Maintenance steps of reducer

In order to ensure the function of various accessories, the reducer needs regular maintenance. In order to optimize the maintenance process and ensure the maintenance quality, detailed maintenance steps will be formulated for users' reference.
1. Disassembly:
(1) Descaling and cleaning the external surface of the disassembled shell, and then cleaning with kerosene;
(2) Drain the lubricating oil in the;
(3) Use the special tool (puller) to remove the belt pulley;
(4) Remove the output part of the reducer, remove the fastening screws of the end cover, separate the end cover with a jacking screw or crowbar, and then remove the gear and bearing on the output shaft with a puller and bearing press;
(5) Remove the input shaft, gear and bearing of the input part in the same way;
(6) Remove the intermediate shaft, gear and bearing by pressing with a bearing press or knocking with a copper rod;
(7) Clean the above removed parts with kerosene;
(8) Check and measure the removed gear, bearing, shaft, end cover, shell and bearing hole, and record the dimensions in detail;
2. Maintenance bearing:
(1) Remove the bearing with a puller or bearing press and clean it with kerosene;
(2) Check the wear condition of the bearing, shake the bearing, measure the shaft and radial clearance (0.02-0.2mm), turn to the bearing and listen to its sound, check the wear degree of the ball and groove surface, whether there are spots and annealing, and replace it if it is serious;
(3) Check and measure the clearance at the joint of bearing and shaft installation with a micrometer, and record the measurement results. The outer circle of conventional fit size should be increased by 0.02-0.05mm, and repair should be carried out if it exceeds the range;
(4) Keep the new bearing clean before assembly;
(5) For the bearing that needs to be filled with grease, the injection amount shall be half of the bearing cavity;
(6) When assembling the bearing with the press in method, a special sleeve or rod shall be used between the press and the bearing body, and the same shall be used during percussion installation to avoid damaging the bearing;
(7) The end face of the inner and outer ring of the bearing shall generally be close to the shaft shoulder and inner hole shoulder. The cone and thrust bearing shall generally not be greater than 0.05mm, and others shall not be greater than 0.1mm;
(8) After the bearing is installed, the contact between the outer circle and the hole in the shell shall be uniform, and the interference is generally between 0.02-0.05mm;
(9) When heating the bearing with oil or hot installing the bearing with bearing heater, the temperature shall not be higher than 120 ℃;
(10) For bearings without installation direction, one end printed with model shall be outward for easy viewing;
(11) Radial non adjustable centripetal bearings shall be installed at both ends of the shaft, and when the axial displacement is limited by the glands at both ends, one end shall be close, and the other end must have axial clearance: the calculation formula is as follows:
C=0.000011 × (80-t) l + 0.15 (where l is the shaft length and t is the room temperature)
(12) The axial clearance of angular contact bearing is generally 0.04-0.1mm, and that of cylindrical (tapered) roller bearing is generally 0.05-0.18mm;
3. Maintenance of gear shaft:
(1) A puller and a press are used to remove the gears and clean them;
(2) Measure the radial runout of the gear, and the allowable range is 0.02-0.05mm;
(3) Observe the surface wear of gear teeth and whether there are deformation, annealing, spots, peeling and other phenomena;
(4) If the wear is serious and the measured size exceeds the allowable range, it shall be replaced;
(5) When assembling a new gear, the gear hole and shaft must meet the requirements, the gear datum plane should fit the shaft shoulder (or the end face of the positioning sleeve), and the gear datum plane should be perpendicular to the axis;
(6) The axial misalignment of the meshing cylindrical gear pair shall meet the standard. When the tooth width b ≤ 100 mm, the axial misalignment shall be less than 0.05b, and when B ≥ 100 mm, the axial misalignment shall be less than 5 mm;
(7) Bevel gears shall be installed according to the matching number of machining;
4. Physical examination and repair of reducer casing:
(1) First, clean the inside of the shell with kerosene and observe whether there is crack or falling off;
(2) Use a dial indicator to measure the size of the inner hole of the assembled bearing in the housing and make records. Generally, the ovality and taper shall be less than 0.03mm, and the inner diameter shall be less than 0-0.02mm (the tolerance of the normal bearing outer circle dimension is zero line);
(3) The measured out of tolerance or damaged shell shall be repaired or replaced;
(4) All parts of the reducer shall be cleaned during installation, and the assembly sequence is opposite to that during disassembly;
(5) Install the output part and apply oil or detergent on the outer surface of the shaft. After the bearing is pressed into the shaft, the inner ring of the bearing must be close to the shaft shoulder or positioning sleeve, and the clearance shall not be greater than 0.05mm;
(6) When installing the gear, the clearance between the gear end face and the shaft shoulder shall not be greater than 0.1mm;
(7) The oil baffle shall be flat and intact. After the inner ring and shaft are fixed, a certain gap (2-3mm) must be maintained between the outer ring and the box;
(8) Install the intermediate shaft, first press the bearing at the fixed end into the housing, then put the gear and intermediate spacer in sequence, and then press the shaft of the bearing at the other end, calibrate the gear keyway below, and then press it in place. Measure the dimension of the end face between the assembly gland and the bearing outer ring, and the clearance is generally c = 0.000011 × (80-t) l + 0.1 (where l is the shaft length and t is the room temperature);
(9) Install the input part, first install the gland at the fixed end, press the bearing at this end, then place the gear and spacer in order, and then press the shaft with the bearing pressed at the other end together. Measure the dimension of the other end, and the normal axial runout clearance of the assembled gland shall not be greater than 0.05-0.1mm;
(10) The gear contact spot shall not be less than 45% along the tooth height direction and 60% along the tooth rectangle direction. The contact shall be uniform and the position shall be close to the middle part of the tooth surface;
(11) When adding new oil, the brand shall be unified and shall not be mixed. The oil level shall be located in the middle of the observation hole of the scale;
(12) Then press in the belt pulley, and the fixing bolt must be equipped with a non-return pad or anti bolt locking plate;
(13) The joint surface of the shell shall be coated with sealant, and the tightening torque of the fastening bolts shall meet the following standard values:
M10 50Nm M12 80Nm M16 190Nm M20 420Nm
M24 650Nm M30 1300Nm M36 2300Nm
(14) Drain all the old oil during maintenance and oil change. The sequence of oil change intervals shall be: 500h for one time, 3 months for the second time, 6 months for the third time and 1 year for the fourth time;
The above is the introduction of the maintenance process of the reducer. According to the introduction, we can more easily understand the maintenance requirements and operation of the equipment, so that we can better ensure the service and life extension of the equipment.