How to judge the fault type of shaft-mounted ZJY150-16-S reducer

To determine the fault type of the ZJY150-16-S shaft-mounted reducer, the core is to quickly locate the fault through the six dimensions of listening to noise, measuring temperature, checking vibration, looking at oil leakage, turning the wheel, and measuring performance, combined with its structural features of shaft-mounted suspension, hollow shaft, and backstop (S).

The six-dimension fault judgment method is as follows:

1. Listen to noise (most intuitive)

(1) Steady and low 'buzzing' sound: normal

(2) Periodic 'click/click' impact sound

Failure: gear wear, pitting, broken teeth, poor meshing

Features: The sound becomes louder during load/shifting

(3) Sharp 'squeaking/howling'

Failure: Bearing lack of oil, ball/raceway peeling, bearing seat loose

(4) Dull 'clanging' noise (model with S)

Failure: Internal wedge/roller of backstop is damaged, one-way braking failure

(5) The noise suddenly becomes louder

Failure: loose installation, coupling misalignment, expansion sleeve slipping

2. Measure temperature (infrared/hand feeling)

(1) Normal: Shell 40–60°C, evenly warm

(2) The overall temperature exceeds 70°C (hot to the touch)

Failure: overload, insufficient lubrication/deterioration, low oil level, poor heat dissipation

(3) Local overheating (bearing end cover/input shaft)

Failure: Bearing damage, assembly too tight, foreign matter intrusion

(4) Abnormal heating of the backstop part

Failure: stuck backstop, worn friction plate, excessive one-way braking resistance

3. Check the vibration (feel/vibration meter)

(1) The whole machine shakes violently and your hands feel numb when touched.

Failure: Loose foot/tie rod, shaft misalignment, loose hollow shaft expansion sleeve

(2) High-frequency vibration of bearing position

Failure: Bearing wear, excessive clearance, cage damage

(3) Vibration increases significantly with load

Failure: poor gear meshing, broken teeth, bent shaft

4. Look for oil leaks (ZJY high frequency)

(1) Oil leakage at input/output shaft end

Failure: oil seal aging, journal wear, installation eccentricity resulting in excessive radial force

(2) Oil leakage on the joint surface of the box

Failure: seal failure, loose bolts, box deformation

(3) Spray oil at the breathable plug

Failure: Internal pressure is too high, oil level is too high, breather plug is blocked

5. Manual cranking (power-off inspection)

(1) Smooth rotation and no jamming: normal

(2) There are frustrations, stucks, and uneven resistance.

Failure: Broken gear teeth, stuck bearings, foreign matter entering

(3) Too loose rotation and large gap

Failure: Severe gear wear, excessive bearing clearance, and expansion sleeve slipping

(4) Abnormal one-way turning resistance (S type)

Failure: Backstop damaged, wedge stuck, one-way braking failure

6. Performance and appearance inspection

(1) The output speed is unstable/powerless and the load decreases

Failure: Broken gear teeth, worn keyway, loose expansion sleeve, slipping backstop

(2) The hollow shaft rotates relative to the host shaft

Failure: loosening/failure of the expansion sleeve, shearing of the flat key

(3) Tooth surface metal peeling, blackening, and gluing

Failure: severe overload, lubrication failure, material fatigue