How to extend the service life of ZJY150-22.4-S reducer gear

Practical method for extending the service life of ZJY150-22.4-S shaft mounted hard tooth surface reducer gears:

1. Accurate control of lubrication management to establish a solid foundation for gear protection: Select industrial gear oil suitable for this model for medium and heavy loads, use N220 closed gear oil for regular working conditions, replace N150 for low temperature working conditions, and N320 for high temperature/heavy load working conditions. It is strictly prohibited to mix different brands/models of oil; The first oil change of the new machine should be completed within 1000 hours of initial operation, and the oil change cycle should be determined according to the working conditions. Under normal working conditions, the oil change should be done every 6000 hours/12 months, and under continuous working conditions/dust and humidity conditions, it should be shortened to 3000-4000 hours/6 months; Thoroughly drain the old oil before changing the oil, rinse the inner wall of the box and the gear meshing surface with new oil of the same model to avoid iron filings and oil residue; Maintain the oil level at the centerline of the sight glass on a daily basis. If it is insufficient, add new oil of the same specification in a timely manner. Check the condition of the oil and replace it immediately if it is cloudy, emulsified, or contains metal debris. Regularly clean the breathable cap filter element to ensure smooth ventilation and prevent abnormal pressure inside the box from causing seal oil leakage and water vapor from entering.

2. Standardize installation and centering operations to eliminate meshing additional loads: During installation, ensure the coaxiality between the output shaft of the reducer and the shaft of the driven equipment, with a radial deviation of ≤ 0.1mm and an angular deviation of ≤ 0.5 °. Forced docking is strictly prohibited to avoid gear wear caused by axial displacement due to biased loads; Shaft mounted installation requires ensuring that the connecting flanges are tightly fitted, and the bolts are evenly tightened to the rated torque in diagonal order to prevent loosening and abnormal gear mesh clearance; After installation, manually rotate the input/output shaft of the gearbox to ensure flexible rotation without any jamming or abnormal friction sound. Then, run it under no-load for 30 minutes to check if the meshing status is normal before loading and running it again.

3. Strictly control the operating conditions to avoid gear overload: it is strictly prohibited for the reducer to operate beyond the rated speed and torque, and frequent emergency start stop and reverse impact should be avoided. When starting, follow the principle of "no-load start, gradual loading" to reduce the instantaneous impact load on the gear; If there is a risk of overload in the supporting equipment, install torque limiters and overload protectors. When the load exceeds 1.2 times the rated value, cut off the power in a timely manner to prevent gears from sticking or breaking due to overload; Reasonably set operating parameters according to working conditions, and regularly arrange shutdowns and rest for continuous working equipment to avoid long-term operation of gears under high temperature and full load conditions, and reduce tooth surface fatigue wear.