Small crawler excavator gear shifting: technical diagnosis and optimization

In-depth analysis of the reasons for gear skipping

1. Severe gear wear

In the gearbox of a small crawler excavator, the gears frequently engage and disengage, and long-term high-intensity operation can easily lead to gear wear, which is a common factor in the "reasons for small crawler excavator gear skipping". Uneven wear on the gear tooth surface will increase the meshing gap. When the gap exceeds the normal range, the gears will easily disengage when the excavator vibrates or the force changes, causing gear skipping. Especially in heavy-load operations, worn gears are under greater pressure and are more likely to skip gears.

2. Failure of the shift mechanism

Problems with the shift mechanism components such as the shift fork and shift shaft can also cause gear skipping. For example, if the shift fork is deformed and cannot accurately push the gear to achieve the shift, or the shift shaft is worn and stuck, resulting in incomplete shifting, the gear will accidentally shift out of gear during operation. In addition, the connection part of the shift lever is loose, resulting in the operator's shifting action not being accurately transmitted to the inside of the gearbox, which may also cause the gear to jump.

3. Hydraulic system abnormality

The hydraulic system plays an important role in the shifting process of the excavator, and "small crawler excavator hydraulic system failure causes gear jumping" should not be ignored. If the hydraulic oil is seriously contaminated and impurities enter the hydraulic valve, the valve core will be stuck, affecting the normal circulation and pressure control of the hydraulic oil, so that the shift cylinder cannot work normally, and then cause the gear to jump. Insufficient pressure in the hydraulic system also cannot provide enough power for the shift, resulting in incomplete shifting and eventually the problem of gear jumping.

Detailed explanation of gear jumping diagnosis skills

1. Appearance inspection

Through the "small crawler excavator gear jumping diagnosis skills", first perform an appearance inspection of the excavator. Check whether the shift lever is loose and whether the bolts at the connection are tight. If the joystick shakes greatly, it is likely that the connecting parts are loose, affecting the accuracy of the shifting operation. At the same time, check whether there is oil leakage on the outside of the gearbox. If there is oil leakage, it may be that the internal seal of the gearbox is damaged, causing hydraulic oil leakage, affecting the normal operation of the shifting hydraulic system.

2. Gear inspection

Open the gearbox and carefully check the wear of the gears. Use professional measuring tools to measure the tooth thickness, tooth surface roughness and meshing clearance of the gears. If the tooth thickness wear exceeds the specified value, or there is obvious fatigue peeling and cracks on the tooth surface, the gear should be replaced in time. In addition, observe the meshing marks of the gears. Under normal circumstances, the meshing marks should be evenly distributed in the middle of the tooth surface. If the meshing marks are abnormal, it means that there is a problem with the gear meshing, which may be one of the reasons for the shifting.

3. Hydraulic system inspection

Perform a comprehensive inspection of the hydraulic system, including the oil quality, oil volume and system pressure of the hydraulic oil. Use an oil quality tester to detect the degree of contamination of the hydraulic oil. If the oil quality does not meet the requirements, the hydraulic oil should be replaced in time and the hydraulic system should be cleaned. Measure the system pressure through the hydraulic pressure gauge, and observe whether the pressure can reach the specified value when shifting gears. If the pressure is insufficient, check whether the hydraulic pump, overflow valve and other components are working properly, and find out the cause of abnormal pressure.

Implementation of the optimization strategy for shifting gears

1. Replace worn parts

Replace new and qualified parts in time for problems such as gear wear and damage to shifting mechanism components. When replacing gears, ensure that the material and precision of the new gears meet the equipment requirements, and install them strictly in accordance with the installation process to ensure the meshing accuracy of the gears. For shifting mechanism components such as shift forks and shift shafts, reliable accessories should also be selected for replacement to ensure the accuracy and reliability of the shifting action.

2. Hydraulic system maintenance

Strengthen the maintenance of the hydraulic system, regularly replace the hydraulic oil and filter element, and keep the hydraulic oil clean. At the same time, clean and repair the hydraulic valves, cylinders and other components to ensure that the valve core is flexible and the cylinder is well sealed. If a leak is found in the hydraulic system, it should be repaired in time to ensure the normal pressure of the hydraulic system. Through these measures, the performance of the hydraulic system is optimized to avoid shifting gears due to hydraulic problems.

3. Operational specification training

Operational specification training is provided to excavator operators to improve their operating skills. When shifting gears, operators should operate the shift lever smoothly to avoid rough shifting. During the operation of the excavator, the gear should be reasonably selected according to the working conditions to avoid frequent gear shifting or forced gear shifting when overloaded. Through standardized operation, the problem of gear jumping caused by human factors can be reduced and the service life of the equipment can be extended.

The problem of small crawler excavator gear jumping involves many aspects. Through in-depth analysis of the "reasons of small crawler excavator gear jumping", the professional "small crawler excavator gear jumping diagnosis skills" are used for accurate diagnosis, and the effective "small crawler excavator gear jumping optimization strategy" is implemented, which can effectively solve the gear jumping problem, improve the operating performance and stability of the excavator, and ensure the smooth progress of engineering construction.