Functions

1. Adjust Speed and Torque: According to the forklift’s operational needs, it adjusts the speed and torque of the power output by the electric motor, ensuring the forklift obtains appropriate speed and torque under different working conditions (e.g., starting, climbing slopes, and transporting heavy loads). For instance, when moving heavy goods, the speed needs to be reduced to increase torque, ensuring the forklift can stably carry and move the goods.
2. Enable Forward and Reverse Movement: By switching between different gear combinations, it changes the direction of power transmission, allowing the forklift to move forward and backward.

3. Interrupt Power Transmission: When the forklift needs to stop or undergo maintenance, the gearbox can interrupt power transmission between the electric motor and the drive wheels, keeping the forklift stationary and ensuring operational safety.

   
   

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Types

Mechanical Gearboxes

• Spur Gear Sliding Gearbox: It has a simple structure and low cost, but requires high skill for shifting operations. Improper shifting may easily cause gear tooth damage. Additionally, it can only use spur gears, resulting in less smooth transmission.
• Helical Gear with Shift Sleeve Gearbox: Its structure is simpler than that of a synchronizer gearbox. It avoids gear tooth damage during shifting, but shifting remains difficult when there is a large speed difference between gears. However, it can use constantly meshed helical gears, enabling relatively smooth transmission.
• Synchronized Shifting Gearbox: It has a complex structure. Through the conical friction of the synchronizing lock ring, it synchronizes the speed of the gears to be meshed, making shifting easy and shock-free. It can also use constantly meshed helical gears for smooth transmission.

Hydraulic Gearboxes

• Hydraulic Torque Converter: It ensures smooth starting of the vehicle, reduces dynamic loads on the transmission system, and eliminates torsional vibrations of the transmission system. When the vehicle reaches the minimum speed or encounters sudden resistance without enough time to shift gears, it prevents the engine from stalling. It can steplessly adjust speed and torque within a certain range under load conditions.
• Hydraulic Clutch: It ensures smooth gear shifting of the vehicle and reduces dynamic loads on the system during shifting. Adopting a multi-disc design, it can transmit large torque while maintaining a small overall size. Continuous oil cooling reduces overheating and wear of the friction discs, extending service life. It also supports remote hydraulic control.

Characteristics

1. High Efficiency and Energy Saving: The electric forklift gearbox has high transmission efficiency, which better converts the electrical energy of the motor into the mechanical energy of the forklift, reducing energy loss, lowering energy consumption, and improving energy utilization efficiency.
2. Low Noise: Compared with the gearbox of internal combustion forklifts, the electric forklift gearbox generates less noise during operation, which helps improve the working environment and reduce noise pollution.
3. Low Maintenance Cost: The electric forklift gearbox has a relatively simple structure, without complex mechanical transmission components or hydraulic systems. Thus, it requires less maintenance work and incurs lower maintenance costs. For example, there is no need to ｒｅｐｌａｃｅ oil, filters, or other components, nor to perform complex hydraulic system maintenance.
4. Precise Control: The electric forklift gearbox can closely cooperate with the motor’s control system to achieve precise control of the forklift’s speed and torque, making the forklift operation more accurate and flexible, and improving work efficiency and operational safety.

Maintenance

1. Regularly Check Fluid Level: Inspect the gearbox oil level to ensure it is within the normal range. Too low a level may cause increased wear of gears and bearings, while too high a level may lead to problems such as excessive oil temperature and oil leakage.
2. ｒｅｐｌａｃｅ Gearbox Oil: ｒｅｐｌａｃｅ the gearbox oil regularly in accordance with the manufacturer’s recommendations. Generally, the oil change interval for electric forklift gearboxes is 1,000–2,000 operating hours or once a year. The specific interval can be adjusted based on the operating environment and frequency.
3. Inspect Gears and Bearings: Regularly check the gears and bearings inside the gearbox for damage such as wear, cracks, or deformation. If damage is found, ｒｅｐｌａｃｅ the damaged components in a timely manner to prevent the failure from worsening.
4. Clean Filters: The gearbox filter is used to filter impurities and contaminants in the oil, keeping the oil clean. Clean or ｒｅｐｌａｃｅ the filter regularly to prevent clogging, which may affect the normal operation of the gearbox.

Common Faults and Solutions

1. Difficult Shifting: This may be caused by faults in the shifting mechanism, damaged synchronizers, or worn gears. Inspect whether the connecting parts of the shifting mechanism are loose or worn, check if the synchronizers work normally, and verify the integrity of the gear teeth. Repair or ｒｅｐｌａｃｅ components based on the inspection results.
2. Abnormal Gearbox Noise: This may be caused by poor gear meshing, damaged bearings, insufficient or deteriorated oil. Check if the gear meshing clearance is normal, inspect for loose or worn bearings, and verify whether the oil level and quality meet requirements. Take corresponding measures to address the problem, such as adjusting the gear clearance, replacing bearings, or adding/replacing oil.
3. Overheating of the Gearbox: This may be caused by excessive or insufficient oil, poor heat dissipation, or overloading. Check if the oil level is appropriate, verify whether the cooling fan operates normally, and check if the forklift has been operating under high load for a long time. Take corresponding measures to solve the problem, such as adjusting the oil level, cleaning the radiator fins, or avoiding prolonged high-load operation.