Technical Information Forklift trucks 9-18 tonnes Kalmar DCD90-180, diesel pepss012 (kalmarKalmar Industries DcD90-180 ‘The DCD90-180 with a lift capacity of 9-18 tonnes is the new generation of forklift trucks in the medium segment of Kalmar’s comprehensive range of 490 ton trucks -a well proven range of trucks incorporating the latest design solutions for optimum productivity overall economy. A comprehensive range of optional ‘equipment packages facilitates adapta tion to special handling environments and different types of goods ‘Type desi nation: Dep100-12 Diesel engine ———— | Counter-balance truck Generation Lift capacity, decitonne: Load centre, decimetre- Operator Environment ‘The Spirit Delta cab is of a completely new and modern design that provides the operator with an efficient and safe place of work. The design of the cab is, the result of a comprehensive analysis, of operators’ working conditions providing optimum visibility with large glass areas and no forward corner posts {o inhibit the field of vision, The instru- ‘ment panel is gently rounded and ergo- nomically designed wit ‘uninhibited clear view of all essential information, Access to the cab is comfortable and secure thanks to the three steps up to the cab and many well located hand rails. All cabs in the series can be tilted, for optimum service access. Noise and vibration levels are extremely low thanks to the insulated mounting to the chassis. The tilting cylinders operate against the cab which is isolated by means of rubber elements, ‘The operator's seat, steering wheel and hydraulic controls are all individually adjustable for optimum working pos tion, Two easily operited, ergonom) cally positioned multifunction levers are provided for gear changing, wine sereen wipers, washers and horn, An extremely powerful heating/ventila tion unit ensures a comfortable cab temperature. An easily replaced fresh air filter cleans the incoming air. Technical Information DCD90-180, “The unit slides out to give easy access for service. Assandal the equipment includes a powerful 3speed fan for cooling, heating, dosing and reir culation, Optional Extras + Extra high cab, +200 mm + Hlevated cab, +300 mm * Overhead guard + Roof mounted grid protection + Complete climate control system + Partially/fully rotatable operator seat Instrumentation ‘The instrument panel has logically ‘grouped units, all within easy reach, Standard instrumentation includes ‘warning lamps for battery charging, ow engine lubrication oil press ow brake pressure, high coolant temperature, high gearbox oil tempers. ture and applied parking brake. In ad. tion, gauges display values for engine coolant temperature, fuel quantity and operating ti ‘Trucks fitted with ECS monitoring are not normally equipped with warning, lamps or gauges. These functions are hhandlled by the ECS which has a single ‘warning lamp and full text display showing current values and any faults Chassis ‘The chassis is built of fully welded! steel profiles which gives a rigid consteuc tion with extremely strong mounting, points for the drive axle and lift equip- ment, Stress concentrations have been elimi nated for optimum tensile strength. ‘The chassis is flexible and is used for a ‘number of different drive line combina- tions. The space at the rear of the chassis is used for counter-weights, the umber of which are adapted to the ‘machine in question, ‘The chassis has an extremely low profile for good visibility. The tanks are Separately constructed and bolted to the chassis in a position that also contributes to good visibilityTechnical Information DCD90-180 Electrical System ‘The electrical system is logically struc- tured, easily serviced and Completely coordinated with the other tracks in the Kalmar range. The system is supplied by two 12V batveries Connected in series charged by an alter hnator, with related electronics for rect fication and current stabilization, The system provides high power levels even at low engine revs. The electrical fuses, relays and connectors are located in an easily accessible position within a central electrical unit inside the cab, behind the operators seat Fuses acral deta ECS (Optional) - Electronic Control System ‘Trucks can be equipped with ECS, a state of the art system for optimum ‘operational security and overall economy. The systems consists of a umber of modules that can be combined in different ways, depending on the nature of the operations. For example, the following functions are available: + Automatic gear changing ‘Coad sensing system) + Lever steering + Ministeering + Monitoring + Electro-servo See also separate information about the Kalmar ECS System, Engine As standard, the DCD90-180 truck is ‘equipped with Volvo's TD6{0VE diesel ‘eigine and as option the DCD90-136 ‘withthe Perkins 1006-6011, both Uurbo-charged straight engines adapted to the 5 ‘working require truck, with high power and torque levels, even at low engine speeds, The ngine has low exhaust emission levels land complies with today’s stringent legal environmental demands (EU, CARB, EPA). Al engines are characterized b fuel consumption and low noi vibration levels. Alternative engines: ++ Perkins 1006-6012 * Volvo TD730VE + Volvo TWD731VE Scania DID + Cummins 6BTA 5.9-C200 See Alternative drive lines table All trucks in the series are equipped ‘vith Car's well proven hydro namic transmission systems (343), With integrated gearbox and torque Comerter for smooth, quick aecelert {tom with 3 minim of clues A.aumber of different transmissions siemsare available depending onthe Selected engine (sce separate combina: tion tabi), Constant mesh gears and ear changing by hydraulically applied Clutches Gowershil) are, however, ommon to all gearboxes Gear changing is electscaly achieved Mia solenoid valves, with thice reverse nd three forwan gears, controlled by jeans of an easily operated multifunc- tion lever Drive axle ‘The Kessler D81 drive axle is of an extremely robust design to be able to cope with tough working environ: ‘ments such as in the paper and pulp industries, saw mills, steel works, ports ind terminals ‘The axle has redtuction in two stages - differential and hub reduction - whieh, ensures a minimum of strain on the transmission system. The drive axle is fitted with hydraulic braking system (See Service Brake System), Parking Brake System ‘The parking brake system consists of a dry dise brake on the in-going shaft of Uiedrive axle. The disc brake isapplied by means of powerful spring in the parking brake cylinder and is released by means of hydraulic pressure from the parking brake valve in the cab, Parking brake Clark 28000 (3 +3 gears) Kalmar Industries Atte Volvo TDG4OVE (6cy/ with turbo) Service Brake System The service brake system is of the Wet Dise Brake type, a system with oit- Cooled discs that are alternately fixed | to and rotating with the hub. When the brakes are applied, the dises are pressed together by hydraulic pressure from the brake pedal, which provides extremely effective braking. The system is virtually maintenance free and can cope with heavy loads over an extended period of time, with no fade and without the need for brake adjust ments. The heat generated during braking is dissipated via a cooling, ‘circuit in which the truck's total volume of hydraulic fluid comes into play. A special filter protects t braking system from any impu Hub redvetion| Wet Dise Brake Kessler drive axleKalmar Industries 7 Technical Information DCD90-180 ise a tea tsa fark unos [2 fh voted ad ao Load diagramme Tre pec, etn ton cent ts, inte 19 T k= eins engjre B= Yoho engine cmon pec rat 7 le It mn Bg nag fromea snr tad fs al 3 4 _ eects bye 1508 \ is9 wocoreo 2 become wees finns a ae a lt ated oad a Bia og pearance eve * | ee “| severe [at rated load fry Sion Say lone [roar bapa fi lic Sabi 160 TOTA7SOS2S is Sever mgt im fo ead to (wacaded he a td ae [irae oa noses i ¢ tte fone ie : Ie Eras Pesan. Tana a entre desigeton 2 ost ene a Rat S0 2096 atresia : Pak trgus 150-3606: ataxe [Nr pelt | H oof epnaers spacer em = Fost onsunpion, somal opiton vb Bs ' & lesmeemor pe power eco aogoo soo. aand 000 |B ft stng ata age co Wom Load Cente, mm JB is ceaaor Ic Gar 20000 0 Ca 28000 A arene engine Iwantscxer- ype estton B. Vat ange fanfocurer toe oes 4: Babes Ete oco1606 modes: . 7 Ptting caps Up to 9000 re i height with Duplex Dupex roe [sews pe Iya mbate and inegrated sesh fork postion carnage he of rs rae oe Ie ine i se 7 Wheels iror [ioe wor near nl [bmrensions, font andrea Py ro Lemos ee [No-ofwhasis Font” wear vent lee ton peste 1h | * jst en foe 19 Somes bate satan —[hpe- feted whee [20 Pang bate system — [peated whee's| fat Raut pressure vax jira | 22 nose ever on 4563535 equal oie Train ead Em) 1A) [2 [23 Fuel wine i a Fert nu vo c [25 Ninn aise with 90" sac wih as [ato a6 Tek [ruc ong witout es Lf rusk ith 15 Jr Togh, bane maar Isr Iseathaigit 16m Distance between serve af ont [L2 from [eon fae ofr sm WWhecisse [3m rack (6) fone [5 fm feng vais, cuter [Rar a [ning ais, ener [e2 rw a [Grune lerance, min ior Ic eit wen ong cab |TA_jram 5 fac wt, ed cab [ron [27 Standard opiox mast Jurong net ron hast het: ax, sro Ios ing, Towards backwards [oP {Grund dlerarce, in fs beens ih nm [Tiness [afm Lang fk as {ow iat soos fre anna, max Wom (at sross fork ams. mn Wom [Sceshi # at wth sess fo amavEVan isa we wh stoned equipment for pol eubmen 2 ore power engines are aalate, up wo 167 KW/230 hp 2 Suorger gorbores ae ava, Clark 22000 (+3) ©) Semiall hoes ave wate frail models SuperElastc) [Ne rserve te vit to ater design and mata sneceatns, whet por nateTechnical Information DCD90-480 Kalmar Industries DED] Ded] DGD] DED] DED] BED BED] DD] ped] Bod] BOOBS veB em 306 | 906 | 2006 | 2008 | 10032 | 20042] 1206 | 12068 | 12022) 2366 | 266 | s8012] aso6 | s609 Bf] oe pa | oe | Mo ee | Mee | ont] Me | Mee | a | Mee |S 00 oo00 2000 ae00_ | is000 000 3000 0000 72000 73500 —| $5000 5000 oa0_[ 050 _| 040 [oso | oad [om] ome ‘ad ‘a0 0380.45 | 035_| 04s | 0.35 | 04s | 0.0 035 038 a0 O40 ‘a0 0.40 a0 a0 a0 ‘9.40 a 30 30 ‘26 | ~30| 28 | 30 [28 [20] 28 30 30, 8 [asset [aia os se_| 6357 a4 [sa [aio as arf [2998 ‘a5_[89_| | [tar ‘a 50 [483 [a3 22 30a [3048 23_| 2833 rat fr aa | 93 |] 15209 [ios 73 | ios] 105, a0 Taso a0 isea0 [19700 | —as000 —]-raapn | 1520 | 0a0e | aaa00 | “a100 7200) 7800. 40300. 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Bats: is 35 305 3a. 3a25. 3580 3560 3380, 3380 3380 380 3380 380 5000. 000. 5000 Er 00 5000. 5000- 5000- 5000 3990. 3980 86 2000- 85 2020, 05. aes 5 5490 a0 3685 00 6 520) B65. 585 685. 540 50, 320 a0 a0 5:0 5:0 340. 210. 2a0, 260) 250. 2507 250. 260 230| | 200 200. 220, 200. 220, 200 '250_| 200 _[ 20 | ~250_| 200 85) S. 30 70 0 20 700_| —9-[—0-[ “400 30] | 200- 200. 200 i200. ib. 200, 4001200 | ~aa00~[“3a00-|~a300—} | 2330 2330. 2360 2350. 2360 2330 2360. 2360- 7360, 570. 370 0 370 B40 570, 700-| “e00-{~610-| Too | “40 a3, oa 0500 ip 1450250 500] aio 14 Jas ssa af. s} a0. F60Kalmar Industries Technical Information DCD90-180 Steering System The steering system is completely hiydrautic and is fe from hydraulic pump 1 (see the hydraulic system {Giagram), viaa priority valve. When the steering wheel is turned, the steering valve transmits a load signal to the priority valve which ensures that the Steering system always has sufficient hydraulic pressure. ‘The steering axle is an extremely robust construction with doubleaction cylinder. ‘The pendulum suspension of the axle over powerful, spherical rubber bear. ings has a long operative lifespan and provides good shockabsorption. The inimal number of parts ensures oper ational reliability, a minimum of service points and easy maintenance. The stecring geometry allows large wheel displacement and thereby, a tight turning circle. Hydraulic System The hydraulic system includes the 1g sub-systems, and cooling. + Parking brake system, + Hydraulic servo (standard) dard form, the hydraulic system is built around two gear wheel type pumps one double and one single. ‘The pumps are driven from the outlet ofthe torque converter: The flow from the pumps is fed to a valve block with a large number of in-built functions (ee diagram). The valve block enables easy installation with a minimum number of hyalraulic lines/hoses. ‘The outer section of the double pump feeds the lift and tilt functions, whilst the inner section feeds other working hyclraulic functions. With full exten- sion of the lift funetion, both sections ofthe double pump operate to provide ‘maximum lift capacity. ‘The separate single pump feeds the hydraulic accumulator, which in turn, supplies the brake and servo systems. Asa safety measure, the accumulator ‘ensures sufficient brake pressure to be able to brake several times, should the engine temporarily stop, The excess flow from the pumps is led to the brike cooling circuit to dissipate the heat generated during braking, before being retumed to the hydraulic ‘an Optional extras: Load sensing variable pumps + Electro-servo controls + Piston type accumulator + Additional hydraulic functions + Hydraulic joystick Dovble-ction — oylinder ‘Steering axle Sivericl eubber bearing & vice ee See Se ereaee: Hydraulic system for ruck with Volvo engine 7. Steering system 3 Soin cian sence bate sytem So. Baitnebvata system Accumulator 22 Servo assisted contol vers, 1B Braraictank +18; Breather fier, hydraulic tank ‘Tracks with Perkins engines ace Systemn with only one double puimp. Ge section of the pump feed the ‘working hydraulics while the other Section feeds the steecing system and charges the accumulator The main Waive is ited with «valve block, input Section and main pressure limitation waveTechnical Information DCD90-180 Kalmar Industries Lift Masts All masts, both duplex and triplex, are constructed on the "free visibility prin- ciple” and can be supplied with the r lift system which, in terms of function, is extremely reliable and secure. ‘The robust mast profiles are of high tensile steel, dimensioned for minimal obstruction of the field of vision and long service life. The lift cylinders are positioned in the “dead” angles of the ‘mast. All mast wheelsare hardened and fitted with high quality bearings. AAs standard, trucks are fitted with the duplex free visibility mast. Optional extras: + Duplex free visibility mast with, freesift Triples fre visibility mast with freelit : Duplex tro. vishity mast Duplex tree #SPiy ast wan Tiples tee telly ast tire 3h oylnden Fork C: Ss Tee ‘Rnuinber oafferent models of fork fi cartes qeenrelitt, ated tien ore excellent throughvision-The stad ‘2 fmodel has manaly moveable ork, nn However ure mujony of eke ac supplied with hydraulic side-shift and = font posttontng, = Optional extras = + Fork positioning/side-shift al + Honk poatoning/sidechit with = levelhog : + HOS pedtioning/sidestilt with = cent leveling = + Stleshi cage z PR Shan ayer : 1 Addidona pes of clamp : attachments 7 + Golframs for steet handling : ray rae S Hare 09 FRAASAN Sloe tons z ee 0 son 260 zee a essofesotasofer sos 500 sero} oo [os ae ws Hae Bel ssef rel rs soo el ener pie ee ead arco safe ors see olsen senfera reser {eo eof SD ott oo asco sof eee see ae eels ee ee ss ooo[ sof rofo0 |e sooo sof a0] et 50 Feaepotinig ad See eo sacs se sor Seeing: Se ee ss roo aes} anodes Forks [=700|8190| 7250) 3865] 8435) 2950] he forks arc one-piece forged in high ofa eof reser tensile steel. The standard fitting is over hooks on the fork carriage, whilst hyclraulically controlled forks are fitted | over rollers running on bearings - four upper rollers and two lower support for each fork, For ease of changing between forksand ther attachments, a fork shaft system, is available, where the forks are ‘mounted on a separate fork holder, fines for hyoraule a St ea 2 foc stt sateen Palo, ‘Groathione 4 4. Forks with ‘ra ering ~ 4). These flures are based on the 120.6 and wth ie dnenaions Wd HS aor 320mm for 1368 4. Standard forks fer manual manoeuvring 2. Forks with rollerKalmar Industries Service Access Routine daily service checks contribute toa safer work place and reduce the risk of breakdowns. Daily service checks are made easier thanks to well thought out and grouped service points. The operator ean reach all service points without having to climb up onto the truck. ‘The cab can be tilted by means of a hydraulic eylinder operated by a ‘manual pump. When the cab has been tilted, the gearbox, hydraulic pumps, hydrtulic fluid fitter, parking brake main valves, control valves, etc., are readily accessible for service. The engine hood is divided into three sections. fixed middle section that bears the silencer and hinged outer sections to each side. Ieleportor ain iter Joafoos ol, lpsuck and filer ca Engine ol, dipstick end filer cop” oolant Screen wash auld Fc, ler eap Main switch, lectical system Batteries 2x2" 140 Ah Tok wth overhead guard. (kaimar ‘yavEN 330 i sumseurrn Beetiee, | i egiunE Sone. eee aon Fay eae almar Industries Sverige AB OLLATRATOM).. excess: 31. +46 372 260 00 ax #46 372 263 90 Technical Information DCD90-480 Standard equipment SGieney and saety of the ruck Rout truck chas 48 on iit Delt operstor envionment With low noise level ‘abe cab insulated against vibration + Powerful venation nit with ef cient filter Roof window of texan Siding window on the lft hand side Washipers, front, rear and 100 Lockable cab doors Wide bottom aecess step and «wo extra steps on both sides ‘Adjustable, shock absorbing, exo nomic operitor seat with safety belt ‘Three-way adjustable steering console Twosway adjustable hydraulic lever console ‘Arm support on right hand side Environnaent fiend penverfl engines Fully dimensioned raliatorforengine fnd-oil cooler for gearbox Powerfal gearboxes with powershift Drive axle with ol cooled dise brakes Free visbility lit equipment icening anke with doubleaction cs Hyadnutic system with finger ip contot Simple, relable clecrical sytem + Comprehensive and logically {rouped instrumentation + Recdlraoe rae pea nd for feverse selector + Lighting: Working lights, indicators brake, reversing tnd positional lights + Lirge'service hatches ae ttable ea for daly inspections Towing pin manta + Complete documentation Safety Al Kalmar tucks are CE-marked and dre construeted toand comply with the following norms vENISSL + ASME B56.1 (USA, trucks up to 13.6, tonnes) + ENT2895 (EMC test, Europe) Optional equipment A\wide range of optional equipment dnd packages are available for our itticks, wo satisfy further specialization and provide added elficiency ‘Alternative engines and gearboxes + Load sensing hydraulic system + Exterior and interior cab equipment, such as aie conditioning, etc + Lighting, mirrors and protective grid + Different types of lit equipment, at tachments, exhaust controls ait ters, ete + ECS with different types of module + Catalytic converter and ps Summary Kalmar's medium trucks are ofa well proven design, manufactured in large Volumes for demanding environments Such a8 Timber, paper and + tect works and foundries Concrete industry + Ports and terminals + Other heavy industries ‘Avwell planned and protected operator environment males Kalmar tracks cient and Comfortable workin implements Readily accessible service points for case of maintenance [Atemative drive tines EEEE fo Sonn “O' Otea EREEE ae =o BETO hove Toosoves rare hn @]o/e/0/4| in soovecrt> "aah /e n esse eanveo sfola fiwierans: anaes 3313 aor EES ean eruesae eshpnane Sse Rn nae ear Pneumatic res 100000767 oowo"/a6pR 32.00120"/200R lovtiona Semisot tyes Super lasti) PO, Box 387 Kalmar Industries Oy Ab FIN-331 01 Tampere, Finland ‘ol #358 3 268 8242 Fax #358 3 265 8201 Ais East Dundee Street ol rt 785 242 2200, Fax +4 785 242 6117 ‘Ottawa, Kaneas 66067, USA Frat Seen oe sia Kalmar Industries USA Inc. 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