Kalmar reachstacker gearbox and drive shaft maintenance

1. Check and add transmission oil

Method:

- Let the engine idle and pull out the dipstick to check the transmission oil level.
- If the oil level is below the minimum mark, add as prescribed.

NOTE: Depending on the model of gearbox, use the proper lubricant.

2. Check the fixing bolts of the drive shaft

Why check?

- Loose bolts are prone to shearing under load and vibration.

Method:

- Check whether the drive shaft fixing bolts are loose.
- Check the universal joint bearings for damage.
- Retighten the loose drive shaft fixing bolts to a torque of 200NM.

3. Check the speed sensor

The role of the speed sensor:

- Send the vehicle speed signal to the relevant control system to ensure that the gear can only be changed when the vehicle speed is lower than 3-5 km/hr. This protects the transmission.

Method:

- Check the speed sensor and its mount for damage.

4. Replace the gearbox filter

Why replace?

- A clogged filter reduces the amount of oil required for gear shifting and lubrication.

Method:

- Remove the old filter element
- Lubricate the seals with transmission oil
- Put the new filter element up to the contact by hand, and then tighten it by 2/3 turns

5. Change transmission oil

Method:

- Loosen the oil drain plug and put the old oil into the oil pan.
- Check old oil for metallic particles to predict transmission component health.
- After draining the old oil, replace the oil drain plug. Add new oil to the minimum (MIN) mark on the dipstick.
- Start the engine, make the oil temperature reach the working temperature, check the oil dipstick, and add oil to the maximum (MAX) scale position of the oil dipstick.

Note: Only DEXRONIII oil can be used for DEF – TE32000 transmission.

6. Check and remove the iron filings on the magnet filter at the bottom of the gearbox

Work content:

- Check the iron filings on the magnet filter to judge and predict the operation of the internal parts of the gearbox.
- Remove iron filings from the magnet filter to restore its ability to attract iron filings.

7. Clean the vent connector

Why clean?

- Let the vapors inside the gearbox escape.
- Prevent pressure build-up in the gearbox.
- If the pressure in the gearbox is too high, it is easy to cause oil leakage from delicate parts or hoses.

8. Check the fixing screws and fixing seats

The function of the fixing seat and the shock absorber:

- Fasten the gearbox to the frame.
- Dampens vibrations during transmission start, run and stop.

Check content:

- Whether the fixing seat and shock absorber are damaged.
- Whether the relevant bolts are loose.