Kalmar ContChamp — Boom, attachment and cab: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the boom, sliding plates, top-lift frame, combination attachment and cab of the Kalmar ContChamp reach stacker, one fact per card, each with its source stated in the text. For the overall picture, see the Kalmar ContChamp technical legacy guide.
Kalmar ContChamp DC: how is the boom built?
As two sections of slender high-tensile steel, one fixed and one telescopic, on a pivot mounting, with a double-acting cylinder for the extension, according to the RS technical handbook (1996 edition), as set out in the HIT SRL technical cards. Stop valves on the lift cylinders keep the load from sinking unintentionally, the same handbook states, the HIT SRL technical desk notes. In the DRD-S technical handbook (2004 edition) these are blocking valves, and a regeneration system speeds up lifting and extension without load.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-boom-construction · HIT ref KCC-062 · fingerprint 8e8ee7 · see HIT ref KCC-063, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-boom-sliding-plates
Kalmar ContChamp DC: what are the wear limits of the boom sliding plates?
At least 15 mm of thickness, no more than 2 mm of difference on a plate worn on one side and no more than 4 mm of gap between sliding surface and plate, according to the RS technical handbook (1996 edition), as logged by the HIT SRL technical desk. Plates beyond the wear limit are removed and planed or replaced, and gaps above 4 mm are closed with spacers, according to the handbook, as recorded at HIT SRL. If the bolts damage the sliding surface of the boom, the handbook has the boom dismantled for service.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-boom-sliding-plates · HIT ref KCC-063 · fingerprint 6cc957 · see HIT ref KCC-064, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-boom-special-lubricant
Kalmar ContChamp DC: how is the extension boom lubricated?
With a glazing knife, in a thin layer of the manufacturer's special lubricant, spread every 200 hours on the fully extended boom, according to the RS technical handbook (1996 edition), as recorded at HIT SRL. The handbook forbids any other lubricant, which could damage the sliding surfaces and the sliding plates. The DRD-S technical handbook (2004 edition) gives the boom sliding plates grease nipples instead.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-boom-special-lubricant · HIT ref KCC-064 · fingerprint f545e7 · see HIT ref KCC-063, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-boom-sliding-plates
Kalmar ContChamp DC 4160-4560 RS: what does the top-lift frame do?
It handles 20 to 40 ft containers, adjusting electro-hydraulically between those lengths with ±800 mm of side shift and ±90° of rotation, according to the 1995 instruction manual, as HIT SRL's technical desk reads it. Stops at 30 ft and 35 ft can be switched in or out, the same manual states. The specification tables of the 1996 technical handbook give the rotation as +185°/-95°.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-top-lift-frame · HIT ref KCC-065 · fingerprint 9b1aa2 · see HIT ref KCC-066, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-attachment-rotation-angle
Kalmar ContChamp DC: how far does the attachment rotate?
+185°/-95°, with a maximum side shift of ±800 mm, according to the specification table of the RS technical handbook (1996 edition), as set out in the HIT SRL technical cards. The RC technical handbook of the same edition and the 1994 data sheets give the same swivelling angle, the HIT SRL technical desk notes. The 1990 technical handbook gives ±95° in its specification table, and the picture captions of the 1995 instruction manual and of the 1996 handbook show ±90°.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-attachment-rotation-angle · HIT ref KCC-066 · fingerprint 92e6db · see HIT ref KCC-065, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-top-lift-frame
Kalmar ContChamp DC: how is the rotator gear clearance checked?
With the top-lift frame resting on a container, the clearance between the gear ring and the gear wheel on the hydraulic motor shaft is measured and kept within 0.3 mm, according to the RS technical handbook (1996 edition), as logged by the HIT SRL technical desk. The handbook recommends this adjustment every 10,000 hours, as recorded at HIT SRL. It is made by loosening the bolts between the yoke and the gear ring, as the handbook describes.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-rotator-gear-clearance · HIT ref KCC-067 · fingerprint ebfb25 · see HIT ref KCC-066, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-attachment-rotation-angle
Kalmar ContChamp DC 4560-4580 RC: what is the combination attachment?
A top-lift frame for 20-40 ft containers joined to two pairs of trailer legs, according to the RC technical handbook (1996 edition), as recorded by the HIT SRL technical desk. The legs are lowered hydraulically, adjust in height by up to 500 mm and swing inwards when raised, which the handbook says lowers the centre of gravity of the attachment, as HIT SRL's technical desk reads it. The legs follow a sequential valve system, and alignment sensors in the trailer shoes report to a lamp panel on the boom, as the handbook gives.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-rc-combination-attachment · HIT ref KCC-068 · fingerprint c45562 · see HIT ref KCC-066, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-attachment-rotation-angle
Kalmar ContChamp DC: what are the support jacks for?
To increase the lifting capacity in the third container row, according to the RS technical handbook (1996 edition), the HIT SRL technical desk notes. The handbook fits them only to certain machines, and its main components table marks them on the DC 4571 SRS5 alone among the RS models.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-support-jacks · HIT ref KCC-069 · fingerprint 0c5199 · see HIT ref KCC-068, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-rc-combination-attachment
Kalmar ContChamp DC: what kind of cab does it have?
A separate safety cab on rubber dampers that slides lengthwise on the chassis, according to the RS technical handbook (1996 edition), as recorded at HIT SRL. Hydraulic sliding of the cab was available to special order, and full air conditioning as an option, the same handbook states.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-operators-cab · HIT ref KCC-070 · fingerprint 30e6cc · see HIT ref KCC-069, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-support-jacks
Kalmar ContChamp DC 4160-4180 RS: what boom and lifting heights does the 1996 handbook give?
15,550 mm of maximum boom height and 12,400 mm under the twist-locks for the DC 4160, according to the specification table of the RS technical handbook (1996 edition), as HIT SRL's technical desk reads it. For the RS5 versions the table prints 17,800 mm of boom height with 14,799 mm under the twist-locks on the DC 4160 RS5 and 14,700 mm on the DC 4171 RS5, while the DC 4180 has 16,500 mm and 12,200 mm, as recorded by the HIT SRL technical desk. The minimum boom height is 4575 mm, or 5100 mm on the DC 4180, and the minimum aisles in the table grow from 12,050 and 14,500 mm on the DC 4160 to 16,000 and 16,250 mm on the DC 4180.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-boom-and-lifting-heights-in-1996 · HIT ref KCC-071 · fingerprint c7e2b0 · see HIT ref KCC-072, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-lifting-height-in-1990
Kalmar ContChamp DC 4160-4560: what lifting height does the 1990 handbook give?
12,000 mm under the twist-locks, according to the specification table of the 1990 technical handbook, as set out in the HIT SRL technical cards. The same table gives boom heights of 4575 mm minimum and 15,550 mm maximum and minimum aisles of 12,050 and 14,500 mm, as in the 1996 handbook. The 1996 handbook gives 12,400 mm under the twist-locks for the DC 4160 instead.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-lifting-height-in-1990 · HIT ref KCC-072 · fingerprint c95d70 · see HIT ref KCC-071, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-boom-and-lifting-heights-in-1996
Kalmar DC4160RS4: what load does it lift?
24,000 kg at load centre L2 and 41,000 kg at load centre L1, where the rating holds up to maximum height with the top lift, according to the 1994 data sheet table, as logged by the HIT SRL technical desk. In the load chart of the same sheet the third row takes 11 t up to the second tier, the second row 24 t up to the third and the first row 41 t up to the fourth, for both 9'6 and 8'6 containers, as recorded at HIT SRL. The capacities that apply are those on the plates and in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-dc4160rs4-capacity · HIT ref KCC-073 · fingerprint 0f7e83 · see HIT ref KCC-074, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-dc4560rc4-capacity
Kalmar DC4560RC4: what load does it lift?
45,000 kg with the bottom lift and 41,000 kg with the top lift at load centre L1, according to the technical data table of the 1994 data sheet, as recorded by the HIT SRL technical desk. At maximum height the bottom-lift figure falls to 41,000 kg, and at load centre L2 the table gives 21,000 kg, as HIT SRL's technical desk reads it. Piggy-back handling is drawn at 45 t with the load at 1790 mm and the rows of the load diagram at 41, 21 and 8 t, and the limits to apply are those in the manual of the specific machine.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-dc4560rc4-capacity · HIT ref KCC-074 · fingerprint 8327ec · see HIT ref KCC-073, https://www.hitsrl.it/technical-resources/guides/kalmar-contchamp/boom-and-spreader/#hit-contchamp-dc4160rs4-capacity