JZQ500-15.75-1F gear reducer no-load trial operation abnormality handling method, the details are as follows:
1. General disposal pre-process
1.1 Emergency stop: If there is any abnormality such as abnormal noise, excessive temperature rise, severe vibration, oil leakage, etc., immediately press the emergency stop button or cut off the power supply. Operation with faults is strictly prohibited.
1.2 Safety isolation: After shutdown, hang a 'No closing for equipment maintenance' warning sign on the electrical control box, wait until the reducer completely stops inertial rotation and naturally cools to room temperature (forced cooling is prohibited) before conducting inspections.
1.3 Record information: record abnormal phenomena (type of abnormal noise, temperature value, vibration position, oil leakage location), occurrence time, and trial operation stage in detail to provide basis for troubleshooting.
2. Common abnormal phenomena and targeted solutions
2.1 Abnormal noise processing
2.1.1 Metal impact sound: Possible causes are excessive gear meshing clearance/tooth surface damage, broken bearing balls, and loose and falling internal parts; the treatment measures are to disassemble the reducer to check the gear meshing status, adjust the meshing gap to the standard value of 0.15~0.3mm, and check the bearing raceways and balls. If damaged, replace the bearing of the same model and tighten the internal bolts to confirm that no parts have fallen off.
2.1.2 Sharp whistling sound: Possible causes are too small gear meshing clearance, insufficient tooth surface lubrication, and excessive coaxiality deviation; the treatment measures are to re-measure the coaxiality of the input shaft and motor, adjust to an error of ≤0.1mm, check the lubricating oil level and add it to 1/2~2/3 of the oil mark, replace the lubricating oil of the appropriate brand, and fine-tune the gear meshing gap to avoid dry friction on the tooth surface.
2.1.3 Continuous friction sound: Possible reasons are that the oil seal is too tight, the end cover interferes with the shaft, and internal debris remains; the treatment measures are to check that the oil seal gland is properly tightened and tightened the bolts to prevent the oil seal lip from excessively squeezing the journal, adjust the position of the end cover to ensure that the gap with the shaft is ≥0.2mm, and disassemble and clean the internal iron filings, sand and other debris.
2.2 Dealing with excessive temperature rise of bearing/casing (temperature rise＞40℃ or absolute temperature＞75℃)
2.2.1 Possible reasons: The bearing assembly is too tight, the grease/oil has deteriorated or the filling amount is improper, the bearing model does not match or the installation direction is wrong.
2.2.2 Treatment measures: Check the assembly status of the bearing. If the interference is too large, re-select the bearing or grind the bearing seat hole to ensure the assembly clearance. Check the status of the lubricating oil. If the oil becomes black and emulsified, drain it immediately and replace it with new oil. Strictly follow the instructions for the filling amount, confirm the bearing model, replace the bearing that matches the equipment and check the installation direction to ensure that the roller direction meets the stress requirements.
2.3 Treatment of severe shell vibration (vibration speed > 2.8mm/s)
2.3.1 Possible reasons: loose anchor bolts, large coupling coaxiality deviation, poor gear dynamic balance, and insufficient base rigidity.
2.3.2 Treatment measures: Retighten the anchor bolts according to the specified torque, install anti-loosening washers, check the fit between the base and the foundation, level the steel plate if necessary, recalibrate the coaxiality of the motor and reducer to ensure uniform end-face clearance. If it is a gear dynamic balance problem, the gear needs to be dynamically balanced. If it exceeds the standard, reprocess or replace the gear.
