1. Preparation and external inspection before disassembly
Before formal disassembly, it is necessary to cut off the power supply and wait for the reducer to cool to room temperature. Observe the appearance of the reducer, check whether there are cracks and deformations in the casing, whether the connection parts are loose, and whether there are traces of oil leakage in the casing seams, shaft extension end or oil drain port.
2. Key points during the disassembly process
Oil draining and cleaning: Place an oil catch basin at the bottom and unscrew the oil drain plug to drain the gear oil. If you plan to reuse it, you need to filter impurities first and clean the oil near the oil drain port.
Open the cover smoothly: Loosen and remove the fixing bolts of the upper cover (or side cover) in diagonal order. Use a jack screw or a copper rod to gently separate the upper cover and the base. Violent prying is strictly prohibited to avoid deformation of the joint surface and subsequent oil leakage.
Position marking: Before taking out the transmission components, be sure to carefully observe and mark the meshing positions of the driving wheel, driven wheel and worm gear to provide a basis for subsequent accurate reassembly.
Standard disassembly: Use a puller or special tools to disassemble bearings and gears. Avoid directly hitting the tooth surface or bearing outer ring to prevent damage to the balls and internal components.
3. Cleaning and inspection of core components (core focus)
Wash the disassembled parts thoroughly with cleaning agent (such as kerosene) and dry them, focusing on checking the wear and damage of the following parts:
Gears/Worm Gears: Inspect tooth surfaces for severe wear, pitting, or spalling. If the tooth thickness wear exceeds 10% of the original tooth thickness, or the peeling area of the worm gear tooth surface exceeds 20%, it must be replaced.
Bearings: Check whether the bearing balls are rusted and whether the inner and outer rings are peeled off. When rotating the bearing manually, if there is sticking or abnormal noise, it means the bearing is damaged and needs to be replaced in time.
Shaft and seals: Check whether the journal is worn and whether the lip of the skeleton oil seal is deformed, aged or worn. Rust on the shaft surface or damage to the oil seal are common causes of oil leakage at the shaft extension end, and need to be repaired or replaced as appropriate.
Shell and end cover: Check whether there are scratches on the sealing surface, and confirm whether the accuracy of the bearing holes and other matching parts is up to standard.
4. Precautions for assembly and debugging
Lubrication and sealing: Before assembly, fully lubricate the shaft, bearings (apply lithium grease) and gears (apply gear oil). All old seals and gaskets must be replaced to ensure a good seal.
Gap adjustment: Install the gear assembly according to the marked position to ensure that the meshing gap meets the design requirements (generally the gear gap is 0.1~0.3mm). When installing the bearing end cover, tighten the bolts symmetrically and adjust the bearing clearance with spacers to ensure that the shaft rotates flexibly and without jamming.
Oil filling and testing: Add gear oil according to the specified model to the standard oil level (too much or too little will affect heat dissipation and lubrication). After the assembly is completed, perform no-load debugging first, observe whether there are any abnormal noise, vibration and temperature rise, and then perform a load test after confirming that they are normal.
