The reducer manufacturer tells you how to maintain and use it by yourself

There is no lubricating oil in the reducer when it leaves the factory. Users must stipulate that lubricating oil should be added before using, and the operation should be carried out in accordance with the manufacturer's instructions. Generally speaking, the gear reducer has a running-in period of about 200 hours (lubricating oil must be replaced for more than 200 hours), which is stipulated by the technical characteristics of the gear reducer in the initial stage of its use in Driving Machinery. Running-in period is an important link to ensure the normal operation of reducer, reduce the failure rate and prolong its service life. However, at present, some users ignore the special technical requirements of the running-in period of the new reducer because of the lack of common knowledge about the use of the reducer, or the insufficient allowable torque, or the desire to gain profits as soon as possible and make the small machine more useful. Some users even think that the manufacturer has a warranty period, the machine is damaged by the manufacturer responsible for maintenance, so the reducer in the running-in period for a long time overload use, resulting in frequent failure of the reducer, which not only affects the normal use of the reducer, shorten the service life of the reducer. Therefore, full attention should be paid to the use and maintenance of reducer during running-in period. First, the use and maintenance of the running-in period 1. Pay attention to the workload during the running-in period. The workload during the running-in period should not exceed 85% of the rated workload, and arrange suitable workload to prevent the overheating caused by the long continuous operation of the reducer. 2. Attention should be paid to frequent observation and abnormalities should be eliminated by stopping in time. Before the cause is not found and the fault is not eliminated, the operation should be stopped. 3. For special reducers, operators should receive training and guidance from manufacturers. They should have a full understanding of the structure and performance of the reducer and acquire certain experience in operation and maintenance before they can operate the reducer. The manufacturer's product operation and maintenance instructions are the necessary data for operators to operate the equipment. Before operating the reducer, the manufacturer must read the operation and maintenance instructions first and operate and maintain according to the requirements of the instructions. And long-term preservation of information, easy maintenance. 4. Rational selection of lubricating oil, especially for reducers with input power greater than 11KW, should be filled with loaded gear oil. Pay attention to check lubricating oil, hydraulic oil, coolant, oil level and quality, and pay attention to check the sealing of the whole machine. The inspection found that there was too much oil shortage, the reasons should be analyzed. At the same time, the lubrication of each lubricating point should be strengthened. It is suggested that grease should be added to the lubricating point every week during the running-in period (except for special requirements). When the vertical reducer with oil pump is connected to the power supply, attention should be paid to the rotation direction of the oil pump, and the clockwise rotation is correct. 5. In order to keep the reducer clean, adjust and tighten the loose parts in time so as to prevent the parts from wearing or losing because of loosening. 6. At the end of the running-in period, the machine should be maintained compulsively, checked and adjusted well, and the replacement of oil should be paid attention to. 2. The characteristics of running-in period: 1. Why do reducers change lubricants regularly during running-in period? Due to the influence of processing, assembling and debugging of parts and components of the new reducer just used, the contact area of the mating surface is smaller and the allowable torsion distance is larger. During the operation of the reducer, the concave and convex parts of the surface of the parts are intertwined and frictioned. The metal debris which is worn down is used as abrasives to continue to participate in the friction, which accelerates the wear of the parts with the surface. Therefore, the content of running-in period can easily cause wear and tear of parts (especially the fitting surface), and the wear rate is too fast. At this time, if the overload operation, it may lead to parts damage and early failure. 2. Why does the screw loosen inexplicably? There are deviations in geometrical shape and fit size of newly processed and assembled parts. In the initial stage of use, the original fastened parts are easy to loosen due to the impact, vibration, alternating load, heating, deformation and other factors, as well as the wear and tear too fast. 3. Leakage occurs because of the loosening of parts, vibration and the influence of heat of decelerator. Leakage occurs on the sealing surface and pipe joint of decelerator. Some defects such as casting are difficult to find during assembly and debugging. However, due to the vibration and impact during operation, this kind of defect is exposed, which is shown as oil leakage. Therefore, leakage occurs occasionally during running-in period. 4. The poor quality of lubricating oil will affect which parts are newly assembled because of the smaller clearance, and because of assembly and other reasons, lubricating oil (grease) is not easy to form uniform oil film on the friction surface to prevent wear and tear. This reduces the lubrication efficiency and causes abnormal wear and tear in the early stage. Serious cases may result in scratches or occlusions on the friction surface of precision matching, which will lead to the occurrence of faults. 5. Operational errors are mostly due to insufficient understanding of the structure and performance of the reducer (especially the new operators), which can easily cause faults due to operational errors, even mechanical accidents and safety accidents. The requirements for the use and maintenance of reducer during running-in period can be summarized as follows: strengthening training, reducing load, paying attention to inspection and strengthening lubrication. As long as attention is paid to the maintenance and maintenance of the gear reducer during the running-in period according to the requirements, it will reduce the occurrence of early failures, prolong service life, improve production efficiency and bring you more benefits.