球磨机使用说明书

河南固德重型机器制造有限公司球磨机使用说明书电话：86-传真：86-邮箱：网址：.com目录一、球磨机介绍………………3二、重要技术参数……………6三、球磨机的安装……………6 1.付底板安装…………42.主底板安装……………93.主轴承及轴承座安装…………………104.筒体安装………………115.安装轴承盖……………146.安装润滑系统…………147.安装传动部……………148.小齿轮轴组的安装……………………169.安装慢速驱动装置、气动离合器及主电机…………1710.二次灌浆……………1811.附件安装……………18四、试运转……………………181、试运转前的准备工作………………182、试运转规定…………18五、球磨机的操作、维护和检修……………191、操作规程……………202、维护规程……………203、检修规程……………21六、常见故障及解决方法……………………22一、球磨机介绍Introductionofballmill球磨机是物料被破碎之后，再进行粉碎的核心设备。合用于粉磨多个矿石及其它物料，被广泛用于选矿，建材及化工等行业，可分为干式和湿式两种磨矿方式。根据排矿方式不同，可分格子型和溢流型两种。根据筒体形状可分为短筒球磨机、长筒球磨机、管磨机和圆锥型磨机四种。Ballmillisthekeyequipmentmaterialbeingbroken,andthentosmash.Suitableforallkindsoforesandothermaterials,iswidelyusedinmineraldressing,buildingmaterialindustryandchemicalindustry,etc,canbedividedintodrytypeandwetgrindingway.Accordingtotherowoforeindifferentways,canbedividedintogridtypeandoverflowtypetwokinds.Accordingtothebarrelshapecanbedividedintoashorttubeballmill,longtubeballmill,tubemill,andconicalgrindingmachine.二、重要技术参数Maintechnicalparameters规格型号Type筒体转速(r/min)Speedofrotary装球量(t)Ballload进料粒度(mm)Inputsize出料粒度(mm)Outputsize产量(t/h)capacity功率(kw)power重量(t)weightφ900×180036-381.5≤200.075-0.890.65-218.54.6φ900×3000362.7≤200.075-0.891.1-3.5225.6φ1200×2400363≤250.075-0.61.5-4.83012φ1200×3000363.5≤250.074-0.41.6-53712.8φ1200×450032.45≤250.074-0.41.6-5.85513.8φ1500×300029.77.5≤250.074-0.42-57515.6φ1500×45002711≤250.074-0.43-69021φ1500×57002812≤250.074-0.43.5-613024.7φ1830×300025.411≤250.074-0.44-1013028φ1830×450025.415≤250.074-0.44.5-1215532φ1830×640024.121≤250.074-0.46.5-1521034φ1830×700024.123≤250.074-0.47.5-1724536Φ2100×300023.715≤250.074-0.46.5-3621034Φ2100×450023..724≤250.074-0.48-4324542φ1830×700023.726≤250.074-0.48-4328050φ2200×450021.527≤250.074-0.49-4528048.5φ2200×650021.735≤250.074-0.414-2637052.8Φ2200×700021.735≤250.074-0.415-2838054φ2200×750021.735≤250.074-0.415-3038056φ2400×45002130≤250.074-0.48.5-6032065φ2700×400020.740≤250.074-0.412-8040094φ2700×450020.748≤250.074-0.412-90430102φ3200×45001865≤250.074-0.425-130800137三、球磨机的安装Theinstallationoftheballmill1.付底板安装Payfloorinstallation1）.在安装主底板前基础表面应去除杂物、污垢，在施工中不得使基础表面沾染油污。磨机各底板采用付底板（平垫铁）调平方式，全部付底板应在指定位置浇注，用于底板安装的平面和水平度安装参考。普通相邻付底板之间的距离宜为300～800mm，每一种地脚螺栓两侧应放置两个付底板。Beforeinstallthebottomfoundationsurfaceshouldberemovingdebris,dirt,andshallnotbemadeintheconstructionfoundationsurfacewithoilpollution.Betweeneachfloorofthemillusepaybaseplate(flatshim)levelingmethod,allshouldpaybackplanecastinginthelocationspecified,usedforinstalledfloorplaneandlevelnessofreference.Generallythedistancebetweentheadjacentpayfloorappropriatefor300~800mm,eachflooronbothsidesoftheanchorboltshouldbeplacedtwopay..安装付底板时应去除掉表面防锈油，付底板安装采用座浆法。配制水平砂浆堆（无收缩细石混凝土）所采用的原材料应符合国标《钢筋混凝土工程施工及验收规范》（修订本）的规定，水平砂浆堆混凝土的强度应高于设备基础一种标号。Installingapayfloorshouldbeclearedsurfacerust-proofoil,payfloorinstallationusinggroutingmethod.Preparationhorizontalslurrypile(nocontract)offinestoneconcreterawmaterialsshouldcomplywiththenationalstandardsadoptedbythe"reinforcedconcreteengineeringconstructionandacceptancenorms"(revisededition),thelevelofmortarofconcretestrengthalabelshouldbehigherthantheequipmentfoundation..在设立付底板（平垫铁）的混凝土基础部位凿粗糙，并去掉浮浆，每块付底板用四个螺栓固定和调节具体见图。用精密水准仪配合，通过调节螺母来调节付底板的水平度和标高，付底板的水平度偏差应不大于0.1mm/m，顶面标高应为主底板底面标高或稍低于底面标高，不允许高于主底板底面标高。Insettingpaybaseplate(flatshim)concretefoundationpartoftheroughcut,andremovethefloatingcement,eachpayfloorwithfourboltsandspecificseechartadjustment.Cooperatewithpreciselevel,byadjustingnuttoadjustthelevelnessofthepayfloorandelevation,thelevelnessofthepayfloordeviationshouldbelessthan0.1mm/m,toplevelshouldgiveprioritytobottombottomelevationorslightlybelowthebottomlevel,abovethemainfloorbottomelevationisnotpermitted.图.付底板调节合格后，用水冲或用压缩空气吹、去除基础上的杂物，按图制作安装好模板，并用水浸润混凝土坑约30min，先涂一层素水泥浆，随即将搅拌好的混凝土灌入模板内。灌时应分层捣固，持续捣至浮浆表层。Payplateadjustmentafterqualified,flushwithwaterorwithcompressedairblowing,cleartheclutteronthebasis,accordingtothefigureinstalledtemplates,andwaterseepageofconcretepit,about30min,putalayerofcementpaste,andthenwillbeshippedwithinthetemplateconcretemixture.Irrigationshouldbelayeredtamping,continuousdaotofloatplasmasurface.图付底板座浆示意图Payplatepasteschematicdiagram付底板座浆混凝土堆凝固后，复测每块付底板水平度和标高。检查合格后去除多出灌浆，夏季盖上草袋并浇水湿润养护，冬季施工应盖上塑料布并加保温方法，还要按规定加早强防冻剂，至座浆混凝土完全固化（最少需48小时）方可安装主底板，养护期间不得碰撞和震动付底板。Payfloorgroutingconcretepileaftersolidification,retesteachpayfloorelevationandlevelness.Inspectionqualifiedaftergrouting,removeexcesswatercoverthestrawbaginsummerandwetcuring,winterconstructionshouldcovertheplasticandinsulationmeasures,butalsoinaccordancewiththeprovisions,andearlystrengthantifreeze,toslurryconcretecured(atleast48hours)toinstallthebaseplate,themaintenanceperiodshallnotpayplatecollisionandvibration.2.主底板安装Themainfloorinstallation1）安装主底板前先清洗各加工面防锈油和铁锈，去除毛刺，与付底板接触的地方如有涂漆，必须清理到完全见金属。Eachprocessingsurfacebeforeyouinstallthefloorcleaningrust-proofoilandrust,deburring,wherecontactwiththepayfloorpaint,ifany,mustbecleartoseethemetalcompletely.2）以设备与主底板连接螺栓孔为基准，划出主底板中心线，并打清晰印坑。用精密水准仪测量每块付底板上表面标高并作统计，同时测量主底板的厚度差，测点在调节斜铁组附近，并统计。Basedonequipmentconnectedtothemainfloorbolthole,underlinethecenterlineofthemainfloor,andmakeclearthesealpit.Eachpayfloorsurfaceelevationismeasuredwithapreciselevelandrecords,measuringthethicknessofthemainflooratthesametime,measuringpointneartheadjustmentAngleirongroup,andrecord.主底板就位前将锈垢油污去除干净的地脚螺栓放入预留套管内，主底板就位的同时穿好地脚螺栓，螺栓应在螺栓孔中间位置。按主底板上表面规定的设计标高拟定每堆付底板上垫片厚度，用尽量少的垫片使底板达成所规定的高度，垫片采用不锈钢钢板。紧固地脚螺栓后，先用精密水准仪、框式水平仪、塞尺测量调节主底板水平度和标高，再用30m长卷尺，挂线调节主底板的纵横向中心线位置和对角线尺寸。主底板和调节垫片之间要全方面接触，用塞尺在侧面检查，并从侧面轻轻敲击调节垫片，以不松动为合格，两主轴承的底板的标高相对差应不大于0.08/1000（进料端应高于出料端），水平度偏差应不大于0.08/1000（中部应高出两边，不允许出现中间凹下状况），纵横向中心线偏差不超出±1.0mm，两主轴承底板中心线平行度偏差不应不不大于0.08/1000，跨度和对角线偏差应不大于1.5mm，筒体与端盖组装后的实际跨度如与设计尺寸存在偏差，在这种状况下应当在获得有关方面同意后，按实际尺寸施工。Beforethemainfloorisinplacewillrustscalereservesmearycleananchorboltintothecasing,themainfloorisinplaceatthesametimeweargoodanchorbolt,boltshouldbeinthemiddleoftheboltholeposition.Accordingtotherequirementsofthemainfloorsurfacedeterminethedesignelevationofeachpiletopaybaseplatethicknessofthegasket,aslittleaspossibleoftheshimplateheightrequired,gasketismadeofstainlesssteelplate.Tightentheanchorbolts,withpreciselevelfirst,boxtypewaterlevelgauge,feeleradjustthemainfloor,levelnessandelevationwitha30mlongmeasuringtape,hanginglinepositionandadjustthebottomhorizontalcenterlineofthediagonalsize.Lordwillfullycontactbetweenbaseplateandtheadjustingshim,checkwithfeelerinflank,andtappingtheadjustmentgasketfromtheside,inordertonotlooseasqualified,twoofthemainbearingfloorelevationrelativedifferenceshouldbelessthan0.08/1000()shouldbehigherthanthematerialfeedendend,levelnesserrorshouldbelessthan0.08/1000(centralshouldbehigherthanthatofbothsides,notallowedtoappearundermiddleconcave),horizontalcenterlinedeviationnotmorethan+/-1.0mm,thecenterlineofthetwomainbearingbaseplateparalleltothedegreeofdeviationshouldnotbegreaterthan0.08/1000,spananddiagonaldeviationshouldbelessthan1.5mm,thecylinderandtheendcoverassemblyaftertheactualspan,thereexisterrorssuchasthesizeanddesign,inthiscaseshouldbeinobtainrelevantapproval,accordingtotheactualconstructionsize地脚螺栓紧固后，螺栓垂直度误差在1/1000mm以内，合格后向地脚螺栓套管内灌入干燥的河沙或填入油麻，在距套管口200mm深时用水泥砂浆封口。地脚螺栓的螺母下面必须加垫圈，地脚螺栓应当用锁紧装置锁紧，可用弹簧垫圈或双螺母，座浆细石混凝土达成设计强度75%以上，才允许拧紧地脚螺栓。Aftertheanchorbolts,boltverticalityerrorwithinthe1/1000mm,afterqualifiedtoanchorboltcasingintodryriversandorfillinoilflax,andin200mmdepthfromcasingmouthsealedwithcementmortar.Undertheanchorboltnutmustaddthegasket,theanchorboltsshouldbeusedforlockingdevicelocking,springwasherordoublenutsareavailable,andapulpfinestoneconcretemeetthedesignstrengthofmorethan75%,areallowedtotightentheanchorbolts.3.主轴承及轴承座安装1）安装前应拆卸主轴承，清洗全部部件上的用于运输的保护性涂层。认真检查全部零件，去除全部可能影响操作的划痕或毛刺。安装主轴承和磨机筒体时，必须特别小心地去除轴承上及轴承座内部管路的任何杂物，并避免杂物进入轴承。铜瓦很容易损坏，表面始终要保护。Beforeinstallationshouldremovethemainbearing,cleanallthepartsontheprotectivecoatingfortransport.Carefullycheckallthepartstoremoveallmayaffecttheoperationofthescratchorburrs.Installthemainbearingandmillcylinder,mustbeespeciallycarefultoremovethebearingandthebearingseatinternalpiping,sundriesandpreventdebrisintothebearing.Coppertileiseasytodamage,thesurfaceisalwayswanttoprotect.用车间内50t起重机将轴承座吊装到主底板上，规定主轴承座与底板的接触沿其四周应均匀接触，局部间隙不得不不大于0.1mm，不接触的边沿长度不得超出100mm，累计总长不超出四周总长的1/4。Usingworkshopwithin50tcranewillbebearingassemblytothemainfloor,requirementsofthemainbearingandthebottomshouldbeevenlyaroundthethecontact,thelocalclearanceshallnotbegreaterthan0.1mm,donottouchtheedgeofthelengthnotexceeding100mm,totallengtharoundnomorethan1/4oflength.3）初步找正轴承座lookingforbearing将轴承座放在主轴承底板上，在轴承座的顶部法兰和轴承座的鞍座上拟定磨机的纵横中心线标记，用冲子打上样冲眼，。P-P上标记K1、K2、K3、K4、N1、N2、N3、N4应当放在两个法兰和鞍座上与中心等距的相似位置上，使（K1-K2）和（K3-K4）达成相似尺寸可使轴承座达成平行，为确保轴承座与磨机中心线垂直，必须让（K1-K4）和（K2-K3）间距相似，最大允许误差±0.4，即：（K1-K2）=（K3-K4）=F±0.4，（K1-K4）=（K2-K3）±0.4。中心线L-L应与磨机中心线相重叠（可用一条长钢丝作模拟），并与主轴承底板的中心线重叠。先固定出料端底座，再调节进料端底座。调节好后拧紧轴承座的螺栓，后来做任何必要的调节均须重新检查全部以前的统计。将瓦体装配（涉及瓦体和铜瓦）安装到轴承座上，找正瓦体装配对瓦座的中心线。按主轴承装配图规定调节好压板与铜瓦和鞍形轴瓦座之间的间隙后，拧紧压板。用水平仪，运用磨机的参考水平中心线调节轴承使两轴承达成相似高度。Putthebearingseatonthemainbearingbaseplate,flangeatthetopofthebearingandbearingsaddledeterminetheverticalandhorizontalcenterlineofmarkofgrinder,punchwithapunchonthesample,P-PmarkK1、K2、K3、K4、N1、N2、N3、N4.Shouldbeplacedintwowiththecenterflangeandthesaddleequidistantonthesameposition.Make(K1,K2)and(K3,K4)toachievethesamesizecanmakethebearingtoparallel,inordertoensurethebearingseatwiththecenterlineoftheverticalgrindingmachine,mustlet(K1-K4)andspacing(K2,K3),themaximumpermissibleerrorofplusorminus0.4.thatis（K1-K2）=（K3-K4）=F±0.4，（K1-K4）=（K2-K3）±0.4.CenterlineofL-Lshouldoverlapwiththemillcenterlinephase(oralongwireforsimulation),andwiththecenterlineofthemainbearingbottomoverlap.Dischargeendofthebasefirst,andthenwewilladjustthefeedendofthebase.Afteradjustaftertightentheboltofthebearing,makeanynecessaryadjustmentsmustbemadetoreviewallpreviousrecords.Thetilebodyassembly(includingtilebodyandcoppertile)installedonthebearingseat,lookingforisthetilebodyassemblycenterlineofbowl.Accordingtotherequirementsofmainbearingassemblydrawingtoadjustpressureplateandcoppertileandbridgethegapbetweenthesaddlebearings,tightentheclamp.Uselevel,usethecenterlineofthereferenceleveladjustmentbearinggrindingmachinetomakethetwobearingstothesameheight4）轴承最后调节Bearingthefinaladjustment磨机筒体就位后，必须进行轴承最后调节。磨机中空轴安装到轴承内，测量中空轴和铜瓦之间的间隙，铜瓦和瓦体之间的间隙应当达成下列规定（见图）：A1+C1=B1+D1，E1+G1=F1+H1,A2+C2=B2+D2，E2+G2=F2+H2以上最大允差为铜瓦直径的0.08mm/m。用直角方尺校正瓦体和瓦座中心线，使两者不重叠度误差在0.75mm以内。Aftermillcylinderinplace,bearingmustbecarriedoutinthefinaladjustment.Millhollowshaftmountedtothebearings,themeasurementofhollowshaftandcoppertile,thegapbetweenthegapbetweencoppertileandtilebodyshouldmeetthefollowingrequirements(seefigure):A1+C1=B1+D1,E1++G1=F1H1,C2=A2+B2+D2,E2+G2=F2+H2Abovethemaximumtolerancesforcoppertilediameterof0.08mm/m.Usesquaremeterscalibrationtileandtilebodycenterline,makenocoincidencedegreeboththeerroriswithin0.75mm.4.筒体安装Cylinderisinstalled1）安装准备Installationpreparation筒体部件由筒体和两端的端盖、中空轴构成，筒体本体在长度方向分为3段，每段在圆周方向再分为2半，安装前彻底清洗筒体法兰及端盖的配合表面，去掉油污和毛刺，去除法兰面、中空轴颈和连接孔内的防锈油，确保法兰对接时干燥清洁，但应注意保护组装标记。检查各连接螺栓、螺母与否损坏，认真清洗并修复，螺栓、螺母必须无松动现象、毛刺等。安装前全部的螺栓、螺母及螺柱都必须表面清洁并干爽，不允许有油污。精确测量筒体的长度，方便实测筒体端盖组装后两中空轴中心的间距。确认对位标记。制作4个装配筒体、端盖用的过冲，直径比螺栓孔小约0.2mm，长度不不大于把和法兰总厚度，两端为锥形，锥度约为1:50。筒体就位后紧固螺栓时要及时搭设紧固螺栓用的脚手架操作台。Attheendsofthecylinderpartsbycylinderandendcover,hollowshaft,cylinderbodyinlengthdirectionintothreesegments,eachsegmentinthecircumferentialdirectionandisdividedintotwoandahalf,andbeforetheinstallationthoroughlycleancylindersurfaceoftheflangeandthematchingbetweentheendcover,removegreaseandburr,removeflangesurfacerust-proofoil,hollowshaftneckandtheconnectionhole,ensurecleanflangebuttwhendry,butshouldpayattentiontoprotecttheassemblymark.Carefullychecktheconnectingbolt,nutwhetherisdamaged,cleaningandrepair,boltandnutmustbefreeofloosephenomenon,burr,etc.Beforeinstallation,allbolts,nutsandstudsmustbecleananddrysurface,thereisnopollution.Accuratelymeasurethelengthofthecylinder,sothatthemeasuredcylinderendcoverassemblyaftertwospacinginthecenterofthehollowshaft.Confirmtheregistrationmark.Makefourcylinder,endcoverassemblywithovershoot,smalldiameterthantheboltholeabout0.2mm,lengthisgreaterthanthetotalthicknessandtheflangeandendsasthecone,taper1:50.Cylinderinplaceaftererectionintimetowhenfasteningboltfasteningboltwithscaffoldingworkstation.2）中间段筒体组装Middlesectionofthecylinderassembly按顶升装置布置图将磨机顶升装置2个托架放在中部尽量靠近法兰的部位，用于支撑中间段筒体。在托架钢支墩下用垫板调节托架的标高，托架高度按筒体放在临时钢架上的纵向中心高出筒体设计中心标高约100mm设立，两托架相对标高差应不大于1mm，钢托架及支墩应确保垂直度不大于0.1/1000；托架纵向中心线要与筒体中心线重叠，其偏差应不大于1mm，横向中心线应与主轴承平行，其偏差应不大于0.2/1000，然后用4根槽钢将两托架上部与基础固定，测量好靠近出料端的托架横向中心距主轴承横向中心线的距离，标示好靠近出料端的托架中心线。在中间段半筒体上根据筒体就位尺寸及靠近出料端的托架距主轴承横向中心线的距离，划好标记线，用车间内50t起重机将中段半筒体吊装就位，就位时中间段半筒体的标记线应对准托架上标示的中心线，将另外中间段半筒体吊装就位，两半中间段筒体组装时用过冲对准铰制螺栓的螺栓孔。中间段半筒体就位时中分法兰倾斜150，吊线复查中间段半筒体出料侧法兰距出料侧主轴承的距离，其偏差应不大于1mm。两半筒体组装螺栓紧固时按交叉分步原则打入、紧固精制螺栓，再拧紧全部螺栓。螺栓紧固完后用0.04mm塞尺检查法兰间的接缝，任何位置塞尺插入深度不得超出25mm。Accordingtothetopofunitlayoutwillmilljack-upunit2bracketinthemiddleasfaraspossibleclosetotheflangeparts,usedtosupportthemiddlesectionofthecylinder.Underthebracketsteelpierswithelevationadjustmentplatebracket,bracketheightaccordingtothecylinderonthetemporarysteellongitudinalcenterabovethecylinderdesignelevationofabout100mmset,twobracketrelativeelevationdifferenceshouldbelessthan1mm,steelbracketandpiersshouldguaranteetheverticalityislessthan0.1/1000;Bracketlongitudinalcenterlinetothecenterlineofthecylinder,thedeviationshouldbelessthan1mm,lateralcenterlinesshouldbeparalleltothemainbearing,thedeviationshouldbelessthan0.2/1000,thentheuppertwobracketswithafourchannelsteelandthebaseisfixed,measuringwellclosetothedischargeendbrackethorizontalcenterdistancefromthecenterlineofthemainbearingtransverseofthelabeledgoodclosetothecenterlineofthedischargeendbracket.Onthemiddlesectionofthehalfcylinderaccordingtothesizeofbarrelisinplaceandclosetothedischargeendbracketfromthecenterlineofthemainbearinghorizontaldistance,rowtagline,intheworkshopof50tcranewillbethemiddlehalfbarrelhoistinginplace,isinplacewhentheidentityofthemiddlesectionofthehalfcylinderlineshouldaimatthecenterofthebracketmarkedontoanotherinthemiddlesectionofthehalfcylinderhoistinginplace,whentwohalf-wayupsectionofthecylinderassemblyusedonhingeboltinthebolthole.Pointsoftheflangeinmiddlesectionofthehalfcylinderinplace150,reviewofthemessengerwiremiddlesectionofthehalfcylinder3）出料端筒体组装Dischargeendofthecylinderassembly在出料端筒体下方尽量靠近法兰的部位，布置4个千斤顶，用枕木和垫板调节好千斤顶的标高和垂直度，在千斤顶上安装两个托架，用于支撑出料端筒体，其安装规定与中间段筒体托架安装规定相似，但托架下方还应用枕木和钢板垫实，作为辅助安全方法。用车间内50t起重机将出料端半筒体在中分面水平状态下，按两段筒体对接标记初步吊装就位，就位时出料端半筒体尽量靠近中间段筒体，通过千斤顶初步对准法兰孔，将该半筒体上的定位销装入法兰孔，按圆周12等分先穿上6个螺栓，然后将另外出料端半筒体吊装就位，两半中间段筒体组装时用过冲对准铰制螺栓的螺栓孔，两半筒体组装螺栓紧固时按交叉分步原则打入、紧固精制螺栓，再拧紧全部螺栓，螺栓紧固完后用0.04mm塞尺检查法兰间的接缝，任何位置塞尺插入深度不得超出25mm。将其它筒体对接法兰定位销装入法兰孔，按圆周12等分穿上12个对接法兰螺栓，以深度千分尺或深度游标卡尺测量两筒体法兰对齐状况，并用千斤顶进行调节，然后按圆周等分成12个点用塞尺测量两个法兰之间间隙。调节间隙均匀且法兰对齐后，逐步拧紧12个螺栓，实现筒体的对接。然后精调两筒体的同心度，法兰同心度规定偏差不大于0.25mm，可用小平尺垂直贴靠在高出的法兰上，然后以塞尺检查平尺底面与另一法兰之间的间隙。调节好同心度后，拧紧全部螺栓，扭矩值应达成设备技术文献规定。拧紧螺栓只能使用校准的扭矩扳手，并且应当对称均匀地把紧。预紧力矩的紧固应当分3个环节来进行：第一步是全部螺栓拧至二分之一的力矩值，第二步是全部螺栓拧至全部的力矩值，第三步是以整个力矩值来重新检查。Asfaraspossibleclosetotheflangeatthebottomofthedischargeendofthecylinderparts,fourjacks,withtieandadjustjackplateoflevelandverticaldegree,installtwobracketsinthejack,usedtosupportthedischargeendofthecylinder,theinstallationrequirementsthesameasthemiddlesectionofthecylinderbracketinstallationrequirements,butbelowthebracketalsousedsleepersandsteelpads,asasupplementarysafetymeasures.Workshopwithin50tcranewilldischargeendofthehalfcylinderinthesplitlevelstatus,accordingtotwopiecesofshellbuttjointmarkpreliminaryhoistinginplace,isinplacewhenthedischargeendhalfbarrelasfaraspossibleclosetothemiddlesectionofthebarrel,throughpreliminaryontheflangehole,jackwillbethelocatingpinonthehalfshellintotheflangehole,accordingtothecircumferenceofacircleof12partsputon6bolts,thenhalfbarrelhoistinginplaceanddischargingend,twohalf-wayupsectionofthecylinderassemblyusedtorushonthehingeboltinthebolthole,twoandahalfcylinderassemblyboltsaccordingtotheprincipleofcrossstepbystepinto,tightenboltsofrefined,tightenallbolts,boltsafteruse0.04mmfeelercheckbetweentheflangejoint,anylocationpininsertiondepthofnomorethan25mm.Willdockothercylinderflangepositioningpinintotheflangehole,accordingtothecircumferenceofacircleof12equalpartsputon12intermediateflangebolts,withadepthmicrometerordepthverniercalipersmeasuretwocylinderflangealignment,andjack,thenaccordingtothecircular,etcinto12pointsgapbetweenthetwoflangesismeasuredwithafeeler.Afteradjustthegapuniformityandflangealignment,graduallytighten12bolts,cylinderofdocking.Thenfinetunetwocylinderconcentricity,deviationislessthan0.25mmflangeconcentricityrequirements,availablexiaopingfeethigherthanthatofverticalstickonflange,thentofeelercheckrulergapbetweenbottomandtheotherflange.Afteradjustgoodconcentricity,tightenallbolts,torquevalueshouldmeettherequirementsofequipmenttechnicaldocuments.Tightentheboltscanonlybeusedforcalibrationoftorquewrench,andshouldbesymmetricalevenlytotight.Pre-tighteningtorquefasteningshouldbedividedintothreestepsto:thefirststepisallboltstwisttohalfofthetorquevalue,thesecondstepistoallthebolttwisttothetorquevalue,thethirdstepisthetorquevaluestocheckagain.4）进料端筒体组装Feedendofthecylinderassembly出料端筒体与中间段筒体组装好后，将筒体下方4个托架中的中间两个托架拆除，并用钢支墩将4个千斤顶替代出来，按条中的程序和规定安装进料端筒体。Dischargeendandmiddlesectionofthecylinderbarrelafterassembled,thecylinderbelowfourbracketinthemiddletwobrackets,withfourjacktoreplacesteelpierswillcomeout,theprograminaccordancewithclauseandaskstoinstallfeedendofthecylinder.5）端盖与筒体之间的安装Betweentheendcoverandthebarrelbodyinstallation端盖采用两台50t行车抬吊就位，端盖和筒体螺栓孔用定位销对齐后穿上1/4数量螺栓，用手拧紧，其中1/3半拧紧，调节同心度在0.25mm以内（办法与筒体对接相似），然后拧紧，检查合格后按规定力矩值，按交叉分步原则拧紧全部螺栓。但要注意安装出料端盖时，连接螺栓应避开大齿轮连接孔。安装完之后全部法兰之间用0.03mm塞尺检查间隙不得插入。Endcoveradoptstwo50tcraneliftingcraneinplace,theendcoverandbarrelboltholewithalocatingpinalignmentputonaquarterthenumberofbolts,handtight,aboutathirdofwhomhalfatight,adjusttheconcentricitywithin0.25mm(dockingmethodwithbarrelisthesame),andthentighten,afterinspection,accordingtotherequiredtorquevalueaccordingtotheprincipleofcrossstepbysteptotightenallbolts.Butshouldpayattentiontowhendischargingendcoverinstallation,connectionboltconnectingholeshouldbetoavoidthebiggear.Afterinstallationofallflangeswith0.03mmfeelercheckclearanceshallnotbeinserted.6）端盖与中空轴组装Withhollowshaftendcoverassembly中空轴按照装配标记与端盖进行安装，用扭矩扳手按设备技术文献规定扭矩分别对内外层螺栓按交叉分步原则拧紧。Hollowshaftaccordingtothetagandtheendcoverassemblyforinstallation,usethetorquewrenchinaccordancewiththeequipmenttechnicaldocumentsrequiredtorquerespectivelyinternalandouterboltsaccordingtotheprincipleofcrossstepbysteptight.7）筒体就位Cylinderinplace中空轴和筒体组装在一起，并经检查无误后，对组装后的筒体必须测量，其总的长度及两轴颈中心的长度，与轴承座中心距比较，如不符需调节轴承座或主底板位置。在向主轴承上安装筒体之前，应再次将主轴承内部及端盖轴颈彻底清洗干净，在安装筒体时绝对严禁在端盖轴颈上拴钢丝绳，在安装过程中要尽量避免灰尘杂物落到轴瓦面上。用顶起装置将筒体装配慢慢的落入轴承，应当采用方法将筒体安装到对的位置，在这个过程中应极其小心和耐心，避免碰伤铜瓦。筒体安装在主轴承上之后，应进行检查。两端盖轴颈上母线应在同一水平面上，其相对标高偏差不应超出1mm，并使进料端高于出料端,然后按条环节进行轴承最后调节和主轴承底板二次灌浆。去掉筒体内支撑，注意不要损伤筒体。拆卸托架和吊耳等。Hollowshaftandcylinderassemblytogether,andaftercheck,afterassemblyofthecylindermustbemeasured,theoveralllengthandthelengthofthetwoshaftcenter,comparedwiththebearingcenterdistance,suchasthepositiontoadjustormainbearingbaseplate.Beforetothemainbearingsareinstalledonthebarrel,shouldbewillagaininsidethemainbearingandendcover,shaftneckthoroughlycleanclean,wheninstallingabarrelabsolutelyforbiddenontheendcovershaftnecktiedrope,duringtheinstallationprocessshouldtrytopreventdust,debrisfallstothebearingsurface.Cylinderwithajackingdeviceslowlyfallintothebearingassembly,shouldtakemeasurestoinstallthecylindertotherightplace,intheprocessshouldbeverycarefulandpatience,toavoidbruisingcoppertile.Cylinderinstalledonthemainbearing,shouldbechecked.Twoendcovershaftneckbusbarshouldbeinthesamehorizontalplane,therelativeelevationdeviationshouldnotbemorethan1mm,andthefeedendishigherthanthedischargingend,andthenpressforbearingendarticlestepsandmainbearingbaseplatesecondarygrouting.Removethecylinderbody,becarefulnottodamagetocylinder.Removethebracketandliftinglugs,etc.5.安装轴承盖Installthebearingcap调节合格后来，用轴承装配图注明的连接件将轴承盖安装到轴承座上，在安装轴承盖之前，拟定两端中空轴标高符合规定，轴颈和轴承座已彻底清洁，没有遗留杂物。将轴承箱内的三舍橡胶密封环、润滑管路系统和温度检测装置按图装好，不得漏装。Adjustmentafterqualified,withthebearingassemblydrawingindicatethefittingswillbebearingcoverinstalledonthebearingseat,beforeinstallingthebearingcover,determineelevationmeetstherequirementsonbothendsofthehollowshaft,shaftandbearingseatcleanthoroughly,nolegacyofsundry.Willthreerubbersealingring,lubricationofthebearinginthepipingsystemandtemperaturetestingequipmentaccordingtothefigureisgood,notpacking.6.安装润滑系统1）轴承稀油润滑站在安装之前，应彻底清洗油箱，经检查合格后方可进行安装。Bearingthinoillubricationstationbeforeinstallation,shouldbethoroughlycleantheoiltank,theinspectionqualifiedrearcanforinstallation现场配管，在一次安装之后，应拆除全部润滑管路钢管进行槽式酸洗，用20%的硫酸或盐酸溶液浸泡40～60分钟，当铁锈被去除之后，将管浸在3%的石灰水中30分钟使其中和，然后用清洁的水冲洗，并用压缩空气吹干（不能用氧气吹），然后在管子内注入润滑油，以防再次生锈，同时将管子两端堵严以防进去脏物。酸洗后不允许再进行焊接操作。将酸洗合格的油管二次装配。并列或交叉的压力管路，两壁之间应有一定的间距，以防振动干扰。回油管路必须向油箱方向倾斜，其坡度为85/1000～100/1000。Fieldpiping,afteraninstallation,shouldberemovedalllubricationpipelinesteelpicklingtrough,with20%sulfuricacidorhydrochloricacidsolutionsoak40~60minutes,afterrustremoval,thetubeimmersedin3%ofthemandlimewater30minutes,thenrinsewithcleanwater,usecompressedairtoblowdry(don'tuseoxygenblowing),theninjectedlubricatingoilinsidethepipe,incaseofrustagainwentintubepluggingstrictatbothendstopreventdirtatthesametime.Afterpicklingoperationbyweldingisnotallowedto.Thepicklingqualifiedtubingassembly.Parallelorintersectingpressurepipeline,shouldhaveacertainspacebetweentwowalls,incasethevibrationdisturbance.Returnlinemustbetiltedinthedirectionofoiltank,thegradientis85/1000~100/1000.润滑系统装配后，都应进行试压，各处冷却水管道实验压力不不大于0.45Mpa，规定在30min没有渗漏现象；高压管路实验压力不低于高压额定压力，试压10min。Lubricationsystemaftertheassembly,allshouldbepressuretest,coolingwaterpipetestpressurenotlessthan0.45Mpa,everywherein30minwithoutleakagephenomenon;High-pressurepipetestpressureisnotlowerthanthehighpressureratedpressure,thepressuretestfor10min.系统油循环Oilcirculationsystem用滤油机向箱加入冲洗油，将用油点的进回油管用软管短接，启动低压泵，交替运行高、低压系统的各个油泵，每台油泵大概两小时，直到滤油器始终保持干净状态时，为油循环合格，恢复全部油管。Toboxtojointheflushingoil,filteroilmachinewillusethepointintothereturnhosehosenipple,startlowpressurepump,alternatelyhighandlowpressuresystemofoilpump,oilpumpforabouttwohourseach,untiltheoilfilterhasmaintainedacleanstate,fortheoilcirculation,restorealltubing.7.安装传动部在安装之前，全部齿面和安装表面必须彻底清洗，特别是齿轮剖分面、齿轮与筒体结合面，解决全部的毛刺和磕碰伤。在向筒体上安装大齿轮之前，应先将下面的齿轮下罩就位，并对齿轮罩进行检查，如发现渗漏或变形，应立刻消除之，将其内部清洗干净。在大齿轮的螺纹孔内安装调节螺栓和锁紧螺母。在最后调节好后，锁紧螺母必须背死以免螺栓松动。如需转动筒体，则必须启动主轴承润滑站，使铜瓦和中空轴之间形成油膜。Beforeinstalling,alltoothsurfacesandinstallationsurfacemustbethoroughlycleanedandsubdivisionsurface,especiallygeargearandcylindersurface,handlealltheburrandknockedwounded.Beforetocylinderareinstalledonthebiggear,shouldbethefollowinggearunderthehoodinplace,andinspectthegearcover,leakage,ordeformationisfound,shallbeimmediatelyeliminate,itsinteriorclean.Inthebiggearofthethreadholeinstallationadjustingboltandlocknut.Afterthefinaladjustlocknutmustbacktodeathsoasnottoloosebolts.Forrotatingcylinder,youmuststartthemainbearinglubricationstation,makestheoilfilmformedbetweencopperandhollowshaft.半齿轮起吊时应以两根等长的吊绳从两边套穿在轮辐的空档内，为避免吊绳损伤齿轮，应在吊绳与大齿轮之间加防护垫。安装期间应在基础上加支撑，支承在筒体上（可用圆钢插入支撑上端圆孔和筒体螺栓孔内使之成一体）避免筒体旋转，第一种半齿轮起吊后扣在筒体上方，并对正筒体法兰和大齿轮法兰的连接螺栓孔，孔基本对好后将3个定位销装入法兰孔，穿入全部螺栓，每隔三个适力拧紧一种（不可太紧），其它用手拧紧即可，将大齿轮安装到筒体法兰上。在调节螺栓处安装定位垫块，螺栓头应对准垫块上的凹槽，用调节螺栓顶紧垫块来微调大齿轮的位置。用手拉葫芦配合行车旋转筒体，拆除筒体固定支撑，启动主轴承润滑站，使安装好的第一种半齿轮慢慢下转到磨机中心线下列的位置，下放过程应缓慢平稳，避免大齿轮和筒体作大幅度的摆动，对钢丝绳产生大的冲击。Halfliftinggearshallbemadeintwoequallengthon