What inspections are required before reactivating a TY100-31.5-3KW gear reducer that has been idle for a long time

1、 Appearance and seal inspection

Clean the surface dust and oil stains of the box, inspect the shell for cracks, deformation, or rust, and focus on checking weak areas such as flange surfaces, bearing seats, and oil drain holes.

Check the rubber components such as the shaft end oil seal and end cap O-ring. If there are signs of aging, cracking, or oil leakage, they must be replaced directly. Apply a small amount of lubricating grease to the oil seal lip.

Confirm that the ventilation plug (respirator) is unobstructed to avoid abnormal pressure rise inside the box during operation.

2、 Full inspection and oil change of lubrication system

Open the oil drain hole to take a sample and observe the condition of the old oil: the oil appears white and emulsified, with a large amount of rust/metal abrasive particles deposited at the bottom, indicating that the oil has completely failed.

If the shutdown exceeds 6 months, the old oil must be drained, and the inside of the box must be flushed with new oil of the same brand. The original factory specified L-CKD 220 heavy-duty gear oil should be added to the centerline position of the window.

In low-temperature environments, it is necessary to preheat the lubricating oil to above 10 ℃ in advance to avoid insufficient oil supply caused by high viscosity during start-up.

3、 Verification of gear and tooth surface condition

Open the observation cover and visually inspect all tooth surfaces: after wiping off slight floating rust, it can be directly put into use. If there are pits or root cracks, the damage level must be evaluated.

Measure the backlash of the gear pair with a feeler gauge and compare it with the original factory record to confirm that there is no abnormal deviation in the meshing clearance after long-term static placement.

Focus on checking whether there are rust mud and water vapor condensation marks at the bottom of the tooth surface to avoid static corrosion caused by long-term oil immersion in the lower part.

4、 Bearing condition inspection

Manually rotate the input shaft and feel the running resistance throughout the entire process. It should be smooth without any jamming or periodic impact noise.

Measure the clearance of the bearing, and control the standard value within the range of 0.02~0.05mm. If it exceeds the range, the bearing needs to be disassembled and replaced.

Confirm that there are no pressure marks formed by long-term static load on the bearing raceway, which is a common cause of abnormal noise after idle.

5、 Electrical system safety testing

Use a 500V megohmmeter to measure the insulation resistance of the matching motor winding to ground, and the value should not be less than 1M Ω. The damp winding needs to be dried.

Check that the wiring terminals are free of oxidation and corrosion, the grounding wire is firmly connected, and the grounding resistance is ≤ 4 Ω.

Confirm that the wiring of accessories such as thermal protectors and temperature sensors is normal, and that the overload and phase loss protection function tests are effective.

6、 Install alignment and tighten fasteners again

Use a torque wrench to tighten all foundation bolts and flange connection bolts according to standard values, eliminating the looseness caused by long-term settlement of the foundation.

Calibrate the coaxiality of the coupling with a laser centering instrument or dial gauge, with an error controlled within the range of ≤ 0.1mm, to avoid additional impact loads caused by axis deviation.

Check that the key connections are rust free, the transmission components are not loose, and the mating surfaces of the pulleys/couplings are not damaged or bumped.