1. Preparation and implementation before idle storage
1. Comprehensive inspection and cleaning: Before shutting down, conduct a comprehensive inspection of the reducer and sizing machine, clean the oil stains, flying particles and other debris on the surface and inside of the machine, and ensure that the areas around the heat sink, cooling fan and respirator are clean and free of blockage.
2. Lubricating system treatment: Drain the old lubricating oil inside the reducer, and use special cleaning agent to carefully flush the inside of the gear box. After cleaning, apply a thick layer of anti-rust grease (such as Vaseline or special anti-rust grease) on the exposed metal surface (such as the shaft extension end) to prevent rust.
3. Sealing and protection: Check and confirm the condition of the oil seal. If stored for 4-6 months, the oil seal lip may stick to the shaft or lose elasticity. It is recommended to replace the oil seal directly. Make sure the vents are not covered by paint, and use anti-rust primer and topcoat to repair any damage to the paint film on the housing.
4. Storage environment control: Store the reducer in a dry, well-ventilated place away from direct sunlight. Control the ambient temperature and humidity to prevent condensation and corrosive gas intrusion.
5. Information registration: Establish a detailed equipment information registration form to record the sealing time, equipment status, maintenance records and person in charge, etc., to provide a basis for subsequent unsealing.
2. Preparation and inspection before restarting
1. Environmental and appearance inspection: Check the peripheral environment of the whole machine and confirm whether there are any abnormal phenomena such as water intrusion in the electrical box. Check whether the reducer housing is cracked or deformed, and whether the connecting parts and anchor bolts are loose.
2. Sealing and lubrication confirmation: Check each sealing surface (shaft seal, joint surface, oil drain plug, etc.) for oil leakage. Inject a sufficient amount of filtered new lubricating oil according to the specified brand to the specified oil level. Over-injection or under-injection is strictly prohibited.
3. Safety and electrical testing: Conduct insulation testing on the electrical system to ensure safety during power outages. Check whether the emergency stop button is sensitive and reliable, and confirm that there is good ventilation near the motor fan.
3. Restart debugging and operation
1. No-load preheating and testing: First pressurize and turn on the empty car to preheat. After the temperature reaches the appropriate range (such as above 22°C), observe whether the reducer is running smoothly and whether there is abnormal noise, vibration or oil leakage.
2. Gradual loading: After confirming that the no-load operation is normal, it cannot be started directly with full load. Special personnel should be arranged to detect the meshing condition of the front gear, gradually increase the load, and observe whether the output performance and temperature rise of the reducer meet the requirements.
3. Operation monitoring: After it is officially put into production, closely monitor the operating temperature (usually should not exceed 80°C or ambient temperature +40°C), oil level and vibration of the reducer. Once an abnormality is discovered, the machine should be shut down immediately for troubleshooting.
