REACHSTACKERS REACHST ACKERS 42 – 45 TONNES TONN ES
TECHNICAL INFORMATION CONTAINER CONTAINER HANDLER, HANDL ER, DRF
Flexible Container Handling Reachstackers from Kalmar combine performance, comfort and reliability.
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.
Capacity and dimensions Maximum lifting capacity
with spherical plane thrust bearings. The
The blocking valves on the lifting and
in confined spaces.
width of the rear fixture (boom suspension)
extension cylinders block the oil flow when
increases the overall rigidity and the good
the boom functions are not in use, which
rearward visibility.
secures the boom position. The base of
The chassis and lifting equipment have
the lifting cylinders has a new design that
been developed to ensure the best possible performance, strength and user-friendli-
The boom has two sections, the inner and
produces smooth stopping and starting
ness. The nature of the working environ-
outer boom. The sliding plates between the
movements.
ment and capacity requirements at differ-
inner and outer boom require no lubrica-
ent load centres determine which model is
tion. The cable-chain which leads hydraulic
The boom’s lifting and extension function
the most suitable.
hoses and cabling to the attachment is
is damped in the end positions for reduced
made of maintenance-free plastic.
wear and greater comfort.
The lifting boom carries the load. The
Lifting boom hydraulics
Rotator
design has been optimised using compu-
Oil is fed to the boom functions by load
The rotator is fixed in the inner boom and
ter simulations and extensive field tests.
sensing pumps. To reduce pressure drops,
enables the container to be rotated. The ro-
The powerful execution in high-tensile
wide hydraulic hoses have been used for
tator consists of an upper and a lower yoke
steel has a minimal number of welds for
the boom functions. A wider hose produces
joined with a powerf ul bearing. Rotatio n
maximum strength. The boom’s fixture in
a lower flow rate with the same volume,
is enabled by two hydraulic motors, which
the frame and the lifting cylinders are fitted
thereby reducing friction and heat development.
drive a gear-ring. Two hydraulic dampers
Lifting boom
help prevent the container from swinging
Attachment
Attachment and rotator hydraulics
Firstly, a large number of computer simula-
The primary function of the attachment is
The functions are fed with a constant pres-
tions have been run in order to eliminate
to firmly attach the container during lifting.
sure, which means there is no pumping of
critical tensions under various kinds of
This is done with four twistlocks which
hydraulic oil when the functions are not in
strain. The simulations were characterised
rotate, thereby securely gripping the
use. One valve serves all the hydraulic func-
by uncompromising demands on the funda-
container’s corner fittings.
tions in the attachment. The valve ensures
mental principles of stability, manoeuvrabil-
that each hydraulic function is fed the exact
ity and visibility. Secondly, the machine has
The mechanical levelling ensures that the
amount of oil needed to optimise the speed
then undergone extensive field-testing to
twistlocks reach the corners, even if the
of the functions’ movements. The attach-
fully ensure its dynamic strength.
container is leaning.
ment functions are damped in the end positions.
The reachstacker is available with a variety of wheelbases to fulfil demands on lifting
The attachment can easily be adapted to different container standards. A hydraulic
Chassis
capacity in relation to manoeuvrability and
motor drives the function via chains. The
The frame forms the basis of the machine’s
operating economy in the best way.
container can also be moved sideways
lifting and manoeuvring characteristics. The
to facilitate loading and unloading, or to
frame’s beam construction, along with its
Increased capacity
compensate for unbalanced loads. Two
width, makes the reachstacker stable, tor-
In some cases, high capacity requirements
hydraulic cylinders perform the side-shift
sion resistant and service-friendly.
in the second and third rows of containers,
movement.
or on the far rail track, call for the benefit of support legs. In other cases, it may be the
Driver environment Ergonomics
The pedals are designed for high comfort,
Controls and instruments are intuitively
with a hanging accelerator. The internal di-
Kalmar’s goal while developing the cabin
positioned and work the way a driver would
mensions are otherwise generous, offering
has been to assure the driver the best con-
expect. Search lights in the buttons and
an open floor space.
ceivable safety, ergonomics and visibility.
switches make them easy to identify and
No machine is better than its driver.
use, even in darkness.
Climate
An electronic controlled heating and ven-
Sound and vibration
The cabin is separately suspended and
In the centre above the steering wheel is
tilation system comes as standard, as do
isolated from the frame with powerful rub-
a display showing operating information,
filters for fresh air and recirculation. An air
ber dampers. Effective shock absorption
warning messages, error codes etc. To the
cooling system is available as an optional
minimises vibration. The cabin is fitted with
left of the display is the panel for warning
extra. The cooling system provides a good
insulation material both inside and out. The
and indication lamps.
cooling effect, even in extremely high temperatures. A pollen filter is available as
maximum noise level inside the cabin is 72 dB (A).
The driver’s seat and control lever for the
an optional extra.
lifting functions can be adjusted to the optimum individual driving position. Left instrument panel Gear selector and multi-function lever Steering wheel panel Direction indicators
Performance Performance is the result of how well
Transmission
the machine’s functions work together.
The transmission transfers power from the engine to the hydraulic pumps and
The efficacy of the lifting equipment is de-
drive line. The engine and gearbox control
termined by a combination of lifting speed,
systems work together to find the optimum
capacity, visibility and user-friendliness.
balance between power and fuel economy
Lifting places heavy demands on the engine
at any given point.
and working hydraulics, but lifting is only part of the operating cycle. Before the
The transmission system consists of a
machine is in position to load or unload,
torque converter and a gearbox. The
the demands are instead on precise control
same gearbox is used whichever engine
with tight turning radius, effective brakes
is chosen. The gearbox is automatic, but
and high pulling power. And of course, all
can partly be shifted manually. The torque
the functions must still perform optimally
converter is a hydraulic coupling positioned
even after heavy use.
between the engine and gearbox. The gearbox and torque converter work together via a joint hydraulic system.
Standard drive train
Engine
A Volvo engine is standard. Cummins is
The engine and transmission cooler is a sin-
available as optional extra. The engine
gle unit that uses the same fan. The engine
provides power for driving and the working
cooler’s separate expansion vessels are
hydraulics. The engines are low-emis-
fitted with a level transmitter that indicates
sion turbo diesels with unit injectors and
low coolant level.
intercoolers. When the engine temperature is too high or The design of the combustion vessels,
the coolant level or oil pressure too low, the
along with the precise fuel injection control,
engine’s power output is actively reduced.
ensures more efficient combustion. Emis-
Should the oil pressure fall below a certain
sions decrease, while power and torque in-
level, the fuel feed to the engine is cut off
crease. The engines fulfil the requirements
automatically.
Cummins QSM11 with air cooled intercooler can be fitted as optional extra.
of 97/68*2004/26 EC stage 3, US EPA Tier 3. Steering system
The steering axle has been cut from a single
The hydraulics that feed oil to the steering
piece of robust steel, which means as few
cylinder is optimised for enhanced driving
maintenance-requiring parts as possible and
sensation. Orbitrol and the priority valve
high structural strength.
jointly provide gentl e yet precise steering
The distributed and redundant control system For the reachstacker to work perfectly
Two things are needed for a command initi-
The power-feed supplies the machine’s
a robust communication network is
ated by the driver to result in a particular
electrical and electrohydraulic functions
needed, along with a system that gives
function, or for several functions to work
with voltage, while the communication sys-
the functions power.
together: power-feed and communication.
tem controls and checks that the functions have been activated, waits in standby mode or indicates a fault.
Kalmar Cabin Unit
Control functions
The system also distributes information to
The driver and machine communicate
the driver such as alarm warnings, operat-
via the Kalmar Information Terminal (KIT)
ing details and action-guided information.
and the Kalmar Information Display (KID).
In these cases, messages are sent from one
Control signals initiated by the driver are
of the nodes in the network, captured by
transferred to the KCU, which handles all
the KCU, and then presented in the KID or
incoming signals from the controls in the
the panel for warning and indication lamps.
cabin, and sends messages out into the
The KID shows information from the control
communication network.
units in the form of messages, status, fault indication etc. Keyboard(KIT) Warning and indication lamps (KIT) Display (KID) Alarm indicator
Reliability High reliability is achieved by reducing the number of components and ensur-
Standard equipment Chassis
• Button for electronic hand brake
Hydraulics
• Safe angled entrance
• Warning buzzer for not activated
• Return filters hydr. Oil (10 micron)
• Lifting eyes front/r ear • Towing pin (incaste d) Body
hand brake, leaving seat
• Load sensing pumps (4 pcs)
• Only first gear activated
• Vane pumps (2 pcs for brakes and cooling)
• Only second gear activated
• Visual level glass hydraulic tank/brake tank
• Steps with anti slip protectio n • Rear view mirrors on each side
• Pressure filter brakes (10 micron)
• Automatic gear shifting
• Regeneration system (lift and Instrumentation
• Graphic display with automatic
extension boom) • Environmental air filter hydraulic tank
Steeringaxle
fault analyses
• Rear axle: Kalmar
- Alignment indicator spreader
Electrics
• Double acting steering cylinder
- Twistlock indicator
• Electrical system 24 V
- System voltage
• Main power switch
Drive train
- Actual gear
• 2 working lights on attachment
• Engine: Volvo or Cummins
- Engine rpm
• 2 working lights on boom
• Transmission: Dana
- Travelling speed
• 2 working lights on front edge cabin
• Engine protectio n system
- Fuel bar
• 2 rear lights on fenders activated
• Transmission protectio n system
- Hydraulic oil temperatur e
• Preheating engine
- Transmission oil temperature
• 2 head lights on front fenders
• Front axle: Axlete ch
- Engine oil pressure
• 2 position lights on each side
in reverse
Service friendly Few, short stoppages for service and maintenance minimise loss of production time. Service accessibility
In the longer term, the reachstacker´s reli-
The top covers on the frame can be re-
ability is a crucial parameter in the overall
moved quickly and easily. Most of the main
handling economy. At the same time, each
components are easily accessible from
machine must be service-friendly so it can
above in the broad frame when inspection
be maintained and repaired quickly and
and maintenance need to be carried out.
easily, thereby maintaining high reliability.
The cabin can also be moved lengthwise thus further increasing ease of access.
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
Contact information:
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Kalmar is a global supplier of heavy materials handling equipment and services for ports, terminals, industry and intermodal handling.
