Introducing generation G: 'a new era in Kalmar counterbalance equipment'

At CeMAT 2011, Cargotec unveils its new DCG90-180 range of Kalmar lift trucks - ushering in the new 'G' generation of counterbalance equipment.

This new range of forklift trucks - with capacities ranging from 9-18 tonnes - is the first of Cargotec's G generation material handling equipment. They promise to deliver improvements in fuel efficiency, safety, serviceability and ergonomics while reducing environmental impact.

Starting with the new DCG90-180 range, the extensive benefits will be gradually phased across Kalmar's entire counterbalance fleet.  G generation features - which include a revolutionary cabin design - will eventually be incorporated on all forklifts, empty and loaded container handlers, reachstackers, and logstackers, as Cargotec aims to extend its market leadership in these sectors.

The new generation has been under development for three years - including a trial phase with rigorous testing.

Thomas Malmborg, Vice President, Forklift Trucks, says: "We are continuously working to improve the efficiency and economy of our customers' operations. The new Kalmar G generation counterbalance equipment is the next step in this process, with benefits for all - from drivers to service engineers and senior management. We have enhanced the cost-efficiency, quality and productivity of our counterbalance machines, resulting in better performance and greater total lifetime savings.
 
"The existing product is obviously the starting point for our development work. We have conducted extensive market research, including discussions with our customers, to make sure we clearly understand the needs of the marketplace."

Gives savings a lift
Like all Cargotec solutions, the new Kalmar DCG90-180 forklifts offer greater total lifetime savings by improving the synchronicity between truck and driver. Each model in the range is designed to keep truck uptime and driver productivity levels high while keeping lifetime operational costs low.

EGO enhances performance
One of the most notable changes ushered in by the G generation is the new EGO cabin. Further improving what was already one of the best on the market, the EGO cabin is markedly different to its predecessor, with major upgrades to ergonomics and visibility inspiring greater driver productivity, efficiency and safety.

 "We have focused on the ergonomics to enhance the operating environment and experience for drivers. We have made sure that the people driving our forklifts can sit genuinely relaxed and comfortable when working - improving their alertness and subsequently enhancing their driving performance," adds Malmborg.

The cabin benefits from a spacious new open design and curved front and rear windows that provide the operator with exceptionally good views diagonally, forwards and backwards. High capacity wipers provide over 90 percent surface coverage of the front window, and roof wipers have been intelligently integrated - maintaining good visibility and safety, even under extreme weather conditions.

The combination of a side-tilting steering wheel, comfort pedals, a rotatable and fully integrated Kalmar seat and complete climate control all combine to further enhance operator comfort and posture. This makes the new EGO cabin a luxurious and flexible working environment which can be tailored exactly to the driver's needs.

For improved health and safety, the EGO cabin uses a solid safety cage construction with profiled beams that eliminate blind spots. Additionally, in the DCG90-180 lift trucks, noise levels are reduced through the use of variable pumps and a temperature-controlled cooling fan that only runs when needed.  

The most innovative generation yet
Other features associated with the G generation of counterbalance equipment are the new electronic steering system and human-machine interface (HMI) which ensures the same set-up, regardless of which Kalmar vehicle you operate. Operators gain greater operating control and precision thanks to the well-placed, ergonomically improved instruments, levers, pedals, panels, switches and display.

Simple and intuitive, the intelligent system will feed the driver exactly the information needed at each moment. The result is a machine that is simple to operate for new drivers, yet allows experienced ones to excel and maximise their skills.

Equally important - and fundamental to all Kalmar equipment - is lifting performance. The DCG90-180 range helps optimise lifting efficiency and lower fuel consumption at the same time, on every lift. New electric and hydraulic systems mean quicker response, higher lifting speed and increased control. Meanwhile, new load sensing hydraulic pumps improve fuel efficiency. This combination helps drivers to be more productive while using less fuel.

Furthermore, uptime and serviceability are significantly increased on these reliable and easy to maintain lift trucks. The improved electronic system of the DCG90-180 is a fast, intelligent and stable system that makes the truck user friendly and reliable. The electronics also incorporate a modern, distributed and redundant CAN-bus that monitors the condition and performance of the engine, gearbox, valves and more.

The drive train is also built with performance, efficiency and reliability in mind. It features a well-proven drive axel shaft and transmission system, with an electronically controlled gearbox. This allows comfortable, efficient and safe driving at all speeds as well as operating the lifting equipment with high precision.

Sustainable, compliant engine options
At the core is a choice of two new EU Stage IIIB / EPA Tier 4i emissions compliant diesel engines. From Volvo and Cummins, both cut particulate emissions by 90 percent as well as reducing nitrogen oxide emissions by half, helping to keep Cargotec at the forefront of environmental sustainability.  Both also improve fuel efficiency whilst maintaining operational reliability, durability and performance by delivering maximum power and torque at low rpm.

A new cooling system further improves uptime by keeping the engine room cooler, promoting a longer lifetime of engine, hydraulic and electrical components. An optional reversible cooling fan helps keep the radiator clean from potentially harmful dirt, dust or particles depending on the intended application of the Kalmar product.

Ease of serviceability
Service accessibility has been dramatically improved for the DCG90-180 range with smart placement of the electric cabinet offering fast and easy access. All hydraulic oil filters can be reached from above at one location. There is also a special drain for drive axle oil which makes it possible to fill oil while standing up. As with previous generations of Kalmar trucks, all check points for daily inspection are directly accessible at ground level on the side of the truck and service intervals for the 9-18 tonne range are after 500 hours of operation.