The additional maintenance of CJY shaft-mounted reducer under special working conditions needs to be combined with the characteristics of the working conditions, and targeted strengthening of lubrication, sealing, cleaning, monitoring and other links. The following are additional maintenance measures for different special working conditions:
1. Heavy load/impact load conditions (such as metallurgy and mining equipment)
(1) Shorten the lubricating oil replacement cycle: from the conventional 6 to 12 months to 3 to 4 months. Thoroughly clean the inner wall and oil passage of the gear box during each oil change to avoid tooth surface wear caused by accumulation of iron filings and impurities.
(2) Strengthen tooth surface lubrication protection: Use extreme pressure industrial gear oil (such as L-CKD 220 or 320), and add gear anti-wear agent to increase the tooth surface load-bearing capacity and prevent tooth surface gluing and pitting corrosion.
(3) Increase the frequency of fastener inspections: Check the connecting bolts of the input shaft, output shaft and coupling every week, as well as the fastening bolts of the reducer installation base, and use a torque wrench to retighten according to the standard torque to prevent loose bolts from causing shafting deviation.
(4) Regularly check the tooth surface contact status: stop the machine every one month to check the gear meshing traces to ensure that the contact spots are evenly distributed. If unilateral contact occurs, correct the shaft system coaxiality in a timely manner.
2. High temperature/high dust working conditions (such as cement kilns, drying equipment)
(1) Install heat dissipation and dustproof accessories: Install an air-cooled radiator or water-cooled jacket on the reducer housing to control the oil temperature not to exceed 80°C; install a double-layer dustproof seal ring and dustproof cover on the shaft extension end to prevent dust from entering the gearbox and bearing parts.
(2) Improve the maintenance level of seals: replace the shaft end sealing ring every 2 to 3 months, and use high-temperature resistant fluororubber seals to replace conventional nitrile rubber seals to avoid high-temperature aging and failure.
(3) Optimize the frequency of lubricating oil monitoring: Take samples every month to detect the viscosity, acid value and impurity content of the lubricating oil. If the oil emulsifies, turns black or the impurities exceed the standard, replace it immediately.
(4) Clean the heat dissipation surface of the casing regularly: Use compressed air to blow away dust and oil on the surface of the casing every week to ensure the heat dissipation surface is clean and avoid rising oil temperature caused by poor heat dissipation.
3. Low temperature/humid working conditions (such as cold storage, outdoor humid environment)
(1) Select low-temperature lubricating oil: Replace with L-CKD low-temperature gear oil (pour point ≤ -25°C) to avoid increased oil viscosity in low-temperature environments, resulting in insufficient lubrication at startup.
(2) Increase moisture-proof and anti-rust measures: install a desiccant breather in the ventilation hole of the gear box, and replace the desiccant regularly; when the machine is shut down for more than 15 days, inject a small amount of anti-rust oil into the gear box, or start the reducer to run without load for 10 minutes to prevent tooth surface and bearing corrosion.
(3) Check the drainage device: Make sure that the drainage screw plug at the bottom of the reducer is unobstructed. After each shutdown, unscrew the drainage screw plug in time to drain the condensed water in the box to avoid oil emulsification.
(4) Strengthen pre-start inspection: Before starting at low temperature, manually crank 3 to 5 turns to confirm that the reducer is running without jamming, and then power on to start to prevent bearing wear due to oil solidification.
