Five problems that can easily occur during the running in period of hard gear reducers due to improper use:
1. Poor lubrication is due to the small fitting clearance of newly assembled components, 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. This reduces lubrication efficiency and causes early abnormal wear of the components. In severe cases, it can cause scratches or biting on the friction surface of precision fit, leading to the occurrence of faults.
2. The wear rate is fast. Due to factors such as the processing, assembly, and debugging of new hard tooth surface reducers and non-standard reducer components, the contact area of the mating surface is small, while the allowable torque is large. During the operation of the reducer, the concave and convex parts on the surface of the parts are interlocked and rubbed against each other. The metal debris that falls off is used as abrasive to continue to participate in friction, further accelerating the wear of the mating surface of the parts. Therefore, during the running in period, it is easy to cause wear and tear of components (especially mating surfaces), and the wear rate is too fast. At this point, if overloaded operation occurs, it may lead to damage to components and early failure.
3. Leakage occurs due to the looseness and vibration of parts, as well as the influence of heat on the gearbox, resulting in leakage on the sealing surface and pipe joints of the gearbox; Partial casting defects are difficult to detect during assembly and debugging, but due to vibration and impact during the operation, these defects are exposed and manifested as oil leakage (seepage). Therefore, leakage may occasionally occur during the running in period.
4. Operational errors are often caused by insufficient understanding of the structure and performance of hard tooth surface reducers and non-standard reducers (especially for new operators), which can easily lead to malfunctions and even mechanical and safety accidents due to operational errors.
5. Loose newly machined and assembled components have deviations in geometric shape and fitting dimensions. In the early stages of use, due to alternating loads such as impact and vibration, as well as factors such as heat and deformation, coupled with rapid wear and tear, it is easy for previously fastened components to become loose.
Gearbox maintenance instructions
When using a new gearbox, it is necessary to replace the oil with new oil after 300 hours of continuous operation, and then every 2500 hours of use. However, the quality of the oil should still be checked regularly during use. If the oil has impurities, aging, or deterioration, it must be replaced at any time.
The reducer should use gear oil of a fixed brand and number, and should not mix different brands, numbers, or types of oil. During the oil change process, the inside of the gearbox should be cleaned first before injecting new oil.
During use, if the oil temperature is found to be too high (above 80 ℃) or there is abnormal noise, the use should be stopped immediately and the cause should be checked. After troubleshooting or replacing the lubricating oil, it can continue to be used.
If the extreme cold is below -10 ℃, the impact of ambient temperature on the gearbox should be considered when selecting, and configurations such as electric heaters can be considered. This is very important for the lubrication and maintenance of the gearbox, and regular observation of oil level movements, noise and vibration should be carried out to see if there are any abnormalities.
Proper maintenance and use of the gearbox are necessary to maximize its functionality.
