Shanghai Saiwei Reducer Co., Ltd
Transmission scheme
Protocol Validation
Confirmation of technical quality scheme, confirmation of delivery service scheme and confirmation of settlement price scheme
Confirmation of cooperation
Installation and commissioning
Precautions before 1.1 installation
Assembly and installation work must be carried out carefully by trained and qualified personnel;
The manufacturer is not responsible for any damage caused by incorrect assembly and installation;
In the planning stage, we should leave enough space for the reducer to prepare for future maintenance and repair work;
Be sure to prepare suitable lifting equipment before starting assembly and installation work;
If the reducer (motor) is equipped with a fan, there should be enough space to be able to suck in air;
The description on the nameplate of the actuator is consistent with the field power supply;
The transmission device should be intact (not damaged during transportation or storage);
Verify that the following requirements have been met:
For standard reducer: ambient temperature 0°C ~ 40°C
Free of oil, acid, harmful gas, steam, radioactive objects, etc;
For special type: the transmission device is configured according to the environmental conditions;
For worm gear reducer: not for reducer with self-locking function
Apply excessive reverse external moment of inertia to avoid damage to the reducer;
In order to ensure good lubrication, the installation position specified in the order must be observed;
Be sure to pay attention to the warning and safety signs of the reducer (motor).
1.2 Preparation before Installation
Thoroughly remove corrosion inhibitor, dirt or the like from the surfaces of the output shaft and flange with a commercially available solvent;
Note: Do not allow the solvent to soak into the sealing lip of the oil seal, otherwise the solvent may damage the oil seal;
If the reducer is stored for more than 1 year, the service life of the lubricant in the bearing will be shortened;
If mineral oil or synthetic oil (CLPHC) is filled and the amount of oil is in accordance with the requirements of the installation position, the reducer can be operated at any time in this case. However, check the oil level before starting;
In some cases, the synthetic oil (CLPPG) is filled, and the oil level is higher. The oil level should be corrected before starting.
Installation of 1.3 reducer
The reducer (motor) can only be installed on the flat, shock-absorbing and torsion-resistant support structure according to the specified installation position; the bottom foot of the box body and the mounting flange cannot be tightened at the same time during the installation process to avoid mutual rivalry;
When bolts or foundation blocks are used to fix the reducer (motor) on its concrete foundation, there should be suitable grooves to accommodate the reducer (motor);
When installing, please check whether the oil filling amount is consistent with the installation position. If the installation position changes, please adjust the oil amount accordingly;
Install the straight-through breather or open the breather to transport the rubber ring;
Do not hit or knock the shaft end;
The vertical installation of the motor shall be shielded to prevent foreign matter or liquid from invading (rain cover C);
Install the junction box with the cable inlet pointing downward.
1.3.1 Installation of solid shaft reducer (motor)
Install and fix input and output drive parts (such as coupling parts, etc.) on the shaft of the reducer;
If these parts need to be pre-heated before installation, refer to the dimensional drawings in the coupling documentation for the correct fit temperature;
The misalignment and neutrality of the shaft may be caused by assembly or actual operation (such as thermal expansion, shaft deflection, insufficient rigidity of the frame, etc.);
Please refer to the manual of the coupling of the corresponding brand for the permitted alignment error of the coupling;
Permitted error of misalignment
The centering should take place in two axial planes perpendicular to each other. You can use a straight edge (radial misalignment) and a feeler gauge (angular misalignment) for centering;
Unless otherwise specified, these parts may be preheated by induction heating, or may be preheated with a burner or in a furnace.
1.3.2 Installation of hollow shaft reducer (motor) with flat key
The shaft end of the solid shaft of the working machine shall be equipped with a flat key in accordance with DIN6885 Standard Part I A, and shall have a central hole in its end face in accordance with DIN Standard 322 DS (with thread);
Check whether the hollow shaft of the reducer and the solid shaft of the working machine are damaged by the shaft seat and the edge part; if necessary, repair and clean up with suitable tools;
The reducer is installed with nut and screw, and its reaction force is provided by the hollow shaft of the reducer;
1 Solid shaft of working machine 2 Hollow shaft of reducer 3 Flat key 4 Nut 5 Screw 6 Nut 7 End plate
1 Solid shaft of working machine 2 Hollow shaft of reducer 3 Flat key 4 Nut 5 Screw 6 Nut 7 End plate
1 Solid shaft of working machine 2 Hollow shaft of reducer 3 Flat key 4 Nut 5 Screw 6 Nut 7 End plate
In addition to the nuts and screws shown in FIGS. 1 and 2, other types of devices may be used, for example, a set of hydraulic lifting devices may be used.
1.3.3 Installation of hollow shaft reducer with expansion disc
The end face of the solid shaft of the working machine shall be provided with a central hole of type DS (with thread) according to DIN standard 322;
Install with integral bushing;
Install the reducer with nut and screw; the reaction force is provided by the hollow shaft of the reducer;
Install with loose bushing;
Push the loose bushing onto the solid shaft of the working machine, fix it firmly in place with a positioning device, and then pull it along the solid shaft of the working machine into the hollow shaft of the reducer (refer to Figure 1 and Figure 2);
The outer surface of the hollow shaft of the reducer can be added with grease at the position of the shrink disc seat;
Tighten all the fastening bolts one by one in sequence, and tighten all the bolts through several cycles;
Tighten the fastening bolts until the front sides of the inner and outer rings are aligned.
Use and maintenance
1.1 add lubricating oil
Unscrew the filler plug, add the correct type of lubricating oil to the position slightly above the oil dipstick or the center line of the oil mirror, and then install the plug;
The reducer (motor) has been refueled without refueling.
1.2 starting
The following items must be checked and recorded before starting:
(1) Oil level height
(2) Lubricating oil cooling or oil supply system pipeline sealing
(3) the effectiveness of the shaft seal
(4) Rotating parts are not in contact with other parts
1.3 operation
When the reducer (motor) is started for the first time, if possible, it should be allowed to run for several hours without load. If there is no abnormality, it can be gradually loaded and the load can be filled at an appropriate time;
In operation, the reducer must be monitored:
Oil temperature (in the process of continuous operation, the design temperature of the reducer is: the temperature of mineral oil used in continuous operation is 90 ℃. At higher temperature, synthetic oil must be used. The highest temperature of short-term work can reach 100 ℃);
Variations in operating noise;
Possible oil leakage at the box and shaft seal;
Correct oil level;
1.4 maintenance
Faults that occur during the warranty period and require repair must be carried out by the customer service department. For failures that occur after the warranty period and cannot be determined, we recommend that the customer contact our customer service department;
Inspection and maintenance cycle:
| Measures | Duration |
|---|---|
| Check the oil temperature | Daily |
| Check the abnormal noise of the reducer | Monthly |
| Check whether the reducer leaks oil | Monthly |
| Check oil level height | Before each start reducer |
| Check for moisture in oil | At least once a year after 400 working hours |
| First oil change | Working for 400 hours after starting |
| The subsequent oil change | Every 18 months or 5000 working hours |
| Cleaning the oil filter | Every 3 months |
| Clean the vent screw valve. | Every 3 months |
| Clean the fan, fan cover and gearbox body | According to requirements or at the same time with oil change |
| Check the cooling coil for scaling | Approximately every 2 years or at the same time as an oil change |
| Check lube oil water cooler | and oil change at the same time |
| Check the tightness of the fastening bolts | After the first oil change, every other oil change thereafter |
| For a comprehensive inspection of the reducer | Approximately every 2 years and at the same time as the oil change |
Possible failures:
| Fault | Reason | Measures |
|---|---|---|
| Large noise at the fasteners of the reducer | The fastener is loose | Tighten the bolts/nuts to the specified torque, and replace the damaged bolts/nuts. |
| Noise change of reducer | The teeth of the gear are damaged. | Contact customer service department · Check all gears and replace damaged parts |
| Excessive bearing clearance | Contact with customer service department · Adjust the clearance of bearing | |
| Bearing damage | Contact the customer service department to replace the damaged bearing | |
| Working temperature too high | The oil level in the tank is too high | Check oil level and adjust if necessary |
| The oil is too old. | Contact the customer service department to check the time of the last oil change and replace it if necessary | |
| The oil is heavily polluted | Contact Customer Service Department · Oil Change | |
| On reducers equipped with lube oil cooling system: the coolant flow rate is too low or too high | Fully adjust the valves of the inlet and outlet pipes and check the free flow of the water cooling device | |
| Coolant temperature too high | Check the temperature and adjust as necessary. | |
| The oil flow through the water cooling device is too low, the reason is: the oil filter is severely blocked | Cleaning the oil filter | |
| Mechanical failure of oil pump | Contact with customer service department, check whether the function of the oil pump is normal, repair or replace the oil pump | |
| On speed reducers equipped with fans: The air inlet of the fan cover and/or the box body are heavily contaminated | Clean the fan cover and box | |
| Reducer equipped with cooling spiral tube: scaling inside the cooling spiral tube | Contact the customer service department to clean or replace the spiral pipe. | |
| The temperature at the bearing is too high | The oil level inside the reducer box is too high or too low | Check the height of the oil level at room temperature and refuel as necessary. |
| The oil is too old. | Contact the customer service department to check the time of the last oil change | |
| Mechanical failure of oil pump | Contact the customer service department to check whether the oil pump is working normally, repair or replace the oil pump | |
| Bearing damage | Contact the customer service department. Check the data obtained by the operator during the vibration measurement. Check and replace the bearing if necessary. | |
| Amplitude rise at bearing | Bearing damage | • Check and replace bearings as required |
| Gear damage | Contact customer service department · Check and replace gears as needed | |
| If the temperature of the non-return device is too high, the non-return function fails. | Damage of non-return device | Contact the customer service department to check and replace the stop device as required. |
| Oil leakage of reducer | Poor sealing of case cover or connection | Check the seal and the connection, if necessary, replace it with a new one and seal the connection. |
| Failure of radial shaft seal | Contact Room Service · New radial seal ring | |
| There is water in the oil | There are sundries in the oil | Use a test tube to check the state of the oil for the presence of moisture. Laboratory analysis of the oil. |
| Failure of lube oil cooler or cooling coil | Contact the customer service department to find and repair the leak and replace the cooler or spiral pipe. | |
| Reducer by the machine between the ventilation over the cold air and produce condensation | Protect the reducer with suitable thermal insulation materials, close the air outlet or change its direction structurally | |
| Pressure monitoring device alarm (speed reducer equipped with pressure lubrication, lubricating oil water cooling device and air cooling device) | Oil pressure <0.5bars | Check the oil level at room temperature, add oil as required, check the oil filter, replace it as required, contact the customer service department, check whether the function of the oil pump is normal, repair or replace the oil pump |
| Alarm from indicator of double switching filter | Double switching filter clogging | Switch the filter according to the instructions, remove the blocked filter element and clean it |
| Fault of oil supply system | See operating instructions for oil supply system | |
| Motor does not start | Power line interruption | Check wiring and correct as required |
| Fuse blowing | Replace fuse | |
| Motor protection device has been operated | Check motor protection for correct setting and discharge faults if required | |
| Motor contactor does not operate, fault in control system | Check control of motor contactor and troubleshoot as required | |
| Motor does not start or start difficult | Motors shall be delta connection, but star connection | Correct wiring mode |
| The voltage or frequency deviates significantly from the rated value at least when starting | Try to improve the power supply situation; check the cross-section of the power cord | |
| Wrong direction of rotation | Motor wiring error | Swap two phase wires |
| Motor rumbling and high current consumption | Winding damage | The motor must be sent to a professional repair shop for repair. |
| rotor touch winding | ||
| The fuse is blown or the motor protection device acts immediately. | Short circuit of conductor | Eliminate short circuit |
| Short circuit in motor | Send to professional repair shop for discharge failure | |
| Wrong wire connection | Correct connection mode | |
| Motor ground short circuit | Send to professional repair shop for discharge failure |
Protocol Validation
Confirmation of technical quality scheme, confirmation of delivery service scheme and confirmation of settlement price scheme
Confirmation of cooperation
Installation and commissioning
Precautions before 1.1 installation
Assembly and installation work must be carried out carefully by trained and qualified personnel;
The manufacturer is not responsible for any damage caused by incorrect assembly and installation;
In the planning stage, we should leave enough space for the reducer to prepare for future maintenance and repair work;
Be sure to prepare suitable lifting equipment before starting assembly and installation work;
If the reducer (motor) is equipped with a fan, there should be enough space to be able to suck in air;
The description on the nameplate of the actuator is consistent with the field power supply;
The transmission device should be intact (not damaged during transportation or storage);
Verify that the following requirements have been met:
For standard reducer: ambient temperature 0°C ~ 40°C
Free of oil, acid, harmful gas, steam, radioactive objects, etc;
For special type: the transmission device is configured according to the environmental conditions;
For worm gear reducer: not for reducer with self-locking function
Apply excessive reverse external moment of inertia to avoid damage to the reducer;
In order to ensure good lubrication, the installation position specified in the order must be observed;
Be sure to pay attention to the warning and safety signs of the reducer (motor).
1.2 Preparation before Installation
Thoroughly remove corrosion inhibitor, dirt or the like from the surfaces of the output shaft and flange with a commercially available solvent;
Note: Do not allow the solvent to soak into the sealing lip of the oil seal, otherwise the solvent may damage the oil seal;
If the reducer is stored for more than 1 year, the service life of the lubricant in the bearing will be shortened;
If mineral oil or synthetic oil (CLPHC) is filled and the amount of oil is in accordance with the requirements of the installation position, the reducer can be operated at any time in this case. However, check the oil level before starting;
In some cases, the synthetic oil (CLPPG) is filled, and the oil level is higher. The oil level should be corrected before starting.
Installation of 1.3 reducer
The reducer (motor) can only be installed on the flat, shock-absorbing and torsion-resistant support structure according to the specified installation position; the bottom foot of the box body and the mounting flange cannot be tightened at the same time during the installation process to avoid mutual rivalry;
When bolts or foundation blocks are used to fix the reducer (motor) on its concrete foundation, there should be suitable grooves to accommodate the reducer (motor);
When installing, please check whether the oil filling amount is consistent with the installation position. If the installation position changes, please adjust the oil amount accordingly;
Install the straight-through breather or open the breather to transport the rubber ring;
Do not hit or knock the shaft end;
The vertical installation of the motor shall be shielded to prevent foreign matter or liquid from invading (rain cover C);
Install the junction box with the cable inlet pointing downward.
1.3.1 Installation of solid shaft reducer (motor)
Install and fix input and output drive parts (such as coupling parts, etc.) on the shaft of the reducer;
If these parts need to be pre-heated before installation, refer to the dimensional drawings in the coupling documentation for the correct fit temperature;
The misalignment and neutrality of the shaft may be caused by assembly or actual operation (such as thermal expansion, shaft deflection, insufficient rigidity of the frame, etc.);
Please refer to the manual of the coupling of the corresponding brand for the permitted alignment error of the coupling;
Permitted error of misalignment
The centering should take place in two axial planes perpendicular to each other. You can use a straight edge (radial misalignment) and a feeler gauge (angular misalignment) for centering;
Unless otherwise specified, these parts may be preheated by induction heating, or may be preheated with a burner or in a furnace.
1.3.2 Installation of hollow shaft reducer (motor) with flat key
The shaft end of the solid shaft of the working machine shall be equipped with a flat key in accordance with DIN6885 Standard Part I A, and shall have a central hole in its end face in accordance with DIN Standard 322 DS (with thread);
Check whether the hollow shaft of the reducer and the solid shaft of the working machine are damaged by the shaft seat and the edge part; if necessary, repair and clean up with suitable tools;
The reducer is installed with nut and screw, and its reaction force is provided by the hollow shaft of the reducer;
1 Solid shaft of working machine 2 Hollow shaft of reducer 3 Flat key 4 Nut 5 Screw 6 Nut 7 End plate
1 Solid shaft of working machine 2 Hollow shaft of reducer 3 Flat key 4 Nut 5 Screw 6 Nut 7 End plate
1 Solid shaft of working machine 2 Hollow shaft of reducer 3 Flat key 4 Nut 5 Screw 6 Nut 7 End plate
In addition to the nuts and screws shown in FIGS. 1 and 2, other types of devices may be used, for example, a set of hydraulic lifting devices may be used.
1.3.3 Installation of hollow shaft reducer with expansion disc
The end face of the solid shaft of the working machine shall be provided with a central hole of type DS (with thread) according to DIN standard 322;
Install with integral bushing;
Install the reducer with nut and screw; the reaction force is provided by the hollow shaft of the reducer;
Install with loose bushing;
Push the loose bushing onto the solid shaft of the working machine, fix it firmly in place with a positioning device, and then pull it along the solid shaft of the working machine into the hollow shaft of the reducer (refer to Figure 1 and Figure 2);
The outer surface of the hollow shaft of the reducer can be added with grease at the position of the shrink disc seat;
Tighten all the fastening bolts one by one in sequence, and tighten all the bolts through several cycles;
Tighten the fastening bolts until the front sides of the inner and outer rings are aligned.
Use and maintenance
1.1 add lubricating oil
Unscrew the filler plug, add the correct type of lubricating oil to the position slightly above the oil dipstick or the center line of the oil mirror, and then install the plug;
The reducer (motor) has been refueled without refueling.
1.2 starting
The following items must be checked and recorded before starting:
(1) Oil level height
(2) Lubricating oil cooling or oil supply system pipeline sealing
(3) the effectiveness of the shaft seal
(4) Rotating parts are not in contact with other parts
1.3 operation
When the reducer (motor) is started for the first time, if possible, it should be allowed to run for several hours without load. If there is no abnormality, it can be gradually loaded and the load can be filled at an appropriate time;
In operation, the reducer must be monitored:
Oil temperature (in the process of continuous operation, the design temperature of the reducer is: the temperature of mineral oil used in continuous operation is 90 ℃. At higher temperature, synthetic oil must be used. The highest temperature of short-term work can reach 100 ℃);
Variations in operating noise;
Possible oil leakage at the box and shaft seal;
Correct oil level;
1.4 maintenance
Faults that occur during the warranty period and require repair must be carried out by the customer service department. For failures that occur after the warranty period and cannot be determined, we recommend that the customer contact our customer service department;
Inspection and maintenance cycle:
| Measures | Duration |
|---|---|
| Check the oil temperature | Daily |
| Check the abnormal noise of the reducer | Monthly |
| Check whether the reducer leaks oil | Monthly |
| Check oil level height | Before each start reducer |
| Check for moisture in oil | At least once a year after 400 working hours |
| First oil change | Working for 400 hours after starting |
| The subsequent oil change | Every 18 months or 5000 working hours |
| Cleaning the oil filter | Every 3 months |
| Clean the vent screw valve. | Every 3 months |
| Clean the fan, fan cover and gearbox body | According to requirements or at the same time with oil change |
| Check the cooling coil for scaling | Approximately every 2 years or at the same time as an oil change |
| Check lube oil water cooler | and oil change at the same time |
| Check the tightness of the fastening bolts | After the first oil change, every other oil change thereafter |
| For a comprehensive inspection of the reducer | Approximately every 2 years and at the same time as the oil change |
Possible failures:
| Fault | Reason | Measures |
|---|---|---|
| Large noise at the fasteners of the reducer | The fastener is loose | Tighten the bolts/nuts to the specified torque, and replace the damaged bolts/nuts. |
| Noise change of reducer | The teeth of the gear are damaged. | Contact customer service department · Check all gears and replace damaged parts |
| Excessive bearing clearance | Contact with customer service department · Adjust the clearance of bearing | |
| Bearing damage | Contact the customer service department to replace the damaged bearing | |
| Working temperature too high | The oil level in the tank is too high | Check oil level and adjust if necessary |
| The oil is too old. | Contact the customer service department to check the time of the last oil change and replace it if necessary | |
| The oil is heavily polluted | Contact Customer Service Department · Oil Change | |
| On reducers equipped with lube oil cooling system: the coolant flow rate is too low or too high | Fully adjust the valves of the inlet and outlet pipes and check the free flow of the water cooling device | |
| Coolant temperature too high | Check the temperature and adjust as necessary. | |
| The oil flow through the water cooling device is too low, the reason is: the oil filter is severely blocked | Cleaning the oil filter | |
| Mechanical failure of oil pump | Contact with customer service department, check whether the function of the oil pump is normal, repair or replace the oil pump | |
| On speed reducers equipped with fans: The air inlet of the fan cover and/or the box body are heavily contaminated | Clean the fan cover and box | |
| Reducer equipped with cooling spiral tube: scaling inside the cooling spiral tube | Contact the customer service department to clean or replace the spiral pipe. | |
| The temperature at the bearing is too high | The oil level inside the reducer box is too high or too low | Check the height of the oil level at room temperature and refuel as necessary. |
| The oil is too old. | Contact the customer service department to check the time of the last oil change | |
| Mechanical failure of oil pump | Contact the customer service department to check whether the oil pump is working normally, repair or replace the oil pump | |
| Bearing damage | Contact the customer service department. Check the data obtained by the operator during the vibration measurement. Check and replace the bearing if necessary. | |
| Amplitude rise at bearing | Bearing damage | • Check and replace bearings as required |
| Gear damage | Contact customer service department · Check and replace gears as needed | |
| If the temperature of the non-return device is too high, the non-return function fails. | Damage of non-return device | Contact the customer service department to check and replace the stop device as required. |
| Oil leakage of reducer | Poor sealing of case cover or connection | Check the seal and the connection, if necessary, replace it with a new one and seal the connection. |
| Failure of radial shaft seal | Contact Room Service · New radial seal ring | |
| There is water in the oil | There are sundries in the oil | Use a test tube to check the state of the oil for the presence of moisture. Laboratory analysis of the oil. |
| Failure of lube oil cooler or cooling coil | Contact the customer service department to find and repair the leak and replace the cooler or spiral pipe. | |
| Reducer by the machine between the ventilation over the cold air and produce condensation | Protect the reducer with suitable thermal insulation materials, close the air outlet or change its direction structurally | |
| Pressure monitoring device alarm (speed reducer equipped with pressure lubrication, lubricating oil water cooling device and air cooling device) | Oil pressure <0.5bars | Check the oil level at room temperature, add oil as required, check the oil filter, replace it as required, contact the customer service department, check whether the function of the oil pump is normal, repair or replace the oil pump |
| Alarm from indicator of double switching filter | Double switching filter clogging | Switch the filter according to the instructions, remove the blocked filter element and clean it |
| Fault of oil supply system | See operating instructions for oil supply system | |
| Motor does not start | Power line interruption | Check wiring and correct as required |
| Fuse blowing | Replace fuse | |
| Motor protection device has been operated | Check motor protection for correct setting and discharge faults if required | |
| Motor contactor does not operate, fault in control system | Check control of motor contactor and troubleshoot as required | |
| Motor does not start or start difficult | Motors shall be delta connection, but star connection | Correct wiring mode |
| The voltage or frequency deviates significantly from the rated value at least when starting | Try to improve the power supply situation; check the cross-section of the power cord | |
| Wrong direction of rotation | Motor wiring error | Swap two phase wires |
| Motor rumbling and high current consumption | Winding damage | The motor must be sent to a professional repair shop for repair. |
| rotor touch winding | ||
| The fuse is blown or the motor protection device acts immediately. | Short circuit of conductor | Eliminate short circuit |
| Short circuit in motor | Send to professional repair shop for discharge failure | |
| Wrong wire connection | Correct connection mode | |
| Motor ground short circuit | Send to professional repair shop for discharge failure |
Address: Floor 3, Building 2, 511 Xiao Wan Road, Fengxian District, Shanghai
Sales Phone:86-21-33501793
Mobile:86-17717387585(Wang Yongfei) 86-15921882564(xu wenyo)
E-mail:4675336@qq.com
QQ：4675336