The first part of the overhaul process is: disassembly of the mechanical parts of the reducer
1. The cleaning of the reducer:
a Preparation before disassembly
b machine cleaning, thoroughly clean the surface of the equipment oil stains, cinder and other dirt;
c When cleaning is completed, transport the cleaned equipment to the equipment maintenance area;
d Clean up the on-site work hygiene.
2, the disassembly of the reducer
a Disassemble the oil plug and release all the gear oil in the reducer;
b clean and clean the dirt outside the reducer;
c remove the breathable cap and grease nozzle;
dRemoving the connecting bolts and positioning pins of the upper and lower casings of the reducer;
eRemove the second, third and fourth shaft end cap bolts of the reducer;
fRemoval of the second, third and fourth shaft end caps of the reducer;
g disassemble the four-axis sealing housing of the reducer;
hRemove the upper and lower tank sight hole cover of the reducer;
i remove the box on the reducer;
j disassemble the one, two, three and four axle assemblies of the reducer;
k disassemble the reducer cooler;
Second reducer mechanical parts detection reducer detection
Axis
a, the shaft must not have deformation, cracks, no rust, damage, etc.;
b. All the matching dimensions and surface roughness on the shaft should meet the technical requirements of the drawings. The tolerance of 0.02mm can be reused, and the repair of 0.02mm or more can be reused.
c. The axial width dimension can be reused without exceeding the limit size of 0.04mm, and should be replaced if it exceeds the limit size of 0.04mm;
d. Perform non-destructive testing on the reducer if necessary.
1.2 gear
a. Gear teeth shall not have broken teeth, and the tooth surface shall not have defects such as cracks or flaking, snaking deformation and interference damage;
b. Early pitting on the tooth surface, if it is no longer developed, it can still be used. However, you may not continue to use it if one of the following conditions is reached.
(1) The height of the pitting area is 100% of the tooth height.
(2) The height of the pitting zone is 30% of the tooth height and the length is 40% of the tooth length.
(3) The height of the pitting zone is 70% of the tooth height, and the length is 10% of the tooth length.
(4) The average diameter of the pittings shall not exceed 2 mm.
1.2.3 Gluing area of ​​the tooth surface When the tooth height is 1/3 and the tooth length is 1/2, it shall not be used continuously. Gears with severe pitting on the tooth surface of the gear and puncture diameter exceeding 2 mm shall not be used continuously;
1.2.4 The size and surface roughness of the bearing should meet the technical requirements of the drawings. It can be reused without exceeding the limit size of 0.02mm, and should be repaired if it exceeds the limit size of 0.02mm;
1.2.5 Perform non-destructive testing of the entire reducer as necessary.
1.4 box and end cover
1.4.1 The sealing groove on the box body shall not be bumped or rusted, and the sealing groove shall not be bumped or rusted;
1.4.2 The joint surface of the box should be flat and tight, the flatness tolerance should not exceed 0.05mm, and the scratch length on the joint surface should not be greater than 2/3 of the joint surface width, and the depth should not exceed 0.3-0.5mm.
1.4.3 The box shall not be cracked or deformed by visual inspection. If there is a slight crack and it is only allowed to repair and repair at the non-mainly stressed part, the welding stress should be eliminated. If the crack has penetrated the two shaft holes, it must be replaced.
1.4.4 The threaded hole on the box body should first be used with the corresponding tap hole, and then the thread gauge should be used to detect and the end of the thread should not be more than 2 turns;
1.4.5 End caps shall not have heavy wear, cracks or deformation, the joint surface shall be flat and tight, and the flatness shall not exceed 0.03mm;
1.5 other parts
1.5.1 The vent plug is unobstructed;
1.5.2 The cooling device is unobstructed, the thread is intact, and there is no leakage.
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