Customers often ask about the proper maintenance of speed reducers. This article will provide a detailed explanation of this topic.crane mounted drill rig
Maintaining a speed reducer is actually quite simple. Regularly changing the lubricating oil and periodically replacing easily worn internal parts will ensure its normal operation. Specifically, it involves the following aspects:
1. Regular Lubricating Oil Changes
A. Change the lubricating oil after the first use or after replacing the worm gear, or after 150-400 hours of operation. Thereafter, the oil change interval should be less than or equal to 4000 hours.
B. Regularly check the oil quantity and quality, maintaining sufficient lubricating oil, and promptly replace any oil mixed with impurities or deteriorated.
C. The oil quantity must be according to the table requirements. Different brands of oil must not be mixed. Oils of the same brand but different viscosities can be mixed.
D. The operating environment temperature for the speed reducer is -40℃ to +40℃. When the ambient temperature is below 0℃, the lubricating oil must be heated to above 0℃ before starting, or a low-pour-point lubricating oil should be used.
Gearbox Plan View
Oil Level Check crane mounted drill rig
Disconnect the power supply to prevent electric shock! Wait for the gearbox to cool down!
Remove the oil level plug to check if the oil is full.
Install the oil level plug.
Oil Inspection
Open the drain plug and take an oil sample.
Check the oil viscosity index:
-If the oil is noticeably cloudy, it is recommended to replace it as soon as possible.
For gearboxes with an oil level plug:
-Check the oil level to ensure it is within acceptable limits.
-Install the oil level plug.
Oil Change
After cooling, the oil viscosity increases, making draining difficult. The gearbox should have its oil changed while it is still at operating temperature.
Disconnect the power supply to prevent electric shock! Wait for the gearbox to cool down until there is no risk of combustion!
Note: The gearbox should still be warm when changing the oil.
•
Place an oil catch pan under the drain plug;
•
Open the oil level plug, breather, and drain plug on the reducer;
•
Drain all the oil;
•
Reinstall the drain plug;
•
Add new oil of the same brand;
•
The oil level should match the installation position;
•
Check the oil level at the oil level plug;
•
Tighten the oil level plug and breather.
•
2. Regularly replace vulnerable parts inside the reducer
Since many parts inside the reducer are vulnerable, we need to perform regular "check-ups" on the reducer. Check for wear on internal components. If wear is found, replace them promptly to ensure normal operation of the reducer. Common vulnerable parts include: gears, oil seals, and bearings. We will introduce them one by one below.
A. Gears are the core components inside a speed reducer. During operation, gears mesh with each other to transmit power. Since gears are generally made of 20CrMNTI material and operate at very high speeds, typically around 1500 RPM, they are prone to wear. Therefore, a thorough inspection of the speed reducer gears should be performed periodically to identify and replace any worn parts promptly.
B. Speed reducers generate a large amount of heat during operation, causing a rapid rise in internal temperature. Oil seals, typically made of rubber, are prone to deformation under high temperatures, leading to lubricating oil leakage and affecting the speed reducer's performance. Therefore, regular inspection for lubricating oil leaks is crucial. If leakage is detected, replace the oil seal immediately and add the appropriate amount of lubricating oil to ensure normal operation of the speed reducer.
C. Bearings are also a common wear component. Because speed reducers typically operate at high speeds, and the bearings within them also rotate at high speeds, they are highly susceptible to damage. Therefore, it's crucial to regularly observe the speed reducer's operation. If any abnormalities are detected, the bearings must be inspected immediately, and any damaged bearings should be replaced promptly.
Finally, we summarize the following points for speed reducer maintenance:
1. Do not strike the speed reducer housing with heavy force to avoid damage.
2. Regularly inspect the mounting base, seals, drive shaft, etc., to ensure they are functioning properly.
3. Under normal use, the maximum temperature of the lubricating oil should be below 85℃. If abnormal oil temperature rise or abnormal noise occurs, the machine must be stopped immediately for inspection. Use can only resume after the fault has been rectified.
4. After replacing new wear parts, a running-in and load test must be performed before formal use.crane mounted drill rig
