What are the precautions for horizontal installation of ZSY280-80-1 gear reducer

1、 Basic and positioning precautions

The basic concrete grade should be ≥ C30, with a load-bearing capacity of not less than 1.5 times the total weight of the equipment. Sufficient space should be reserved for oil discharge, maintenance and heat dissipation, and the machine body should not be installed tightly against the ground in a closed manner.

The flatness of the foundation table surface should be ≤ 0.05mm/m, and the deviation of the foot hole position should be ≤ ± 2mm. It is forbidden to forcefully pry the machine body for alignment; The thickness of the pre embedded steel plate should be ≥ 20mm, and it should be welded firmly to the foundation reinforcement.

When lifting, the box must be equipped with lifting rings. It is strictly prohibited to directly lift the input/output shaft extension end or motor flange to avoid shaft deformation.

Insert a combination of inclined and flat iron pads between the base and foundation, with no more than 3 pads per group, and a contact surface adhesion rate of ≥ 70%. After positioning, spot weld the pads to prevent displacement during operation.

2、 Levelness and box accuracy control

Using a frame level with an accuracy of 0.02mm/m, measure the longitudinal (axis direction) and transverse (vertical axis direction) levelness simultaneously on the plane of the box.

Requirement for compliance: Longitudinal levelness error ≤ 0.1mm/m, tightened to 0.08mm/m under high-speed heavy load conditions; Horizontal levelness error ≤ 0.2mm/m.

After the horizontal adjustment is completed, tighten the 8.8 grade high-strength anchor bolts diagonally in three rounds to avoid twisting and deformation of the box caused by unilateral force; After tightening, retest the levelness, expose 2-3 threads of the bolt thread, and install anti loosening gaskets.

3、 Specification for shaft alignment and connection

Priority should be given to using laser centering instruments or dial indicators to calibrate coaxiality: the radial deviation of rigid couplings should be ≤ 0.05mm, the radial deviation of elastic couplings should be ≤ 0.15mm, and the angular deviation should be strictly controlled within the specified range.

When connecting the input shaft to the motor and the output shaft to the working machine, it is forbidden to directly strike the shaft end with a hammer to install the coupling, in order to avoid impact damage to the bearings and shaft mating surfaces.

All connecting bolts should be tightened with the specified torque, and key parts can be coated with thread locking agent to prevent loosening. After running for one week, all anchor bolts and connecting bolts should be tightened again.

4、 Special requirements for lubrication and sealing

Add L-CKD 220 # extreme pressure industrial gear oil for the first time, keeping the oil level at the center line of the oil mark. It is forbidden for the oil level to be too high, causing excessive temperature rise, or too low, causing insufficient lubrication.

When cleaning the rust proof layer of the input and output shafts, it is strictly prohibited to soak the oil seal lip with strong solvents to prevent oil leakage due to aging of the oil seal; Apply a small amount of sealant evenly when installing the end cap sealing surface to avoid oil leakage from the joint surface.

Be sure to remove the rubber plug that seals the ventilation plug during transportation and replace it with the original factory ventilation cap to prevent abnormal increase in internal pressure during operation and rupture of the seal.

5、 Key points for trial operation after installation

First, manually turn the wheel several times to confirm that the entire rotation is flexible without any jamming or abnormal noise, and then jog to verify that the rotation direction is correct.

Run continuously for 2 hours without load, monitor the temperature rise of the body to ≤ 35 ℃, the temperature of the bearing parts to ≤ 70 ℃, and ensure that there is no sudden change in vibration values. After confirming that there is no leakage at all sealing points, gradually load to the rated working condition.

After the first 50 hours of operation, the oil should be forcibly changed to completely remove any remaining installation impurities inside the casing. Subsequently, the oil should be changed every 3000 hours or regularly every year.