BASIC

Training module
Analysis of polyurethane tires and wheels

Name Date

Apply to:
Objective Module Summary
B
M After completing this module and given the During the module you:
W examples of tire and wheel failure with a
1.I see incorrect warranty requests.
WB 80% accuracy, will be able to:
WR 2. See the six most common tire failures and
FC/FP
oDetermine the reason for the failure. wheels.
FC 4000 oRecommend a suitable replacement.
3. You will learn how much heat is generated in the
GPW oExplain why it is the best choice
tires and wheels and why it should be mini-
PC 3000 economic.
mitigated the heat.
PC 3500
PE 3000 Reasons for this module. 4. You will learn how to select a replacement
PE 4000 oThe tires and wheels comprise the majority suitable tires and wheels.
PR 3000 maintenance category in a forklift. 5. You will learn about the total cost of reem-
PW 3000
oThe tires and wheels that have failed are to place tires and wheels.
RC
sometimes requested incorrectly for warranty
RC 3000 6. See the procedures for putting in and taking out
and when the claims are rejected
RR 3000
the reason that customers get upset the drums of the traction and load wheels.
RR 3500
unnecessarily. 7. You will have the opportunity to practice; evaluating
RR/RD 5000
oWhen tires and wheels fail, customers failures in tires and wheels, specifying their
RR/RD 5000S
they often choose tires and wheels of appropriate replacements.
RR/RD 5200
lowest price without appreciating how long they last. 8. It will be demonstrated, through the test of
RR/RD 5200S
SC Often, the reason is that the client is trying skills, your ability to determine
SC 4000 to lower maintenance costs or the reason for the wheel failure, will recommend
SP36 think (with good intentions) that "of a replacement with accuracy, and will explain the
SP42 they will wear out anyway. because it is the cheapest.
SP48 Despues de terminar este modulo, comprenderá
SP 3000 those misconceptions. You will learn why the
SP 3200 cheaper tires are often a costly mistake.
SP 3400 It will diagnose the source of the tire failures.
ST 3000 and wheels, and will determine a suitable replacement.
SX 3000 By logging this, you will have the necessary skills.
TS to help the client reduce costs for
TSP tires and wheels, reducing equipment downtime
TSP 6000 and finally improve customer service.
TW
TWR/TR 3000
WAVE
WE/WS 2000
WE/WS 2300
WP 2000
WP 2300

11670 ILLUSTRATION 1

9/04
Crown 2005 DP00652-TRM C Rev. 9/05
Page1of31 Translated: Printed in U.S.A.
Ing. Edgar Prado
 Training module
Analysis of polyurethane tires and wheels
Skills test Decisive point

Your instructor will randomly select tires and wheels. You may be able to skip the parts of
with failures. For each failed wheel and tire the knowledge (reading) and practice of this module yes
the instructor will give the type of composition, the use of demonstrate to the instructor that you can perform and fulfill
forklift, the application and the service distance. with all the requirements of the test of
With 80% accuracy you must: skills.

State the reason for the failure. Can you do this?

Recommend a suitable replacement.
Explain why the long-lasting tire is the Inform your instructor that you are ready to proceed with the
more economical. skills test, that is, the analysis of the
polyurethane tires and wheels.

No/Not sure

Continue reading this module. Later you will have

the opportunity to practice achieving the goals
from this module before taking the test of
skills.

Crown 2005 DP00652-TRM

Page 2 of 31
Translated:
Eng. Edgar Prado
Training module
Analysis of polyurethane tires and wheels
Warranty Claims Technician: "excessive heating. An overload"
usually causes this. The operators
Tire and wheel failures are often they are probably overheating the wheels of
diagnosed as defective. When the load when carrying and bringing heavier loads than the
warranty claims are submitted, perceiving lifting capacity.
what are defective wheels, customers are ...
it may be giving a false expectation of Client: "So I need to talk to my
refund and are often frustrated and operators about observing the weight of the load.
unnecessarily dissatisfied with the service;
when the warranty is rejected. Technician: "yes. Also, if you wish, you could try using
another series 300 of loading wheel. Its forklift
Example: currently equipped with load wheels -302
which are excellent for operations of
Here is a situation that the technicians encounter processing. However, other components
they face: with similar characteristics can result in a
better solution
Technician: "I took a look at your PE4000 and the wheels"
loading need to be replaced. This customer may not yet be happy to hear that
The load wheels will not be covered under warranty.
Client: "What do you mean! The team barely has but at least they will understand why and that
one month of use. they must do to make them last longer. Everything that
tienes que hacer es comprometerte contigo mismo a
Technician: "Well, at least they are under warranty. The learn how to properly diagnose faults
send it to the factory and we will respond to the wheels of tires and wheels and be able to recommend a
as soon as possible. appropriate replacement.

(A few weeks later)

Technician: "I have bad news for you. I sent the wheels to
the factory and rejected the warranty.

Client: "Are you pulling my leg? Why?"

Technician: "I'm not very sure, but the report says

something about failure due to overload. That
usually means that its operators are
handling heavier loads than capacity
from the elevator. At the bottom it says that it will go to
have to pay for the load wheels that I put on
on your forklift a few days ago

Imagine yourself as a customer, would you be happy? Here you go.

I show how it should have happened:

Technician: "take a look at your PE4000 and the wheels"

They need to be replaced.

Client: "What do you mean! The equipment is barely...

un mes de uso”.

Technician: "I don't understand something, it's not right. I threw it away."

a look at the load wheels and I have information

which you might be interested in. Let me show you.
There are large parts of the circumference of the wheel.
losses, at first glance it seems to be due to a
adhesion failure but do you see the white spots on the
poly material?

Client: "Yes, what causes that?"

Crown 2005 DP00652-TRM Page 3 of 31
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Eng. Edgar Prado
 Training module
Analysis of polyurethane tires and wheels
Tire and wheel failures Normal wear and tear (not covered by warranty)

Most tire and wheel failures can be The Caster wheel shown in illustration 3 and the
attributed to one of the following conditions: traction wheel in illustration 4 are examples of
normal wear.
Normal Wear
Waste
Square wheels (Flat Spot)
Overloads
Operator abuse or poor conditions of
floor.
Adhesion failure or material defect.

NOTE: warming is a factor in four of

six categories of failure (wastes, wheels
squared, overloads, and adhesion failures). This
Caster wheel with cracks due to fatigue
it is an important factor in the determination of
solution to failures, because it minimizes heat,
will help maximize the service life of the tire and
wheel.

The last category, adhesion failure and/or defects

of the material, it is the only category to which it applies
guarantee.

Traction wheel with fatigue cracks

When under load, the wheels flex a

little while they turn and over time cause cracks of
fatigue this develops similarly to cracks
developed in the metal that is bent
repeatedly, time and time again. Also, while the
wheel wears out, the composition becomes more
thin thus decreasing the load capacity.
As the wheels wear out, the development of
fatigue cracks accelerate.

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Ing. Edgar Prado
Training module
Analysis of polyurethane tires and wheels
See how the conic composition in the wheel of Refer to the load wheel in the photo below.
loading of illustration 5. This is an example of See that the tread is no longer attached to the
conicity. Conicity is the result of rotating with the dough is partially showing removed from
Charging and wear is normal in electric scooters. the mass. The waste was embedded in the
Conicity can contribute to wheel failure loading wheel and eventually caused the belt
due to overload (see page 7) because the The filming will be completely separated from the hub.
conicity reduces the contact surface or load of
the wheel. Waste such as embedded screws
in the wheel of illustration 6 (photo in the background) also
Conicity will cause bumping (sudden or abrupt impact) in
(Conical wear)
the wheel which can lead to the heat being
accumulate and fail the wheel.

A good cleaning of the facilities is very

important to reduce waste on the floor.
The floors should be swept at every change to help with
ensure a more extensive wheel life.

Tread band

Line of
Adhesion

The conicity is a positive wear indicator and

it is an indication of a high-quality wheel already
that the cheapest wheels do not last long enough
to develop conicity. Conicity also us
it says that a good choice of composition was made
for the application of the equipment. Maza

Waste (not covered by warranty)

The waste on the floor embedded in the tires and

Wheels are a common problem. Refer to the Fun
Illustration 6. Waste often perforates the
polyurethane and make their way to the adhesion line
causing the tread to separate from the
fun. Once the tread band starts to
to separate, and even if the waste is removed, the
tire or wheel eventually fails and here is the Waste
why Tread band

While the tire or wheel spins, the tread band

Part of the rubber band is no longer attached to
bending. Bending generates heat in a way similar to the hammer is shown moved to the right
heat generated by rubbing your hands. If the band of
the rod separates from the hub (even if it's a little), the
bending along with heat will cause separation
progressively worsening until the wheel
failure.

Screw embedded in the tread

Crown 2005 DP00652-TRM Page 5 of 31

Translated:
Ing. Edgar Prado
 Training module
Analysis of polyurethane tires and wheels
Square wheels (flat spotting) 2. Covered by warranty

[Link] covered by warranty Refer to figure 8. Although it is to be tires.

squared especially in traction tires
The wheel shown in illustration 7 has the wheel where there is no apparent abrasion, this is usually
square due to sliding. The sliding debido a defecto de fabricación. Normalmente, esas
it is evident by the rough area on the band of Square tires are caused when the
filming is not covered by warranty. The adjustment forklift is operated from a long distance
inadequate braking can cause the wheel to causing the tire to heat up significantly. If
traction or the caster wheels slide. For the the elevator is stopped immediately
loading wheels, the waste on the floor after the 'warming up' and let the tire
they usually cause wheel slip. I cooled down without moving the forklift, it can be done.
square the tire. The polyurethane tires are
To address the sliding and the appropriate they will naturally "pre-form" when allowed to
brake adjustment, refer to section M5.0 of cool down during the operation. In most of the
service manual. cases take the reform and it becomes
If the load wheel comes into contact with the imperceptible within a few minutes of operation.
waste on the ground and cannot pass over it If the lallantaa has a permanent deformation, this
waste, the loading wheel will get stuck will indicate a material defect and will require
causing the wheel to skid without turning, making replacement.
square the wheel. Some good facilities is
very important to reduce waste in the
floor. The floors must be swept at each change to
help ensure a longer wheeled life.
The training of the operator can also help to Square Wheel
extend the life of the wheels.

Square wheel
(Rough area)

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Crown 2005 DP00652-TRM
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Ing. Edgar Prado
Training module
Analysis of polyurethane tires and wheels
Overload (not covered by warranty) electric make sure to check the forks,
wheel bearings and improper alignment adjustment
Failure due to overload caused to the load wheel the load wheel. Bent forks, bearings and
shown in illustration 9 and is indicated by the wheels that do not rotate freely contribute to the
large portion of polyurethane that was lost. heat accumulation.

In illustrations 9 and 10, the critical temperature of

the material was exceeded (the temperature at which the Failure due to
overload
the tread band of the wheel softens and liquefies) and is
usually caused by continuous moving
at high speeds with extreme loads.
Inadequate maintenance of the bearings and
incorrect adjustment of the load wheel separators
they can also cause this condition.

An overloaded wheel will often show signs of

white peeling of material and polyurethane
melted indicating excessive heat accumulation
(see illustrations 9 and 10).
Overload is often confused with failure of Also, note when it happened.
adhesion because the tread separates from the overload. The amount of weight that a
my. The reason why the band separates from The forklift operation can vary a lot with the
the hub's rotation is due to the fact that most of seasons, and the overload can be just a
heat accumulates at the adhesion line and this is the problem during certain seasons of the year. For
point at which the polyurethane flexes in its for example, in spring some departments
majority. The bending and warming causes the they transport heavier items than usual such as
the tread band separates from the hub and such as fertilizers, decorative stones, soil, etc.
eventually causes the wheel or tire to fail. in this case, the operator's education can be
beneficial.
It is determined that the failure in the wheel and the tire is
due to overload, especially on scooters

An overload caused the tread to soften and melt on both wheels.

Crown 2005 DP00652-TRM Page 7 of 31

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Ing. Edgar Prado
 Training Module
Analysis of polyurethane tires and wheels
Refer to illustration 11. A tire or wheel that Traction wheel
lose a part of the tread (fragment) or
it is visibly deformed, indicates abuse of
operator and/or poor floor conditions and it is not
covered by the warranty.

Some problems in the applications that can

causing that type of failures are:

Waste
Holes or cracks in the floor.
Floors with a rough surface mostly.
Inadequate alignment of the trailer to the dock.
Moving very quickly over the ramps of
coupling to the trailer.
Hits

Load wheel

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Crown 2005 DP00652-TRM
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Eng. Edgar Prado
Training module
Analysis of polyurethane tires and wheels
Failure due to adhesion (covered by warranty) indication that the adhesive did not set
appropriately to the mace.
The photos shown in illustration 12 and 13 are
examples of adhesion failure. Adhesion failures
adhesion is usually related to the A small crack is visible between
manufacturing processes, not to the application. the hammer and the tread band
Tread band

Adhesion failures usually show little or

no evidence of destroyed polyurethane and can
be visible as a line separation between the
tread band and the adhesive. In some cases the
failure due to adhesion cannot be seen but can be
heard like a squeak while the wheel or
tire spins.
Fun Adhesion failure
At other times the tread can be
completely withdrawn from the mace or the mace to him
there's a little bit of this left. Usually the points without
adhesive is evident on the club. This is a

The mace has been moved to show that the mace and Mark on the hammer, there is no adhesive.
the rollers are completely separated

Adhesion failure

The tread is partially removed from the hub.

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Ing. Edgar Prado
 Training module
Analysis of polyurethane tires and wheels
A review about heat

Heat is a very important factor in failures of

tires and wheels. Due to friction, whenever
A wheel or tire moves, heat is generated. Already
that the force (weight and speed) increases the heat
also. The heat dissipates slowly through the
material of the polyurethane of the tire/wheel and dissipates
faster through the mace. So the mace
acts as a heat dissipator or radiator.

Illustration 14 shows examples of weight and

speed that acts on several tires and wheels.

Take note of the load wheel of the PE of the

illustration above. For its size, the wheels of
loads carry extreme amounts of weight, they spin
very fast and generate large amounts of heat.
It is critical in this situation to choose a wheel made
with quality polyurethane components and a
a mass that will dissipate a large amount of heat. The
molds can be made of cast iron or of
steel (pipe). A cast iron mallet contains
more metal than a tube which helps dissipate more the
heat. A greater number of bearings can also
improve weight distribution and reduce the
generation of heat. Refer to figure 15.

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Crown 2005 DP00652-TRM
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Ing. Edgar Prado
Training module
Analysis of polyurethane tires and wheels

The low-profile traction wheels also help. Remember that if you minimize heat, you help to
to minimize the heat. Take your time now and read the maximize the service life of the tire and wheel.
product reference 8.5 (bulletin PF 10382) for
information related to those tires.

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Ing. Edgar Prado
 Training module
Analysis of polyurethane tires and wheels
Replacement of the tire and wheel

There are 5 steps to choose a replacement wheel or

tire and these are listed below. Followed by the
explanation of each step.

1. Determine why the tire or wheel failed.

2. Identify the type of composition of the band of

filming of the wheel currently installed in the
forklift.

3. Determine the application of the forklift.

4. Determine the optimal replacement tire or wheel.

5. Offer your suggestion.

Step 1 - Determine why the tire failed.

Knowing how the tire or wheel failed will help you

determine if the composition of the tread band Step 2 - Identify the type of composition of the
should continue to be used or if a composition tread band of the installed wheel
it will distinctly improve performance and service life. currently in the elevator.
CROWN offers a variety of different
compositions so that it can equal the Lo siguiente es identificar el tipo de composición de
characteristics of the band's composition the current tread used in the elevator.
wheels according to the application of the forklift. All genuine CROWN wheels have a
For example: if a load wheel with composition identification code printed on the hammer and the
-201 fails quickly due to overload and is used in integrated system of CROWN parts with number of
long trajectory applications, a composition composition printed on the wheel. Refer to the
series 300 (refer to the selection guide of illustration 18.
applications, PF14565) would be the best choice as
replacement. NOTE: the composition of the load wheels and
Tires cannot be identified by color. All
Remember, if you determine that a tire failure or the load wheels are orange and the tires are
the wheel is due to overload, be sure to check black or cream (non-staining).
the fork, wheel bearings, and the adjustment of the bushings
from the load wheel. Bent forks, bearings and
wheels that turn freely contribute to the
accumulation of warming.

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Ing. Edgar Prado
Training module
Analysis of polyurethane tires and wheels
Step 3 - Determine the application of the forklift The selection of high-performance wheels and tires
and saving on costs has never been the easiest.
Basketball players need sneakers that Crown's wheel and tire solutions include a
they can endure the abuse. They need a sneaker variety of components and tread bands,
that has excellent traction, support, and stability categorized by four levels of performance for
for a quick movement forward, towards satisfy their needs.
back, side to side, start and stop. For
for long distances, runners need shoes that Light service: these wheels and tires
be light, providing excellent traction economic ones are the most suitable for
while running forward, have flexibility Light load series and intermittent use of the equipment.
and protect them from impacts when running long distances 100 If used in higher applications
distances. Athletes equip themselves with shoes for demand, frequency costs of
maximize your performance and protect your feet, change will adversely impact the
ankles and legs of damage; while they obtain the savings.
greater benefit of life from their shoes. The Media range: the compounds in the tires
serious basketball players do not wear the same ones and mid-range tires series 200 are
tennis the runners. The athletes have to Seriedesigned for provide a mayor
wear shoes that fit your sport or application. 200 performance than the series 100. They are the most
suitable for light and medium loads and
The same is true for forklifts. For short transfer distances.
maximize the performance of the forklift and its lifespan High capacity: for the typical demand of
of service for wheels and tires, forklifts most of the applications, the
must be equipped with wheels and tires that Series characteristics of the compounds of the
fit into the application. 300 high capacity wheels and tires of the
series 300 are designed for high
Below are examples for common types of capacities and long distances of transport.
application. When you select a replacement for Heavy service: the most applications
tire or wheel, determine the category that best claimants will benefit from the
fit to the forklift application. Series of formulated compounds of the wheels and
400 heavy-duty tires of the 400 series,
Light service applications (forklifts) with maximum performance for capabilities
walking operator. maximums and extreme trajectories.
Long distance applications.
High performance operations. The application selection guide (PF 14565)
Rough floors and entering trailers or docks of shown in illustration 19 on page 14
load. will help you find the most suitable compounds
Freezing environments and wet floors. to the application. It can suggest more than one
composed for a given application. Although those
Step 4 - Determine the optimal tire or wheel of compounds can have the same characteristics
replacement. in their role, different manufacturing processes through which
suppliers will ensure that each compound has a
Using the information from the first three steps, unique performance. The judgment of these compounds
select the series that corresponds to the application similar in the customer's location will test the
(see the table on the right). most valuable compound.

NOTE: for the approved compounds in each

Crown model, consult the service manuals.

Design of the tread of the tires

traction.

When choosing traction tires, you will need to choose a

design of tread band. In addition to a tire
{"suave":"smooth","ranura al centro":"slot in the center","ranura a 22°":"slot at 22°"}

light slot at 22° (-04), diamond slot (-05) and

step contour (-07), available for
forklifts PE, PW, PR, PC, TWR/TR, SP, RR and
RD. Refer to the application selection guide.

Crown 2005 DP00652-TRM Page 13 of 31

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 Training module
Analysis of polyurethane tires and wheels

Page 14 of 31
Crown 2005 DP00652-TRM
Translated:
Ing. Edgar Prado
Training module
Analysis of polyurethane tires and wheels
Step 5 - Offer your suggestion to the customer

Hable con su supervisor y departamento de partes

About your choice of wheels and tires. The customer
could have some previously tested wheels and
he decided in his choice. Or he could consult with the
seller or service manager for your opinion. If
everyone agrees that you have selected the
better wheel or tire, offer the client your advice.

Cost of wheels and tires

The cost of replacement wheels and tires is not

just the price of the wheels and tires. That is just
a part of the cost. The total cost is made up of
direct and indirect costs.

Direct costs include wheels, bearings,

unforeseen events and labor.
Indirect costs consist of time
inactive, loss of productivity and since
could you provide other forklifts; their
sources of work.

The wheels and tires account for between 20% and

60% of the maintenance cost of the
forklift. So do not install automatically
tires or wheels of the same compound when making
a replacement. You can reduce costs of
maintenance when using a compound that fits
better to the application of the forklift.

Take a moment now and read the references.

of product 7.8 (PF 11293). This was initially
created for the customers and it is an explanation
excellent of the total cost of the load wheels.

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 Training module
Analysis of polyurethane tires and wheels
The following information is not part of the test.
skills but has been added to this module
to support it.

Wheels and tires installed under pressure.

To reduce the cost of replacing wheels and

tires, the hub can be removed from most of
the tires and some wheels, and these hubs
They can be reused in new tires or wheels.

To replace the tire or wheel:

Remove the jack from the damaged tire or wheel.

NOTE
Do not press the sledgehammer through the old tire towards
the new tire in a single operation. This method
it may probably cause the hammer to
misalignment causing the new tire to fail
prematurely.

2. Place the new wheel on a steel plate

plan. This will ensure an even distribution
of the force and pressure when the hammer is
being pushed into the tire. Some tires have
to be elevated to allow the part
the convex part of the mass protrudes slightly out of
the tire. To raise, fit the tire however you can
necessary.

3. Position the mallet over the wheel.

4. If the hub has to be embedded in the rim

or it is convex in shape, place a ring
steel cylindrical on the mace that has the
outer diameter slightly below the diameter
exterior of the mace.

5. Apply a layer of oil to the outside of

the mace.

6. Put the hammer inside the tire. Refer to the

following tables and illustrations for the
depth of the mace.

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Ing. Edgar Prado
Training module
Analysis of polyurethane tires and wheels
NOTES: To determine the part number of the
The reference illustrations (see the lastwheelone) hub assembly of your forklift,
column of the table below) start at the refiérase al manual de servicio. Usted también
page 19. Those illustrations may not be you can contact your parts department
an exact representation of its tire or wheel. (warehouse) which will ask you for the serial number of the
These are for your reference and have been provided. forklift.
to show the position of the club with respect to
to the tire.
Traction tire table
Model Assembly Dimension "A" Side of the mace Illustration of
Wheel/Hub for measurement reference (Example)
mm Inch.
GPW 042032 8.5±1 0.33±0.04 Interior 23 (A)
WP2000 127249 A ras A ras Interior 23 (B)
WP2300
W, WB, WR, 113363-001 12.5±1 0.50±0.04 Note 1
{"PW":"PW","PE":"PE","PC":"PC","PR":"PR"}
["-003","-013"] 23 (C)
TW, TWR/TR
PE3500, PE4000 113363-015 12.5±1 0.50±0.04 Note 1
PW3500, PC3000, until -022 23 (C)
PR3000,
TWR/TR 3500
PC3500 113363-015 12.5±1 0.50±0.04 Note 1 23 (C)
until -028
PC3500 N01223-All A ras A ras Note 1 23 (B)
FC 103159-Everything 6.5±1 0.25±0.04 Exterior (note 2) 23 (D)
FC 105942-All 6.5±1 0.25±0.04 Exterior (note 3) 23 (D)
FC 105943-All 19±1 0.75±0.04 Exterior (note 3) 24 (E)
FC 111081-Everyone 6.5±1 0.25±0.04 Exterior (note 2) 23 (D)
FC 111082-Everyone 6.5±1 0.25±0.04 Exterior (note 3) 23 (D)
FC 111083-All 6.5±1 0.25±0.04 Exterior (note 3) 24 (E)
FC4000 128401-Everything A ras A ras Interior 23 (B)
FC4000 128402-Everything 25.5±1 1±0.04 Interior 23 (A)
FC4000 128403-Everything 27.5±1 1.08±0.04 Interior 23 (A)
FC4000 128404-Everyone A ras A ras Interior 23 (B)
FC4000 128405-All 25.5±1 1±0.04 Interior 23 (A)
FC4000 128406-Everything 44.5±1 1.75±0.04 interior 23 (A)
NOTE 1: measurement from the inner or outer side of the hub. The wheel must be centered on the hub.
NOTE 2: for your reference, the internal dimension is 38 mm ±1 mm (1.5 in. ±0.04 in).
NOTE 3: for your reference, the inner dimension is 63.5 mm ±1 mm (2.5 in ±0.04 in).

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 Training module
Analysis of polyurethane tires and wheels
Traction tire table (continued)
Model Assembly Dimension 'A' Side of the mace Illustration of
Wheel/Hub for the measurement reference (Example)
mm Mite.
RC, RC3000 111910-004 38±1 1.5±0.04 Exterior 24 (F)
-009, -010
-015
RC, RC3000 111910-010 12.5±1 0.5±0.04 Exterior 24 (F)
-012, -013,
-014
RC, RC3000 114491-001 40.5±1 1.59±0.04 Exterior 24 (F)
["-008","-009","-010"]
-011
RC, RC3000 114492-001 15±1 0.59±0.04 Exterior 24 (G)
["-008","-009","-010"]
-011
RC, RC3000 119212-001 25.5±1 1±0.04 Exterior 24 (F)
SC 087880-004 A ras A ras Exterior 23 (B)
SC 111910-002 12.5±1 0.5±0.04 Exterior 24 (F)
-003.
SC 114492-002 15±1 0.59±0.04 Exterior 24 (G)
-005.
SC 119212-001 25.5±1 1.00±0.04 Exterior 24 (F)
SC4000 124316-Everyone A ras A ras Interior 23 (B)
SC4000 124808-Everything A ras A ras Interior 23 (B)
RR, RS, RD 087880-001 A ras A ras Exterior 23 (B)
RR3000 115028-Everyone A ras A ras Exterior 23 (B)
RS3000
RD3000
RR5000/5000S 121500-Everyone 34±0.5 1.344±0.02 Interior 23 (A)
RD5000/5000S
RR5200/5200S,
RD5200/5200S
SP36, SP42, 113363-002 A ras A ras Exterior 23 (B)
SP48 ["-004","-007"]
-009
SP3000 087880-001 A ras A ras Exterior 23 (B)
SP3200 -003, -005, -008
until -016
SP3400 ["-003","-009","-014"]
up to -017
TS, TSP 125382-All A ras A ras Exterior 23 (B)
TSP6000 132462-Everyone A ras A ras Interior 23 (A)

Page 18 of 31
Crown 2005 DP00652-TRM
Translated:
Ing. Edgar Prado
Training module
Analysis of polyurethane tires and wheels

Crown 2005 DP00652-TRM Page 19 of 31

Translated:
Eng. Edgar Prado
 Training module
Analysis of polyurethane tires and wheels

Page 20 of 31
Crown 2005 DP00652-TRM
Tradujo:
Eng. Edgar Prado
Training module
Analysis of polyurethane tires and wheels
Load Wheels Table
Model Assembly Dimension 'A' Side of the mace Illustration of
Wheel/Spear for the measurement reference (Example)
mm Inch.
RR, RS, RD 105090 A ras A ras Interior or exterior 25 (A)
RR3000, RS3000 (the hammer is
centered)
RD3000 105091 A ras A ras Interior or exterior 25 (B)
RR/RD5000 the mace is
RR/RD5000S centered)
RR/RD5200,
RR/RD5200S
TS, TSP 100236-Everyone 28±1 1.12±0.04 Exterior 25 (B)
TSP6000 132458-Everything A ras A ras Exterior 25 (B)

Crown 2005 DP00652-TRM Page 21 of 31

Translated:
Eng. Edgar Prado
 Training module
Analysis of polyurethane tires and wheels
Are you ready for the skills test? Normal Wear
Waste
YES Square Wheels (Flat Spot)
Tell your instructor that you are ready to do the Overloads
tire analysis skills test Abuse of the operator or poor conditions of
polyurethane wheels. floor.
Adhesion failure or material defect.
NO/IT IS NOT SURE
Would you use a different compound on the wheel of
Keep reading. Some practice questions have Replacement? If your answer is YES, please indicate
have been provided to help you prepare for the which compound would you use.
skills test. When you feel ready
for the skills test, tell your instructor If (specify which series)__________________
who is ready to take the skills test No
of the analysis of polyurethane tires and wheels.
2. The load wheel shown in illustration 27
Practice of the tire analysis module and it is made of a compound -301. This failed
polyurethane wheels. after 7 weeks and I was mounted on a
PE4000. The skateboard was used in a factory
When I finish the practical part of this large for transporting parts to various places
module, review one of the six most common failures from the factory. The floors are smooth and are swept.
listed after the question 'What caused the' weekly. What caused the wheel
tire or wheel will fail?” Feel free to will it fall?
refer to the information of this module or
ask the instructor while completing this part
of the module. The answers begin on page
28.

1. The caster wheel shown in illustration 26

it is made of compound -305. This failed
after a month and I was mounted on a
RR5000 forklift. The forklift was used.
in a large warehouse. The floors are smooth and
It happens at every shift change. What caused that.
Will the wheel fall?
Desgaste Normal
Waste
Square wheels (Flat Spot)
Overloads
Abuse of the operator or poor conditions of
floor.
Adhesion failure or material defect.

Would you use a different compound on the wheel of

replacement? If your answer is YES, please indicate
Which compound would you use?

If (specify which series)__________________

No

Page 22 of 31
Crown 2005 DP00652-TRM
Tradujo:
Ing. Edgar Prado
Training module
Analysis of polyurethane wheels and tires
3. The traction tire shown in the illustration 4. The loading wheel shown in illustration 29
28 is made of a compound -343. This is a failure. It is made of a compound -305. This failed.
after 4 weeks and I was mounted on a after 8 weeks and I was mounted on a
RC3000 forklift. The forklift was used. PC3000. The forklift was used in a
in a warehouse for loading trailers and is used to large factory to transport parts to various places
times in freezers. The floors are rough, factory places. The floors were smooth and
they have some holes and cracks and are swept sweeps after each shift change.
weekly. What caused the tire to fail? What caused the wheel to fail?

Normal Wear
Waste Normal Wear
Square wheels (Flat Spot) Waste
Overloads Square wheels (Flat Spot)
Operator abuse or poor conditions of Overloads
floor. Abuse of the operator or poor conditions of the
Adhesion failure or material defect.
floor.
Adhesion failure or material defect.
Would you use a different compound on the wheel of
Replacement? If your answer is YES, please indicate Would you use a different compound on the wheel of
Which compound would you use.
replacement? If your answer is YES, please indicate
Which compound would you use.
If (specify which series)__________________
No If (specify which series)__________________
No

Crown 2005 DP00652-TRM Page 23 of 31

Translated:
Eng. Edgar Prado
 Training module
Analysis of polyurethane tires and wheels
5. The traction tire shown in the illustration 6. The load wheel shown in illustration 31
30 is made of a compound -352. This failure It is made of a compound -301. This is a failure.
after 2 weeks I was mounted on a after 4 weeks and I was mounted on a
RR5200 forklift. The forklift was used. PE3500. The forklift was used in docks of
in a small factory. This equipment was used load to load trailers. The floors are smooth and
to store and retrieve material in the area They are swept weekly. What caused the
of the factory storage and later for Will the wheel fail?
take the material to various parts of the factory.
The floors are rough, they have some holes,
cracks and they were dirty. What caused the
Will the tire fail?

Normal Wear
Waste
Square Wheels (Flat Spot)
Overloads
Normal Wear
Abuse of the operator or poor conditions of the
Waste
floor.
Square wheels (Flat Spot)
Adhesion failure or material defect.
Overloads
Operator abuse or poor conditions of
Would you use a different compound on the wheel of
floor.
replacement? If your answer is YES, please indicate
Adhesion failure or material defect.
Which compound would you use?

Would you use a different compound on the wheel of

replacement? If your answer is YES, please indicate If (specify which series)__________________
Which compound would you use? No

If (specify which series)__________________

No

Page 24 of 31
Crown 2005 DP00652-TRM
Tradujo:
Ing. Edgar Prado
Training module
Analysis of polyurethane tires and wheels
7. The loading wheel shown in illustration 32 8. The loading wheel shown in illustration 33
It is made of a compound -201. This failed. it is made of a compound -302. This failed
after 4 weeks and I was mounted on a after 21 weeks and I was mounted on a
The elevator was used in a factory. RR5000 forklift. The forklift was used
large for transporting materials. The floors for the handling of materials in various
they are smooth and sweep every shift change. What departments and in the warehouse in a small
What caused the wheel to fail? factory. The floors are rough and swept.
necessary. What caused the wheel to fail?

Normal Wear
Waste
Square wheels (Flat Spot) Normal Wear
Overloads Waste
Abuse of the operator or poor conditions of the Square Wheels (Flat Spot)
floor. Overloads
Adhesion failure or material defect. Operator abuse or poor conditions of
floor.
Would you use a different compound on the wheel of Adhesion failure or material defect.
replacement? If your answer is YES, please indicate
Which compound would you use. Would you use a different compound on the wheel of
Replacement? If your answer is YES, please indicate
If (specify which series)__________________ Which compound would you use?
No
If (specify which series)__________________
No

Crown 2005 DP00652-TRM Page 25 of 31

Translated:
Engineer Edgar Prado
 Training module
Analysis of polyurethane tires and wheels
9. The traction tire shown in the illustration 10. The load wheel shown in illustration 35
34 is made of a compound -341. This failed. It is made of a compound -305. This failed.
after 6 weeks and I was mounted on a after 6 weeks and I was mounted on a
RC3000 forklift. The forklift was RR3000 forklift. The forklift was
used to load trailers. Store and used in a factory to transport materials
unload material onto racks, handle material in from the warehouse to the assembly area. The
different departments, etc. The floors were floors are smooth but dirty. What caused the
they were wiped clean at every shift change. What Will the wheel fail?
What caused the tire to fail?

Normal Wear
Wastes
Square wheels (Flat Spot)
Overloads
Operator abuse or poor conditions of Normal Wear
floor. Wastes
Adhesion failure or material defect. Square Wheels (Flat Spot)
Overloads
Would you use a different compound on the wheel of Operator abuse or poor conditions of
replacement? If your answer is YES, please indicate floor.
Which compound would you use? Adhesion failure or material defect.

If (specify which series)__________________ Would you use a different compound on the wheel of
No replacement? If your answer is YES, please indicate
Which compound would you use?

If (specify which series)__________________

No

Page 26 of 31
Crown 2005 DP00652-TRM
Tradujo:
Eng. Edgar Prado
Training module
Analysis of polyurethane tires and wheels
11. The traction tire shown in the illustration 12. The load wheel shown in illustration 37
36 is made of a compound -243. This is a failure. it is made of a compound -201. This failed
after 4 weeks and I was riding on a after 4 weeks and I was mounted on a
RR5200. The forklift was used in a PE4000. The lift was used in a
large factory. It was used to store and large factory to transport materials. The
remove material from the racks in the area of Floors are smooth and are swept with every change of
factory storage and then for shift. What caused the wheel to fail?
release material to other places in the factory. The
floors are smooth and are swept every change of
shift. What caused the tire to fail?

Normal Wear
Normal Wear Waste
Waste Square Wheels (Flat Spot)
Square Wheels (Flat Spot) Overloads
Overloads Abuse of the operator or poor conditions of
Abuse of the operator or poor conditions of floor.
floor. Adhesion failure or material defect.
Adhesion failure or material defect.
Would you use a different compound on the wheel of
Would you use a different compound on the wheel of replacement? If your answer is YES, please indicate
replacement? If your answer is YES, please indicate Which compound would you use?
Which compound would you use.
If (specify which series)__________________
If (specify which series)__________________ No
No
13. Write an explanation of why the more...
A tire or wheel is more economical.

Crown 2005 DP00652-TRM Page 27 of 31

Tradujo:
Ing. Edgar Prado
 Training module
Analysis of polyurethane tires and wheels
Answer sheet for the module practice
analysis of polyurethane tires and wheels. 5. Cause of the failure: refer to illustration 30 of
page 24. The tire has many cracks and has
1. Cause of the failure: refer to illustration 26 of lost small and large parts of the band
page 22. Since the tread is shooting. This is an indication of "abuse of the
separated from the dough and there is no indication that operator or poor floor conditions.
the band is destroyed (without bumps or holes for
wastes, etc.) and it seems that there are points of Use of the compound: the selection of the compound
loss of adhesive in the drum, the response for the traction wheel in this forklift
the correct term is 'failure due to adhesion'. is limited due to the requirements of
braking. Please refer to the service manual for the
Use of the compound: the failure was due to approved compounds. Other compounds
manufacturing defect and could not be prevented. approved could be tested to extend
Since the adhesion failure could be the the life of service. Suggest to the operator that
result of a 'bad batch', do not give in to reduce speed or avoid cracks, holes,
compound used unless the failure persists. , when possible; it would be helpful in this
If necessary, switch to another compound of application.
another series 300 with the same characteristics.
6. Cause of the failure: refer to illustration 31 in
2. Cause of the failure: refer to illustration 27 in page 24. The discolored part of the wheel is
page 22. The hole indicates that a nail, flat wheel condition and was caused by
screw, etc., penetrated the tread band and slip. "square wheel" is the category
it probably caused to separate slightly correct for this failure.
from the mace. Over time, the bending and the heat
caused the total separation of the track band Use of the compound: the series 200 compound is
so that the failure is due to the more resistant to the trend of wheels
waste on the floor square and more suitable for applications in
docks or trailer entry.
Use of the compound: there should be no change in
the composition. Some conicity is evident 7. Cause of failure: refer to illustration 32 in
but it is normal wear. The component -301 is Page 25. The wheel lost a large part
good choice for this application. but the part of the tread band that
it seems to have slightly melted
3. Cause of the failure: refer to illustration 28 in and contains small white dots. The dots
page 23. The big lost piece on the side of whites are an indication of excessive heat
the tire indicates that the tire hit a piece of caused by "overload".
metal, passed over a large hole in the concrete,
etc., this is a sign of "operator abuse or Use of the compound: the compound series 300
poor conditions of the floor. it would be more appropriate for applications of
transport due to its increased resistance
Use of the compound: compound series 200 to the heat.
it would be a better adaptation for this application.
Its hardness "SHORE A" decreases further. 8. Cause of the failure: refer to failure 33 in the
suitable for rough floor conditions. page 25. The wheel is worn out so the
the correct category of failure is 'normal wear'.
4. Cause of the failure: refer to illustration 29 of
page 23. The wheel is intact without any holes, Use of the compound: the wheel was
cracks, etc. And requires change due to worn out after 21 weeks, which is
normal wear (conicity) a fulfilling life of service for this
application. Compound -302 is a good
Use of the compound: the compound -305 is election and should continue to be used.
performing quite well in this
application. Other compounds of the 300 series with
similar characteristics could be tested
to try to extend the service life.

Page 28 of 31
Crown 2005 DP00652-TRM
Tradujo:
Ing. Edgar Prado
Training module
Analysis of polyurethane tires and wheels

The cost of replacement tires or wheels

9. Cause of the failure: refer to illustration 34 in constitutes approximately half of the cost
Page 26. The filming has begun. total. The tires and wheels that last longer
to separate from the mass and has a small they reduce downtime, labor costs
evidence of the destruction of the poly. This is a work, cost of bearings, etc. The wheels and tires
indication of 'adhesion failure' they last a long time are a good investment because
you reduce the costs totals of
Use of the compound: the failure was due to maintenance.
manufacturing defect and could not be prevented.
Since the adhesion failure could have been the After you have completed the practical part of the
result of 'a bad batch', noceda to module and feels ready for the test of
composed used as long as the failure persists. skills, tell your instructor that you are ready to
If necessary, switch to another compound of the the skills test of Wheel Analysis and
series 300 with similar characteristics. polyurethane wheels. If you don't feel ready, take your time.
a time and review the information in this module of
10. Cause of the failure: refer to illustration 35 of new to help you prepare for the test
page 26. The grooves on the tread of skills.
they indicate that the load wheel turned on
waste so the failure was due to
waste on the floor

Use of the compound: the failure was due to

waste or that a piece of wood is
a bull in the loading wheel dragging the wheel
while moving. Change the compound
this type of failure will not be eliminated. The compounds
From the 300 series, these are the most suitable for this.
application.

11. Cause of the failure: refer to illustration 36 of

Page 27. The poly is melted and has a failure.
permanent by square wheel.

Use of the compound: since the cause of the

square wheel was excessive heat, choose a
composed of the 300 series would be the best
selection for this application. Check the manual
of service for the suitable compounds for
this forklift.

12. Cause of the failure: refer to illustration 37 of

page 27. The wheel may have lost everything
tread and the tread that
it seems to have melted. It doesn't seem
to have points on the adhesive of the mass
So my concern is that the failure does not seem to be a failure due to

adhesion or waste. Since the band of

The rod is melted, the failure was caused by
overload

Use of the compound: series 300 compounds

they are the most suitable for applications of
transport where heat is a problem.

Crown 2005 DP00652-TRM Page29of31

Translated:
Eng. Edgar Prado
Training module
Analysis of polyurethane tires and wheels
C
Page only for NOTES.

September 4

Crown 2005 DP00652-TRM Page 30 of 31 Translated: Printed in U.S.A.

Ing. Edgar Prado
 Skills test
Analysis of polyurethane tires and wheels
DP00652

Student Name Date

! CAUTION
Before starting any work, make sure to refer to and follow all safety recommendations.
fixed in the Crown parts and service manual. In addition, Crown recommends that participants use the
personal protective equipment, such as glasses, gloves, and safety shoes, whenever they perform
maintenance tasks on Crown equipment.

Your instructor will randomly select wheels and tires with failure. For each tire and wheel, the instructor will provide you with
the type of compound, the use of the forklift, application, and service distance. With an accuracy of 80%,
you have to:
oState the reason for the failure of the tires and wheels.
oRecommend an appropriate replacement.
oExplain why tires that last longer are more economical.

Module: Analysis of Polyurethane Tires and Wheels successfully completed:

Instructor's Signature Date

Instructor's Name (printed)

9/04

Crown 2005 DP00652-TRM Page 31 of 31 Translated: Printed in U.S.A.

Ing. Edgar Prado