Kalmar Heavy Forklifts.

DCG180-330
18 – 33 tonne 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. No other Looking at your forklifts in this light, the choice of
piece of machinery matches a forklift’s combination brand will come naturally. Only the best is good
of raw strength, mobility and versatility. But it’s a enough. Kalmar is equally renowned for its robust
tough job. and reliable product quality as for its global service
network and supreme customer support.
The sheer weight of thousands of tonnes lifted each
day wears the mechanics and the materials. Yet the Heavy forklifts are Kalmar territory since 1949 –
forklift must perform flawlessly every day of the making your material handling the strongest link in
week. Reliably, productively, safely. the logistic value chain.

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
customer’s – demands of product quality and
delivery precision, throughout your terminal, factory
or assembly line.
4 good reasons to choose Kalmar

Productivity Trust and reliability

Product quality, reliability Kalmar is a trusted partner,
and manoeuvring precision present on all continents
allow operators to work and with more than 1,500
with maximum productivity. service and support staff
globally.

Total cost of ownership Ergonomics and safety

Cost-efficient to own and Excellent visibility, low noise
operate thanks to its level, user-friendly adjustments,
adaptability, energy and more, ensure excellent
conversion and uptime. ergonomics and safety.

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-manoeuvring.

Our Cummins and Volvo engines are powerful, Many operators testify to the forklift’s improved
yet highly fuel efficient. All engine alternatives are operational capabilities, especially when fine
compliant with emission standard Stage IV/Tier 4 Final. manoeuvring, such as side-shift and fork
positioning. Also, the lowering speed has been
The variable pumps automatically sense the load in increased, preparing the machine faster for the
every operation and adjust the oil flow accordingly, next lift.
allowing for faster lifting cycles up to 40% while
reducing fuel consumption. This will help to improve
your productivity as you can do more lifts per hour.

Drive modes.
Choose between three different drive modes, each optimised 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 If total cost of operations
performance of your and economy to outweighs the need for
machine, allowing you to optimise performance, Economy
increase the number of profitability. mode reduces fuel
tonnes moved per hour. consumption by up to 15%.

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

Reducing
lifetime costs.
Purchase 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 Thanks to improved and more durable components,
uses up to 15% less fuel* in standard configuration. service intervals have been extended. The first service
Add Kalmar’s renowned product quality and reliability, is due after 500 hours, compared to 50 hours for our
increasing efficiency and uptime, and you see the true previous model.
value of Kalmar.
The risk of unplanned standstills has been reduced due
The forklift’s variable pumps and fan are automatically to intelligent error detection built into the new control
adjusted to the precise need. The pumps and the fan system, which accurately pinpoints potential problems
are only operated at full speed when necessary, in clear text on a display in the cabin.
reducing fuel consumption and noise. Another cost
saving feature is Economy mode, an engine setting
available to the operator from within
the cabin, which further lowers
fuel consumption.
Cost saving features.
Fuel-efficient engine.
The new Stage IV/Tier 4 Final compliant engines
reduce fuel consumption by up to 5%*.

Economy drive mode.

Using Economy drive mode, fuel consumption
is reduced by up to 15%.

Energy efficient systems.

Optimised variable hydraulic system and variable
cooling fan allows for savings up to 10%.

Increased uptime.
Longer service intervals and improved problem
detection reduce downtime.

Total lifetime savings.

Adding all energy saving features, savings
up to 30% are possible.

* Compared to Kalmar DCF180-330 with Stage IIIB engine.

Operational savings

Maintenance savings
Lifetime savings
Environmental savings Purchase price represents only a small
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
Prioritising safety
and operator
ergonomics.
Safety always comes first. Kalmar makes every effort to guarantee that
our machines 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.

First introduced in 2011, our EGO cabin offers The wheel is tiltable sideways, allowing the
the ultimate in ergonomics and safety. operator to temporarily change his visual angle,
Numerous electronically operated adjustments to see around bulky load in front of him. A new
allow the operator to tailor his workplace. The 300 mm lower carriage, available with the
curved windows, which greatly improve visibility, DCG180–250 versions, further improves visibility
have already become a classic with Kalmar. in the forward direction.

The operator console is the operator’s extended

arm, 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.
Kalmar Lifetime
Services.
Kalmar Care, making sure Optimise your fleet
your business never stops. with Kalmar Insight.
We offer four different types of service and maintenance Kalmar Insight is a performance management tool for cargo
contracts. Each is designed to help you improve your and material handling, which gives you a valuable and easy
operational efficiency, drive productivity and secure to use overview of your daily operations based on equipment
financial predictability. Each contract type includes a status and performance. Making it quicker for you to take
set of standardized service modules to meet your action on relevant information that will help you improve your
business needs. operations, your equipment’s performance and your business.

Kalmar Insight comes fitted in all new Kalmar machines and

When the right part matters. can be retrofitted to existing Kalmar machines or those built by
other manufacturers.
When something needs to be replaced you need a quality
part that meets your exact needs – urgently. Kalmar
Genuine Parts offers a rapid delivery service for over
50,000 premium-quality genuine parts to anywhere in
the world, with installation support if needed.

24 hrs
Most of our parts can be
delivered to you within 24 hours.
Kalmar Insight: view each machine’s movements as they occur.
 All the support
you need.
Financing options for you.
You may choose to buy your new forklift outright or
consider leasing or renting your equipment. Kalmar
offers a range of leasing and renting options that
give you the financial predictability you need and the
option to upgrade your equipment after a fixed period.
With our leasing packages, you can focus on your
core operations, while we perform all your service
and maintenance needs. Kalmar can also look at you
trading-in your old equipment.

Kalmar Training Academy.

For your team to get the most out of their new
forklift the Kalmar Training Academy offers a range
of courses for both your technicians and operators.
Operators will be shown how to optimise their day-
to-day operational performance and what needs to
be checked daily before operations begin.

Technicians will be given the knowledge needed to

keep your new truck in top condition. Courses are a
Kalmar Insight: view each operator’s performance in real time. mix of theory and hands-on experience and can be
held at Kalmar or at your site.
 Dimensions. b
a

Model designation
DCG180-12LB
Diesel engine
Counterbalance truck H5

Generation H4
H3
Lifting capacity, in decitonnes H6
Load centre, in decimetres H8 H2

Low built tilt cylinders a

L3 L2 L4
L L1

Lifting capacity in tonnes

A1
100 100

40 b
Model designation
Power source V1 V B
MAIN DATA
35 Rated capacity / rated load kg
DCG330-12
Load center distance mm L4
DCG300-12
30 Load distance, center of drive axle to fork mm L2
DCG280-12 R2
Wheelbase R1 mm L3
DCG250-12
25
DCG220-12 Service weight kg
Axle loading, unloaded front kg
WEIGHTS

DCG200-12
Lifting capacity, in tonnes

20
DCG180-12 Axle loading, loaded front kg
Axle loading, unloaded rear kg
15 Axle loading, loaded rear kg

10 Type, front / rear

Tyre size, front inch
WHEELS

5 Tyre size, rear inch

600 900 1200 1400 1600 1800 2000 Number of wheels, front / rear (x = driven wheels)
Load centre, mm Track width, front / rear mm S
Tyre pressure MPa
DCG180-250: Full lifting capacity up to 7000 mm lift height with
duplex/duplex freelift masts, integrated sideshift/fork positioning
carriage and forkshaft system. Mast tilt, α = forward / β = backward ° α/β
DCG280-330: Full lifting capacity up to 7000 mm lift height with Height of mast lowered mm H3
duplex/duplex freelift masts, integrated sideshift/fork positioning Lift height mm H4
carriage and forkshaft system.
Height of mast extended mm H5
Truck height – EGO / OHG cabin roof mm H6
Seat height mm H8
Height when tilting EGO cab / OHG mm T1
Width when tilting EGO cab / OHG mm T2
Truck length (to face of forks) mm L
DIMENSIONS

Truck width mm B
Fork dimensions, width mm b
Fork dimensions, thickness mm a
Fork dimensions, length of fork arm mm l
Fork carriage width mm b3
Width over fork arms, minimum / maximum mm V
Sideshift ± @ width over forks mm V1 / V
Ground clearance, laden, below mast mm
Ground clearance, machine mm
Min. ailse width for 90° stacking with forks mm A1
Turning radius mm R1
Internal turning radius mm R2

Operating pressure for hydraulics MPa

OTHERS

Hydraulic oil tank, capacity l

Fuel tank, capacity l
AdBlue tank, capacity l
 H5

H4
H3
T1
H6
H8 H2

L3 L2 L4 S
L L1 T2

A1
100 100
H5

H4 b
H3
T1 V1 V B
H2

R2
R1
S
T2

100

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

b
DCG180-12 DCG200-12 DCG220-12 DCG250-12 DCG280-12 DCG300-12 DCG330-12
V1 DieselV B Diesel Diesel Diesel Diesel Diesel Diesel
18000 20000 22000 25000 28000 30000 33000
1200 1200 1200 1200 1200 1200 1200
1070 1070 1070 1070 1125 1125 1125
4000 4000 4000 4250 4750 4750 4750

28500 29800 31200 32900 38300 39500 41500

15000 15000 15000 15500 20500 20500 20500
43200 46300 49500 53800 61700 64900 68800
13500 14800 16200 17400 17800 19000 21000
3300 3500 3700 4100 4100 4300 4800

Pneumatic / Pneumatic
14.00×24 14.00×24 14.00×24 14.00×24 16.00×25 16.00×25 16.00×25
14.00×24 14.00×24 14.00×24 14.00×24 16.00×25 16.00×25 16.00×25
4* – 2 4* – 2 4* – 2 4* – 2 4* – 2 4* – 2 4* – 2
2200 / 2140 2200 / 2140 2200 / 2140 2200 / 2140 2540 / 2440 2540 / 2440 2540 / 2440
1,0 1,0 1,0 1,0 1,0 1,0 1,0

5 / 10 5 / 10 5 / 10 5 / 10 5 / 10 5 / 10 5 / 10
4320 4320 4320 4320 4520 4520 4520
5000 5000 5000 5000 5000 5000 5000
6820 6820 6820 6820 7020 7020 7020
3270 3270 3300 3270 3415 3415 3415
2150 2150 2150 2150 2300 2300 2300
3800 3800 3800 3800 3800 3800 3800
3700 3700 3700 3700 3800 3800 3800
6090 6090 6090 6340 6925 6925 6925
3050 3050 3050 3050 3430 3430 3430
250 250 250 250 300 300 300
110 110 110 110 110 110 110
2400 2400 2400 2400 2400 2400 2400

2700 / 800 2700 / 800 2700 / 800 2700 / 800 3150 / 850 3150 / 850 3150 / 850
557 / 1585 557 / 1585 557 / 1585 557 / 1585 575 / 2000 575 / 2000 575 / 2000
- - - - - - -
300 300 300 300 300 300 300
9270 9270 9270 9550 10325 10325 10325
5600 5600 5600 5875 6600 6600 6600
425 425 425 550 950 950 950

16.5 18 20 22 19.5 20.5 22

330 330 330 330 330 330 330
300 300 300 375 450 450 450
35 35 35 35 35 35 35
Drive train and performance.
DCG180-250 DCG280-330
Manufacturer’s type designation Cummins QSB6,7 (Turbo-Intercooler) Cummins QSB6,7 (Turbo-Intercooler)
Fuel, type of engine Diesel, 4-stroke Diesel, 4-stroke
Rating ISO 3046 / at revs kW / rpm 168 / 2200 168 / 2200
Peak power at revs kW / rpm 188 / 1900 188 / 1900
ENGINE

Power at machine max revs kW / rpm 186 / 2000 172 / 2150

Peak torque ISO 3046 / at revs Nm / rpm 1186 / 1300 1186 / 1300
Number of cylinders / displacement cm³ 6 / 6686 6 / 6686
Fuel consumption, normal driving l/h 9-11 13-15
AdBlue consumption, normal driving % of diesel 4-6 4-6
Emission standard EU Stage V / USA EPA Tier 4(f) EU Stage V / USA EPA Tier 4(f)

Manufacturer’s type designation Dana TE17000 Dana TE17000

GEARBOX & MISC

Clutch, type Torque converter Torque converter

Gearbox, type Hydrodynamic Powershift Hydrodynamic Powershift
Numbers of gears, forward / reverse 3/3 3/3
Alternator, type / power W AC / 1960 AC / 1960
Starting battery, voltage / capacity V / Ah 2×12 / 145 2×12 / 145
Driving axle, manufacturer / type Kessler D91 / Differential and hub reduction AxleTech PRC3806 / Differential and hub reduction

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

Lifting speed Unloaded (m/s) 0.39 0.39 0.39 0.39 0.37 0.37 0.37
At 80% rated load (m/s) 0.37 0.37 0.37 0.37 0.35 0.35 0.35
Lowering speed Unloaded (m/s) 0.34 0.34 0.34 0.34 0.32 0.32 0.32
PERFORMANCE, CUMMINS QSB6,7

At rated load (m/s) 0.4 0.4 0.4 0.4 0.4 0.4 0.4
Travelling speed, F / R Unloaded (km/h) 27 / 27 27 / 27 27 / 27 27 / 27 27 / 27 27 / 27 27 / 27
At rated load (km/h) 23 / 23 23 / 23 223 / 23 23 / 23 24 / 24 24 / 24 24 / 24
Gradeability, max. Unloaded (%) 91 84 78 72 61 59 55
At rated load (%) 45 41 38 35 31 30 27
Gradeability, at 2 km/h Unloaded (%) 60 56 53 49 43 41 39
At rated load (%) 33 30 28 26 23 22 20
Drawbar pull Max. (kN) 189 189 189 189 197 197 197
Noise level, inside LpAZ*, EGO cabin (dB(A)) 75 75 75 75 75 75 75
LpAZ*, EGO cabin OHG (dB(A)) - - - - - - -
Noise level, outside LWA** (dB(A)) 110 110 110 110 110 110 110

* Noise level according to EN12053 ** Noise level according to 2000/14/EC

 DCG180-250 DCG280-330
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 kW / rpm 185 / 2200 185 / 2200
Peak power at revs kW / rpm - -
ENGINE

Power at machine max revs kW / rpm - -

Peak torque ISO 3046 / at revs Nm / rpm 1160 / 1200 1160 / 1200
Number of cylinders / displacement cm³ 6 / 7700 6 / 7700
Fuel consumption, normal driving l/h 8-11 12-14
AdBlue consumption, normal driving % of diesel 3-5 3-5
Emission standard Stage IV / Tier 4 final Stage IV / Tier 4 final

Manufacturer’s type designation Dana TE17000 Dana TE17000

GEARBOX & MISC

Clutch, type Torque converter Torque converter

Gearbox, type Hydrodynamic Powershift Hydrodynamic Powershift
Numbers of gears, forward / reverse 3/3 3/3
Alternator, type / power W AC / 3080 AC / 3080
Starting battery, voltage / capacity V / Ah 2×12 / 145 2×12 / 145
Driving axle, manufacturer / type Kessler D91 / Differential and hub reduction AxleTech PRC3806 / Differential and hub reduction

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

Lifting speed Unloaded (m/s) 0.33 0.33 0.33 0.33 0.35 0.35 0.35
At rated load (m/s) 0.32 0.32 0.32 0.32 0.33 0.33 0.33
Lowering speed Unloaded (m/s) 0.38 0.38 0.38 0.38 0.38 0.38 0.38
PERFORMANCE, VOLVO TAD 871VE

At rated load (m/s) 0.38 0.38 0.38 0.38 0.38 0.38 0.38
Travelling speed, F / R Unloaded (km/h) 24 / 24 24 / 24 24 / 24 24 / 24 24 / 24 24 / 24 24 / 24
At rated load (km/h) 23 / 23 23 / 23 23 / 23 23 / 23 23 / 23 23 / 23 23 / 23
Gradeability, max. Unloaded (%) 74 69 65 60 65 62 58
At rated load (%) 38 35 32 29 32 30 28
Gradeability, at 2 km/h Unloaded (%) 51 48 44 41 43 41 39
At rated load (%) 28 26 24 22 24 22 21
Drawbar pull Max. (kN) 173 173 173 173 213 213 213
Noise level, inside LpAZ*, EGO cabin (dB(A)) 72 72 72 72 73 73 73
LpAZ*, EGO cabin OHG (dB(A)) - - - - - - -
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

Lifting equipment.
We offer a full range of duplex, triplex and free-lift equipment. 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
3500 –
4000 3820 5820 – 4020 6020 –
DUPLEX STD

4500 4070 6320 – 4270 6520 –

5000 4320 6820 – 4520 7020 –
5500 4570 7320 – 4770 7520 –
6000 4820 7820 – 5020 8020 –
6500 5070 8320 – 5270 8520 –
7000 5320 8820 – 5520 9020 –

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
3500
4000 3920 5920 2000 4020 6020 2000
DUPLEX FFL

4500 4170 6420 2250 4270 6520 2250

5000 4420 6920 2500 4520 7020 2500
5500 4670 7420 2750 4770 7520 2750
6000 5020 8020 3000

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
4550 3500 6350 1700 - - -
4625 - - - 3680 6630 1625
5150 3700 6950 1900 - - -
TRI.

5900 - - - 4220* 8150* 2080

6500 4150 8300 2350 - - -

* Might be slightly reduced if smallest available tyres are chosen.

Carriage sideshift / fork Carriage with kissing forks Fork shaft system Coil ram
positioning for steel handling (Hook on type or roller type)

Duplex standard Duplex free lift Triplex full free lift

Standard equipment.
Chassis/Body Steering system
• Towing pin • Steering axel Kalmar, including double acting
• Steps with anti slip protection steering cylinder.
• Rear view mirror left and right side mounted on
front mudguards Drivetrain
• Strong and protective mudguards • Driveaxle DCG180-250: Kessler
DCG280-330: Axletech
Cabin
• EGO Cabin Hydraulics
• Clear and tempered panes of safety glass, • Electrical servo
thickness 6 mm • Level sight glass on hydraulic oil tank
• Std seat incl. 2-point belt with (orange). • Variable pumps
• Clear windows incl. sliding windows in left and right • High pressure filter
door. • Automatic raised engine rpm when load handling
• Complete doors with locks left and right side. function is used
• Complete manouevre system right hand console • Tilt angels std 5F/10B
incl. light controls, toggle wheel for display, levers
for load handling system (electric adjustable, Electric system
2-way´s.) • Electrical system 24 V,
• Multi function lever left side incl. horn, turn signal. • Rear lights and brake lights, LED.
• Brake system with pedal left and right side. • Working lights on front mudguards, LED.
• Internal comfort incl. mirror, handles, interior • Working light mast 2 pcs.
lighting etc. • Indicator lamps incl. hazard lights, LED..
• Wiper and washers front/rear and roof window. • Main power switch
• Hydraulic steering system incl. electrically
adjustable steering wheel in height-, manually Wheels
adjustable laterally and longitudinally with steering • Continental
wheel knob. DCG180-250 14.00x24
• External reverse lights. DCG280-330 16.00x25
• Cab tilting
• Instep handle, left side Fleet management
• Automatic heat and ventilation (ECH) with fresh air • Equipped with telemetric hardware for
inlet filter. Kalmar Insight.
• Speed control pedal right side.
• Kalmar std Key system. Color
• Cup holder • Cab: frame RAL 7011/70”,
• Coat hook covers ”RAL 7021/10”
• Colour display: • Chassis: Kalmar Red 2012
- Fuel level, indicator. (Base ref.RAL 3000/75)
- Engine, transmission temperature. • Lifting equipment: Kalmar Black
- Oil pressure engine. (Base ref.RAL 7021/30)
- Battery voltage.
- Clock and date. Documentation & decals
- Hour meter. • Operators manual
- Service time indicator. • Maintenance manual
- Speed. • Parts catalouge
- Engine speed (RPM). • Load diagram in cab
- Various information via pop-up. • Warning decals
- AdBlue indicator • Information decals
• Diagram, fuses
• Noise plate (legal requirement in EU/EEC)
Published by Kalmar, part of Cargotec. Copyright © Cargotec 2018.
All rights reserved. No part of this publication may be copied or
reproduced without permission of the copyright owner. The content
of this document is provided “as is”, without warranties of any kind
with regards to its accuracy or reliability and excluding all implied
SB-LTG33-EN-WW / 2019.08.27

warranties. We reserve the rights to make changes to any of the

items described in this document without prior notice. The content
of each service and availability of particular services may vary.