What are the common errors during the installation of ZQ500-40.17-3CA reducer

As a ZQ series soft tooth surface reducer, the installation process of ZQ500-40.17-3CA needs to comply with the general specifications for the base, shaft system, sealing, and other aspects of the series. Common installation errors are mainly concentrated in key links such as foundation installation, shaft alignment, component assembly, and lubrication test run. The specific steps are as follows:

Basic and fixed related errors

The installation base does not meet the standard: Some installations may ignore the flatness and strength requirements of the base, and directly install the reducer on an unfinished foundation. If the flatness error of the base exceeds 0.05mm/m, or if the concrete foundation has not completed secondary grouting and curing to C30 strength, the deformation and vibration transmission of the base during operation will cause uneven stress on the reducer housing. In addition, residual oil and dust on the surface of the base can also cause the installation surface to not fit tightly, further exacerbating operational vibration.

Improper bolt tightening operation: When tightening anchor bolts or flange bolts, the principle of symmetrical and gradual tightening is not followed, but the tightening sequence is arbitrary, which can easily cause distortion of the box or flange under stress; And the tightening force of the bolts cannot be controlled accurately. Over tightening will cause deformation of the box, damage the installation benchmark of the internal shaft system, while over loosening will cause displacement during equipment operation, leading to vibration and component wear. Some installations may also miss spring washers, which cannot prevent bolt loosening during operation.

Axis alignment and connection error

Excessive coaxiality deviation of the shaft system: This is a common error during installation. Many operations rely solely on visual inspection or rough alignment of the input and output shafts of the motor and reducer using a steel tape measure, without precise calibration using a dial gauge or laser alignment instrument, resulting in coaxiality deviation exceeding the allowable range of 0.05mm. This error can cause gear meshing to be biased and the shaft to bear abnormal force, leading to overheating, abnormal noise, and in severe cases, it can also cause the output shaft to break.

Improper assembly of couplings and keyways: firstly, selecting the wrong type of coupling, misusing rigid couplings without reserving deviation compensation space, and amplifying the impact of misalignment of the shaft system; Secondly, when installing the coupling, hard tapping with a hammer can cause deformation of the shaft end and damage to the bearings; The third issue is improper fit between the flat key and the keyway. Tightness can cause assembly difficulties and damage to the keyway, while looseness can result in slipping and abnormal noise during transmission, affecting the stability of power transmission.

Sealing and box assembly errors

Improper installation of seals: When installing the shaft seal, special fixtures were not used, but instead tilted and pressed into the sealing groove, or lubricant was not applied to the oil seal lip, which can easily cause damage to the oil seal lip and rapid wear and oil leakage after operation; When assembling the joint surface of the box, the sealant is not evenly applied, and the thickness of the adhesive layer deviates from the standard of 0.1mm. Being too thick or too thin can cause poor sealing. After tightening the bolts, there may also be excessive overflow of the adhesive layer or sealing failure.

Negligence in box closing operation: The flatness of the joint surface of the box was not checked before closing. If there are scratches or rust on the joint surface that have not been treated, it will result in gaps after closing the box; Partial installation may also omit the positioning pin of the box and directly tighten the bolts, causing misalignment of the upper and lower parts of the box and damaging the meshing accuracy of the internal gears.