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Judgment Of Common Faults Of Forklift Clutch

- Dec 24, 2018 -

Judgment of common faults of forklift clutch

The basic function of the forklift clutch is to transfer or cut off the internal combustion engine power to the transmission system, ensure the smooth start of the forklift, change the transmission ratio and prevent overload. Common faults include skidding, incomplete separation, ringing and starting trembling. The fault phenomena and causes are analyzed as follows.

1. The clutch slips

1. Malfunction

Forklifts feel insufficient power when they start, operate or go uphill. Although the accelerator is increased, the vehicle speed cannot be accelerated. When skid is serious, can smell from clutch place sends out the burnt odour.

2. Fault reasons

(1) the clutch pedal has no free travel, so that the separation bearing is pressed on the separation lever and the pressure plate is in a semi-detached state.

(2) the coupling bolt between the clutch cover and the flywheel is loose.

(3) the friction sheet becomes thinner with wear.

(4) the spring force of the pressure plate is weakened.

(5) oil stains, hardening and rivet exposure on the friction plate.

3. Analyze and judge

(1) put forward gear or backward gear, tighten the hand brake, and shake the forwarding motor with the hand crank handle, which proves that the clutch slips.

(2) if there is no hand crank handle, the engine should be started, the hand brake should be tightened, the low-speed gear should be put on, and the clutch pedal should be slowly released to start. If the throttle is gradually increased, the vehicle will not move and the engine will not stall

The clutc slipped.

Two, the separation is not complete

1. Malfunction

When the engine is running at idle speed, it is difficult to fully step down the clutch pedal, and the transmission gear has a crash sound. If forced into gear, do not lift the clutch pedal, the vehicle will rush forward or engine stall.

2. Fault reasons

(1) the free stroke of the clutch pedal is too large or the separation lever is adjusted too low.

(2) double plate clutch intermediate pressure plate limit screw adjustment is not appropriate or individual separation spring too soft, intermediate pressure plate wear too thin

(3) the clutch driven plate is deformed or the rivet is loose, and the inner end of the separation lever is uneven or deformed.

(4) after the replacement of the friction plate, the new friction plate is too thick, the driven plate is installed incorrectly instead, and the screw of the separation lever bracket is loose, etc.

(5) the clutch driven disk hub and the transmission's first shaft keyway are stuck due to corrosion, making it difficult for the driven disk to move.

(6) the clutch of the hydraulic control system, when there is air in the pipeline, lack of oil, the main pump or the sub-pump leather bowl is damaged, will also cause incomplete separation fault.

3. Analyze and judge

(1) check whether the free stroke of the clutch pedal is too large, and adjust it if it is too large.

(2) check whether the separation lever is in contact with the separation bearing and the height is inconsistent, and whether the fixing screw of the separation lever is loose or the separation lever is bent and deormed.

(3) double plate clutch, should check the middle pressure plate limit screw is in line with the requirements, whether the three separate springs are too soft or broken.

(4) for the newly replaced friction disc, if the friction disc is too thick, an appropriate gasket (the gasket thickness should be the same) can be added between the clutch cover and the transmission pin for adjustment. If the driven disk hub is positive, but the wrong, should be reassembled.

(5) if none of the above inspections and adjustments is effective, the clutch shall be removed, the technical status of each part shall be disassembled and inspected, and the parts shall be repaired or replaced when necessary.

(6) clutch with hydraulic control device, should be timely remove air in the pipeline or replace the total, sub pump leather bowl.

Third, the clutch rings

1. Malfunction

Clutch part place is different, send ring opportunity is different also, have a plenty of when stepping clutch pedal to send ring, have a plenty of when lifting pedal to send ring, still have a plenty of when clutch is united, send ring.

2. Fault reasons

(1) lack of lubricating oil or excessive wear of the separated bearing.

(2) excessive wear of the pin hole of the separation lever support.

(3) the clutch friction plate rivet is loose or exposed.

(4) the clutch driven plate rivet is loose.

(5) the clutch pedal or the return spring of the disengaging bearing breaks off, becomes too soft or falls off.

(6) excessive wear of the intermediate pressure plate driving pin and pin hole of the double-plate clutch.

(7) excessive wear of clutch driven disc keyway and transmission first shaft key tooth.

3. Analyze and judge

(1) step down the clutch pedal a little to make the separated bearing in contact with the separated lever. If it rings at this time, the separated bearing will ring. Lubricating oil shall be added first. If it is invalid, the separated bearing shall be damaged and the separated bearing shall be replaced.

(2) double plate clutch, if the pedal is pressed to the end of the sound, the sound disappears after the release of the pedal, it is caused by excessive wear and tear of the middle pressure plate transmission pin hole and transmission pin. When the noise is not too serious, can continue to use, sound serious when will drive pin rotate 90 ° use or replace the drive pin.

(3) when the pedal has just stepped or just lifted the pedal, that is, the clutch driven disc and pressure disc in just to separate or just to combine the instantaneous sound, generally for the pressure disc between the protruding part and the window hole or the separation lever and the window hole, and the transmission between the first shaft and the driven disc hub due to excessive clearance.

(4) friction plate rivet loose or exposed rivet, scraping pressure plate or flywheel will also appear sound.

(5) there is still a sound when the pedal is fully lifted, which is caused by the sound of no clearance between the clutch disengaging bearing and the disengaging lever or too small clearance. If hook pedal with the foot, sound disappears, return spring for pedal is too soft or fall off.

(6) when stepping down the clutch pedal, the sound is in front of the clutch, which may be excessive wear of needle roller bearing at the rear end of the crankshaft. When lifting up the clutch pedal, the sound is behind the clutch, which may be the fault sound of the transmission. Diagnosis and exclusion should be made separately.

Four, start trembling

1. Malfunction

The forklift car body shook when it started.

2. Fault reasons

(1) the height of the separation lever is not consistent, the spring of the pressure plate is not uniform or individual fracture, and the pressure plate has grooves, etc.

(2) the driven plate is loose with the hub rivet, the friction sheet rivet is exposed, and the driven plate is deformed and uneven.

(3) engine bolts loose, transmission and flywheel housing bolts loose, clutch cover bolts loose, flywheel bolts loose, etc., will cause vehicle starting jitter.

3. Analyze and judge

(1) first step and lift the clutch pedal to check whether the clutch disengaging bearing is flexible in advance and backward. If it is possible to do so, it is necessary to check whether the return spring of the detached bearing falls off, breaks off or is too weak in elasticity.

(2) remove the bottom cover of the clutch housing and check whether the height of the separation lever is consistent. If the height is inconsistent, it shall be adjusted again. If the head of the separation lever is worn excessively, it shall be replaced or repaired.

(3) check whether the fastening bolts of transmission and flywheel housing, engine fastening bolts and clutch cover fastening bolts are loose, and tighten them if they are loose.

(4) clutch driven disc hub rivet loose, friction piece uneven, pressure plate groove and friction piece rivet,,, should be tightened or repaired. To break or spring with compression


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