kalmar heavy forklifts dcg180-330...forklift’s combination of raw strength, mobility and...
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Kalmar Heavy Forklifts DCG180-33040,000 – 72,000 lbs capacity
A vital part of your logistics No chain is stronger than its weakest link, as the saying goes. Nothing could be more true when it comes to managing heavy or bulky components between the key stages of the logistic value chain. On or off ships or trains. Between the foundry and the factory. From assembly to transportation.
This is the domain of the heavy forklift truck. No other piece of machinery matches a forklift’s combination of raw strength, mobility and versatility. But it’s a tough job.
The sheer weight of thousands of tons lifted each day wears the mechanics and the materials. Yet the forklift must perform flawlessly every day of the week. Reliably, productively, safely.
Your forklift is a vital part of your logistics or production. In seamless interaction with a skilled operator, the forklift must meet your – and your customers’ – demands of product quality and delivery precision, throughout your terminal, factory or assembly line.
Looking at your forklifts in this light, the choice of brand will come naturally. Only the best is good enough. Kalmar is equally renowned for its robust and reliable product quality as for its global service network and supreme customer support.
Heavy forklift trucks are Kalmar territory since 1949 – making your material handling the strongest link in the logistic value chain.
Productivity
Product quality, reliability and maneuvering precision
allow operators to work with maximum
productivity.
Ergonomics and safety
Excellent visibility, low noise level, user-friendly adjustments,
and more, ensure excellent ergonomics and safety.
Trust and reliability
Kalmar is a trusted partner, present on all continents
and with more than 1,500 service and support staff
globally.
Total cost of ownership
Cost-efficient to own and operate thanks to its adapt-
ability, energy conversion and uptime.
4 good reasons to choose Kalmar
It is no surprise that customer survey results coincide with Kalmar core values. After all, we listen attentively to customers when designing and developing our forklifts. Looking at the big picture, adding up things that truly matter, it will always pay off to choose Kalmar.
Designed for maximum productivity
Your Kalmar forklift will always deliver what your operations require. With Power mode activated, operators will have the power necessary to go all-in at every instant and work with maximum productivity. Pushing it hard, while ensuring best-in-class fine- maneuvering.
Our Cummins and Volvo engines are pow-erful, yet highly fuel efficient. All engine alternatives are compliant with emission standard Tier 4 Final. The variable pumps automatically sense the load in every operation and adjust the
oil flow accordingly, allowing up to 40% faster lifting cycles while reducing fuel consumption. This will dramatically improve your produc tivity – depending on number of lift cycles.
Many operators testify to Kalmar forklifts’ improved operational capabilities, especially when fine maneuvering, such as side-shift and fork positioning. Also, the lowering speed has been increased, pre-paring the machine faster for the next lift.*
PowerBrings out maximum performance of your machine, allowing you to increase the number of tons moved per hour.
EconomyIf total cost of operations outweighs the need for performance, Economy mode reduces fuel consumption by up to 15%.
NormalBalances power and economy to optimize profitability.
Drive modesChoose between three different drive modes, each optimized to meet your operational requirements. The forklift can be adapted to every task at hand, shifting many times during the day. The operator easily shifts between modes by using the cabin display screen.
* DCG180-250, lift/lowering speed compared to DCF180-250.
Operational savings
Maintenance savings
Environmental savings
Resale value
Purchaseprice
Reducing lifetime costsPurchase price is only one of many factors affecting total cost of ownership. In fact, price is a minor cost factor looking over the lifetime of your forklift. What truly matters in the long run is cost control and operational efficiency – and that will show clearly on your bottom line.
Compared to our previous model, the new DCG180-330 uses up to 15% less fuel* in standard configuration. Add Kalmar’s renowned product quality and reliability, increasing efficiency and uptime, and you see the true value of Kalmar.
The forklift’s variable pumps and fan are automatically adjusted to the precise need.
The pumps and the fan are only operated at full speed when necessary, reducing fuel consumption and noise. Another cost saving feature is Economy mode, an engine setting available to the operator from within the cabin, which lowers fuel consumption even more.
Thanks to improved and more durable components, service intervals have been extended. The first service is due after 500 hours, compared to 50 hours for our previous model.
The risk of unplanned standstills has been reduced due to intelligent error detection built into the new control system, which accurately pinpoints potential problems in clear text on a display in the cabin.
Lifetime savingsPurchase price represents only a small part of the total cost of ownership. What matters in the long run is reducing operational and maintenance costs. And that is what Kalmar is all about.
* Compared to Kalmar DCF180-330 with Tier 3 / Tier 4 Final engine.
Cost saving features
Fuel-efficient engineThe new Tier 4 Final compliant engines reduce fuel consumption by up to 5%*.
Energy efficient systemsOptimized variable hydraulic system and variable cooling fan allows for savings up to 10%*.
Total lifetime savingsAdding all energy saving features, savings up to 30%* are possible.
Economy drive modeUsing Economy drive mode, fuel consumption is reduced by up to 15%*.
Increased uptimeLonger service intervals and improved problem detection reduce downtime.
Prioritizing safety and operator ergonomicsSafety always comes first. Kalmar makes every effort to offer machines that are safe to operate at every worksite around the world. We spend extensive R&D resources to ensure the driver’s environment in the cabin is optimal regarding ergonomics, visibility and noise.
Our EGO cabin offers the ultimate in ergonomics. Numerous electronically operated adjustments allow the operator to customize his workplace. The curved windows, which greatly improve visibility, have already become a classic with Kalmar.
The wheel is tiltable sideways, allowing the operator to temporarily change his visual angle, to see around bulky load in front of him. A new 11.8” lower carriage, available with the DCG180–250 versions, further improves visibility in the forward direction.
The operator console comfortably supports the operator’s arm and is easy to understand, use and adjust. Designed for maximum ergonomics and flexibility, the console puts controls, switches and indicators within easy reach to the operator, ensuring the most efficient forklift operation possible.
Keeping you operational at all times
The DCG180 -330 is the fourth machine to be released from Kalmar’s G-generation. Service engineers are familiar with the concept, allowing them to reuse skills and knowledge thus simplifying service. The new and intelligent control system ensures that operators are alerted as soon as some-thing is wrong, or even risks becoming a problem. This means that many faults can be eliminated before they arise. Supporting you also means simplifying the use of our products – in terms of servicea-bility, service accessibility and error preven-tion. Our main concern is to keep you oper-ational at all times, reducing the risk of unplanned downtime. Precisely narrowing
down a problem also simplifies service and repairs, reducing downtime and putting you back in operation faster. Besides forklifts, Kalmar offers reachstack-ers, terminal tractors, empty container han-dlers and other types of terminal equipment. Therefore, we have more people in the field ready to provide fast assistance, whenever you need it. Kalmar offers extensive service and support packages, available to you wherever your operation may be located. As part of a world-wide industrial group, Kalmar is better positioned than most other forklift manufac-turers to provide a truly global service.
80,000
50,000
70,000
40,000
60,000
30,000
20,000
24 36 48 56 64 72 80
DCG200-12
DCG220-12
DCG300-12
DCG280-12
DCG330-12
DCG180-12
DCG250-12
H6
H8 H2
H3H4
H5
L3L
L2 L4L1
a
ba
T1
ST2
A1100 100
V1 V B
b
R1R2
H6
H8 H2
H3H4
H5
L3L
L2 L4L1
a
ba
T1
ST2
A1100 100
V1 V B
b
R1R2
H6
H8 H2
H3H4
H5
L3L
L2 L4L1
a
βα
T1
ST2
A14 4
V1 V B
b
R1R2
Dimensions
Model designation
Diesel engine Counterbalance truck GenerationLifting capacity, in decitonnes Load center, in decimetres Low built tilt cylinders
DCG180-12LB
Lifting capacity in pounds
DCG180-12LB DCG200-12LB DCG220-12LB DCG250-12LB DCG280-12LB DCG300-12LB DCG330-12LB
MA
IN D
ATA
Model designation DCG180-12LB DCG200-12LB DCG220-12LB DCG250-12LB DCG280-12LB DCG300-12LB DCG330-12LB
Power source Diesel Diesel Diesel Diesel Diesel Diesel Diesel
Rated capacity / rated load lb
Load center distance in L4
Load distance, center of drive axle to fork in L2
Wheelbase in L3W
EIG
HTS
Service weight lb
Axle loading, loaded front lb
Axle loading, loaded rear lb
Axle loading, unloaded front lb
Axle loading, unloaded rear lb
WH
EE
LS
Type, front / rear Pneumatic / Pneumatic
Tire size, front in
Tire size, rear in
Number of wheels, front / rear (x = driven wheels)
Track width, front / rear lb S
Tire pressure psi
DIM
EN
SIO
NS
° α / β
in H3
in H4
in H5
in H6
in H8
in T1
in T2
in L
in B
in b
in a
in l
in b3
in V
in V1 / V
in
in
in A1
in R1
Mast tilt, α = forward / β = backward
Height of mast lowered
Lift height
Height of mast extended
Truck height – EGO / OHG cabin roof
Seat height
Height when tilting EGO cab / OHG
Width when tilting EGO cab / OHG
Truck length (to face of forks)
Truck width
Fork dimensions, width
Fork dimensions, thickness
Fork dimensions, length of fork arm
Fork carriage width
Width over fork arms, maximum / minimum
Sideshift ± @ width over forks
Ground clearance, laden, below mast
Ground clearance, machine
Min. ailse width for 90° stacking with forks
Turning radius
Internal turning radius in R2
OTH
ER
S
Operating pressure for hydraulics psi
Hydraulic oil tank, capacity gal
Fuel tank, capacity gal
AdBlue tank, capacity gal
Lift
ing
cap
acity
, in
lbs
Load center, inch
DCG180-250: Full lifting capacity up to 276 in lift height with duplex/duplex freelift masts, integrated sideshift/fork positioning carriage and forkshaft system.
DCG280-330: Full lifting capacity up to 276 in lift height with duplex/duplex freelift masts, integrated sideshift/fork positioning carriage and forkshaft system.
40,000 44,000 48,000 55,000 60,500 65,000 72,000
48 48 48 48 48 48 48
42 42 42 42 44 44 44
157 157 157 167 187 187 187
62,800 65,700 68,800 72,500 84,400 87,100 91,500
33,100 33,100 33,100 34,200 45,200 45,200 45,200
95,200 102,100 109,100 118,600 136,000 143,100 151,700
29,800 32,600 35,700 38,400 39,200 41,900 46,300
7,300 7,700 8,200 9,000 9,000 9,500 10,600
14.00x24 14.00x24 14.00x24 14.00x24 16.00x25 16.00x25 16.00x25
14.00x24 14.00x24 14.00x24 14.00x24 16.00x25 16.00x25 16.00x25
4x – 2 4x – 2 4x – 2 4x – 2 4x – 2 4x – 2 4x – 2
87 / 84 87 / 84 87 / 84 87 / 84 100 / 96 100 / 96 100 / 96
145 145 145 145 145 145 145
5 / 10 5 / 10 5 / 10 5 / 10 5 / 10 5 / 10 5 / 10
170 170 170 170 178 178 178
197 197 197 197 197 197 197
269 269 269 269 276 276 276
129 129 130 129 134 134 134
85 85 85 85 91 91 91
150 150 150 150 150 150 150
146 146 146 146 150 150 150
240 240 240 250 273 273 273
120 120 120 120 135 135 135
9.8 9.8 9.8 9.8 11.8 11.8 11.8
4.3 4.3 4.3 4.3 4.3 4.3 4.3
94.5 94.5 94.5 94.5 94.5 94.5 94.5
- - - - - - -
106 / 31.5 106 / 31.5 106 / 31.5 106 / 31.5 124 / 61 124 / 61 124 / 61
22 – 62.4 22 – 62.4 22 – 62.4 22 – 62.4 16 – 92.5 16 – 92.5 16 – 92.5
- - - - - - -
12 12 12 12 12 12 12
365 365 365 376 406 406 406
220 220 220 231 260 260 260
17 17 17 22 37 37 37
2,393 2,611 2,901 3,191 2,828 2,973 3,191
87 87 87 87 87 87 87
79 79 79 99 119 119 119
9 9 9 9 9 9 9
EN
GIN
E
Manufacturer’s type designation
Fuel, type of engine
Rating ISO 3046 / at revs hp-rpm
Peak torque ISO 3046 / at revs lbf-rpm
Number of cylinders / displacement in³
Fuel consumption, normal driving gal/h
AdBlue consumption, normal driving % of diesel
Emission standard
DCG180-250
Cummins B6.7 (Turbo-Intercooler)
Diesel, 4-stroke
225 / 2200
700 / 1500
6 / 409
2.4-2.9
3-5
Tier 4 Final
DCG280-330
Cummins B6.7 (Turbo-Intercooler)
Diesel, 4-stroke
225 / 2200
700 / 1500
6 / 409
3.4-4.0
3-5
Tier 4 Final
GE
AR
BO
X &
MIS
C
Manufacturer’s type designation Dana TE17000 Dana TE17000
Clutch, type Torque converter Torque converter
Gearbox, type Hydrodynamic Powershift Hydrodynamic Powershift
Numbers of gears, forward / reverse
Alternator, type / power Amp
Starting battery, voltage / capacity V / Ah
Driving axle, manufacturer / type Kessler D91 / Differential and hub reduction AxleTech / Differential and hub reduction
DCG 180-12LB
DCG 200-12LB
DCG 220-12LB
DCG 250-12LB
DCG 280-12LB
DCG 300-12LB
DCG 330-12LB
PE
RFO
RM
AN
CE
, CU
MM
INS
QS
B6.
7
Lifting speed Unloaded (ft/s)
At rated load (ft/s)
Lowering speed Unloaded (ft/s)
At rated load (ft/s)
Traveling speed, F / R Unloaded (mph)
At rated load (mph)
Gradeability, max. Unloaded (%)
At rated load (%)
Gradeability, at 1.2 mph Unloaded (%)
At rated load (%)
Drawbar pull Max. (lbf)
Noise level, inside LpAZ*, EGO cabin (dB(A))
LpAZ*, EGO cabin OHG (dB(A))
Noise level, outside LWA** (dB(A))
* Noise level according to EN12053 ** Noise level according to 2000/14/EC
DCG180-250 DCG280-330
EN
GIN
E
Manufacturer’s type designation Volvo TAD 871VE (Turbo-Intercooler) Volvo TAD 871VE (Turbo-Intercooler)
Fuel, type of engine Diesel, 4-stroke Diesel, 4-stroke
Rating ISO 3046 / at revs hp-rpm
Peak torque ISO 3046 / at revs lbf-rpm
Number of cylinders / displacement in³
Fuel consumption, normal driving gal/h
AdBlue consumption, normal driving % of diesel
Emission standard Tier 4 final Tier 4 final
GE
AR
BO
X &
MIS
C
Manufacturer’s type designation Dana TE17000 Dana TE17000
Clutch, type Torque converter Torque converter
Gearbox, type Hydrodynamic Powershift Hydrodynamic Powershift
Numbers of gears, forward / reverse
Alternator, type / power Amp
Starting battery, voltage / capacity V / Ah
Driving axle, manufacturer / type Kessler D91 / Differential and hub reduction AxleTech / Differential and hub reduction
DCG 180-12LB
DCG 200-12LB
DCG 220-12LB
DCG 250-12LB
DCG 280-12LB
DCG 300-12LB
DCG 330-12LB
PE
RFO
RM
AN
CE
, VO
LVO
TA
D 8
71V
E
Lifting speed Unloaded (ft/s)
At rated load (ft/s)
Lowering speed Unloaded (ft/s)
At rated load (ft/s)
Traveling speed, F / R Unloaded (mph)
At rated load (mph)
Gradeability, max. Unloaded (%)
At rated load (%)
Gradeability, at 1.2 mph Unloaded (%)
At rated load (%)
Drawbar pull Max. (lbf)
Noise level, inside LpAZ*, EGO cabin (dB(A))
LpAZ*, EGO cabin OHG (dB(A))
Noise level, outside LWA** (dB(A))
* Noise level according to EN12053 ** Noise level according to 2000/14/EC
Drivetrain and performance
3 / 3 3 / 3
AC / 28 AC / 28
2×12 / 145 2×12 / 145
1.10 1.10 1.10 1.10 1.15 1.15 1.15
1.05 1.05 1.05 1.05 1.10 1.10 1.10
1.25 1.25 1.25 1.25 1.25 1.25 1.25
1.25 1.25 1.25 1.25 1.25 1.25 1.25
17 / 17 17 / 17 17 / 17 17 / 17 17 / 17 17 / 17 17 / 17
16 / 16 16 / 16 16 / 16 16 / 16 15.5 / 15.5 15.5 / 15.5 15.5 / 15.5
74 69 65 60 67 64 60
38 35 32 29 33 31 29
51 48 44 41 48 46 43
28 26 24 22 24 23 21
38,900 38,900 38,900 38,900 49,000 49,000 49,000
72 72 72 72 73 73 73
- - - - - - -
109 109 109 109 110 110 110
248 / 2200 248 / 2200
855 / 1200 855 / 1200
6 / 470 6 / 470
2.1-2.9 3.2-3.7
3-5 3-5
3 / 3 3 / 3
AC / 44 AC / 44
2×12 / 145 2×12 / 145
1.10 1.10 1.10 1.10 1.10 1.10 1.10
1.10 1.10 1.10 1.10 1.10 1.10 1.10
1.25 1.25 1.25 1.25 1.25 1.25 1.25
1.25 1.25 1.25 1.25 1.25 1.25 1.25
15 / 15 15 / 15 15 / 15 15 / 15 15 / 15 15 / 15 15 / 15
14 / 14 14 / 14 14 / 14 14 / 14 14 / 14 14 / 14 14 / 14
74 69 65 60 65 62 58
38 35 32 29 32 30 28
51 48 44 41 43 41 39
28 26 14 22 14 22 21
38,900 38,900 38,900 38,900 47,900 47,900 47,900
72 72 72 72 73 73 73
- - - - - - -
109 109 109 109 110 110 110
Lifting equipmentWe offer a full range of duplex, triplex and free-lift mast types. Based on our long tradition as a supplier of heavy forklifts, our lifting equipment is robust and of the highest quality.
Duplex standard Duplex free lift Triplex full free lift
Fork shaft system (Quick change system)
Coil ramCarriage sideshift / fork positioning
Carriage with kissing forks for steel handling
Lift height H4
Mast height Free lift H2
Mast height Free lift H2H3 min H5 max H3 min H5 max
DCG180-250 DCG280-330
DU
PLE
X S
TD
Lift height H4
Mast height Free lift H2
Mast height Free lift H2H3 min H5 max H3 min H5 max
DCG180-250 DCG280-330
DU
PLE
X F
FL
Lift height H4
Mast height Free lift H2
Mast height Free lift H2H3 min H5 max H3 min H5 max
DCG180-250 DCG280-330
TR
I.
138 –
157 150 229 – 158 237 –
177 160 249 – 168 257 –
197 170 269 – 178 276 –
217 180 288 – 188 296 –
236 190 308 – 198 316 –
256 200 328 – 207 335 –
276 209 347 – 217 355 –
138
157 154 233 79 158 237 79
177 164 253 89 168 257 89
197 174 272 98 178 276 98
217 184 292 108 188 296 108
236 198 316 118
203 146 274 75
232 166 321 82
Chassis/Body• Towing pin.• Steps with anti slip protection.• Rear view mirror left and right side mounted on
front mudguards.• Strong and protective mudguards.
Cabin• EGO Cabin.• Clear and tempered panes of safety glass,
thickness 1/4”.• Standard seat with high visibility 2-point
orange belt.• Clear windows incl. sliding windows in left and
right doors.• Complete doors with locks left and right side.• Right hand console system with light controls,
toggle wheel for display, levers for load handlingsystem (electric adjustable, 2-way´s).
• Left-side multi-function lever with horn and turnsignals.
• Brake system with dual pedals(left and right side).
• Internal comfort with mirror, handles, interiorlighting etc.
• Wiper and washers front/rear and roof window.• Hydraulic steering system with electrically
adjustable steering wheel height, manuallyadjustable laterally and longitudinally withsteering wheel knob.
• External reverse lights.• Tilting cab with manual pump.• Instep handle, left side.• Automatic heat and ventilation (Electronic
Climate Control) with fresh air inlet filter.• Speed control pedal right side.• Kalmar standard key system.• Cup holder.• Coat hook.• Color display:
- Fuel level indicator.- Engine / transmission temperature.- Engine oil pressure.- Battery voltage.- Clock and date.- Hour meter.- Service time indicator.- Speed.- Engine speed (RPM).- Various information via pop-up.- AdBlue indicator.
Steering system• Kalmar steer axle, including double acting
steering cylinder.
Drivetrain• Drive axle DCG180-250: Kessler.
DCG280-330: Axletech.
Hydraulics• Electrical servo.• Level sight glass on hydraulic oil tank.• Variable pumps.• High pressure filter.• Automatic raised engine rpm when load
handling function is used.• Standard tilt angles 5°F / 10°B.
Electric system• Electrical system 24V.• LED rear lights and brake lights.• LED work lights on front fenders.• LED work lights on front mast.• LED indicator lamps and hazard lights.• Main power switch.
Wheels• DCG180-250 14.00x24.• DCG280-330 16.00x25.
Color• Cab: frame RAL 7011/70,
covers RAL 7021/10.• Chassis: Kalmar Red 2012
(Base ref. RAL 3000/75).• Lifting equipment: Kalmar Black
(Base ref. RAL 7021/30).
Documentation & decals• Operators manual.• Maintenance manual.• Parts catalog.• Capacity diagram in cab.• Warning decals.• Information decals.• Electrical fuse diagram.• Noise plate.
Standard equipment
MAKING YOUR EVERY MOVE COUNT
Kalmar offers the widest range of cargo handling solutions and services to ports, terminals, distribution centres and to heavy industry. Kalmar is the industry forerunner in terminal automation and in energy efficient container handling, with one in four container movements around the globe being handled by a Kalmar solution. Through its extensive product portfolio, global service network and ability to enable a seamless integration of different terminal processes, Kalmar improves the efficiency of every move. www.kalmarglobal.com
Kalmar USA Inc.415 E. Dundee St.Ottawa, KS 66067tel. 785-242-2200fax 785-242-8573www.kalmarusa.com S
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