How to change tires on forklifts? The instruction manual contains information on the operation and maintenance of the original forklift. Additional equipment is sometimes installed that can change performance by describing

  (except brake systems of hydrostatic type) operate on the principle of friction, and friction leads to heat generation. Too frequent and intensive use of the brakes leads to their overheating and premature wear, which, in turn, can lead to breakage of the brakes. The most common examples of “abuse” of brakes are:

an unskilled operator is not able to calculate his strengths and abilities of the machine: he accelerates the car too much, and then brakes too sharply and quickly;

the brakes are often activated unintentionally: if the operator is used to keeping his foot on the brake pedals, he often makes random presses;

operators working in a hurry (in order to achieve greater productivity or overfulfill the standards) when working at short distances, first squeeze the gas strongly, and then sharply hit the brakes to stop.

To extend the life of the brakes, Kawasaki experts recommend that novice operators release the gas pedal and start to slow down the car a little earlier, so that the loader moves by inertia and braking occurs due to the mass of the machine and the load being carried, and the brake pedal to be pressed when the machine is already practically stopped.

It is also important to understand the principles of the most effective use of clutch release. “We often see how many operators don’t know how to use the clutch,” says Phillips, “When they load material into the back of a truck or hopper, they drive with the brakes on, which causes them to wear out instantly.”

Clutch disengagement allows the transmission to shift to neutral during the braking cycle. “By depressing the release pedal, you switch to neutral gear, and after that you can brake,” Phillips explains, “After that, if you press the gas pedal with the brakes on, to start working with the hydraulic equipment of the machine (for example, if If you want to raise or lower the bucket or control the movement of the boom), the truck will no longer accelerate against braking. "

“If the operator uses the clutch pedal correctly, then when working with a hydraulic tool, the transmission will shut off and there will be no negative effect on the brake system,” the expert adds.

Handle the gearbox correctly
“Wearing the gearbox and its clutch can be a serious problem if you shift gears incorrectly. After all, incorrect operation of the gearbox can cause additional wear,” says Ellis.

Most often this is due to high gears. “In other words, the operator uses the gearbox and torque converter to change the direction of the machine,” says Phillips. The operator starts the reverse gear, rides for a while, and then with one push switches the gearbox to the forward speed and squeezes the gas, or vice versa. "Operators manage to carry out loading and unloading operations that require constant forward and reverse gear shifting without a single brake pedal! It turns out that all these loads fall on the gearbox and torque converter, which consequently overheat."

Most often, the situation is aggravated by the fact that operators seek to reduce the execution time of the work cycle to increase productivity. This can lead to premature failure of these costly systems. Thus, manufacturers have to come up with ways to get out of this situation.

For example, Volvo has developed the Optishift transmission system, which is installed by default on large models of loaders produced by the company, and allows the operator to immediately switch to high gears, but automatically activates the brakes in this case. “We call it reverse braking,” says Phillips, “Whenever the operator tries to change the direction of the machine, the loader's on-board computer will detect that high gear is shifting and will automatically activate the brakes to stop the machine. Thus, even if the operator has this bad habit, he won’t need to relearn the gearbox: the machine will take care of a possible problem and be able to prevent it. "

Loaders are also equipped with additional automated functions that help protect critical equipment components and assemblies. For example, loaders have protection against overheating. “If an overheat of any system (for example, an engine or transmission) occurs, the engine will go into a deformed operation mode to prevent possible damage,” comments Chesterman, “If the axes overheat in our Tier 4i engines, then the operator receives the appropriate warning."

Modern forklifts equipped with smart electronics are able to warn the operator about the occurrence of problems and other types. Sensors transmit data to the operator (indicators of temperature, liquid level, pressure, etc.) from systems operating in critical mode. These data are displayed on the dashboard or on-board computer display. The signal LEDs and instrument dials are arranged so that the operator draws attention to the operation of alarms during operation before any breakdown occurs.

Do not be lazy to waste time warming up the machine and shutting down

Loader operators are often tempted to skip the recommended warm-up of the machine before starting work. However, such negligence negatively affects the condition of the engine and hydraulic system.

“Cold oil doesn’t lubricate parts as well and circulate as well in a circuit as a heated fluid. So warming the machine to the recommended temperature will help extend the life of its key components,” Ellis advises. “Continuous checks of fluid levels are equally important.” daily maintenance. "

“After the operator has started the loader, he must let it warm up to the temperature specified by the machine manufacturer in the operating manual for it,” adds Chesterman, “Additional systems, such as the hydraulic system and axles, do not warm up completely until the machine has started "So the operator should keep in mind that for the first few minutes, until these systems have reached the required temperature level, the machine will not operate at maximum productivity."

It is equally important to give the machine some time to complete work at the end of the shift. “All these roomy diesel engines are now equipped with turbochargers,” says Phillips, “The turbocharger speed averages between 40,000 and 50,000 rpm. If you don't let the engine idle for two or three minutes and cool down a bit, then at the time the engine is turned off, its turbocharger will still operate at about 40 thousand revolutions. "

At the moment of engine shutdown, the oil ceases to be supplied to the turbocharger. “Thus, the turbocharger undergoes tremendous stress and wear at this point,” Phillips concludes, “if you let the engine a couple of minutes to cool before the machine turns off, then the turbocharger is guaranteed to stop spinning at this point. However, if the turbocharger continues to rotate after shutdown of the motor, then its bearings will spin in an unlubricated state, which will lead to overheating and a decrease in the service life of this extremely expensive component. "

Manufacturers of special equipment invent new solutions to reduce these risks. “We equip our technology with shutdown timers,” says Phillips, “In other words, after the operator shuts off the engine, the machine will idle for another three minutes and then shut down.” The cost of this function more than covers the enormous potential costs of replacing a turbocharger in an engine.

Take care of the tires

There are a number of factors that can cause premature wear and tire failure.

“Inexperienced operators tend to slip tires when driving, and this is almost the most detrimental effect on the car. When the traction is disturbed, the tire stops working,” says Phillips, “They don’t use differential locks to lock the front axle and "distribute power to both front wheels instead of one, which would reduce slippage."

Inadequate tire inflation pressure is another common cause of increased tire wear. “We often observe that a significant part of tire damage occurs due to improper inflation,” says Phillips, “For radial tires, low pressure leads to increased heat generation during operation due to the fact that the entire weight of the machine is applied to the contact point of the tire. Thus, if the tire is not inflated to a tough condition, it will overheat. This will result in wear of the rubber surface and a decrease in tire life. "

To solve this problem, John Deere offers an integrated tire inflation pressure monitoring system as an option with his loaders. The differential auto lock system monitors wheel slippage and automatically blocks the differential, reducing tire wear and improving traction, resulting in an increase in overall machine performance.

In some cases, wheel slippage is not the fault of the operator. “The wheels can slip due to the fact that the type of wheels for a particular model is incorrectly selected and does not fit the specific working conditions,” says Phillips, “We’ll give an analogy: if you equip, for example, an all-wheel drive truck with winter tires, then the benefit of this You’ll only extract in the snow, and the remaining 90% of the time they will only interfere. "

It is very important to choose the right tires for a specific work task. This will help ensure an optimal life. “Carefully choose a tread pattern based on your needs,” Ellis advises. For example, off-road tires with a more widely spaced tread pattern will wear out faster on paved surfaces. "If you always have to work on concrete or asphalt, it is better to choose a tread L4 or L5 to minimize tire wear. If you work on the roads, then you should look at off-road tires with a more aggressive tread pattern. Thus, "the tread should be selected based on the type of wear your tires will suffer."

Loaders   - An indispensable equipment in any enterprise where the constant loading and unloading of goods and their storage are carried out. Using this type of equipment can significantly save time on loading operations. In addition, many of the work in the warehouse is simply beyond the reach of the average person, so the technique comes to the rescue.

There are a large number of manufacturers of warehouse equipment. Some of them have already established themselves as suppliers of high-class machines. Chinese forklifts are considered one of the most sought-after machines in the modern technology market. And this is no coincidence. Their price is slightly different from European manufacturers, and the quality remains at the level. In addition, firms from China supply high-quality spare parts and accessories.

Tires for loaders   are an integral part of this type of technology. There are two main types of tires.

Pneumatic tires

This type of tire is designed to work on uneven surfaces. They perfectly smooth out all shocks during movements, while maintaining the suspension of the car. Their main disadvantage is their vulnerability to cuts and punctures. But they can also be used when working in snowy areas. Snow chains are available as optional equipment. They are mounted on the drive wheels, and the operation of the machine becomes more efficient.

Solid tires

Specialists involved in the technical equipment of warehouse equipment will help you choose the most suitable option for all kinds of working conditions of the equipment. With the right choice, tires can last a long time without creating problems with their replacement.

TO   category:

Electric cars

Change of tires of wheels of electric cars and loaders

When rubber is worn, the old bandage is removed and the rubber bandage is put on. This operation is carried out under a screw or hydraulic press with a force of about 500 kg. It is not recommended to use a pneumatic hammer to remove the bandage and its nozzle, since the ring may be skewed and the bandage and rubber damaged. Below is a method of removing a bandage with worn rubber and fittings of a new bandage on the front wheel of an electric car EK-2. In a similar way, the wheel bandages of other electric cars and loaders are replaced.

To remove and attach the bandages from mild steel, a support part (Fig. 75) is made with a diameter of 3-4 mm less than the diameter of the bandage so that it can sit on this part freely during the pressing. The height of this part of the part should be greater than the height of the bandage. 10-15 mm.

The steel ring 4 should have an internal diameter of 1.5-2 mm larger than the diameter of the bandage, and the outer diameter should be such that the ring does not press the rubber of the bandage.

To remove the bandage, a locking bolt 5 is turned out, the wheel is mounted on the supporting part and a ring is applied to it. A press, directed vertically downward along arrow P, will upset the bandage on the support part.

After this, it is necessary to inspect the wheel seat, clean it of dirt and rust, remove burrs and burrs, grease with machine oil and install on the supporting part.

Fig. 75. Change of bandages of wheels.

Heat the new bandage in a water bath to a temperature of 50-60 ° C, then carefully install it on the wheel; put the ring on the bandage so that it does not touch the rubber and press with the press. In this case, it is necessary to ensure that the force from the press is transmitted evenly to the entire ring. When landing the bandage to the entire height of the wheel, you must stop pressing so that it does not go further than necessary. After the nozzle in the bandage, a hole is drilled along the hole of the wheel drum, a thread is cut and a locking bolt is screwed.

Tire removal
WARNING!

Bleed the tire completely before removing it. The air pressure in the tires can cause them to explode, as a result of which people can be injured or killed.

Firmly hold the tools with which you remove the tires, as if the tool slips, it can cause damage.

Note:   Loaders can use several types of wheels. When removing tires, refer to Figure 24.

1. If a 4-piece rim is used, turn the valve ¼ of a full turn and remove it.

2. Place the wheel on the press. Position the press base in the middle of the wheel. Press the press to open the circlip

3. Take out a lock ring of a wheel, and also an additional tape (only 4-component models), using special tools.

4. Lift the press and remove the circlip and extra belt (4-piece models only) from the wheel.

5. To remove the TBS, click on it towards the inside of the tire.

Attaching the tire to the rim

WARNING!

Failure to follow these procedures may result in wheel damage or bruising or death:

- Clean and inspect all parts of the wheel before installing the tire.

- DO NOT use damaged or repaired wheel parts.

Do not use a steel hammer when working with wheels. Use rubber, lead, plastic or copper hammers to connect the parts of the wheel.

WARNING!

Do not lubricate the tire bead with antifreeze or petroleum lubricant. Their evaporation can cause an explosion during inflation or use.

1. Clean the outside and inside of the bead. Lubricate the tire bead and its inside. Grease TBS well.

Note:If the width of the inner side surface of the wheel rim is less than 7 inches (17.5 cm), the TBS must have one valve hole to accommodate the needle valve. If the width of the inner side surface of the wheel rim is more than 6 inches, the TBS should have two needle valve openings. One hole is located in the middle, and the second side, for the exact positioning of the valve in the hole. An unused hole must be covered with a small plastic plug.

2. Lubricate the needle valve and the hole to be used (see Note) by inserting and pulling out the greased valve. If using a 3- or 4-piece rim, pull out the valve. If a 2-piece rim is used, leave the valve in the hole.
If the TBS has two valve openings, lubricate the plastic plug and insert into the opening that will not be used.

3. Place the TBS inside the tire, making sure the TBS wings are not curled. Mark the tire to mark the position of the valve hole in the TBS.

4. Lubricate the rim thoroughly. In 4-piece models, lubricate the extra tape. Slide the tire and TBS onto the wheel.

Align the valve hole in the TBS with the valve itself. Lubricate and insert the valve into the hole. Make sure it is fully inserted.

5. Place the tire on a flat surface. Turn the valve ¼ turn to secure the ring at the edges of the valve hole on the rim.

6. Lift the tire and place the press, “threading” it through the hole in the tire. Insert the following parts into the wheel:

• 
  Extra tape (4-piece rims only)
• 
  Snap ring lock
• 
  Snap ring

7. Insert the optional tape. Make sure that it is not too depressed and does not interfere with valve operation. Put the press on the lock ring lock.

Press and hold it in this state until the circlip is in place.

8. Insert the equipment into the groove of the retaining ring on one side and the pressure grip on the other. Remove the screw grip. Remove the press and make sure that all parts of the wheel are in place. Replace the valve core.

9. Inflate tires to a pressure of 103 kPa. Plug the hole with a stopper using a hammer to ensure a tight fit. Move the press.

Inflating pneumatic tubeless tires

WARNING!

Adding air pressure to the tires should only occur with a protective guard. See Figure 31. Check the guard for damage before use. When increasing pressure, use the holder to secure the valve core. Make sure that the hose is long enough for the operator to move a safe distance when pumping. Do not sit or stand near the fence.

Add air to the tire until the pressure value is equal to that indicated on the nameplate. Put the cap on the valve so that the air does not come back.

FIGURE 31. Inflation of tubeless tires
Wheel setting
Establish a wheel on a nave. Tighten the nuts in accordance with the Maintenance Schedule section of this manual. If two-piece rims are used, make sure that the nuts connecting the two parts together are tightened.

Solid tires and lock tires
WARNING!

Tire replacement and repair should only be carried out by qualified personnel.

Always wear safety glasses.

1. Place the loader on the bars as described in the “Installing the loader on the bars” section at the beginning of this section.

2. Loosen the nuts and remove the wheels from the loader. Do not forget that loader tires are heavier than usual.

Note:See Figure 32. when removing the wheels. Several types of wheels can be used on this series of loaders.

FIGURE 32. STRUCTURE OF THE WHOLE-TIRE COVER WITH LOCK AND RIM

Dismantling a solid tire with a lock from the rim (See Figure 33)

WARNING!

Hold the tools firmly with which you remove the tires, as if the tool slips, it can cause serious damage.

Step 1.Place the wheel on a flat surface. Make sure that the distance from the wheel to the press is at least 150-200 mm (6-8 inches).

FIGURE 33. TIRE REMOVAL FROM WHEEL

Mounting the solid tire on the rim

(See Figure 34)

Note:After removing the wheels, see Figure 32. Several types of wheels can be used on loaders.

Step2. Place the safety guard on the bus. Use a press to remove the tire from the rim

WARNING!

Failure to follow these procedures can result in damage to the tire and wheelbase, as well as harm to humans.

Clean and inspect all parts of the wheel before installing the tire.

- DO NOT use damaged or damaged parts of the wheel.
- Make sure that all parts of the wheel are in place.
- DO NOT use different parts from different manufacturers on the same wheel.

Step 1.

Lubricate the wheel rim and the inside of the tire.
FIGURE 34. TIRE INSTALLATION ON A WHEEL

- DO NOT use tires, treadmills, or parts of a wheel from different companies on the same truck.
CAUTION!

Too much grease can cause the tire to slip around the wheel rim.

Step 2   Place the rim on the press. Put the tire on top. Put the safety guard on the bus. Use the press to mount the tire to the rim
Operating methods with a new or remanufactured engine
For the first 50 hours of operation, a new or remanufactured engine must operate under special conditions. These conditions are used to prevent breakdown or damage to the engine when its new parts have not yet “adjusted” to each other.

1. Verify that the oil and coolant levels are normal.
2. At the first start, start the engine for half an hour. Check sensors and indicators for proper operation. Check for leaks.
3. During the first 4 hours of operation, under normal conditions, loads of 50% of the maximum capacity of the truck can be transported. The minimum load of the loader should be 75% of the load capacity. Change the engine speed, go from idle to full throttle and back to idle. During the first 50 hours of operation, avoid long periods of engine operation at high speeds. High engine speeds at low load can damage the cylinders.

Forklift storage
The following procedures are advisable only if the air temperature is greater than 0ْ C. Adapt these procedures to the existing conditions and the changes that are taking place. The preparation required for storage depends on the following:

Short-term storage is 1-6 months. Long-term - from 6 months.

Location of storage. A loader stored inside a room does not require such protection from external factors as the one stored on the street.
Short-term storage

To store the loader for 1 to 6 months, follow these steps:

1. Check lubrication and fuel level. Fill the fuel tank completely. Ensure that the coolant protects the cooling mechanism and engine even at the lowest temperatures expected during storage. Make sure the protective covers and levels are installed correctly.

2. Fully lower the forks or carriage. Tilt the mast forward so that the ends of the forks touch the floor. The cylinder rod must be covered with a film of oil.

3. Check that all switches and levers are in the off position.

4. If the forklift is to be stored on an inclined surface, place it on the side opposite to the inclined side so that the forklift does not move. Do not use the parking brake.

5. Disconnect the battery cables. Additionally, insulate the cable connectors and battery terminals to prevent corrosion.

6. Check tire pressure. Make sure that it matches the nameplate.

7. Clean the loader and engine to prevent corrosion.

8. If the truck will not be stored indoors, cover it to prevent damage from the weather. In wet weather, protection will not prevent corrosion that occurs during prolonged storage outside a dry room.

Long term storage
To store the loader from 6 months, follow these steps:

1. Complete all that is required for short-term storage.

2. Cover all exterior lights, grille, and air intakes with waterproof material. To fix it, use tape.

3. Remove the batteries. Put them in a safe place. Make sure that there are no obstacles. For a long time, a non-working battery may be damaged. If possible, it is recommended to use it on other machines.

4. Cover the loader with protective material.

LOADER TRANSPORT
P WARNING!

Keep a safe distance from the corners of the docks, ramps, platforms, and similar work surfaces. Make sure there is enough space for the "Turn Back". When moving in front, remember that when you want to turn at the edge of a surface, it is on that surface that you will have to "turn backwards." This may cause the truck to fall.

WARNING!

If the truck falls off the dock, do not jump out! Hold the steering wheel firmly, bring your feet together and lean toward the opposite side of the fall.

Before starting the loader on any transport, make sure that at your chosen course there is enough space to place the loader.

Bridges, crossings, high-voltage lines, natural obstacles can interfere with the passage. Mast removal may be required.

If the truck will be transported using a trailer, use blocks to prevent the trailer from moving during loading or unloading of the truck. If a cargo ladder is used, make sure that it matches the parameters.

If the loader is equipped with lifting loops, use a crane to load and unload the loader into vehicles. If the loader is not equipped with lifting loops, do not lift the loader using other means of loading and unloading.

Loading

If some parts or accessories of the loader must be dismantled for loading, see the “Repair Instructions” section of this manual.

The operator must not leave the truck if it is in danger. Before loading onto vehicles, do the following:

A. Install the parking brake.

B. If the mast is mounted on the forklift, fully lower the forks and the load carriage. Tilt the mast forward so that the ends of the forks touch the floor.

C. Put the automatic transmission in neutral. If the loader has a manual gearbox, leave it engaged. Do not leave the manual gearbox in neutral!

D. Turn the switch to OFF to stop the engine. Make sure that all switches are in this position.

E. Place blocks in front and behind the truck to prevent it from moving undesiredly. Make sure the blocks are attached to the surface.

If the truck is equipped with an LPG fuel system and is stopped for a short time, close the tank fuel valve. If he will be in this position for a night or longer, leave the truck on the street or remove the tank.

No matter what the equipment is and how it is not operated, it will still be serviced and will be the most frequent breakdowns both among the Japanese and the Germans, and especially the Chinese.
Most often, you have to change.
These are driving wheels, on different techniques they are different, you need not be too lazy and see what's down there.
One of the wheel options

To change it, you need to raise the bottom by 30 cm, there are very good jacks with low grip, but if it is not there you can do it with improvised means. You will need wooden blocks that need to be put under the car so that your hands do not cut off. Next, the head and extension cord and with sudden movements you need to break the nuts or bolts. Sometimes it happens that the wheel sticks very tightly and you have to cut it off with a grinder after removing the gear assembly and the wheel. But this is VERY rare, it is necessary to start the equipment to such an extent that ........ we will not be bad. They took it off - they set it up just as strongly cross it, stretched it out and that's it.

Support wheels. Here, the same thing on different equipment, they look different and the sizes are different, to find out what you have to look at what's down there. One of the options for the support wheel is

Or with a fork assembly.

In the support wheels themselves there are bearings that also fail, plus there is a bearing on the plug itself, there are ordinary bearings and are assembled together with the fork. If we are talking about replacing only the support wheel, then we take a couple of wrenches or heads with extension cords as well wooden blocks and something long so that the wheel can be fixed as it rotates in a circle when you unscrew the nut. They unscrewed the nut, removed the wheel, there can be all sorts of different washer bushings, then we put everything in place. All.

Fork rollers - wheels. They look like this -

Or with a bearing

Or assembled with brackets

These videos are only three types or are only assembled with brackets. Depending on the wear of the seats of the fingers of the rollers, it is necessary to decide what to change already during the play. If you’re not very much killed, then you can get by with the wheels if it’s badly broken then the assembly. Sometimes I had such an owner of the Lema equipment - there it is necessary if you want to deploy a larger diameter for the mind, make bushings for this diameter and insert it and hammer fingers into them. prices and downtime ........ the client did not like this situation, okay, master of the master. He indicated that it was necessary to do what was found out and whether or not it was up to me to make a decision. To replace, you would need to poke out the same size as the cotter pin, wooden blocks. We fill the machine on its side so that it is convenient to work, we fix the equipment better on the wall. When you work with a hammer and sometimes the stacker can move with a sledgehammer, so you need to fix it. We knock out these cotter pins before WD process. It is necessary to knock out sharply, precisely, so that the punch is in the diameter of the hairpin. It is difficult to drill because these cotter pins are red-hot. Assemble the wheels in reverse order.

After removing the plastic protection, you can see where they stand, in which chain. As a rule, they stand on the hydraulics and the course - moving forward and backward. Lifting can also be a contactor. The principle of its operation is the same as that of a car relay, plus or minus power is suitable for the contactor, and accordingly, the control wire can be either plus or minus. If there is power, the contactor clicks; the technique works; if it does not click, it means no or plus or minus.

To check you need a tester for 300 rubles, we put it on a constant voltage according to the battery voltage and we check that there are minus and plus power to thin wires. Well then, if it is a contactor - by disconnecting the power from the battery, we change the contactor.

This is an optical sensor. It works on metal when the metal in the form of lowering the handle or something else looking where it is standing, crosses its field (there should be a gap between it and the metal), it works, almost all sensors have an LED when it works, it lights up. If it’s off, you need to look for why it’s off. It changes easily - you cut off the solder and you're done.

Microswitches and sensors. They are -

They stand on the mast on the steps and in places where the handle bends.
These mickeys can be checked as follows. As a rule, there is a plus or minus. It closes, the power circuit is respectively a plus or minus, too, if it clicks but the tester does not ring on its outputs, the mikrik is malfunctioning. Change it easily - solder and solder as it was. In all cases, when you change something in the electrician, you need to disconnect the connector from the battery.

Spare parts - consumables are not so expensive, they are sold freely, buying is also not a problem, 80 percent of what was transported to the Moscow region is available, but of course there is something but it is exclusive, you just need to know how to change and which tool you need. As a rule - a sledgehammer and keys from the nearest mag.auto parts. Pay a lot of money when you can do it yourself ............ meaning?

  Here are the most frequent breakdowns that you can fix yourself. Well, or pay dollars .........