1. Preparation before refueling
1. Stop and power off: The reducer must be completely stopped and the power supply cut off to prevent accidental start-up of the equipment during the refueling process and personal injury.
2. Cooling: Wait for the reducer to naturally cool down to below 40°C or room temperature. It is strictly forbidden to refuel when the equipment is at high temperature or running to avoid hot oil burns and oil oxidation.
3. Clean the working area: Clean the oil filler port, oil level mirror and the oil dirt and dust within 5cm of the surrounding area to prevent impurities from entering the inside of the box.
4. Prepare tools and oil products: Prepare funnels, filters with filtration accuracy ≤25 μm (or 10 μm), waste oil collection containers, rags and other tools, and confirm that the lubricating oil model meets the equipment requirements.
2. Refueling steps
1. Confirm the oil level status: Check the current oil level through the oil level mirror or oil level bolt to confirm the degree of oil shortage. K series reducers usually use the center line of the oil level mirror or the position indicated by the oil level bolt as the standard.
2. Open the oil filling port: remove the oil filling plug or vent hole on the top of the reducer as an oil filling channel.
3. Filter and oil injection: Slowly inject new oil into the box through the filter and funnel. Keep the injection angle at 45°-60° to avoid bubbles. The oil injection speed is controlled at ≤5L/min, and the difference between the oil temperature and room temperature is ≤5°C.
4. Control the amount of refueling:
General standard: The oil level should be maintained at 1/2 to 2/3 of the height of the oil level mirror, or reach the position indicated by the oil level bolt.
Special requirements of K series: Different installation methods (M1-M6) have significant differences in oil volume. For example, K37 M1 installation requires 0.50L and M2 installation requires 1.00L; K187 M1 installation requires 53.0L and M2 installation requires 152.0L. It is strictly prohibited to preset a fixed increase or decrease ratio, and the corresponding value must be based on the equipment nameplate or instruction manual.
5. Seal inspection: After the oil filling is completed, tighten the oil filling hole plug, breather and oil drain plug to ensure that there is no leakage in the seal.
3. Verification after refueling
1. No-load operation: Start the reducer and run it for 5-30 minutes without load, and monitor the oil temperature (≤80°C), noise (≤85dB) and vibration.
2. Review the oil level: Check the oil level again after shutting down. If the oil level drops due to changes in oil distribution, it needs to be replenished to the standard range.
3. Leakage inspection: Check whether there is oil leakage in the shaft end seal, flange connection and other parts. After confirming that there is no abnormality, it can be put into formal operation.
4. Key things to note
Oil taboos: It is strictly prohibited to use engine oil and hydraulic oil instead of gear oil; it is strictly prohibited to mix different brands, different types (mineral oil and synthetic oil) or new and old oils.
Excessive risk: If the oil content exceeds the standard by 10%-20%, the temperature rise will increase by 15-20℃, and the oil churning loss will increase by 37%, which may cause oil leakage and oil seal damage.
Oil shortage inspection: If oil shortage is found, the source of leakage (such as oil seal aging, box cracks) must be checked simultaneously and repaired to avoid repeated oil shortage.
First oil change: After the new reducer runs for 100-400 hours for the first time, it is mandatory to change the new oil and clean the inside to remove metal debris generated during the running-in period.
Following the above operating specifications can ensure the normal operation of the K series gear reducer lubrication system, extend the service life of the equipment and reduce the failure rate.
