CHAPTER 8 LUFFING REDUCTION GEAR

GENERAL SAFETY REQUIRMENTS

Before handling (an installation, operation, maintenance, inspection etc.)

this reduction gear, you must read thoroughly this operation manual and
other schedules without fails, and use correctly to understand the informations
for the knowledges and safeties of this devices.
Please store to the place where the users can be seen anytime without fail,
after you read this.
The rank of safety matters that demand special attention has been
classified as “warning” “caution” in this operation manual.

Warning describes a condition or operation

！ Warning that involves some risk of injury to personnel.

Caution describes a condition or operation

！ Caution
that involves some risk of damage to equipment.

That, even the item that entered on a caution depends on situation

it ties it to the important result and there is possibility.
Please defend it without fail because we are entering whichever important
contents.

！ Warning

●Person who had expert knowledges and skills, carry out the works of transport,
installation, wiring, operation, maintenance and inspection.

●Please install the safety device on the machine side, in the case that it is used to
the lifting and the personal transportation device.

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 Contents

1. Introduction

2. Inspection on receipt of products

3. Transport

4. Installation

5. Operation

5-1 Procedure of operation

5-2 Keep or pause for long term

6. Lubrication

6-1 Recommended lubricant

6-2 Exchange standard

7. Maintenance

8. Exchange the part

9. Disassembly and assembly

10. Trouble shooting

11. Attached drawings

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1. Introduction

Before handling this reduction gear, there is the fear that damages it
within short term when you use it wrong method, although it is easy reach of
the maintenance.
Please read thoroughly this operation manual before handling,
because it is described the matters that demand the warnings and cautions at
the time of the handling.

2. Inspection on receipt of products

！ Caution

●Please confirm the top or bottom of the package made of wood, before open it.

●Please confirm the products, whether or not be the same as an order.

Please check the following items due to a sense, although we are sending
the products after inspecting strictly.

(1) Please confirm the product whether or not the same as an order, by seeing
the nameplate of it.
(2) Are not the screw and the like getting loose bill of every part?
(3) The damaged parts which happened during transport?
Please contact an our company agency or our company sales section right
away, if there is the problems of above items and others.

3. Transport

！ Warning

●Never be below the lifting products due to transport.

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 ！ Caution

●Be careful to fall down during transportation.

Do not lift the whole machine using the hook installed the reduction gear.

●Please confirm the mass of the reduction gear by the name plate, package, outline
drawing and this operation manual before lifting.

4. Installation

！ Warning

●Do not touch to the edge of key grove etc. in the end of output shaft with the raw hand.

●Please remove the key installed output shaft of the reduction gear, before operating
it only.

●Please install the cover to rotating part to prevent touch.

！ Caution

●Do not use on out of scope for specification.

●Do not put around the products to intercept the wind.

●Do not step on the reduction gear and hang of it.

●Please set the damage prevention device such as an oil receiver, to use the food
machine etc. to prevent the damage of its products from the leakage oil.

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 ！ Caution

●Please confirm the direction of rotation before connecting with a partner machine.

●Please take care the centering, the belt tension and the parallel of the pulleys etc,
in the case of setting this to the machine.

●Please adjust the belt correctly in the case of using the belt drive.

●Please make sure that the bolts of the pulley and the coupling are tightened before
operation.

1) It is most important matter, that the connection between the prime movers or
driven ones become the same center like all the reduction gears. The flexible
coupling is used to absorb the little difference of the center. Please fix it the
knocks or the setting bolts etc., because the center sometimes slide during
operation after setting.

2) Please make the foundation and the bed to be the sufficient strength and
tighten the bolts certainly. It becomes the cause of a vibration and noise.

3) Please install the couplings, the sprockets and the pinions to the input or
output shafts after warming them without fail. There are the fears that the
bearings are damaged and the inside clearances are changed, when you push
and strike to the shaft strongly.

5. Operation

！ Warning

●Never touch or approach to the rotating parts (output shaft etc.) during operation.

！ Caution

●Please do not insert the things, to the opening of the reduction gear.
There is that of a device damage.

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 5-1.procedure of operation

(1) Our products are exclusively supplied without oil and so oil has to be
filled to the specified level. (Ref. Table 1)

(2) Supply oil from the specified inlet port to prevent dust and rainwater etc.

(3) Check the oil level by use of oil gauge, when the product is not in
operation, and oil is at ordinary temperature.

(4) Check all of the bolts are tightened.

(5) Before starting operation under no-load, perform inching operation and
check the rotating direction. Then perform no-load operation to make
sure that the operation is smooth.
After that, start operation under load increasing the load gradually.

(6) We recommend to measure the temperature, vibration and noise at

operation and to record the results of measurement.
These records will be a good guide to inspection and maintenance.

5-2.Keep or pause for long term

After delivery, if keeping or pausing for long term, put oil in the reducer
to specified amount of oil. And circulate oil by no-load running regularly
(once a month at least) to protect rust. If it is impossible to do no-load
running, fill them with oil. Before operation change for new recommended oil.

6. Lubrication

6-1. Recommended lubricant

We recommend the following as a lubricant.

(Extreme-pressure gear oil/SP system for an industry )

ambient
ISO VG EXXON MOBIL SHELL
temperature
-10℃∼+15℃ 68∼100 Mobil gear 626∼627 OMALA 68∼100
0℃∼+30℃ 150 Mobil gear 629 OMALA 150
+10℃∼+50℃ 220 Mobil gear 630 OMALA 220
-Table 1-

Above lubricant is JIS K2219 2 seed gear oil.

Oil quantity About 7 L（Confirm with the oil gauge）

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※In the case that there is the place of grease lubrication I recommend the following.
Nippon o il Co.,Ltd. Idemitsu Kosan Co.,Ltd. Shell Sekiyu KK ExxonMobil Sekiyu K.K

Multi knock grease 2 Daphne Eponex grease EP2 Shell Albania grease 2 Mobilux 2

6-2.Exchange standard

After an operation start

1st time ･･････････････ The early time 500 hours or 3 months.
2nd thereafter ････････ The early time, every 1500 hours or 6 months.

Note) (1) The purpose of the new oil exchange is in that removes the foreign
substance in oil at the same time as the deterioration measure of oil.
Please exchange it with new oil certainly without judging with only the
nature of oil.

(2) This exchange standard is a rough rule.

Please intend to earlier exchange, watching the load condition, rise of
temperature, dirt of oil after operation. And hasten more and please
intend it to a that exchange.

7. Maintenance and inspection

！ Warning

●Never touch the rotating parts (output shaft etc.), in the maintenance and inspection
during operation.

●Do not insert a finger, to the opening hole of the reduction gear.
There is that of a device damage.

●Do not touch with the hand, directory. Because the reduction gear become a high
temperature fairly during operation.

！ Caution

●Please carry out the diagnosis of case that abnormality occurred on the basis of
this operation manual. Never drive until measure processing is performed
and investigate the cause of abnormality.

●Please carry out the exchange of a lubricant in accordance with this operation manual.
Oil seed is used the one that is an our company recommendation without fail.

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●We take no responsibility, because the reconstruction of the product by a customer is
out of the guarantee of our company.

The maintenance and the inspection are important to do periodically.

Please carry out them in accordance with a following maintenance inspection listing.

Item Contents Time Measure

Oil quantity To an oil gauge Once a day Treat in a level
Lubricant
The early time 500 hours
1st
Exchange the oil of or 3 months
Exchange
the whole quantity. 2nd The early time every 1500
thereafter hours or 6 months
The To judge by
Watching Once a day
deterioration analysis result
Oil leakage Watching Once a day Repair
Bolt
Watching and Increasing
Looseness
tapping tighten
Air breather At the time the lubricant Exchange if it
Watching
of clogging exchange contains the oil.
Temperature Measure if it is
Touching Once a day
Changes abnormality
Vibration Touching Once a day 〃
Noise Hearing Once a day 〃

※A more reliable judgment can be done if a lubricating oil manufacturer

is asked for the analysis of the lubricating oil.

8. Exchange of a part

The exchange of a part may become necessary throughout using period.

When you exchange the parts, please use the recommended parts of our
company without fail.
Please prepare the spare parts for oil seals and o-rings, because they are
the articles of consumption.
The exchange standard is in the case that it did an oil leakage or when
overhaul.

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9. Disassembly and assembly

9-1.Disassembly

(1) Understand the structure of a reduction gear and decide a disassembly

order and prepare a necessary tool.

(2) Remove the dirt, accumulations that are adhering to a reduction

gear before disassembly.

(3) Stamp the marks on the divided flanges, not to mistake to assemble again.

(4) Be careful to change the thickness (the number of sheets) of adjustment

shim for tooth contact, using the bevel gears.

(5) Use the screw added to the bearing cover, drawing out them.

(6) Do not damage the rotated surface of the shaft, drawing out the covers
with oil seals.

(7) Do not damage to the shafts, removing the gears, bearings, couplings etc.
from them

(8) Remove liquid packing of the joints of the casings and covers.

(9) Store the disassembled parts, not to lose.

9-2. Assembly

(1) Confirm whether all the parts are assembled and please clean up them
with washing oil.

(2) Set the gears and the bearings to the shafts after warming them in
the oil bath until decided temperature.

(3) Spread the liquid packing to the joints of the casing and covers.
Be careful to spread around bolt hole especially, becoming the source
of oil leakage.

(4) Assemble to confirm the marks and the assembly direction.

(5) Adjust the tooth contact with the shims, using the bevel gears.

(6) Tighten the bolts and nuts with the prescription torque according to the
assembly drawings.

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 (7) Set the coupling and the sprocket to the shafts after warming them.

(8) Check the parts are remained.

10. Trouble shooting

Phenomenon Inspection point Cause Measure
Oil quantity is too much Regular level.
Defect of air bre ather Exchange or clean up
Biting of contamination Removal or Exchange
The abrasion of the
Repair or exchange
seal ring
Defect of setting Proper setting
Defect ( deformation )
(1) O il seal Exchange
of the seal
Defect of lubric ation to
Proper lubr icatio n
the oil seal
Life of the o il seal Exchange
Defect of seal due to the
unusual pressure Reduce the unusual pressure
occurrence
1) Oil leakage
Looseness of the bolt Increased tighten
Deterioration of liquid
Disasse mbly and spread it
packing
Defect of packing and
( 2) Joint Exchange
o-ring
Wounds and edges of
Repair
the joints
Biting of contamination Removal
(3) Screw part
Looseness of the bolt Increased tighten
(bolt hole and pipe joint)
Oil quantity is too much Regular level
(4) Air breather Heat expansion Refer to the clause of overheat
Defective of setting Proper setting
(5) Others Crack of the casing Repair or exchange
Oil quantity is too much
In a regular level adjustment
or less
Unsuitability of oil
specific ation Exchange to the recommended oil
(Especial1y viscosity)
2) Overheat (1) Casing Over load Control of road
Adjustment of a surroundings
Atmosphere temperature
Removal of dirt
Investigation and measures
Abnormality of a gear
of a cause

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 Phenomenon Inspection point Cause Measure
Defective of lubr ication Proper lubr icatio n
(2) O il seal Defective of seal Exchange
Defective of setting Proper setting
Defective of lubr ication Proper lubr icatio n
2) Overheat Less cle arance of a Exchange a bearing of proper
bearing clearance
(3) Bear ing unit
Defective of setting Proper setting
Abnormality of a
Exchange a bearing
bearing
Less stiffness of
Stiffness up
(1) Foundation foundation
Looseness of the bolt Increased tighten
(2) Coupling Miss centering Adjustment of center
Investigation and
(3) Gear Damage of gear
3) Vibration measures of a cause
/noise Investigation and
(4) Bear ing Damage of be aring
measures of a cause
Abnormality of the Investigation and
prime mover and measures of a cause
(5) Other influence
the driven one
Over load Control of load

11.Attached drawing

(1) Outline drawing D/#: G3084755E

(2) Assembly drawing D/#: G3085248E
(3) Parts list D/#: G4089028E

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