What Are The Precautions For Daily Maintenance Of The Reducer?

1. Installation and adjustment

a. In order to ensure the assembly accuracy of the reducer, it is not necessary to start the machine during installation and do not damage the sealing and filling. You can check by opening the oil cover or use kerosene (diesel) to wash the surface of the gear with anti-rust grease.

b. Flexible couplings can also be used between the reducer and the motor or the main engine and other couplings. Gear couplings or other non-rigid couplings can also be used.

c. The reducer should be installed steadily and firmly, and the base adjustment gasket must be tight (steel gasket is used). The deviation of the coaxiality with the coupling shall not be greater than the allowable value of the coupling used.

d. Check whether the bolts on each contact surface of the box body are loose, and re-tighten them if they are loose.

2. Use and maintenance

a. The load test must be carried out before the reducer is officially used.

b. Before the load test, add lubricating oil according to the position of the oil mark, turn it by hand to make the output shaft rotate one circle, it must be flexible, and then run for two hours without abnormal noise.

c. During the load test, the load should be gradually loaded to full load (25%, 50%, 75%, and 100% should be loaded in four stages when possible), and the operation time of each stage should be no less than 2 hours, and it should be stable and without For shock, vibration and oil leakage, drain off the lubricating oil in the machine or filter the oil with a 200-mesh filter before use if you are sure that there is no fault.

d. If there is any abnormality during the test run, the cause should be found out, eliminated, and the manufacturer should be notified immediately.

e. The reducer should be overhauled once half a year in operation. Afterwards, the tooth surface should be checked regularly (weekly) for defects such as pitting, scratches, and bonding. If the defect area exceeds 20% along the tooth length and tooth height direction, continue to develop the application. Replace the gear pair.

3. Lubrication

a. The gear adopts two forms of oil pool lubrication and circulating lubrication. The lubricating oil is selected according to the equipment description. The soft tooth surface and medium-hard tooth surface reducer adopts: N100～150, and the hard tooth surface and planetary reducer adopts: N220～320.

b. The lubricating oil should be regularly checked and replaced. When the newly installed reducer is used for the first time, it must be replaced with new oil after 10-15 days of operation. In the future, the quality of the oil should be checked regularly (2-3 months), and the oil should be replaced immediately when it is found not to meet the requirements. Generally, the oil should be changed at least once every six months. When testing the oil quality, the lubricant must be changed in time if one of the following situations is encountered:

——The content of foreign matter in the lubricating oil exceeds 2%;
——Metal abrasive in lubricating oil exceeds 0.5%;
——The water content in the lubricating oil exceeds 2%;

c. The daily maintenance of the reducer is mainly to inspect for oil leakage, check the liquid level in the tank in time, whether the lubrication is good, whether the screws are firm and intact, check the temperature of the equipment regularly, and use a lead wire to bite it for a certain period of time. Enter the meshing position of the gear to measure the wear of the tooth.
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