1. Maintenance of forklift gearbox
Lift the forklift engine with a crane, take out the torque converter first, and then remove the entire forklift gearbox. Before disassembling, the forklift gearbox oil must be drained, and then the gearbox top cover should be removed, the forklift fuel supply pump should be removed and inspected for damage. Then remove the front and rear gear 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 fault maintenance can refer to the following methods:
01 Torque converter fault part
1). The engine speed of the forklift decreases, the processing method is to increase the engine speed;
2). There are air bubbles in the oil, directly check the tightness of the pipeline and whether the hydraulic oil of the forklift is deteriorated;
3) The oil temperature rise is too high or too low.
02 Transmission part
1). Friction plates are stuck or worn, check the forklift friction plates for glue, uneven contact, warpage;
2). Forklift sealing ring or O-ring rubbing, check whether the sealing ring and groove width are rubbing or damaged.
03 Oil temperature is too high
1). The torque converter works in the low speed ratio area for a long time, the torque converter efficiency is very low, or it is in the stall state for too long, so this working condition should be changed and the above working conditions should be avoided.
2) At a high speed ratio, the one-way clutch is stuck and loses control, which should be checked and eliminated.
3). The amount of refueling is too small, or bubbles are generated in the system, the amount of oil should be increased to adjust the pressure of the exhaust valve.
4) If the quality of the oil is unqualified, new oil should be replaced.
04 Transmission part
1). Clutch obstacles, check whether the friction plate slips;
2) If the bearing is damaged, check whether the mating surface is damaged.
05 The gearbox does not work
1). Check whether the control valve has spring stuck and broken;
2). Check whether the main oil pressure is normal, if it is abnormal, check whether the triple pump is too worn or damaged;
3) If the main oil pressure is normal, check the clutch oil pressure. If abnormal, check whether the sealing ring or O-ring is worn or damaged. Check the clutch and clutch piston ring for damage;
4). Check whether the oil pressure of the torque converter is normal. If it is abnormal, check the torque converter.
2. Heli forklift gearbox maintenance requires the following steps to check
1. Thoroughly clean the Heli forklift gearbox cooler and cooling oil pipe with a special cleaning agent to ensure that there is no debris and the oil passage is unobstructed. After installation, check the flow pressure. Under normal circumstances, the gearbox pressure must reach at least 12KG . If necessary, replace the oil pipe of the water tank cooler;
2. Check whether the torque converter is installed 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 screws of the torque converter are too long and the machine is tightly fitted after the installation bolts are tightened;
5. Check the runout of the forklift flywheel (reference value: below 1.0mm);
6. Check whether the gear lever, throttle cable and vacuum pipeline are adjusted well;
7. Fill the automatic transmission oil specified by the manufacturer (manual gear models need to add additional gear oil), check the oil level, not too much or too little;
8. Check that the machine foot glue is not damaged;
9. Make sure that all the wire plugs and ground wires are completely installed, and the transmission shaft and half shaft are assembled according to the regulations;
10. The forklift gearbox is a very important system in the body of the forklift, which directly affects the safety of driving. It is recommended that repairs should be carried out in time if problems are found.
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. For forklift trucks with automatic transmission of working oil, 6 # hydraulic transmission oil and gearbox oil are used. For manual transmission, gear oil is used. Use oil temperature 70-95C, the use time can not be too long after more than 95C;
3. Clean and maintain the automatic transmission. Generally, it is necessary to replace the forklift truck gearbox lubricating oil speed box every six months for cleaning and maintenance;
4. The replacement and cleaning cycle of the forklift oil filter, the new car is within 50h, every 200h and 1200h thereafter, and the special harsh environment should be every 600h;
5. When shifting the forklift, the micro valve should be closed before shifting; when braking, the micro valve must be closed before braking; to prevent damage to the clutch or brake failure.
