Maintenance and Care Tips for Reducers

Proper maintenance and lubrication are key to the longevity and efficiency of a reducer(Maintenance and Care Tips for Reducers). Below are essential steps and guidelines for the maintenance and care of reducers.

1. Lubrication Before Operation

Before putting the reducer into operation, it is crucial to fill it with the recommended type and quantity of grease or oil. Typically, reducers use lubricating oil, and for vertical installations, additional lubrication measures may be necessary since the oil may not fully lubricate the topmost bearings.

Ensure that the reducer is filled with an appropriate amount of lubricating oil before operation. Reducers are generally equipped with an oil inlet and an oil drain plug, so the installation position must be specified when ordering the reducer to ensure proper lubrication.

Important:

• The operating oil temperature should not exceed 80°C.
• Combination reducers that are lubricated for life are typically filled with synthetic oil at the factory, but reducers supplied by the manufacturer often do not come with oil and will have an oil plug and drain plug.
• The lubrication oil quantity listed for reducers in this guide is an estimate. The oil level plug should be set according to the installation position to ensure proper lubrication. The oil quantity should be adjusted according to the specific installation method. If the transmitted power exceeds the thermal capacity of the reducer, external cooling devices must be provided.

2. Grease Selection and Maintenance

The choice of lubricant depends on the load carried by the reducer bearings. For heavy loads, it is important to select grease with a small penetration depth. When operating under high pressure, the grease should not only have a low penetration depth but also possess a high oil film strength and extreme pressure (EP) properties.

When choosing grease based on environmental conditions:

• Calcium-based grease is not easily soluble in water and is suitable for dry or low-moisture environments.
• The main indicators for selecting grease based on operating temperature are the dropping point, oxidation stability, and low-temperature performance. The dropping point can generally be used to evaluate high-temperature performance, and the actual operating temperature of the bearings should be 10-20°C lower than the dropping point. For synthetic lubricants, the operating temperature should be 20-30°C below the dropping point.

Note: Different lubricating oils or greases should not be mixed. The positions of the oil level screw, drain plug, and vent must be determined by the installation position.

3. Oil Level Check

To ensure proper lubrication, regular oil level checks are essential:

1. Cut off the power to prevent electric shock. Wait for the reducer to cool down.
2. Remove the oil level screw and check if the oil is at the required level.
3. Reinstall the oil level screw after checking.

4. Oil Quality Check

Regularly checking the oil quality ensures that the lubricant is still effective:

1. Cut off the power and allow the reducer to cool down.
2. Open the drain plug and take a sample of the oil.
3. Check the oil’s viscosity index. If the oil is noticeably cloudy or has deteriorated, it is advisable to change it.
4. For reducers with an oil level screw, check the oil level to ensure it is within the proper range.
5. Reinstall the oil level screw after checking.

5. Oil Replacement

Changing the oil at the proper time ensures smooth operation and prevents damage:

1. Cut off the power to prevent electric shock. Wait for the reducer to cool down to a safe temperature.
   • Note: The reducer should remain slightly warm during the oil change for easier draining.
2. Place an oil collection tray under the drain plug.
3. Open the oil level screw, vent, and drain plug.
4. Completely drain the old oil.
5. Reinstall the drain plug.
6. Refill with new oil of the same brand and grade.
7. Ensure the oil level matches the required level based on the installation position.
8. Check the oil level at the oil level screw.
9. Tighten the oil level screw and the vent.

6. Additional Notes for Oil Change

• The viscosity of oil increases after cooling, making it harder to drain. It is important to change the oil while the reducer is at its operating temperature for easier drainage.
• Always use the appropriate type and amount of oil specified for the reducer model to ensure optimal performance.

By following these maintenance and lubrication practices, the reducer will perform efficiently and have a longer operational lifespan. Proper care and attention to lubrication are key to preventing damage, reducing wear, and ensuring smooth operation in high-load applications.