1、 Forklift gearbox maintenance
Lift out the forklift engine with a crane, take out the torque converter first, and then remove the whole forklift gearbox. Before disassembly, the forklift gearbox oil shall be discharged first, and then the upper cover of the gearbox shall be removed. The forklift oil supply pump shall be removed and checked for damage. Then remove the front and rear clutch assemblies and check whether they are damaged and worn. If they need to be replaced, they must be replaced with new parts. Check and clean again, then install the gearbox in sequence, and then install it on the forklift. Refer to the following methods for specific fault maintenance:
01 torque converter fault section
1) . the engine speed of forklift truck decreases, and the treatment method is to increase the engine speed;
2) If there are bubbles in the oil, directly check the tightness of the pipeline and whether the forklift hydraulic oil is deteriorated;
3) . the oil temperature rise is too high or too low.
02 transmission section
1) . the friction plate is stuck or worn. Check whether the friction plate of the forklift has glue, uneven contact and warpage;
2) The forklift seal ring or O-ring shall be grinded, and the seal ring and groove width shall be inspected for grinding or damage.
03 oil temperature too high
1) . if the torque converter works 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 working condition should be changed and attention should be paid to avoid the above working conditions.
2) At high speed ratio, the one-way clutch is stuck and out of control. Check and eliminate it.
3) If the amount of oil is too small or bubbles are generated in the system, increase the amount of oil and adjust the pressure of the discharge valve.
4) If the oil quality is unqualified, replace it with new oil.
04 transmission section
1) If the clutch is blocked, check whether the friction plate slips;
2) If the bearing is damaged, check whether the mating surface is damaged.
05 transmission inoperative
1) Check whether the control valve has a spring stuck or broken;
2) Check whether the main oil pressure is normal. If not, check whether the triplet pump is excessively worn or damaged;
3) If the main oil pressure is normal, check the clutch oil pressure. If not, check whether the sealing 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、 Check the following steps after maintenance of Heli forklift gearbox
1. Thoroughly clean the gearbox cooler and cooling oil pipe of Heli forklift with special cleaning agent to ensure that there are no sundries, the oil passage is unobstructed, and the installation
After completion, check the flow pressure. Under normal conditions, the pressure of the gearbox should be at least 12kg. Replace the oil pipe of water tank cooler if necessary;
2. Check whether the torque converter is installed in place;
3. Check whether locating pins and screws between engine and Heli forklift gearbox are installed completely;
4. Check whether the torque converter screws are too long and whether the machine fits tightly after the mounting bolts are tightened;
5. Check the runout of forklift flywheel (reference value: below 1.0mm);
6. Check whether the shift lever, accelerator cable and vacuum pipeline are properly adjusted;
7. Fill the automatic transmission oil specified by the original manufacturer (additional gear oil shall be added for manual models), and check the oil level, not too much or too little;
8. Check that the machine foot glue is not damaged;
9. Ensure that all wire plugs and grounding wires are completely installed, and the transmission shaft and half shaft are assembled as required;
10. The forklift gearbox is a very important system in the forklift truck body, which directly affects the safety of driving. It is recommended to repair it in time once any problem is found.
3、 Maintenance method of forklift gearbox
1. In order to ensure the service 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. The forklift with automatic working fluid uses 6\n\e hydraulic transmission oil and wave box oil, and the forklift with manual transmission uses gear oil. The service oil temperature is 70-95c, and the service time shall not be too long after it is greater than 95C;
3. Clean and maintain the automatic transmission. Generally, it is necessary to replace the lubricating oil speed box of the forklift transmission every half a year for cleaning and maintenance;
4. The replacement and cleaning cycle of forklift oil filter shall be within 50h for new vehicles, every 200H and 1200h thereafter, and every 600H for particularly harsh environments;
5. When the forklift is driving and shifting gears, close the micro valve first, and then shift gears; When braking, the inching valve must be closed before braking; To prevent clutch damage or brake failure.
