How does the transmission system of a forklift work properly?

As we all know, the transmission system of a forklift is the main source of power for the forklift. Therefore, in order to ensure the smooth operation of the forklift, we must ensure the normal operation of the transmission system. The following is a detailed analysis of the HYDER forklift gearbox:

 

The role of the forklift gearbox

Since the engine cannot be reversed, the forward and reverse movements of the HYDER forklift need to be solved by the transmission. The main functions of the gearbox include adapting to the vehicle's starting, acceleration, climbing and high-speed driving on flat roads under various road conditions. In these cases, the gearbox can transform the torque and vehicle speed output by the engine to meet different driving requirements. In addition, the gearbox can also cut off the operation of the engine from the drive system for a long time, so that the two are separated from each other, ensuring the efficient operation of the forklift under different working conditions.

 

How to use the forklift gearbox

When shifting or changing gears, the accelerator pedal (throttle) should be relaxed. After the throttle is fully closed, the clutch pedal should be stepped on, and the desired gear should be pushed or pulled quickly and correctly, and then the clutch should be released. When shifting gears, do not push or pull hard to avoid the gears making a knocking sound.

 

Torque converter and gearbox

1.5T to 3T HYDER forklift

The hydraulic transmission gearbox of 1.5T to 3T HYDER forklift consists of a torque converter and a power shift gearbox with one gear each for the front and rear. The installed single-stage two-phase three-wheel integrated hydraulic torque converter has the automatic adaptability of hydraulic transmission output, and can change the output torque and speed with the change of external load, while absorbing and eliminating the impact vibration from the engine and external load to the transmission system. The gearbox outputs with differential half-shaft gears, adopts power shift, and is equipped with micro-valve and buffer valve. It is simple and convenient to operate, starts smoothly, and reduces the labor intensity of the operator.

5T to 6T HYDER forklift

The hydraulic transmission gearbox used in 5T to 6T HYDER forklift has a single-stage three-phase four-wheel integrated hydraulic torque converter, which has the characteristics of large torque ratio, high efficiency, simple structure and convenient maintenance. It has two gears for forward and reverse, soft and stable operation, and micro-motion characteristics.

HYDER forklift gearbox maintenance tips

In order to ensure the normal operation and long-term use of HYDER forklift gearbox, regular maintenance is required:

 

Hydraulic control oil circuit pressure: 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 should be maintained between 1.1 and 1.4Mpa.

Working oil: Use 20# turbine oil or 6# hydraulic transmission oil, turbine oil, the oil temperature should be maintained between 70-95°C, and the use time should not be too long when the oil temperature is greater than 95°C.

Oil filter replacement and cleaning cycle: The first replacement and cleaning of new vehicles should be carried out within 50 hours, and then every 200 hours and 1200 hours. In special environments, it should be carried out every 600 hours.

When shifting gears during driving: the micro valve should be closed before shifting gears; when braking, the micro valve should also be closed before braking to prevent clutch damage or brake failure.

Improvement of heat treatment process for input gear of HYDER forklift gearbox

As a key component of the transmission system, the input gear of HYDER forklift has strict requirements in terms of surface hardness, wear resistance, overall strength and core toughness. User feedback shows that the main failure forms of the gearbox include gear tooth surface wear, pitting, wear of spline tooth surface, etc., and fracture failure occasionally occurs at the output shaft neck. Although such parts only account for 1/4 of the total number of gearbox parts, they have a great impact on the gearbox's function of transmitting power and motion. If one of the parts fails, the gearbox system will fail.

 

In response to these problems, HYDER has formulated reasonable and effective heat treatment process measures to ensure its quality through in-depth analysis of the performance requirements of the gearbox input gear. These measures include material selection, surface carburizing and improvement of related heat treatment processes, thereby improving the strength reliability of parts and extending their service life.

 

Through the above measures, HYDER forklifts have achieved efficient and reliable operation in gearbox design, use and maintenance, ensuring the excellent performance of forklifts under various working conditions and providing users with an excellent user experience.