Need to repair a gearbox? We guarantee the restoration of the performance of worn or damaged gearbox parts in a short time.

How is a gearbox repaired at BAS-AGRO GROUP? The process of gearbox repair may vary depending on the type of gearbox, the degree of damage and other factors. But in general, the gearbox repair process consists of the following stages:

1. Diagnosis of damage. A specialist inspects and diagnoses the gearbox, determining the degree of damage and the need to replace parts.
2. Disassembly of the gearbox. The reducer is disassembled into separate parts to inspect each of them and detect damage. After that, the parts are washed and cleaned of contaminants.
3. Troubleshooting. After inspecting the parts, specialists identify damaged and worn parts that need to be replaced or restored.
4. Restoration of parts. Worn-out parts can be restored by repairing them or manufacturing new parts.
5. Assembling the gearbox. After the parts are replaced or refurbished, the gearbox is put back together and assembled.
6. Adjustment of the gearbox. After the gearbox is assembled, it is adjusted to the required operating mode and checked for compliance with the requirements of the technical specifications.
7. Testing. After the gearbox is set up, it is tested for performance and compliance with the requirements.
8. Acceptance and shipment. After passing all the stages of repair, the gearbox is accepted and prepared for shipment to the customer.

To get a gearbox repair service, you can contact us by phone +38 (067) 470-35-44 or e-mail [email protected], or we invite you to visit our office at 8/1 Khomenka Lane, Cherkasy, Ukraine.

Always with care, your Bas.ua is a manufacturer of reliable spare parts for agricultural machinery.

Additional information:

1. General information about the role of gearboxes in agricultural machinery.
2. Problems that can occur with gearboxes.
3. Description of the main diagnostic methods.
4. Tools and equipment needed to disassemble the gearbox.
5. Procedure for disassembling the gearbox.
6. Inspecting and assessing the condition of gearbox components and assemblies.
7. Description of the main methods of repairing agricultural machinery gearboxes.
8. Replacing failed gear unit parts.
9. Assessment of the quality of agricultural machinery gearbox repair.

1.General information about the role of gearboxes in agricultural machinery

Gearboxes are an important component of agricultural machinery. They transmit power from the engine to other components and mechanisms, ensuring the correct operation of the machines. Gearboxes are used in various machines such as tractors, combines, seeders, and others.

The main function of a gearbox is to reduce the speed of rotation of the motor shaft and increase the output torque, which allows moving heavy loads. For example, a gearbox in a combine reduces the shaft speed from the engine and transmits this power to the cutting and transport mechanisms.

In agricultural machinery, where heavy loads and rough environments operate, gearboxes are subject to significant wear and tear and can fail due to mechanical damage, excessive vibration, improper installation, and other factors. If a gearbox breaks down, it needs to be repaired or replaced.

It is important to keep in mind that repairing agricultural machinery gearboxes requires certain knowledge and experience, so it is best to contact professionals who have the necessary knowledge and tools to carry out high-quality repairs.

2.Problems that can occur with gearboxes

In agricultural machinery, gearboxes are subject to significant wear and tear due to the high loads and rough environment in which they operate. Below are some of the problems that can occur with gearboxes:

1. Wear of internal parts: Constant load can cause wear and tear on internal parts such as gears, bearings, shafts, etc.
2. Damage to the gears: Gears can be damaged due to shock, vibration, or elevated temperatures. This can lead to a decrease in gearbox efficiency and can cause breakdowns.
3. Improper installation: Improper installation can result in uneven load on the gear unit, which can accelerate wear.
4. Overheating: Overheating can occur due to elevated temperatures, which can be caused by excessive load, poor cooling, or improper use of lubricant.
5. Lubricant leakage: Lubricant leakage can occur due to damaged seals or improper use of lubricant. This can lead to poor gearbox performance and reduced service life.

Solving these problems requires experience and knowledge of repairing agricultural machinery gearboxes. Incorrect repairs can lead to deterioration of the gearbox and danger to the user of the equipment.

3.Description of the main diagnostic methods

Diagnosing gear units is an important step in the gear unit repair process. The main purpose of diagnostics is to identify the problem and determine the necessary work to solve it. Below are some of the main methods for diagnosing gearboxes:

1. Visual inspection: This method involves inspecting the gearbox for external damage, wear, or signs of overheating. Visual inspection can also help identify lubricant leaks that may be causing the gearbox to malfunction.
2. Noise measurement: Checking the noise level can help identify problems with bearings or gears. Noise can be an indicator of wear and tear or a malfunction in the machinery.
3. Pressure and temperature measurements: Measuring oil pressure and temperature can indicate problems with proper cooling or lubrication of the gearbox. Based on the temperature readings, you can determine whether the lubricant needs to be changed.
4. Disassembly and internal inspection: This method requires disassembling the gearbox and inspecting its internal parts. Internal inspection can help detect wear on parts, identify problems with seals or bearings, and determine which parts need to be replaced.
5. Performance testing: A performance test can help determine if the repair has solved the problem and if the gearbox can operate normally. The performance test can be performed on special stands or on the equipment itself. During the test, you can check the operation of the gearbox at different speeds and loads.
6. Oil analysis: An oil examination can help identify problems with the gearbox, such as contamination, oxidation, water, and other impurities. Such problems can cause wear on parts or lead to gearbox malfunction.

Combining several diagnostic methods can help reduce the risk of error in identifying the problem and develop a proper gearbox repair plan. Diagnosing gearboxes is an important step in the gearbox maintenance process because it can save time and money on future repairs.

4.Tools and equipment needed to disassemble the gearbox

To disassemble the gearbox of agricultural machinery, you need to have a certain set of tools and equipment. Here are some of them:

1. Wrenches: To disassemble the gearbox, you need to have a set of wrenches of different sizes to unscrew the bolts and nuts.
2. Heavy hammer: A heavy hammer will help separate the different parts of the gearbox that may be stuck.
3. Screwdrivers: Different types of screwdrivers may be needed to remove pins, springs, and other parts of the gearbox.
4. Press: A press may be needed to remove bearings and other parts.
5. Saws: You may need a saw to cut off parts of metal or plastic.
6. Measuring tools: Measuring tools such as micrometers, calipers, measuring rulers, etc. may be required to measure the dimensions of parts.
7. Lubricants: Different types of lubricants such as grease, sealants, and others may be required during gearbox repair.
8. A powerful computer: A powerful computer with the appropriate software to analyze the data obtained from the gearbox may be required to diagnose the gearbox.

Having these tools and equipment available is essential for successful gearbox repair. Failure to have the necessary equipment can cause delays and negatively affect the quality of the repair.

5.Procedure for disassembling the gearbox

When disassembling the gearbox of agricultural machinery, a certain sequence of actions must be followed. Here is a detailed description of the steps to follow:

1. Make sure that the equipment is in a safe condition and remove the battery to avoid accidental start-up.
2. Remove the gearbox cover and remove all parts that may be damaged during operation.
3. Disconnect the shaft from the motor and remove it from the gearbox.
4. Disconnect the clutch from the gearbox to be able to remove it from the machine.
5. Remove the bearings from the shafts and inspect them for damage.
6. Remove each part of the gearbox and carefully loosen each part from the legs.
7. Inspect all parts for damage, assess the degree of wear and the need for replacement.
8. Clean each part from dirt and grease residues.
9. Install new parts, if ordered, or repair damaged parts.
10. Reassemble the gearbox in the reverse order and install it on the machine.
11. Fill the gearbox with the required amount of lubricant and check the operation of the gearbox.

Remember that disassembling the gearbox is a complex process, so you need to have experience and the necessary knowledge. If you are not confident in your abilities, it is better to contact a professional.

6.Inspecting and assessing the condition of gearbox components and assemblies

Inspecting and assessing the condition of gearbox components and assemblies is an important step in the diagnosis and repair of agricultural machinery. To do this, perform the following steps:

1. Inspection of appearance: Check the appearance of the gearbox for damage and wear, such as cracks, bends, or scratches.
2. Strength check: Check the strength of each part, especially the connections and fasteners. Visually check that all fasteners are tightened to the correct level and that they are not difficult to loosen.
3. Check for wear and tear: Inspect each part for signs of wear, including scrapes, scratches, stretch marks, and loose teeth. Pay particular attention to bearings, which can fail after prolonged use.
4. Check the dimensions: Check the dimensions and shape of each part, especially the gear teeth. Check for deformation and wear of the teeth.
5. Corrosion inspection: Check for corrosion on each part of the gear unit. If there is evidence of corrosion, the parts must be cleaned and lubricated.
6. Bearing inspection: Check the bearings for damage and wear. Note how smoothly they run and if there is any noise or vibration.
7. Determine the necessary repairs: After inspecting and assessing the condition of the gearbox parts and assemblies, determine the necessary repair work. This may include replacing some parts, restoring them, or replacing bearings.

It is also important to note that in some cases, repairing the gearbox may be inexpedient and ineffective. For example, if the gearbox is too worn or damaged, it may be better to purchase a new one.

All identified problems and repair needs should be recorded in a diagnostic report. This will help to make an accurate estimate of the work required to restore the gearbox and ensure that the right materials and tools are used for the repair.

If any problems are detected with the gearbox, it is important to stop its operation immediately and have it diagnosed and repaired. Ignoring problems can lead to increased wear and tear on parts, increased risk of failure, and increased repair costs.

7.Description of the main methods of repairing agricultural machinery gearboxes

The main methods of repairing agricultural machinery gearboxes can be divided into the following:

1. Replacement of parts. This method is used when parts are worn or damaged and cannot be restored. To replace parts, special tools and equipment may be required, such as presses, machines, boreholes, and others.
2. Restoration of parts. This method is used when parts are worn or damaged but can be restored. Various technologies are used to restore parts, such as welding, hardening, curing, and others.
3. Adjustment. This method is used when the problem with the gearbox is incorrect adjustment. Special tools may be required for adjustment, such as measuring devices, nut pullers, and others.
4. Lubrication. This method is used when the problem with the gearbox is insufficient or improper lubrication of the parts. A variety of lubricants and other agents can be used for lubrication.
5. Assemble and check the operation. After the necessary repairs have been carried out, the gearbox must be assembled and tested on a special stand to check that it works correctly and without interruption.

Each repair method requires certain knowledge and experience, so it is recommended to contact a specialist to carry out the repair work.

8.Replacing failed gear unit parts

After inspecting and diagnosing the gearbox, it may be found that some parts have failed and need to be replaced. Below are some general tips for replacing agricultural machinery gearbox parts:

1. Use only high quality replacement parts from reputable manufacturers.
2. Before replacing parts, make sure that they exactly match the manufacturer's specifications.
3. Before installing new parts, ensure that they are properly lubricated and protected from contamination.
4. When replacing bearings, follow all the manufacturer's installation and adjustment instructions.
5. When replacing gears, check for wear and scratches and cracks. If necessary, they should also be adjusted to the manufacturer's specifications.
6. After replacing the parts, reassemble the gear unit and check for proper operation.
7. Do not forget to properly dispose of old parts that have been removed from the gear unit.

Replacing gearbox parts can be a complicated process, so if you do not have sufficient expertise, it is better to contact specialists who can do the repair correctly and efficiently. Spare parts for agricultural machinery can be purchased in our online store.

9.Assessment of the quality of agricultural machinery gearbox repair

Evaluating the quality of the agricultural machinery gearbox repair is an important step that guarantees the safety of the machinery and extends its service life. A variety of methods can be used for this purpose, including:

1. Testing the gearbox in an open area: in this case, the machinery with the repaired gearbox is used for several hours or even days to check its operation and condition.
2. Testing the gearbox on a special bench: to conduct this test, it is necessary to use special equipment that allows you to create conditions as close as possible to operational ones.
3. Visual inspection: after the repair, it is necessary to carry out a detailed visual inspection of all components and parts of the gearbox in order to identify possible defects or deviations from the standard.
4. Measurement of parameters: some parameters of the gearbox can be measured using special devices. For example, measurement of lubricant temperature and pressure, vibration, shaft speed, etc.

After assessing the quality of the repair, you can draw conclusions about the restoration of the gearbox and make a decision about its further operation. It is important to note that the quality of the repair depends on the professional training of specialists and the use of high-quality materials and equipment.