Key points to note during operation and maintenance of ZD soft tooth surface reducer after modification

Key points for maintenance of modified reducer

The internal parts of the modified reducer need to be run-in. Insufficient maintenance at this stage will lead to long-term faults. At the same time, high temperatures in summer will amplify various equipment problems. Lubrication is the key to determining the life of the reducer.

Things to note during the running-in and running-in stages

After the modification is completed, do not directly start working at full load. Just put the machine into use and run it for about 2 hours without any abnormal noise or leakage. After confirming that there is no abnormal noise or leakage, slowly increase the load to 25%, 50%, and 75%. When the condition is stable, run it at full load. If it is fully loaded as soon as it is put into use, it will easily damage the gears and bearings that have not been run-in.

The first oil change is required after the equipment has been running for 200-400 hours. The running-in of parts will grind out fine metal particles, which will mix in the oil and continue to circulate, which will continue to scratch the transmission pair. The first oil change is to completely discharge these grinding debris to reduce subsequent wear.

Protection for use in high temperature environments in summer

When the ambient temperature is high, the engine oil is prone to aging and deterioration, the viscosity will decrease, and the heat dissipation pressure will also increase. Pay more attention to the box temperature. During normal operation, the outer shell temperature cannot exceed 60°C, and the internal oil temperature is best controlled within 80°C. If the temperature rises abnormally, the machine must be shut down immediately for investigation, and production cannot be continued.

At 11-15 noon, when the environment is the hottest, the load can be appropriately reduced by 15-20%. Do not run hard at full load for a long time. After working continuously for 2 hours, it is best to stop and let it cool down naturally for half an hour to alleviate heat accumulation in the equipment.

The heat dissipation components should be cleaned frequently. If the surface of the casing, heat sink, and cooling fan are clogged with dust and oil, the heat dissipation capacity will be greatly reduced, and the temperature will rise higher and higher. In addition, the breathable respirator must be unobstructed. Once blocked, the pressure inside the box will be high, and oil leakage will easily occur under high temperature conditions.

Practical control of lubrication

Lubricating oil cannot be chosen casually. Priority should be given to the heavy-duty industrial gear oil recommended by the original manufacturer. For high-temperature operations in summer, high-viscosity and temperature-resistant models can be selected to ensure that the oil film will not break during operation. It is strictly forbidden to mix gear oils of different brands and types. After mixing, the oil will react and become ineffective.

Make it a habit to check the oil level every week. It is most appropriate to keep the oil level in the range of one-half to two-thirds of the observation window. If too much oil is added, the oil churning loss will increase, and the equipment will become overheated and oil will leak easily; if too little oil is added, the gear bearings will not be fully protected by the oil film, and dry friction will heat up quickly and damage the accessories.

Pay more attention to the condition of the oil. If the oil turns black, turns into a milky white emulsified state, or if metal powder impurities are seen in the oil, change the oil immediately. When encountering severe working conditions such as high temperature, heavy dust, and continuous heavy load, do not stick to the regular oil change interval. It is recommended to shorten the oil change interval to every three months.