In detail: do-it-yourself electric stacker repair from a real master for the site my.housecope.com.
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.
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Video (click to play). |
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:
- if the load does not rise, check the oil level;
- if a leak is found from under the spring under the handle, replace the plunger cuff;
- if a leak appears near the valve lever - the seals are worn out, put new ones;
- if the oil is at the correct level and the cart does not lift the load, check the valves;
- 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.
- oil leak from the pump wear of the cuff, damage to the pump piston
- when pumping up the pump, unstable raising or slow lowering of the working cylinder - repair of valves or wear of the cuff, damage to the working cylinder
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Later, we will consider the malfunction of the valves of the rocker of the jack stacker
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The 340A takes hydraulics directly from 24V (over 8 kW). Not too much?
Iskra 11 214 210
0 136 503 010
ONL 24V
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Posts: 2293
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Posts: 2293
With all this, the question of not protecting the transistors, but eliminating the cause of their burnout, remains to float on the surface, like everything that floats in an ice hole.
Starters in cars consume 40-100 A, depending on the model, at a rated power of 1-1.5 kW. It's not about the starters.
The point is the following (as the famous hero in the movie "Jack Vosmerkin - American" said), 20A XX is if it's okay - to select transistors or invent another powerful key, and if too much - to change or repair the hydraulic motor.
Here's another nuance - the -350A fuse is indicated on the diagram. In reality, A.
This is the whole point. Whether the motor is overloaded or not and what, if so.
Vityai measured the idle current of the motor (with the hydra disconnected) - 20A. Is not 0.5kW too much idle?
The 340A takes hydraulics directly from 24V (over 8 kW). Not too much? - no load.
And what's in your name (motor)
Iskra 11 214 210
0 136 503 010
ONL 24V
In the duress, power was supplied to the motor - after all, it works, only in the mode or not and for a long time, it is NOT CLEAR.
It is necessary infa on at least a similar stacker.
Connection wire according to the scheme 16 mm sq. In fact, in my opinion, less. But our ten, turned on as a jumper, when forcibly turned on after a couple of minutes of work, began to smoke, maybe the wrong ten. 
Our company has been repairing hand-held hydraulic stackers for 13 years. The rich experience of our craftsmen and the availability of spare parts allows our specialists to quickly and efficiently help our customers. Our mobile teams will provide prompt repair of hand stackers. Repair of hand stackers of various brands and models.We carry out repairs of the hand stacker both on the road and in our workshops. We can repair the stacker 24 hours a day.
The main types of work on the repair of hand stackers:
- repair of the hydraulic unit of the stacker = from 2000 rubles
- straightening the forks on a hand stacker = from 4000 rubles
- then. manual stacker = from 800 rubles
- replacement of rollers and wheels of a hand stacker = from 100 rubles
Our experts will help you calculate the exact cost of repairing a stacker. We carry out repair and maintenance of any stackers and in any condition. Our masters will always give instructions on how to work with this type of equipment. They will always write recommendations for the planned repair and maintenance of the stacker. Our company also sells spare parts for all types and types of hand stackers. One of the activities of our company - used sale stackers We also carry out buyout of non-working stackers in any condition , any brands and types. Or exchange of old equipment for a workable one with a guarantee. Another type of our activity is Used carts for sale
- Members
- 130 posts
- City: Alchevsk
- replacement of steering wheels and fork rollers
- Replacing the control handle spring
- handle repair
- geometry restoration welding
- repair of a hydraulic mechanism or waterworks
- replacement of the fork and its axis
- replacement of bearings in rollers
- other repair work under the contract
Hello dear forum users.
We are restoring the manual hydraulic stacker VV1000 / 1600G (SB INMART, Slovakia), practically new. A couple of years ago, the ear of the lever of the piston button was torn off along the weld, during the repair process the springs of the needle valve, the bypass piston, the piston with a spring were lost, the stacker was sent for storage.
Since it is not possible to order original parts, the piston button was carved, new rubber seals were made for it and the bypass valve piston, and the springs were selected.
After the first assembly, the forks were jerky: when the pump piston was raised, the cylinder rod was lowered. After lifting the load to the required height, a slow lowering of 100-150 mm was observed. Connecting this with incomplete closure of the needle valve, they installed a reinforced spring, changed the dimensions of the piston button. As a result, the load stopped spontaneously lowering, the jerks during lifting decreased, but did not disappear. We checked the carrying capacity: we raised 200-250 kg, it is physically impossible to squeeze the lever anymore.
The waterworks were dismantled again. We scaled the section of the hydraulic system from the collection of spare parts in Compass to clarify the valve strokes and the lengths of the springs. We picked up a new spring of the bypass valve, the force on the lever when lifting loads weighing 200-300 kg became less, the jerks of the stem practically disappeared.
The result is satisfactory, but a new problem has arisen. After half a day of inactivity, the pump stopped working. At the first working stroke of the piston, a jerk of the cylinder rod occurs, then the pump pumps to idle, without developing pressure. There are practically no oil leaks - a dozen drops on the piston button, there is no visible air leakage by the pump. They disassembled it again, washed the hydraulic system, poured new oil - everything works, a couple of hours have passed - the pump does not pump again.
We assume a malfunction of the pump check valve or a small leak of air along the pump piston cuff, leading to airing, although there is no visible wear of the cuff. What can be wrong?
Post has been edited by Morygin: 13 November 2015 - 22:01
As the well-known wisdom says, what is more complex is broken faster and more often. But this does not mean that what is more simply arranged does not break at all. Therefore, hydraulic hand stackers, which are of the simplest design, can also malfunction.
Only professionals can cope with many problems, so most often in case of trouble, you need to contact the service center. But there are situations that you can handle on your own. Let's talk about them in more detail.
Common minor breakdowns
If a warehouse owner decides to buy a handheld stacker, then he should know how to deal with the following problems (or have a professional on staff who knows about it):
Of course, in order to carry out such manipulations, a specialist who is very well versed in the device of technology must work in the warehouse.
We can recommend the Pramac Group and Eurolifter stackers as the most reliable and easy to repair.
· You can also clean or replace the valve.
Our company is engaged in the repair and maintenance of warehouse lifting equipment and hydraulic systems.
The RemGru company is engaged in the modification of warehouse equipment and the creation of new non-standard equipment for individual projects.
The site provides a large catalog of technical documentation for warehouse equipment.
We are engaged in the sale of spare parts for warehouse lifting equipment. The most demanded spare parts for hydraulic carts and stackers are always available, as well as any spare parts on request.
Warehouse equipment diagrams and specifications
Good afternoon, in this section you can find technical data sheets for the most popular types of warehouse equipment, such as:
Passport for hydraulic carts Lema of the following models:
LM 20-1150 × 550, LM 20-800 × 550, LM 20-900 × 550, LM 20-1000 × 550, LM 20-800 × 450, LM 20-1150 × 450, LM 25-1150 × 550, LM 25-1150 × 685, LM 15-1300 × 550, LM 15-1500 × 550, LM 15-1800 × 550, LM 15-2000 × 550, LM 20-1150 × 550-galv, LM 20-1150 × 550- lite 
Passport for pallet trucks Otto-Kurtbach of the following models:
OK 25-115, OK 25-80, OK 25-90, OK 25-100, OK 20-150, OK 25-1150 × 685, OK 20-180, OK 20-200, OK 20-250, OK 20- 300, OK 30-115, OK 20-low-61, OK 20-low-51, OK 10-low-35, OK 20-steel, OK 20-galv, OK 15-4-way, OK 20-115- QL, OK 25-break, OK 20-500R, OK 20-700R, OK 20-1000R, OK 20-1500R, OK 20-1150 × 838, OK 25-1150 × 450, OK 35-150, OK 35-180 , OK 35-200, OK 35-250 
Passport for hydraulic trolley KT20H of the following models:
KT20H, KT20L, KT25H, TX25L, KT30H 
Passport for self-propelled carts Lema PL15: 
Passport for self-propelled cart Lema PL-20, PLP-20: 
Passport for the Lema PLx self-propelled cart: 
Passport for Lema hand stackers of the following models:
LM-0516, LM-1016, LM-1020, LM-1030, LM-1516 
Passport for hand stacker OK-Jung 1016: 
Passport for electric stackers Lema LM-E of the following models:
LM-E-1016, LM-E-1020, LM-E-1025, LM-E-1030, LM-E-1035 
Passport for self-propelled stackers Lema LM-EL of the following models:
LM-EL 1025, LM-EL 1030, LM-EL 1035, LM-EL 1525, LM-EL 1530, LM-EL 1535, LM-EL 1540, LM-EL 1545, LM-EL 1550, LM-EL 2025 
Passport for self-propelled stackers OK-Besser of the following models: Besser 1232F, Besser 1232, Besser 1232U, Besser 1232UF, Besser 1246F, Besser 1529, Besser 1529F, Besser 1532, Besser 1536, Besser 1536F, Besser 1540, Besser 1543F, Besser 1546F, Besser 1546UF, Besser 1546F, Besser 1546UF, Besser 
Passport for self-propelled stackers OK-Optimal of the following models:
Optimal 1216, Optimal 1229, Optimal 1229F, Optimal 1232, Optimal 1236 
One of the main “assistants” in the warehouse is an electric stacker, without which it is impossible to imagine the work of a modern warehouse. Using such a stacker, it is possible to move cargo from one end of the warehouse to the other in a matter of minutes, without any great effort.
1. Height of lifting of the load. The height of the storage will depend on what height the stacker is capable of lifting the load, which saves the area of the warehouse.
2. Carrying capacity. Its performance will also depend on the lifting capacity of the stacker.
3. Dimensions. As a rule, there is no excess space in the warehouse, and all that is possible is used for storage. With a small stacker, you can work in the narrowest areas of the warehouse.
4. The capacity of the storage battery. The word “electric stacker” itself says that it will need electricity for its operation, and since it is a mobile machine, built-in rechargeable batteries are used to power it. The capacity of the battery will determine how much you can work without recharging, although many neglect this factor. As you know, it takes several hours to charge the batteries, that is, all this time the stacker will simply be idle.
There are two types of electric powered stackers: self-propelled, and those that are driven by human physical strength. Self-propelled stackers are much easier to operate, but they are more expensive, and when choosing, these factors should be taken into account, depending on what tasks are to be performed with their help.
Electric stackers are equipped with an electro-hydraulic drive for lifting loads to a height. They are practically silent in operation, as an electric drive is used for control.To service them, you do not need to hire a qualified specialist, this technique is not whimsical, and its maintenance is minimized.
Most warehouse facilities and supermarket shopping use a stacker for lifting and transporting palletized cargo. Unfortunately, in practice, during their operation, the instructions and regulatory technical requirements for working on a stacker are not always followed, which include: a relatively flat floor surface, work at an air temperature of 5 degrees, moderate movement speed, normalized uniform weight distribution.
More common breakdowns are:
– gradual roller wear stacker or deformation from overload and defective surfaces;
– more complex damage (defective modification of the forks themselves, fracture of the welded seam) due to a violation of lifting goods in excess of the established norm, collision with other stackers.
– indentation of the forks of the stacker roller wheels, which occurs when driving with the pallet forks not raised to a small height (this also applies to forks without luggage).
This is a complex technical process that requires a professional store of knowledge, skills and additional equipment. It is best to entrust your stacker to a professional. There are technical points when operations must be performed exclusively in the conditions of a service company. Due to independent poor-quality intervention, you will have to completely replace the stacker electric unit, restore the wiring, and, perhaps, correct the geometry.
Repair stacker in many ways is similar to the repair of a rocket, but not in everything, since the stacker differs in the design of a metal mast and hydraulics with a high lifting capacity. In order to contact warehouse equipment repair shops as little as possible, adhere to technical operating rules and periodically carry out maintenance checks of the stackers, change the oil and check the wear of parts.
Professional team «Warehouse mix» will return to operation qualitatively repaired equipment with the optimal time spent and with a budgetary approach to calculating the cost.
The cost of repairs generally depends on the truck brand and its current condition. It is advisable to start overhaul if the cost of repairing the machine, its instruments and component parts is no more than 60 percent of the original price of the stacker.
The main items of repair work hand stacker:
replacement / repair of the hydraulic system;
repair (welding / straightening) of the frame and forks of the stacker;
maintenance of the stacker;
welding / restoration of the handle together with the lever device;
replacement of rollers / wheels of a stacker;
updating the color or painting of individual parts of the stacker;
oil change of the hydraulic unit of the stacker regardless of the season.
All repairs are guaranteed.
Repair of an electric lift truck is similar to the above positions, but slightly more complicated. Possible damage can be found in electrical appliances, which can only be corrected with a complete replacement of the electric equipment element of the stacker.
What is being repaired in electric stacker:
eliminate the bent forks, straighten the mast metal structure and overpower the stacker frame;
repair or partially restore chassis of various levels of complexity;
upgrade wheels and rollers of the stacker, change brackets and bearings;
select wheels in accordance with the quality of the floor and the conditions of their use.
Average repair cost self-propelled stacker depends on whether the battery needs to be replaced and whether there is a need for painting. Complex repair measures can be carried out according to the wishes of the client, both at a stationary storage place and in a service workshop.
Planned repairs include:
elimination and installation of wheels / rollers of the stacker due to their deterioration;
diagnostics, refurbishment of the stacker battery;
diagnostics / repair of stacker electrical equipment;
Maintenance and replacement of spare parts for the stacker.
Repair involves the following work:
replacement / repair of the stacker battery;
repair of all components of the electronic stacker system;
replacement of the cargo tires and the support bracket of the stacker;
change of the spring of the motion regulator and the repair kit of the hydraulic unit;
in-depth, according to the technical regulations, maintenance of the self-propelled stacker;
pre-sale diagnostics, preventive maintenance and preparation of the stacker (if necessary).
Repair is a delicate and demanded business, so try to choose a repair organization with a service that suits you, prices and a high-quality approach to repair work, so that simple equipment and costs are optimal, and your investment in it justifies itself.
We provide services for the repair of stackers to our customers. Forklift repairs include technical inspections, in connection with which work is carried out on a periodic inspection. Our highly qualified specialists with modern high-quality tools and equipment will carry out high-quality service and repair of your stackers.
We will carry out any work required:
Sooner or later the moment comes when the stackers need to be repaired, associated with the replacement of rollers. Usually stacker manufacturers install cheap rollers and wheels on stackers in order to reduce the cost of their products. We offer you the installation of modern rollers and wheels, taking into account the peculiarities of the operation of the stacker. We will also advise you on the rules for choosing wheels and rollers for a stacker, taking into account the specifics of the flooring of your warehouse.
As part of this service, we will carry out a high-quality repair of the stacker and replace all mechanisms and assemblies that have worn out their service life. Also, during the overhaul, we will clean the stacker from dirt and corrosion, returning it to its original appearance. You can find out about the cost and guarantees for overhaul of the stacker from our managers.
Our company carries out maintenance and repair of hydraulic stackers and electric stackers (of all types and manufacturers) in Moscow and the regions at affordable prices. We also sell spare parts and functional units.
We offer owners of warehouses that operate more than 10-15 stackers and hydraulic carts their maintenance and ongoing repairs under a contract. Each period of time (month) stipulated in the contract, our specialists will carry out diagnostics and preventive maintenance of your carts right on the spot. This service will extend the life of your warehouse equipment and ensure uninterrupted work in the warehouse! Thanks to the highly qualified maintenance of pallet trucks, you don't have to worry about the health of your warehouse equipment!
If you want to update or expand your own warehouse equipment park, we are glad to offer you a wide range of pallet trucks, stackers and other warehouse equipment!
Naturally you can spend stacker repair and on our own, because almost any enterprise has full-time mechanics. But in this case, there are no guarantees regarding the quality of the repair performed.Most of the stackers, with the exception of the simplest ones with manual hydraulics, have rather complex schemes that ensure a continuous and most importantly efficient process of functioning of mechanical forklifts. Therefore, interference in the process of non-professional repairs in their complex system may entail the need to urgently search for considerable financial resources to purchase new equipment to replace the damaged one.
But in fact, the breakdown and the subsequent stacker repair can have a very serious impact on the operation of the entire enterprise. So, if an enterprise produces any product, the absence of a stacker when delivering raw materials to production workshops inevitably causes downtime and, as a result, a decrease in production and sales volumes, and the result of all this is a drop in the company's profit.
When the stacker used in the loading of finished products breaks down, delivery times may be disrupted, which entail controversial situations in relations with customers. Litigation, the imposition of penalties and, again, a decrease in the company's income are possible.
All of the above proves the need to carry out stacker repair professional and timely. Moreover, most of the companies that carry out repairs of this kind have in their staff highly qualified mechanics who have rich experience and constantly improve their skills at various seminars organized by manufacturers of warehouse equipment.
It should be noted that most of the equipment repair companies at the time of the repair have the opportunity to provide their own stacker for operation, which satisfies all the needs of your warehouse.
It is also very practical to conclude a maintenance agreement for warehouse equipment, which involves periodic diagnostics of equipment and maintenance with a clear implementation of all the manufacturer's recommendations. Such maintenance of stackers allows you to avoid unexpected spending of financial resources for unscheduled repairs.
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The main staff of our company is specialists whose profile: repair of self-propelled stackers, repair of self-propelled carts, repair of reach trucks .We know about stackersalmost everything. They are interesting to us.
We are interested in new products in the field warehouse equipment more than an auto technique. Due to the high level of our specialists, who have rich experience and knowledge both in mechanics and in electronics and hydraulics, it allows us not only to carry out minor repairs and scheduled maintenance, but also to cope with complex diagnostics and repair, usually within one trip. All mobile vehicles are equipped with the necessary equipment and spare parts.
Specialists of our company undergo compulsory training at manufacturers' factories on the subject of use, scope, maintenance and repair of warehouse equipment and equipment: hand pallet trucks, self-propelled, electric, lifting tables and much more.
Overhaul of stackers
Capital service repair of stackers, includes the replacement of all nodes and mechanisms that require replacement or have worn out. The overhaul of the stacker is carried out at the customer's site or on the basis of our service center, depending on the wishes of the customer and the necessary volumes of repair of the stacker. Spare parts for stacker repair included in the cost of overhaul.
Stacker overhaul costdepends on: 1) whether the battery needs to be replaced 2) whether painting is required. The average cost of overhaul of a self-propelled stacker is from 88000r. Depends on the brand and condition of the battery. But does not exceed 60% from the market value of the stacker.
If there are more than 5 stackers a discount 10%
Repair of hydraulic push-type stackers
We repair this equipment on the day of contact on the spot, regardless of the brand (if bending and straightening of the frame is not required)
Stacker overhaul hydraulic push type.
The overhaul service for stackers includes the replacement of all components and mechanisms that require replacement or have worn out.
The cost of this service is from 14000 RUR Depends on the brand of condition. But does not exceed 60% from the market value of the stacker.
If there are more than 5 stackers a discount 10%
We repair this equipment on the day of contact on the spot, regardless of the brand (if bending and straightening of the frame is not required)
Today we are servicing 486 electric push-type stackers of different brands (all X5 stackers (intersection, five, roundabout). Every mechanic with his eyes closed will find a breakdown in this type of equipment. Almost always all spare parts are available for this type of equipment. ...
Overhaul of the electric pusher type stacker.
The cost of this service is from 25000 RUR Depends on the brand and condition of the battery. But does not exceed 60% from the market value of the stacker.
If there are more than 5 stackers a discount 10%
People, people! I thought for a long time where to shove this post, it doesn't seem to fit anywhere (((I decided to go to the smoking room ((In general, we have a CBD12 electric pallet porter). People bought it from the forklift company, he worked in the production of curbs. He stopped moving at maximum speed. Small works, lifting and lowering too. All limit switches looked like everything is there. They gave a verdict that the brain came to 3.14 zdets. They sent them to Moscow to their head office. They returned them saying that everything was gut. I ask, how did they check? They say, but they just put it on. another cart and everything works. (they probably lie) .. There is only a user manual. The wiring diagram is very small and even on KETAYSKY (((((I'm not strong in it). to the service staff of this technique, and says do as you want (((((No one has come across such a thing?
If anyone responds, I will try to post at least some photos
I forgot completely .. Forclift no longer gives any data
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9) Overhaul of a loader (full restoration, overhaul of main components and assemblies, painting, recycling)
10) Tire fitting (wheel change, rearrangement)
11) Repair of other warehouse equipment (stackers, reach trucks)
12) Repair of hydraulic carts ROKLA (full cycle)
13) Redemption of used loaders (in any condition)
14) Redemption of BU ROKLA trolleys (in any condition)
15) Trade In (exchange of faulty equipment for a refurbished one)
16) Sale of spare parts for forklifts (prices below market)
17) Sale of tires for forklifts (prices below market)
18) Sale of used forklifts (prices below market)
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Video (click to play). |
"REPAIR OF LOADERS"
