Regardless of the type of machinery, different lubricating oils are prohibited from being mixed for use, and reducers are no exception. For reducers, the positions of the oil level plug, drain plug, and breather are determined by their installation locations. When it comes to the use, inspection, and maintenance of the lubricating oil in reducers, the following aspects mainly need to be considered:
Cut off the power supply to prevent electric shock!
Wait for the reducer to cool down!
Remove the oil level plug to check if the oil is full.
Reinstall the oil level plug.
The oil level inspection is a fundamental yet crucial step. In industrial settings, incorrect oil levels can lead to a series of problems. If the oil level is too low, the gears in the reducer may not be adequately lubricated, resulting in increased friction and wear. This can cause premature damage to the gear teeth, generating abnormal noises during operation and gradually reducing the efficiency of the reducer. On the other hand, if the oil level is too high, the rotating parts will churn the oil excessively. This not only causes energy losses due to the additional resistance but also may lead to oil leakage from seals, contaminating the surrounding environment and potentially causing safety hazards. Regular oil level checks, following strict safety procedures like power disconnection, are essential for maintaining the optimal performance of the reducer.
Cut off the power supply to prevent electric shock!
Wait for the reducer to cool down!
Open the drain plug and take an oil sample.
Check the viscosity index of the oil.
If the oil is obviously turbid, it is recommended to replace it as soon as possible.
For reducers with oil level plugs:
Check if the oil level is up to standard.
Reinstall the oil level plug.
Oil inspection goes beyond just a simple visual check of its clarity. The viscosity index is a key parameter that reflects the oil’s ability to flow under different temperatures. In a crane reducer, which often operates under varying load and temperature conditions, a proper viscosity is vital. When the oil’s viscosity is too low, it may not be able to form a sufficient lubricating film between the gears, leading to metal-to-metal contact and accelerated wear. Conversely, if the viscosity is too high, especially in cold start situations, the oil will be too thick to flow quickly to the required parts, causing initial operation difficulties and potential damage to components. Analyzing the oil sample in a professional laboratory can provide detailed information about its additive content, oxidation level, and presence of contaminants, all of which help in deciding whether the oil needs replacement.
Since the viscosity of the oil increases after cooling, making it difficult to drain, the reducer should have its oil changed at the operating temperature.
Cut off the power supply to prevent electric shock!
Wait until the reducer has cooled down to a point where there is no risk of combustion!
Note: The reducer should still be warm during oil change.
Place an oil pan under the drain plug.
Open the oil level plug, the breather, and the drain plug.
Drain all the oil.
Install the drain plug.
Pour in new oil of the same brand.
The oil quantity should be consistent with the installation position.
Check the oil level at the oil level plug.
Tighten the oil level plug and the breather.
The process of oil replacement requires meticulous attention to detail. When changing the oil, the choice of new oil is of utmost importance. Using the wrong grade or brand of oil can have severe consequences. The new oil must have the right additives to combat oxidation, corrosion, and foaming, which are common issues in reducer operation. Lisaks, during the draining process, ensuring that all the old oil is completely removed is crucial. Any residual old oil can contaminate the new oil, reducing its effectiveness. The proper tightening of the plugs and breather after filling with new oil is also essential to prevent oil leakage and ensure correct pressure regulation within the reducer housing.
In modern crane operations, with the increasing complexity and automation of equipment, the maintenance of reducers has become more sophisticated. Advanced sensors can now be installed in reducers to continuously monitor oil parameters such as temperature, viscosity, and contamination levels in real-time. These sensors are connected to a central control system, which can automatically alert maintenance personnel when any parameter goes out of the normal range. This enables proactive maintenance, reducing unplanned downtime and enhancing the overall safety and productivity of crane operations.
Moreover, the development of new lubricating oils is also revolutionizing reducer maintenance. Environmentally friendly oils with lower toxicity and better biodegradability are being developed, which not only reduce the environmental impact during use and disposal but also offer improved performance. These oils often have enhanced anti-wear and extreme pressure properties, allowing reducers to operate more smoothly under heavy loads. In addition, the study of tribology, the science of friction, wear, and lubrication, is constantly providing new insights into how to optimize the lubrication process in reducers, leading to longer service lives and more reliable performance.
