DIY Balkankar checkpoint repair

Instructions for the repair and maintenance of forklifts Balkankar

For a more detailed study of the design, as well as the operating conditions of the equipment, the Rabochaya Hod company invites you to familiarize yourself with the official documentation for the repair and maintenance of Balkankar forklifts, which is especially useful for novice drivers to carry out daily, weekly technical inspections.

Repair manuals for forklifts Balkankar

For repair shops, as well as self-repair of the engine or other elements of the loader, there are repair manuals, where all recommendations for repair and maintenance are collected.

Hello dear motorists, DIY masters!
Before we begin to consider the procedures that go into repairing a gearbox, a few words about what it is - a gearbox (gearbox). A gearbox is a vehicle unit designed to change the torque frequency within a wider range than the engine can provide.

On modern cars, the main types of gearboxes are used: mechanical and automatic, which, in turn, have subspecies. We will consider in detail the question of how to repair manual transmissions. The main directions of this repair.

Important! Experts strongly recommend that owners of automatic transmissions (automatic transmissions) not try to repair them on their own. In addition, avoid repairing the automatic transmission with the help of craftsmen from the garage next door.

Remember that sometimes the automatic transmission costs 1/3 of the price of the entire car. And how much it costs to repair a gearbox depends on which car model and what kind of malfunction occurred in the gearbox of your car.

Video (click to play).

Naturally, within the framework of one post, we cannot, and did not set ourselves such a goal, to list the entire technological process of repairing a gearbox with our own hands. To do this, there are instructions or repair manuals for each brand or model of car.

But the reasons for the occurrence of malfunctions, and, accordingly, an understanding of what kind of repair of a manual transmission is necessary, and how much it will cost to repair a transmission, we will consider with you.

The first thing that is diagnosed while the car is moving is the ease and smoothness of engaging all gears. If you feel (and the muscle memory of your hand will tell you) that gear shifting is difficult, then you need to carry out TO2 - a thorough examination of the gearbox.

During TO2, the gearbox mountings to the crankcase, bearing caps of the intermediate and driven shafts are checked and tightened. If necessary, change the oil in the gearbox crankcase

Important! Repair of the gearbox of any car can be postponed if TO1 KP is performed on time and correctly: the oil level is checked in the KP once a year or after 15,000 - 25,000 thousand km. mileage.

The main faults requiring prompt repair of a manual transmission are: Difficulty shifting gears; spontaneous shutdown of transmission; gearbox noise, oil leakage or gearbox overheating.

The reasons for the difficult inclusion of the transfer:

• Spherical joint seizes;
• The gear shift lever or forks are deformed;
• Plugged rod sockets, as a result of a tight rod stroke, blocking crackers jam.

Reasons for spontaneous disengagement of gears:

• Worn clutch teeth or synchronizer locking rings;
• Worn balls or stem seats;
• Reducing the elasticity of the retainer springs

Causes of KP noise: wear of gears, bearings, synchronizers, play of shafts along the axle, insufficient oil level or its contamination.

Causes of oil leakage from the gearbox: weak fastening of the crankcase cover, worn out shaft seals, weakened fastening at the junction of the gearbox and clutch, wear of the gaskets.

The cause of gearbox overheatingthe oil level is usually insufficient.

In all these cases, the repair of manual transmissions is carried out using repair kits or restoration of damaged gearbox parts. Accordingly, the cost of repairing a transmission will depend on the degree of failure in each individual case.

Repair of loaders "BALKANKAR"
Loaders made in the Republic of Bulgaria, despite the abundance of Japanese, Chinese and other special equipment on the market, occupy one of the leading positions in Russia. This is due to the low prices for the loaders themselves, as well as the availability of the entire range of spare parts and components.
Repair of bulgarian forklifts:
Our company is a service department of the company "BENA-M", one of the main suppliers of forklifts and spare parts from Bulgaria. This makes our work on servicing Bulgarian equipment the fastest and highest quality, with the constant availability of components.
Repairs are carried out both at the customer's site and at the service center in the Lyubertsy district. We provide a full range of services, such as repair of engines and fuel equipment, gearboxes (GDS), steering and driving axles, hydraulic systems, electrical equipment, electric motors, as well.

Repair of forklift trucks "KOMATSU"
One of the leading positions in the Russian special equipment market is occupied by the Japanese company Komatsu.
Forklift trucks of this manufacturer are equipped with gas-petrol and diesel engines, which is reflected in the designation of their model - FG ……… or FD ……. ... Engines are installed on gas-petrol forklifts - Toyota 5K, Nissan K15, Nissan K21, Nissan H15, Nissan K25, Nissan H20, Nissan H25, Nissan TB42, depending on the model and capacity. On diesel - Isuzu 4LB1, Isuzu C240, Komatsu 4D92E, Komatsu 4D94LE, Komatsu 4D98E, Komatsu S4D95LE-3, Komatsu 6D102E, depending on the model and capacity. Forklift trucks are available with various types of transmission, both with a manual transmission (manual transmission) and with an automatic transmission (automatic transmission).

Repair of forklift trucks "MITSUBISHI"
Mitsubishi Forklift Trucks has long established itself as a manufacturer of reliable warehouse equipment. The most common forklift trucks from this manufacturer are Mitsubishi FD15-35 and Mitsubishi FG15-35, depending on the capacity and type of fuel, with automatic and manual transmissions. Models FD15-35 are diesel versions, where Mitsubishi S4Q2 or Mitsubishi S4S engines are used, respectively, with a lifting capacity from 1500 to 3500 kg. FG15-35 - models with gasoline engines Nissan K15, Nissan K21, Nissan K25 (earlier, with engines Mitsubishi 4G15, Mitsubishi 4G33), respectively, with a carrying capacity from 1500 to 3500kg.

Our company specializes in the service and repair of forklifts in the Moscow region. We offer services for the maintenance and repair of handling, warehouse equipment from major global manufacturers such as Balkancar, Komatsu, Toyota, Nissan, Mitsubishi, Heli, etc.

Forklifts of the Bulgarian brand "Balkankar" are one of the most popular types of loading and unloading equipment on the domestic market. Their main advantages in comparison with other similar machines are high carrying capacity and reliability at an acceptable price level for the unit itself. Naturally, any equipment breaks down from time to time, which means that if you have an electric or diesel Balkancar in your property, sooner or later you will need to repair it.

The most frequently performed types of repair and maintenance of Balkankar loaders are:

• diagnostics of breakdowns;
• tuning the fuel pump;
• repair of gearbox and engine;
• elimination of faults in the loader's electrics and hydraulics;
• repair of fuel equipment;
• alignment and painting of the car body.

Overhaul usually includes:

Washing, removing rust and old paint, leveling, filler, priming, sanding and painting

Replacing or repairing brake pads, bearings and cylinders, and adjusting gearboxes

Repair or replacement of wires, contacts and switches

Replacing grease, springs, tips and bearings

Replacing the valve, pump, cylinders and flushing the oil tank

Replacing cuffs, bearings and guides

Truck interior parts including steering wheel and seat

The most important factor for the operation of Balkankar electric forklift trucks is the serviceability of their batteries. Otherwise, burning and sticking of contacts are possible, as well as destruction of contact holders and overheating of starting resistors. Batteries are usually replaced rather than repaired.

Also, one of the biggest problems in this case is the failure of electrical connections as a result of exposure to an aggressive environment (high humidity, the presence of vapors affecting the metal in the air). In such conditions, timely diagnostics and systematic maintenance will help to avoid frequent breakdowns of the loader.

Repair of the hydraulic system and the chassis of the loader, as well as the brakes and steering in electric machines, practically do not differ from performing similar work on vehicles with internal combustion engines.

The most common types of breakdowns for diesel forklifts "Balkankar" are:

• difficulty starting the engine. Such a malfunction is often the cause of problems with the fuel equipment. For example, diesel engines of the most common models of this technology have built-in fuel pumps of the Mefin brand, which are especially sensitive to air entering the system. In addition, the design also contains filter elements and a fuel priming pump, the clogging of which or, again, air ingress, leads to an insufficient level of fuel supply, which, accordingly, prevents the fuel pump from operating. Another reason for problems with starting the engine may be a malfunction of the starter or lack of compression;
• malfunctions of the gearbox (GDS), as a result of which the loader may stop moving in one direction or another, as well as with difficulty lift the load. The problem can be eliminated by adjusting the electromagnet or distributor of the gas generator, or by adding a working fluid to it. Sometimes the solution lies in the repair of electrical equipment used to switch the "reverse";
• breakage of the hydraulic distributor valve and wear of the hydraulic pump, resulting in a decrease in the weight of the load that the machine can lift;
• problems with the braking system. They are usually eliminated by replacing the oil seals on the front hubs or brake cylinders.

In order to not have to deal with the repair of Balkankar loaders too often, their owners and maintenance personnel should follow the following recommendations:

• comply with the maximum loading capacity requirements for the loader;
• ensure timely and correct charging of batteries;
• timely carry out scheduled inspections, service work and overhaul of equipment. During a major overhaul, all worn out units, assemblies and parts should be replaced, which, with an average frequency of about once every 2-3 years, can amount to up to a third of all equipment;
• use the services of only an experienced driver who knows how to properly handle the equipment;
• to have a spare version - a loader, which is mostly not involved in the work, but serves to ensure the continuity of the technological process even in the event of a breakdown of the main equipment.

Loaders have become firmly established in various fields of activity. They automate the process of lifting, moving and unloading heavy objects. Loader Balkankar - equipment made in Bulgaria. It is produced by one of the most reliable companies in Europe, it is popular not only in the countries of the former USSR, but also in other world states. The main advantages of this transport are: reliability, simplicity, ease of use.

Bulgarian forklifts Balkankar have the following main elements:

• cabin;
• engine;
• counterweight;
• frame;
• transmission;
• steered wheels;
• forklift;
• fork grip;
• driving wheels.

Balkancar is capable of moving loads over long distances. High maneuverability allows you to operate the device in confined spaces.

Compact size, maneuverability, height and unloading power are the main characteristics that make the device suitable for work in any warehouse.

Diesel loader DV-1661 is a universal forklift for unloading and loading operations, transportation of items on pallets or in special containers over short distances.

• high maneuverability;
• small dimensions;
• the ability to work with a small distance between the shelves, in a confined space;
• use for loading and unloading in factories and warehouses, containers, wagons;
• wide operating temperature range: from -25 ° С to + 35 ° С (in ports and at railway stations);
• easy operation, simple control;
• a comfortable working place, which is adjustable in height, shock-absorbed, with a long stroke;
• good noise insulation and vibration protection, which is facilitated by the elastic system of the cab suspension to the chassis;
• the instrument panel is an independent module; equipped with backlight;
• compact steering column; a lot of free space around the pedals;
• welded chassis design - developed by the Balkankar company - provides reliable fastening of various devices;
• steerable axle with solid welded structure, hydraulic cylinder with piston rod;
• simple kinematic diagram.

This model is produced by the manufacturer in 2 modifications: with a rise level to a height of 3.3 m and 2.8 m.

The main working body is a pitchfork on a vertical cart. But instead of them, you can install another attachment (bucket, side grips, pusher).

Diesel loader DV-1788 is a universal handling equipment capable of transporting items in special containers or on pallets over short distances.

Key features and specifications:

• steering, hydrostatic booster;
• pneumatic or solid tires of the "superelastic" type;
• the main working body is a pitchfork on a vertical cart; instead of them, you can install another attachment (bucket, side grips, pusher);
• scope of use: canvas with a smooth, hard surface (concrete, asphalt); for work in closed rooms, it is necessary to equip the loader with a catalyst;
• wide operating temperature range: from -25 ° С to + 35 ° С;
• hydrodynamic transmission, inching valve, blocking that prevents the engine from igniting if the reverse is forward or reverse;
• on the control panel, the device shows data on the amount of fuel, the temperature of the coolant, the spent engine hours;
• welded chassis structure ensures reliable fastening of various fixtures;
• steering axle with robust welded construction, hydraulic cylinder with piston rod.

This model is produced by the manufacturer in 2 modifications: with a lifting level to a height of 3.3 m and 4.5 m. The carrying capacity is 3000 kg.

Loader Balkankar DV-1792 is designed to work in open areas and in closed spaces, for loading and unloading operations. It is highly maneuverable and reliable.

The main advantages of the DV-1792 auto-loader:

• high maneuverability;
• small dimensions;
• the ability to work with a small distance between the shelves, in a confined space;
• use for loading and unloading in factories and warehouses, containers, wagons;
• wide operating temperature range: from -25 ° С to + 35 ° С (in ports and at railway stations);
• easy operation, simple control;
• the ability to change motors within different modifications.

Balkancar DV-1792 also has disadvantages: increased noise level and gas pollution when working in closed rooms.

This model is produced by the manufacturer in 2 modifications: with a lifting level to a height of 3.3 m and 4.5 m. The carrying capacity is 3500 kg. The manufacturer produced this model at one time in the form of electric forklifts. The standard equipment is equipped with a diesel 4-cylinder engine.

Design features, technical characteristics:

• fuel pump, 2 gear speeds;
• hand parking brake;
• the main working body is the forks on a vertical cart, but instead of them, you can install another attachment (bucket, side grips, pusher);
• massive all-welded chassis, to which the loading and main running gears are attached.

The scope of this forklift is: factory and warehouse areas, containers, railway cars, caravan trailers. The smooth operation of the mechanism allows the use of special equipment for loading and unloading fragile items, glass containers, medicines.

The Bulgarian company produces 50 basic models and over 1200 modifications. Among them are universal, special and specialized loaders.

Characteristics of the Balkancar range:

• different types of drives;
• lifting capacity from 0.1 to 8 t;
• lifting height from 2 to 6 m.

One of the models - B 687 PiccoloE - is an electric forklift with a lifting capacity of up to 1.2 tons. Features: compactness, avant-garde design, high maneuverability, ergonomics, reliability. Mechanical control with one-stage transmission. The chassis structure is welded, one-piece. The most important parameters of the electric forklift are configured through digital settings using an autocalibrator.

The guarantee of a long and productive work of any equipment is correct operation and timely maintenance. But over time, the mechanism of the machine wears out, loaders need to be repaired. Check the technical documentation before contacting a specialized workshop. The repair manual presents the main types of faults that you can fix yourself. A complex problem will be solved by a repair company.

The main types of repair work for the Balkancar forklift:

• malfunctioning of the fuel pump;
• malfunctions in the electrics or hydraulics of special equipment;
• malfunctions of fuel equipment;
• breakdowns in the gearbox and engine;
• painting works, body alignment.

In stores, a wide range of spare parts for forklifts are presented, so there will be no problems finding accessories and equipment.

The accumulator is the main part of special equipment. Its malfunction threatens with sticking and burning of contacts, overheating of starting resistors, destruction of contact holders. The battery is rarely rebuilt; it is replaced with a new part.

If the machine is operated in an aggressive environment (high humidity, large temperature fluctuations), there is a high risk of failure of electrical connections. Timely diagnostics and maintenance will help to avoid this.