Kalmar Heavy Forklifts

DCG180-330
40,000 – 72,000 lbs capacity
A vital part of 4 good reasons to choose Kalmar

your logistics Productivity

Product quality, reliability
and maneuvering precision
Trust and reliability
Kalmar is a trusted partner,
present on all continents
allow operators to work and with more than 1,500
No chain is stronger than its weakest link, Your forklift is a vital part of your logistics or with maximum service and support staff
productivity. globally.
as the saying goes. Nothing could be more production. In seamless interaction with a
true when it comes to managing heavy or skilled operator, the forklift must meet your
bulky components between the key stages – and your customers’ – demands of
of the logistic value chain. On or off ships or product quality and delivery precision,
trains. Between the foundry and the factory. throughout your terminal, factory or
From assembly to transportation. assembly line. Total cost of ownership Ergonomics and safety
Cost-efficient to own and Excellent visibility, low noise
This is the domain of the heavy forklift truck. Looking at your forklifts in this light, the operate thanks to its adapt- level, user-friendly adjustments,
No other piece of machinery matches a choice of brand will come naturally. Only the ability, energy conversion and more, ensure excellent
and uptime. ergonomics and safety.
forklift’s combination of raw strength, best is good enough. Kalmar is equally
mobility and versatility. But it’s a tough job. renowned for its robust and reliable product
quality as for its global service network and
The sheer weight of thousands of tons lifted supreme customer support.
each day wears the mechanics and the
materials. Yet the forklift must perform Heavy forklift trucks are Kalmar territory
flawlessly every day of the week. Reliably, since 1949 – making your material handling
productively, safely. the strongest link in the logistic value chain. 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
Your Kalmar forklift will always deliver what oil flow accordingly, allowing up to 40%
your operations require. With Power mode faster lifting cycles while reducing fuel
activated, operators will have the power consumption. This will dramatically
necessary to go all-in at every instant and improve your produc­tivity – depending
work with maximum productivity. Pushing it on number of lift cycles.

for maximum
hard, while ensuring best-in-class fine-
maneuvering. Many operators testify to Kalmar forklifts’
improved operational capabilities,
Our Cummins and Volvo engines are pow- especially when fine maneuvering, such as
erful, yet highly fuel efficient. All engine side-shift and fork positioning. Also, the

productivity
alternatives are compliant with emission lowering speed has been increased, pre-
standard Tier 4 Final. paring the machine faster for the next lift.*

The variable pumps automatically sense

the load in every operation and adjust the

Drive modes
Choose 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.

Power Normal Economy

Brings out maximum Balances power and If total cost of operations
performance of your economy to optimize outweighs the need for
machine, allowing you to profitability. performance, Economy
increase the number of mode reduces fuel
tons moved per hour. consumption by up to
15%.

* DCG180-250, lift/lowering speed compared to DCF180-250.

Reducing Cost saving features

lifetime costs
Fuel-efficient engine Economy drive mode
The new Tier 4 Final compliant Using Economy drive mode, fuel
engines reduce fuel consumption consumption is reduced by up to
by up to 5%*. 15%*.

Purchase price is only one of many The pumps and the fan are only operated at
factors affecting total cost of ownership. full speed when necessary, reducing fuel
In fact, price is a minor cost factor consumption and noise. Another cost saving Energy efficient systems Increased uptime
looking over the lifetime of your forklift. feature is Economy mode, an engine setting Optimized variable hydraulic system Longer service intervals and
What truly matters in the long run is cost available to the operator from within the and variable cooling fan allows for improved problem detection reduce
control and operational efficiency – and cabin, which lowers fuel consumption even savings up to 10%*. downtime.
that will show clearly on your bottom more.
line.
Thanks to improved and more durable
Compared to our previous model, the components, service intervals have been
new DCG180-330 uses up to 15% less extended. The first service is due after 500 Total lifetime savings
fuel* in standard configuration. Add hours, compared to 50 hours for our Adding all energy saving features, savings up to 30%* are possible.
Kalmar’s renowned product quality and previous model.
reliability, increasing efficiency and
uptime, and you see the true value of The risk of unplanned standstills has been
Kalmar. reduced due to intelligent error detection
built into the new control system, which
The forklift’s variable pumps and fan are accurately pinpoints potential problems in
automatically adjusted to the precise need. clear text on a display in the cabin.

Operational savings

Lifetime savings
Maintenance savings

Purchase price represents only a small

Environmental savings part of the total cost of ownership.
What matters in the long run is reducing
Resale value operational and maintenance costs.
And that is what Kalmar is all about.
Purchase
price

* Compared to Kalmar DCF180-330 with Tier 3 / Tier 4 Final engine.

Prioritizing safety
and operator
ergonomics
Safety always comes first. Kalmar makes The wheel is tiltable sideways, allowing the
every effort to offer machines that are safe operator to temporarily change his visual
to operate at every worksite around the angle, to see around bulky load in front of
world. We spend extensive R&D resources him. A new 11.8” lower carriage, available
to ensure the driver’s environment in the with the DCG180–250 versions, further
cabin is optimal regarding ergonomics, improves visibility in the forward direction.
visibility and noise.
The operator console comfortably supports
Our EGO cabin offers the ultimate in the operator’s arm and is easy to
ergonomics. Numerous electronically understand, use and adjust. Designed for
operated adjustments allow the operator to maximum ergonomics and flexibility, the
customize his workplace. The curved console puts controls, switches and
windows, which greatly improve visibility, indicators within easy reach to the operator,
have already become a classic with Kalmar. ensuring the most efficient forklift operation
possible.
Keeping you
The DCG180 -330 is the fourth machine to down a problem also simplifies service and
be released from Kalmar’s G-generation. repairs, reducing downtime and putting you
Service engineers are familiar with the back in operation faster.
concept, allowing them to reuse skills and
knowledge thus simplifying service. The Besides forklifts, Kalmar offers reachstack-

operational at
new and intelligent control system ensures ers, terminal tractors, empty container han-
that operators are alerted as soon as some- dlers and other types of terminal equipment.
thing is wrong, or even risks becoming a Therefore, we have more people in the field
problem. This means that many faults can ready to provide fast assistance, whenever
be eliminated before they arise. you need it.

all times 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-
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
ational at all times, reducing the risk of positioned than most other forklift manufac-
unplanned downtime. Precisely narrowing turers to provide a truly global service.
 H5

H4
H3
T1
H6
H8 H2
a a
b b a

Dimensions L
L3 L2 L4
L1
S
T2

Model designation H5 H5
4
A1
4

DCG180-12LB H4 H4 b
H3 H3
Diesel engine H6 H6
T1 T1 V1 V B
H8 H8 H2 H2
Counterbalance truck
a a
Generation
R2
Lifting capacity, in decitonnes L3 L2 L4
L3 L2 L4 S S
R1

Load center, in decimetres L L L1 L1 T2 T2

Low built tilt cylinders

A1 A1 DCG180-12LB DCG200-12LB DCG220-12LB DCG250-12LB DCG280-12LB DCG300-12LB DCG330-12LB

Model designation 100 100 100 100 DCG180-12LB DCG200-12LB DCG220-12LB DCG250-12LB DCG280-12LB DCG300-12LB DCG330-12LB
Power source Diesel Diesel Diesel Diesel Diesel Diesel Diesel

MAIN DATA
Rated capacity / rated load lb b b 40,000 44,000 48,000 55,000 60,500 65,000 72,000
Load center distance V1 in L4
V B V1 V 48
B 48 48 48 48 48 48

Lifting capacity in pounds Load distance, center of drive axle to fork in L2 42 42 42 42 44 44 44

Wheelbase in L3 157 157 157 167 187 187 187

R2 R2
Service weight R1 R1 lb 62,800 65,700 68,800 72,500 84,400 87,100 91,500
80,000
Axle loading, loaded front lb
WEIGHTS

95,200 102,100 109,100 118,600 136,000 143,100 151,700

DCG330-12
Axle loading, loaded rear lb 7,300 7,700 8,200 9,000 9,000 9,500 10,600
70,000 Axle loading, unloaded front lb
DCG300-12 33,100 33,100 33,100 34,200 45,200 45,200 45,200
DCG280-12 Axle loading, unloaded rear lb 29,800 32,600 35,700 38,400 39,200 41,900 46,300
60,000
DCG250-12
Type, front / rear Pneumatic / Pneumatic
50,000 DCG220-12
Tire size, front in 14.00x24 14.00x24 14.00x24 14.00x24 16.00x25 16.00x25 16.00x25
DCG200-12
WHEELS

Tire size, rear in 14.00x24 14.00x24 14.00x24 14.00x24 16.00x25 16.00x25 16.00x25
DCG180-12
40,000 Number of wheels, front / rear (x = driven wheels)
Lifting capacity, in lbs

4x – 2 4x – 2 4x – 2 4x – 2 4x – 2 4x – 2 4x – 2
Track width, front / rear lb S 87 / 84 87 / 84 87 / 84 87 / 84 100 / 96 100 / 96 100 / 96
30,000 Tire pressure psi 145 145 145 145 145 145 145

20,000 Mast tilt, α = forward / β = backward ° α/β 5 / 10 5 / 10 5 / 10 5 / 10 5 / 10 5 / 10 5 / 10

Height of mast lowered in H3 170 170 170 170 178 178 178

24 36 48 56 64 72 80
Lift height in H4 197 197 197 197 197 197 197
Height of mast extended in H5 269 269 269 269 276 276 276
Load center, inch
Truck height – EGO / OHG cabin roof in H6 129 129 130 129 134 134 134
DCG180-250: Full lifting capacity up to 276 in lift height with Seat height in H8 85 85 85 85 91 91 91
duplex/duplex freelift masts, integrated sideshift/fork positioning Height when tilting EGO cab / OHG in T1 150 150 150 150 150 150 150
carriage and forkshaft system.
Width when tilting EGO cab / OHG in T2 146 146 146 146 150 150 150
DCG280-330: Full lifting capacity up to 276 in lift height with
Truck length (to face of forks) in L 240 240 240 250 273 273 273
duplex/duplex freelift masts, integrated sideshift/fork positioning
DIMENSIONS

carriage and forkshaft system. Truck width in B 120 120 120 120 135 135 135
Fork dimensions, width in b 9.8 9.8 9.8 9.8 11.8 11.8 11.8
Fork dimensions, thickness in a 4.3 4.3 4.3 4.3 4.3 4.3 4.3
Fork dimensions, length of fork arm in l 94.5 94.5 94.5 94.5 94.5 94.5 94.5
Fork carriage width in b3 - - - - - - -
Width over fork arms, maximum / minimum in V 106 / 31.5 106 / 31.5 106 / 31.5 106 / 31.5 124 / 61 124 / 61 124 / 61
Sideshift ± @ width over forks in V1 / V 22 – 62.4 22 – 62.4 22 – 62.4 22 – 62.4 16 – 92.5 16 – 92.5 16 – 92.5
Ground clearance, laden, below mast in - - - - - - -
Ground clearance, machine in 12 12 12 12 12 12 12
Min. ailse width for 90° stacking with forks in A1 365 365 365 376 406 406 406
Turning radius in R1 220 220 220 231 260 260 260
Internal turning radius in R2 17 17 17 22 37 37 37

Operating pressure for hydraulics psi 2,393 2,611 2,901 3,191 2,828 2,973 3,191
OTHERS

Hydraulic oil tank, capacity gal 87 87 87 87 87 87 87

Fuel tank, capacity gal 79 79 79 99 119 119 119
AdBlue tank, capacity gal 9 9 9 9 9 9 9
Drivetrain and performance
DCG180-250 DCG280-330 DCG180-250 DCG280-330
Manufacturer’s type designation Cummins B6.7 (Turbo-Intercooler) Cummins B6.7 (Turbo-Intercooler) Manufacturer’s type designation Volvo TAD 871VE (Turbo-Intercooler) Volvo TAD 871VE (Turbo-Intercooler)
Fuel, type of engine Diesel, 4-stroke Diesel, 4-stroke Fuel, type of engine Diesel, 4-stroke Diesel, 4-stroke
Rating ISO 3046 / at revs hp-rpm 225 / 2200 225 / 2200 Rating ISO 3046 / at revs hp-rpm 248 / 2200 248 / 2200
ENGINE

ENGINE
Peak torque ISO 3046 / at revs lbf-rpm 700 / 1500 700 / 1500 Peak torque ISO 3046 / at revs lbf-rpm 855 / 1200 855 / 1200
Number of cylinders / displacement in³ 6 / 409 6 / 409 Number of cylinders / displacement in³ 6 / 470 6 / 470
Fuel consumption, normal driving gal/h 2.4-2.9 3.4-4.0 Fuel consumption, normal driving gal/h 2.1-2.9 3.2-3.7
AdBlue consumption, normal driving % of diesel 3-5 3-5 AdBlue consumption, normal driving % of diesel 3-5 3-5
Emission standard Tier 4 Final Tier 4 Final Emission standard Tier 4 final Tier 4 final

Manufacturer’s type designation Dana TE17000 Dana TE17000 Manufacturer’s type designation Dana TE17000 Dana TE17000
GEARBOX & MISC

GEARBOX & MISC

Clutch, type Torque converter Torque converter Clutch, type Torque converter Torque converter
Gearbox, type Hydrodynamic Powershift Hydrodynamic Powershift Gearbox, type Hydrodynamic Powershift Hydrodynamic Powershift
Numbers of gears, forward / reverse 3/3 3/3 Numbers of gears, forward / reverse 3/3 3/3
Alternator, type / power Amp AC / 28 AC / 28 Alternator, type / power Amp AC / 44 AC / 44
Starting battery, voltage / capacity V / Ah 2×12 / 145 2×12 / 145 Starting battery, voltage / capacity V / Ah 2×12 / 145 2×12 / 145
Driving axle, manufacturer / type Kessler D91 / Differential and hub reduction AxleTech / Differential and hub reduction Driving axle, manufacturer / type Kessler D91 / Differential and hub reduction AxleTech / Differential and hub reduction

DCG DCG DCG DCG DCG DCG DCG DCG DCG DCG DCG DCG DCG DCG
180-12LB 200-12LB 220-12LB 250-12LB 280-12LB 300-12LB 330-12LB 180-12LB 200-12LB 220-12LB 250-12LB 280-12LB 300-12LB 330-12LB
Lifting speed Unloaded (ft/s) 1.10 1.10 1.10 1.10 1.15 1.15 1.15 Lifting speed Unloaded (ft/s) 1.10 1.10 1.10 1.10 1.10 1.10 1.10
At rated load (ft/s) 1.05 1.05 1.05 1.05 1.10 1.10 1.10 At rated load (ft/s) 1.10 1.10 1.10 1.10 1.10 1.10 1.10
Lowering speed Unloaded (ft/s) 1.25 1.25 1.25 1.25 1.25 1.25 1.25 Lowering speed Unloaded (ft/s) 1.25 1.25 1.25 1.25 1.25 1.25 1.25
PERFORMANCE, CUMMINS QSB6.7

PERFORMANCE, VOLVO TAD 871VE

At rated load (ft/s) 1.25 1.25 1.25 1.25 1.25 1.25 1.25 At rated load (ft/s) 1.25 1.25 1.25 1.25 1.25 1.25 1.25
Traveling speed, F / R Unloaded (mph) 17 / 17 17 / 17 17 / 17 17 / 17 17 / 17 17 / 17 17 / 17 Traveling speed, F / R Unloaded (mph) 15 / 15 15 / 15 15 / 15 15 / 15 15 / 15 15 / 15 15 / 15
At rated load (mph) 16 / 16 16 / 16 16 / 16 16 / 16 15.5 / 15.5 15.5 / 15.5 15.5 / 15.5 At rated load (mph) 14 / 14 14 / 14 14 / 14 14 / 14 14 / 14 14 / 14 14 / 14
Gradeability, max. Unloaded (%) 74 69 65 60 67 64 60 Gradeability, max. Unloaded (%) 74 69 65 60 65 62 58
At rated load (%) 38 35 32 29 33 31 29 At rated load (%) 38 35 32 29 32 30 28
Gradeability, at 1.2 mph Unloaded (%) 51 48 44 41 48 46 43 Gradeability, at 1.2 mph Unloaded (%) 51 48 44 41 43 41 39
At rated load (%) 28 26 24 22 24 23 21 At rated load (%) 28 26 14 22 14 22 21
Drawbar pull Max. (lbf) 38,900 38,900 38,900 38,900 49,000 49,000 49,000 Drawbar pull Max. (lbf) 38,900 38,900 38,900 38,900 47,900 47,900 47,900
Noise level, inside LpAZ*, EGO cabin (dB(A)) 72 72 72 72 73 73 73 Noise level, inside LpAZ*, EGO cabin (dB(A)) 72 72 72 72 73 73 73
LpAZ*, EGO cabin OHG (dB(A)) - - - - - - - LpAZ*, EGO cabin OHG (dB(A)) - - - - - - -
Noise level, outside LWA** (dB(A)) 109 109 109 109 110 110 110 Noise level, outside LWA** (dB(A)) 109 109 109 109 110 110 110

* Noise level according to EN12053 ** Noise level according to 2000/14/EC * Noise level according to EN12053 ** Noise level according to 2000/14/EC
Lifting equipment
We 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.

Mast height Free lift Mast height Free lift

Lift height H4 H3 min H5 max H2 H3 min H5 max H2
DCG180-250 DCG280-330 Carriage sideshift / fork Carriage with kissing forks Fork shaft system Coil ram
138 – positioning for steel handling (Quick change system)
157 150 229 – 158 237 –
DUPLEX STD

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 –

Mast height Free lift Mast height Free lift

Lift height H2 H2
H3 min H5 max H3 min H5 max
H4
DCG180-250 DCG280-330
138
157 154 233 79 158 237 79
DUPLEX FFL

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

Mast height Free lift Mast height Free lift

Lift height H2 H2
H3 min H5 max H3 min H5 max
H4
DCG180-250 DCG280-330
203 146 274 75 Duplex standard Duplex free lift Triplex full free lift
TRI.

232 166 321 82

Standard equipment
Chassis/Body
• Towing pin. Steering system
• Steps with anti slip protection. • Kalmar steer axle, including double acting
• Rear view mirror left and right side mounted on steering cylinder.
front mudguards.
• Strong and protective mudguards. Drivetrain
• Drive axle DCG180-250: Kessler.
Cabin DCG280-330: Axletech.
• EGO Cabin.
• Clear and tempered panes of safety glass, Hydraulics
thickness 1/4”. • Electrical servo.
• Standard seat with high visibility 2-point • Level sight glass on hydraulic oil tank.
orange belt. • Variable pumps.
• Clear windows incl. sliding windows in left and • High pressure filter.
right doors. • Automatic raised engine rpm when load
• Complete doors with locks left and right side. handling function is used.
• Right hand console system with light controls, • Standard tilt angles 5°F / 10°B.
toggle wheel for display, levers for load handling
system (electric adjustable, 2-way´s). Electric system
• Left-side multi-function lever with horn and turn • Electrical system 24V.
signals. • LED rear lights and brake lights.
• Brake system with dual pedals • LED work lights on front fenders.
(left and right side). • LED work lights on front mast.
• Internal comfort with mirror, handles, interior • LED indicator lamps and hazard lights.
lighting etc. • Main power switch.
• Wiper and washers front/rear and roof window.
• Hydraulic steering system with electrically Wheels
adjustable steering wheel height, manually • DCG180-250 14.00x24.
adjustable laterally and longitudinally with • DCG280-330 16.00x25.
steering wheel knob.
• External reverse lights. Color
• Tilting cab with manual pump. • Cab: frame RAL 7011/70,
• Instep handle, left side. covers RAL 7021/10.
• Automatic heat and ventilation (Electronic • Chassis: Kalmar Red 2012
Climate Control) with fresh air inlet filter. (Base ref. RAL 3000/75).
• Speed control pedal right side. • Lifting equipment: Kalmar Black
• Kalmar standard key system. (Base ref. RAL 7021/30).
• Cup holder.
• Coat hook. Documentation & decals
• Color display: • Operators manual.
- Fuel level indicator. • Maintenance manual.
- Engine / transmission temperature. • Parts catalog.
- Engine oil pressure. • Capacity diagram in cab.
- Battery voltage. • Warning decals.
- Clock and date. • Information decals.
- Hour meter. • Electrical fuse diagram.
- Service time indicator. • Noise plate.
- Speed.
- Engine speed (RPM).
- Various information via pop-up.
- AdBlue indicator.
 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
SB-LTG33-EN-US / 2017.11.01_1

Kalmar USA Inc.

415 E. Dundee St.
Ottawa, KS 66067
tel. 785-242-2200
fax 785-242-8573
www.kalmarusa.com