Reducer

Reducers are suitable for mechanical transmission in industries such as metallurgy, mining, transportation, cement, construction, chemical engineering, textile, light industry, and energy.

Installation and maintenance of reducers

1.The reducer should be installed horizontally and must not be tilted longitudinally or laterally.

2. The installation of the connecting parts between input and output should adopt the method of hot mounting and cold shrinking. It is strictly forbidden to use the assembly method of forced impact or shock.

3. After the reducer is installed, it must rotate smoothly by hand, and the installation error must not exceed the allowable value of the coupling used. When power is transmitted by V-belt pulleys, unbalanced mass should be eliminated to reduce vibration noise and increase the service life of bearings.

4. All fixing bolts must be uniform and firm, and must not be loose. When the impact load is large and the start-up is frequent, positioning screws should be provided for the base and the foundation.

5.Before starting the reducer, lubricating oil must be added and the correct oil level requirement must be met. Under no circumstances should the oil level be lower than the minimum position.

6. Before the installed reducer is officially put into use, a load test must be conducted. Before the load test, it should be run idle for two hours. When the idle run is normal, the load test should be started. If conditions permit, the load should be gradually increased in the following four stages: The first stage is 25% of the rated load; The second stage is 50% of the rated load; The third stage is 75% of the rated load; The fourth stage is 100% of the rated load. If the on-site conditions do not allow for gradual loading, at least two hours of idle operation and four hours of full-load operation must be carried out. The operation time of each stage is based on the oil temperature equilibrium, but it must not be less than two hours. The maximum oil temperature must not exceed 90℃. Under normal circumstances, the reducer should operate smoothly without any impact, vibration or leakage.

7. During operation, if a significant increase in oil temperature, deterioration of oil quality, or abnormal noise is detected, use should be stopped immediately. The cause should be checked and eliminated.

8. When a new reducer or newly replaced gears are used for the first time, the oil should be changed after running for 10 to 15 days. Under normal circumstances, for reducers that operate continuously for 24 hours a day, the oil should not be changed more than once every 3 months, and for reducers that operate for no more than 10 hours a day, the oil should not be changed more than once every 6 months.

Lubrication of the reducer

1.The reducer adopts two lubrication methods: oil pool lubrication and circulating lubrication. For reducers with high ambient temperature, large power, high speed and continuous operation, circulating lubrication should be adopted as much as possible to lower the oil temperature and fully exert the load-bearing capacity of the reducer.

2.When the working environment temperature is relatively low, measures should be taken to ensure that the oil temperature remains above 0℃.

3. The oil level height for oil pool lubrication is specified to be 2 to 5 times the module higher than the top of the internal gear. (For two-stage reducers, the high-speed stage is used; for three-stage reducers, the intermediate stage is used as the internal gear.)

4. When the ambient temperature exceeds 38℃, medium extreme pressure gear oil N320 (or VG320, Mobil632) should be selected. When the ambient temperature is ≤38℃ or circulating lubrication is adopted, medium pressure gear oil N220 (or VG220, Mobil630) should be selected.