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Common causes Gearbox fork is loose or deformed; positioning groove and positioning pin on the shift shaft are worn, the surface has irregular steps, and it gets stuck during shifting; the gearbox is deformed; the pin tightly linked lever is loose or improperly adjusted; Axis limit screw loosening. Of course, when the clutch is not completely separated and the small brake malfunctions, it can also cause a failure.
2. Automatically disengage
The common reason is that gear end face wear is too large, so that the gear meshing surface is too short, and the gear body wears taper and generates axial force, resulting in unblocking; the positioning pin breaks, the positioning steel ball fails, and vibration is caused to cause uncoupling; The fork and gear fork groove are worn and the fork is loose, causing the slide gear to produce axial turbulence and cause a gear shift.
3. Chaos
Common causes: Positioning pin, positioning steel ball spring failure or break; excessive wear of the shift head and its associated shift shaft; excessive wear of the positioning guide.
4. Noisy in use
If the gear side clearance in the gearbox is changed or repaired is too small, or if the gear is worn during long-term operation and the backlash is too large, noise will be generated due to poor meshing. In addition, the wear of rolling bearings or spacers and the lack of lubricant in the gearbox can cause abnormal noise in the gearbox during operation.
Gearbox gear repair
1. Commutation method
Once the gear is worn on one side, the structure can be repositioned or flipped 180 degrees when used. For example, the Dongfang Hong-75 tractor's final drive size reduction gear has a symmetrical left and right structure. Once the gear is worn on one side, it can be used as a right-to-back pair.
2. Insert ring method
The tower gear is a combination of several gears, and the degree of wear of each gear is not the same. If only the gear teeth of the individual gears wear out of tolerance, the method of repairing the gear rings is repaired. The method is to first anneal the specially repaired gears, remove all the gear teeth from the car, and make a circle press-fitted to the gear teeth of the car. To prevent the new gear ring from loosening, weld the gears circumferentially along the ring gear and gear joints. Welding, or drilling along the circumference after the distribution and stability to be fixed.
3. Insert method
For gears with small loads and low speeds, they can be repaired after inserting them individually. The method is to etch or mill the dovetail groove on the machine tool root, press the new tooth embryo with the same groove type into a certain amount of interference, and weld it to work.
4. Surfacing method
When the individual teeth of the gears collapse, or the wear of the tooth surfaces and tooth ends exceeds the limit, the surfacing repair can be performed according to the degree of damage. Before welding, use grease or hot alkaline water to clean grease stains, rust, and rust on the surface of gears to reveal metallic luster. The welding electrode used for welding should be the same or similar to the gear material. After the surfacing is repaired and machined to restore the tooth profile, the repaired gear must be tempered to eliminate internal stresses.
Transmission Case Repair
1. Repair of the bearing seat hole When the bearing seat hole wears excessively, it can be repaired by using a boring insert. Insert material can choose HT20-40 gray cast iron. When inserting, first set the outer diameter size of the sleeve, press into the bearing seat hole, then set the inner diameter of the standard size. After boring, the cylindricity deviation of each shaft hole should not exceed 0.03mm; the common axis of the coaxial two holes and the verticality deviation of the processed surface should not be greater than 0.05mm in the length of 100mm; the holes in the different shafts The misalignment of the axis parallelism should be no more than 0.06mm over the entire length.
2. Repair of cracks and perforations in the transmission housing Cracks and perforations in the housing can be repaired using patches, welding repairs or glue repairs. When repairing the patch, several holes with a diameter of 4.9mm can be drilled around the crack or perforation, tapping the thread of M6, finding a piece of iron about 3mm thick, and drilling a hole with a diameter of 6.5mm in the corresponding position of the iron plate. After inserting the asbestos pad between the iron plate and the side wall, tighten the iron plate and the shell with the M61.0 screw. When welding, a hole with a diameter of 3.5 mm must be drilled at both ends of the crack. After the V-shaped groove is opened along the crack, cold welding is performed using a copper-iron electrode or a cast iron electrode. When repairing, it must also stop the hole, open the V-shaped groove, and then fill with epoxy resin.
Common causes Gearbox fork is loose or deformed; positioning groove and positioning pin on the shift shaft are worn, the surface has irregular steps, and it gets stuck during shifting; the gearbox is deformed; the pin tightly linked lever is loose or improperly adjusted; Axis limit screw loosening. Of course, when the clutch is not completely separated and the small brake malfunctions, it can also cause a failure.
2. Automatically disengage
The common reason is that gear end face wear is too large, so that the gear meshing surface is too short, and the gear body wears taper and generates axial force, resulting in unblocking; the positioning pin breaks, the positioning steel ball fails, and vibration is caused to cause uncoupling; The fork and gear fork groove are worn and the fork is loose, causing the slide gear to produce axial turbulence and cause a gear shift.
3. Chaos
Common causes: Positioning pin, positioning steel ball spring failure or break; excessive wear of the shift head and its associated shift shaft; excessive wear of the positioning guide.
4. Noisy in use
If the gear side clearance in the gearbox is changed or repaired is too small, or if the gear is worn during long-term operation and the backlash is too large, noise will be generated due to poor meshing. In addition, the wear of rolling bearings or spacers and the lack of lubricant in the gearbox can cause abnormal noise in the gearbox during operation.
Gearbox gear repair
1. Commutation method
Once the gear is worn on one side, the structure can be repositioned or flipped 180 degrees when used. For example, the Dongfang Hong-75 tractor's final drive size reduction gear has a symmetrical left and right structure. Once the gear is worn on one side, it can be used as a right-to-back pair.
2. Insert ring method
The tower gear is a combination of several gears, and the degree of wear of each gear is not the same. If only the gear teeth of the individual gears wear out of tolerance, the method of repairing the gear rings is repaired. The method is to first anneal the specially repaired gears, remove all the gear teeth from the car, and make a circle press-fitted to the gear teeth of the car. To prevent the new gear ring from loosening, weld the gears circumferentially along the ring gear and gear joints. Welding, or drilling along the circumference after the distribution and stability to be fixed.
3. Insert method
For gears with small loads and low speeds, they can be repaired after inserting them individually. The method is to etch or mill the dovetail groove on the machine tool root, press the new tooth embryo with the same groove type into a certain amount of interference, and weld it to work.
4. Surfacing method
When the individual teeth of the gears collapse, or the wear of the tooth surfaces and tooth ends exceeds the limit, the surfacing repair can be performed according to the degree of damage. Before welding, use grease or hot alkaline water to clean grease stains, rust, and rust on the surface of gears to reveal metallic luster. The welding electrode used for welding should be the same or similar to the gear material. After the surfacing is repaired and machined to restore the tooth profile, the repaired gear must be tempered to eliminate internal stresses.
Transmission Case Repair
1. Repair of the bearing seat hole When the bearing seat hole wears excessively, it can be repaired by using a boring insert. Insert material can choose HT20-40 gray cast iron. When inserting, first set the outer diameter size of the sleeve, press into the bearing seat hole, then set the inner diameter of the standard size. After boring, the cylindricity deviation of each shaft hole should not exceed 0.03mm; the common axis of the coaxial two holes and the verticality deviation of the processed surface should not be greater than 0.05mm in the length of 100mm; the holes in the different shafts The misalignment of the axis parallelism should be no more than 0.06mm over the entire length.
2. Repair of cracks and perforations in the transmission housing Cracks and perforations in the housing can be repaired using patches, welding repairs or glue repairs. When repairing the patch, several holes with a diameter of 4.9mm can be drilled around the crack or perforation, tapping the thread of M6, finding a piece of iron about 3mm thick, and drilling a hole with a diameter of 6.5mm in the corresponding position of the iron plate. After inserting the asbestos pad between the iron plate and the side wall, tighten the iron plate and the shell with the M61.0 screw. When welding, a hole with a diameter of 3.5 mm must be drilled at both ends of the crack. After the V-shaped groove is opened along the crack, cold welding is performed using a copper-iron electrode or a cast iron electrode. When repairing, it must also stop the hole, open the V-shaped groove, and then fill with epoxy resin.
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