Kalmar DCE80-100E, Technical Handbook

Page: 267 / 317

DCE80-100E
Technical Handbook
Mast and carriage
Service
7 P. Group 80
TDCE01
04GB
Inspection of lifting chains
To increase safety, the lifting chains should be inspected regularly
in accordance with the points below. This should be carried out
during each 1000 h service.
For inspection, the whole length of each chain should be thor-
oughly clean. Carry out the inspection without any load on the
forks.
1. The chain extension should not exceed 3%.
Measure the extension across the 25 links that run across
the guide sprocket most frequently during lifting. The exten-
sion will be greatest here. Compare the value obtained with
that in the table. If the 3% limit is exceeded, the chain or
chains must be replaced.
Check that no pins are loose in the outer washers.
2. Check that there are no visible cracks in any of the links.
3. Check that there is no mechanical damage.
4. Check that the chain is not corroded.
5. Check that the chain bends easily around the guide sprocket
and does not jam when bent.
6. Drive the truck onto a flat surface and set the mast to the ver-
tical position (0° tilt). Lower the forks to the bottom position.
Check that there is a space of 10-20 mm between the forks
and the ground. If not, adjust the lifting chains equally.
After inspection, spray the chains with chain spray.
Inspection of the lifting mast
1. Inspect the lifting mast for damage or wear on the outer or
inner masts.
2. Investigate whether any wear of the lifting mast has been
caused by the support wheels or by worn down sliding
plates.
3. Run the carriage up and down the mast and listen for any un-
usual sounds from the ball bearings.
4. Check that the hose guide pulley runs freely and that it does
not damage the hoses.
5. Run the carriage up and down and check that the hoses do
not tend to climb over one another. If they do, find out wheth-
er the hoses are twisted, by disconnecting the appropriate
hose connections.
Max permissible
Dimension P Dimension dimension
Inch mm across 25 across 25
links of new links at 3%
chain, mm extension, mm
3/4 19,05 476.25 490
1 25,4 635 654
1 1/4 31,75 793.75 817
1 1/2 38,1 952,5 981
2 50,8 1270 1308
2 1/2 63,5 1587,5 1635
IMPORTANT!
If a lifting chain does not pass this
inspection, replace the whole chain.
Lifting chains must not be joined or
re-riveted.
WARNING!
Never carry out service work on a lift-
ing mast when the engine is running.