For the WPWDX155-60-4KW reducer (high-torque heavy-duty type, the worm gear is mostly tin bronze, and the worm is alloy nitride steel), to prevent impurities from invading the worm gear meshing surface, we need to start from the four dimensions of 'source protection, process isolation, regular cleaning, and abnormal control.' The following are practical measures that can be implemented directly:
Thoroughly clean the parts before installation: When disassembling the reducer, use kerosene/special cleaning agent to clean the worm gear, worm, casing inner wall and bearing seat to remove processing residual iron filings, burrs and oil; wipe dry with a clean rag before installation. Do not use lint-covered cloth.
Optimize the installation environment: Choose a dust-free, dry site for installation, and avoid operating in dusty, oily or humid environments; during the installation process, the exposed surfaces of the parts must be covered with dust-proof cloth in time to prevent impurities from falling.
Check the integrity of the seals: Before installation, confirm that the input shaft and output shaft oil seals (the skeleton oil seal model is adapted) are not damaged or deformed, and the sealing gasket (or sealant) on the casing joint surface is evenly applied to avoid dust leakage and water ingress in the gaps after installation.
Choose a clean lubricating medium: Inject special extreme pressure gear oil for worm gears (320# recommended). Before refueling, check whether the oil is turbid and contains impurities. If necessary, filter the oil through a filter before injecting. It is strictly prohibited to mix oils of different brands and models.
Install an air intake dust-proof device: Install a fine filter (pore diameter ≤ 0.1mm) at the vent cap of the reducer to prevent air from carrying dust into the interior of the casing; clean the filter regularly (every 1,000 hours) to avoid clogging and causing excessive internal pressure.
Improve the equipment operating environment: If the equipment is in dusty and oily working conditions (such as mines and cement plants), install a protective cover (sealed or semi-sealed) for the reducer to isolate external impurities; regularly clean the protective cover and dust on the reducer casing.
Control the process of refueling and oil change: When changing the oil, completely drain the old oil (including the sediment at the bottom of the casing), flush the inside of the casing 1-2 times with new oil and then refill it; the refueling port must be equipped with a sealing cap, and tighten it in time after refueling to prevent impurities from intruding from the refueling port.
Regularly check the sealing status: stop the machine every 1500 hours to check whether the shaft oil seal and the joint surface of the casing are leaking. If there are signs of oil leakage or dust intrusion, replace the damaged seals or re-apply sealant in time.
Avoid maintenance with impurities: During maintenance (such as replacing bearings, adjusting meshing clearance), tools need to be clean and dry, disassembled parts need to be placed in a clean container or rag, and direct contact with the ground is prohibited; after maintenance, clean the inside of the casing promptly before assembling.
Handle abnormal pollution signals: If metal shavings and impurity particles are found in the oil (through oil sample observation or oil analysis), immediately stop the machine to check whether the worm gear meshing surface and bearings are worn, check the source of impurities (such as seal failure, external intrusion), and clean thoroughly before running.
