The amount of reducer lubricating oil added needs to be strictly controlled within a reasonable range (usually 1/2 to 2/3 of the oil window or oil dipstick). Too much or too little oil will destroy the normal operation of the reducer and cause the following series of failures:
1. The consequences of adding too much lubricating oil
Many people have the misunderstanding that "the more lubricating oil, the better", but excessive lubrication will bring serious negative effects:
Abnormal rise in temperature: Excessive lubricating oil will cause the gear to violently stir the oil during operation, increasing operating resistance and power loss. This severe friction and agitation will generate a large amount of heat, causing the reducer oil temperature to be too high.
Exacerbating the risk of oil leakage: Serious splashing of lubricating oil will increase the pressure inside the machine, and a large amount of oil will accumulate in the shaft seal and joint surface. At the same time, the hydraulic pressure will directly impact the oil seal, which can easily cause the seal to deform or even rupture, causing oil leakage.
Accelerated component wear: The continued rise in oil temperature will reduce the viscosity of the lubricating oil, causing it to lose its proper lubrication performance. This not only directly affects the normal lubrication of gears and bearings, but also shortens the service life of the equipment.
2. Consequences of adding less lubricating oil
Insufficient lubricating oil can also cause fatal damage to the reducer:
Mechanical wear and damage: When the oil level is too low, gears and bearings are not adequately lubricated and direct contact between metal surfaces occurs (dry friction). This can quickly lead to tooth surface scratches, abrasions, and even gear ablation and cracks.
Bearing overheating and abnormal noise: Poor lubrication will cause heat dissipation in the bearing parts to be blocked, causing the bearing temperature to rise sharply, and causing noise or abnormal noise during operation.
Vibration and transmission failure: Long-term insufficient lubrication and component wear will cause the gear meshing gap to increase and the accuracy to decrease, which will in turn cause the vibration of the reducer to increase, which may eventually lead to the failure of the entire transmission system.
Summary suggestions: During daily maintenance, the oil level and oil quality of the reducer should be checked regularly, and filling should be carried out in strict accordance with the oil filling table or oil mark instructions marked by the manufacturer to avoid equipment shutdown or damage caused by improper oil quantity.
