Gearbox Preheating Processing: First 100-Hour Operation

Regardless of the type of speed reducer, its performance in the first 100-hour determines its long-term operational reliability. Different types of speed reducers have different requirements for the oil during the preheating stage. Worm gear reducers need to have their oil changed after the first 24-hour of operation, gear reducers can have their oil changed after 100 hours of operation, while planetary reducers need to have their oil changed after the first 50-hour operation.

The first 10-hour Preheating：The first 10-hour operation for a new speed reducer are relatively risky, as its surface has rough metal particles that need to be ground smooth before it can better help the speed reducer bear the load.

No-load test run:Before applying any load, the reducer needs to be run under no-load for a period of time to check for oil leaks and whether the temperature rise is normal.

Half-load operation:After no-load test run, running under half load for a period of time can effectively help smooth out the rough metal particles on the surface of the reducer.

Temperature monitoring during preheating:It is normal for the temperature of the speed reducer to rise by 50 degrees Fahrenheit during the first hour of operation and then stabilize. However, if the temperature of the speed reducer continues to rise after 2 hours of operation, it indicates that there is a problem with the speed reducer.

First oil change:Worm gear reducers require oil changes 24 hours after initial operation: worm gears operate through sliding contact, resulting in a larger contact area and thus generating more debris, necessitating early oil replacement.
The oil in a gear reducer needs to be changed after the first 100-hour run: Gear reducers use rolling contact operation with very little sliding, so there are fewer and smaller debris generated during the preheating period, and the first oil change should be done relatively late.
Planetary gear reducers require oil changes between the first 50-100 hours of operation: the planetary gears have rolling contact with the ring gear and sun gear, but the planetary bearings and planetary carrier pins have sliding contact under load, so their oil change intervals fall between those of worm gear reducers and gear reducers.

Preheating status verification:After the initial oil change, gradually increase the load until it reaches the rated load. Observe the temperature change. If it fluctuates and rises, wait for the temperature to stabilize before fully increasing the load. If it continues to rise, stop the machine and check for any interference from components.

Subsequent maintenance:After the 100-hour preheating period, routine preventative maintenance can begin. The gear teeth are sufficiently smooth, and the bearings and seals have achieved good contact and friction.