I. Core Components of Atlas Copco
Specialized Tool Set
Assembly and Disassembly Tools: Includes socket wrenches for fitting the gearbox bolts (with torque scale), gear remover (to prevent damage to the shaft system during disassembly), bearing puller (for extracting deep groove ball bearings or tapered roller bearings), hex key wrench set (matching the fixing screws of the gearbox cover).
Measuring Tools: Dial indicator and magnetic gauge holder (for detecting the gear meshing clearance and the radial runout of the shaft system), feeler gauge (for measuring the bearing clearance), internal diameter micrometer (for checking the wear of the gearbox housing).
Cleaning Tools: High-pressure air blow gun (for cleaning oil stains and debris), special brush (for cleaning the gap between the gear teeth), ultrasonic cleaning basket (for cleaning precision parts).
Supplies and Spare Parts
Seals: Customized specifications of nitrile rubber oil seals (to prevent lubricating oil leakage), oil-resistant asbestos gaskets or silicone rubber seals (for the joint surface of the gearbox upper and lower covers).
Lubricating Medium: Specialized gear oil for oil-free air compressors (usually synthetic type, suitable for high-temperature conditions, and not contaminating the system with compressed air) and solid lubricating grease (for pre-lubrication of bearings and meshing surfaces).
Wear Parts: Spare bearings (configured according to the gearbox model, mostly double-sealed type), locating pins (to ensure precise assembly alignment of the gearbox).
Auxiliary Supplies
Gearbox cleaning agent (neutral formula, not corroding the metal surface), lint-free wipes (to avoid fiber residue), thread locking adhesive (to prevent bolt loosening), maintenance-specific workbench cloth (to prevent parts from being scratched).
II. Atlas Copco Compatibility and Advantages
Oil-free Model Compatibility: Designed based on the structural characteristics of the oil-free air compressor gearbox (usually used to drive the compressor main unit and not in direct contact with compressed air), avoiding the use of fuel-based materials that pollute the system, in line with the cleanliness requirements of oil-free equipment.
One-stop Maintenance: Tools and consumables are pre-matched with the gearbox model (such as transmission ratio, bearing specifications, seal dimensions), eliminating the need to purchase individual spare parts, reducing compatibility errors.
Professional Standards: Tool accuracy conforms to mechanical maintenance specifications (such as torque wrench error ≤ ±3%), consumable performance meets the operating conditions of the gearbox (such as oil seal temperature resistance ≥ 120℃, gear oil oxidation life ≥ 2000 hours).
III. Typical Maintenance Process Application of Atlas Copco
Disassembly Phase: Use specialized wrenches to remove the gearbox cover at the specified torque, safely remove the gear shaft using the remover, and disassemble the bearings using the puller (to avoid violent operation that may cause damage to the shaft neck).
Testing Phase: Use the dial indicator to measure the radial runout and meshing clearance of the gears (standard values are usually 0.15-0.3mm), check the bearing clearance (if exceeding 0.2mm, replacement is required), and measure the flatness of the mating surface of the housing.
Cleaning and Replacement: Ultrasonic clean the gears and shaft system parts, replace worn bearings and aging seals, apply special lubricating grease to the meshing surface of the gears.
Reassembly and Calibration: Precisely reset the housing according to the locating pins, evenly tighten the bolts (follow the diagonal step-by-step tightening principle), and finally test the flexibility of the shaft system rotation and the sealing performance.
