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

PERFORMANCE

operators for a basic type of machine, but

with superior performance characteristics. We

AVAILABILITY

ERGONOMICS

RELIABILITY

ing machines.

DRIVING

MAINTENANCE

Drawing on our global experience we know

LIFTING

INTELLIGENCE

CAPACITY AND
DIMENSIONS

SIMPLICITY

then decided to build a family of integrated

top-lift handlers that would surpass all exist-

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

We have examined and evaluated every nut,

The technical optimisation of the Kalmar DCF

the design and development of the Kalmar

bolt and component to ensure we provided a

means that you will get the best technology

DCF.

machine with the highest possible specifica-

available but still have the feeling of hav-

tion.

ing a reliable, simple, safe and hard working

machine.

Technical solutions are only the tool.

When appropriate simple technical solutions

Not the goal.

were available we have applied them, and

There is new leveraging technology under the

when the need was for more sophisticated

Providing the highest possible

skin of the DCF in order to provide the best

systems we have installed them to boost your

throughput.

everyday performance and availability.

uptime and productivity.

This is what its 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.

Ergonomics

The heart of top performance in top-lift handling

To obtain the maximum out of your invest-

We focus on four important

Electronic accelerator.

ment, you can never underestimate the

ergonomic areas:

Central operation/warning display.

importance of the drivers working environ-

Operation

Separately suspended and isolated cabin.

ment. High throughput demands full driver

Visibility

Shock absorption to minimise vibrations.

concentration and efficiency to keep up the

Sound and vibrations

Maximum sound level inside is 70 dB (A).

container moves, but also to avoid injuries

Climate

Generous interior dimensions and floor

and costly damages.

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

space.
Optimised visibility 360 all around.
Electronically controlled heating/

This is what ergonomics is all about. Being

Consider this:

comfortable and aware.

ventilation.

Individually adjustable controls, steering

The driver environment in Kalmar DCF is the

Filters for fresh air and recirculation.

High performance air conditioning system,

wheel and seat.

comfortable Spirit Delta high visibility cabin;

Intuitively positioned instruments.

appreciated by professional drivers, proven

Switches and buttons with lights.

on thousands of Kalmar container handlers all

Comfort pedals.

optional.
Pollen filter, optional.

over the world.

A
A

A
A
A
A
B
B
B
B
C
C
C
C
D
D
D
D
E
E
E
E
F
F
F
F
G
G
G
G
H
H
H
H
III
I

Left instrument panel

Gear selector and multi-function lever
Steering wheel panel
Direction indicators
Prepared for terminal and
dashboard attachment
Hydraulic controls
Panel for hydraulic functions

Emergency switch

Parking brake

A
B
C
D
E
F
G
H
I

Capacity and dimensions

Matching your handling and throughput needs

When we designed the Kalmar DCF top-lift

Three models cover container handling

In spite of its size and capacity the Kalmar

we already knew the detailed status of all the

between 36 45 tonnes capacity, 20-40

DCF has a short turning radius. Together with

main alternatives on the market. Hence, we

containers and up to five high stacking at full

the optimised visibility and good manoeuvra-

designed a machine which meets or exceeds

capacity. This means that you may easily find

bility it saves terminal space and makes the

the specifications of the others on the spec

the right machine or combination of machines

machine a smooth operator in confined aisles.

sheet and in reality.

to suit your operational requirements.

The counterweight and lifting height requirements have been matched with a modern

You can choose between three basic models,

The design of the chassis, mast, carriage and

chassis to keep down the overall weight but

each optimised according to lifting capacity

spreader has resulted in machines with very

with no sacrifice in stability.

stability overall dimensions weight top-

good dimensional-, stability- and operational

lift speed and driving performance.

characteristics.

41000 kg

45000 kg

36000 kg

41000 kg

45000 kg

36000 kg

41000 kg

45000 kg

36000 kg

41000 kg

45000 kg

36000 kg

41000 kg

45000 kg

DCF360CSG

DCF410CSG

Capacity and weight

Lifting capacity

Classification
Load centre

Weight

Weight rear axle

DCF360CSG

DCF410CSG

DCF450CSG

45000

36000

41000

attachment retracted

L4

mm

1750

1750

1750

attachment extended

L7

mm

1955

1955

1955

Service weight
Weight front axle

kg

DCF450CSG

kg

66400

69750

75000

unloaded

kg

41300

42290

44000

at rated load

kg

94800

101450

110500

unloaded

kg

25100

27460

31000

at rated load

kg

7600

9300

9500

The mast and carriage are computer designed

ity spreader it allows you to fully utilise the

Additionally, we have ensured that every

and optimised (FEM and Catia V5) which al-

capabilities of mast tilt, slewing, extension,

single detail, component and system have

lowed for a decrease in the front axle weight.

sideshift at full lifting height and full capacity.

been selected and manufactured to provide

Together with Kalmars integrated high capac-

No compromises.

the highest possible reliability.

A1
A2

H5
H4
H3

V1 S B V

H6
H8

H10

R2

R1
L3

100

L2

L4
L7

100

Dimensions
Truck

DCF450CSG

mm

10970

10970

11020

Truck width

mm

4450

4450

4450

Truck height

H6

mm

4650

4720

4720

Seat height

H8

mm

3560

3630

3630

Distance between front axle center front side of mast

L2

mm

900

900

950

Wheelbase

L3

mm

6000

6000

6000

Turning radius,

mm

3020 2820

3020 2820

3020 2820

outer

R1

mm

8660

8660

8660

inner

R2

mm

1090

1090

1090

mm

280

280

280

mm

11990

11990

11990

Ground clearance

min. under truck

Min. track with for 90

stacking

with 20 container

A1

with 40 container

A2

mm

14680

14680

14680

Height under twistlocks

4-high 5-high mast

H4

mm

12090

15160

15160

min.

H10

mm

2080

2160

2160

min.

H3

mm

7700

9190

9190

Mast height,

max
Attachment

DCF410CSG

Truck length, with attachment

Track (c-c), front rear

Standard duplex mast

(5 high 86, 5 high 96)

DCF360CSG

H5

mm

15170

17170

17170

Mast tilting, forwards backwards

5 10

5 10

5 10

Width, min max

mm

12170 6070

Hydraulic slewing
Side shift, either side center
Levelling

V1

12170 6070

12170 6070

mm

400

400

400

Lifting performance

In the palm of your hands

1
2
3

The lifting equipment of Kalmar DCF is an inte-

grated assembly consisting of mast, carriage,

spreader, hydraulics and control system. This

is to ensure you get a reliable and good run-

ning machine with high availability even after

long shifts and high load stresses.

A major objective in the development process has been to combine optimum functionality for the driver together with high performance in lifting and load handling.
To leverage operational productivity its essential that the driver has full control over every
moment of the handling sequence. This starts
with the 360 visibility from the Spirit Delta
cabin and is followed by the open design of

the mast and gantry. The visual contact with

the stack, container corners, twist-locks and

spreader is optimised.

Fine-tuning the spreader to handle uneven

levels or loads, mast tilt, extension, twist-lock

landing is accomplished utilising a power-

ful electronic support feedback and control

system.

Performance
Lifting speed
Lowering speed
Driving speed

Drawbar pull

DCF410CSG

DCF450CSG

unloaded

m/s

0,42

0,42

0,42

at rated load

m/s

0,25

0,25

0,25

unloaded

m/s

0,31

0,31

0,31

at rated load

m/s

0,36

0,36

0,36
26

unloaded
at rated load

Gradeability

DCF360CSG

at 2 km/h

forward

km/h

26

26

reverse

km/h

26

26

26

forward

km/h

23

23

23

reverse

km/h

23

23

23

unloaded

38

38

38

at rated load

27

27

27

max, unloaded

38

38

38

max

kN

368

368

368

1
2
3
4
1

Mast

The
2 Kalmar DCF has as standard a duplex free

The mast is made for high reliability and sim-

visibility mast, made of high strength steel to

ple maintenance. It requires only two hoses

provide a long life with minimal deflection at

and one cable passing over the mast roller to

4 lifting heights. Maximum lifting height is

high

feed the hydraulic and electrical functions of

15160
mm or five containers high under the
5

the spreader.

twist-locks. The mast is equipped with the

6

new Kalmar high speed lifting system, which

7

provides very fast handling of loads up to 22

tonnes.

1
2

Carriage

The
3 integrated gantry with high-strength roller
bearings makes for a secure and durable
4

setup. The benefits of an integrated gantry are

5
increased
capacity and a decreased loss of

load
6 centre. The gantry is a completely new
design, made of solid steel instead of welded
7

beams, which improves reliability and see

Sideshift 400 mm

Levelling 5

through visibility.
Key functions:
Levelling corrects the inclination of the
spreader to uneven containers.
Slewing compensates when the machine
is not positioned 90 to stack.
Side-shift compensates when the
machine is positioned right or left of the
container.
Extend/Retract extends the capability

Slewing 3.

Extend/retract, 200 mm

when loading/unloading trucks or rail cars.

1
2
3

Spreader

The
integrated spreader is suspended from
4

The mechanical and electrical safety inter-lock

The lowering interrupt system prevents chain

four (4) hydraulic cylinders, which compen-

systems prevent locking or releasing the

slack once it is landed on the container. Lights

sate for unevenly loaded or stacked con-

twist-locks if the spreader is not properly posi-

on the instrument panel and spreader indi-

6
tainers.
Powered pile slope is optional. The

tioned on the container. It also prevents lifting

cate proper use of the spreader and locked/

spreader
is easily adjustable with the touch of
7

of the spreader when the twist-locks are not

unlocked twist-locks.

a button for 20 or 40 containers and can be

fully engaged or fully released.

side-shifted 400 mm either side of centre. Two

The Kalmar spreader will handle all ISO stand-

additional hydraulic cylinders provide precise

ard containers ranging from 20 to 53 long

control of the slewing function.

and 8 wide to 86 wide. All containers must

have the standard ISO 20 or 40 footprint.

Driving performance

The basic set up is a key factor for high productivity

2
3
4

Engine

Steering system

Optimised ergonomics. Perfect matching of

capacity. Efficient lifting.

The
Cummins and Volvo engines provide
3

The
steering axle is built from a single piece
6

power
for driving and the working hydraulics.
4

of
7 high strength steel, which means as fewer

The forth key factor for high top-lift productiv-

The
engines are low-emission turbo diesels
5

parts requiring less maintenance and higher

ity is the basic machine set up. Heavy loads

with fuel injectors and intercoolers. The de-

structural integrity. The suspension points on

and high lifting speed, for example, put critical

sign of the combustion chambers, along with

the steering axle utilise a maintenance-free

demands on the engine and hydraulic power

the precise fuel injection control, ensures

plastic. The hydraulics that feed oil to the

support. Fast positioning during the stack-

more efficient combustion to provide lower

steering cylinder is optimised for enhanced

ing cycle requires precise control with tight

emissions with increased torque and power.

driving feel. The orbitrol and the priority valve

turning radius, effective and reliable brakes

The engines meet the Tier 3 requirements,

jointly provide gentle yet precise steering

and high engine torque. Fast transportation

and the sound and vibration standards.

movements.

6
7

2
3
4

requires good stability, reliable brakes and

smooth transmission.

The radiator is a 3 chamber design with a sin-

gle fan to provide cooling for the engine and

Brakes

Of course, all the working components and

transmission. The engine coolers separate

The
brake circuit is separated from the
7

systems have to cope with the most demand-

expansion chambers are fitted with a level

hydraulic system and has its own tank,

ing stresses during long shifts and heavy

sensor that indicates low coolant level.

cooler and high-pressure filter. A temperature

operations everyday.

transmitter in the brake oil tank regulates

the cooling fan. The foot-brake valve, which

Transmission

We have put highest priority on overall techni-

cal reliability. Looking at the choice of each

The
transmission transfers power from the
4

enough so that the driver can brake optimally

component, long running cycle times and

engine
to the hydraulic pumps and drive line.
5

yet gently. The parking brake is activated

how it all comes together. We have incorpo-

The
engine and gearbox control systems
6

automatically when the ignition is turned off.

rated into the DCF several major components

work together to find the optimum balance

and systems from our extremely reliable

between power and fuel economy at any

DRF reachstacker. More than 1000 of these

given time. The transmission system consists

machines have been delivered in the past few

of a torque converter and a gearbox. The

years and have proven the durability of the

gearbox is automatic, but can partly be

components and systems, and its low running

shifted manually.

costs.

controls the oil feed to the brakes, is sensitive

1
2
3
4

Chassis

Drive line

The
propeller shaft and drive
5

The
frame forms the basis of the machines
2

axle
transfer the power
6

lifting
and manoeuvring characteristics and
3

from
the transmission
7

was
designed exclusively for a top-lift opera4

to the driving wheels.

tion. The beam construction, along with its

The mountings on the

width, makes the DCF stable, torsion resistant

propeller shaft are fitted

and service-friendly.

with cross-flanges for op-

5
6
7

timum strength. The drive axle

The frame is 3D modulated (Catia V5) and

gears down in two stages, differential

designed (FEM) in order to eliminate criti-

and hub reduction. The engine provides

cal tensions under various kinds of strain.

maximum torque at the drive wheels, which

The mechanically welded chassis has been

spares the transmission.

optimised according to strength, weight and

stability.

1
2
3
4
5
6
7

Wheels and tyres

Tires are an important cost factor to consider
when improving operational performance.
Therefore the Kalmar DCF410 and 450 are
fitted with 18.0033 tires, all models use
identical sizes on both drive and steer wheels.
This improves the machine stability, comfort
and reliability and requires only one single
spare tire. The larger dimension tires should
decrease the tire wear and tear and improve
the tire life.

1
2
3
4
5
6
7

1
2
3
4
5

2
1

3
4
3

Drive train

Engine

5
6

6
7

Manufacturer type designation

Fuel type of engine

5
7
6
7

Transmission

Displacement

cm

Rating ISO 3046

Option

Cummins QSM11 Tier 3

Volvo TAD1250VE Tier 3

Diesel 4 stroke

Diesel 4 stroke

1080

1213

kW rpm

261 2000

260 1600

Peak torque ISO 3046

Nm rpm

1830 1100-1400

1760 1400

Number of cylinders compression

cm

6 18,1:1

6 16,3:1

Fuel consumption, normal driving

l/h

18-22

18-22

Alternator type power

AC 2400

AC 2400

Start battery, voltage capacity

V Ah

Manufacturer type designation

Clutch, type
Gearbox, type
Numbers of gears, forward reverse

Driving axle

Standard

Type

212 140

212 140

Dana 15.7 TE32000

Dana 15.7 TE32000

Torque converter

Torque converter

Powershift

Powershift

44

44

Hub reduction

Hub reduction

Intelligence

The simple way to put bits and pieces together

All vehicles today cars, highway trucks,

It is designed to get the most out of the

wheel-loaders, cranes etc are constructed

machine during the top-lift operations, to

with more and more sophisticated compo-

improve safety, to avoid unnecessary damage

nents and systems. Each part interacts closely

on components, to advise of scheduled pre-

with the others and to reach the full potential

ventive maintenance, to get machine statistics

requires computer assistance.

and so on.

This built-in intelligence is designed to support

and leverage your container operations, not
confuse it.
The Kalmar DCF posses a well proven, thoroughly tested and optimised control system,
which supports your driver, mechanics and
financial controller. And it is simple to use.

KCU

KID
KIT

KDU

Kalmar Cabin Unit

EDC TCU

Kalmar Information Terminal

KDU KDU

Kalmar Information Display

Electronic Diesel Control
Transmission Control Unit
Kalmar Distributed Unit

The communication network layout.

The reliable distributed control system.

Two things are needed for a command initi-

Both the power-feed and communication

The data transfer is secured by a CAN-bus

ated by the driver to result in a particular

system form an integrated network distrib-

(two-wire) technology, which means high reli-

function, or for several functions to work

uted to the critical areas of the machine. The

ability and extremely low risk for disruption.

together: power-feed and communication.

main components of the network are the

CAN-bus loops have been used in the Kalmar

control units (nodes). Each node has its own

machines since 1995.

The power-feed supplies the machines

processor and integrates with each other. All

electrical or electro-hydraulic functions with

communication, control signals and signal

The power-feed for the functions are supplied

voltage. The communication system controls

information are sent via data buses. All nodes

separately via distribution boxes located in

and checks that the functions have been

in the network are talking and listening to

the cabin. The power is distributed and guided

activated, waits in standby mode or indicates

each other.

by instructions generated from the communi-

faults.

10

cation network.

Control functions support the driver.

The driver and machine communicate very
simple via the Kalmar Information Terminal
and the Information Display located right in
front of the driver in the cabin. The two-way
communication from the driver to the machine and opposite is handled by the KCU
(Kalmar Cabin Unit) which is the control node
for the entire network.
Information to the driver comprises alarm
warnings, operating details and action-guided
information. Messages, status, fault indications etc are presented on the Information
Display, while warnings and other monitoring
indications are presented to the left.
Messages are only presented when they are
relevant to the driver and the operation, so
the driver can focus on the job instead of
checking meters and indicators.

Engine revs, travelling speed,

time and fuel.
Heating/Ventilation
and Air conditioning.

Engine
Temperature
and pressure.

Service information.

Transmission
Temperature
and pressure.

Battery status.

11

Availability

We have made sure your

investment becomes profitable
To understand the full potential of your investment requires being aware of the details,
features and technical matters in a machine
like the Kalmar DCF.
But when it comes to availability it is critical
that it operates constantly and is kept in good
condition with an absolute minimum of maintenance and repairs.

Less stops and no stops.

Reliability starts already

The Kalmar DCF is designed for long shifts,

The indicator and monitoring support built

at the concept stage.

which means that you may have to replace

into our control system make sure that the

One of the guiding principles in designing the

the driver before you have to call it in for fuel.

machine wont be misused or maintained

DCF was to minimise the number of potential

The good weight/engine power relationship

incorrectly. The driver and mechanics will

sources of error. Therefore the machines con-

combined with a fuel tank designed for 50

always get indications and guidance in time to

sist of as few components and moving parts

hours of operation make these machines run

avoid unnecessary and costly wear and tear

as possible. The functionality and operational

the extra hours you want them to.

or technical breakdowns. No unwanted stops.

reliability is assured by extensive testing.

The service intervals have been extended to

500 hours, which means that you dont have
to take the machine out of work more than 6
times a year (3000 hours utilisation).
The DCF is designed for fast daily inspection
and preventive maintenance. All checkpoints
are easy accessible and concentrated to specific locations. Lubrication free components or
central lubrication points have been utilised.
The wet disc brake system is practically maintenance free.

12

Fewer components
makes for increased
reliability, only two hoses
and one harness runs
over the mast wheel.

1
2
3
4
5
6
7

The reliable and maintenance

friendly hydraulic system.
1

1
2
2
3
3
4
4
5
5
6
6

2
3
4

4
5

The hydraulic system is critical.

Other improving features:

No other part of the machine is working so

hard under continuous pressure. To secure

improves the hoses lifetime (slower flow,

the reliability we have minimised the number

1
3

less friction and less heating).

of hydraulic components and couplings.

The main valve has an integrated servo which
helps increase precision and control over the
oil flow. The hydraulic oil is fed to the carriage
and spreader by a variable piston pump,
which saves a lot of power and energy com-

Large dimensions of hydraulic hoses

24 Thermostatic cooling of both the main

3
5
4
6
5
7
6

system and the brake system improves

the oil lifetime (temperature control,
optimised working temperature).

1
2

1
2
3

High density filter improves the oil lifetime

2
3
4

(clean oil).

354 ORFS leak proof couplings all around

4
5
6

56
7

improves reliability (minimises leakage).

All main hydraulic components at ground

6
7

level are gathered on a separate plate,

bolted to the chassis and therefore simple

to remove.

pared to continuous oil circulation. Another

innovative solution the valve for the gantry

A safe communication network

and spreader functions has been mounted on

The control and monitoring system is the

the gantry. The result is an instant and accu-

new Kalmar control system, but already suc-

rate connection between lever and function.

cessfully applied in more than 1000 Kalmar

This also minimises the number of hydraulic

machines worldwide.

components in the chassis.

This new reduntant CAN-bus system is proven
In order to maintain optimum functionality

to be excellent in functionality and reliability.

in the system even under extreme operat-

The network of control nodes allows for less

ing conditions, cleaning and cooling of the

wiring and connectors which reduces the

hydraulic oil is highly efficient. The hydraulic

number of sources of error. The power-feed

brake circuit is separated from the main sys-

for each node and the transfer of control

tem and is fitted with its own filters.

signals are independent of the other nodes,

which means the risk of disruption becomes
minimal. The redundant design means that
there are always two paths to choose to
maintain communication, which results in
extra safety and reliability.

13

Notes

14

15

Cargotec improves the efficiency of cargo flows on land and at sea wherever cargo is on the move.
Cargotecs daughter brands Hiab, Kalmar and MacGregor are recognised leaders in cargo and load handling
solutions around the world. Cargotecs global network is positioned close to customers and offers extensive
services that ensure the continuous, reliable and sustainable performance of equipment.
Cargotecs class B shares are quoted on the NASDAQ OMX Helsinki. www.cargotec.com

Cargotec Sweden AB
Torggatan 3
SE-340 10, Lidhult, Sweden
tel. +46 372 260 00
fax +46 372 263 90
www.cargotec.com

TI-LC45-EN-WW / 2010.02.15

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our products and solutions closer to our customer.