Kalmar DCD90-180, DCD90-6, DCD136-6, DCD160-12 Technical Information

GB
Technical Information
Forklift
trucks
9-18 tonnes
Kalmar DCD90-180, diesel
Ka
lmar Industries
DCD90·180
The DCD90-180 with a lift
cap
acity
of
9-
18 tonnes
is the n
ew
generation
of
fo
rklift trucks in the medium segment
of
Kalmar's c
ompr
ehen sive range
of
4-
90 ton trucks - a well prov
en
range
of
tru
cks incorporating the latest design
so
lutions for o
ptimum productivity and
overa
ll
eco
nom
y.
A compr
ehe nsi
ve
range of o p tional
e
quipm
en t
pac
kages facilitat
es adapta­tion to sp ecial h andling environments and
different typ es
of
goods.
Ty
pe designation:
DCD100·
12
Co
unter_-b
alan
ce
tru
ck
Dk
sel engine
::"_J
I T
Generation
---
- -
Lift
capacity, dec
itonnes
Load ce
ntr
e, decimetre
Opera
tor
Environment
The S
pir
it Delta cab is
of a co
mple
tely
n
ew
and mod e
rn des
ign that p rovid
es
th
e operator
with
an efficie
nt and
safe
place of wo rk.
Th
e design
of
the cab is
th
e result
of a co
mpr
eh ensi
ve
analysis
of
ope
rators ' working condition s
providing o
ptimum
visibility w it h large
glass areas and n o forward
corner p osts
to inhibit
th
e field of vision . The ins
tru
-
ment panel is gently ro
und
ed and ergo-
nomically designed
with
an
uninhibited clear
vi
ew
of a
ll
essential
informati
on. Access
to
the cab is
comfortable a
nd
secure thanks to the
thr
ee
ste p s
up
to th
e c
ab
and many well
located ha
nd
rails.
All cabs in th e seri
es can be tilted, for
op
timum
service
access. Noi
se
and
vibration levels are extr
emely l
ow
thank
s to the insulated mounting to the
ch assis. The tilting cylinders
ope
rate
against the
cab
whi
ch is isolated by
m
ea
ns
of
r ubb
er
elements.
The
ope
rator 's seat, steerin
g whe el and
hy
dr
aulic contr
ols are a
ll
individually
adjustable for
op
timum working
pos
i­tion. Two easily operated , ergonomi­cally p osition ed multi-function l
eve
rs
are provid
ed for gear chang in
g,
wind-
scree
n wipers, washers a
nd horn
.
An
extremely
powe
rful h
eating/ve
ntila-
tio n unit e ns
ur
es a comfort
abl e cab
te
mp
erature. An easily replaced fre
sh
a
ir
filter cleans the incomin
g a
ir.
2
Technical Information DCD90-
180
Th
e unit sli
des
out to give easy access
for
se
rvice.
As
standard, t he e quipment
includ
es
a p
owe
rful
3-spee
d fan for
coo
lin
g, heat
ing, defrosting and recir-
culation.
O
pti
onal Extra
s:
• Extr
a h igh
cab
, +200
mm
• Elevated cab, + 300
mm
• Overhea
d g uard
• Roof mounted grid p rotection
• Co
mpl
ete
climate co
ntr
ol system
• Partially /fully rotatable
oper
ator se
at
Ins
trumenta
tion
Th
e instrument panel has logically
grou
pe
d units , a
ll
w ithin easy r each.
Sta
nd
ard ins
trument
ation includes
wa
rnin
g lamps for batte ry chargin
g,
l
ow
engine lubrication o
il
pressm e,
l
ow brake pressure, high
coo
lant
te m
pe
rature, high gearb
ox
oil tempera-
tur
e a
nd
applied parking brake.
In
add i-
tion, gauges display valu
es for engine
coolant
temperature, fu el quantity a
nd
op erating time .
Truc ks fitted w ith
ECS
mo nitorin
g are
not normally e
quipp
ed with wa
rnin
g
la
mp
s o r gauges. Th
ese functions are
handled by the
ECS
w hic h has a single
war
ning la
mp and
full text display
sh
ow
ing c urren t valu
es and
any faults
that
occ
ur.
Chassis
Th e chassis is built
of
fully welded ste
el
p ro
fil
es which g ives a rigid con
struc-
tion w
ith extr
emely strong mounting
po
int
s for the drive axle a
nd
lift equip-
ment.
S
tr
ess concentr ations have been elimi-
Jut
ed for o
ptimum
te nsile stren gth.
Th e chassis is flexible and is used
fo
r a
numb
er
of
differe nt drive line comb
ina-
tion s. The sp ace at the re
ar
of the
c
ha
ssis is used for count
er-weights, the
numb
er
of
w hich are adapted
to th
e
m
ac
hine in question.
Th e chassis
ha
s an
ext
rem e ly l
ow
profil
e for good visibilit
y.
Th e tanks are
separate
ly con
str
ucted and bolted to
th
e chassis in a position that al
so
co
ntribu
tes to good visibilit
y.
Technical Information DCD90-180
Electrical System
The elect
rical system is logically struc-
tured, easily serviced a
nd
comp
letely
coordi
nat
ed
wit
h the
other
trucks
in
the
Kalmar range.
The
system
is
suppli
ed
by
two
12V batteries
connected
in
ser
ies c harged by
an alt
er-
nator,
with related electronics for recti-
ficati
on
and
current
stab
ilization.
The
system
provides
high
power
levels
even
at
low
engin e revs. Th e electrical
fuses, relays and
connectors
are
l
ocated
in
an
easily accessible
position
withi
n a
centra
l electrical unit inside
the
cab,
behind
the
operator
's seat.
KL898
Central electrica l unit
ECS (Optional)
· Electronic Control
System
Trucks can
be
equ
ipp
ed with
ECS,
a
sta
te
of
the
art
system for
optimum
operational security
and
overa
ll
eco
nomy.
The
systems consists
of
a
numb
er
of
modules that
can
be
combined
in different ways,
depending
on
the
nature
of
the
operations. For
examp
le,
the
foll
owing
function s are
ava
il
able:
• Automatic
gear
changing
(Load sensing system)
• Lever
steering
• Mini-steering
• Monitoring
• Electr
o-servo
See also
separate informati
on
about
the
Kalmar
ECS
System.
Engine
As
standard,
the
DCD90-180
truck
is
equipped
with
Volvo 's TD640VE diesel
engine and as
option
the
DCD90-136
with
the
Perkins 1006-60T1,
both
turbo-charged straig
ht
six diesel
engines
adapted
to
the
specialized
working requirements
of
a forkl ift
truck
, w i
th
high
power
and
torque
level
s,
even
at l
ow
engine
speeds. The
eng
ine has l
ow
exhaust
emission l
eve
ls
and
comp
lies
wit
h today's stringent
legal
enviro
nment
al
demands
(EU,
CARB,
EPA).
All engines
are characterized by l
ow
fuel consumpti
on
and l
ow
noise and
vibration levels. Alternative engines:
• Perkins l 006-60T2
Volvo TD730VE
• Volvo TWD731VE
• Scania DI9
• C
ummins 6BTA
5.9-C200
See
Alternative drive lin
es
table
Transmission
Al
l trucks in
the
series
are
equipped
wit
h Clark's well
proven
hydro-
dynamic transmission systems
(3+3)
,
with integrated gea
rb
ox
and
torque
converter
, for
smooth, quick
acce
lera-
tion w
ith
a minimum
of
"clutch-slip".
A
number
of
different transmissi
ons
systems are ava ilable,
depending
on
the
sel
ected
engine
(see separate combin
a-
tion
table). Constant
mesh
gears and
gear
cha
nging by hydraulically
applied
clutches
(Powers
hift) are, h
owever
,
common
to all gearboxes.
Gear ch anging is el
ectrically achieved
via sol
enoid
valves,
with
three
reverse
and
three
forward gears,
controll
ed
by
means
of
an
easily
ope
rated multi-func-
tion lever.
Drive
axle
The
Kessler
D81
drive axle is
of
an
extreme
ly robust design to
be
able to
cope with
tough working environ-
ments
such
as
in
the
paper
and
pulp
industries, saw mills,
steel wo
rks,
ports
and terminals.
The
axle has reduction in
two
stages -
diff
ere
ntial and
hub
reduction -which
ensures
a minimum
of
strain
on
the
transmission system.
The
drive axle is
fitted w
ith
hydraulic braking system
(see
Servi
ce
Brake System).
Parking Brake System
The
parking brake system consists
of
a
dry
disc
brake
on
the
in-going shaft
of
the
drive axle. The disc brake
is
applied
by
means
of
a powerful spring in
the
parking
brake
cylind
er
and
is released
by
means
of
hydraulic
pressure
from
the
parking brake valve
in
the
cab.
Kalmar Industries
Volvo
TD640VE (6-cyl with turbo)
Service Brake System
The
service brake system
is
of
the
Wet
Disc Brake type, a system w
ith oil
-
coo
led discs
that
are alternate
ly
fixed
to
and rotating
with
the
hub.
When
the
brakes
are
app
li.ed,
the
discs are
pressed
together
by
hydraulic
pressure
from
the
brake pedal,
which provides
extremely effective braking.
The
system is v
irtually maintenance
free
and
can
cope
wit
h heavy l
oads
over
an
extended
period
of
time,
with
no fade
and
w i
thout
the
need
for
brake
adjust-
ments. The
heat
generated
durin
g
braking is dissipated via a
coo
ling
circ
uit
in w hi
ch
th e
truck
's total
volume
of
hydraulic fluid
comes
int
o
play. A
spec
ial filter
protects
the
braking system from any impmities.
Hub reduction
Kessler drive
axle
3
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