For ZD15-2.5-2 reducer lubrication system faults, the fault type needs to be located first and then dealt with accordingly. The specific steps can be implemented directly:
1. Troubleshooting of abnormal oil level
The oil level is too low: Stop the machine and cool it to room temperature, add the brand of lubricating oil specified in the instruction manual to the center line of the oil window; check the oil seal and flange seal for oil leakage, replace damaged seals, and tighten loose bolts; if there is sandhole leakage in the shell, repair or replace the shell with oil-resistant sealant.
The oil level is too high: drain excess lubricating oil to the standard oil level; check whether it is caused by water intrusion or excessive refueling. If water intrusion occurs, the lubricating oil must be completely replaced and the breather plug must be checked to see if it is blocked.
2. Troubleshooting of oil quality deterioration
If the oil turns black and contains impurities: drain the old oil immediately and flush the tank and oil circuit with kerosene or special cleaning agent; disassemble and inspect the filter, clean the filter screen of impurities or replace the filter element; add new oil after reinstallation, and replace it again after the first 50 hours of operation to ensure that the oil circuit is clean.
Oil emulsification: Replace all lubricating oil, check whether water has entered the reducer housing (such as seal failure, humid environment), repair the water inlet point; install a desiccant or improve ventilation conditions to prevent emulsification again.
3. Troubleshooting of lubrication circuit blockage
Symptoms: The temperature of bearings and gears rises too quickly, and the local temperature exceeds 80°C.
Treatment: Disassemble the lubrication pipeline and oil passage, and use compressed air to blow out the clogged parts; check whether the oil pump (if any) is stuck, repair or replace the damaged oil pump; replace the filter, and clean impurities regularly to avoid clogging again.
4. Troubleshooting of poor lubrication (insufficient oil supply)
Reasons: Insufficient oil pump pressure, oil line leakage, and oil nozzle blockage.
Treatment: Adjust the oil pump pressure to the rated value; check the oil line joints, tighten or replace the seals; clean the oil nozzle blockage to ensure that the lubricating oil reaches the meshing surface and bearing raceway directly; if it is splash lubrication, confirm that the oil level is sufficient and the gear rotation is normal with oil.
5. Verification after troubleshooting
After repair, add qualified lubricating oil, run without load for 1 to 2 hours, and monitor the temperature and noise to be normal; load to rated load and run, confirm that the temperature rise of the bearings and gears is ≤40°C, there is no abnormal noise, and there is no leakage at the seal.
