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Forklift Transmission Maintenance Tips

Nov 10, 2023

Transmission is an important part of internal combustion forklifts, including 4WD rough terrain diesel forklift, LPG and traditional diesel forklifts, and good maintenance methods can greatly improve the service life of forklifts.


1, Forklift Transmission Maintenance

Lift out the forklift engine with the crane, first remove the torque converter, and then remove the whole forklift gearbox. Before disassembling, the forklift transmission oil should be put out first, and then the upper cover of the wave box should be removed, and the forklift supply oil pump should be removed and checked for damage. Then remove the front and rear gear clutch assembly, check whether there is damage and wear and other conditions, need to replace must be replaced with new parts. Check and clean again, and 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) Forklift engine speed decline, the treatment method is to increase the engine speed;

2) There are 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) the friction plate is stuck or worn, check whether the forklift friction plate has glue, uneven contact, warping;

2) forklift seal ring or O-ring grinding, check whether the seal ring and groove width is worn or damaged.

03 The Oil Temperature Is Too High

1) 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, should change this working condition and pay attention to avoid the above working condition.

2) at high speed ratio, one-way clutch stuck, out of control, should be checked and excluded.

3) the amount of fuel is too small, or the system produces bubbles, should increase the amount of fuel to adjust the pressure of the valve.

4) the quality of the oil is not qualified, should be replaced with new oil.

04 Transmission Part

1) clutch obstacles, check whether the friction sheet is slipping;

2) Bearing damage, check whether the mating surface is damaged.

05 Transmission Not Working

1) check whether the control valve spring stuck and broken;

2) check whether the main oil pressure is normal, if not normal check whether the triple pump wear too much or damage;

3) if the main oil pressure is normal check the clutch oil pressure is abnormal check whether the seal ring or O-ring wear or damage. Check whether the clutch and clutch piston ring are damaged;


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



2, The Forklift Transmission Needs To Be Inspected In The Following Steps After Maintenance

1) With a special cleaning agent to thoroughly clean the forklift gearbox cooler and cooling oil pipe, to ensure that there is no debris, the oil passage is unimpeded, after installation, check the flow pressure, under normal circumstances, the pressure of the gearbox should reach at least 12KG or more. Replace water tank cooler tubing if necessary;

2) Check whether the converter is installed in place;

3) Check whether the positioning pins and screws between the engine and the heli forklift gearbox are fully installed;

4) Check whether the torque converter screw is too long and whether the machine is tightly fitted after the installation bolt is tightened;

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

6) Check whether the gear lever, throttle cable and vacuum tube are adjusted well;

7) Fill the automatic transmission oil specified by the original factory (manual transmission models should also add gear oil), check the oil level height, not too much or too little;

8) Check that the foot glue is not damaged;

9) Make sure that all wires are inserted and the wire is 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, and it is recommended that maintenance should be carried out in time once the problem is found.



3, Forklift Transmission Maintenance Tips

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

2) Working oil automatic transmission model forklift use 6# hydraulic transmission oil and wave box oil, manual transmission model gear oil. Use oil temperature 70-95C, greater than 95C after the use of time can not be too long;

3) Clean and maintain the automatic transmission, under normal circumstances, it is necessary to replace the forklift oil speed box every six months for cleaning and maintenance;

4) Forklift oil filter replacement and cleaning cycle, the new car within 50h, after every 200h, 1200h, special harsh environment should be every 600h;

5) Forklift driving shift, should first close the micro-valve, and then shift; When braking, the micro-valve must be closed before braking; To prevent clutch damage or brake failure.


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