Kalmar DCF280-520

Lift trucks 28 – 52 tonnes

Technical information, Stage III

 Welcome to a new world of heavy-duty handling
The Kalmar F generation heavy-duty
lift trucks are based on long experience
and smart utilisation of the lastest tech-
nology. A machine loaded with customer
value.

The heavy-duty lift trucks have been

developed for a broad spectrum of heavy
handling applications. Very strong
emphasis has been put on providing our
customers, not only a machine, but pro-
ductivity and cost efficiency.

This is a machine generation which re-

flects the overall increased demands and
requirements among our customers all
over the world.

PRODUCTIVITY COST EFFICIENCY

DIMENSIONING RUNNING COST
GENERAL PERFORMANCE AVAILABILITY
APPLICATION FLEXIBILITY RELIABILITY
OPERATIONAL PERFORMANCE INTELLIGENCE
ERGONOMICS MAINTENANCE

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
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 it’s 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
to provide the best everyday performance cost possible”.
We have learnt that demanding custom- and availability.
ers have two main priorities when it
comes to machine choice and decision –
productivity and cost efficiency. All other
aspects are there to fulfil these priorities
and add even more customer value.

2
Made for top performance
To obtain the maximum out of your We focus on four important • Electronic accelerator pedal.
investment, you can never underestimate ergonomic areas: • Central operation/warning display.
the importance of the drivers’ working • Operation
• Separately suspended and isolated
environment. High productivity requires • Visibility cabin.
full driver concentration and efficiency to
• Sound and vibrations • Shock absorption to minimise
keep up handling speed, but also to avoid
• Climate vibrations.
accidents causing injuries and costly
damages. • Maximum sound level inside is 70 dB (A).
The result is a cabin where everything
• Generous interior dimensions and
This is what ergonomics is all about. Be- is optimised to improve driver perform-
floor space.
ing comfortable and aware. ance.
• Optimised visibility – 360˚ all around.
Consider this: • Electronically controlled heating/
The driver environment in Kalmar Heavy
• Individually adjustable controls, ventilation.
Lift Trucks is the efficient Spirit Delta
high visibility cabin; appreciated by pro- steering wheel and seat. • Filters for fresh air and recirculation.
fessional drivers, proven on thousands • Intuitively positioned instruments. • High performance air conditioning
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
F
E
F Panel for hydraulic functions
C D E F G G
G
F A
D E F G H G
H
H Hydraulic controls
G (levers for electrical servo) A B
E F G H I H
I
H
I Control switch A B C
F G H I
I Parking brake B C D
G H I
C D E
H I
D E F
I
E F G

F G H

G H I

H I

3
 Match your specific handling requirements
When we designed the Kalmar F-series a
b
we already knew the detailed status of
all the main alternatives on the market.
Hence, we designed a machine which
meets or exceeds the specifications of the DCF370-12
others – on the spec sheet and in reality.
H5

You can choose between several basic H4

H3
models, each optimised according to lift- H6
H8
ing capacity – stability – overall dimen- a
H2

sions – weight – and driving performance.

S L3 L2 L4
L L1
Ten models covering loads between
28 – 52 tonnes, specified for a compre-
hensive range of lifting heights at 1200 A1
100 100
mm load centre, including the side-shift/
fork positioning carriage. This means that
b
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-
Dimensions
tional characteristics.
Lifting capacity Rated (kg)
Load centre (mm) L4
In spite of its size and capacity the Truck Truck length (mm) L

machines have short turning radius. Truck width (mm) B

Height, basic machine, Spirit Delta (mm) H6
Together with the optimised visibility Seat height, Spirit Delta (mm) H8
and good manoeuvrability, it saves site Distance between centre of front axle – front face of fork arm (mm) L2

space and makes the machine a smooth Wheelbase (mm) L3

Track (c-c) front – rear (mm) S
operator in confined spaces. The coun- Turning radius, outer – inner (mm) R1 – R2

terweight and lifting height requirements Ground clearance, min. (mm)

Height when tilting cab, max. Spirit Delta (mm) T1
have been matched with a modern chassis Width when tilting cab, max. Spirit Delta (mm) T2
to keep down the overall weight but with Min. ailse width for 90° stacking with forks (mm) A1

no sacrifice in stability. Standard duplex mast Lifting height (mm) H4

Mast height, min. (mm) H3
Mast height, max (mm) H5
Additionally, we have ensured that every Mast tilting, forward – backward* (°) α–ß
Ground clearance, min.
single detail, component and system have Forks Width (mm) b
been selected and manufactured to pro- Thickness (mm) a

vide the highest possible reliability. Length of fork arm (mm) l

Width across fork arms, max. – min. (mm) V
Sideshift ± at width across fork arms (mm) V1 – V
Weight Service weight (kg)
Axle load front, unloaded (kg)
Axle load front, at rated load (kg)
Axle load back, unloaded (kg)
Axle load back, at rated load (kg)
Wheels / tyres Type, front – rear
Dimensions, front – rear (inch)
Number of wheels, front – rear (*driven)
Pressure (Mpa)
Steering system Type – manoeuvring
Service brake system Type – affected wheels
Parking brake system Type – affected wheels
Hydraulic pressure Max. (Mpa)
Hydraulic fluid volume (l)
Fuel volume (l)

4
 DCF450-12CS
55 DCF280-12LB
DCF520-12
DCF500-12
50

DCF450-12 / CS
45
DCF420-12 / CS

40
DCF370-12 / CS

35
DCF330-12 / LB

DCF300-12 / LB
30
DCF280-12 / LB
Lifting capacity, in tonne

25 T1

20

S
15 T2
600 900 1200 1400 1600 1800 2000

Load centre, mm

DCF280-330 (1) / DCF370-520 (2) models: Full lifting capacity up to

7.000 (1) / 10.000 (2) mm lift height with duplex/duplex freelift masts
and integrated sideshift/fork positioning carriage.

DCF280-12 DCF300-12 DCF330-12 DCF370-12 DCF420-12 DCF450-12 DCF500-12 DCF520-12

• LB • LB • LB • CS • CS • CS • •

28000 30000 33000 37000 42000 45000 50000 52000

1200 1200 1200 1200 1200 1200 1200 1200
6675 6675 6925 7345 7845 7950 8550 8550
3410 3410 3410 4150 4150 4150 4150 4150
3650 3415 3650 3415 3650 3415 3725 4550 3725 4620 3825 4720 3825 3825
2300 2300 2300 2350 3460 2350 3530 2450 3630 2450 2450
1125 1125 1125 1295 1295 1400 1440 1440
4500 4500 4750 5000 5500 5500 6000 6000
2540 – 2440 2540 – 2440 2540 – 2440 3030 – 2625 3030 – 2625 3030 – 2815 3030 – 2815 3030 – 2815
6600 – 950 6600 – 950 6600 – 950 6900 – 1000 7400 – 1100 8150 – 1100 8650 – 1200 8650 – 1200
300 300 300 300 300 300 300 300
– – – – – – – –
– – – – – – – –
10325 10325 10325 10795 11295 12100 12600 12600
5000 5000 5000 5000 5000 5000 5000 5000
4520 4520 4520 5050 5050 5050 5600 5600
7020 7020 7020 7550 7550 7550 8100 8100
5 – 10 5 – 10 5 – 10 5 – 10 5 – 10 5 – 10 5 – 10 5 – 10
– – – – – – – –
300 300 300 300 300 300 300 300
110 110 110 135 135 135 145 145
2400 2400 2400 2400 2400 2400 2400 2400
2750 – 1550 2750 – 1550 2750 – 1550 2750 – 1950 2750 – 1950 2750 – 1950 2700 – 1900 2700 – 1900
300 – 2150 300 – 2150 300 – 2150 200 – 2350 200 – 2350 200 – 2350 200 – 2300 200 – 2300
38300 39600 40600 50100 51900 56000 61500 63000
19600 19600 19600 26400 27400 28800 33000 34000
61700 64900 68800 81800 88400 95100 105300 108800
18700 20000 21000 23700 24500 27200 28500 29000
4600 4700 4800 5300 5500 5900 6200 6200
Pneumatic – Pneumatic
16.00×25 – 16.00×25 18.00×25 – 18.00×25 18.00×33 – 18.00×33
4* – 2 4* – 2 4* – 2 4* – 2 4* – 2 4* – 2 4* – 2 4* – 2
1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0
Hydraulic servo – Steering wheel
Oil cooled disc brakes (Wet disc brakes) – drive wheels
Dry, spring activated disc brake – drive wheels
17,0 17,0 17,0 15,0 17,0 18,0 20,0 20,0
600 600 600 600 600 600 600 600
400 400 400 400 400 400 400 400

5
 Versatility provides productivity
The standard lifting equipment of Kalmar 1 Duplex standard mast
is an integrated assembly consisting of a The
2 Duplex mast is a well proven design
free visibility duplex mast, side-shift/fork which minimises the concealed angles for
3
positioning carriage and forks, hydraulics the driver.
and control system. This is to ensure you 4

get a reliable and good running machine 5

1
with high availability even after long
6 2
shifts and high load stresses in general
3
cargo handling. 7
4

5
A major objective in the development
6
process has been to combine optimum
7
functionality for the driver together with
high performance in lifting and load Full visual contact with the load and attachement,
is provided by the Spirit Delta cabin and the open
handling.
design of the mast and carriage.

The mast and carriage are computer

designed and optimised (FEM and Catia
V5) which allowed for a decrease in the
front axle weight. Together with Kalmar’s Due to the wide range of optional equip-
integrated high capacity carriage it allows ment the machines can be equipped with
you to fully utilise the capabilities of mast a lifting equipment adapted to almost
tilt, side-shift at full lifting height and full every application.
capacity. No compromises.

2 Duplex free-lift mast

The
3 Duplex mast is also available in a
Duplex standard, clear view
Free-lift version for certain lifting heights
DCF280-330 / LB DCF370-450 / CS DCF500 DCF520 4
Lift
height, Mast height Free lift, Mast height Free lift, Mast height Free lift, Mast height Free lift,
and models, providing full free-lift as well
H4 H3 min. H5 max. H2 H3 min. H5 max. H2 H3 min. H5 max. H2 H3 min. H5 max. H2 as
5 exceptionally good through visibility.
4000 4020 6020 – 4550 6550 – 5100 7100 – 5100 7100 –
4500 4270 6520 – 4800 7050 – 5350 7600 – 5350 7600 – 6
5000 4520 7020 – 5050 7550 – 5600 8100 – 5600 8100 – 1
5500 4770 7520 – 5300 8050 – – – – – – – 7
2
6000 5020 8020 – 5550 8550 – 6100 9100 – – – –
6500 5270 8520 – 5800 9050 – – – – – – – 3

7000 5520 9020 – – – – 6600 10100 – – – – 4

7500 – – – 6300 10050 – 6850 10600 – – – –
5
10000 – – – 7550 12550 – – – – – – –
6

7
Duplex free-lift, clear view*
DCF280-330 / LB DCF370-450 / CS DCF500 DCF520
Lift
height, Mast height Free lift, 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 H3 min. H5 max. H2
4000 4020 6020 2000 4550 6550 2000 – – – – – –
4500 4270 6520 2250 4800 7050 2250 – – – – – –
5000 4520 7020 2500 5050 7550 2500 5050 7550 2500 5050 7550 2500
5500 4770 7520 2750 5300 8050 2750 – – – – – –
6000 5020 8020 3000 5550 8550 3000 – – – – – –

* Duplex freelift and triplex mast requires el-hydr. servo incl minilevers.

Triplex free-lift, clear view*

DCF280-330 / LB DCF370-450 / CS DCF500 DCF520
Lift
height, Mast height Free lift, 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 H3 min. H5 max. H2
5900 4220** 8150** 2080 – – – – – – – – –
6000 – – – 4310** 8210** 2000 – – – – – –

* Duplex freelift and triplex mast requires el-hydr. servo incl minilevers.
** Might be slightly reduced if the smallest available tyres are choosed.

6
 1

1 Standard carriage 1 2

Sideshift/fork
2 positioning carriage 2 3
hydraulic operated of free visibility type.
3 3 4
The functions includes sideshift and fork
positioning.
4 4 5

5 5 6

6
1 6 7

7
2 Carriage for steel application 7

This
3 carriage of free visibility type in-
cludes sideshift and fork positioning. The
4
forks could be positioned againts each
other
5 to become a sort of flexible coil ram.
6

1 Fork shaft system 1 2

A2smooth way to improve handling flex-
2 3
ibility is to use the fork shaft system. The
3 3 4
system enables the driver to quick and
easy
4 change between different carriers 4 5
or
5 attachments like extra long forks, coil 5 6
ram, inverted forks etc. The carriage
6 6 7
is equipped with a separate shaft
holder.
7 The fork shaft system could 7

be of pin-type or hook-on type.

1

1 2

1 2 3

2 Coil ram 3 Top-lift attachment 4 Inverted forks

The
3 coil ram is made for intensive han-
The
4
container top-lift attachment is The
5
inverted forks are easily mounted on
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
4 5 6
together with fork shaft system and sup- It is used together with either standard carrier for the top lift attachments. The
ported
5 with side-shift function. forks
6 or inverted forks. The hydraulics inversion
7 also means that the basic lifting
6 for
7 the twist-locks is connected through height is maintained.
1
quick couplings.
7
2

5
1

6
2

7
3

7
 1

The basic set up 2

A key factor for heavy duty handling 4 Drive line

productivity is the basic machine set up. The
5 propeller shaft and drive axle trans-
Heavy loads and high lifting speed, for fer the power from the transmission to
6
example, put critical demands on the the driving wheels. The mountings on
engine and hydraulic power support. Fast the
7 propeller shaft are fitted with cross-

positioning during the handling cycle flanges for optimum strength. The drive
1
requires precise control with tight turn- axle gears down in two stages, differential
ing radius, effective and reliable brakes and
2 hub reduction. The engine provides

and high engine torque. Fast handling maximum

3
torque at the drive wheels,
requires good stability, reliable brakes which spares the transmission.
4
and smooth transmission.
5 Steering system
Of course, all the working components The
6 steering axle is built from a single
and systems have to cope with the most piece of high strength steel, which means
1 7
demanding stresses during long shifts fewer parts requiring less maintenance
and heavy operations everyday. 2 Engine and higher structural integrity. The sus-
The
3 Volvo engines provide power for pension points on the steering axle utilise
We have put highest priority on over- driving and the working hydraulics. The a maintenance-free plastic. The hydrau-
4
all technical reliability. Looking at the engines are low-emission turbo diesels lics that feed oil to the steering cylinder
choice of each component, long running with
5 fuel injectors and intercoolers. The are optimised for enhanced driving feel.
cycle times and how it all comes together. design
6 of the combustion chambers, along The orbitrol and the priority valve jointly
We have incorporated into the Heavy with the precise fuel injection control, provide gentle, yet precise, steering
7
Lift Trucks several major components ensures more efficient combustion to movements.
and systems from our extremely reliable provide lower emissions with increased
DRF reachstacker. Thousands of these torque and power. The engines meet the
machines have been delivered in the past Stage 3A and Tier 3 requirements, and
years and have proven the durability of the sound and vibration standards.
the components and systems, and its low
running costs. The radiator is a 3 chamber design with
a single fan to provide cooling for the
1 Chassis engine and transmission. The engine
The
2 frame forms the basis of the ma- cooler’s separate expansion
chine’s lifting and manoeuvring charac- chambers are fitted with
3
teristics and was designed exclusively a level sensor that
for
4 heavy duty operation. The beam indicates
1
low coolant
construction,
5 along with its width, makes level.
2
the Heavy Lift Trucks stable, torsion
6
resistant and service-friendly. 3 Transmission
7 The
4 transmission trans-
The frame is 3D modulated (Catia V5) fers power from the engine to
5
and designed (FEM) in order to eliminate the hydraulic pumps and drive line. The
critical tensions under various kinds of engine
6 and gearbox control systems work
strain. The mechanically welded chassis together
7 to find the optimum balance 1
has been optimised according to strength, between power and fuel economy at any
2
weight and stability. given time. The transmission system con-
sists of a torque converter and a gearbox. 3

The gearbox is automatic, but can partly 4

be shifted manually.
5

8
1

6
1
7
2

1 6
1

2 7
2
1
3 3
2
1 4
4
3
2 5
5
4
3 6
6 Brakes Wheels and tyres
5
4 The
7 Kalmar machines have, like 7 its pred- Tyres are an important cost factor to
6
5 ecessors, the smooth, reliable and almost consider when improving operational
7 maintenance-free wet disc brakes. To get performance. Therefore, all models use
6
cleanliness the brake circuit can, as an identical sizes on both drive and steer
7 option, be separated from the main hy- wheels. This improves the machine sta-
draulic system with its own tank, cooler bility, comfort and reliability and requires
and high-pressure filter. A temperature only one single spare tyre.
transmitter in the brake oil tank regulates
the cooling fan. The foot-brake valve,
which controls the oil feed to the brakes,
is sensitive enough so that the driver can
brake optimally yet gently. The parking
brake is activated automatically when the
ignition is turned off.

9
 The basic set up is a key factor
for high productivity
Drive train – DCF280-330 / LB Volvo TAD760VE Cummins QSB6,7

Engine Manufacturer, type designation Volvo TAD760VE Cummins QSB6,7

(Turbo-Intercooler) (Turbo-Intercooler)
Fuel – type of engine Diesel – 4-stroke Diesel – 4-stroke
Rating ISO 3046 – at revs (kW – rpm) 180 – 2200 194 – 2200
Peak torque ISO 3046 – at revs (Nm – rpm) 1100 – 1500 990 – 1400
Number of cylinders – displacement (cm³) 6 – 7150 6 – 6700
Fuel consumption, normal driving (l/h) 16 20
Gearbox Manufacturer, type designation Dana TE17000 Dana TE17000
Clutch, type Torque converter Torque converter
Gearbox, type Powershift Powershift
Numbers of gears, forward – reverse 3–3 3–3
Alternator Type – power (W) AC – 1920 AC – 1920
Starting battery Voltage – capacity (V – Ah) 2×12 – 140 2×12 – 140
Driving axle Manufacturer – Type AxleTech – Differential AxleTech – Differential
and hub reduction and hub reduction

Performance – Volvo TAD760VE DCF280-12 / LB DCF300-12 / LB DCF330-12 / LB

Lifting speed Unloaded (m/s) 0,35 0,35 0,35

At rated load (m/s) 0,18 0,18 0,18
Lowering speed Unloaded (m/s) 0,38 0,38 0,38
At rated load (m/s) 0,47 0,47 0,47
Travelling speed, F/R Unloaded (km/h) 27,5 – 27,5 27,5 – 27,5 27,5 – 27,5
At rated load (km/h) 25,5 – 25,5 25,5 – 25,5 25,5 – 25,5
Gradeability, max. Unloaded (%) 30 30 30
At rated load (%) 27,5 27,5 27,5
Gradeability, at 2 km/h Unloaded (%) 30 30 30
At rated load (%) 19,5 19,5 19,5
Drawbar pull Max. (kN) 209 209 209
Noise level, inside LpAZ*, Spirit Delta (dB(A)) 72 72 72
Noise level, outside LwAZ** (dB(A)) – – –

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

Performance – Cummins QSB6,7 DCF280-12 / LB DCF300-12 / LB DCF330-12 / LB

Lifting speed Unloaded (m/s) 0,35 0,35 0,35

At rated load (m/s) 0,18 0,18 0,18
Lowering speed Unloaded (m/s) 0,38 0,38 0,38
At rated load (m/s) 0,47 0,47 0,47
Travelling speed, F/R Unloaded (km/h) 27,5 – 27,5 27,5 – 27,5 27,5 – 27,5
At rated load (km/h) 25,5 – 25,5 25,5 – 25,5 25,5 – 25,5
Gradeability, max. Unloaded (%) 52,5 52,5 52,5
At rated load (%) 27,5 27,5 27,5
Gradeability, at 2 km/h Unloaded (%) 36,5 36,5 36,5
At rated load (%) 19,5 19,5 19,5
Drawbar pull Max. (kN) 209 209 209
Noise level, inside LpAZ*, Spirit Delta (dB(A)) 72 72 72
Noise level, outside LwAZ** (dB(A)) – – –

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

10
Drive train – DCF370-520, DCF370-450CS Volvo TAD952VE Volvo TAD1250VE Cummins QSM11

Engine Manufacturer, type designation Volvo TAD952VE Volvo TAD1250VE Cummins QSM11
(Turbo-Intercooler) (Turbo-Intercooler) (Turbo-Intercooler)
Fuel – type of engine Diesel – 4-stroke Diesel – 4-stroke Diesel – 4-stroke
Rating ISO 3046 – at revs (kW – rpm) 252 – 1900 260 – 1600 261 – 2000
Peak torque ISO 3046 – at revs (Nm – rpm) 1735 – 1300 1760 – 1400 1830 – 1100-1400
Number of cylinders – displacement (cm³) 6 – 9400 6 – 12130 6 – 10800
Fuel consumption, normal driving (l/h) 20 20 20
Gearbox Manufacturer, type designation Dana TE32000 Dana TE32000 Dana TE32000
Clutch, type Torque converter Torque converter Torque converter
Gearbox, type Powershift Powershift Powershift
Numbers of gears, forward – reverse 4–4 4–4 4–4
Alternator Type – power (W) AC – 1920 AC – 1920 AC – 1920
Starting battery Voltage – capacity (V – Ah) 2×12 – 140 2×12 – 140 2×12 – 140
Driving axle Manufacturer – Type AxleTech – Differential AxleTech – Differential AxleTech – Differential
and hub reduction and hub reduction and hub reduction

Performance – Volvo TAD952VE DCF370-12 / CS DCF420-12 / CS

Lifting speed Unloaded (m/s) 0,35 0,35

At rated load (m/s) 0,18 0,18
Lowering speed Unloaded (m/s) 0,38 0,38
At rated load (m/s) 0,47 0,47
Travelling speed, F/R Unloaded (km/h) 27,5 – 27,5 27,5 – 27,5
At rated load (km/h) 25,5 – 25,5 25,5 – 25,5
Gradeability, max. Unloaded (%) 30 30
At rated load (%) 27,5 27,5
Gradeability, at 2 km/h Unloaded (%) 30 30
At rated load (%) 19,5 19,5
Drawbar pull Max. (kN) 209 209
Noise level, inside LpAZ*, Spirit Delta (dB(A)) 72 72
Noise level, outside LwAZ** (dB(A)) – –

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

Performance – Volvo TAD1250VE DCF370-12 / CS DCF420-12 / CS DCF450-12 / CS DCF500-12 DCF520-12

Lifting speed Unloaded (m/s) 0,34 0,34 0,34 0,34 0,34

At rated load (m/s) 0,27 0,27 0,27 0,27 0,27
Lowering speed Unloaded (m/s) 0,22 0,22 0,22 0,22 0,22
At rated load (m/s) 0,40 0,40 0,40 0,40 0,40
Travelling speed, F/R Unloaded (km/h) 27 – 27 27 – 27 27 – 27 27 – 27 27 – 27
At rated load (km/h) 24 – 24 23 – 23 22 – 22 21 – 21 20 – 20
Gradeability, max. Unloaded (%) 35 35 35 35 35
At rated load (%) 34 32 31 29 33
Gradeability, at 2 km/h Unloaded (%) 35 35 35 35 35
At rated load (%) 31 29 28 26 25
Drawbar pull Max. (kN) 329 329 329 329 329
Noise level, inside LpAZ*, Spirit Delta (dB(A)) 72 72 72 72 72
Noise level, outside LwAZ** (dB(A)) – – – – –

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

Performance – Cummins QSM11 DCF370-12 / CS DCF420-12 / CS DCF450-12 / CS DCF500-12 DCF520-12

Lifting speed Unloaded (m/s) 0,34 0,34 0,30 0,30 0,30

At rated load (m/s) 0,27 0,27 0,25 0,25 0,25
Lowering speed Unloaded (m/s) 0,22 0,22 0,22 0,22 0,22
At rated load (m/s) 0,40 0,40 0,40 0,40 0,40
Travelling speed, F/R Unloaded (km/h) 24 – 24 24 – 24 27 – 27 25 – 25 25 – 25
At rated load (km/h) 20 – 20 20 – 20 22 – 22 21 – 21 21 – 21
Gradeability, max. Unloaded (%) 35 35 35 35 35
At rated load (%) 43 43 34 33 33
Gradeability, at 2 km/h Unloaded (%) 35 35 35 35 35
At rated load (%) 28 28 26 25 25
Drawbar pull Max. (kN) 379 379 368 368 368
Noise level, inside LpAZ*, Spirit Delta (dB(A)) 72 72 72 72 72
Noise level, outside LwAZ** (dB(A)) – – – – –

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

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,
wheel-loaders, cranes etc – are con- to support and leverage your handling thoroughly tested and optimised control
structed with more and more sophisti- operations, not confuse it. system, which supports your driver,
cated components and systems. Each part mechanics and financial controller. And it
interacts closely with the others and to is simple to use.
reach the full potential requires compu-
ter assistance.

KCU
KCU
Kalmar Cabin Unit
KCU
KIT
KCU
KIT
KCU
KIT
Kalmar Information Terminal
KCU
KID
KIT
KID
KIT
KID
KIT
EDC
KID
Kalmar Information Display
EDC
KID KID
EDC
KID
TCU
EDC
TCU
EDC
Electronic Diesel Control
KIT TCU
EDC
KDU
TCU
KCU KDU
TCU
KDU
TCU
Transmission Control Unit
KDU
KDU
KDU Kalmar Distributed Unit

EDC TCU
KDU KDU

The communication network layout.

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 signal’s 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 machine’s 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
Communication one of the power distribution boxes. The
The distributed power-feed and com- The greatest benefit of using CAN-bus distribution boxes are located inside the
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
the nodes’ processors. The network loop the messages from the communication
The most important components in the for both the CAN-bus and the nodes’ network.
network are the control units (nodes). processor feed are redundant.

They distribute control of the machine’s 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
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
Control functions
– support the driver
The driver and machine communicate
very simple via the Kalmar Information
Terminal (KIT) and the Information
Display located right in front of the driver
in the cabin. The two-way communica-
tion – 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 (KID), while
warnings and other monitoring indica-
tions are presented to the left.

Messages are only presented when they

are relevant to the driver and the opera-
tion. The driver can focus on the job in-
stead of checking meters and indicators.

Engine revs, travelling speed,

time and fuel. Engine
Heating/Ventilation Temperature
and Air conditioning. and pressure.

Transmission
Temperature
Service information. and pressure.

Battery status.

13
 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 F-generation.

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 for planned A safe communication network Reliability starts already at the
mainenance The control and monitoring system is the concept stage
The service intervals have been extended Kalmar control system, already success- One of the guiding principles in design-
to 500 hours, which means that you don’t fully applied in more than 1.000 Kalmar ing the DCF was to minimise the number
have to take the machine out of work machines worldwide. of potential sources of error. Therefore
more than 6 times a year (3.000 hours the machines consist of as few compo-
utilisation). This reduntant CAN-bus system is nents and moving parts as possible. The
proven to be excellent in functionality functionality and operational reliability
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-
All checkpoints are easy accessible tors which reduces the number of sources
and concentrated to specific locations. of error. The power-feed for each node
Lubrication free components or central and the transfer of control signals are
lubrication points have been utilised. independent of the other nodes, which
The wet disc brake system is practically means the risk of disruption becomes
maintenance free. minimal. The redundant design means
that there are always two paths to choose
The indicator and monitoring support to maintain communication, which re-
built into our control system make sure sults in extra safety and reliability.
that the machine won’t be misused or
maintained incorrectly. The driver and
mechanics will always get indications
and guidance in time to avoid unneces-
sary and costly wear and tear or technical
breakdowns. No unwanted stops.
To increase workplace safety the machine can be
fitted with alcohol interlock.

14
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.
secure the reliability we have minimised the steering always receives enough
the number of hydraulic components and pressure. The hydraulic oil pump for load Oil supply and temperature control is
couplings. handling is disconnected during forward handled through Kalmars distributed
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
security regardless of the handling Information Display (KID) in the cabin.
operation the hydraulic system is based All three pumps interact together, using
on three fixed displacement vane pumps the same oil tank and filters, which are
– 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
2
2
3
3
4
4
5
5
6
6
1
7
7
2

3 1

4 2

5 1 3

6 2 4

1 7 3 5

2 4 6
1
Other improving features: 3
2
High density filter improves the oil 5 All main hydraulic components at 7
1 Large dimensions of hydraulic hoses 4
lifetime (clean oil). 6
ground level are gathered on a sepa-
3
improves the hose´s lifetime (slower rate plate, bolted to the chassis and
2 5 7
flow, less friction and less heating).
4 ORFS – leak proof couplings all therefore simple to remove.
3
1 6
5
around improves reliability (mini-
4
2 Thermostatic cooling of both the 7 mises leakage).
6
5
3
main system and the brake system
7
improves the oil lifetime (tem-
6
4
perature control, optimised working
7
5 temperature).
6

15
Global presence and local service bring
our products and solutions closer to our customer.

TI-LT52-EN-NCE / 2012.05.10

Cargotec improves the efficiency of cargo flows on land and at sea – wherever cargo is on the move. Cargotec Sweden AB
Cargotec’s daughter brands Hiab, Kalmar and MacGregor are recognised leaders in cargo and load handling Torggatan 3
SE-340 10, Lidhult, Sweden
solutions around the world. Cargotec’s global network is positioned close to customers and offers extensive
tel. +46 372 260 00
services that ensure the continuous, reliable and sustainable performance of equipment. fax +46 372 263 90
Cargotec’s class B shares are quoted on the NASDAQ OMX Helsinki. www.cargotec.com www.cargotec.com