Maintenance Procedures for Reducers

In order to ensure the function of various accessories, the reducer needs regular maintenance.In order to optimize the maintenance process and ensure maintenance quality, detailed maintenance steps will be formulated for users' reference.
1. Disassembly:
(1) Descale and clean the outer surface of the disassembled case, and then wash it with kerosene;
(2) Drain lubricating oil;
(3) Use a special tool (pull tube) to remove the pulley;
(4) Remove the output part of the reducer, remove the fastening screws of the end cover, separate the end cover with the top cover screw or a crowbar, and then use a puller and a bearing press to remove the gear and bearing.
(5) Remove the input shaft, gears and bearings of the input section in the same way;
(6) Remove the intermediate shaft, gears and bearings by knocking out with a bearing press or with a copper rod;
(7) Clean the above parts with kerosene;
(8) Check and measure the removed gears, bearings, shafts, end covers, housings and bearing holes, and record the dimensions in detail;
2. Maintenance of bearings:
(1) Remove the bearing with a puller or bearing, and clean things with kerosene;
(2) Check the wear of the bearing, shake the bearing, measure the shaft and radial clearance (0.02-0.2mm), turn the bearing and listen to its sound, check the wear degree of the ball and groove surface, whether it is a bit and anneal if it is Seriously, replace it;
(3) Check the clearance between the bearing and the shaft installation joint with a micrometer, and record the measurement results.The outer ring of the regular fit size should be increased by 0.02-0.05mm, if it exceeds the range, it should be repaired;
(4) Keep new bearings clean before assembly;
(5) For bearings that need to be filled with grease, the injection volume should be half of the bearing cavity;
(6) When the bearing is assembled with a press, a special sleeve or rod should be used between the press and the bearing body, and the same purpose is used during the installation of the impact machine to avoid damage to the bearing;
(7) The end faces of the inner and outer rings of the bearing are usually close to the shaft shoulder and inner bore shoulder.Taper and thrust bearings are generally not larger than 0.05mm, and others are not larger than 0.1mm;
(8) After installing the bearing, the contact between the outer ring and the hole in the housing should be uniform, and the interference is usually between 0.02-0.05mm;
(9) When heating the bearing with oil or installing the bearing with a bearing heater, the temperature shall not be higher than 120°C;
(10) For bearings with no installation direction, the end printed with the model should face the appearance for easy observation;
(11) Centrifugal bearings that are not radially adjustable should be installed at both ends of the shaft, and when the axial displacement is restricted by the glands at both ends, one end should be closed and the other end must have an axial clearance: the calculation formula is as follows:
C = 0.000011 x (80-T) L + 0.15 (where L is the axial length and T is room temperature)
(12) The axial clearance of angular contact bearings is usually 0.04-0.1mm, and that of cylindrical (tapered) roller bearings is usually 0.05-0.18mm;
3. Maintenance of the gear shaft:
(1) Tractors and presses are used to remove the gears and clean them;
(2) Measure the radial runout of the gear, the allowable range is 0.02-0.05mm;
(3) Observe the surface wear of gear teeth, whether there is deformation, annealing, spots, peeling and other phenomena;
(4) If the wear is serious and the measured size exceeds the allowable range, it should be replaced;
(5) When assembling a new gear, the gear hole and shaft must meet the requirements, the gear base plate should be fitted with a shaft shoulder (or the end face of the positioning sleeve), and the gear plane should be perpendicular to the axis;
(6) The axial misalignment of the meshing cylindrical gear pair should meet the standard.When the tooth width B≤100mm, the axial misalignment should be less than 0.05b, and when B≥100mm, the axial misalignment should be less than 5mm;
(7) The bevel gear should be installed according to the processing number of matching quantity;
4. Physical inspection and repair of reducer casing:
(1) First, clean the inside of the shell with kerosene, and observe whether there is any crack or drop;
(2) Use the dial indicator to measure the size of the inner hole of the assembled bearing in the housing and record it.Generally, the ellipse and taper should be less than 0.03mm, and the inner diameter should be less than 0-0.02mm (the tolerance of the normal bearing outer ring size is the zero line);
(3) Measurements of tolerance or damaged housings should be repaired or replaced;
(4) All parts should be cleaned during installation, and the assembly sequence is reversed during disassembly;
(5) Install the output section and apply oil or detergent to 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 the positioning sleeve, and the clearance shall not be greater than 0.05mm;
(6) When installing the gear, the gap between the gear end face and the shaft shoulder shall not be greater than 0.1mm;
(7) The oil baffle should be flat and complete.After the inner ring and the shaft are fixed, a certain gap (2-3mm) must be maintained between the outer ring and the box;
(8) To install the intermediate shaft, first press the bearing at the fixed end into the housing, then put the gear and the intermediate spacer into the other end in sequence, then press the shaft of the bearing, align the keyway of the gear below, and press it into place.Measure the size of the end face between the assembled gland and the bearing outer ring, and the clearance is usually 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 time, then place the gears and spacers in order, and press the shaft together with the bearing.Measure the size of the other end, the normal axial beating gap of the assembled gland shall not be greater than 0.05-0.1mm;
(10) The gear contact point is not less than 45% along the tooth height direction and 60% along the tooth rectangular direction.The contact should be uniform and the position should be close to the middle part of the tooth surface;
(11) When adding new oil, the brand should be unified and not mixed.The oil level should be in the middle of the scale observation hole;
(12) Then press the pulley, the fixing bolt must be equipped with a return pad or an anti-bolt locking plate;
(13) The joint surface of the shell should be coated with sealant, and the tightening torque of the fastening bolts should meet the following standard values:
M10 50nm M12 80nm M16 190nm M20 420nm
M24 650nm M30 1300nm M36 2300nm
(14) Drain all old oil during maintenance and oil changes.The sequence of oil change intervals should be: 500H once, 3 months for the second time, 6 months for the third time, 1 year for the fourth time;
The above is the maintenance process of introducing the reducer.According to the introduction, we can more easily understand the maintenance requirements and operation of the equipment, allowing us to better ensure the service and life extension of the equipment.