Reducer Installation and Maintenance Guide

A reducer, also known as a speed reducer or gearbox, is a mechanical device used across various industries to decrease the speed of an input power source by increasing torque. Commonly found in machinery for manufacturing, automotive, aerospace, and construction, reducers are integral in adapting the high-speed rotational energy from engines or motors to a usable speed for industrial equipment and conveyors. They come in several types, such as planetary, worm gear, and helical, each offering different performance characteristics to suit specific applications. Their widespread use underlines their importance in enhancing efficiency and precision in mechanical operations.

1. Preparation work before installation of reducer

Before the reducer is officially put into use, a series of preparatory work needs to be carried out to ensure that the equipment can run smoothly and efficiently.

Checking and adjusting the ventilation valve: first of all, make sure that the ventilation valve is in the open state, so as to ensure that the pressure inside the speed reducer is balanced, and to avoid the damage of the equipment caused by the unbalanced pressure.
Consult the manufacturer: Since there are various ways to install the reducer, each of them may have different effects on the operation of the equipment. Therefore, before installation, be sure to consult the manufacturer for professional installation guidance to ensure correct installation.

2. Precautions when installing the reducer

When installing the speed reducer, you need to pay attention to the following key points:

Installation position of components: The installation position of components such as the venting valve, exhaust valve, oil level check bolt and oil drain bolt is different for different installation methods. The mounting position of these components must be strictly determined according to the instruction manual provided by the manufacturer.
Lubricant Addition: The amount of lubricant added varies for different installation methods. The proper amount of lubricant must be added according to the manufacturer's instructions to ensure the normal operation of the reducer.
Judgment of oil quantity: It may be difficult to accurately judge the oil quantity during the operation of the reducer. Therefore, during installation and maintenance, special attention should be paid to the checking of oil quantity to ensure that the oil quantity is moderate, neither too much nor too little.

3. Precautions for oiling the reducer

In splash lubricated reducers, it is particularly important to fill the oil correctly, especially when the load is close to the thermal power.

Refueling method:

First remove the vent valve and oil level check bolt.
Add oil through the vent valve until the oil level is visible at the oil level check bolt.

Oil level checking method:

With the gearbox stopped, remove the oil level check bolt and check that the oil level is below it.

Oil draining and checking method:

Remove the bottom oil discharge bolt for oil discharge and oil inspection to ensure the cleanliness and quality of the oil.

4. Inspection contents during the operation of the gearbox

During the operation of the reducer, the following inspections need to be carried out regularly:

Cleanliness check: check whether the reducer and its cooling system and other accessories are clean to prevent dust and impurities from entering the inside of the equipment.
Temperature measurement: Measure the temperature of the reducer's high-speed shaft, low-speed shaft and the shell temperature at the bearing to ensure that the temperature is within the normal range.
Oil heater check: Make sure the oil heater is not operating incorrectly so as not to cause the oil temperature to be too high or too low.
Vibration check: check whether the vibration of the reducer is normal, abnormal vibration may be the precursor of equipment failure.
Listening to abnormal sound: listen to the reducer in all places whether there is abnormal sound, abnormal sound may be the signal of the internal problems of the equipment.
Oil leakage check: check whether there is oil leakage in all parts of the reducer, whether the color of the lubricant is normal, to ensure the normal operation of the lubricant system.
Cooling system check: confirm whether the reducer cooling system is running normally, the cooling system is essential to maintain the temperature of the equipment.
Air filter check: check whether the air filter is clean to ensure air circulation and normal operation of the equipment.
Bolt check: Check whether the bolts are obviously loose to ensure the tightness of the equipment components.

5. Inspection contents after gearbox shutdown

After the reducer is shut down, the following inspections are required:

Oil level check: check whether the lubricant oil level is normal, whether there is any obvious change in the grease, and make sure the oil quantity is moderate.
Bolt fastening: Confirm whether the bolts are fastened to prevent equipment failure caused by loose bolts.
Coupling alignment: check whether the coupling is centered or not, a misaligned coupling may lead to unstable equipment operation.
Air filter cleaning: check whether the air filter is clean to ensure air circulation and normal operation of the equipment.
Cooling system cleaning: Check whether the cooling system is clean to ensure the cooling effect.
Bearing check: check whether each bearing is damaged, the damage of the bearing will affect the running efficiency of the equipment.
Oil seal check: check whether each oil seal is damaged or not, the damage of oil seal will lead to oil leakage problem.
Gear inspection: check whether the position of each gear is changed, whether the gear teeth are damaged, whether the meshing area meets the requirements, to ensure the normal meshing and operation of the gear.
Equipment cleaning: Confirm that the reducer and ancillary equipment are clean, including whether the ventilation valve is damaged to prevent dust and impurities from entering the internal equipment.
Manual coiling check: manually coiling, check whether there is any abnormal sound and jamming phenomenon, to ensure the flexibility of equipment operation.

6. Confirmation of the installation method for the gearbox in the workshop

When installing the reducer, the workshop needs to carry out the following confirmation work:

Ventilation valve check: check whether the rubber of the ventilation valve is removed and whether the ventilation valve is damaged to ensure the normal operation of the ventilation valve.
Confirmation of component installation position: Confirm the installation position of the venting valve, oil drain bolt, and oil level adjusting bolt according to the different installation methods of the reducer to ensure the correctness of the installation.
Oil level adjusting bolt marking: Specify that the oil level adjusting bolt is a red bolt and paint it red after the position is confirmed to facilitate identification and maintenance.
Lubricating oil check: check the lubricating oil of the reducer according to the position of the oil level adjusting bolt to ensure the lubricating oil quantity and lubricating effect to ensure the normal operation of the equipment.
Training and record: According to the above information, the workshop should organize and carry out the training on the installation and use of the reducer for the maintenance workers, and send the training record to the equipment department to ensure that the maintenance workers have a full understanding of the installation and maintenance of the reducer.
Record and rectification of problems: Record, report and rectify the problems checked to ensure the safe and stable operation of the equipment.

By following the above guidelines, it is possible to ensure proper installation and maintenance of the reducer, thereby extending its service life and improving efficiency. Regular inspection and maintenance not only prevents potential malfunctions, but also ensures that the reducer operates in optimal condition, saving costs and improving productivity for the organization.