Regular oil changes aren't just for your car. Almost all reducers use oil to keep operations smooth and efficient. This oil has some specific purposes, namely to minimize friction and wear, dissipate heat and lubricate bearings and component seals. The exchange rate reduction would not last without it.
Friction is inevitable when downshifting. Their job is to transmit energy, which means they will repeatedly push against each other. Proper lubrication can prevent friction from causing premature damage and wear. Proper lubrication will also dissipate heat from the gears. Oil does a lot for your system.
Over time, oxidation, operating temperatures, condensation, and frequent starts/stops cause the oil to break down. It may even be contaminated and require modification. Depending on the gearbox and oil type, the recommended oil change time may be slightly different. Some conditions require more frequent changes and we will cover that too.
How often is it really necessary to change the oil?
When first setting up a brand new gearbox, it is recommended to change the oil after 24 hours of operation in a worm gear or 100 hours in a shaft-mounted gearbox. This initial oil change must take into account the running-in of the gears. When the gears initially rotate together, there will be wear particles that mix with the oil. Draining this oil will remove any particles from the gearbox, extending the life of the gearbox.
After the initial break-in period, it is acceptable to filter the oil and reuse it, but we strongly recommend using new oil.
Once the gearbox is working, it will need much less frequent oil changes. In an established system, replace conventional oil every six months or 2,500 hours of operation. Whichever comes first will be fine.
To avoid gearbox failures due to lubrication, it is essential to monitor the oil. This will alert you to oil level drops, oil degradation, and contamination before the problem becomes a problem.
What about synthetics? More time between changes.
Synthetic lubricants can increase your operating time by up to 8,000 hours for a shaft mount and perhaps even more for a worm drive. These lubricants are affected by the heat of your unit, just like their mineral counterparts. This means that high temperatures will shorten the life of synthetic lubricants. However, even at 212 degrees, these synthetics outperform mineral options in terms of longevity.
Regardless of the type of oil, a good lubrication system is essential for the operation of your transmission. You won't be able to get optimal performance or full service life from your parts without them.
Faced with unique conditions? Change the oil more frequently.
On the opposite end of the spectrum, some conditions mean you'll change your oil more often . Some environments place additional strain on downshift systems. These conditions mean that the oil is working harder and therefore requires more frequent changes.
The unique conditions come down to two things: intense temperatures or contamination. On the hot side of things, sustained temperatures approaching 200 degrees for long periods will put more pressure on the oil.
Likewise, heavy intermittent loads require an increase in the frequency of oil changes. Load changes cause gears and oil to heat up and then cool down quickly. Temperature changes are similar to driving in stop-and-go traffic. It will consume the oil faster than normal.
Contamination can come from several sources. Not always considered, contaminants form during the running-in and wear of internal gears. Magnetic drain plugs are essential components, they protect gears and also extend oil life by collecting stray metals circulating inside the gearbox.
Extremely dusty or dirty environments are typical examples of the source of contamination. Humid environments or applications that experience large temperature fluctuations can cause condensation inside the reducer, adding water to the oil. Any contamination will reduce the effectiveness of your oil. It is important to regularly check the quality and change the oil if it is contaminated.
What happens if I don't change my oil regularly?
We have determined that there are regular maintenance schedules for oil changes and also special considerations. But what happens if you don't follow the advice?
Damage resulting from inadequate lubrication may be subtle at first and take time to manifest, but it is widespread. Every time the machine runs with contaminated or worn oil, there is an increase in friction and, therefore, an increase in wear on the system.
All the parts inside your gearbox are in constant motion, some of which move at high speeds. When coupled with old or impure oil, this means accelerated wear of gears and bearings will occur. Eventually, one or more of these parts will show signs of wear or failure, probably much sooner than expected. This is the cost of putting off oil changes and routine maintenance.
Alternatively, changing the oil according to the schedules set out above will protect the internal mechanisms of your gearbox. Having to repair or replace a reducer will not only delay operation, but cost much more than preventative inspections and oil changes. So keep your unit's maintenance schedule handy and change the oil immediately.
