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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