Complete steps for dismantling and repairing the grinder reducer

1、 Preparation and safety isolation before maintenance

Safety isolation: Cut off the power supply and hang warning signs, strictly implement the "LOTO" system to ensure safe operation.

Reference materials: Refer to the disassembly manual of this model reducer to clarify special design, assembly requirements, and various tolerance standards.

Tool preparation: Prepare specialized wrenches, pullers, copper rods, hydraulic jacks, feeler gauges, etc. It is strictly prohibited to use mismatched tools.

Environmental cleaning: Ensure that the work area is spacious and dry, and place an oil basin at the bottom to clean the maintenance site.

2、 External disassembly and oil drainage

External oil drainage: Unscrew the bottom oil drain plug and drain the gear oil completely. If planning to reuse, impurities need to be filtered first.

Disassemble attachments: Remove the coupling or pulley (slowly apply force with a puller, and locally heat or infiltrate kerosene assistance when stuck), and remove accessories such as fan cover, oil pipe, sensor, etc.

Photo marking: Before disassembly, it is necessary to take photos or mark the original position and direction of components such as couplings, end caps, gears, etc. to prevent assembly misalignment.

3、 Shell separation and internal disassembly

Separate the shell: Loosen the end cap bolts in diagonal order, gently tap the edge of the end cap with a copper rod or use a top wire to separate the upper and lower shells. Violent disassembly is strictly prohibited to avoid deformation of the joint surface.

Remove components: First, remove the locating pin, and then remove the gears and bearings in order. For medium-sized reducers, the rotor needs to be disassembled synchronously at both ends to avoid component deformation caused by one-sided force.

Violence is strictly prohibited: Bearing disassembly must use a puller or press, and it is strictly prohibited to directly strike the bearing or gear meshing surface.

4、 Component cleaning and precision testing

Thoroughly clean: Use a cleaning agent (such as kerosene) to thoroughly clean all parts, remove oil stains and metal debris, and inspect the interior of the box for any abnormal wear marks.

Gear inspection: Check the wear of the tooth surface, with a focus on observing whether the contact spot area of the tooth surface is ≥ 60%~70%.

Bearing inspection: Measure the radial clearance of the bearing (generally standard is 0.02-0.2mm), rotate the bearing and listen for its sound, check for spots, annealing or rust on the surface of the ball and groove, and replace it if it is severely worn.

Dimensional measurement: Use microm

eters and other measuring tools to measure the fit dimensions of the shaft neck and bearing holes, confirm if they exceed the tolerance range, summarize various dimensional deviations, and determine repair items.

5、 Standardized reassembly and gap adjustment

Replace vulnerable parts: All disassembled sealing rings and gaskets must be replaced with new ones, and an appropriate amount of lubricating grease (such as molybdenum disulfide or lithium based grease) should be applied during assembly.

Bearing installation: Use hot installation method (oil temperature or heater temperature controlled at ≤ 120 ℃) or press in method to install bearings, paying attention to the axial clearance between cone and thrust bearings, which is generally not greater than 0.05mm.

Gear assembly: Reinstall the gear components according to the marked positions to ensure that the meshing clearance meets the design requirements (generally the gear clearance is 0.05-0.3mm, refer to the instruction manual for details), which can be measured using a feeler gauge or lead pressure method.

Tightening and sealing: Symmetrically tighten the end cap bolts, adjust the bearing preload force through gaskets or adjusting screws, and ensure that the shaft rotates flexibly without jamming.