Extend Life of Speed

Reducers by Avoiding
Pitfalls
Summary
Standard gear speed reducers are usually durable pieces of
equipment. Built-in safety factors protect them against the
severity of most applications. But, despite this protection and the
general ruggedness of the equipment, reducers can be destroyed
by neglect, carelessness, failure to follow instructions, and
misuse. This article includes the more common examples of
reasons for enclosed gear drive failure.

Falk Corporation
4 pages
May 2003

SKF Reliability Systems

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 Extend Life of Speed Reducers by Avoiding Pitfalls
Introduction
Standard gear speed reducers are usually
durable pieces of equipment. Built-in safety
factors protect them against the severity of
most applications. But, despite this protection
and the general ruggedness of the equipment,
reducers can be destroyed by neglect,
carelessness, failure to follow instructions, and
misuse.
The following are among the more common
examples of reasons for enclosed gear drive
failure:
1. Not matching reducer rating to motor
horsepower. Overloads eventually take their
toll on a reducer even though there are built-in
strengths to handle momentary peak loads. A
motor upon starting will deliver torque to the
utmost of its capability. If you use a motor
with too much capacity and continually push
your driven equipment beyond its rated
capacity, you will overpower those built-in
strengths. You may also damage the
equipment the reducer is driving.
2. Overlooking lubrication. This is certain
death to a gear speed reducer. Follow
lubricating instructions. These instructions
6. Hammering the coupling on the reducer
cover frequency of lubrication, as well as oil
shaft. Never hammer a coupling hub,
2003 SKF Reliability Systems All Rights Reserved
level, viscosity, and grade. And remember:
most gear drives are shipped without oil. You
have to fill with oil before placing in service.
Check lubricant level periodically, and
especially if a unit has been inactive and then
returned to use. As a rule of thumb, most
operating reducers should be checked for oil
level every six months or at 2,500 running
hours, whichever occurs first. Any evidence of
oil leakage should prompt more frequent
attention.
3. Disregarding problems of vertical
installations. If you need to drive a vertical
shaft, never flop a standard unit so that it
drives up or down. If you do, your drive wont
last long. Most gear speed reducers are
designed and built for horizontal installations.
By turning a standard unit of this type on end,
it will probably lose its oil. Even if it doesnt,
proper amounts of lubricating fluid may not be
reaching all rotating elements. If a unit is
driving up or down, special bearings may be
needed. Right-angle or vertical units are
available and should be used to drive vertical
shafts.
4. Neglecting seasonal oil changes in outside
units. Industrial gear drives used in unheated
installations in cold weather climates require
seasonal oil changes-a thinner oil in winter, a
thicker oil in warm weather. Set up a periodic
reminder system. Equipment manufacturers
usually furnish specific recommendations on
frequency of oil changes and viscosities.
5. Not keeping breathers in good order. It is a
good idea to check breathers at regular
intervals, especially on reducers used in dusty
areas. If the breathers become clogged,
pressure can build up inside that can affect the
seals and permit oil leakage, which could ruin
not only your reducer, but also, some of the
equipment around it.
2
 Extend Life of Speed Reducers by Avoiding Pitfalls

sprocket, or pinion on a shaft. An endwise

blow could damage the gears and bearings.
Instead, heat the hub (to a maximum of 275F)
and slide it right onto the shaft.

7. Omitting shaft alignment or failing to

check alignment periodically. Dont regard a
flexible coupling as a universal joint. It can
tolerate some misalignment, but continued use
with misalignment could break the shaft of the
gear reducer, or damage the driven machine.
And vibration could ruin other parts of the
driven equipment. Even if nothing breaks, you
will shorten the life of your reducer. Do the
best job you can in aligning equipment. Then,
the coupling will function as it is supposed to
by accommodating reasonable amounts of
misalignment and, if a resilient type,
combating shocks.

8. Installing reducer on a slope. A little tilt,

even to a rugged piece of equipment, can
shorten reducer life. Standard splash-
lubricated reducers are designed to provide
good lubrication on the level. Unless
otherwise specified, your unit will probably
need level mounting. If you need a gear drive
that will operate on a slope, specify the degree
of slope when you order the reducer.
9. Careless positioning of chain sprockets. If
you mount the sprockets too far out on the
shafts, youll create excessive overhung loads,
which will cause shaft deflections, and
damaging bearing loads.
11. Improper shimming of mounting pads
before tightening nuts or anchor bolts.
Reducer housings are not always as rugged as
they seem. If theres a gap under one of the
mounting pads of a reducer with a cast iron
housing, you can crack the housing when
tightening a nut. Or if the reducer has a steel
housing, you can distort it, thereby
misaligning the gears. Either way, youll have
little or no warning of impending gear failure.

10. Belt tension. Many modern V-belts have 12. Not storing the units in a proper area
imbedded steel cables and just do not stretch. when not in use. Even when theyre not
So whether installing belt or chain, make operating, gear reducers should be stored
certain you provide the tension specified by inside in a dry area whenever possible. If they
the manufacturer. There seems to be a general have to be stored outside, they should be
tendency to over tighten. Too much tension under shelter to prevent the formation of rust,
will drastically shorten the life of the bearings which can etch the bearings.
in the reducer and connected equipment.
Every four months the internal parts should be
sprayed with a rust preventive. The same
should be done at 12-month intervals for units
stored indoors. Rust should be removed with
2003 SKF Reliability Systems All Rights Reserved 3
 Extend Life of Speed Reducers by Avoiding Pitfalls

wire brushes as soon as discovered. Etched

bearings, however, should be replaced unless
approved for operation by the bearing
manufacturer.

Conclusions
As is obvious from the foregoing list, it is not
difficult to destroy a speed reducer. Check
your present maintenance practices. If the
workers in your plant are guilty of any of the
abuses, you will know why you are not getting
better service and longer life from gear speed
reducers.

About Falk
Falk is a world-leading manufacturer of
industrial mechanical power transmission
solutions. Falk leverages its legacy in power
transmission solutions - from standard and
custom gear drives, to couplings and
backstops, to unmatched service and support -
to provide the best customer experience and
the lowest total cost of ownership through its
reliability, leadership, and speed.

The Falk Corporation

3001 West Canal Street
Milwaukee, WI 53208-4200 USA
Phone: 414.342.3131
Fax: 414.937.4359

2003 SKF Reliability Systems All Rights Reserved 4