Oil quality inspection
Color Change
Under normal circumstances, the reducer lubricant should be clear or slightly yellowish. If the lubricant is found to be black or dark brown, it is likely that the lubricant has been oxidized or contaminated. For example, when the gears inside the reducer wear and produce a large amount of metal debris, these debris will mix into the lubricant, causing the color to change. In addition, if the lubricant works in a high temperature environment for a long time, it will also accelerate the oxidation process and make its color darker.
Turbidity changes
Clear lubricating oil is the basis for ensuring good lubrication. If the lubricating oil becomes turbid, it may be because of water or impurities. For example, in a humid working environment, poor sealing of the reducer may cause water to enter the lubricating oil, forming an emulsification phenomenon, making the lubricating oil turbid and white. At the same time, impurities such as dust and dirt from the outside will also make the oil turbid and affect its lubrication performance.
Changes in smell
Normal lubricating oil has a slight petroleum smell. When lubricating oil has a pungent, burnt or sour smell, it usually means that the lubricating oil has deteriorated. For example, if the gears are over-frictioned and generate high temperatures, the lubricating oil may decompose and produce a burnt smell; if the lubricating oil is contaminated by microorganisms or corroded by chemicals, it may produce a sour smell.
Run parameter check
Oil temperature change
The oil temperature of a normally operating reducer should be kept within a relatively stable range. The normal range of oil temperature varies for different types of reducers and working environments, but is generally between 60 and 90°C. If the oil temperature continues to rise and exceeds the normal range under the same workload and environment, it may be because the lubricating performance of the lubricating oil has decreased, resulting in increased friction between the gears and bearings. This may be caused by aging of the lubricating oil, deterioration of the oil quality, or insufficient oil. At this time, you need to consider replacing the lubricating oil.
Equipment vibration and noise changes
When the lubricating oil performance of the reducer is good, the equipment runs smoothly, and the vibration and noise are at a low level. If the vibration amplitude of the equipment is found to increase or abnormal noise occurs, such as sharp friction or humming, in addition to checking whether the mechanical parts are damaged, it may also be caused by the failure of the lubricating oil. For example, if the lubricating oil is insufficient or the oil quality deteriorates, the oil film cannot be effectively formed to buffer the impact and friction of the gears and bearings, which will cause an increase in vibration and noise.
Runtime and workload checks
Run time
Generally speaking, the first lubricant oil change should be performed after the reducer is put into use for the first time 2000-3000 hours. This is because during this period, the lubricant has been run-in and consumed to a certain extent, and its performance may decline. After that, the lubricant oil should be changed every 1-2 years according to the specific working conditions of the reducer and the recommendations of the instruction manual.
Workload
If the hot delivery roller has a heavy workload, such as frequent transportation of large and heavy billets, or a harsh working environment, such as high temperature, high humidity, and dust, the lubricant will be consumed and deteriorated faster. In this case, even if the operating time has not reached the specified replacement cycle, it is necessary to comprehensively judge whether the lubricant needs to be replaced in advance based on the oil quality, oil temperature, and equipment operating conditions.
