Z5011检验报告书

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INSPECTION DATABOOK 检验数据报告

IDB NO. IDB 编号

REV. 版次

ITEM/MATERIAL 设备/材料名称 FU270 石灰石粉刮板机

ITEM NO. 设备位号 Z5011 VENDOR JOB NUMBER

工厂令号 T2010-011

VENDOR 厂商湖北宜都运机机电设备有限责任公司

VENDOR STAMP 厂商盖章

VENDOR Q.C.SIGNATURE 厂商质量控制人员签字

PROJECT 项目名称：NINH BINH FINE COAL BASED UREA PLANT

越南（煤头）化肥项目（50061）

CLIENT 项目业主：VIETNAM NATIONAL CHEMICAL CORPORATION

越南国家化学总公司(VINACHEM)

M.R. REV.

P.O. REV: SR CODE : B10004

CHECKED ON / / 检查

BY INSPECTOR 检验人员

I.A.政府授权

THE PRESENT BOOK IS COMPOSED BY 文件组成 SHEETS

NUMBERED 编号 FROM TO

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INSPECTION DATABOOK CONTENTS检验数据报告书目录

编号

NO.文件名称 Documents name

页数

Page

备注

Remarks

00Inspection Data Report

检验数据报告

01Contents

目录 1

02Manufacturer License

制造许可证 2~3

03Quality Certificate

ISO9001：2000质量体系认证 4

04Products Certificate

产品合格证 5

05Nameplate copying

铭牌复印件 6

06Chain bar, scraper Material certificates

链杆合格证及链杆,销轴,刮板材质证明书 7~10

07Chain Flaw Detection Report

链杆磁粉探伤检验报告单 11

08Head and tail shaft part material certificates

头尾轴类零件材质证明书 12~14

09MACHINING PROCESS inspection report

机加工序过程检验记录 15

10Iron material certificate

铸件（ZG310-570）材质证明书 16

11Chain wheel heat treatment test report

链轮类热处理报告

17

12Casing material certificate

壳体材质证明书 18~19

13Wear resist rod material certificate

耐磨条材质证明书 20

14Welding rod ,stick quality certificates

焊条,焊丝质量证明书 21~22

15

Equipment painting instructions and inspection

report

设备涂漆说明及油漆检验报告

23~26

16Final inspection report

最终产品检验报告 27~28

17Parts list

备件清单 29

18General assembly drawing

装配图总图 30

19En masse conveyor operation instructions

埋机使用说明书 31~57

20Reducer operation and certificate

减速器使用说明书及合格证 58~75

21Motor operation and certificate

电机使用说明书及全合格证 76~90

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湖北宜都运机机电设备有限责任公司

Hubei Yidu Yunji Mec&Elec Equipment Co., Ltd.链杆磁粉探伤检验报告单

Chain flaw detection inspection report

序号

SERIAL NUMBER

日期

DATE

型号

TYPE

材质

MATERIAL

数量

QUANTITY

检验结果工时

WORKING-HOUR

备注

MARK合格

QUALIFICATION

不合格

DISQUALIFICATION

1 2010-6-20 3002 20CrMnTi 140 140 0

2

3

4

5

6

7

8

9

合计

签字: 周静日期: 2010.6.25

SIGNED BY DATE

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Hubei Yidu Yunji Mec&Elec Equi pment Co., Ltd.

机加工序过程检验记录表

Machining process inspection record table

生产号: T2010-011 产品型号: FU270 设备位号 :Z5011 单位：mm 编号：YDYJ-ZJ-15-011

Production No.： Product model： Item No: Unit Number轴类 shaft:

名称 Name

图号

Drawing

No.

轴长

Length

of shaft

中心距 Center distance

轴承位 Bearing position 轮位 Ø

Wheel position

键槽 Keyway

链轮位Chain

wheel

position

Ø

键槽 Keyway

判定结果 Judge result 数量(件)

Quantity交检人

Inspector

日期

Date

备注

RemarksB D

前

Front Ø

后

Back Ø

宽

Width

深

Depth

宽

Width

深

Depth

合格

Pass

不合格

Not Pass

头轴

(B024/1500)808 601 230.5 80+0.02 80+0.02 95-0.01 25 9 70-0.01 20 7.5 √ 1 胡汉国 10.8.4

尾轴

(B025/1500)685 599 224.5 65+0.02 65+0.02 80+0 22 9 √ 1 马振喜 10.8.3

轮类 Wheel ：

名称

Name

图号

Drawing

No.

轮毂位 Ø

Wheel hub

position

毂长

Length

of hub

齿数

Number

of teeth

节距

Pitch

外径

outside

diameter

齿宽

Width of

teeth

底径

Bottom

diameter

键槽 keyway

钻定位孔

Location gauge

hole

判定结果

Judge result

数量（件）

Quantity

交检人

Inspector

日期

Date

备注

Remarks宽

Width

深

Depth

合格

Pass

不合格

Not Pass

头轮

(B020/1002) 95+0.02

140 7 142 355 54 25 5.4 √ 1 周心足 10.8.12

尾轮

(B021/1002)80+0.03 120 262 60 22 5.4 √ 1 周心足 10.8.12

大链轮

(ML2.2-32)70+0.03 110 32 38.1 408 23.4 366 20 4.9 √ 1 周心足 10.8.12

小链轮

XL2...5X-1780+0.03 109 17 38.1 224 23.4 185 22 5.4 1 周心足 10.8.12

检验员 Checker: Date：2010 年 8 月 12 日

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Hubei Yidu Yunji Mec&Elec Equipment Co., Ltd.热处理检验报告单

Heat treatment test report

生产号: T2010-011 产品型号: FU270 设备位号 :Z5011 检测工具：手持式硬度计编号：YDYJ-ZJ-16-011

Production No.： Product model： Item No: Numbe

序号 NO

名称/图号 Name/ Drawing No.

数量（件） Quantity

材质 MATERIAL

处理部位 PART OF DISPOSAL

热处理方式 Heat treatment ways

淬火介质MEDIUM

硬度 HARDNESS NUMBER

1 头轮齿片 B020/5001

SPROCKET1 42CrMo

齿工作面

WORKING FACE

双液淬火

DOUBLE REFINING

水+空气

WATER+AIRHRC54

2 尾轮 B021/1002

TAILER WHEEL1 ZG310-570

齿工作面

WORKING FACE

双液淬火

DOUBLE REFINING

水+空气

WATER+AIRHRC54.2

3 大链轮 ML2.2-32

BIG CHAIN WHEEL1 ZG310-570

齿工作面

WORKING FACE

双液淬火

DOUBLE REFINING

水+空气

WATER+AIRHRC46

4 小链轮 XL2.5X-17

SMALL CHAIN WHEEL1 ZG310-570

齿工作面

WORKING FACE

双液淬火

DOUBLE REFINING

水+空气

WATER+AIRHRC45

签字: 周静日期: 2010 年 8 月 13 日

SIGNED BY DATE

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Hubei Yidu Yunji Mec&Elec Equipment Co., Ltd.

油漆说明

Heat treatment test report

生产号: T2010-011 产品型号:FU270 设备位号 :Z5011 编号：YDYJ-ZJ-17-011

Production No.： Product model： Item No: NO

序号

No.

设备名称

Item Description

操作温度

Open.

Temp.℃

喷砂处理

Surface Treatment

底漆

Primer

中间漆

Intermediate

面漆

Finish

油漆系统

Total DFT

μm

ρ No DFT

μm ρ No

DFT

μm ρ No

DFT

μm DFT

μm

1 设备主体室温 Sa2 1/2 P-1 40 P-5 50 P-4 50 140

2 设备附件室温 Sa2 1/2 P-1 40 P-5 80 P-4 50 170

注:1.油漆产品编号（ρ No）

a.P-1 环氧富锌底漆

b.P-2 有机硅高温底漆

c.P-3 高温面漆

e.P-4 聚氨脂面漆

f.P-5 无机富锌底漆

2.设备及钢结构外表面涂色及标志色规定

a. 设备及钢结构外表面:灰色 RaL 7045

b 标识颜色 RaL3020

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湖北宜都运机机电设备有限责任公司 Hubei Yidu Yunji Mec&Elec Equipment Co., Ltd.

埋刮机最终产品检验报告

Final inspection report for en masse conveyor

编号 Document number ：YDYJ-ZJ-10-10-011 规格型号:FU270Size

产品编号: T2010-011#

Product No :

设备位号 Z5011

LtemNo:

序号

No

检测项目

Examination Items

技术要求

Standard Stiulation

实测结果 Actual Examination

Resut

检验结论

Conclusion

1

头部

Head

section

头轮齿对中

Centering of sprocket

tooth

2mm 2mm■合格 Pass

□不合格 Not Pass

2

头轮与脱链板间隙 Clearance

between sprocket and its

stripper ≤3mm3mm

■合格 Pass


3头轮旋转 Rotation of

the head wheel

手扳即动

can turn by hand

手扳即动

can turn by hand

■合格 Pass


4

头轴左右装

Assembly type of the

head shaft

左装

Left-mounted

左装

Left-mounted

■合格 Pass


5

尾部

Tailer

section

尾轮对中 Centering

of sprocket toot2mm 2mm

■合格 Pass


6尾部张紧调装置

Tension unit150 150

■合格 Pass


7尾轮旋转 Rotation of

the tail wheel

手扳即动

can turn by hand

手扳即动

can turn by hand

■合格 Pass


8

转速传感器 Speed

sensor 配置方向

mounted direction

右装

Right-mounted

右装

Right-mounted

■合格 Pass


9

中间段

Intermedatesection

壳体长度

Length of casing

L=2.0m

L=1.45m ±2mm符合要求

Conform

■合格 Pass


10表面平度 Flatness of

casing surface±2mm

符合要求

Conform

■合格 Pass


11两端法兰平面度

Flatness of end

flangesof casing

±3mm 符合要求

Conform

■合格 Pass


12 刮板链条

Chain

scraper

刮板型号 Size of flight

节距=142mm刮板厚 12mm

符合要求 Conform

■合格 Pass□不合格 Not Pass

13材质

Material

链杆,销轴材质:20CrMnTi

刮板材质:16Mn

符合要求

Conform

■合格 Pass


14刮板与链杆的焊接

Weld between theflights and link

应满足设计要求

It should meet the designrequirement

符合要求

Conform

■合格 Pass


15电机

motor

型号及功率

Type & Power

Y100L2-4 N=3KW

符合要求

Conform

■合格 Pass


16通电空运转

Run without a load运行正常

符合要求

Conform

■合格 Pass


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湖北宜都运机机电设备有限责任公司 Hubei Yidu Yunji Mec&Elec Equipment Co., Ltd.

埋刮机最终产品检验报告

Final inspection report for en masse conveyor

编号 Document number ：YDYJ-ZJ-10-10-011 规格型号:FU270Size

产品编号: T2010-011#

Product No :

设备位号 Z5011

Ltem No:

序号

No

检测项目

Examination Items

技术要求

Standard Stiulation

实测结果 Actual Examination

Resut

检验结论

Conclusion

17

减速器

Reducer

型号及功率

Type & Ratio

XWD3-7-1/87

I=87

符合要求

Conform

■ 合格 Pass

□ 不合格 Not Pass

18通电空运转

Run without a load运行正常

符合要求

Conform

■合格 Pass


19铭牌安装位置及拓印图

Position and Rubbings of Nameplate

符合图样及标准

Conformig to Drawing

and Standard

符合要求

Conform

■ 合格 Pass


20标志,油漆和包装

Stamping ,painting and packing

符合图样及标准

Conformig to Drawing

and Standard

符合要求

Conform

■ 合格 Pass


结论（Conclusion）：

合格 Pass

部件检验员：

Examiner

成品检验员

ExaminerDate：2010 年 8 月 24 日

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湖北宜都运机机电设备

有限责任公司

HUBEI YIDU YUNJI MEC&

ELEC EQUIPMENT CO.,

LTD.

NINH BINH FINE COAL BASED UREA PLANT

PROJECT POWER STATION UNIT

合同号 50061-SCD-003

Contract No.:

越南（煤头）化肥项目热电站单元订单号 09-A-4-0002-21

P.O. No. :

Z5011

埋刮板输送机安装所需的备件列表

Parts list

页数:

Page:1 of 1

序号

No.

设备名称

Device Name

备件名称

Description

规格

Specifications

单位

Unit

数量

Quantity

设备位号

Equipment No.

备注

Remark

1FU270 石灰石粉刮

板机

FU270 type

En-masse conveyor

刮板链条

Chain Scraper

Chain pitch ：t=142mm

节距：t=142mm

节

Pitch5

Z5011

2

刮板链条销轴

Connecting pin

for chain

scraper

套

set5

3

4

5

6

编制/日期

Compile /date

吕平

2010.6.10

校核/日期

Check/date

向绪杰

2010.6.10

审核/日期

Verify/date

辛祖善

2010.6.10

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水平型埋刮板输送机

安装.操作.维护

说明书


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尊敬的用户：

欢迎您选用本公司生产的埋刮板输送机。

埋刮板输送机虽然属于低速运行机器，但人体接触到其中的旋转部

件或直线运行部件后，仍有可能导致伤亡事故！

电控装置及电机采用当地供电标准。所有电器设备的外壳应有良好

的接地。所有电器设备中带电部位人体均不得直接接触，否则有触电的

危险！

所有输送易燃，易爆物料的输送机附近严禁烟火。这类输送机上的

防爆口应定期检查，若有异常应及时修复，以减少事故隐患！

本设备的运行好坏和使用寿命的长短，不仅取决于合理的设计、

制造，而且还取决于正确的安装和操作。请施工（建设）单位和用户在

安装和使用前认真阅读本说明书，以避免不必要的损失。若有什么要求

和困难，请及时与本公司联系。

联系地址：湖北省宜都市莲花堰鸦来线北侧

邮政编码：443300

电话：0717-4843222 4843333

传真：0717-4843444

电子邮件：[email protected]

网址：www.ydyj.net


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目录

一、水平型埋刮板输送机安装使用说明图 ...................................... 34

二、安装 ............................................................................................. 35

三、调试 ........................................................................................... 39

四、操作和维修 ........................................................................... 40

五、故障处理 ....................................................................................... 41

附表 I 轴承一览表 ………………………………………………4附 2 主要易损件明细表……………………………………………..43

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一、水平型埋刮板输送机安装使用说明图

图 1

出轴在左边为左装,否则为右装,头部

侧板上标有机器运行方向,刮板链条的

运行方向必须与此相同.

过渡段一端与中间段联接，

另一端与头部联接.

与基础牢固联接驱动装置驱动装置必须与

加料口一般现场焊接,焊后应

中间段

尾部左右各有一丝杆,用于

张紧程度,若刮板链请调节某一

(跑偏调节见后详细说明)

础焊接,上部用压块压住壳体.

尾部及中间支架的下部与基

接在一起,下部与基础焊接,

支架头部支架上部与头部壳体焊

板链条的条跑偏,

纠正跑偏.以

割去加料口内部盖板.

边的丝杆,

头部头部有左装,右装之分,从尾部看头部,

调节刮

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技术参数表

主机参数

机器型号 FU270

物料

名称石灰石粉

机槽宽度(mm) 270 容重((t/m3) 1.2

名义承载深度(mm) 150 粒度(mm)

输送量(t/h) 25 温度(℃)

输送距离(mm) 7788 含水率(%)

提升高度(mm) 0

驱动装置

电机型号 Y10024

头轮转速（r/min） 8.7 电机功率 3KW

倾斜角度(°) 0 减速器型号 XWD3-7-1/87

刮板链条

型式 S30T 减速器速比 I=87

节距(mm) 142 大链轮 Z=32

运行速度(m/s) 0.16 小链轮 Z=17

开式链传动 24A-1X80

施工依据

设计标准达式 : GB10596.1-89《埋刮板输送机型式与基本参数》

检验标准 GB10596.2-89《埋刮板输送机技术条件》

整机试验和检验标准 GB10596.3-89《埋刮板输送机试验方法》

验收规范 GB50270-98《连续输送设备安装工程施工及验收规范》

二、安装

1 安装前的准备

1.1 设备到厂后，应按我公司提供的《装箱单》将机器的各零部件进行清点、分类、检查，

妥善保存。不应露天堆放，以免锈蚀。

1.2 安装前应仔细核对(实测)主机和地基、平台的安装尺寸。如发现问题应及时处理。我公司

一般随设备或其它途径给用户提供有《安装布置图》。

1.3 准备必要的安装工具和材料。如:扳手、电焊机、氧割、钢丝绳、细钢丝等。

1.4 安装时必须有钳工、电焊工、起重工、电工等工种的人员参加。

2 主机的安装

请参见《安装布置图》或本说明书的“安装使用说明图”。

2.1 安装时首先用水平仪找平地基和安装支架的水平度，然后点焊固定安装支架。

2.2 按我公司提供的“安装布置图”从头部开始顺序组装，安装时应保证机壳的水平和垂直度，

特别要保证底板对接平齐，允许沿运行方向下错 0.5-1mm，避免侧板左右的错位，以确保刮板

链条运动时不致产生卡碰现象。

2.3 埋刮板输送机机身组装后，应测定其总的直线度，若直线度超过下述要求，须进行校正。

输送机总长度在 30m 以下时直线度 5mm

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输送机总长度在 30m 以上时直线度 8mm

直线度的测量方法：摘自 GB10596.3-89

图 2：直线度测量方法

a.找出头部和尾部对称中心 A、B 两点，在输送机一侧拉细钢丝 L1，且 L1 可作铅垂方向的平

动。(见图 2)

b.使 L1 距 A、B 两点连线的距离为 S，S 为 1/2 槽宽+80mm。

C.检查 L1 距机槽外侧的垂直距离Δmax 和Δmin。

d.测定结果计算：

直线度=Δmax-Δmin

其中:Δmax--测量点距机槽外侧的最大值(mm)。

Δmin--测量点距机槽外侧的最小值(mm)。

2.4 头部必须牢固地安装在地基或支架上以保证运行平稳，中间段及尾部一般用压块固定，以

防止机身运行时产生摇摆现象。当输送 200℃以上物料时，加料口应设有伸缩节，此时尾部和

中间段不得焊死在支架上。

2.5 头部和尾部必须对中，两轮轴应保持平行，以免刮板链条在运行中跑偏。一般，头轮轴

已在出厂时调整好，安装时不得拆开，尾轮轴是可以调整的，调整的方法详见“调试”一节。

3 刮板链条的安装

3.1 刮板链条是埋刮板输送机的关键零部件，在安装前应检查刮板链条的关节是否灵活，若转

动不灵活时，应拆下，用砂纸打磨销轴和链杆孔，不得涂抹润滑油、脂，确保转动灵活后方可

安装。

3.2 装入刮板链条前应先将头部、尾部端盖板及观察盖打开，将尾轴调至头部方向的最前端，

判断刮板链条的方向，可参阅下图 3，准备好刮板链条所需要的数量，其余作为备件。

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•图 3 ：刮板链条与头轮的正确安装

头轮轮齿拨动刮板链条的链杆大头端向前运动不得装反

图 3仅表示头轮如图所示方向旋转时头轮轮齿与刮板链条的啮合情况。•

3.3 组装刮板链条时，应根据输送机的长度和安装现场的具体情况确定合适的安装方法。

根据我公司多年实践，本说明书推荐的安装方法如下：(参阅图 4)

图 4：刮板链条安装方法示意图

3.3.1 在安装头部前，准备两根钢丝绳或结实的麻绳，绳子的长度应比机身长 3-4m，然后安装

过渡段，并将上下绳分别向尾部方向拉出，顺次安装中间段、尾部等部件，主机安装后，上下

两绳已分别被拉至尾部。

3.3.2 首先安装下部刮板链条，在尾部下端用绳子将第一组刮板链条(一般取 10 节为一组)

系紧，在头部拉下部的绳子，将第一组刮板链条拉入，然后再取一组与第一组刮板链条联接起

来。继续在头部拉下部的绳子。依次逐步装入刮板链条。当下部的绳子从头部拉出时，下腔的

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刮板链条就装好了。

3.3.3 接着安装上部的刮板链条，方法和安装下部的刮板链条相同。但必须注意上部的刮板链

条和下部的刮板链条方向相反。如头部逆时针旋转时，下部的刮板链条小头朝头部方向，大头

朝尾部方向，上部的刮板链条的小头朝尾部方向，大头朝头部方向。

3.3.4 刮板链条的连接。首先在头部将上、下部刮板链条连接起来。然后在尾部拉上部或下部的刮板链条，将刮

板链条拉紧，最后取合适的长度，并在尾部把刮板链条连接起来。至此，主机及刮板链条都安

装完毕。

3.3.5 注意事项。

a.刮板链条的安装必须正确无误，不得与头轮旋向相反。

b.刮板链条连接时必须把弹性卡圈卡紧或销轴挡圈焊牢。否则刮板链条在运行中销轴将有脱

落而导致严重事故的可能。

4 驱动装置的安装

电机减速机与传动机构应牢固地焊接在地基平台或主机头部上，具体情况请参见《技术协

议》及《合同》条款。安装时减速机的出轴必须和头轮出轴平行。若为开式链传动时，大小链

轮的中心线必须在一条直线上；若为滑块直联时，头轴中心和减速机出轴中心必须在一条直线

上。检查方法可采用下图 5 所示的方法，驱动装置调正后，与地基牢固焊接起来，或用地脚螺

栓紧固，使设备运行平稳。 ••

图 5：驱动装置安装质量检验方法

5 加料口的安装

考虑到埋刮板输送机及其它相关设备的安装、制造误差，为了减少施工中的修、配、改，

加料口在出厂时一般不与主机焊接在一起，而以单件的形式发货。安装时，确定好加料口的

位置后，与主机的上盖板焊接起来，焊后应割去加料口内的盖板。

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三、调试 1 试车前的准备

完成机器各部分安装工作后,即可进行空车试验,空车试验前应做好以下工作：

1.1 所有轴承传动链部分以及减速机内部应有足够的润滑油、脂，润滑的部位及材料参阅"操

作与维修"一节。

1.2 检查机槽内部是否有遗留的工具和材料等杂物，如有应予清除，以免产生故障。

1.3 初步检查链条松紧度是否合适,判断的方法如下：

首先扳动电机 -----减速器间的联轴节或电机风扇叶片使下部链条拉直，然后检查头轮脱

链部位的情况（如图 6 所示）

图 6：链条张紧程度检测方法

若符合上述情况，则表明刮板链条已有了比较合适的松紧，但这只是初步的，开车后仍需

进一步观察和调整,下文将进一步说明。

2 空车试验

经过仔细检查，符合上述情况后,即可空车试验，空车试验时，要求至少有三人参加，

即头部一人，尾部一人，电工一人。

2.1 首先点动开车，点动开车时，头部观察人员必须注意头轮旋向是否正确，若有误，请电工

将电机换向。

2.2 再次点动开车，头部观察人员从头部观察盖观察刮板链条绕出头轮情况，若发现刮板链

条有起拱现象，则应调节尾部丝杆，以进一步张紧，直到符合上述图示情况。

2.3 继续点动开车，这次时间可稍长一点，尾部观察人员应从尾部端盖板处观察刮板链条是

否有跑偏现象。若有，应调节某一边的丝杆以纠正跑偏。

2.4 若头轮旋向正确，张紧合适，尾部无跑偏现象，则可进入空车试运转，但此时，观察人

刮板链条起拱

链条过松

刮板链条贴近导轨时，打开输送机

中部的中间段盖板，用手提刮板链

条，若能提起50--100，则合适；

否则，则链条过紧。

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员、操作人员不得远离岗位。若发现有异常情况，应及时停车处理。

2.5 说明：埋刮板输送机的刮板链条是在导轨上作滑动摩擦前进的，所以在空车时，会有一

定的噪音，这是正常情况。这种噪音会在负载运行时明显降低。但各种卡碰的噪音是异常情况，

应及时检查排除。

3 负载试车。

空车运转 2 小时后，即可进行负载试车。

物料装入输送机时应均匀加料，逐渐增加，不得骤然大量装料。另外，还应检查物料是否

符合输送机的使用要求。如：粒度是否过大，含水率是否过高等等。若不符合，则应采取措施

解决，否则不可进行负载试车。

3.1 负载试车时，还应观察卸料是否顺畅。若不顺畅应及时解决。

3.2 空车，负载试车时均应做好原始记录。其中包括电压、电流、功率及输送量等。并检查

是否与设计要求相吻合。

3.3 负载试车 8 小时后，即可停止试验。停机前应先停止加料，使机槽内物料排卸空后方可停

车。

3.4 将头部、尾部端盖板及所有观察盖都盖好。至此，埋刮板输送机的安装和调试就完成了。

4 油漆处理

埋刮板输送机及附件上所有的焊接过的部位均应进行表面除锈处理。并涂刷防锈底漆一

层，与主机颜色一致的面漆二层。每层油漆的干膜厚度25-35μm，油漆厚度为 75-105μm。

四、操作和维修

1.每次启动后，应先空载运转一定时间，待设备运转正常后方可加料，应保持加料均匀，

不得大量突增或过载运行。

2.如无特殊情况，不得负载停车。一般应在停止加料后，待机槽内物料基本卸空时再停车。

如满载运输发生紧急停车后的启动，必须先点动几次或适量排除机槽内的物料。

3.若有数台输送机组合成一条流水线，启动时应先开动最后一台，然后逐台往前开动，停

车顺序相反。这也可采取电器联锁控制

4.操作人员应经常检查机器各部件，特别是刮板链条和驱动装置应保证完好无损状态。一

旦发现有残缺损伤的机件(如刮板严重变形或脱落、链条的开口销脱落、弯曲段中间导轨严重

磨损等)，应及时修复或更换。

5.运行过程中应严防铁件、大块硬物、杂物等混入输送机内，以免损伤设备或造成其它事

故。

6.注意保持所有轴承和驱动部分良好润滑，埋刮板输送机各部位的润滑，可参见下表。但

应注意刮板链条、支承导轨及头轮、尾轮等部件不得涂抹润滑油脂。

7.埋刮板输送机在一般情况下，半年小修一次，一年中修一次，三年大修一次。大修时埋

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刮板输送机的全部零件都应拆除清理，更换磨损零件。电动机、减速器按各自产品的技术要求

进行维护和修理。

8. 输送机属季节性工作的，在停机期间，应对其进行检修、保养。刮板链条销轴和链杆

之间可滴入少许 10 号机油，以避免锈蚀后，无法转动；若输送粮食类物料、可滴入食用油少

许。

润滑部位名称润滑材料润滑油(脂)用量润滑周期润滑方法

头尾轴承 3#锂基润滑脂 500小时用注油器或涂抹

拉紧装置调节螺

杆 3#锂基润滑脂 800小时涂抹

开式传动链 220#开式齿轮油 1.5月涂沫

减速器

XWD3-7-1/87

极压齿轮油

L-CKC1002.3L 参照生产厂家说明书

电动机参照生产厂家说明书

五、故障处理当输送机发生故障时，请作好记录，分析原因，及时处理。

在您要求提供服务前，请先按下表自检，若有困难时，请及时与我们联系。

故障情况原因分析处理办法

刮板链条跑偏

1．输送机安装不良,全机直线度偏差过大检查安装质量并调整消除

2．壳体可能变形校正壳体

3．尾轮调节行程不一致，尾轮偏斜均匀调节

刮板链条拉断

1．有硬物落入机槽内卡住链条清除杂物

2．个别链节制造质量差更换链节并检查试验

3．链条磨损严重更换链条

4．满载起动或突然大量加料人工排料后均匀加料

5．链条上的卡圈脱落，使销轴脱出检查并坚固所有未装牢的卡

圈

刮板弯扭或断裂

1．壳体不直，法兰或导轨错位重新校正

2，有硬物落入机槽清除杂物

3．刮板与链杆末焊透更换链节

4．刮板链条与头轮啮合不良。检查调整

运行中刮板链条突

然冲击，发出声响

1．有硬物，铁件落入机槽清除杂物

2．某个链节转动不灵活卸下销轴修理

头轮和刮板链条啮

合不良

1．头轮轴偏斜校正轴的水平并调整

2．头轮安装不对中校正头轮

3．长期运行后链条节距增大更换链条

浮链 1．链条张紧度不够调整紧张装置

2．物料在机壳底板上形成压结料层进行清理，必要时加压轨

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EN MASSE CONVEYOR

(HORIZONTAL TYPE)

OPERATION INSTRUCTION

Hubei Yidu Yunji Mec& Elec Equipment Co., Ltd.

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SAFETY WARNING

En masse conveyor is equipment in low speed, but it still can cause anaccident of injuries and deaths when human body touches the rotary parts or therectilinear running parts.. All the casing of electric equipment should be of better ground connection.Human body should not directly touch the parts with electricity of all the electricequipment, or you will get an electric shock.

All en masse conveyor that convey the material that easy to burn or explode,its must be prevent from fire. The explosion doors should be checked regularly. Ifthere is something abnormal, its must be repaired to remove the hidden peril ofaccident.

The running and working life of this equipment are depended on not only

reasonable design and manufacture but also the correct installation andoperation.

Please read carefully this operation instruction before you will install and usethis equipment in order to avoid the unnecessary loss, If you have somedifficulties and requirements, please hesitate to connect us.

Address： North of Lianhua Yanya, Yidu City, Hubei Province

Postcode：443300

Tel：0717-4843222 4843333

Fax：0717-4843444

Email：[email protected]

Website：http://www.ydyj.net

Hubei Yidu Yunji Mec& Elec Equipment Co., Ltd.

http://www.ydyj.net/



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CONTENTS

Drawings for Installation and Operation ……………………47

II INSTALLATION 48

III REGULATION AND TESTING 52

Ⅳ OPERATION AND MAINTENANC 54

V TROUBLE SHOOTING 55

Appendix 1 List of Bearing 56

Appendix 2 List for Rapidly Wear Parts ‥ 57

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for Installation and Operation" in this operation instruction.

2.1 when installing, at first you must find the levels of the foundations and the

supports with the level instrument, then fit the supports by point welding.

2.2 It should be installed from the driving end in accordance with "The Plan

Drawing for Installation”. You must ensure that the casing is horizontal and

vertical to the foundation, especially ensure the connection of the bottom plate is

even. The lower of 0.5-1mm along the running direction of chain scraper should

be allowed. The misalignment of the side panel must be avoided to ensure the

smooth moving of the chain scraper.

When assembling the intermediate casing, if the bolts for flange between two

sections interfere with those of bottom (cover) plates, you first should take off the

interfered bolt in bottom (cover) plates and fit the flange bolts, then assembling

the bolts in bottom (cover) plates.

2.3 The linearity should be checked after completing the assembly of the casings,

if the straightness beyond the following requirement, it must be aligned correctly.The overall length of the en masse conveyor less than 30m: Linearity is

5mm.

The overall length of the en masse conveyor more than 30m: Linearity is

8mm.

Figure 2

a. Find out the point A and B in the symmetry center line of the driving end and

tension end, put a fine wire rope that can move vertically on one side of the en

masse conveyor. (See figure 2)

b. The distance of L1 to A and B is S, S is half of the trough width plus 80mm.

c. Check the vertical distance Δmax. and Δmin. Between L1 and the side

panel of the trough.

d. Calculating of the measured result.

Linearity = Δmax. - Δmin.

Δmax. is the maximum distance between the measuring point and the

outside of the trough.(unit: mm)

Δmin. is the minimum distance between the measuring point and the

outside of the trough. (unit: mm)

2.4 The driving end must be stability fitted to the foundation or the supports to

ensure the smooth running of the machine. Usually, the basic casing and the

tension end were fitted with pressure block to avoid the vibrating when the

machine is running. When temperature of the material is over 200℃, flexible joints must be used at the inlet position. The tension end and the basic casing

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can’t be welded with the supports.

2.5 The driving end and the tension end must be centered; the two wheel-shafts

should be parallel to avoid deviation of chain scraper in running. Usually the

sprocket shaft has been regulated before delivery, so don ’t take it apart when

installing. The trailing shaft is adjustable. How to regulate it, please refer to

"Regulation and Testing".

3 Installation of the Chain Scraper

3.1 Chain scraper is the key parts of the en masse conveyor; the mobility of the

joints must be checked before installation. If it doesn't work well, you must take it

apart and grind the pin and the hole of connecting link with abrasive paper, but

you can't spread Albany grease on them. Ensure it will rotate well before

installation.

3.2 Before installing the chain scrapers, the back plate of the driving end and the

tension end must be removed and the inspection door on them will be opened.You should move the trailing shaft to the zero tension distance and decide the

direction of chain scraper (refer to the figure 3). Then you will prepare the

required quantity chain scraper, the rest are used as space parts.

Figure 3

Correct installation of the chain scraper and the sprocket

Teeth of the sprocket lead the male end of the chain scraper in the direction of

the rotation. It can't be reversible.

Figure 3 only shows that the teeth of the sprocket mated with the chain

scraper when the rotation direction of the sprocket is the same as figure 3.3.3 When assembling chain scraper, you must determine the suitable method of

installation according to site conditions and the length of the en masse conveyor.

We recommend the following method, based on many years of our experience.

(Refer to figure 4)

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Driving End

Adapter Section

Intermediate Section

Wire rope

Figure 4

3.3.1 Before installing the driving end, two length of wire rope or two length of

twine rope will be prepared. Length of the rope is 3-4 meters longer than the

machine’s. Then installing the adapter section, pull out the upper and lower ropes

towards the tension end. Then installing the basic casings and the tension end inorder. After completing the installation of the main equipment, the two length of

rope has been pulled out of the tension end.

3.3.2 At first, install the chain scraper in the lower part of the casing. Usually ten

pitches will be one group. The first group of the chain scraper was fastened at the

lower part of the tension end with rope, pulling the first group into the casing from

driving end. Then take another group to link with the first group and do the

procedure as the first group, so the chain scrapers will be installed in regular

order. Installation of the chain scraper in the lower part will be completed when

the lower rope is pulled out of the driving end.

3.3.3 Then install the chain scraper in the upper part of the case and do the same

as the lower part, but the travel direction of the upper part is opposite to the lower

part. The male end of the chain in the lower part is in the direction to the tension

end and it in the upper part is reversible.

3.3.4 Connection of chain scrapers

First the upper chain scraper is connected with the lower chain scraper in the

driving end, then pull the upper or lower chain scraper to make them tight in the

tension end. Finally connecting the chain scraper in the tension end by suitable

length. Now, the installation of the chain scraper is completed.

3.3.5 Notes:a. The chain scraper must be installed correctly; it must travel in the sprocket

rotation direction.

b. When assembling the chain scrapers, circlips or retaining ring must be fitted

firmly, otherwise, it is possible that the serious accident will be caused by the

loose of the connection pins during its running

４ Installation of the Driving Arrangement

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The motor, reducer and transmission mechanism must be welded firmly on the

foundation platform or the driving end.

The details refer to the articles in the

"technology agreement” and the

contract. When installing, the gearbox

output-shaft and the sprocket shaft

must be parallel. If it is open chain

transmission, the centerline of the two

chain wheels is in alignment. If it is

connected directly, the centerline of the

output shaft of the driving end and

reducer is in alignment, too. Checking

the alignment between the chain wheel

and the pinion by means of a straight

edge (shown as figure 5). When thedriving arrangement has been

regulated, it will be fitted to the

foundation or tighten them with the foundation bolts to ensure the smooth running.

Figure 5

. Installation of Inlet

Considering the errors in installation and manufacture of en masse conveyor,

inlets have not been welded to the main equipment before it arrived at the work

site in order to reduce modifications in site assembly. The inlets will be delivered

separately. When being installed, it will be positioned and welded to the top cover,

then cutting the cover in the inlet.

Ⅲ、REGULATION AND TESTING

１.Making preparation before testing

The machine will be tested without load after completing the installation; the

following preparations will be made before the testing.

1.1 Enough grease and lubricating-oil should be given to the driving chain part of

bearing and reducer. The lubrication position and material refer to “operation andmaintenance”.

1.2 Checking that if some tools or materials have been left in the casing, and

removing it to avoid accident.

1.3 Checking the degree of tightness of the chain, the following should be carried

out

First, turn the coupling between the motor and the reducer or the fan of the

motor to pull the chain in the lower part straight, and then check the chain above

the sprocket scraper. (Refer to figure 6)

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Figure 6

If it is

conformed to

the above,

the degree of

tension of

chain is

suitable. But

it will still be

adjustable

after starting.

2. Testing of the En masse conveyor without Load. Carefully inspect the machine, if it conform to the above, it can carry on

no-load testing now. At least three persons will be present. Two persons will

observe the driving end and the tension end, and the third one will be an

electrician.

2.1 First, make a point contact of the switch to start the machine, the inspector in

the driving end must observe the sprocket rotation direction from the inspection

door, if it is in error, the electrician must change the rotation direction of the motor.

2.2 Remake a point contact to start the machine, the inspector will observe the

motion of the chain scraper when it move out of the sprocket through the

inspection door. If it accumulates, adjust the tension screw bar of the tension end

to make further tension until it conforms to the above figure 6.

2.3 Make a bit long point contact to start the machine, the inspector near the

tension end should observe whether or not the chain scraper is against side

running of the machine. If there is deviation, you should adjust the screw bar on

the side of the tension end.

2.4 If all above is OK, then the en masse conveyor will be operated without load.

The inspector and operator must be at their position, if there is something

abnormal, it should be stopped and corrected in time.

2.5 Note: For the chain scraper move on the runner with sliding friction, it will benoisy to some extent, it is normal, it will distinctly decrease when it run with load.

But the noise of the collision is abnormal that should be checked and removed in

time.

3. Testing of the En masse conveyor with Load.

After the machine running without load for two hours, it can be tested with load.

It will be evenly fed with materials and increase gradually. In addition, whether the

materials meet the requirements of the machine should be checked. For example,

sizes of granular and moisture etc. If it can't meet the requirement, the testing with

load can't be done.

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for en masse conveyor, Minor repairs should be carried out every half a year,

Medium repairs should be carried out every year and general repairs should be

carried out every three years. When carrying on general repairs, every part of it

should be separated and be checked, replace the worn parts. Maintenance and

repairing for the motor and the gearbox refer to their technology requirements

Description of

Lubricated

Part

Lubricating Material Lubricating CycleLubricating

Method

Each rotative Bearing 1# lithium-base grease 500 hours

Spreading or

Using Grease

Gun

Runner of Tension

Device1# lithium-base grease 800 hours Spreading

Opening Transmission

ChainOpen-type gear oil(220#) 1.5 months Spreading

Reducer

XWD3-7-1/87

极压齿轮油(2.3L)

L-CKC100

Carry out operation refer to

“operation instruction”

Motor Carry out operation refer to “operation instruction”

8 If the conveyor only works in some season, it must be checked and kept in good

repair. Drop a little engine oil of No. 10 into the joint of links and pins to avoid

rusting. If the equipment is for conveying grain, cooking oil should be dropped in.

V、 TROUBLE SHOOTING

If the equipment is in trouble, please make a detailed record, analyze the cause

and correct it in time.

Please check according to the following table before you ask for our service, if

there are some difficulties; do not hesitate to contact us.Trouble Cause Correcting

Chain scraper is against

running side of en masse

conveyor

1. Not good installation,

Linearity is too large

1. Check the installation quality and

correct it

2. Deforming of casing 2. Correcting the casing

3. Adjusting tension distance,

trailing wheel is inclined3. Adjust evenly

Chain scraper broken

1. Some hard matters drop into the

trough1. Get the hard matters out

2. Links worn serious 2. Replace links

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3. Full load starting and sudden feeding

much

3. Get out the material by men, then

feed evenly

4. Circlips on the chain fall off so that

the pins come off.4. Point weld circlips

Flights deformed or

broken

1. Casing is not straight, flanges and

runner are not in correct location1. Recorrect them

2. Some hard matters drop into the

trough2. Take out the hard matters

3. Non-penetration of the flights to the

links3. Replace the pitch of chain scraper

4. Chain scraper engage into the

sprocket not well4. Check and regulate it

Sudden shock with sound

from the chain scraperwhile running

1. Some hard matters or iron parts drop

into the trough1. Get them out

2. Not flexible return of one pitch of

chain2. Take out the pins and repair them

Not good mating of chain

scraper to the sprocket

1. Sprocket shaft is inclined. 1. Regulate shaft horizontal

2. Sprocket is not in the center 2. Correct the sprocket location

3. Creasing of pitch distance for long

time running3. Replace the chain

Chain floating

1. Chain is not get enough tightening 1. Adjust the tension device

2. Pressed layer of material in the

bottom plate has been made

2. Get the material out, press runner

will be used when it is necessary

Our company will set up a complete file for every consumer, if you will order

the spare parts, you only tell us the order contract no. or the type and its

description and quantity of the spare parts.

In addition, our company manufactures all kinds of bucket elevator, screw

conveyor,TD75 and DTII type belt conveyor, air cushion belt conveyor and the

gates &valves for bulk materials etc.

Welcome to inquire about those products。

Appendix 1

List of Bearing

Type Self-aligning Roller

Bearings for Driving EndGB288-87

Quantity Self-aligning Ball Bearings

for Tension EndGB281-84

Quantity

FU270 53516 2 1510 2

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Appendix 2.

List of Rapidly Wear Parts

5 Trailing Wheel FU270.3-1

4 Sprocket FU270.2-1

3 Circlip FU270.1-2

2 Pin FU270.1-1

1 Chain Scraper FU270.1

Item Description Drawing No.

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Contents

1. Inspection and Acceptance of New Reducer…………..…....60

2. Storage …………………………………………………….…….61

3. Transportation………………………………………..…… ..…..62

4. Installation Notice…………………………………….………...62

5. Mounting with main machine………………………………….62

6. Oper ation…………………………………………….……...…..63

7. General Inspection and repairing………………..…..…….....64

8. Dismounting and Installation ………………………………...66

9. Solutions &Reasons for the General Faults of Reducers…67

10. Structure Drawings……………...……………………………..69

11. Bearing and oil seal…………………………………..………..71

12. After-sale Services………………..……..…………..……..….73

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1. Inspection and Acceptance of New Reducer

NOTICE A．Make sure the front and back side of package before opening it

B．Make sure receiving right product ordered.

C．Keep the nameplate always with the reducer.

1.1Designation

B W D E 3 – 17 -7.5

B: B series planetary cycloidal reducer

W: Installation type: W is horizontal type, L is vertical type

D: Prime power (double shaft no mark):

D: Y series motor

Y: Y series motor specially for cycloidial reducer

B: YB series explosion motor

T: YCT electromagnetism speed-adjustable motor

Z: Z2 series DC motorP: YEJ series electromagnetism brake motor

N: cone-type brake motor

M: oil motor

V: Frequency-variable speed-adjustable motor

E: E is double stage, S is three stage, single stage no mark

3: Size of reducer (Referred to Table 1)

17: Ratio of reducer (Referred to Table 2)

7.5: Power of motor

X W E D 1.5 – 3 - 17

X: X series planetary cycloidal pinwheel reducer

W: Installation type: W is horizontal type, L is vertical type

E: E is double stage, S is three stage, single stage no mark

D: Prime power (double shaft no mark), same as B series.

1.5: Power of motor

3: Size of reducer (Referred to Table 1)

17: Ratio of reducer (Referred to Table 2)

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Table 1 Size of Reducer Table 2 Ratio

Single

StageDouble stage

Single

StageDouble Stage

B09 X1B109

X31B1+B09 X3+X1 11 121 1849

B0 X2B20

X42

B2+B0

X4+X217 187 2065

B1 X3B30

X52

B3+B0

X5+X223 289 2537

B2 X4B31

X53

B3+B1

X5+X329 391 3481

B3 X5

B41

X63

B4+B1

X6+X3 35 473 4189

B4 X6B52

X84

B5+B2

X8+X443 595 5133

B5 X7 X8B53

X85

B5+B3

X8+X559 731 7569

B6 X9B63

X95

B6+B3

X9+X571 841

B7 X10B74

X106

B7+B4

X10+X687 1003

B8 X11 B84X116

B8+B4X11+X6

1225

B9 X12B85

X117

B8+B5

X11+X7150

2. Storage

For store reducer it is necessary to note the following recommendations.

Storage Place

Store reducers in a clean, dry place.

Maintenance in Storage Period

Treatment against Rust

Renew of oil: one year for grease lubrication, six months for oil lubrication.

Contact factory when using out of China.

Using of storage reducer

Oil seal should be checked for it will be easy influenced by temperature and time.

If it is ageing please replace it.When starting running reducer, please check whether it has anomaly noise,

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vibration, heating. Check the brake also if have one. Contact with our

nearest agent and after-sale office in your place.

3. Transportation

DANGEROUS!

Keep distance with reducer when it is hung.

Make sure that the weight of reducer should be no more than Normal loading

of lifting device. The weight of reducer could be got from nameplate, paper

packing, drawing, samples etc.

4.Installation Notice

Installation place Ambient temperature: -10℃ to 40℃

Moisture: under 85%

Altitude: blow 1000 meter

Air environment: no corrosive, explosive air, good circulation of air

Location: indoor

a. If installation place cannot meet the above condition, reducer should be non

standard. Under this situation, contact with our company.

b. Mounting in place where can be done maintenance and inspection or other

works.

c. Mounting on rigid frame.

Installation angle

Reducer with grease lubricated can be installed at any direction.

Reducer with oil: the oblique angle of shaft center line should be no more than

15°, otherwise connect with our company. (Reducer on request must install at

this angle)

Strict loading condition

In case of big vibration and start-up frequency, fasten pins are recommendedon frame, which should be up to 8.8 class mounting hex bolt.

5．Mounting with main machine

Rotary Direction

Single stage and three stage reducer: Input shaft and output shaft have

opposite rotary direction.

Double stage reducer: Input shaft and output shaft have same rotary direction.

5.2 Mounting of connection parts

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No wallop or push or pull loading on shaft when mounting coupling, otherwise

it will damage bearing and brake circle.

Method of heating of coupling is recommended.

5.2.1 Use coupling: to use flexible coupling if could, and the tolerance is no more

than 0.15mm.

5.2.2 Use chain, sprocket wheel and gear:

a. Chain transmission: the angle between shaft and chain should be 90°.

b. Please check the chain instruction for its tension.

c. Pitch circle diameter of sprocket wheel and gear should be 3 times of

shaft’s.

d. The force point of sprocket wheel and gear should try to near the side of

reducer.

5.2.3 Use V- belt:

a. The tension of V-belt cannot be too big, please according to v-belt

catalogue.b. This parallel distance of two v-belts should be less than 20ˊ.

c. Parts and materials of hung belts should have same girth when belts

running together.

6．Operation

No oil is filled before leaving factory for convenient transportation, so complete

recommended oil before starting reducer.

It is necessary to note the following recommendations after installation, filling

oil and connection with prime power.

a. Right connection of electrical wire

b. Proper fitted with your machine or equipment

c. Fastness the mounting hex bolt.

d. Right rotary direction according to instruction.

e. The oil level is above the middle of oil gauge when reducer stops operation.

After the above check, do no load running, and increase loading gradually.

Make sure the following points:

a. Keep the reducer smooth on mounting surface.b. Choose rigid mounting surface to make sure that the reducer not vibration.

c. Make the reducer’s shaft be concentric with main machine.

d. Avoid the vibration of main machine (equipment) influencing the reducer.

e. No big ascent or descent of the voltage.

f. Current value is not above the normal value on nameplate.

If find any abnormity, please stop running and contact our nearest agent or

sales office.

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7. General inspections and repairing

7.1 Inspection

Do take the following inspections periodically and eliminate potential faults:

a. Current value of motor is less than value on nameplate.

b. Is there any exceptional noise or big change of noise?

c. Exceptional vibration.

d. Extremely high surface temperature (It is normal that reducer surface

temperature is 60 degree higher than ambient temperature).

e. The oil level is in or above the middle of oil gauge.

f. If got a pump, make sure it is work normal.

g. No oil leakage.

h. Fasten installed hex bolts

i. Fasten chain or V-beltsPlease deal the above faults as “Solutions and Reasons for the General

Faults of Reducers” if appear, otherwise contact with nearest agent or sales

office.

7.2 Lubrication

Table 3

Single

Stage

Size 09 0 1 2 3 4 5 6 7 8 9

Horizontal Grease Oil bath

Vertical Grease Oil bath Gear oil pump

Double

Stage

Size 109 20 30 31 41 52 53 63 74 84 85

Horizontal Grease Oil bath

Vertical Grease Oil bath Gear oil pump

Note: Grease lubrication can increase life and no need of lubrication maintenance.

Please illustrate it when order.

Table 4 Maintenance of different lubrication method

LubricationOil or grease

Before operationinterval Recommendation Liter

Reducer

Oil

lubricated

Oil bath Need 7.3.1 7.3.2 7.3.3

Circle lubricate

Grease

lubricated

Free maintenance No need 7.3.1 7.3.2 7.3.3

Need maintenance

Motor &

bearing

Grease

lubricated

No need

7.3 Complementary and replacement of oil (grease)

7.3.1 Interval of replacement

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Table 5A Interval & Replacement of oil

Interval time Task

300hours continuously working or a month Check oil

1500hours continuously working or six months Replace oil

Please contact us if use special model or general model in low or high

temperature or other special environment.

Table 5B Interval & Replacement of grease

Running time Task Remark

< 10hours/day Once per 2-4 months Shorten interval time if working in bad

environment10-24hours/day Once per 300-600hours

Replacement of oil: once pre 5000hours or 1-2 year(s)

7.3.2 Oil (grease) recommendationPlease use the recommended oil (grease).

Table 6A Recommended oil (grease)

Ambient temperature Esso Mobil Shell GB

-10℃- 0℃ EP68 626 68 CK68

0℃-35℃ EP100 627 100 CK100

30℃-50℃ EP220 630 220 CKC220

Please contact our technical dept. if ambient temperature is higher than in

table sheet.

Recommended grease: molybdenum disulfide-2, extreme-pressure lithiumbased grease-2L-2, 00# grease special for cycloidal reducer.

7.3.3 Liter

Table 7 Value of Liter

Size 09 0 1 2 3 4 5 6 7 8 9

Horizontal 0.2 0.4 0.5 0.75 1.4 2.2 4.5 7 14 30 56

Vertical 0.3 0.6 1.2 1.8 2.5 3.8 6 11 14 20 60

Size 109 20 30 31 41 42 52 53 63 74 84

Horizontal 0.43 0.85 1.3 1.5 2.2 6 6 6 10 16 35

Vertical 0.43 0.85 3 3 4 6 6 6 11 14 15

7.3.4 Please replace new oil when restart reducer stored for a long time.

7.4 Accessory Maintenance

The maintenance of accessories should depend on their using terms.

Generally speaking, please check accessories and replace them every

10000hours or 2 years. It’s helpful for long life.

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Table 8 Maintenance of accessories

Name Material Notice

Cycloidal wheel Bearing steel Replace when gear face or hole damaged

Gear Pin& sleeve Bearing steel Replace if damaged

Shaft pin Bearing steel Replace if damaged

Shaft sleeve Bearing steel Replace if damaged

bearing Bearing steel Replace if damaged

Oil seal Chemigum Replace and smear butter

Oil gauge polycarbonate Clean with neutral detergent

Gasket oil resistant rubber

asbestos

Paint sealant on two sides

8. Dismounting and Installation

DANGEROUS

Prohibit dismounting or reworking of reducer if it with explosion-proof motor.

Otherwise it may explosion, fire, electric shock, injury, damaging equipment.

8.1 Dismounting and Reinstallation of reducer

Outflow the oil if it is filled with oil.

(picture 1) Main accessories dismounting order

a. Make output shaft up---screw out the long hex bolt on reducer

body---dismount low speed part

b. Reducing part: output shaft sleeve—shaft retaining ring---high speed

bearing A---gasket or retaining ring---pin wheel A---gas ring---cam

sleeve(including its bearing)---pin wheel B---Key---retaining ring---needle tooth

shell---needle tooth sleeve.

c. Low speed part: end-shield---bearing stop-ring---output shaft (output

bearing A.B)

8.2 Reinstallation of reducer

The order of reinstallation is contrary to dismounting. Pay attention to thefollowing points:

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a. The remarks of pin wheel and cam sleeve face to installed person when put the

pin wheel to bearing.

b. Facing the remarks of two pin wheels, installed them while the two marks have

an angle of 180°.

c. After installation, rotate from the high speed shaft. Be sure of no abnormity

before prepared running

9. Solutions and Reasons for the General Faults of

Reducers

Table 9

Motor doesn't run when unloading

No electricity Supply electricity

Inferior of electro circuit Check electro circuit

Fuse blowed Replace fuse

Protection device works Preclude and rework

Locked of loading Check loading and protection device

Motor stator coil disconnected Repair by technicians

Bearing damaged Replace bearing

A phase work in 3-phase motorMeasure voltage, check coil of transformer,

contactor, fuse, etc and repair them

Motor runs but reducerGear damaged Repair by technicians

doesn’t run when unloading

Output

shaft rotary

whenunloading

Add

loading

Thermal

protection

overheating

thermal protection

capacity not enoughReplace right thermal protection

Overloading Lessen loading

Fuse blowedFuse capacity not enough Replace right fuse


Very low speed

and high

temperature

Descend of voltage Connect with power company


Short -circuit of the stator circuit Repair by technicians

Doesn’t work

Uninstalled of key Install the key


Protection device not work well Adjust protection device

Rotary inversely Wrong wire connection Right the connection

Fuse blowed

Circuit wires short-circuit Repair by technician

Poor connect of motor and starter Connect them well

Temperature increased quickly


Descent or ascent of voltage Contact with power company

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High ambient temperature Adopt Good air circulation method


Pin wheel worn or damaged Replace pin wheel

Oil leakage

Input and output shaft Oil seal worn or damaged Replace oil seal

Pin wheel cover or frame

partHex bolt loosed Fasten hex bolt

Oil leaked to inner part of

motor


Over oil Outflow of oil

Exceptional noise and big vibration

Foreign objects in gear Replace bearing

Foreign objects in pin wheel faceRemove foreign objects and

check if damaged

Pin wheel face damaged Replace pin wheel

reducer crooked for unsmoothsurface

Smooth mounting surface

Vibration with machine Strengthen mount frame, raise its rigid

Not concentric with machine shaft Keep them Concentric

Vibration from machine Run reducer separately and check if vibrates

Exceptional noise from motorInvaded by foreign objects Remove foreign objects


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Table 10 Parts of reducer

No. Parts No. Parts No. Parts No. parts

1 Output shaft 13 Input bearing C 25 Needle-tooth pin 37 Oil breath

2 Fasten ring 14 Packing piece 26 Needle-tooth shell 38 Oil seal3 Oil seal 15 Pin wheel 27 Needle-tooth sleeve 39 Oil gauge(horizontal)

4 End-shield 16 Cam sleeve bearing 28 Pin sleeve 40 Motor

5 Bearing stop-ring 17 Packing piece 29 Pin wheel 41 Reducer pump

6 Gasket A 18 Input bearing B 30 Fan cover 42 Frame

7 Output bearing A 19 Oil seal 31 Fan back-up cover 43 Air vent plug

8 Oil plug 20 Fan 32 Interval ring 44 Middle bearing A

9 Gasket B 21 Input shaft 33 Key 45 Middle bearing B

10 Output bearing B 22 Key 34 Key 46 Oil seal

11 Retaining ring for shaft 23 Gasket C 35 Oil plug 47 Cam sleeve bearing12 Input bearing A 24 Pin shaft 36 Oil gauge(vertical)

11. Bearing and oil seal

11.1 Bearing

Table 11 Output bearing

Reducer model Output shaft

Single stage Double stage Bearing A Bearing B

09 6205 6108

0 66027 6207

1 6208N 6208

2 20 6211N 6213

3 30.31 6213N 6215

4 41.42 6217N 6218

5 52.53 6220N 6221

6 63 3203722 6224

7 74 3203724 6226

8 84.85 3203728 6232

9 95 3203736 6340

Note: referred to drawing Ⅱ(single stage) and drawingⅤ(double stage).

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Table 12 Input shaft bearing

Reducer model Input shaft Input shaft with motor

Single stage Double stage Bearing A Bearing B Cam sleeve bearing Bearing A Bearing B

09 6201 6302 502205 6201

0 20.30 6201 6302 502205 6201 6205

1 31.41 6302 6304 502206 6302 6207

2 42.52 6403 6404 502307 6403 6209

3 53.63 6405 6406 502309 6405 6210

4 74.84 6406 6407 502312 6403 6212

5 85.95 6407 6410 502219 6407 6215

6 6409 6413 502222 6409 6215

7 42410 6415 502228

8 42414 6420 502328

9 42419 6426 502336

Note: referred to drawing Ⅱand drawing Ⅳ(single stage) and drawingⅤ(double

stage).

Table 13 Bearing of middle shaft

Reducer modelMiddle shaft

Bearing A Bearing B Bearing C Qty

20 6403 6404 502307

31 6405 6404 502309

31 6405 6406 50230941 6406 6407 502312

42 6406 6407 502312

52 6407 6410 502219

53 6407 6410 502219

63 6409 6413 502222

74 42410 6415 502228

84 42414 6420 502328

85 42414 6420 502328

95 42419 6426 502336Note: referred to drawingⅤ.

11.2 Oil seal

Table 14 Oil seal

Reducer

model

Output shaft Input shaft Input shaft with motor

Dimension

(mm)

Qty Dimension

(mm)

Qty Dimension

(mm)

Qty

Horizontal Vertical

09 30*52*10 1 1 20*35*10 1 30*60*10 1

0 45*65*12 1 1 20*35*10 1 35*60*12 11 50*72*12 1 2 35*62*12 1 45*62*12 1

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2 65*90*12 1 2 40*65*12 1 50*72*12 1

3 80*105*12 1 2 50*72*12 1 55*80*12 1

4 100*130*12 1 2 60*85*12 1 65*90*12 1

5 115*140*14 1 2 80*105*12 1 80*105*12 1

6 130*160*15 1 2 100*130*12 1 100*130*12 17 150*180*16 1 2 90*120*12 1 1

8 170*200*18 1 2 130*160*15 1 1

9 220*260*18 1 2 160*190*16 1 1

02 65*90*12 1 2 20*35*10 1 35*60*12 1

13 80*105*12 1 2 35*62*12 1 45*62*12 1

14 100*130*12 1 2 35*62*12 1 45*62*12 1

24 100*130*12 1 2 40*65*12 1 50*72*12 1

25 115*140*14 1 2 40*65*12 1 50*72*12 1

35 115*140*14 1 2 50*72*12 1 55*80*12 1

36 130*160*15 1 2 50*72*12 1 55*80*12 1

74 150*180*16 1 2 60*85*12 1 65*90*12 1

84 170*200*18 1 2 60*85*12 1 65*90*12 1

85 170*200*18 1 2 80*105*12 1 80*105*12 1

95 220*260*18 1 2 80*105*12 1 80*105*12 1

12. After-sale service

After-sale service is only for our company’s products.

Due time 18 months after leaving factory or 12 month after running

ServicesIncluded

During the due time, provided reducer installed rightly and underright running (except the following situations), our company will be

repair and replace reducer of parts free after inspection. BUT other

fees caused will not bear by us.

Not

Included

Conditions

a. Wrong installed or connection with other machine (equipment).

b. Insufficient maintenance, not refer to instruction.

c. Wrong lubricant or not use recommended oil (grease).

d. Inferior connection or special model on customer request.

e. Reworking or change structure of product.

f. Parts or materials installed by customer.g. Earthquake, fire disaster, moisture, lighting strike and other

force majeure.

h. Natural dissipative, ageing etc under right running condition.

i. Others not responsible by our company.

Note: after-sale service telephone: +86-0519-6555838

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Packing list

No Qty

1 Cyclo Pin Wheel Reducer

2 B. X series reducer instruction

3 Conformity certificate

4 Accessories

5 Packing list 1 pc

Reference: Date:

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