BOXER

4000 / 5000 / 6000

CONTAINER CRANE

BOXER

O
Modern container handling by double trolley gantry cranes

BOXER

THE BOXER:
THE HIGH-SPEED CRANE WITH
ULTIMATE PRECISION.

The rapid tempo of globalisation also

sets the pace of the container handling
business. The number of containers
moved year by year across the oceans
and then onto land already amounts to
several hundred million today. Tendency:
increasing.
The volume of trade results in increasing
demands on ports and it goes without
saying also on cranes.
It must always be possible to operate
these cranes exactly as high-performance
instruments in all climates and to fulfil
many requirements, e.g. regarding handling speed and handling performance,
but also regarding adaptation to the new
ship sizes and beams.

O
Containers in a stacking yard

A PERFECT CRANE SYSTEM FOR

CONTAINER HANDLING.

Q INFO
What exactly characterises the best container terminals?
What are the important factors?
Q The essential factors are:
low operational costs
high performance
permanent availability
Q In detail it depends on:

efficient and safe handling of containers

maximisation of handling rates and thus short turnaround times of the ships
economical unloading
low maintenance and operational costs
long service life.
The Boxer with its machinery house trolley on a mono-box boom is the
guarantor of such peak performance in the field of container handling.

BOXER

AN ENGINEERING CLASSIC BUILT

FOR THE FUTURE: THE BOXER WITH
THE MACHINERY HOUSE TROLLEY.

THE TECHNICAL CONCEPT.

O
Machinery trolley on mono box boom

The first container cranes in Europe

were two cranes completely imported
from the USA. Container cranes have
been built on this side of the pond from
1968 onwards for the first time by
Kocks. Since that time, we have reinvented parts and details of the crane again
and again up to the present generation:
the Boxer.
Our engineers always have one thing in
mind when developing this crane: maximising performance while minimising
operational costs. They have achieved
this, for example, in the case of the
mono-box boom with optimised stability
and in the case of the machinery house
trolley with extremely high performance
rates. This trolley essentially consists of
hoisting mechanisms arranged on the
motor-driven trolley.

Thanks to this particular fact, a hoisting

rope system with very short ropes and
perfect coordination results. It should be
taken into account that optimal rope
running is, among others, the prerequisite for effective use of the electronic
anti-sway device and of the positioning
control system of the load.
The short hoisting ropes have many
decisive advantages: these ropes
assure lower spare part costs and provide the advantage that the ropes do
not have to be readjusted very often.
Even the rope changing periods
become considerably shorter. The reason is very simple: the hoisting ropes
of the Boxer can be replaced within
2 shifts with the crane set out of operation and with the waterside boom in
stowed position.

Q INFO
Typically Boxer
extremely precise: electronic
anti-sway device and positioning
control system
absolutely inexpensive to maintain:
short hoisting ropes, high-quality
components with easy maintenance
requirements
very low degree of wear: minimised
number of components
extremely light and stable: dynamic
deformations under extreme
conditions have been calculated
and minimised.

BOXER

In contrast, the long ropes of a crane

with a stationary hoisting mechanism
require up to 5 shifts. The highlight of
the Boxer: processing of ships is not
interrupted precious berths are not
blocked.
One further advantage of short
hoisting ropes: vertical swinging does
not exist (this is only a problem in
the case of long flexible ropes). If a
container is hooked in the ship's cell,
the snag-load device acting on the
rope fix point or integrated in the drive
chain assures that the hoisting ropes
ease off under control. Thus the crane
is protected against extreme overload
conditions.
And there is an additional overload
protection: load cells integrated in the
rope fix points switch off the hoisting
mechanisms as soon as the nominal
load is exceeded.
With regard to the number of system
components, our engineers attached
great importance to confining themselves to the absolutely necessary points.
A low number of components means
lower maintenance costs. Performance
losses are simultaneously minimised.
Thus the rope system of the Boxer
requires e.g. only one rope pulley for
each hoisting rope.

O
Rope system of the Boxer

O
Snag-load device integrated in the hoisting drive chain

O
Snag-load device acting on the rope fix point

The rigid gantry structure is also an

exceptional point: this structure corresponds to the solid box girder principle
and forms the solid lower structure of
the crane and meets the loading applied.

As an experienced specialist in the

field of lightweight structures, Kocks
is able to realise lightweight super
post-Panamax cranes on narrow crane
gauges (from 18 through 24 m), so
that it is possible to operate large-sized
cranes with high handling rates on
older quays with limited corner loads.

The latest methods of stress analysis

measuring values from the wind tunnel
and the intention to create an optimal
crane system give the Boxer its concrete
form. Apart from all German engineering
rules, daily practical experience also
provides the inspiration for all further
developments. Thus deformations under
extreme conditions are not accidental.
These have already been calculated
during the projecting and construction
phase and taken into account during
dimensioning. Only a rigid and less
flexible structure is the solid basis of
a high-performance crane.

The Boxer with its special machinery

house trolley offers optimal control
of the load, i.e. in the case of manual
operation as well as in the case of
automatic operation: thanks to optimal
rope guiding and shortest hoisting
rope lengths.
Standstill periods due to maintenance
are minimised, high availability is assured.

O
Rope system of a container crane with stationary hoist and trolley
drive including catenary trolleys.

BOXER

THERE ARE MANY REASONS

FOR CHOOSING THE BOXER.
THE MOST COMPELLING ARE:

01 THE BOOMS
The weight and stability of the boom
system of the boxer with waterside
boom and bridge girder in mono-box
design have been optimised. The
characteristic feature of this structure
is the fact that it is subject to extremely
easy maintenance: the structure can
be easily reached from the exterior side
via the machinery house trolley and the
interior is accessible.

THE TECHNICAL HIGHLIGHTS.

The bridge girder is suspended via steel

structural hinges and separate shear
transmission elements providing decisive
structural advantages.
When using the stability reserves, even
extremely heavy loads can be handled in
special cases assuming well-founded
know-how and a heavy-load hook beam.

The waterside boom is connected with

the bridge girder via a low-maintenance
pivot and an adjustable boom support
locking device. The boom support locking device is a speciality of Kocks: it not
only releases the pivot from vertical
loads but also assures a jerk-free transition.
The cable carrier beam is arranged at
the landside end of the boom. In case
of maximum landside outreach and in
case of maintenance, the cable carriages
are positioned on this beam. These can
always be reached without difficulty: this
is assured by the easily accessible and
extremely safe platform system.

O Gantry structure with inside elevator and stairs

O Boom connection to gantry on waterside

03 THE TIES
The sophisticated tie system consists
of waterside and landside ties forming
the suspension of the booms and also
assuring the special stability of the
crane. The landside ties are provided
with steel-on-steel hinges.
This is quite different in the case of the
waterside ties: in order to assure hoisting of the boom, these are equipped
with maintenance-free hinged bushings.

O Boom connection to the gantry at landside

O Mechanical lock between waterside and

landside boom

We offer two types of trolley rails:

as a welded rail: this rail can be
calculated in the stress analysis
as a load-bearing part by 75 % of
its cross-section.
as a bolted rail: with or without
flexible lining.

02 THE GANTRY
Boxer gantries are rigid and non-swinging, because the light box design
with strengthening by diagonals and
bracings has a particularly clever effect.
Due to our flexibility and creativity in
the design, versions with a personnel
elevator and stair ascent in the gantry
leg are possible.

O Landside tie links

BOXER

O Waterside tie links

BOXER

04 ACCESS TO THE CRANE

The integrated concept of the
Boxer allows the complete structure
to be reached easily and safely.
Therefore ladders, stairs and platforms
complement one another to form an
intelligent system of access. This also
permits, on request, comfortable stairs
as the main ascent and /or a personnel
elevator in one of the gantry legs.

05 THE MACHINERY HOUSE

TROLLEY
The machinery house trolley as the
performance-dominating crane component of the Boxer is sophisticated
technical engineering. It houses the
hoisting mechanism provided, depending on requirements, with a central spur
gear reducer, with two separate spur
gear reducers or with two plane-tary
gearboxes installed in the drum.

O Machinery trolley on the waterside boom

O Ascent platforms at pylon

Four single-wheel drives assure the optimal traction of the wheels on the trolley
rail and thus a trolley operated without
obstructions. Horizontal guide rollers
assure almost wear-free running of the
flangeless wheels.
We can also supply the machinery
house trolley as a special version in
the form of a slewing trolley. Then
the interaction of roller bearing slewing
ring and slewing drive with planetary
gearbox (as compact design) assures
the excellent slewing possibility via a
slewing range of almost 360 degrees.
Kocks machinery house trolleys reach
a speed of more than 230 m /min
including high acceleration values of
0.83 m/sec2.

O Hoisting winch with central gearbox

O Hoisting winch with two gearboxes

By the way: the weather-proof casing

in the area of the machinery house can,
on request, also be built as a noisereducing casing in the lateral walls
as well as in the platform.
And as it is understood that performance
also implies convenience, all components can always be reached and replaced easily for maintenance purposes.
O Hoisting winch with two planetary gears

O Machinery house trolley on mono-box boom

BOXER

06 THE BOOM HOIST MECHANISM

Assuring maximum safety for all crane
components is a core value of Kocks.
This applies in particular in the case
of the boom hoisting winch. This winch
is arranged in the machinery house
within the gantry and is equipped with
a safety brake as well as an emergency
drive. Thus the boom can be kept safe
in case of excessive speed or failure of
the drive. The emergency drive assures
safe movement into the end position.
In case of maintenance, a travelling
crane is provided, which can set parts
onto the quay or pick up these parts
from the quay.

07 DRIVERS CABIN
The cabin of the panoramic view type
provides much comfort and a full range
of visibility. It is suspended directly
at the machinery house trolley, but can
also be uncoupled from the trolley.
In this case it is drawn via a separate
cabin carriage.

O Emergency drive for boom hoist

O Emergency band brake at boom hoist

The elements and indication devices

required for operation are designed
carefully and arranged meticulously in
accordance with ergonomic aspects.
In this cabin, the crane driver has everything under control.

O Maintenance crane inside of machinery house

O Ergonomical operator seat

O Ergonomical arrangement of control elements

BOXER

08 THE CRANE TRAVEL

MECHANISMS
We also set standards with regard to
the crane travel mechanism. The wheels
are arranged in a bogie equalising
system and are driven either as single
wheels or in pairs. Either as support
of the wheels or in the gearboxes: antifriction bearings from European suppliers are a must.
In case of endangered areas, we have
developed floodable travel mechanisms
or, where necessary, also curvable
trucks, thus assuring curving up to
90 degrees.

09 THE ELECTRICAL EQUIPMENT

The freely programmable electrical
control, too, is state-of-the-art technical
engineering. It is based on approved
industry components communicating via
bus systems with the digital three-phase
frequency converters.

O Curveable travelling unit with guide rollers

O Gantry drive unit

O Cubicles inside electrical house

O Separate working station for engineers

O View to cubicles on trolley

O Arrangement of instruments on trolley

Anti-sway guiding of the hoist load or

optimised hoist load guiding can be realised for optimal operating conditions.
Semi-automatic or fully automatic operation assures continuously high handling
rates during long periods of operation.
The communication of the devices is
assured in accordance with the usual
industrial standards by Industrial
Ethernet, profibus or CANbus, to a large
extent via LWL connections.

O Power suppy by sealed spiral cable reel

BOXER

O Curveable track for 90 degrees curve

O Festoon system with driven carriages to harmonise acceleration

BOXER

THEORY:
MAXIMUM HANDLING RATES
WITH HIGHEST RELIABILITY.
SOLUTION: THE BOXER.

THE BOXER IN OPERATION.

The Boxer is used where containers

are to be handled.
In this context, the Boxer proves to be an
extremely efficient and simultaneously
reliable device: in case of single lift operation, the Boxer effects 40-45 moves per
hour, in 20' or 40' twin lift operation, the
Boxer yields double the result. The clever
constructional design machinery house
trolley on mono-box boom ensures
optimal control of the load, either during
manual operation or in automatic mode.
Moreover, complete additional modes
of operation can be realised, for example
magnet operation or service with grabs.
Thus a pure container crane becomes
a multipurpose crane.

O
Postpanamax and super postpanamax container gantry cranes

When unloading ships, above all high

performance rates are required during
continuous operation. The Boxer is one
of the most favoured solutions worldwide.

Q INFO
The Boxer is characterised
as follows:

high handling rates

high positioning accuracy
high working speeds
low maintenance expense
no interference or interruption
of ship unloading by replacement
of hoisting ropes
high availability
low dead weight
high performance parameters even
on narrow crane gauges
long service life
high resale value

BOXER

WHY KOCKS?
CRANE CONSTRUCTION SINCE 1872.

Q KNOW HOW
Kocks has developed high-performance
ship unloaders since 1913. We are considered pioneers in the development of
container cranes in Europe and we are
leaders on the world market in the field
of Goliath cranes. Kocks sets standards
for the high performance of cranes.

Q SERVICE
Perfect maintenance is part of a good
product for us. We therefore train the
personnel of our customers intensely
in the fields of crane theory and crane
practice. We want to assure that
continuous availability of the cranes
is guaranteed.

Our engineers consistently apply the

approved regulations of German engineering when continuously developing and
designing cranes. Designing and classification for continuous operation is carried
out particularly conscientiously.

If a failure should occur in spite of

everything, we assist quickly and in a
flexible and unbureaucratic way.
Around the clock.

The goal always remains the same: increased efficiency, safety and environmental
friendliness of the cranes.
Q QUALITY
To us quality means: a sophisticated
product concept, profound know-how in
the fields of design and control as well
as the greatest accuracy with regard to
fabrication and execution. It goes without saying that our engineers test and
check all mechanical and electrical
components meticulously.
This provides decisive advantages:
maximum efficiency and reliability
of the cranes
low operational costs
long service life (even under the
toughest operating conditions).

O
Home of Kocks Krane in Bremen

THE COMPANY KOCKS.

Q PARTNER APPROACH
The Boxer is an extremely durable
product. The decision in favour of the
Boxer means the start of a comprehensive relationship between customer
and supplier, which is evident from the
many repeat and follow-up orders.
We therefore attach great importance to
ensuring that this relationship is fair and
with long-term benefits for both sides.
For us this starts long before the signing
of contract. We will be pleased to advise
you, simply give us a call.

BOXER

THE BOXER THE ESSENTIAL

TECHNICAL DATA.

AN OVERVIEW OF THE BOXER.

BOXER 4000

Q
Q
Q
Q
Q
Q

Capacity below spreader

Handling mode
Outreach waterside
Outreach landside
Rail centre gantry
Hoisting height

40 t
20 /40 ft
40 m
0 to 25 m
50 /80 /100 ft
30 m

Q
Q
Q
Q
Q

Operating speeds
Hoisting and lowering
Trolley travelling
Gantry travelling
Boom raising
Boxes per hour

60 / 90 m /min
150 m /min
45 m /min
5 min
40

Acceleration
a = 1m /sec2
a = 0.65 m /sec2
a = 0.15 m /sec2

65 t
20 /40 ft / twin twenty
50 m
0 to 25 m
50 /80 /100 ft
36 m

Q
Q
Q
Q
Q

Operating speeds
Hoisting and lowering
Trolley travelling
Gantry travelling
Boom raising
Boxes per hour

Acceleration
90 /120 m/min
a = 1m / sec2
150 m / min
a = 0.72 m / sec2
45 m /min
a = 0.15 m /sec2
5 min
40 single lift / 80 twin lift

BOXER 5000

Q
Q
Q
Q
Q
Q

Capacity below spreader

Handling mode
Outreach waterside
Outreach landside
Rail centre gantry
Hoisting height

BOXER

AN OVERVIEW OF THE BOXER.

BOXER 6000

Q Capacity below spreader

Q Handling mode
Q
Q
Q
Q

Outreach waterside
Outreach landside
Rail centre gantry
Hoisting height

65 / 60 t
20 /40 ft / twin twenty/
double twin twenty
= / > 60 m
0 to 30 m
50 / 80 /100 ft
42 m

Q
Q
Q
Q
Q

Operating speeds
Hoisting and lowering
Trolley travelling
Gantry travelling
Boom raising
Boxes per hour

Acceleration
120 /160 m/min
a = 1m/sec2
200 to 240 m/min a = 0.83 m/sec2
45 m/min
a = 0.15 m/sec2
5 min
45 single lift / 80 twin lift /
90 to 100 double twin twenty

BOXER

KRANUNION.
WORLD MARKET LEADERS
UNITED.

Kranunion is an association of three crane manufacturers

specialised in hoisting and transporting heavy loads.
KIROW
ARDELT
KOCKS

is the world market leader for railway cranes

and slag pot carriers
is the world market leader for double jib level
luffing cranes
is the world market leader for Goliath cranes

Central to all Kranunion products are the technical design

concepts created by our experts. Of course, we continue to
optimise those fundamental concepts even further in the
interests of our customers. Kranunion products are therefore
based on practical requirements and are a symbiosis of
tradition and innovation combining the tried and tested with
the new.
Customers who choose Kranunion choose great German
engineering skill: for environmentally-friendly and safe, modern
technology, for low operating costs, for high performance and
reliability.

KOCKS
WESERSTRASSE 64
28757 BREMEN /GERMANY
PHONE
FAX
E-MAIL

+49 (0)421 66.01 0

+49 (0)421 66.01 400
INFO@KOCKSKRANE.DE

WWW

KOCKSKRANE.DE

KOCKS IS A MEMBER OF KRANUNION.