1. Key operating specifications
1. Shutdown inspection
Be sure to check the oil level with the reducer completely stopped. During operation, the internal worm gear will cause the lubricating oil to splash. At this time, the observed oil level will be significantly higher due to the oil adhering to the gear and box wall, which cannot reflect the real oil amount and can easily lead to misjudgment.
2. Correct oil level
Just add lubricating oil to 1/2 to 2/3 of the oil window (or oil gauge).
Too little oil: It will lead to insufficient lubrication and heat dissipation, accelerate the wear of worm gears and bearings, and even cause serious failures.
Excessive oil volume: It will increase the internal oil stirring resistance, causing the oil temperature to rise abnormally. At the same time, excessive hydraulic pressure will impact the oil seal, which can easily cause oil leakage.
3. Standardize oil replenishment
When the oil level is found to be lower than the lower limit of the oil window, the machine should be stopped immediately and replenished to the specified position after the equipment cools down.
The lubricating oil specified in the equipment manual must be used (usually special oil for worm gears, such as L-CKE/P type or VG460 industrial gear oil). It is strictly prohibited to mix lubricating oils of different brands and grades.
The oil replenishment process needs to be kept clean to prevent dust, moisture and other impurities from entering the box.
2. Oil change and maintenance intervals
First oil change: After a new reducer or a worm gear pair is replaced, the lubricating oil should be changed after 150-400 hours of first operation to remove metal debris generated during the running-in period.
Routine oil change: Depending on the working conditions, it is usually changed every 2000-4000 hours or every six months to one year. Under severe working conditions such as high temperature, dusty, heavy load, etc., the oil change interval should be appropriately shortened.
Daily inspection: Check the oil level, oil temperature, and whether there are abnormal noises and oil leakage every shift or every day.
3. Important safety and fault warning
Temperature monitoring: During normal operation, the temperature of the reducer housing should not exceed 85°C. If the oil temperature rises abnormally, stop the machine immediately and check the load, lubrication and cooling conditions.
Judgment of abnormal noise: If there is a "clicking" impact sound or a continuous "buzzing" resonance sound during operation, it may be a signal of tooth surface peeling, bearing damage or improper assembly, and the machine needs to be stopped immediately for investigation.
Oil quality inspection: Observe the condition of the lubricating oil regularly. If the oil becomes black, turbid, emulsified (milky white, indicating water has entered) or contains obvious metal debris, it must be replaced immediately and the internal wear and tear must be checked.
Safe Operation: Before any inspection or maintenance is performed, the power must be cut off and the equipment must be locked out and tagged out to ensure that the equipment does not start accidentally. When the machine is just shut down, the temperature of the box and oil is very high. You need to wait for cooling or take protective measures to prevent burns.
