Kalmar DCG90, DCG180 Service Manual

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Kalmar DCG90-180

Lift trucks 9 – 18 tonnes

Technical information, Stage IIIB/Tier 4i

Designed to deliver greater total lifetime savings

The DCG90-180 is a range of new Kalmar trucks with a lifting capacity of 9 – 18 tonnes. The new DCG90-180 is the result of our customer-focused product development activities as well as our deep commitment to improving the performance of lift trucks. In fact, DCG90-180 capitalizes on insights we have gained from the more than 10.000 worldwide users of Kalmar trucks with this lifting capacity.

Introducing Kalmar DCG90-180

The new Kalmar DCG90-180 is designed, built and delivered to offer greater

total lifetime savings. This new range of Kalmar trucks offer these savings by improving the performance of your truck- and-driver teams. Below is a summary of how the Kalmar DCG90-180 benefits your business.

Give your savings a lift

The following pages provide you more details about the Kalmar DCG90-180. Contact your local Cargotec representative for a closer look and a test drive.

Model designation

DCG160-12

Diesel engine

Counterbalance truck

Generation

Lifting capacity, in decitonnes

Load centre, in decimetres

Dimensions

 

 

DCG90-6

DCG100-6

DCG120-6

DCG127-6

Lifting capacity

Rated (kg)

 

9000

10000

12000

12700

 

Load centre (mm)

L4

600

600

600

600

Truck

Truck length (mm)

L

4470

4720

4725

4725

 

Truck width (mm)

B

2480

2480

2480

2480

 

Height, basic machine, EGO cabin (mm)

H6

2895

2895

2895

2920

 

Height, basic machine, EGO cabin, OHG (mm)

H6

2895

2895

2895

2895

 

Seat height, EGO cabin (mm)

H8

1770

1770

1770

1790

 

Distance between centre of front axle – front face of fork arm (mm)

L2

895

895

900

900

 

Wheelbase (mm)

L3

2800

3000

3000

3000

 

Track (c-c), front – rear (mm)

S

1840 – 1960

1840 – 1960

1840 – 1960

1840 – 1960

 

Turning radius, outer – inner (mm)

R1 – R2

3950 – 75

4180 – 75

4180 – 75

4180 – 75

 

Ground clearance, min. (mm)

 

330

330

330

330

 

Height when tilting cab, max. EGO cabin, OHG (mm)

T1

3370

3370

3370

3395

 

Width when tilting cab, max. EGO cabin, OHG (mm)

T2

3350

3350

3350

3380

 

Min. ailse width for 90° stacking with forks (mm)

A1

6240

6470

6475

6475

Standard duplex mast

Lifting height (mm)

H4

5000

5000

5000

5000

 

Mast height, min. (mm)

H3

4015

4015

4015

4035

 

Mast height, max (mm)

H5

6515

6515

6515

6535

 

Mast tilting, forward – backward (°)

α - β

5 – 10

5 – 10

5 – 10

5 – 10

 

Ground clearance, min. (mm)

 

250

250

250

250

Forks

Width (mm)

b

200

200

200

200

 

Thickness (mm)

a

65

65

70

70

 

Length of fork arm (mm)

l

1200

1200

1200

1200

 

Width across fork arms, max. – min. (mm)

V

2330 – 570

2330 – 570

2330 – 570

2330 – 570

 

Sideshift ± at width across fork arms (mm)

V1 – V

440 – 1450

440 – 1450

440 – 1450

440 – 1450

Weight

Service weight (kg)

 

15200

15600

16200

16700

 

Axle load front, unloaded (kg)

 

7800

8100

8300

8300

 

Axle load front, at rated load (kg)

 

21700

23100

26500

27350

 

Axle load back, unloaded (kg)

 

7400

7500

7900

8400

 

Axle load back, at rated load (kg)

 

2500

2500

1900

2050

Wheels / tyres

Type, front – rear

 

 

Pneumatic – Pneumatic

 

 

Dimensions, front – rear / ply (inch)

 

11,00×20/16PR

11,00×20/16PR

11,00×20/16PR

12,00×20/20PR

 

Number of wheels, front – rear (*driven)

 

4* – 2

4* – 2

4* – 2

4* – 2

 

Pressure (Mpa)

 

0,9

0,9

0,9

0,9

Steering system

Type – manoeuvring

 

 

Hydraulic servo – Steering wheel

 

Service brake system

Type – affected wheels

 

Oil cooled disc brakes (Wet disc brakes) – drive wheels

Parking brake system

Type – affected wheels

 

Dry, spring activated disc brake – drive wheels

Hydraulic pressure

Max. (Mpa)

 

16,0

17,0

17,5

18,0

Hydraulic fluid volume

(l)

 

215

220

220

220

Fuel volume

(l)

 

152

170

170

170

AdBlue volume*

(l)

 

15

15

15

15

*Only Volvo TAD761VE

 

 

 

 

 

 

2

Kalmar DCG90, DCG180 Service Manual

α

β

 

20

 

 

 

 

 

 

 

 

 

 

 

18

DCG180-6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

16

DCG160-6

DCG160-9

DCG160-12

 

 

 

 

H5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DCG150-6

 

DCG150-12

 

 

 

 

 

H4

 

 

 

DCG140-6

 

 

 

 

 

 

 

 

 

14

 

 

 

 

 

 

 

H3

 

 

 

 

 

 

 

 

 

 

T1

 

 

 

 

 

 

 

 

 

 

 

 

 

DCG127-6

 

 

 

 

 

H6

 

H2

 

 

 

DCG120-6

 

DCG120-12

 

 

 

H8

 

 

 

12

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

a

 

 

 

 

 

 

 

 

 

 

 

 

tonnesin

10

DCG100-6

 

DCG100-12

 

 

 

L3

L2

L4

S

DCG90-6

 

 

 

 

 

 

 

 

 

 

 

L

 

L1

T2

 

 

 

 

 

 

 

 

capacity,

8

 

 

 

 

 

 

 

 

 

 

6

 

 

 

 

 

 

 

 

A1

 

 

 

 

 

 

 

 

 

 

 

 

Lifting

 

 

 

 

 

 

 

 

100

 

100

 

 

 

 

 

 

 

 

 

 

b

 

 

 

 

 

 

 

 

 

 

 

 

4

600

900

1200

1400

1600

1800

2000

 

V1

V B

 

 

 

 

 

 

 

 

Load centre, mm

DCG90-6 to DCG180-6 models:

 

R2

Full lifting capacity up to 5000 mm lift height with duplex/duplex

R1

 

freelift/triplex masts and integrated sideshift/fork positioning carriage.

DCG140-6

DCG150-6

DCG100-12

DCG120-12

DCG150-12

DCG160-6

DCG160-9

DCG160-12

DCG180-6

DCG70-32 E3

DCG70-35 E4

14000

15000

10000

12000

15000

16000

16000

16000

18000

7000

7000

600

600

1200

1200

12000

600

900

1200

600

1220

1220

4985

5055

5065

5315

5325

5305

5315

5575

5065

5595

5845

2480

2540

2540

2540

2540

2540

2540

2540

2540

2540

2540

2920

2920

2920

2920

2920

2920

2920

2920

2920

2920

2920

2895

2895

2895

2895

2895

2895

2895

2895

2895

2895

2895

1770

1770

1770

1770

1770

1770

1770

1770

1770

1770

1770

910

980

990

1000

980

990

1000

990

1265

1265

3250

3250

3250

3500

3500

3500

3500

3750

3250

3250

3500

1855 – 1960

1855 – 1960

1855 – 1960

1855 – 1960

1855 – 1960

1855 – 1960

1855 – 1960

1855 – 1960

1855 – 1960

1855 – 1960

2210 – 1960

4360 – 125

4360 – 125

4360 – 125

4785 – 420

4785 – 420

4785 – 420

4785 – 420

5175 – 600

4570 – 270

4360 – 125

4785 – 420

350

350

350

350

350

350

350

350

350

350

350

3395

3395

3395

3395

3395

3395

3395

3395

3395

3395

3395

3380

3380

3380

3380

3380

3380

3380

3380

3380

3380

3380

6665

6735

7945

8370

8380

7160

8160

8770

6745

8900/13800

9200/13900

5000

5000

5000

5000

5000

5000

5000

5000

5000

7000

10000

4035

4195

4195

4195

4195

4195

4195

4195

4195

5195

7075

6535

6695

6695

6695

6695

6695

6695

6695

6695

8695

12075

5 – 10

5 – 10

5 – 10

5 – 10

5 – 10

5 – 10

5 – 10

5 – 10

5 – 10

3 – 5

3 – 5

250

250

250

250

250

250

250

250

250

250

250

200

200

220

220

250

200

220

250

220

6064

6064

80

80

90

90

100

80

90

100

90

2120

2120

1200

1200

2400

2400

2400

1200

1800

2400

1200

2330 – 570

2360 – 600

2360 – 640

2360 – 640

2360 – 700

2360 – 600

2360 – 640

2360 – 700

2360 – 640

440 – 1450

440 – 1480

430 – 1500

430 – 1500

430 – 1530

440 –1480

430 – 1500

415 – 1530

430 – 1500

140

140

16900

19800

18600

19700

22300

19200

21200

22400

21600

22900

23900

8400

10300

10000

10100

10200

10200

10200

10500

10300

14700

15600

28900

32650

26700

29600

34600

34800

34800

35800

37100

27100

27600

8500

9500

8600

9600

12000

11000

11000

11900

11300

8200

8300

2000

2150

1900

2100

2600

2400

2400

2600

2500

2800

3300

 

 

 

 

 

Pneumatic – Pneumatic

 

 

 

 

 

12,00×20/20PR

12,00×20/20PR

12,00×20/20PR

12,00×20/20PR

12,00×20/20PR

12,00×20/20PR

12,00×20/20PR

12,00×20/20PR

12,00×20/20PR HD

12,00×20/20PR

12,00×20/20PR

4* – 2

4* – 2

4* – 2

4* – 2

4* – 2

4* – 2

4* – 2

4* – 2

4* – 2

4* – 2

4* – 2

0,9

0,9

0,9

0,9

0,9

0,9

1,0

1,0

1,0

0,9

0,9

 

 

 

 

Hydraulic servo – Steering wheel

 

 

 

 

 

 

 

 

Oil cooled disc brakes (Wet disc brakes) – drive wheels

 

 

 

 

 

 

 

 

Dry, spring activated disc brake – drive wheels

 

 

 

 

19,0

16,5

12,5

15,0

17,0

17,0

17,5

18,0

19,0

19,5

20,0

220

220

220

220

220

220

220

220

220

220

220

170

170

170

170

170

170

170

170

170

170

170

15

15

15

15

15

15

15

15

15

15

15

3

New EGO cabin:

our most productive driving environment. Ever.

Improving a driver’s working environment – the cabin – stimulates productivity, efficiency and safety. That’s why the new DCG90-180 incorporates our most productive driving environment: the new EGO cabin. It’s loaded with outstanding ergonomics and smart features that help drivers optimally perform their work. As important, the truck has new electric and hydraulic systems as well as modern lifting equipment to help drivers boost productivity and operational savings.

EGO cabin enables driver productivity

The new EGO cabin is a spacious workplace. Its curved glass window gives the operator excellent side-to-side and overhead visibility. Below is a closer look at some of the interior of DCG90-180.

Ergonomic steering wheel

It’s adjustable and can also be tilted to the side. This decreases stress on the operator during driving and reversing.

Climate package

Complete and flexible climate control system that matches the high demands of the climate tested EGO cabin. Large air intakes. Easy filter replacement in the front. Complete driving comfort from well-dimensioned and -designed components.

Comfort pedals

A new flexible and safe pedal system with an adjustable pedal angle. Improves ergonomics and minimizes strain on the driver’s foot. A floor-based solution gives a hanging pedal feel.

Work console

Easy to set, adjust, use and understand. All necessary controls, switches, levers and indicators easily accessible for effective operations. Clear and well-placed panels and steering wheel controls for data display.

Windshield wipers

Provides over 90% coverage of the curved front window. Roof wipers are also integrated. It all means superior visibility and safety.

Operating console

The complete unit for operators who use the mini-wheel or steering lever. Integrated gear knobs. Fully adjustable and individually tested for optimal ergonomics. The ergonomic steering wheel is folded forward without limiting vision.

Ergonomic multi-seat

Rotatable and fully integrated. Built for maximum sitting posture, comfort and ergonomics during long shifts and demanding operations.

Optimized visibility

Completely new open design. Designed with smart profiles and curved front and rear windows. An optimized view at all angles, with an exceptionally good view diagonally forwards and backwards. Strong outdoors feeling.

4

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