Precautions during running in of hard gear reducer

There are five problems that are easy to occur due to improper use of hard tooth surface reducer during running in period:

1. Poor lubrication. Due to the small fit clearance of newly assembled parts, and due to assembly and other reasons, lubricating oil (grease) is not easy to form a uniform oil film on the friction surface to prevent wear. So as to reduce the lubrication efficiency and cause early abnormal wear of parts. In severe cases, it will cause scratch or bite on the friction surface of precision fit, resulting in failure.

2. The wear speed is fast. Due to the influence of processing, assembly and commissioning of new hard tooth surface reducer and non-standard reducer parts, the contact area of mating surface is small and the allowable torque is large. During the operation of the reducer, the concave convex parts of the part surface are embedded and rubbed with each other, and the metal debris worn down continue to participate in the friction as abrasive, which further accelerates the wear of the part mating surface. Therefore, during the running in period, it is easy to cause the wear of parts (especially the mating surface), and the wear speed is too fast. At this time, if overload operation, it may cause damage to parts and early failure.

3. Leakage will occur at the sealing surface and pipe joint of the reducer due to the loosening of parts, vibration and heating of the reducer; Some casting defects are difficult to find during assembly and commissioning, but due to the vibration and impact during operation, such defects are exposed as oil leakage (seepage). Therefore, leakage occurs occasionally during the running in period.

4. Most of the operation errors are due to insufficient understanding of the structure and performance of hard tooth surface reducer and non-standard reducer (especially the new operator), which is easy to cause faults due to operation errors, and even mechanical accidents and safety accidents.

5. The newly processed and assembled parts are subject to geometric shape and fit size deviation. At the initial stage of use, due to the impact, vibration and other alternating loads, as well as the influence of heating, deformation and other factors, coupled with rapid wear and other reasons, it is easy to loosen the originally fastened parts.

Instructions for reducer maintenance

When a new reducer is used, it is necessary to replace the oil after 300 hours of continuous operation, and then replace the oil every 2500 hours of operation. However, the quality of the oil should still be checked regularly during use. If the oil has impurities, aging and deterioration, it must be replaced at any time.

Gear oil of fixed brand and number shall be used for reducer, and different brands, numbers or types of oil shall not be mixed. During oil change, clean the inside of the reducer before injecting new oil.

During use, when the oil temperature is too high (above 80 ℃) and abnormal noise are found, the use shall be stopped immediately and the causes shall be checked. After troubleshooting or changing the lubricating oil, it can be used again.

If it is extremely cold, such as below - 10 ℃, the impact of ambient temperature on the reducer needs to be considered during model selection. Configurations such as charged heater can be considered, which is very important for the lubrication and maintenance of the reducer. Regularly observe the oil level trend, noise and vibration.

Correct maintenance and use of the reducer can maximize its function.