How to maintain CJY250-5.2-22KW shaft mounted reducer
CJY250-5.2-22KW Shaft mounted Reducer Maintenance Guide1. Daily inspection and operation monitoring
Lubrication status: Check the oil level daily (at the centerline of the oil gauge window) to ensure that ISO VG 220-320 extreme pressure gear oil is used and the oil temperature is ≤ 85 ℃.
Vibration and noise: The vibration value during operation should be ≤ 4.5mm/s (RMS value), and abnormal noise may indicate gear wear or bearing failure.
Temperature monitoring: If the surface temperature of the shell is ≤ 80 ℃ and the oil temperature exceeds 90 ℃, the machine should be stopped to investigate heat dissipation or load issues.
2. Maintenance of lubrication system
Oil change cycle:
First run: Replace the lubricating oil after 400 hours (remove metal debris during the running in period).
Normal operating conditions: Replace every 2000-3000 hours or 6 months, and reduce harsh environments (high temperature, dust) to 1000-1500 hours.
Oil change steps:
After shutdown, wait for the oil temperature to drop below 40 ℃, drain the old oil and flush the oil circuit (flush with new oil for 1-2 minutes).
Add new oil to the center line of the oil level window, let it stand for 10 minutes, and then recheck the oil level.
3. Mechanical component inspection
Gears and bearings:
Disassemble and inspect the gear meshing surface every 3000-5000 hours. If the tooth thickness wear exceeds 10%, it needs to be replaced.
Replace the bearing when the clearance is greater than 0.05mm or the temperature is abnormal (temperature rise at the end cover is greater than 15 ℃).
Seal: Replace the shaft end oil seal every 12 months and check whether the O-ring is aging.
4. Installation and fastening
Requirement for alignment: The coaxiality error between the motor and the reducer should be ≤ 0.05mm, and the pre tightening force of the coupling should be uniform.
Bolt tightening: The anchor bolts should be tightened in diagonal order (such as M8 bolts with a torque of 20-25N · m), and re tightened twice within 72 hours.
5. Special measures for high-temperature environments
Heat dissipation optimization: Clean the dust accumulation on the heat sink and install a forced air cooling or circulating oil cooling system if necessary.
Oil upgrade: Switching to synthetic heavy-duty gear oil (such as ISO VG 320) for high-temperature conditions, shortening the oil change cycle to 2000 hours.
6. Emergency handling of faults
Oil leakage: Immediately stop the machine and replace the sealing gasket or oil seal to avoid excessive oil level exacerbating the leakage.
Broken teeth/stuck teeth: Stop the machine to check the gear meshing status, replace damaged parts, and adjust the axial clearance.
