DIY balkankar forklift 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.

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Choosing the right handling equipment

The repair manuals contain the documentation necessary for the maintenance and diagnostics of the balkankar loader. The manuals are intended for fitters and other professionals involved in the repair of balkankar forklifts and who are familiar with the general structure of these machines. The repair manuals provide detailed technical data, the procedure for disassembling and assembling all units and assemblies.

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.

Dear customers, our company also offers overhaul repairs of the legendary company "BALKANCAR" forklift trucks, produced with a reliable diesel engine "Perkins", or purchase refurbished forklift trucks of the following models:

• "BALKANCAR" DV-1621, g / p = 1.25 t;
• "BALKANCAR" DV-1616, g / p = 1.6 t;
• "BALKANCAR" DV-1788, g / p = 3 t;
• "BALKANCAR" DV-1792, lifting capacity = 3.5 tons.

It is also possible to repair or sell electric forklifts of the BALKANKAR company, models EB 687 and EB 717.

Electric lift trucks "Balkankar" EB 687 with a lifting capacity of 1000 kg are indispensable for working in elevators, wagons, containers and trucks. They are produced in four standard modifications: EB 687.22, EB 687.28, EB 687.33 and EB 687.45 with corresponding maximum lifting heights of 2.2; 2.8; 3.3 and 4.5 m at the construction height of loaders - 1680, 1900, 2200 and 2080 mm.

Electric forklifts ЕВ 687.28 and ЕВ 687.45 are equipped with a freewheel function –1400 and 1520 mm, respectively. The width of the working aisle for all four Balkankar electric forklift models is 2850 mm. The loaders of the EB 687 model have a small turning radius; they are powered by traction batteries with a voltage of 80 volts and a capacity of 210-240 Ah.

Electric forklift "Balkankar" EB 717 is a universal wheeled electric forklift for work in workshops, as well as in warehouses with heights of storage of goods up to 5200 mm. Turning radius -1940 mm.

Electric lift trucks "Balkankar" EB 717 have a lifting capacity of 2000 kg and are produced in two main models: EB 717.33 and EB 717.45 with a lifting height of 3300 and 4500 mm, respectively, a construction height of 2200 and 2150 mm, a working aisle width of 3360 and 3395 mm, and a dead weight with a battery - 3500 and 4000 kg, respectively. The EB 717.45 model also has a free play of 1510 mm. Electric forklifts are powered from traction batteries with a voltage of 80 volts and a capacity of 280-400 A. h.

This auto-loader BALKANKAR 1792, lifting capacity - 3.5 tons, lifting height of the forks - 3.3 meters! After overhaul! Price - 380,000 rubles.

A short list of the work performed:
0. Disassembly into units, fault detection;
1. Engine overhaul: piston group, fuel system, oil seals, filters, etc .;
2. Overhaul of automatic transmission;
3. Replacement and repair of the hydraulic system;
4.Replacement and repair of the brake system;
5. Overhaul of the steering axle and all hydraulic cylinders;
6. Assembly, testing and painting.

FrontCar LLC expresses its respect to you and thanks you for your interest in the forklift trucks of our company. At your interest, we want to offer forklift trucks developed on the basis (chassis frame) of Lviv, but already completely modernized, with the localization of the production of parts and assemblies in Russia, corresponding to foreign counterparts, while retaining its small cost, simplicity and reliability, which will ensure the smooth operation of your enterprise!

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.

The main types of diesel forklift problems:

1. Difficulty starting. The reason may be in the fuel equipment, starter malfunction, or lack of compression. Built-in fuel pumps are air-sensitive.
2. If the equipment hardly lifts the load, does not move to the side, then the reason is in the gearbox.
3. Valve breakage, hydraulic pump wear. Signs: the machine lifts lighter weight than stated in the technical specifications.
4. Brake system problems. Solution: replacement of oil seals and brake cylinders.

Compliance with the rules of operation and timely maintenance of vehicles will extend the service life.

The wiring diagrams on most diesel forklifts are of the same type. They are necessary for the repair and restoration of electrical wiring, replacement of individual elements, connection of additional units.

The diagram will help you quickly and without any problems figure out where the element and the wire of the system are. With its help, you can carry out repair work yourself.

Bulgarian cars and diesel forklifts. Overhaul and refurbishment in 2016.

A complete high-quality repair of the engine, gearbox (gdp), driving and steering axle was carried out. Lifting device. 80% of new spare parts and components have been installed.

Perfect technical condition!

Price as in the photo 380,000 rubles. Payment in cash or by bank transfer.

There are other loaders from 235,000 rubles. Call, specify.

For sale loader Bulgarian diesel Balkankar DV-1792 after overhaul (all repaired). Lifting capacity 3.5 t, lifting height 3.3 m, automatic hydrodynamic gearbox.

Sale of Bulgarian forklift trucks and diesel cars. The well-known brand "Balkankar Record" Plovdiv (Bulgaria)

Loaders after complete and partial overhaul.

Prices from 280,000 to 410,000 rubles, depending on the work performed.

We can repair the forklift according to your budget.

Loader model: DV 1792.33 (Recycle)

Loading capacity of the loader in kg, with the center of the load - 500 mm 3500

Fork lifting height, mm 3300

Loader length without fork, mm 2750

Diesel forklift Balkankar RECORD is a universal forklift. It is designed for loading and unloading operations and transportation of goods over short distances on installed pallets or in other containers. This loader is small-sized and maneuverable, does not require a large distance between racks, can work in containers, wagons, trucks, in factory workshops and warehouses.

Forklift truck Record is used to work on sites with asphalt and concrete surfaces in well-ventilated warehouses, at railway stations, in ports at temperatures from -25C to + 35C. For work in closed rooms, a catalyst is installed on it.

Loader Bulgarian Balkancar Balkankar

Overall dimensions: length of the back of the fork mm 2726

Turning radius - outer mm 2440

Working aisle width with pallets 1000x1200 mm 4150

Travel speed with load km / h 22

Lifting speed with load m / s 0.40

Unladen weight kg 4800

Electric forklift Balkancar Balkankar recycle 2017

length to the back of the fork mm 2300

Turning radius outside mm 1925

Travel speed with load Km / h 14

Hoisting speed with load m / s 0.25

Unladen weight kg 3500

Bulgarian forklift Balkankar dv1792, after a full cap. repair.

80% of new parts. Engine, gearbox, axles, bodywork, electrics - everything is new.

- Lifting height of the forks 3.3 meters.

- Front and rear lights.

The price is negotiable. Delivery is possible. Payment of cash / non-cash

We collect loaders for your budget.

Skid steer loader for warehouse, electric production Bulgaria

Balkancar Balkankar EB687.22

Lift height 2200 mm - assorted

Battery Iskra Bulgaria 2х40B / 210 Ah, new 2017 year, filled, charged

Loader dimensions (with boom with a lifting height of 2200 mm)

Designed for work in a warehouse, closed room, between shelves, narrow corridor, etc.

Loader Bulgarian. Year of release 2003.

Excellent technical condition.

Carrying capacity 3.5 tons. The lifting height of the forks is 3.5 meters.

Inflatable wheels. The length of the pitchfork is 1 meter.

Cash price RUB 255,000 By bank transfer + 10%.

In stock and on order, spare parts, components, consumables for the repair and maintenance of diesel forklifts:

Balkancar, Dimex, Komatsu, Doossan, Toyota, Caterpillar, Nissan, Manitou, STILL, Hangcha, Jungheinrich, Hyundai, Pramac Lifter, Atlet, LOC, Dalian, Linde, Veni, Grost, OMG, Heli, Yale, Mitsubishi, Crown, Hyster , Clark, Daewoo, Universal, Haulotte, Lema.

- Repair of diesel engines and turbines (Perkins, Cummins, Nissan, Isuzu, Kubota, Hyundai, Xinchai);

- Repair of hydraulic systems and lifting devices, replacement of casings, masts, systems for grabbing cargo;

- Repair of transmission (gearbox, automatic transmission) and chassis of diesel loaders;

Guarantee, short terms, quality of performance.

• Carrying out scheduled maintenance TO

• Minimum terms of repair, mobile mobile team of craftsmen.

• A constant assortment of warehouse leftovers of spare parts and consumables for equipment (filters, oils, belts).

• We supply spare parts for any model of hoisting warehouse.

Repair of loaders BALKANCAR (Balkankar)

In the company "Skladskaya Tekhnika M" the main direction is the repair of forklifts and warehouse equipment, including repair of loaders BALKANCAR ... Our highly trained mechanics will service, repair, maintain and repair of loaders BALKANCAR ... Our specialists also go to the customer for scheduled maintenance, immediately eliminate the problems that have arisen right at the place of operation of the loader. A large assortment of spare parts for Balkankar loaders allows us to carry out repair work efficiently and in a short time.

• Diagnostics of loaders Balkankar
• Repair and adjustment of the high pressure fuel pump (TNVD)
• Routine repair of forklifts or individual units
• Overhaul of engines and gas drives
• Checking and repairing fuel equipment
• Overhaul of loader electrics
• Repair of hydraulic cylinders and hydraulic valves
• General overhaul of forklifts with painting

Maintenance services and repair of loaders BALKANCAR held throughout Moscow and the Moscow region.

• Loader diagnostics and then only repair
• Before any repairs begin, the client is informed of the scope of work, the cost of repairs and spare parts.
• No work, including additional work, is performed without the client's consent.
• We provide a tow truck

The advantages of service in the company "Warehouse Technics M"

• The experts of our company accurately determine the spare parts and consumables necessary for the repair of Balkankar forklifts.
• Our prices for service and repair of loaders BALKANCAR - optimal.
• We offer a flexible system of discounts.

Top-level service and attractive prices will make us reliable business partners for a long time.

Bulgarian forklifts produced under the Balkancar brand have long been known in our country. Back in the Soviet era, special equipment from Bulgaria was the main one in many warehouses and manufacturing enterprises. And today these loaders are widely popular in Russia due to their reliability in operation and low cost. However, like any other similar special equipment, after long-term operation, it will probably also need, at a minimum, to carry out routine maintenance with the replacement of some worn-out parts. To diagnose and repair the Balkancar loader with high quality - contact the specialized service company "SpetsTechRemont".

Replacing the clutch basket (with disc)

Changing the oil in the engine with filter

Replacing the pump (water pump)

Replacing steering tips

Replacing the power steering

Bleeding the fuel system

Bleeding the brake system

Flushing the fuel system

Repair of the steering bridge

Warehouse forklifts from the Bulgarian manufacturer Balankar are in demand among Russian buyers of warehouse equipment.Balankars are distinguished by their reliability and carrying capacity. Compared to similar machines from other manufacturers, they demonstrate high functionality at a relatively inexpensive unit cost. The battery is a vulnerable part of electric forklifts. They fail, both under severe operating conditions and under aggressive environmental influences. For diesel forklifts Balankar, the following breakdowns are characteristic:

• the engine does not start;
• gearbox malfunctions;
• hydraulic pump wear;
• breakage of the hydraulic distributor valve;
• failure of the brake system.

Service company "LAD" carries out repair work and maintenance of diesel and electric Balankar forklifts. Our specialists:

• diagnose equipment;
• the Balancar engine will be repaired;
• eliminate transmission breakdowns;
• will repair the driving and control bridges;
• lifting devices will be repaired;
• set up the fuel pump;
• eliminate problems in the loader electrics;
• will replace the hydraulic valve, pump, cylinder;
• align and paint the case, remove rust.

When warehouse equipment breaks down and fails, you should not restore it yourself. Lack of experience will negatively affect the state of technology and lead to new breakdowns. You will waste valuable time and the warehouse will be disrupted. In addition, an experienced technician will give you advice on how to avoid similar breakdowns in the future. By ordering a repair in the SKLAD company, you will be sure of the originality and quality of spare parts for your Balancar.

Repair and maintenance of forklifts Balkancar
WarehouseTechResource - The first service company in the warehouse equipment market

The main activity of our company is servicing the famous Balkancar forklifts.

We have been repairing and servicing Balkancar loading equipment since 2001. Years of experience accumulated in the field of service and repair of forklifts Balkancar allows us to declare with confidence that we are the best in this business.

WE HAVE ONLY 100% QUALITY SPARE PARTS FROM PROVEN WORLDWIDE SUPPLIERS-MANUFACTURERS! GUARANTEE UP TO 6 M.

Our help in repairing your Balkancar loaders is worth taking!

In a short time we will repair the D2500 engine for the Balkankar loader or, if necessary, install a new engine on the loader.

Possible malfunctions of the D2500 engine of the Balkankar loader:

1. Clogged fuel system and fuel filter.
2. Defective fuel priming pump.
3. High pressure fuel pump (high pressure fuel pump) malfunction.
4. Air in the fuel system.
5. Damage to the high pressure fuel pump drive.
6. Defective injectors.
7. Defective starting heater.
8. Clogged air filter.
9. Inaccurate valve adjustment.
10. Engine shutdown mechanism malfunction.
11. Wear of parts of the piston group.

Repair of the D3900 engine

Our specialists will diagnose and repair the D3900 engine or, if necessary, install a new engine.

Possible malfunctions of the D3900 engine of the Balkankar loader:

1. Starter malfunction.
2. Clogged fuel system.
3. Dirty fuel filter.
4. Malfunction of the engine starter.
5. Incorrect adjustment of the high pressure fuel pump (injection pump).
6. Incorrect valve adjustment.
7. Insufficient compression.
8. Wear of parts of the piston group, etc.

In a short time we will carry out the repair of Bulgarian forklifts:

OVERALL REPAIR OF POWER UNITS:

OVERALL REPAIRS OF ENGINES "BALKANKAR" D2500K, D3900K

1. repair or replacement of the crankshaft, camshaft
2. replacement of the piston group, piston rings
3. replacement of valves, valve guides, liners
4. replacement or repair of connecting rods and bushings
5. replacement of cylinder head gaskets, seals
6. boring and "liner" of the cylinder block

REPAIR OF AUTOMATIC GEARBOXES FOR LOADERS "BALKANKAR" (ГДП 6855, 6860.5, 6860.6)

1. replacement of friction discs, seals, pumps
2. replacement or repair of shafts, bearings
3. replacement of working elements of the torque converter
4. adjustment and adjustment of control systems

RUNNING REPAIR OF UNITS AND SYSTEMS OF THE LOADER "BALKANKAR"

1. replacement of wheel disks, hubs, bolts, nuts, washers
2. replacement of bearings and hub seals
3. repair or replacement of half-shafts
4. repair of the main gear and differential

MANAGED BRIDGE

1. replacement of wheel disks, hubs, bolts, nuts, washers
2. replacement of bearings and hub seals
3. replacement of steering tips, rods, axles, bushings
4. repair or replacement of steering cylinders

LIFTING DEVICE

1. replacement of rollers, bearings, bushings, liners, chains
2. repair or replacement of mast lift and tilt cylinders

BRAKE SYSTEM

1. replacement of brake drums
2. replacement and adjustment of brake pads of the main and hand brakes
3. replacement of master and wheel brake cylinders
4. replacement of brake pipes

FUEL SYSTEM

1. adjustment or replacement of nozzles, nozzles
2. replacement of fuel filters and filter elements
3. replacement of fuel pipes
4. adjustment, repair or replacement of high pressure fuel pumps and carburetors
5. repair or replacement of fuel priming pumps
6. flushing fuel tanks

COOLING SYSTEM

1. flushing the system
2. radiator replacement
3. replacement of the water pump and fan

Repair of injection pump loader Balkankar

The high pressure fuel pump is a key element to keep the forklift engine running smoothly.

Signs that indicate the need to repair the injection pump of the Balkankar loader:

1. Drop in power and dynamic characteristics of the motor;
2. Extraneous noise in the engine;
3. Increased fuel consumption;
4. Interruptions in the operation of the power unit at idle;
5. Unusual exhaust color, smokiness.

Transmission (power transmission) - in mechanical engineering, a set of assembly units and mechanisms that connect the engine (motor) with the driving wheels of a vehicle (loader), as well as systems that ensure the operation of the transmission. In the general case, the transmission is designed to transfer torque from the engine to the wheels (working body), change the tractive effort, speed and direction of movement. In modern forklifts, part of the transmission (hydrodynamic transmission) is part of the power unit.

The company AvtoKar-M produces all types of repairs for forklifts made in Bulgaria: Balkankar RECORD, APEX, BILLO, DIMEX.

We repair the engine D3900K, GDP 6844, 6855, 6860, cardan joint, drive axle reducer for a Bulgarian loader.

Departure to the customer for diagnostics before a complete overhaul of the loader. Repair of individual components and assemblies. Up to 180 days warranty.

Any special equipment requires regular maintenance, and loaders are no exception. Specialized equipment is an integral system of nodes connected to each other, and the failure of even one of them can lead to an increase in the load on many parts of the system. Without timely maintenance, equipment tends to wear out prematurely, sometimes without even recouping its cost. That is why it is so important to provide a well-thought-out systematic service of loading equipment, which allows you to notice and restore operability in time before a complete failure of the equipment occurs, which will require huge repair costs, or even purchase another loader.

It is not uncommon when company owners forget or do not understand the need for timely service of forklifts, and even try to save on spare parts, and also use low-quality consumables because of their low cost. Naturally, in such conditions, the likelihood of breakdowns is greatly increased even for loaders that are initially in excellent working order.

What can be done to prevent this from happening?

It is clear that maintaining your own repair team and a lot of special equipment for servicing your own fleet of forklifts may not be very profitable, especially if the fleet is small and has only a few pieces of equipment. Most often it is cheaper to conclude a contract for professional service of a forklift.

High-quality service solves the entire existing complex of tasks, and involves not only diagnosing and identifying problems at an early stage, but also setting up loader assemblies, replacing consumables, carrying out repair work, consulting on the correct and efficient operation of loaders, and even the possibility of free training for drivers to work on loaders of one model or another. Moreover, diagnostics, adjustment and repairs are carried out with high accuracy through the use of computerized technology. You can be confident in the quality of spare parts and consumables, since service centers usually work directly with manufacturers.

Of course, using the services of professionals involves costs, but they always pay off.

If your forklift is under warranty, we recommend that you carefully study the warranty and contractual conditions, and strictly adhere to their implementation. If the equipment was operated correctly, and the need for repair arose due to manufacturer's defects, the service center specialists will fix the breakdowns free of charge. It is also worth monitoring the absence of violations in relation to the contractual procedure for carrying out repair work, and perform scheduled maintenance only at the agreed service centers.

Subject to the conclusion of an agreement for the maintenance of forklifts with the Odessa forklift company, the guarantee for the purchase of new equipment is 64 months and 12 - for used forklifts. For a better understanding of the professionalism of our specialists, we present a far from complete list of forklifts, maintenance and repair of which we can provide:

Depending on the model of the loader, the order of preventive maintenance measures may be different, and depends primarily on the recommendations of a particular manufacturer. Nevertheless, in many cases, it is customary to distinguish such types of maintenance as:

• shift (EO);
• scheduled (maintenance);
• seasonal (CO);
• when storing;
• during long-term storage;
• when removed from storage.

The specific composition of operations during the service maintenance of loaders of different models may differ significantly, however, many operations are typical for most models. The differences depend mainly on the design of certain units, which are determined by the purpose of the special equipment and the type of drive.

The frequency of maintenance performed each shift is 8-10 hours of loading work (the duration of the work shift). EO is carried out by the driver himself and includes daily inspections and actions to prepare the loader for operation, maintenance during operation, return of equipment to the parking lot (to the garage).

Inspection of equipment before work usually includes checking the completeness and general condition of the working units. Before starting the engine, the operator should check:

• the level and suitability of the oil in the crankcase;
• the presence of a sufficient volume of fuel in the tank, as well as radiator coolant in and working fluid in the hydraulic system;
• optimum tension of drive belts (fan, generator);
• reliability of wheel fastening, tire pressure and degree of wear;
• Are the threaded connections of the most loaded components tightened?

If leaks, fuel shortages and other inconsistencies are found, they must be eliminated before starting work.

After warming up the engine, the function is checked:

• undercarriage;
• measuring and control devices;
• working equipment;
• hydraulic drive;
• brakes;
• steering control.

At the end of the work shift, in the parking lot, cleaning, inspection, elimination of detected faults and lubrication of working units are performed.

Scheduled maintenance can be of different types (TO-1, TO-2), and it is performed, depending on the type of equipment, after about 100 hours of operation of the loader for TO-1 and after 500 hours for TO-2.

Unlike the daily maintenance, TO-1 is carried out by a team of specialists, with the participation of the loader operator and, in addition to the activities of the daily maintenance, includes:

• additional checks and tuning of the engine, chassis and working equipment;
• checking all fasteners, including the nuts of the cylinder head studs;
• adjustment of steering units, brake and clutch systems;
• full inspection of the joints of pipelines with an assessment of the condition of the hoses themselves;
• drainage of sediment from the fuel filter.

Carrying out the second maintenance (TO-2) consists of all actions typical for EO and TO-1, to which are also added:

• checking and cleaning spark plugs;
• adjustment of gaps in the wiring;
• cleaning and tuning the carburetor;
• checking and adjusting the optimal clearances between pushers and valves (increased clearances lead to knocking, and due to reduced clearances, compression and power are lost);
• inspection and cleaning of the breaker contact pads;
• adjustment of bearing assemblies;
• replacement of lubricants;
• disassembling the fuel sump, washing the mesh and filter;
• adjustment of the valves of the hydraulic system;
• stripping battery terminals;
• inspection of the condition of the collector and generator brushes;
• inspection and cleaning of the brake system;
• setting the optimal tension in chain mechanisms;
• adjustment of steering clearances;
• checking and tightening bolted and nut connections at the points of attachment of working mechanisms to the loader frame.

The frequency of seasonal maintenance is 2 times a year (in spring and autumn, when changing between summer and winter seasons). CO contains all the activities of TO-2, and also additionally includes:

• flushing the cooling system, changing / filling fluid;
• flushing the fuel tank and fuel lines;
• seasonal replacement of lubricants and working fluids;
• control of electrolyte density;
• cleaning and lubricating the elements of the manual braking system.

The list of operations when staging the loader for storage:

• cleaning equipment from dirt and possible cargo residues;
• washing, drying and delivery to the place of storage;
• inspection and assessment of technical condition, elimination of malfunctions;
• inspection of painted surfaces and restoration of paint in places of damage;
• degreasing and coating with a safety lubricant of unpainted parts, hinges, threaded connections, springs, protruding parts of rods, rubbing surfaces of fixing mechanisms;
• checking the tightness of the components of the hydraulic system;
• control of the completeness and correctness of the loader installation.

Maintenance of the forklift during storage, allows you to prevent or eliminate damage to equipment during storage and consists of the following operations:

• checking the position of the components of the equipment and completeness, elimination of detected faults or deficiencies;
• checking the integrity of the protective coating of the surfaces of the loader, cleaning from corrosion, restoring the coating.

The maintenance frequency of the forklift during storage is usually 2 months for enclosed spaces, or every month for storage under shelters or outdoors.

After the end of the storage period, the loader must be prepared for operation: re-preserve, mount the previously removed equipment, reassemble the units, and make the necessary adjustments to the equipment.

When servicing, it is customary to distinguish between current repairs and major repairs.

The maintenance of the loader is designed to ensure its operability in the period until the next scheduled repair work.

Overhaul involves ensuring the working condition of the loader for a period approximately equal to the full resource of the equipment.

In the company "Odessa loader" you can purchase repair kits, spare parts and consumables for the entire period of operation of your loaders. A wide range of spare parts and consumables for:

• forklifts Toyota, Komatsu, Nissan, Mitsubishi, TCM, Bobcat, Moffett, Shangli, Clark, Sumitomo (Yale), CAT (Caterpillar), Bendi, Case, Crown, Daewoo, Dantruck, EP, Furukawa, Goodsense, Hitachi (TCM) , Hyster, Linde, Liugong, New Holland Skidsteer, Nichiyu, NYK, Sauer-Danfoss, Still, Stocka (Still), Xilin, Yale, including spare parts and consumables for engines 1Z, 2Z, 1DZ / 5FD, 1DZ / 7FD, 2J, 2J / 5FD, 4P, 4Y / 5FG, 4Y / 7FG, 5K / 7FG, 5K / 5FG, 4D95, 4D94E, 4TNV94, 6D95, 6D95L, 6D102, S6D102E, 4JG2, 6BG1, 6BB1, 6BJ340, C S4S, S6S, 4G33, 4G63, 4G64, S4L, S4E, 6D16, H15, H20, H25, TD27, J15, SD22, SD25, A15, Z24, TB42, TD42 and P40;
• Bulgarian Balkancar forklifts, including shock absorbers, camshafts, valve guides, inlet and outlet valves, block liners, cylinder heads, flywheel and distribution gear housings, sets of thrust washers and other parts for D2500 and D3900 engines;
• Lviv loaders - oil tanks, cardan shafts, hydraulic cylinders, axles, bushings, bearings, as well as clutch housings, flywheels and other components for engines D-144, D-243, Gas-51 and Gas-52.

The repair and maintenance operations of forklift trucks must not be allowed by persons without appropriate work skills and knowledge of safety.

Below are some of the most important guidelines that can be followed to significantly reduce or completely prevent personal injury:

• maintenance and repair operations should be carried out with the engine stopped;
• the bucket or the forks of the loader must be lowered, the first gear and the parking brake must be engaged, and the rolling of the wheels must be prevented by special shoes (the use of objects not intended for this is unacceptable);
• do not service and repair the forklift raised by jacks;
• before the start of repair operations, supports should be placed under the beams of buckets and bridges;
• it is forbidden to dismantle tires until the air is completely released from them;
• care must be taken when opening the filler cap if the engine has not yet been stopped or immediately after it has stopped;
• when inspecting batteries, it is extremely important to ensure that the electrolyte does not come into contact with open skin or eyes (otherwise, serious burns are possible);
• when preparing the electrolyte, first pour water, and only then pour in a thin stream, stirring, the acid (do the opposite, pour water into acid is prohibited).

Directly the schedule for the implementation of maintenance and repairs is drawn up by the owner of the enterprise. Since such planning is based on the manufacturer's instructions for a specific loader, this means that the service schedule should include its own procedure for carrying out measures for each model of special equipment.

The exact indicators of the frequency of repairs or maintenance can be determined based on the actual data of the loader's operating hours in operating hours, which is specified according to the meter readings, or according to the operating time log.

Timely professional service allows you to do without serious breakdowns and significantly increase the operating time of the loader before overhaul. Practice shows that with the correct organization of the maintenance service, the operating time before overhaul reaches 50 thousand operating hours, and these data speak for themselves.