Setup Guide

1. The gearbox installation location must have sufficient rigidity to prevent vibration.

2. In cases where impact loads, overloads, or seizure are likely, hydraulic couplings, output torque limiters, clutches, and similar devices should be used.

Note: Clutches are available in many types and for various applications; therefore, their correct selection and proper operation in transmitting motion from the motor to the gearbox and from the gearbox to the machine have a significant effect on the service life of the gearbox.

3. Before start-up, ensure that the gearbox output shaft is perfectly aligned with the machine input shaft. This issue accounts for the highest percentage of gearbox failures.

Note 1: Proper gearbox operation cannot be expected without correct machine design and assembly.

Note 2: When fitting the output shaft or machine input shafts into the gearbox hollow shaft machined to H7 tolerance, an h6 tolerance must be applied. Mismatch of tolerances or improper installation can cause irreversible damage to all gearbox components.

Note 3: Accurate keyway tolerances ensure smooth operation of both the gearbox and the machine; lack of accuracy results in excessive noise and premature failures.

4. In gearmotors, the motor must not be mounted directly to the frame. Doing so causes misalignment between the motor and gearbox shafts and leads to problems such as bearing damage, bearing overheating, input shaft breakage, excessive gearbox noise, and oil leakage from the seals. In such cases, it is sufficient to mount only the gearbox securely and accurately leveled on the frame.

Note: When installing the electric motor via a coupling, shaft alignment between the motor and the gearbox is of critical importance.

5. When power is transmitted from the electric motor to the gearbox via belt and pulley, belt tensioning must be carried out carefully and inspected at scheduled intervals, as belts stretch and loosen over time, resulting in excessive slippage.

Note: If the belt is too loose, excessive slippage occurs and speed transmission is incorrect; if it is overly tight, excessive radial loads are applied to the bearings, causing overheating and failure.

6. If the gearbox is painted after installation on the machine, the oil seals must be protected from paint contamination to prevent damage.

7. To prevent corrosion of the gearbox base and the mounting frame, first clean the contact surfaces and then apply grease.

8. Before start-up, always ensure that the oil level in the gearbox is sufficient.

Note: Some gearboxes are supplied with a “No Oil” label and must be filled with the specified amount of oil during installation.

9. For worm gearboxes of types VF, MVF, RVF, MRVF, VF-VF, and MVF-VF, it is recommended to apply 50% to 70% of the rated load during the initial operating period and only apply full load after 300 operating hours. Additionally, the oil in these gearboxes must be drained after the first 48 hours of operation, the housing cleaned, and new oil filled to the normal level. This is because, during the initial running-in period, very fine bronze particles—generated by the bedding-in of the worm shaft and bronze worm wheel—accumulate in the housing and, if not removed, can gradually damage the bearings.

10. For gearboxes requiring mineral oils, it is recommended to drain the initial oil after 500 to 1000 operating hours, flush the housing, and refill with clean oil to the normal level. Thereafter, the gearbox oil must be replaced every 4000 operating hours.

11. If it is expected that the gearbox will remain unused for a relatively long period before commissioning, the housing should be completely filled with oil and inspected again prior to start-up.

12. In gearboxes filled with combined grease, no additional lubrication is required at start-up. The lubricant should be replaced after every 8000 operating hours.

13. Before starting the gearbox, always ensure that the machine operates freely and smoothly, as any obstruction in smooth operation can lead to rapid gearbox failure (even during start-up).

Note: In certain machines, such as stone-cutting machines that use water, freezing in winter can cause excessive resistance; therefore, smooth operation must be ensured before start-up.

14. Gearboxes used in shaft-mounted configurations must be installed with a reaction arm, and mounting them directly to the frame is strictly prohibited.

Note: Shaft-mounted gearboxes refer to gearboxes whose hollow shaft is mounted directly onto the machine input shaft, including all hollow-shaft gearboxes installed in this manner.

15. Any disassembly and reassembly, modification of the gearbox structure, drilling of the housing, or alteration of mounting bases will result in gearbox damage and void the warranty. Additionally, it has been observed that some users drill the gearbox housing without disassembly, causing metal chips to enter the gearbox and leading to rapid wear of the gears.