Kalmar DCE80-100E, Technical Handbook

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DCE80-100E
Technical Handbook
Safety regulations
5 P. Group 00
TDCE01
04GB
z Tyre changing can be dangerous and should only
be carried out by specially trained personnel using
proper tools and procedures.
Failure to comply with these procedures may re-
sult in faulty positioning of the tyre and/or rim and
cause the assembly to burst with explosive force
sufficient to cause physical injury or death. Never
fit or use damaged tyres or rims.
z Never attempt to weld on an inflated tyre/rim
assembly.
z Never let anyone assemble or disassemble tyres
without proper training.
z Never run the truck on one tyre of a dual assembly.
The load capacuty of a single tyre is then danger-
ous-ly exceeded and operation in this manner may
damage the rim.
z Deflation and dismantling
– Always block the tyre and wheel on the opposite
side of the vehicle before you place the jack in
position. Always crib up the blocks to prevent
the jack from slipping.
– Always check the tyre/rim assembly for proper
component seating prior to removal from the
truck.
– Always deflate the tyre by removing the valve
core prior to removing the complete assembly
from the truck or dismantling any of the compo-
nent. Before loosening mounting bolts, run a
wire through the valve stem to ensure that it is
not blocked. Ice or dirt can prevent all the air
from escaping. Deflate and remove valve cores
from both tyres of a dual assembly.
– Never position body in front of the rim during de-
flation.
– Always follow assembly and dismantling proce-
dures outlined in the manufacturer’s instruction
manual, or other reconized industry instruction
manuals. Use proper rubber lubricant.
– Never use a steel hammer to assembling or dis-
mantling rim components – use a lead, brass or
plastic type mallets. The correct tools are avail-
able through rim/wheel distributors.
– remove bead seat band slowly to prevent acci-
dents. support the band with your thigh and roll
it slowly to the ground in order to protect back
and toes.
– Disassembly tools apply pressure to rim flanges
to unseat tyre beads. Keep your fingers clear.
Slant disassembly tool about 10 degrees to
keep it firmly in place. Always stand to one side
when applyin g hydraulic pressure. Should the
tool slip off, it may cause fatal injury .
z Rim inspection
– Check rim components periodically for fatigue
cracks. Replace all cracked, badly worn,
damaged and severely rusted components.
– Always select the correct tyre size and construc-
tion matching the manufacturer’s rim or wheel
rating and size.
– Do not use over-size tyres, too large for the
rims, e.g. 14.5 inch tyres with 14 inch rims or
16.5 inch tyres with 16 inch rims.
– Never use damaged, worn or corroded rims/
wheels or fitting hardware. Always verify that the
rim is in a serviceable conditioning.
– Always clean and repaint lightly rusted rims.
– Never use a rim/wheel component that can not
be identified. Check rim parts against multi-
piece rim/wheel matching charts.
z Assembly and inflation
– It is important that the inflation equipment is
equipped with a water separator to remove
moist-ure from the air line in order to prevent co-
orosion. Check the separator periodically to en-
sure that it is working properly.
– Make sure that the lockring is in its right position.
– Never mix different manufacurer’s parts since
this is potentially dangerous. Always check
manu-
facturer for approval.
– Never seat rings with hammering while the tyre
is inflated. Do not hammer on an inflated or par-
tially inflated tyre/rim assembly.
– Always double check to ensure that the rim as-
semblies have been correctly assembled and
that securing studs and nuts are tightened to the
correct torque setting.
– Never inflate tyres before all side and lockrings
are in place. Check components for proper
assembly after pumping to approximately 5 psi
(=34 kPa, =0.34 bar)
– When adding air to a tyre on an industrial truck,
use a clip-on chuck and stay out of the danger
area. If the tyres has been run flat then the rim
must be dismantled and all parts inspected for
damage.
– Under-inflated tyres have a serious effect on the
stability of the truck and reduces the safe load
handling capacity. Always maintain tyres at the
correct inflation pressures. Check inflation
pressure daily. Do not over-inflate.
– Inspect tyres regulary – every day if possible.
Look for and remove broken glass, torn pieces
of tread, embedded metal chips etc. Inspect for
uneven or rapid tread wear, usually caused by
mechanical irregularities, such as brakes out of
adjustment or excessive toe-in and toe-out. If
discovered, correct the irregularity immediately.
z When installing and tightening trail wheel bolts, ob-
serve the following:
– Ensure that trail wheel or hub mounting surfac-
es and trail wheel fastener mounting surfaces
are clean and free from paint and grease.
– Tighten bolts to specified torque settings. use
staggered sequence; i.e. top bolt, bottom bolt
etc.
Safety instructions for working with tyres