Forklift gearbox maintenance method

1. Forklift gearbox repair

Lift the forklift engine with a crane, take out the torque converter first, and then take out the entire forklift gearbox. Before disassembling, it is necessary to fill the forklift transmission oil first, and then start to remove the upper cover of the gearbox, remove the forklift fuel pump and check for damage. Then remove the front and rear clutch assembly, check for damage and wear, etc. If you need to replace it, you must replace it with a new one. Check and clean again, then install the gearbox in order, and then install it on the forklift. Specific troubleshooting can refer to the following methods:

01 Torque converter fault part

1) The engine speed of the forklift drops, the solution is to increase the engine speed;

2) There are bubbles in the oil, directly check the pipeline tightness and whether the forklift hydraulic oil has deteriorated;

3) The oil temperature rise is too high or too low.

02 gearbox part

1), the friction plate is stuck or worn, check whether the forklift friction plate has glue, uneven contact, and warpage;

2). Forklift seal ring or O-ring is worn out, check whether the seal ring and groove width are worn out or damaged.

03 oil temperature is too high

1) The torque converter has been working in the low speed ratio area for a long time, the efficiency of the torque converter is very low, or the time in the stall state is too long, this kind of working condition should be changed and attention should be paid to avoid the above working condition.

2) At a high speed ratio, the one-way clutch is stuck and loses control. It should be checked and ruled out.

3). Too little fuel, or air bubbles are generated in the system, increase the fuel to adjust the discharge valve pressure.

4) If the quality of the oil is unqualified, new oil should be replaced.

04 Gearbox part

1), clutch obstacle, check whether the friction plate is slipping;

2). If the bearing is damaged, check whether the mating surface is damaged.

05 Gearbox does not work

1) Check whether the control valve has spring stuck or broken;

2) Check whether the main oil pressure is normal, if it is abnormal, check whether the triple pump is worn or damaged;

3) If the main oil pressure is normal, check the clutch oil pressure. If it is abnormal, check whether the seal ring or O-ring is worn or damaged. Check whether the clutch and clutch piston ring are damaged;

4). Check whether the oil pressure of the torque converter is normal. If not, check the torque converter.

2. After the fork speed box is repaired, the following steps should be checked

1. The cleaning agent of the brick door thoroughly cleans the gearbox cooler and cooling oil pipe of LGFT forklift truck to ensure that there is no debris and the oil passage is unobstructed. After installation, check the flow pressure. Under normal circumstances, the pressure of the gearbox must be at least 12KG or more. . Replace the oil pipe of the water tank cooler if necessary;

2. Check whether the torque converter is in place;

3. Check whether the positioning pins and various screws between the engine and the Heli forklift gearbox are fully installed;

4. Check whether the torque converter screws are too long and whether the machine fits tightly after the installation bolts are tightened;

5. Check the flywheel runout of the forklift (reference value: below 1.0mm);

6. Check whether the shift lever, throttle cable and vacuum line are well adjusted;

7.Fill the automatic transmission oil specified by the original factory (additional gear oil is required for manual transmission models), and check the oil level, not too much or too little;

8. Check that the machine foot glue is not damaged;

9. Make sure that the wire insertion and grounding wires are completely installed, and the drive shaft and half shaft are assembled according to the regulations;

10. Forklift gearbox is a very important system in the forklift body, which directly affects the safety of driving. It is recommended-once a problem is found, it should be repaired in time.

3. Maintenance method of forklift gearbox

1. In order to ensure the life of the mechanical parts and sealing elements of the hydraulic control oil circuit, the normal pressure of the control oil circuit is 1.1/u1.4Mpa;

2. Working fluid: Forklift trucks with automatic transmission use 6# hydraulic transmission oil and gear oil, and for manual transmission vehicles, gear oil is used. The use oil temperature is 70-95C, and the use time should not be too long after it is greater than 95C;

3. Clean and maintain the automatic gearbox. Under normal circumstances, it needs to be replaced every six months-the second forklift gearbox lubricating oil gearbox is cleaned and maintained;

4. The replacement and cleaning cycle of the forklift oil filter should be within 50h for new vehicles, and every 200h, 1200h thereafter, and every 600h for special harsh environments;

5. When the forklift is driving and shifting gears, the micro valve should be closed before shifting; when braking, the micro valve must be closed before braking to prevent clutch damage or brake failure.

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