The correct installation and operation of reducer is an important link to ensure the normal operation of mechanical equipment. Therefore, it is necessary to strictly follow the installation and operation procedures to install and use the reducer.

Main steps of installation

The first step

Before installation, confirm whether the motor and reducer are in good condition, and strictly check whether the dimensions of the parts connected with the motor and reducer match, including the dimensions and fit tolerance of the positioning boss, input shaft and reducer groove of the motor.

Step two

Screw down the screw on the outer dust hole of the reducer flange, adjust the PCS system clamping ring to align the side hole with the dust hole, insert the inner hexagon and tighten it. After that, remove the motor shaft key.

The third step

Connect the motor and reducer naturally. When connecting, the concentricity of the output shaft of the reducer and the input shaft of the motor must be consistent, and the outer flange of the two must be parallel. If the centrality is not consistent, the motor shaft will be broken or the reducer gear will be worn.

In addition, it is strictly forbidden to strike with hammer during installation to prevent bearing or gear from being damaged by excessive axial force or radial force. Be sure to tighten the mounting bolt before tightening the tightening bolt. Before installation, wipe the antirust oil of motor input shaft, positioning boss and reducer connection with gasoline or zinc sodium water. Its purpose is to ensure the tightness of the connection and the flexibility of operation, and to prevent unnecessary wear.

Before connecting the motor with the reducer, the keyway of the motor shaft should be perpendicular to the tightening bolt. In order to ensure uniform stress, first screw on the mounting bolts at any diagonal position, but do not tighten them, then screw on the mounting bolts at the other two diagonal positions, and then tighten the four mounting bolts one by one. Finally, tighten the tension bolt.

All tightening bolts shall be fixed and checked with torque wrench according to the marked fixed torque data. The correct installation between reducer and mechanical equipment is similar to that between reducer and drive motor. The key is to ensure the concentricity of the output shaft of the reducer is consistent with the shaft of the driven part.

Installation precautions

1. Connection between reducer and working machine: the reducer is directly installed on the main shaft of the working machine. When the reducer is running, the counter torque acting on the reducer case body is balanced by the counter torque bracket installed on the reducer case body or by other methods.

2. Installation of counter torque support: the counter torque support shall be installed on the side of the working machine facing the reducer to reduce the bending moment attached to the shaft of the working machine. Rubber and other elastomers are used in the shaft sleeve at the connection end of the counter torque bracket and the fixed support to prevent deflection and absorb the torque fluctuation.

3. Installation relationship between reducer and working machine: in order to avoid deflection of main shaft of working machine and additional force on bearing of reducer, the distance between reducer and working machine shall be as small as possible without affecting normal operation, with the value of 5-10mm.

4. When installing the reducer, attention should be paid to the alignment of the transmission center axis, and the error should not be greater than the compensation amount of the coupling used. Good alignment can prolong service life and obtain ideal transmission efficiency.

5. When installing the transmission parts on the output shaft, it is not allowed to knock with a hammer. Generally, the assembly fixture and the internal thread of the shaft end are used to press the transmission parts in with bolts, otherwise the internal parts of the reducer may be damaged. It is better not to use rigid fixed coupling, because improper installation of this kind of coupling will cause unnecessary additional load, resulting in early damage of bearing and even fracture of output shaft.

6. The reducer shall be firmly installed on a stable horizontal foundation or base, the oil in the oil drain tank shall be able to be discharged, and the cooling air circulation shall be smooth. If the foundation is not reliable, it will cause vibration and noise during operation, and damage the bearing and gear. When there are protrusions in the transmission connecting parts or when the gears and sprockets are used for transmission, the installation of protective devices should be considered. When the output shaft bears large radial load, the reinforced type should be selected.

7. According to the provisions of the installation device to ensure that the staff can easily get close to the oil level, vent plug, drain plug. After installation in place, the accuracy of installation position and the reliability of each fastener should be comprehensively checked in order, and it should be able to rotate flexibly after installation. The reducer adopts oil pool splash lubrication. Before operation, the user needs to remove the plug of the vent and replace it with the vent plug.

According to different installation positions, open the screw of the oil level plug and check the height of the oil level line. Add oil from the oil level plug until the lubricating oil overflows from the screw hole of the oil level plug. After the oil level plug is screwed on, no-load test run can be carried out.

8. The trial operation time shall not be less than 2 hours. The operation shall be stable, without impact, vibration, noise and oil leakage, and any abnormality shall be eliminated in time. In addition, after a period of operation, the oil level should be checked again to prevent possible leakage caused by the casing. If the ambient temperature is too high or too low, the brand of lubricating oil can be changed.