7 Steps to Success
Step 1: Preparation
Thoroughly clean all parts—rolling bearings with gasoline, other parts with kerosene. Apply lubricating oil to mating surfaces immediately after cleaning to prevent rust. Check nameplate parameters. Remove anti-corrosion coating from output shaft—keep solvent away from oil seals.
Step 2: Bearing Installation
Heat bearings to 100℃ (oil bath method, never exceed 120℃). Quickly mount onto shaft journal. Use a copper rod with a cushion to gently tap until seated against shaft shoulder. Bearing inner ring must contact shoulder tightly—0.05mm feeler gauge should not pass through.
Step 3: Gear Installation
Install larger gears first, then smaller ones. For interference fits, heat gears and press into position. Verify proper seating. Never hammer.
Step 4: Clearance Adjustment
Measure backlash using lead wire method—must meet drawing specifications. Check contact pattern with coloring method—contact should be at least 40% along tooth height and 50% along tooth length. Adjust using shims or fine-tuning positions.
Step 5: Housing Closure
Apply sealant to housing split surfaces—no gaskets allowed. Insert taper pins for positioning first, then tighten bolts symmetrically (from center outward in multiple passes to specified torque). For shrink disc installation, tighten screws evenly clockwise—keep outer ring parallel.
Step 6: Test Run
Run no-load forward and reverse for 1-2 hours, then gradually load to rated capacity. Monitor bearing temperature—rise should not exceed 40℃, temperature difference between bearings不超过15℃. Operation should be smooth with no abnormal noise or leaks.
Step 7: Final Steps
Fill with lubricant to specified level. Install inspection cover and vent cap—vent must be open before operation. Clean exterior, apply rust preventive oil to extension shafts.
Golden Rules
Must Do:
- Heat bearings to 100℃ for installation
- Use copper rod with cushion for tapping
- Tighten bolts symmetrically in multiple passes
- Monitor temperature throughout test run
Never Do:
- Hammer directly on any parts
- Heat bearings above 120℃
- Add gaskets between housing split surfaces
- Operate with vent cap closed
Quick Checklist
Bearing seated: 0.05mm feeler gauge no-go
Backlash: Meets drawing specifications
Contact pattern: Height ≥40%, length ≥50%
Bolt torque: Achieves specified value
Temperature rise: ≤40℃
Leaks: None
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