1. Foundation fixing and leveling issues
1. The foundation is weak or uneven: The reducer must be installed on a flat, solid foundation or frame with sufficient stiffness. An unstable foundation will cause vibration and abnormal noise when the equipment is running, and accelerate the wear of bearings and gears.
2. Insufficient leveling accuracy: A high-precision level must be used for leveling on the input/output shaft flange surface or datum surface during installation. The level error should usually be controlled within 0.1mm/m. Inclined installation will aggravate the eccentric load wear of gears.
3. Improper tightening of anchor bolts: they must be tightened gradually to the specified torque in 2-3 times in a diagonal sequence. Tightening at one time or in the wrong sequence will cause the box to be deformed due to uneven stress, causing oil leakage or damage to internal parts.
2. Axis alignment problem
1. Excessive concentricity deviation: This is one of the most common installation problems. If the concentricity deviation between the motor shaft and the reducer input shaft, the reducer output shaft and the working machine shaft exceeds 0.1mm, it must be readjusted. Poor alignment will produce additional radial loads, causing bearing overheating, damage, and even fracture of the output shaft.
2. Improper coupling selection: It is recommended to avoid the use of rigid fixed couplings because it cannot compensate for small alignment deviations during installation and will directly transmit stress to the reducer bearings. It is recommended to use elastic couplings to buffer installation stresses and vibrations during operation.
3. Lubrication management issues
1. Wrong lubricating oil type or quantity: Lubricating oil must be added strictly in accordance with the nameplate or instructions (such as N220-N320 gear oil commonly used in WP series). Insufficient oil will lead to poor lubrication and increased wear; too much oil will cause increased oil churning losses, severe heating and oil leakage at the seal. At rest, the oil level should be in the middle of the oil window or between the specified lines.
2. Ignore the vent plug: Before operation, the vent screw plug at the top must be removed and replaced with the vent plug. If you forget this step, the pressure inside the box will increase as the temperature rises, causing the lubricating oil to be squeezed out from the weak seal, causing oil leakage.
3. Insufficient lubrication in vertical installation: If the location permits, try to avoid vertical installation. When installed vertically, the lubricating oil is easily lost from the meshing surface after shutdown, causing the gear to be in a semi-dry friction state when starting next time, causing serious wear. If it must be installed vertically, it is necessary to increase the amount of oil or choose a model with forced lubrication.
4. Assembly operation problems
1. Violent knocking: When installing transmission parts such as pulleys and couplings on the output shaft, it is strictly prohibited to use a hammer to knock directly. Assembly clamps should be used or the internal threads of the shaft end should be used to press the transmission parts in smoothly through bolts to avoid damaging the internal bearings and gears.
2. Failure to clean before installation: Failure to thoroughly clean the motor shaft and reducer input hole of oil, burrs, and impurities before installation may result in excessive tightness, poor concentricity, or damage to seals.
3. Ignoring the first oil change: After the new reducer has been operated for 100 hours for the first time, the interior must be cleaned and new oil replaced to remove metal particles produced during the running-in period. Thereafter, change the oil every approximately 2500 operating hours.
