The owner's manual contains information about the operation and maintenance of the original forklift. Sometimes additional equipment is installed that may change the performance described in this manual.

High-quality installation of forklift tires ensures the correct fit of the tire on the rim. Professional work- excellent result. Our service center installs pneumatic tires for forklifts and solid tires with landing diameters up to 15 inches.

Today it is not difficult, but it is problematic to mount them on rims (wheel discs). From us you can not only purchase tires of the desired type and size, but also install/dismount them.
To perform such an operation, a force of 10 to 160 tons may be required. Even with a small diameter forklift tire, special conditions are required, otherwise misalignment can reduce the service life of the wheel by half. Our service has the necessary equipment that allows you to quickly carry out high-quality installation / dismantling of pneumatic and solid (other names for tires: superelastic, gusmatic) tires for loaders with different bore diameters. We carry out installation using technology that eliminates distortion of the rubber inside the tire, which will protect against uneven tread wear.

We carry out tire fitting of tires for cars and electric forklifts of the following brands: Toyota, Komatsu, TCM, Mitsubishi, Nissan, Caterpillar, Jungheinrich, Linde, Still, Nichiyu, Heli, Hangcha, JAC, Utilev, Maximal, Dalian, TFN, Daewoo-Doosan ; Hyundai, Clark, Yale, Hyster, Manitou and many others

If necessary, we can arrange for the collection of worn tires on rims, mount new tires on rims and deliver them back to you to the place of operation.

To carry out tire fitting work, you need to contact our specialists by calling 8-495-775-44-66 ext. 1202, 1201

Cost of tire fitting and delivery of tires for forklifts

Why is it profitable to change tires at Eurowarehouse?

• When purchasing a set of tires and wheels for a loader from our company, the installation service is provided free of charge
• NO DOWNTIME! Additional free service for the provision of replacement wheels “superelastic” (removal/installation of replacement wheels – FREE!). And while the new wheels are being installed, your equipment is working in normal mode! The service is provided when purchasing tires from our company and simultaneously replacing sets of tires on two loaders.

The range of replacement wheels is limited; before carrying out tire fitting work, you need to contact our specialists by calling 8-495-775-44-66 ext. 1202, 1201

(except hydrostatic brake systems) operate on the principle of friction, and friction leads to heat generation. Using your brakes too often and too hard will cause them to overheat and wear out prematurely, which in turn can lead to brake failure. The most common examples of brake “abuse” are:

an unskilled operator does not know how to calculate his strength and the capabilities of the machine: he accelerates the machine 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 pedal, he often makes accidental presses;

Operators working in a hurry (for the sake of achieving greater productivity or exceeding standards) when working over short distances, first squeeze the gas hard, and then slam on the brakes to stop.

To extend brake life, Kawasaki experts recommend that novice operators release the gas pedal and start slowing the machine a little earlier, so that the loader coasts and braking occurs due to the weight of the machine itself and the cargo being transported, and press the brake pedal when the machine is almost stopped.

It is also important to understand the principles of how to use clutch release most effectively. “We often see a lot of operators who don't know how to use the clutch release,” says Phillips. “When they're loading material into a truck bed or bin, they drive with the brakes on, which wears out the brakes instantly.”

Disengaging the clutch allows the transmission to shift into neutral during the braking cycle. “Pressing the release pedal puts you in neutral and then you can apply the brakes,” explains Phillips. “After that, if you press the accelerator pedal with the brakes on to start working on the machine's hydraulics (for example, if You want to raise or lower the bucket or control the movement of the boom), then the loader will no longer accelerate against braking."

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

Most often this happens due to high gears. “In other words, the operator uses the gearbox and torque converter to change the direction of the machine,” Phillips says. The operator engages reverse, drives for a while, and then with one push switches the gearbox to forward speed and squeezes the gas, or vice versa. “Operators manage to carry out loading and unloading operations that require constant switching between forward and reverse, without even pressing the brake pedal! It turns out that all these loads fall to the share of the gearbox and torque converter, which as a result overheat.”

More often than not, the situation is made worse by operators seeking to reduce cycle times to improve productivity. This can lead to premature failure of these expensive systems. Thus, manufacturers have to come up with ways to overcome this situation.

For example, Volvo has developed an Optishift transmission system, which is installed by default on large models of the company's forklifts, and allows the operator to immediately shift into high gears, but automatically activates the brakes in this case. “We call this reverse braking,” says Phillips, “Whenever the operator tries to change the direction of the machine, the on-board computer will detect that a high gear shift is occurring and automatically apply the brakes to stop the machine. So, even if the operator has this bad habit, he will not need to relearn how to operate the gearbox: the car will take care of itself possible problem and can prevent it."

The loaders also come with additional automated features to help protect critical components and equipment. For example, forklifts are protected against overheating. “If any system (such as the engine or transmission) overheats, the engine will go into overdrive to prevent potential damage,” comments Chesterman. “If the axles overheat on our Tier 4i engines, the operator will receive the appropriate warning."

Modern forklifts, equipped with smart electronics, are able to warn the operator of problems and other types. Sensors transmit data to the operator (temperature, liquid level, pressure, etc.) from systems operating in critical mode. This data is displayed on the dashboard or on-board computer display. Alarm LEDs and instrument dials are positioned to alert the operator to alarms during operation before any failure occurs.

Forklift 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 does not lubricate parts as well and does not circulate as well as warm fluid, so warming up the machine to the recommended temperature will help increase the life of its key components,” advises Ellis. daily maintenance."

“Once the operator starts the forklift, he should allow it to warm up to the temperature specified by the machine manufacturer in the machine's owner's manual,” adds Chesterman. “Additional systems, such as the hydraulic system and axles, do not fully warm up until the machine is in operation. So the operator must keep in mind that for the first few minutes, while these systems have not yet reached the required temperature level, the machine will not operate at maximum performance."

It is equally important to give the machine some time to complete its work at the end of the shift. "All these roomy diesel engines are now equipped with turbochargers," says Phillips. "Turbocharger speeds average between 40,000 and 50,000 rpm. If you do not allow the car's engine to idle for two or three minutes and cool down a little, then when the engine is turned off, its turbocharger will still be running at about 40 thousand revolutions."

When the engine is switched off, oil stops flowing to the turbocharger. “So the turbocharger is under a tremendous amount of stress and wear at this point,” Phillips concludes. “If you give the engine a couple of minutes to cool before turning off the car, the turbocharger is guaranteed to stop spinning by that point. However, if the turbo continues to spin after shutting down motor, its bearings will spin in an ungreased state, which will lead to overheating and reduced service life of this extremely expensive component."

Manufacturers of special equipment are constantly inventing new solutions to reduce these risks. “We equip our machines with shutdown timers,” says Phillips, “in other words, after the operator turns off the engine, the machine will idle for three minutes and then shut down.” The cost of this feature more than covers the huge potential cost of replacing the turbocharger in the engine.

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

"Inexperienced operators tend to spin their tires when driving, which is one of the most detrimental effects on a machine. When traction is lost, the tire stops doing its job," says Phillips. "They don't use differential locks to lock the front axle and provide power distribution to both front wheels instead of just one, which would reduce slipping."

Inadequate tire inflation pressure is another common cause of excessive tire wear. “We often see that a significant portion of tire failures are due to improper inflation,” says Phillips. “For radial tires, low pressure results in increased operating heat due to the full weight of the vehicle being applied to the point where the tire contacts the surface. Thus, if a tire is not inflated to a tight level, it will overheat, causing wear on the rubber surface and reducing the life of the tire."

To solve this problem, John Deere offers an integrated tire pressure monitoring system as an option on its loaders. The Auto Differential Lock system detects wheel slip and automatically locks the differential, reducing tire wear and improving traction for improved overall machine performance.

In some cases, wheel slip is not the fault of the operator. “Wheels can spin because the wheel type for a particular model is not properly selected for the specific operating conditions,” says Phillips. “As an analogy, if you equip, for example, a four-wheel drive truck with winter tires, then it will benefit You will only extract when it snows, and the other 90% of the time they will only get in the way."

It is very important to select the right tires for a specific work task. This will help ensure their optimal lifespan. "Choose your tread pattern carefully based on your needs," advises Ellis. For example, all-terrain 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 surfaces, then it is better to choose an L4 or L5 tread to minimize tire wear. If you work off-road, then you should take a closer look at all-terrain tires with a more aggressive tread pattern. Thus, The tread should be selected based on the type of wear your tires will be subject to."

Let the air out of the tire completely before removing it. Tire pressure can cause tires to explode, resulting in injury or death.

Be sure to hold the tools you use to remove tires firmly, as damage may result if the tool slips.

Note: Several types of wheels can be used on forklifts. Refer to Figure 24 when removing tires.

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

2. Place the wheel on the press. Place the base of the press in the middle of the wheel. Press down to open the locking ring

3. Remove the wheel retaining ring as well as the extra strap (4-piece models only) using the special tools.

4. Raise the press and remove the retaining ring and extra band (4-piece models only) from the wheel.

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

Installing the tire on the rim

WARNING!

Failure to follow these procedures may result in wheel damage or injury 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 on wheels. Use rubber, lead, plastic or copper hammers to connect the wheel parts.

WARNING!

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

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

Note: If the inner sidewall width 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 inner sidewall width of the wheel rim is greater than 6 inches, the TBS must have two holes for the needle valves. One hole is located in the middle, and the second on the side, for precise positioning of the valve in the hole. The hole that is not in use should be closed with a small plastic plug.

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

3. Place the TBS inside the tire, making sure the TBS wings are not bent. Make a mark on the tire to mark the position of the valve hole in the TBS.

4. Lubricate the rim thoroughly. On 4-piece models, lubricate the additional tape. Place the tire and TBS on 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 to 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)
• 
  Retaining ring lock
• 
  Retaining ring

7. Insert additional tape. Make sure that it is not pressed in too much and does not interfere with the operation of the valve. Place the press on the locking ring lock.

Press down with a press and hold it in this position until the locking ring is in place.

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

9. Inflate the tires to 103 kPa. Plug the hole with the plug using a hammer to ensure a tight seal. Move the press away.

Inflating pneumatic tubeless tires

WARNING!

Adding air pressure to tires should only be done with a protective guard in place. See Figure 31. Check the guard for damage before use. When pressure increases, use a holder to secure the valve core. Make sure the hose is long enough to allow the operator to stand a safe distance when inflating. Do not sit or stand near the fence.

Add air to the tire until the tire pressure is equal to the pressure indicated on the tire rating plate. Place the cap on the valve to prevent air from escaping.

FIGURE 31. Inflating tubeless tires
Wheel installation
Install the wheel onto the hub. Tighten the nuts in accordance with the “Schedule” section maintenance» of this manual. If using two-piece rims, make sure the nuts holding the two pieces together are tight.

Solid tires and tires with a lock
WARNING!

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

Always wear safety glasses.

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

2. Unscrew the nuts and remove the wheels from the loader. Keep in mind that forklift tires are heavier than normal tires.

Note: See Figure 32 when removing wheels. Loaders in this series can use several types of wheels.

FIGURE 32. STRUCTURE OF SOLID TIRE WITH LOCK AND RIM

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

WARNING!

Be sure to hold the tools you use to remove tires firmly, 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. REMOVING THE TIRE FROM THE WHEEL

Installing a solid tire on a rim

(See Figure 34)

Note: After removing the wheels, see Figure 32. Forklifts can use several types of wheels.

Step 2. Place a tire guard on the tire. Use a press to remove the tire from the rim

WARNING!

Failure to follow these procedures may result in damage to the tire and wheelbase and may result in personal injury.

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

- DO NOT use damaged or repaired wheel parts.
- 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. INSTALLING THE TIRE ON THE WHEEL

- DO NOT use tires, treads or wheel parts from different companies on the same forklift.
CAREFULLY!

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

Step 2. Place the rim on the press. Place the tire on top. Place a tire guard on the tire. Use a press to install the tire onto the rim
Methods of operation with a new or rebuilt engine
For the first 50 hours of operation, a new or remanufactured engine must be operated under special conditions. These conditions serve to prevent breakdown or damage to the engine when its new parts have not yet “adjusted” to each other.

1. Make sure the oil and coolant levels are correct.
2. When starting for the first time, start the engine for half an hour. Check sensors and indicators for proper operation. Check if there are any leaks anywhere.
3. During the first 4 hours of operation normal conditions Loads up to 50% of the maximum lifting capacity of the forklift can be transported. The minimum load on the forklift should be 75% of the lifting 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 running the engine at high speeds. High engine speeds with a small load can damage the cylinders.

Forklift storage
The following procedures are only appropriate if the air temperature is above 0°C. Adapt these procedures to the existing conditions and changes occurring. The preparation required for storage depends on the following:

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

Storage location. A forklift stored indoors does not require such protection from external factors like the one stored outside.
Short term storage

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

1. Check lubrication and fuel level. Fill the fuel tank completely. Ensure that the coolant will protect the cooling mechanism and engine even at the coldest temperatures expected during storage. Make sure correct installation protective covers and levels.

2. Lower the forks or carriage completely. Tilt the mast forward until the tips of the forks touch the floor. The cylinder rod must be coated 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 opposite side of the incline 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 poles to prevent corrosion.

6. Check tire pressure. Make sure it matches what is shown on the nameplate.

7. Clean the truck and engine to prevent corrosion.

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

Long-term storage
To store the forklift for 6 months or more, follow these steps:

1. Complete all short-term storage requirements.

2. Cover all exterior lights, grille, and air intakes with waterproof material. Use tape to secure it.

3. Remove the batteries. Put them in a safe place. Make sure there are no obstacles to this. A battery that is not used for a long time may be damaged. It is recommended to use it on other machines if possible.

4. Cover the forklift with protective material.

TRANSPORTING THE LOADER
P WARNING!

Keep a safe distance from dock corners, ramps, platforms and similar work surfaces. Make sure there is enough space to “Turn Backwards”. When driving forward, remember that when you want to turn at the edge of a surface, it is on this surface that you will have to “turn backwards.” This may cause the forklift to fall.

WARNING!

If the forklift falls off the dock, don't jump out! Hold the handlebars firmly, bring your feet together and lean toward the side opposite to where you are falling.

Before placing a forklift on any vehicle, check that the course you have chosen has enough space to accommodate the forklift.

Bridges, crossings, lines high voltage, natural obstacles may interfere with travel. The mast may need to be removed.

If the forklift will be transported on a trailer, use blocks to prevent the trailer from moving while loading or unloading the forklift. If a cargo ramp is used, make sure it fits the specifications.

If the forklift is equipped with lifting eyes, use a crane to load and unload the forklift onto the vehicle. If the forklift is not equipped with lifting eyes, do not lift the forklift using any other means of loading or unloading.

Loading

If some parts or equipment of the forklift must be removed for loading, see the Repair Instructions section of this manual.

The operator should not leave the forklift if he or she is in danger. Before loading onto transport, do the following:

A. Set the parking brake.

B. If the forklift is equipped with a mast, lower the forks and load carriage completely. Tilt the mast forward so that the ends of the forks touch the floor.

C. Place the automatic transmission in neutral. If the forklift has a manual transmission, leave it engaged. Do not leave the manual transmission in neutral!

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

E. Place blocks at the front and rear of the forklift to prevent unwanted movement. Make sure the blocks are attached to the surface.

If the forklift is equipped with an LPG fuel system and is stopped for a short period of time, close the fuel tank valve. If it will remain in this position overnight or longer, leave the forklift outside or remove the tank.

Today it's hard to imagine modern enterprise without the use of special equipment, which helps to quickly and efficiently perform all necessary loading and unloading operations. Unfortunately, over a certain period of time, even new technology requires technical inspection and preventive maintenance. The most common parts that need to be repaired and replaced are the forklift's electronics and tires. ITS-Holding company offers high-quality and inexpensive tires for forklifts at an affordable price to every client.

The main causes and stages of tire wear.

— The first stage or simple wear of the loader tires. This type of wear is characterized by damage, which is achieved by fifty percent wear of the rubber surface.

— Damage of varying depths in the form of small potholes across the entire surface of rubber tires. Improper operation of equipment, various debris on the floor covering, driving on a curved surface are the main reasons for significant damage to the rubber covering.

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— Metal thresholds, sharp surfaces, and uneven floors are the main reasons for the appearance of cuts in the rubber surface.

— When making sharp maneuvers or not following operating rules, abrasions may occur on the rubber coating of the tires.

How to change tires on a forklift?

— First of all, you need to evaluate all the loader tires for wear and determine the need for replacement. If the damage is minor, you can try to restore the surface using available methods. If the tire is severely worn or damaged, it must be replaced with a new one.

— When the degree of tire wear has been determined, you need to prepare a place for all necessary work. You also need to prepare all the necessary tools and new tires for replacement.

— To quickly and efficiently replace a tire, you need to use a jack. To remove the nuts from the wheel, you must use an air impact wrench. It is best to entrust this procedure to a professional master. This will guarantee a long service life for the new tires.

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— In addition, to avoid premature tire wear, you must follow the operating instructions for the forklift, and also clean the floor covering from dangerous objects that could damage the rubber surface of the forklift tires.

TO category:

Electric cars

Changing wheel tires for electric cars and forklifts

When the rubber wears out, remove the old bandage and put on a bandage with rubber. 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 attachment, as this may distort the ring and damage the bandage and rubber. Below is a method for removing a tire with worn tires and attaching a new tire to the front wheel of an EK-2 electric car. A similar method is used to replace wheel tires on other electric cars and forklifts.

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

Steel ring 4 should have an internal diameter 1.5-2 mm larger than the diameter of the bandage, and the outer diameter should be such that the ring does not put pressure on the rubber of the bandage.

To remove the bandage, lock bolt 5 is unscrewed, the wheel is installed on the supporting part and a ring is placed on it. The press with pressure directed vertically downwards in the direction of arrow P will press the bandage onto the supporting part.

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

Rice. 75. Changing wheel tires.

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