ZLYJ EXTRUDER GEARBOX MANUAL CHAPTER TWO

Attention:

      ◇ Cut off and prevent (by a warning tag, etc.) the re-connection of power supply to the motor before installing the couplings.

      ◇ Striking by hammer or other similar tools is not allowed when mounting the couplings and small gears onto the shaft end.

      ◇ Ensure the correct tension of belt when installing belt wheel.

              ◇ Do not install or uninstall the screw by force in respect of the output part.

Protective hood shall be provided to the outside rotating parts of the reducer (such as the coupling, belt pulley, etc.).

Remove thoroughly the antirust, dirt or other stains on the end and flange surface of connecting shaft. Solvent is permitted for cleaning but it shall be prevented from flowing to the lip seal of sealing elements of shaft end.

V. Operation of Reducer

Examinations before operation:

u     Before operation, check whether the reducer has lubricating oil to the appropriate level inside it. Supplement the oil in case of shortage.

u     All connecting parts shall be secure. All protective devices shall be complete.

u     Check whether the ambient environment is below 0℃, if yes, preheat the lubricating oil to above 0℃.

Operation of reducer:

u      Run the reducer for 5~10 minutes without load (if the reducer is equipped with the gear pump of motor, start the pump first) to appropriately lubricate the bearings and gears. If the reducer is used for the first time, after the idle running, add loads step by step at 20% of rated load each time for 1~2 hours until the full rated load. Put into service if everything is OK.

u      During the operation, monitor and write down from time to time the temperature rise of the reducer. If the temperature rise of the reducer exceeds 70℃ or the oil temperature exceeds 100℃, stop the reducer to find out and solve the problems. Contact our after-sales service department if necessary. Replace the lubricating oil before starting the reducer again.

u      The reducer shall be stopped as follows: Shut down the feeding hopper and, after all the materials in the bucket has been transported out, turn off the power supply to the reducer (if the reducer is equipped with the gear pump of motor, shut down the pump first)

u      Run the reducer every 2 to 3 weeks in the event of long idleness.

u      Conduct anti-rust measures to the inside and outside of reducer in the event of idleness over 6 months:

Fill in lubricating oil up to full, coat the shaft end and unpainted surface with anti-rust wax materials and protect with lubricating grease the lip seal of sealing parts of axles against the penetration of antirust.

Attention:

◇ During the early stage of operation, the oil pump may incur loud noise resulted from the high viscosity of lubricating oil and the large suction resistance against the oil pump, which would gradually die away along with the temperature rise of the lubricating oil

◇ If the oil pump incurs loud noise during the normal operation of reducer, clean the oil filter to get the oil pipeline through.

Monitor from time to time the oil leak of the reducer during its operation, and, if any, stop the reducer to solve the problem.

VI. Repair and Maintenance

u      Time interval of repair and maintenance

Time interval

Repair and maintenance

Normal operation

Check the temperature of reducer:

no more than 90 when using mineral lubricating oil

          no more than 100 when using synthetic lubricating oil

Check whether there is abnormal noise of reducer

Check whether there is leakage of  reducer

After 500~800 hours operation

First lubricating oil replacement after initial operation

Check the oil level to determine the oil filling

Every 3000-hour operation, at least once half a year

Check the lubricating oil, and, in case of outdoor or damp environment, ensure that the water content in lubricating oil shall be no more than 500ppm

Replace the mineral lubricating oil (working hour less than 8h per day)

Clean the air plug

As per operating condition, at least once 3 month

Replace the mineral lubricating oil (long time continuous work)

Check whether there is any joint bolt loosing

Check the situations of contamination and lubricating and cooling devices

Clean the filter of lubricating oil and replace filter core if required

As per operating condition, at least once a year

Replace the synthetic lubricating oil

As per the environment and operating condition

Improve or replace the protective (rustproof) paint on surface

Clean the exterior surface and of reducer

Check the accessory devices equipped

u      Time interval of lubricating oil replacement

Regularly replace the lubricating oil of special type reducer that works in severe environment.  The figure below shows the time interval of lubricating oil replacement in normal environment. CLP HC refers to PAO synthetic lubricating oil