heavy loads and high lifting speed, for choice of each component, long running est Volvo and Cummins diesel engines. the engine to the hydraulic pumps and
example, put critical demands on the cycle times and how it all comes together. These
3 engines also combine high power drive
4 line. The engine and gearbox
engine and hydraulic power support. Fast We have incorporated into the Heavy output and efficient fuel consumption. control systems work together to find the
4 5
positioning during the handling cycle Lift Trucks several major components optimum balance between power and fuel
requires precise control with tight turn- and systems from our extremely reliable 5 economy
6 at any given point.
ing radius, effective and reliable brakes DRF reachstacker. Thousands of these
6 7
and high engine torque. Fast handling machines have been delivered in the past The transmission system consists of a
requires good stability, reliable brakes years and have proven the durability of 7 torque converter and a gearbox. The gear-
and smooth transmission. the components and systems, and its low box is automatic, but can partly be shifted
running costs. manually.
1
Of course, all the working components
2
and systems have to cope with the most
demanding stresses during long shifts 3 Drive line
and heavy operations everyday. The propeller shaft and drive axle trans-
4
fer the power from the transmission to
the
5 driving wheels. The mountings on
the propeller shaft are fitted with cross-
6
flanges for optimum strength. The drive
Chassis axle
7 gears down in two stages, differential
The frame forms the basis of the ma- and hub reduction. The engine provides
chines lifting and manoeuvring charac- 1 maximum torque at the drive wheels,
teristics and was designed exclusively which spares the transmission.
2
for heavy duty operation. The beam
construction, along with its width, makes 3
the Heavy Lift Trucks stable, torsion
4 1
resistant and service-friendly.
5 2 1
The frame is 3D modulated (Catia V5)
6 3 2 1
and designed (FEM) in order to eliminate 1
critical tensions under various kinds of 7 4 3 2
2
strain. The mechanically welded chassis
5 4 3
has been optimised according to strength, 3

weight and stability. 4 6 5 4


1
5 7 6 5
2

Steering system Wheels and tyres 6 Brakes 7 6 3


The steering axle is built from a single Tyres are an important cost factor to The
7 Kalmar machines have, like its pred-
7 4
piece of high strength steel, which means consider when improving operational ecessors, the smooth, reliable and almost
fewer parts requiring less maintenance performance. Therefore, all models use maintenance-free wet disc brakes. To get 5 SCR Catalyst
and higher structural integrity. The sus- identical sizes on both drive and steer cleanliness the brake circuit can, as an The
6 SCR engines are optimised for effi-
1
pension points on the steering axle utilise wheels. This improves the machine sta- option, be separated from the main hy- cient combustion, which provides the fuel
7
a maintenance-free plastic. The hydrau- bility, comfort and reliability and requires draulic system with its own tank, cooler 2 efficiency and low particulate emission
lics that feed oil to the steering cylinder only one single spare tyre. and high-pressure filter. A temperature benefits. To combat the resultant NOx
3
are optimised for enhanced driving feel. transmitter in the brake oil tank regulates emissions, AdBlue is injected into the
The orbitrol and the priority valve jointly the cooling fan. The foot-brake valve, 4 AdBlue tank and pump The AdBlue tank is heated by engine cool- exhaust gas. The exhaust gas and AdBlue
provide gentle, yet precise, steering which controls the oil feed to the brakes, The AdBlue tank* has a volume of 20 l ant and the AdBlue hoses are heated by then enter a catalytic converter, which
5
movements. is sensitive enough so that the driver can and is equipped with a level sensor which electricity to prevent freezing in cold cli- turns the NOx into harmless nitrogen gas
brake optimally yet gently. The parking notifies
6 the driver when its time to fill up mates. (Freezing point of AdBlue -11C). and water vapour. The cleaning process of
brake is activated automatically when the the tank. The filling of AdBlue is usually the catalyst is done automatically by the
7
ignition is turned off. done together with the filling of diesel. system during normal driving.

*EU Stage IV / EPA Tier 4 final.

8 9
The basic set up is a key factor
for high productivity
Drive train Volvo TAD1171VE Drive train Cummins QSM11

Engine Manufacturer, type designation Volvo - TAD1171VE Engine Manufacturer, type designation Cummins QSM11
(Turbo-Intercooler) (Turbo-Intercooler)
Engine emission approvals Stage IV Engine emission approvals Stage IIIA
Fuel type of engine Diesel 4-stroke Fuel type of engine Diesel 4-stroke
Rating ISO 3046 at revs (kW rpm) 265 2100 Rating ISO 3046 at revs (kW rpm) 261 2000
Peak torque ISO 3046 at revs (Nm rpm) 1750 1260 Peak torque ISO 3046 at revs (Nm rpm) 1830 1100-1400
Number of cylinders displacement (cm) 6 10084 Number of cylinders displacement (cm) 6 10800
Fuel consumption, normal driving (l/h) 16-22 Fuel consumption, normal driving (l/h) 18-23
AdBlue consumption, normal driving (% of diesel) 3-5 AdBlue consumption, normal driving (% of diesel) 3-5
Gearbox Manufacturer type designation Dana TE32000 Gearbox Manufacturer, type designation Dana TE32000
Clutch, type Torque converter Clutch, type Torque converter
Gearbox, type Powershift Gearbox, type Powershift
Numbers of gears, forward reverse 33 Numbers of gears, forward reverse 44
Alternator Type power (W) AC 3080 Alternator Type power (W) AC 1920
Starting battery Voltage capacity (V Ah) 212 145 Starting battery Voltage capacity (V Ah) 212 140
Driving axle Type AxleTech Differential Driving axle Manufacturer Type AxleTech Differential
and hub reduction and hub reduction

Performance, Volvo TAD1171VE DCF370-12 / CS DCF420-12 / CS DCF450-12 / CS DCF500-12 DCF520-12 Performance, Cummins QSM11 DCF370-12 / CS DCF420-12 / CS DCF450-12 / CS DCF500-12 DCF520-12

Lifting speed Unloaded (m/s) 0,35 0,35 0,35 0,35 0,35 Lifting speed Unloaded (m/s) 0,35 0,35 0,35 0,35 0,35
At rated load (m/s) 0,25 0,25 0,25 0,25 0,25 At rated load (m/s) 0,25 0,25 0,25 0,25 0,25
Lowering speed Unloaded (m/s) 0,25 0,25 0,25 0,25 0,25 Lowering speed Unloaded (m/s) 0,25 0,25 0,25 0,25 0,25
At rated load (m/s) 0,40 0,40 0,40 0,40 0,40 At rated load (m/s) 0,40 0,40 0,40 0,40 0,40
Travelling speed, F R Unloaded (km/h) 26 26 26 26 28 28 27 27 27 27 Travelling speed, F R Unloaded (km/h) 26 26 26 26 28 28 27 27 27 27
At rated load (km/h) 24 24 23 23 22 22 21 21 21 21 At rated load (km/h) 24 24 23 23 22 22 21 21 21 21
Gradeability, max. Unloaded (%) 84 79 57 51 49 Gradeability, max. Unloaded (%) 119 109 74 64 62
At rated load (%) 38 35 28 25 24 At rated load (%) 47 43 34 30 29
Gradeability, at 2 km/h Unloaded (%) 55 52 40 36 35 Gradeability, at 2 km/h Unloaded (%) 54 52 45 40 39
At rated load (%) 28 25 20 18 17 At rated load (%) 27 25 22 20 19
Drawbar pull Max. (kN) 326 326 286 286 286 Drawbar pull Max. (kN) 386 386 338 338 338
Noise level, inside LpAZ*, Spirit Delta (dB(A)) 72 72 72 72 72 Noise level, inside LpAZ*, Spirit Delta (dB(A)) 72 72 72 72 72
Noise level, outside LwAZ** (dB(A)) 111 111 111 111 111 Noise level, outside LwAZ** (dB(A)) 111 111 111 111 111

* LpAZ according to EN12053 ** LwAZ according to 2000/14/EC * LpAZ according to EN12053 ** LwAZ according to 2000/14/EC

10 11
The simple way to reach new levels of utilisation
All vehicles today cars, highway trucks, This built-in intelligence is designed The Kalmar F-series posses a well proven, Control functions
wheel-loaders, cranes etc are con- to support and leverage your handling thoroughly tested and optimised control support the driver
structed with more and more sophisti- operations, not confuse it. system, which supports your driver, The driver and machine communicate
cated components and systems. Each part mechanics and financial controller. And it very simple via the Kalmar Information
interacts closely with the others and to is simple to use. Terminal (KIT) and the Information
reach the full potential requires compu- Display located right in front of the driver
ter assistance. in the cabin. The two-way communica-
tion from the driver to the machine and
opposite is handled by the KCU (Kalmar
KCU Kalmar Cabin Unit
Cabin Unit) which is the control node for
KCU
KCU
KIT
KCU the entire network.
KIT
KCU
KIT
Kalmar Information Terminal
KCU
KID
KIT
KID
KIT
KID
KIT Kalmar Information Display
Information to the driver comprises
EDC
KID
EDC
KID KID
EDC
KID
TCU
EDC Electronic Diesel Control
KIT
TCU
EDC
TCU
EDC
KDU
TCU
alarm warnings, operating details and
KCU KDU
TCU
KDU
TCU
Transmission Control Unit
action-guided information. Messages,
KDU
KDU
KDU Kalmar Distributed Unit status, fault indications etc are presented
on the Information Display (KID), while
EDC TCU warnings and other monitoring indica-
KDU KDU
tions are presented to the left.

Messages are only presented when they


The communication network layout. are relevant to the driver and the opera-
tion. The driver can focus on the job in-
stead of checking meters and indicators.
The reliable distributed The nodes transmit their signals in The Transmission Control Unit (TCU),
control system messages on the network. Each message which is the gearbox node, deals with the
Two things are needed for a command contains several signals and has its own gearbox. The unit is connected in a sepa-
initiated by the driver to result in a par- address. Any units that need to know the rate CAN-bus loop with the EDC engine
ticular function, or for several functions status of a signal listen out for the address node (Engine Diesel Control) and KCU.
to work together: power supply and com- of the signals message. All the nodes in The engine node controls the fuel injec-
munication. the network listen to each other. tion and receives its control signals from
its own transmitters on the engine.
The power-feed supplies the machines CAN-bus is a two-wire transfer of data
electrical or electro-hydraulic functions and a definition of a bus type. CAN-bus Power supply
with voltage. The communication system technology has been chosen because it Power-feed for the functions differ from
controls and checks that the functions provides a reliable, robust transfer of data the feed required for communication
have been activated, waits in standby and is difficult to disrupt. CAN-bus loops and feeding of the nodes processors.
mode or indicates faults. have been used in Kalmar machines since Each distribution unit (node) in the
1995. distributed network is fed voltage from Engine revs, travelling speed,
Engine
Communication one of the power distribution boxes. The time and fuel.
Heating/Ventilation Temperature
The distributed power-feed and com- The greatest benefit of using CAN-bus distribution boxes are located inside the and Air conditioning. and pressure.
munication network consists of electrical technology is that the amount of cabling cabin and on one side of the frame. The
components and a microcomputer-based can be reduced. All that is needed to distribution units (nodes) guide power
system for controlling and monitoring establish communication are two data- from the distribution box to the required
the functions. bearing leads and two leads for feeding functions based on the instructions in
Transmission
the nodes processors. The network loop the messages from the communication Temperature
The most important components in the for both the CAN-bus and the nodes network. Service information. and pressure.
network are the control units (nodes). processor feed are redundant.

They distribute control of the machines The Kalmar Cabin Unit (KCU) is the con-
functions. Each node has its own proces- trol node for the entire network. There
sor. The nodes integrate with each other are several nodes, called KDUs (Kalmar Battery status.
and all communication; control signals Distribution Units), in the network. Each
and signal information are sent via data node is positioned near to the functions it
buses. is designed to deal with.

12 13
We have made sure
your investment becomes profitable The hydraulic system is critical The distribution of pressure between ture, to match the hydraulic brake heat
No other part of the machine is working working hydraulics and steering is done generation as well as feeding the overall
so hard under continuous pressure. To by the priority valve which ensures that system during tough handling cycles.
To understand the full potential of your
secure the reliability we have minimised the steering always receives enough
investment requires being aware of the
the number of hydraulic components and pressure. The hydraulic oil pump for load Oil supply and temperature control is
details, features and technical matters in
couplings. handling is disconnected during forward handled through Kalmars distributed
a machine like the Kalmar F-generation.
driving, to use the engine power to best control system. All indications are pre-
To ensure optimum oil pressure and effect. sented when appropriate on the Kalmar
But when it comes to availability it is
security regardless of the handling Information Display (KID) in the cabin.
critical that it operates constantly and is
operation the hydraulic system is based All three pumps interact together, using
kept in good condition with an absolute
on three fixed displacement vane pumps the same oil tank and filters, which are
minimum of maintenance and repairs.
one for the brake system, cooling and located inside the tank. The system is
filtering, one for working hydraulics and equipped with one oil cooler and a sepa-
one supporting both steering and work- rate fan to secure the right oil tempera-
ing hydraulics.
1

7 The reliable and maintenance


friendly hydraulic system.
1
1
Less stops for planned A safe communication network Reliability starts already at the 2
2
mainenance The control and monitoring system is the concept stage
3
The service intervals have been extended Kalmar control system, already success- One of the guiding principles in design- 3

to 500 hours, which means that you dont fully applied in more than 1.000 Kalmar ing the DCF was to minimise the number 4
4

have to take the machine out of work machines worldwide. of potential sources of error. Therefore 5
5
more than 6 times a year (3.000 hours the machines consist of as few compo-
6
utilisation). This reduntant CAN-bus system is nents and moving parts as possible. The 6
1
proven to be excellent in functionality functionality and operational reliability 7
7
2
The DCF is designed for fast daily in- and reliability. The network of control is assured by extensive testing.
spection and preventive maintenance. nodes allows for less wiring and connec- 3 1

All checkpoints are easy accessible tors which reduces the number of sources 4 2
and concentrated to specific locations. of error. The power-feed for each node
5 1 3
Lubrication free components or central and the transfer of control signals are
lubrication points have been utilised. independent of the other nodes, which 6 2 4

The wet disc brake system is practically means the risk of disruption becomes 1 7 3 5
maintenance free. minimal. The redundant design means
2 4 6
that there are always two paths to choose 1

The indicator and monitoring support to maintain communication, which re- Other improving features: 3
2
High density filter improves the oil 5 All main hydraulic components at 7
built into our control system make sure sults in extra safety and reliability. 1 Large dimensions of hydraulic hoses 4
lifetime (clean oil). 6
ground level are gathered on a sepa-
3
that the machine wont be misused or improves the hoses lifetime (slower rate plate, bolted to the chassis and
2 5 7
maintained incorrectly. The driver and flow, less friction and less heating).
4 ORFS leak proof couplings all therefore simple to remove.
mechanics will always get indications 3
1 6
5
around improves reliability (mini-
and guidance in time to avoid unneces- 4
2 Thermostatic cooling of both the 7 mises leakage).
6
sary and costly wear and tear or technical main system and the brake system
5
3
breakdowns. No unwanted stops. improves the oil lifetime (tem-
7
6
4
To increase workplace safety the machine can be perature control, optimised working
fitted with alcohol interlock. 7
5 temperature).
6

14 15
MAKING YOUR EVERY MOVE COUNT

Kalmar offers the widest range of cargo handling solutions and services to ports, terminals, distribution centres and
to heavy industry. Kalmar is the industry forerunner in terminal automation and in energy efficient container handling,
with one in four container movements around the globe being handled by a Kalmar solution. Through its extensive
product portfolio, global service network and ability to enable a seamless integration of different terminal processes,
Kalmar improves the efficiency of every move. www.kalmarglobal.com

Kalmar is part of Cargotec. Cargotecs sales totalled approximately EUR 3.2 billion in 2013 and it employs approxi-
mately 11,000 people. Cargotecs class B shares are quoted on NASDAQ OMX Helsinki under symbol CGCBV.
www.cargotec.com
TI-LT52-EN-CE / 2015.11.30

Cargotec Sweden AB
Torggatan 3
SE-340 10, Lidhult, Sweden
tel. +46 372 260 10