DIY electric forklift repair

Do-it-yourself rohly repair is a quick and inexpensive way to bring useful warehouse equipment into working order. Many breakdowns can be repaired without the help of specialists, but you should not be overconfident. Sometimes it is better to take the device to a service.

The hydraulic shovel is a handy transporter. It moves loads mainly on pallets. A special feature is the presence of a hydraulic jack that raises and lowers the forks. Such carts are used in warehouses, in large stores. They greatly facilitate the work of storekeepers and auxiliary staff of retail outlets. That is why do-it-yourself repair of hydraulic carts is an interesting and useful topic.

Rohly's design is simple. Metal forks mounted on wheels securely hold the load. They are raised and lowered using a hydraulic handle. The height of the forks can be adjusted. The lifting capacity of some models reaches 2.5–5 tons.

Rice. 1. Do-it-yourself rohly repair

Dismantling rokhly is a simple undertaking if you study the design features of the equipment. For example, there are trolleys with built-in brakes, rolling casters, single or twin wheels. How to disassemble a rokhlya without damaging it? First, familiarize yourself with the main types of malfunctions and their causes.

1. Malfunctions and repairs of the waterworks

The hydraulic unit is the most important element of the trolley. Repairing it may involve replacing valves or seals, grease, or the entire body. It is better to entrust the solution to the problem to specialists. It is easy to find hydraulic faults: a squeak is heard, loads are being lifted or lowered heavily.

2. Repair or replacement of the valve

Unstable lifting, slow lowering of the cylinder, the appearance of a leak in the pumping part of the hydraulics is a reason to make sure that the valve is working properly.

Damage to the hydraulic lever handle is the most common. They appear due to the careless handling of technology. Sometimes, for repairs, it is enough to change the stepper lever or spring, in some cases, the entire handle. Also, experts can resort to welding.

Frequent use of the fork will abrade, deform and break the forks. To repair them, reinforcement, adjustment of the length of the rods, welding and straightening are used.

5. Malfunctions of the chassis

The undercarriage consists of several elements, each of which can fail. These can be wheels and bearings. Fasteners often break down: axles, carriages, brackets and other components that are easy to replace on your own, without contacting the masters.

Rollers and steering wheels allow the cart to move, transporting the load in the desired direction. Exceeding the permissible load or careless operation will lead to breakage of these elements. Repair involves replacing old parts with new ones. You need to choose wheels instead of faulty ones, based on the characteristics of the trolley, cargo and the specifics of the floors in the warehouse. For example, you can supply wheels made of polyamide, metal-polyurethane or metal-rubber.

Rice. 3. Replacing wheels and rollers

7. Oil change, or Do-it-yourself rohly repair, if the load does not rise

Do-it-yourself repair of the rocket (the load does not rise) can be done quite easily if the reason lies in the lack of oil. For this, hydraulic or simple spindle oil is introduced into the hydraulic unit through the filler bolt. It is impossible to fill in a simple motor, it does not have the required viscosity. Grease may have leaked out through the seal.In this case, it should be replaced.

It seems that the health of the internal contents of the rohly is more important than its appearance. This is not entirely true. Painting individual elements or the entire trolley is not only about aesthetics, but also protection. The paint protects the equipment from corrosion and excess dirt. On clean surfaces, hydraulic leaks are detected more quickly.

As already mentioned, wheels and casters often fail. You can replace them yourself.

The roller axles fix the pins, they should be knocked out. This is done using a punch with a diameter of 4–5 mm and a hammer. When the pins on both sides are removed, knock out the axes of the fork rollers. To do this, use the same hammer and drift, but with a larger diameter. If there is corrosion on the axles, concentrated acetic acid will help facilitate the removal process (a few drops above the bearing - and after 15 minutes the roller can be released).

Since the hoisting trolley is an important helper in warehouses of different types, questions of how to repair the spoiler arise quite often. Here are some tips:

1. if the load does not rise, check the oil level;
2. if a leak is found from under the spring under the handle, replace the plunger cuff;
3. if a leak appears near the valve lever - the seals are worn out, put new ones;
4. if the oil is at the correct level and the cart does not lift the load, check the valves;
5. if the cart is hard to move with the load, lubricate or replace the roller bearings.

People who are well versed in mechanisms and who have been using equipment of this type for a long time will be able to independently adjust the rocket. If the experience is not enough or the cause of the breakdown cannot be determined, it is better to entrust the repair to specialists.

Forklifts refer to a special type of transport that is used for unloading / loading, moving and bulky goods. Lifting is carried out by a special mechanism - a pitchfork. Today, this special equipment is widely used at transport terminals and warehouses.

1. Due to the use of special equipment at the limit of capabilities, breakdowns often occur. Most often, in such cases, the oil seals of the hydraulic system suffer, and the devices for grabbing goods fail.
2. Failure to comply with the speed limit is another reason for undercarriage breakdowns.
3. Special equipment is intended for use in closed spaces, precipitation falling on the loader body can adversely affect its condition. Water can trigger the onset of corrosive processes.
4. Poor quality fuel will damage the fuel system. Fuel filters are the first to suffer, and when they no longer cope, the engine fails.
5. Bad batteries are another common problem.

Repair of forklifts can be planned and overhaul. The second option is practically impossible without the involvement of technical specialists who are familiar with the device and operating standards for special equipment. Minor defects and defects in the forklift operation can be eliminated on the spot. If the owner of special equipment does not want to overpay for repairs in a specialized organization, then it is necessary to train personnel and purchase the necessary diagnostic equipment that allows you to identify deficiencies and eliminate them at an early stage. In order not to carry out repairs of forklifts often, it is necessary to adhere to the rules of technical operation and regularly carry out maintenance.

• natural wear and tear, development of the resource of mechanisms;
• systematic violation of operating rules;
• excess loads in excess of the permissible norm;
• mechanical damage;
• lack of lubrication between rubbing elements;
• hydraulic failure.

As for the repair of this lifting equipment, the trolleys of the "old" generation can still be repaired on their own. And more modern ones, which are oversaturated with additional systems, are best delivered to a service center. This will avoid unnecessary damage.

Repair of forklifts is a set of measures that are aimed at eliminating malfunctions of a particular part of construction equipment.

Repair of forklift trucks provides for solving problems with the engine. Renovation work includes:

• diesel service;
• troubleshooting;
• internal combustion engine compression measurement.

The order of work depends on the type of motor: electric or diesel.

Repair of electric forklifts can be associated with troubleshooting the engine of the unit.

Possible malfunctions of electric motors and methods for their elimination:

1. Sparking brushes. This happens if they are of the wrong brand, size, or are broken. In this case, they must be replaced. If the problem is that the insulation is protruding above the collector plates, it is recommended to cut channels 1-1.5 mm deep between the plates.
2. Manifold noise. It is necessary to inspect the bearings. Replace worn-out spare parts. Grind the manifold.
3. Overheating of the electric motor. This may be due to an increased temperature of the electrolyte in the battery, so the electronics are malfunctioning. In this case, observe the temperature regime of operation, measure the resistance of individual coils and replace the faulty ones.
4. Noise during operation. It could be due to worn bearings that need to be replaced. Also, the cause of the problem can be brushes that are strongly pressed against the collector. In this case, it is recommended to adjust the pressure of the brushes.
5. Together with the load, the unit does not move, but without the load, the movement occurs in a jerk. It is necessary to check the excitation coils and replace the worn out parts.

Malfunctions in the engine of a diesel forklift are associated with overheating of this part.

If the motor overheats, do the following:

1. Park equipment in a safe place.
2. Leave the engine idling and open the hood.
3. Inspect the fan, if it does not work, then the engine must be stopped.
4. As soon as the pointer arrow returns from the red zone to the white one, you need to turn off the motor.
5. After the engine has cooled down, you need to check the coolant level, the serviceability of the fan belt, the engine oil level, and the clogged radiator circuits.
6. If the level of coolant or engine oil is insufficient, then it is necessary to restore their volume in the engine.
7. Clean and flush the elements of the cooling system.
8. Check the radiator honeycomb. They must be cleaned with compressed air, steam or water. Protective goggles should be worn during work.

Do not open the radiator cap until the engine has completely cooled down. If the plug is opened immediately after stopping the engine, a person may get thermal burns.

Repair work depends on the type of transmission: automatic or semi-automatic.

In semi-automatic gearboxes, problems are most often associated with the front axle engagement clutch.

• the mechanism refuses to switch;
• there is a burning smell;
• gears slip;
• poor adhesion;
• oil and coolant leaks;
• grinding or shaking;
• howling, muffled sounds and buzzing;
• there is no reaction to switching on.

In order to eliminate failures, it is recommended to do the following:

1. Check the quality and level of the filled oil.
2. Diagnose engine operation.
3. Check the unit is braked.
4. Read off the pressure readings in the control system.
5. Perform road tests.
6. Check control cable.

Troubleshooting repairs include procedures such as:

1. Dismantling the checkpoint.
2. Complete disassembly and overhaul of gearbox components.
3. Replacement of faulty or worn out parts of the mechanism.
4. Collection of equipment in its original state.
5. Installation of the mechanism on the unit.
6. Vehicle testing.

The main reasons for the failure of an automatic transmission:

• contamination of the heat exchanger;
• failures in the pumping system;
• malfunctions of solenoids or their malfunction;
• insufficient pressure in the cooling system;
• low oil level;
• overheating of the gearbox.

Loader automatic transmission repair includes:

1. Elimination of oil leakage on the box body. In this case, it is necessary to replace the pallet gaskets and oil seals.
2. Cleaning the valve body from dirt from the clutch packs. It is necessary to disassemble the valve body and replace the failed spools. You may also need to clean the hydraulic plate.
3. Solenoid repair. The bronze bushings and the end of the solenoids should be replaced.
4. Elimination of malfunctions of the electronic control unit. It is necessary to replace the unit or restore the loops if they are damaged.

If the planetary gear set is out of order or several systems have stopped working at once, a complete replacement of the automatic transmission will be required.

Repair of forklift trucks provides for the elimination of malfunctions in the operation of the hydraulic cylinder and the entire hydraulic system.

The main breakdowns and methods of their elimination:

1. The pump rotates, but the power cylinder does not move. It is necessary to check the oil level, top up if necessary. Clean and tighten the suction pipe, replace the spring and adjust the valves. Valve cleaning and repair may be required. If these steps did not help, you need to disassemble the pipelines, rinse and blow them with compressed air.
2. The lifting device tilts quickly. In this case, it is recommended to adjust or repair the throttle, valve and remove the cuffs. If air has entered the hydraulic system, it must be removed.
3. The distributor does not work. Repair damage to the command device and replace the spring that sets the plunger to neutral.
4. The load is moving in jerks. It will be necessary to remove air trapped in the hydraulic system, oil the lifting cylinder seal pack.
5. The lifting device tilts slowly. This occurs when the regulated throttle is clogged or damaged.

Repair of the loader injection pump is necessary when:

• the power and dynamics of the engine decreases;
• the power unit is unstable at idle;
• fuel consumption increases;
• the color of the exhaust gas changes.

The fuel pump fails due to breakage or burnout of the control board contacts and failures in the operation of power transistors.

In order to adjust the maximum engine idle speed, the spring rate must be changed.

The restoration of the high pressure fuel pump involves the following operations:

1. Installation of high-pressure fuel pump on the stand and connection of the fuel line.
2. Adjustment of the starting fuel supply by 50-100%.
3. Setting the control lever to the extreme position.
4. Tighten the corrector screw until it stops.
5. Setting the required fuel supply at the nominal camshaft speed.
6. Adjustment of the fan start-up at 10-15 rpm in 1 minute.
7. Checking the fuel system.
8. Checking the complete shutdown of the fuel supply through the injectors.
9. Adjustment of the speed of the pump camshaft.
10. Adjustment of the fuel supply in accordance with the required reserve of engine torque.

Faults and repairs of skid steer loaders starters:

1. Insufficient or too large charge of the starter battery. It is necessary to adjust the battery charging relay and troubleshoot the generator.
2. Fast battery discharge. In this case, it is necessary to increase the electrolyte level, adjust its density, replace the battery if the capacity has decreased due to strong sulfitation.
3. The starter does not respond when the key is turned.It is necessary to check the reliability of the ground contact, tighten the wire securing bolts, replace the transmission lock switch, inspect the connector for damage, replace the pull-out relay, check the armature.
4. The starter turns, but the crankshaft is in place. The bendix and the defective part of the gearbox should be replaced.
5. After starting the engine, the starter motor rotates with the flywheel. It is recommended to replace the contact group of the lock and the solenoid relay.
6. The starter motor turns the engine slowly. It is necessary to check the length and freedom of movement of the brushes in the brush holder.

If wheel beating is heard, then loose bearings, wheel nuts and bent rims may be the cause of such a malfunction of the front loader steering axle. To eliminate the damage, you need to adjust the bearings, tighten the nuts and replace the rims.

The reason for the noise in the drive axle in the area of ​​the hubs can be a small clearance in the bearings, seizing or breakage of these elements and a lack of lubrication. The solution to the problem is to adjust, replace and lubricate this part.

If the differential housing overheats, add oil, replace the overtightened skid steer bearings, adjust the clearance between the crown and pinion gears, and eliminate the jam of the satellite wheel in the crosspiece.

To eliminate oil leakage through the seal in the hub or oily pads, it is necessary to replace the worn out hub seals.

If the loader does not move when the traction motor is on, replace the half-shaft and the torn rotor key.

The noise of the drive axle can be caused by insufficient oil, broken or broken bearings and gears. To fix the problem, you need to add oil and replace the damaged parts.

Price for engine repair:

• diesel service - from 1,600 rubles;
• internal combustion engine compression measurement - from 2,000 rubles;
• oil change - from 4,000 rubles;
• overhaul - from 25,000 rubles.

The price for the restoration of a high-pressure fuel pump is from 1,000 rubles.

The cost of repairing a gearbox - from 7,000 rubles, a hydraulic system - from 5,000 rubles, a starter - from 1,500 rubles, a bridge - 4,000 rubles.

The company "PartCela" carries out repairs of electric forklifts of all brands, as well as chargers for them. We eliminate problems of any complexity, highly qualified personnel, modern tools. Diagnostics and preliminary estimate for work. Warranty for work.

If you are planning to repair an electric forklift, you should, approximately, imagine what kind of work will be carried out by the company that will carry out the repair.

The above content is not the characteristics of the estimate, for each separate reason it will be modified.
Have you decided to repair your electric forklift truck? Contact the "PartCela" company, our specialists will help you!

Loading equipment is intensively used in various spheres of human activity. It facilitates the processes associated with the use of physical force to lift various types of goods or materials. Compact cars are very popular, which can move in closed areas of warehouses, supermarkets or construction sites. In the course of long-term operation, even the most reliable working units of mini-loaders can fail.

As a rule, specialized companies are engaged in the repair of equipment of this type, which have the necessary set of equipment and spare parts at their disposal. The restoration of the working capacity of the loading machines can be carried out independently. To do this, you need to have a certain stock of knowledge and skills, as well as a set of locksmith tools. Very often the bucket breaks down, which is the main working part of the machine.

The main faults are considered to be wear of the knife, teeth or bottom, as well as the appearance of tears or cracks on the side walls of the container.When repairing outside the workshop, you can use loose rail elements, pieces of durable sheet metal or various improvised items to replace the blade. They help to restore the functioning of the loader for a long time. During the overhaul of the bucket, its components are replaced. The metal material is fixed to the base of the working vessel using a welding machine.

Loaders, which are now offered by manufacturing companies, are distinguished by their simplicity of design and versatility of operation. Therefore, the elimination of minor breakdowns on their own does not threaten to disrupt their functionality. However, the installation of attachments, the repair of parts or work units, as well as the replacement of consumables can only be carried out with strict adherence to the instructions for servicing this type of equipment.

If the loader is out of order, the price of restoration work will depend on the complexity of the breakdown and the cost of spare parts. Self-repair will help save money, as well as get more information about the design of the equipment in use. In order to correctly establish a breakdown of a technical device, you can invite a specialist who will help you carry out professional diagnostics.

Repair of electric cars and electric forklifts divided into planned and unscheduled - emergency.

Scheduled repairs are foreseen in advance, while the wear of machine parts is determined during the next technical inspection, then the time is assigned for the repair.

Unscheduled repairs (emergency) are not foreseen in advance. It is produced when parts of the machine break down due to overloading or improper operation.

An electric car, like any machine, requires constant monitoring (inspection), identification and elimination of malfunctions, cleaning, lubrication and adjustment of units. Subject to these conditions, the machine can work for a long time and trouble-free. Each electric car and electric forklift is supplied with a factory instruction, according to which, after a certain period of time, it is required to carry out mandatory technical inspections.

It is recommended to carry out the following technical inspections: daily (on the day of use), weekly, monthly and annual, and each of them is carried out in a certain amount established by the instructions.

During daily inspection, it is recommended to: inspect the exterior of the machine, check the operation of the controller, brakes, lifting device, signal and lighting equipment. After that, a log entry is made about the state of the machine. During a weekly inspection, in addition to lubrication, the following is carried out: a) adjustment of the brakes, checking their pads and brake band; b) checking the rubber tires and the fastening of the wheel bearing caps; c) checking the fastening bolts and tightening the nuts; d) checking the steering and adjusting the backlash; e) checking the propeller shaft and spline connection.

During the monthly inspection, everything that is done during the weekly inspection, and additionally the following: a) check the lubricant level in the drive axle and steering wheel housings; b) checking the level of the brake fluid and adding it, if necessary, to the master brake cylinder; c) cleaning the chain of the lifting mechanism and the vertical frame from dust and dirt, as well as their lubrication; d) cleaning of dust and dirt from all external parts of the electric vehicle or loader (before cleaning, the flooring is removed, the working cylinder and piston of the lift or spool valve are checked and malfunctions are eliminated); e) replacement of wheel rims with worn-out rubber; f) cleaning of damaged paint areas from rust and complete painting of the machine.

Forklift loaders are produced with a lifting capacity of 3.5 tons with a lifting height of up to 6 m and a speed of movement with a load of up to 20 and without a load of up to 40 km / h.
Organization of maintenance and renovation construction machines.

Roll of paper is fed electric forklift from the storage warehouse to the unwinding device 1 of unit 2 of the impregnating and drying plant.
Repair ceilings made of reinforced concrete slabs. Wood fiber slabs.

Loading containers and packages into on-board vehicles can be carried out by rolling the cargo from the unloading platform into the body of the vehicle or using forklift loadersequipped with a large set of interchangeable working equipment (pipe grippers.

platform lifts, for renovation urban networks and buildings - towers for lifting ships sailing in canals with
The fourth group of hoisting-and-transport machines includes auto-loaders and electric forklifts (sometimes called autocars and electric cars).

Loaders or loading machines performing the tasks of picking up, lifting, stacking and transporting goods are gaining popularity in trade and sectors of the national economy. Technique is indispensable for mass production of products, and is expensive. Therefore, it is so important to provide lifelong technical support, machine performance.

As a result of non-observance of the operating rules and for a number of other reasons, self-propelled loading equipment will have to be repaired. Repairs are made on their own, if you have the skills of a mechanic, most resort to the services of special services. This article will serve as a kind of guide in case you have problems with damage, failure of the loading device, will present a rating of companies specializing in the repair of forklifts and individual parts.

Repair of forklifts is a set of works and measures that are aimed at eliminating malfunctions and failures, restoring the full ability of the unit to potentially perform its functions. It can be planned, when a preliminary diagnosis was carried out, which showed the need for its implementation. But more often you have to deal with the unplanned, that is, out of necessity, after a breakdown.

As a rule, early repairs save you costs and resources. To this end, it is important to carry out timely maintenance of forklifts, involving qualified specialists who are able to perform high-quality diagnostic work, and give recommendations on preventive maintenance.

Installing the engine on a forklift after a thorough overhaul

Depending on the purpose, volume and nature of the repair is subdivided into:

The purpose of the current one is to prevent and eliminate breakdowns in the device, restore or replace units and parts, with the exception of basic ones. It has no special requirements for the place of its implementation, most often it occurs on the territory of the owner of the car. Depending on the degree of complexity, the availability of spare parts lasts from a couple of hours to 2-3 days. The reasons for the current repair work are wear of the cuff, bushings, oil seals, etc., operation on poor quality fuel.

Overhaul of forklifts is a complete disassembly of the device (one of the units), determination of the root cause of the malfunction, assessment of the equipment suitability, replacement of defective parts or their restoration. It is performed if the current one has not brought the loader into operation. Overhaul of forklifts takes about a month.

The most frequent parts that break due to one reason or another are: steering axle, loader gearbox, less often automatic transmission, engine. This is due to unevenness in the warehouse floors, adjacent territories.
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It is not difficult to carry out primitive service and repair of forklifts on your own. Modern loading machines, due to their simplicity of design and versatility, make it possible to do this without risk to them. Pay attention to the main vulnerability - nodes and parts suffering from weather conditions, movement on uneven surfaces, non-compliance with the appropriate speed limit.

Loader undercarriage repair

However, the installation of attachments, the repair of units and some parts of the mechanism, the replacement of consumables must be carried out following the recommendations set out in the instructions. These actions will save finances, learn better the technique. The repair offered by the service is safer, better quality and more efficient. Professionals will solve problems that have arisen not only with minor breakdowns, but also with malfunctions of a serious nature. They will cope with emergencies requiring replacement of units, rare spare parts.

It is necessary to contact specialists first of all to perform the following work:

• repair of the loader engine;
• gearbox repair;
• restoration of wheel mechanisms, polyurethane rollers;
• turning and milling works;
• loader boom repair;
• repair of the starter and rotor.

To avoid premature failure of the transfer and storage machine's transmission, service the gear shifting unit daily. Emphasis is placed on the serviceability of the shaft, cylinder and piston of gears, gears of the drive of the steering control pump. The mechanism that is expressed by extraneous noise, knocks, lack of ease of switching on and off, smooth running indicates the need for diagnostics and adjustment.

Failures occur as a result of bearing wear, wear of seats, deformation of friction discs, failure of the armature clutch, reverse plates and other common causes.

Repair of loader gearboxes begins with an inspection to determine the integrity of the transmission case. Then, during disassembly, the condition of the shaft, spindle, gear is analyzed. With minor changes in the state of the elements, they are restored. If the wear is significant, they are replaced with new products. The bearing seats, as well as keyed connections, are carefully checked; whether the gears are meshing correctly. There must be no sticking or slippage.

If the cylinders and pistons of the first gear have no scratches, deformations, chips, they are in order. The presence of such malfunctions entails the replacement of non-renewable equipment. If necessary, the bearing bores are restored, the friction discs, seals, drums must be changed.

Timeliness and clarity are characteristic of the changeover valve for normal operation. But it is better to adjust it in a specialized workshop. After these steps proceed with the assembly of the gearbox.
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