MLX 系列减速机操作手册英文版

MLX Series Gear Box of Cement Mill

Operating Manual

·Transmission device and gear box shall be operated by the personal who is familiar with the operating.Please read the manual carefully before operating.

·This gear box has been drained out of oil when delivered from the workshop, therefore,please fuel the oil according to the operating manual.

·Please hand over this operating manual to the actual operating personal

·Be sure to keep this operating manual in good way.

Safety Caution

●Before using(installation,operation,maintenance,spot check,etc.),must be

familiar with this operating manual and other subsidiary information and operate correctly.Being familiar with the machine knowledge,safety considerations and matters should be paid attention to and then use it.After reading,it should be in actual use personnel's custody and kept in visible place.

●While carrying,setting up,routing the pipes,the machine running,operation,

maintenance and inspection,it must be implemented by the personnel with professional knowledge and skills.Otherwise,it may result in injury or damage

the machine.

●Set safety protection facilities beside manned unit,to avoid unit’s rapid moving

cause human injury and unit damaged

●When using the lifting unit,set safety facilities beside it to avoid lifting body

falling and cause human injury and unit damaged

●During equipments'running,please do not dismantle reducer.In addition,even if

the equipments stop,the input,output flange of gear unit in connection status with the motor and the other machine,please do not dismantle anything except the checking oil port,oil discharge port,checking cover portion,because it may result in gear meshing offsetting,falling and flying away quickly and other personal injury or damage to the unit.

●Do not use it outside the range of the reducer's specifications.It may lead to

personal injury and device damage.

●Do not put fingers and objects into the opening of the reducer,which may cause

injury and device damage.

●Do not use the damaged reducer,which may cause injury and device damage.

●The product transformation by customer privately is outside the scope of the

company's quality assurance,which our company is not responsible for.

●Do not remove the nameplate.

●Please refer to the instructions of the oil station for the usage of gearbox of

takeout oil station and oil station.

Contents

Ⅰ.Overview

Ⅱ.Performance Parameter

1．Operational Environment

2．Product Specifications

Ⅲ．Receiving Inspection

1．Precautions

2．Inspection Requirements

Ⅳ.Lifting、Carriage and Preservation

1．Lifting

2．Carriage

3．Preservation

Ⅴ．Installation and Alignment

1．Precautions of Installation

2．Foundation

3．Alignment

Ⅵ．Records of Field installation，Adjustment and Test Run

Ⅶ.Operation and Maintenance of Reduction Gearbox

1．Start

2．Shut-down

3．Maintenance

Ⅷ.Regular Checking

Ⅸ.Precautions of Dismounting and Assembling of Reduction Gearbox 1．Dismounting

2．Checking

3.Assembling

Ⅰ.Overview

The speed reducer gearbox for MLX(1)50series vertical grinding mills adopts the joint transmission with cone gear pair,gear pair with parallel axes and planetary gear pair.A pair of orthogonal transmission cone gear pair,a gear pair with parallel axes and a set of input shaft for vertical planetary gear transmission;they are connected by pairs of gear coupling.The sun wheel is supported on the thrust block. The vertical mill’s axial bearing is supported by12fan-shaped tilting tile thrust bearing.The two degrees of freedom make internal gear ring and three planetary wheels bear force evenly.The inner gear ring is rigidly fixed on the box body,which, designed into cylinder housing shape,provides an ideal support form for the axial thrust bearing.Besides,the inside and outside walls of cylinder casing are configured with symmetrical reinforcement,thus the body has very good rigidity.The0utput shaft and planet carrier become integrated,making the instructor simple and reasonable.

The cone gear adopts Klingelnberg style spiral gear.The parallel shaft gear pair, the sun wheel,and the planet wheel are involute straight tooth.These gears adopt high strength carburized steel,witch,after carburized gear-grinding,are of high precision.

All the supporting bearings of the speed reducer gearbox are rolling bearings. The axial thrust bearings are tilting tile thrust bearings.Consisting of several piece of fan bearing shell,they bear the axial thrust of vertical grinding mill.During operation, the bearing bushing is always soaked in the oil tank and constantly offered with fresh lubrication oil through the ring nozzle.So the oil tank always maintains a certain level.

Lubricating oil system uses independent stations.And there is oil pressure,oil temperature automatic protection system,making the operation of the whole equipment safe and reliable.

Ⅱ.Performance Parameter

1.Operational Environment

Ambient temperature:－20℃～＋40℃

Ambient humidity:Below85%

Air environment:there should be no corrosive gas,explosive gas and steam,etc.there should be no dust either,and the ventilation should be good.

-If the installation is in an environment violating the above requirements,it belongs to special order.Please contact with us.

-When making the order,if it is pointed out that the equipment will be installed outdoor and explosion-proof,and everything follows the requirements,the installation under certain circumstance is without problem.

-The operation should be in a place where the inspection and maintenance,etc.are easy to do.

-It should be installed on the platform with good rigidity.

2.Product Specifications(For the detail,please refer to the drawing)

Ⅲ．Receiving Inspection

1.Precautions

Open the box after you check the above and below.Do not let it hurt others.

Check whether the goods you received is the same as you ordered.If you installed the wrong product,this might bring damage to people or the machine.

Do not remove the nameplate.

2.Inspection requirements

As for the driving device and the reducer,you should check the following items.

If there are any problems,please contact our representatives,our own store or office which is nearest to you.

(1)Whether what is written on the nameplate is the same as what you ordered.

(2)Whether there is any damage in transit.

(3)Whether the bolts and nuts becomes flexible.

Ⅳ.Lifting、Carriage and Preservation

1．Lifting

·Please do not stand under the goods to prevent from the safe accident when lifting.

·Please pay attention to the lifting position and lift as shown in the illustration lightly.

·Pay attention to the risk of falling and reversion when https://www.360docs.net/doc/5c15529716.html,e lifting bolts and lifting hole to lift the actuating unit or gear box.But after they are installed in the equipment,so not use lifting bolts or lifting hole to lift the whole equipment.

Because falling,inversion or lifting bolts and holes’damage will lead injury or equipment damaged.

·Weight of the driving device and the reducer shall be confirmed according to the nameplate,case,outside view and the sample before lifting.And if it is beyond the rated weight,the lifting shall be not allowed to prevent from the accident.

Notice：Lifting directly by the output flange is definitely not allowed

2．Carriage

·Lubricating oil in the gears box shall

be eliminated before the carriage.

·Gears box shall be fixed reliably.

·Measures to protect from wind,rain

and moisture shall be taken.

·Place it directly on the ground is not

allowed

3．Preservation

When the driving device or the reducer doesn’t work immediately,they shall be

kept according to the matters detailed as below.

1）Preservation place

·The place shall be clean and dry.The outdoor environment is not OK,also with the moisture,dust,temperature variation and corrosive gas.

·The input and output shaft must be applied by the slushing oil

·the lubricating oil after resolved shall be wrapped by the plastic to prevent from the other things.

·The wind,rain,moisture-proof measures shall be taken in the preservation.

·Place it directly on the ground is not allowed.

2）Preservation period

·Preservation period shall be in the period of the rust protection as below

·Please kindly contact us while the special rust protection specification is necessary when the preservation period is longer than the period of the rust protection as below

·Pleas kindly contact us if the export products need the rust protection specification based on the export.

·standard rust protection specifications

1External rust protection

The reducer has been coated with rust protection oil for delivery.The

rust protection condition shall be checked in the period of6months.

And the rust protection measure shall be done when necessary.

2Internal rust protection

Rust protection period6months

Preservation requirement The environment without moisture,dust,big

temperature change and corrosive gas is OK.The

goods usually be kept in the warehouse or the

indoor factory

3）Use after the preservation

·The oil seal shall be checked whether to be changed while it is influenced by the environment outside such as temperature and ultraviolet rays.So every time inspecting is necessary to change a new one for a long storage.

·If the abnormal phenomenon appears,please contact with the agency,sales or business shop promptly.At the same time you shall inspect whether the voice, vibration or fever appears when start running.

Ⅴ．Installation and Alignment

1．Precautions of Installation

Do not use the machine in explosive atmosphere.Please use anti-explosion motor;otherwise it might lead to explosion,ignite,electric shock,human injuries fire, or damage to the machine.

If you adopt anti-explosion motor,please choose the right model that suit the environment(there is gas or explosive atmosphere).Otherwise,otherwise it might lead to explosion,fire electric shock,human injuries and fire.

There must be nothing inflammable near the driving device;otherwise,it might cause fire.

Do not put anything that will block the airflow near the driving device and reducer,otherwise,it will result in bad cooling,overheat or fire.

Do not step on the driving device or reducer,otherwise,it might lead to human injuries or damage to the machine.

2.Foundation

The reduction gearbox must be put on the foundation that has good rigidity,no vibration and is even.For example,the reducer can be put on the foundation frame that has a mechanically processed carrying plane,and the foundation frame should be

connected with concrete foundation.After alignment,the reducer box center should be positioned by the taper pin and then use the bolts to connect it with the foundation frame.

3．Alignment

1）Alignment of the motor and the reducer.

The main shaft connects reduction gearbox and main motor must be in the same line with shaft of motor in the operation.In order to meet this need,axial horizon and vertical running must use special measuring device to measure.Specifically as shown below:

Coupling type Radical running Axial running（R=200）

Rigid coupling0.030.02

Flexible coupling0.080.08

If R>200mm，the axial running value can increase accordingly

2）Installation and alignment of reducer box and grinding mill installation.

·Before connecting to other machine please confirm the direction.Or the equipment will be damaged resulting from the wrong direction.

·Never put too much impact pressure or too high loader because this will lead the damage to the bearing and rid of the lantern ring.

·The installation of the reduction gearbox and the grinding mill must be right and careful.Disc and the thrust axis must be cleaned and not any stain should be left. The mouth size of the disc and the thrust axis unit’s connection must be measured and have detailed records.The connection between the disc and the thrust axis table bolts must be tightened.The thrust axis units connected to the disc cannot be deformed or distorted.The thrust axis station’s axial running tolerance cannot exceed0.13mm.

3）Reducer installation and connection of the high and low pressure lubrication oil station:

Reduction gearbox with high and low pressure lubrication oil station installation work must be properly detailed.Allocate pipe according to the scene.Low pressure oil outlet end of lubrication oil station and the inlet oil tube of the reduction gear box must be connected by steel pipe.All the16high oil pressure of the oil station outlet16tubes should be connected to the16high pressure sliding bearings of the reduction gear box.Please pay particular attention to:as there are4high pressure oil pump on the oil station,every high pressure pump leads4high pressure oil tubes, when connecting to gearbox,the four pumps’oil-out and gearbox’oil-inlet must be cross and linked uniformly.

During the installation of the mill and gear box or in any other case,if the lubrication system does not work,never allow gearbox slowly rotate or jigger.Note that that the reducer box cannot reversion work.

Ⅵ．Records of Field installation，Adjustment and Test Run

1.Type of reduction gearbox

2.Factory Number of reduction gearbox

3.Specifications and models of grinding mills

4.Specification,model,the power,speed,voltage,current of main drive motors

5.Driving direction(From the main motor)

6.Detailed record should be done in the process of alignment during installation,

·Result record of alignment between reduction gearbox and the motor.

·Result record of alignment between reduction gearbox and the grinding mill.

7.Run-in testing record

Start work time：Year Month Day

Run down time：Year Month Day

Grinding mill load：

Running time：

No.Drive

time

year-mo

nth-day

Stoppin

g time

year-mo

nth-day

Host

load

（T）

Motor

stator

voltag

e（V）

Motor

stator

starting

current

(A)

Motor

stator

working

current

（A）

Temp(。C)

Remarks

Roo

m

temp

Tank temp

Ma

x.

Mi

n.

Before

test

After

test

VII.Operation and Maintenance of Reduction Gearbox

1．Start

1）Preparations before start

·Lubrication oil will be discharged.Therefore,recommended lubrication oil shall

be filled before operation.

·Install outside lubrication oil tubes and please make sure that cotton yarn or scrap

iron is not left in tubes.Tubes shall be cleaned.

·Check whether the safe controlling and auto-protection system works reliably.

·Check whether instruments of systems are successfully installed.

·Check whether the oil level gauge works normally.

·Check whether the lubrication system is leaking.

·When temperature of the bearing is lower than35℃,please heat it to more than 35℃by a oil heater.

2）Preparations before starting oil pump

·Check whether the oil pump works normally.

·Check Oil pressure

3)Preparations before starting reduction gearbox

·The reduction gearbox shall be started without load when the high-pressure oil pump is not working.It is forbidden to start main motor when the high-pressure oil pump is not working and the main equipment is loaded.

·Please observe the temperature rise of bearing bush when it is unloaded.When the temperature rise stops,please increase load gradually.Under any circumstance,load shall be increased gradually after the temperature rise stops.

·Load shall be increased evenly.Two cylinders shall be working simultaneously.

·Check whether there are strange sound and vibrating in reduction gearbox.

·Check whether the temperature of thrust pad in thrust bear is normal.Please stop the motor when the temperature is more than75℃.

·When output oil temperature of oil cooler is blow25℃or above50℃,the main electric motor shall not be started.

4)Considerations and requirements before the main motor starts.

Dead load and loaded test run can be proceeded according to the on–load running testing schedule about reduction gearbox.

Check whether some abnormal noise and vibration happens.

Check whether the temperature of thrust bearing liner is normal,once it exceeds 75°，machine should come to a halt.

No main motor should be started if the oil temperature of oil cooler outlet below in25°or above50°。

5）Starting sequence

Low tension oil pump should be started firstly,when it works fine(about3~5 minutes),high tension oil pump can be started.The main motor of reduction gearbox can be started after the high tension oil pump works almost ten minutes(Attention:main motor can be started after the oil station works for an hour when it first works).

2.Stopping

Points for attention before stopping and stopping sequence

Unload material from millstone before mill stop working;stopping with loaded is strictly forbidden.

1)Unload material from millstone

2)Main motor comes to a halt.

3)Stop providing water to the oil cooler.

The cooling water tends to freeze in winter so that cooling water should not be closed totally or discharge all the water in case of freeze.The lubricating oil must be in liquid state if you start the main motor in winter.If lubricating oil is in starchiness state and not easy to produce oil slick,it is likely to impair thrust bearing。

4）oil pump comes to a halt

When the grinding mill stops,lubricating oil pump should be stopped after10 minutes(High-pressure pump stops firstly and then low pressure pump)

If the mill stop for a short time,there is no need to stop oil pump to ensure the mill can start in any time.

Before starting the grinding mill,starting the oil pump comes first and then checks the oil level in thrust bearing oil-bath of reduction gears.Only when the oil level is higher than the marked level of thrust bearing,grinding mill can be started.

2.Maintenance

In order to guarantee good working conditions,please pay attention to the notes

below when on continuously running.

1)Check and record the press table,thermometer and other data in accordance

with the prescribed time.

2)if there is any abnormal situation,find the reason and stop running equipment

when necessary.

3)Pay attention to reduction gearbox overload.

4)Pay attention to oil filtering.

When on first commissioning,after running3~4hours,the filter should be cleaned.Generally speaking,the filter should be cleaned every200hours.Pay attention to Source and categories impurities when cleaning the filter.

5)Check the connection bolts.

After the first running20hours and every1000hours from then,all connection bolts on the box and foundation connecting should be checked whether they are flexible or not.And check the foundation framework whether horizontal or not.If there is,please correct in time.

6)Check the relative position between thrust bearing and box.

The relative position size"a"between thrust bearing and box should be checked every2000hours.(Details see assembly drawing).Check the data with previous data every time,if there is too big changes,stop running and check the reason.

7)Check the sound and vibration of gearbox,analyze the reason if the sound or vibrating amplitude becoming big.

8)Check whether oil leakage of the gear box joints,once discovered,the reason should be found and the problem should be solved in time.

Ⅷ.Regular Checking

1.Reduction gearbox should be completely inspected after running2000hours or longer(generally no more than1year).It can be the down to check or during other machines maintenance period.

2.Inspection Item

Check point Inspection Item Note

Thrust bearing The relative position dimension of

thrust plummer block and box is“a”Compare with the record of factory

Test thermocouple wire connection condition by thrust segment temperature Dismantle the prothole cover of thrust bearing box

whether there are something under

the thrust bearing box

Angle gear Contact condition of tooth flanks Dismantle the

prothole cover of box

Whether fuel spray nozzle is

blocking;Whether connecting bolt

of oil tube is loose

Box and pipeline Check to see whether the following

parts are loose

1connecting bolt of lubricating oil

pipe and box

2connecting bolt of gear box and

foundation

3connecting bolt of mill and thrust

plummer block

Input coupling Whether connecting bolt is loose

Oil station Clean the inside of fuel tank If the old oil needs to

be changed,release

the old oil and then

clean the tank.

Check the following equipment

1oil pump

2oil cooler

3heater

4pressure relay,oil temperature and other instruments.Check when the pressure or oil mass is not enough.

Make sure the calibration value is correct when cooling ability decreases or water mixes in the oil.

3.After2000hours’running,you have to change the oil once.Check the quality of lubricating oil often.If the physical and chemical property of the oil can’t make the gear box working normally,the oil should be https://www.360docs.net/doc/5c15529716.html,ually,the lubricating oil should be changed every6months’running.When changing the oil,should check the nozzle of gear case to see whether they are blocked.If blocked,should clean it in time. The new oil for changing should meet the specified model.

Ⅸ.Precautions of Dismounting and Assembling of Reduction Gearbox

After a certain time of running,it is necessary to conduct a comprehensive inspection and maintenance to the gearbox.If need repair check and update installation for the gearbox,please inform Nanjing High-precision Gear Group Co., LTD.,to obtain timely help.

1．Precautions and requirements of disassembly

1）Disassembly and inspection should be conducted in a special clean area without other sundries.

2）During disassembly,external oil line should be https://www.360docs.net/doc/5c15529716.html,e plastic cloth to thoroughly bind up the end of the pipe to prevent greasy dirt permeating oil tube.

3）Disassembling any parts,pay attention to the assembly mark and alignment pin position.Make sure to restore to its original position before reassemble.

4）Prevent any debris fell into the casing,and keep body clean.

5）Install and dismantle thrust shaft units with hydraulic tools.Get in touch with the manufacturing plant if without the tools.

2．Checking

After removing the gear transmission parts,spare parts should be checked for full and record the detailed list.

·Tooth surface contact conditions;

·Bearing wearing conditions;

·Check the running-in of Thrust Segment,and check its height tolerance no more than±0.025mm,if exceed,bearing surface must be regrind and manual reconditioned.

·Confirm spare parts changing list after inspection.

3．Assembly

·When reduction gearbox needs reassemble,should according to the requirements of assembly drawing and technical condition needs.

·All parts must be thoroughly cleaned,when need reassemble.

·Bolt,nut and other connection components,if locking element damaged must be replaced new one during disassembling

·During the installation of body parts,clean the sealant on the joint surface and replace them by new ones.

·Replaced to the new lubricating oil when in larger maintenance,and do the double check to the Gear box of the correction.