What oil should be added to the gear reducer? Comprehensive analysis of lubricant selection and maintenance guide
As the core component of the industrial transmission system, the gear reducer has a direct impact on the equipment life and operating efficiency. This article will combine the industry hot spots and technical discussions in the past 10 days to provide you with a detailed analysis of the lubricant selection standards, common problems and maintenance suggestions for gear reducers.
1. Selection criteria for gear reducer lubricating oil
The following lubricant selection reference table is recommended based on ISO viscosity grade and gear type:
| Reducer type | ambient temperature | Recommended oil types | ISO viscosity grade |
|---|---|---|---|
| Parallel shaft gear reducer | -10℃~40℃ | Mineral gear oil | ISO VG 150-220 |
| Planetary gear reducer | -20℃~50℃ | Synthetic gear oil | ISO VG 220-320 |
| Worm gear reducer | 0℃~60℃ | Oil with extreme pressure additives | ISO VG 320-460 |
2. Lubrication issues that have attracted recent attention in the industry
1.The Controversy Between Synthetic Oils and Traditional Mineral Oils: The latest research shows that under high temperature conditions, the antioxidant performance of synthetic oil is 3-5 times higher than that of mineral oil, but the cost is 40-60% higher.
2.The rise of environmentally friendly lubricants: New EU regulations require the use of biodegradable lubricants in industrial equipment starting from 2024. Many manufacturers have launched bio-based gear oils that comply with ISO 6743-6 standards.
3.Intelligent lubrication system application: Real-time monitoring of oil status through IoT sensors enables on-demand oil change, which can extend the oil change cycle by 30-50%.
3. Lubricating oil replacement cycle reference
| Working conditions | Mineral oil replacement cycle | Synthetic oil change interval |
|---|---|---|
| Normal temperature and light load (<8 hours/day) | 4000-6000 hours | 8000-10000 hours |
| High temperature and heavy load (24 hours continuous) | 2000-3000 hours | 5000-6000 hours |
| Dusty and humid environment | 1500-2000 hours | 3000-4000 hours |
4. Frequently Asked Questions
1.Q: Can gear oils of different brands be mixed?
Answer: In principle, it is not recommended to mix. Different formulas may cause chemical reactions. If you need to change brands, the fuel tank should be thoroughly cleaned.
2.Q: How to determine if the lubricating oil needs to be replaced?
Answer: The oil needs to be changed immediately if the following conditions occur: ① The viscosity change exceeds ±15%; ② The acid value exceeds 2 mgKOH/g; ③ The moisture content is >0.1%.
3.Q: How to choose oil in extreme low temperature environment?
Answer: You should choose synthetic oil with a pour point more than 15°C lower than the ambient temperature, such as polyalphaolefin (PAO) oil.
5. Maintenance suggestions
1. Establish a lubrication file to record the time, oil type and amount of each refueling/oil change.
2. Regularly take samples for inspection. It is recommended to conduct oil analysis every 6 months.
3. Keep the fuel tank clean and clean the oil circuit when changing oil.
4. Pay attention to the oil level and oil temperature. If there is an abnormal increase, the cause needs to be investigated.
According to the latest industry statistics, about 37% of gear reducer failures are directly related to improper lubrication. Proper selection and maintenance of lubricants can extend the service life of equipment by 2-3 times and reduce maintenance costs by more than 40%. It is recommended that users select oil based on actual working conditions, refer to the equipment manual and the recommendations of professional lubrication engineers.
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