For damaged repair or replacement of core components (such as gears, bearings, shafts, etc.) of the ZLY560-12.5-III hardened gear reducer, a plan needs to be formulated based on the damage type and working condition requirements. The specific process is as follows: 1. Gear damage assessment‌ Broken teeth/chips‌: Visual inspection of the fracture shape (brittle fractures are crystalline, fatigue fractures have ridges), magnetic particle inspection to detect tooth surface cracks, and ultrasonic inspection to detect internal defects. ‌Wear/pitting‌: Measure the amount of tooth thickness reduction (>5% needs to be replaced), check the contact marks on the tooth surface (unilateral meshing indicates axis misalignment)‌. 2. Bearing fault judgment: detect the clearance (rolling bearings >0.03mm need to be replaced), auscultate abnormal sounds (high-frequency sharp sounds indicate raceway damage), and check the integrity of the cage. 3. If the straightness deviation of the shafting system is >0.05mm/m, it needs to be straightened. If the journal wear exceeds 0.02mm, it can be repaired by chrome plating. If the keyway is worn, it can be re-milled. 2. Maintenance Read More

To reduce ZLY630-10-1 The temperature rise of the type hard tooth surface reducer needs to start from the four core dimensions of heat dissipation optimization, friction control, load matching, and structural maintenance. Combined with this type of reducer (medium hard tooth surface, single machine transmission ratio 10, center distance 630mm, commonly used in heavy-duty industrial scenarios), the following specific methods can be adopted, sorted by priority and practicality: 1. Optimize the lubrication system: reduce frictional heat generation (core method) ZLY630-10-1 As a heavy-duty hard-tooth surface reducer, frictional heat generation from gear meshing and bearing operation is the main source of temperature rise. Reasonable lubrication can directly reduce the friction coefficient and reduce heat generation. 1. Select suitable lubricating oil products a. Viscosity matching: Select industrial gear oil with appropriate viscosity according to operating conditions (load, speed, ambient temperature) to avoid 'excessive viscosity increasing friction resistance, and too low viscosity leading to lubrication failure'. Read More

WPKA120-40-B The fault diagnosis and maintenance of the worm gear reducer can refer to the following experience: Fault diagnosis, listening and positioning: The sound of metal friction may be due to lack of oil or oil deterioration, so you need to check the oil level in the oil window immediately and touch the box to see if it is hot; regular impact sounds may be broken teeth or damaged bearing cages, you can stop the machine and turn it manually to feel if there is any jamming; high-frequency whistling sounds may be poor alignment of the coupling, use a screwdriver to hold the bearing end and listen to the sound changes. Touch diagnosis: touch the bearing seat, and if it is hot (>70°C), the bearing may be lacking grease or damaged; touch the box joint surface, and if oil leakage or scaling occurs, the seal may be failed; touch the output shaft, if there is obvious swing, the bearing may be worn. Visual inspection: Check the lubricating oil. If the oil window is turbid, it may be oil emulsification. If the oil is black, it may be metal wear. Check the coupling. If the elastic gasket is cracked, replace it immediately. If the alignment is offset, use a ruler to roughly measure the gap. Read More

Judging the degree of wear of the worm gear of the WPKA175-15-A reducer requires comprehensive visual inspection, operating status analysis and precise measurement. The specific methods are as follows: 1. Appearance inspection‌Tooth surface wear characteristics‌If scratches, grooves or accumulation of metal debris along the sliding direction appear on the tooth surface of the worm gear (copper alloy), the surface roughness will increase significantly, indicating the existence of uniform wear‌. If the tooth surface of the worm (steel) is partially polished or dented, material transfer may occur due to sliding friction. Gluing damage is manifested as metal adhesion, tearing or melted plaques on the tooth surface, which are dark brown in color. In severe cases, traces of 'bite welding' can be seen. ‌Pitting Corrosion and Cracks‌Scattered pits (pitting corrosion) or fine cracks in the tooth root appear on the tooth surface, which require observation with a magnifying glass, indicating the risk of fatigue wear‌. 2. Operating status monitoring ‌ Abnormal noise and vibration ‌ The noise in the initial stage of wear changes from 'smooth sound' to 'rustling sound', and 'piercing screams' or periodic impact sounds appear during gluing. Vibration amplitude exceeds 0 Read More

The following is the daily maintenance plan for parallel shaft F77-55-3KW-4P gear reducer bearings, combining lubrication management, condition monitoring and preventive maintenance measures: 1. Lubrication management ‌ Grease selection and filling ‌ Use lithium-based grease (such as NLGI level 2), and the filling amount is 1/2-2/3 of the bearing cavity space. Replenish grease every 3-6 months, shortened to 1-2 months in high temperature or dusty environments. ‌Lubrication system inspection‌Check the oil level window (if available) every week to ensure that the grease is not dried out or contaminated‌. Replace the grease immediately if it is found to be discolored (blackened) or contains metal particles. 2. Operating status monitoring‌Vibration and temperature detection‌Use a vibration meter to detect the bearing parts every day. The effective value of the vibration speed should be ≤4.5mm/s‌. An infrared temperature measuring gun monitors the temperature of the outer ring of the bearing, and the temperature rise is ≤25℃ (limited to ambient temperature +40℃). ‌Judgement of sound and abnormal noise‌During normal operation, the bearing sound is even and periodic. Read More

The essence of the poor lubrication of the hard-tooth surface F97-Y7.5-NA40-M4 reducer bearing is that 'the lubricating medium does not continuously and stably act on the rolling contact surface of the bearing according to the design requirements.' The reason can be from the lubricating medium itself, the lubrication system/ The four core dimensions of structure, installation operation, and working environment are disassembled. The specific analysis is as follows: 1. Reasons related to lubricating medium (core factors) The performance, state or Selection of the lubricating medium (usually gear oil, some bearings use grease alone) directly determines the lubrication effect, and is the most common source of failure: Lubricating oil Selection Error not pressed The manual of the reducer requires the selection of oil: for example, the misuse of low-viscosity oil (cannot form enough oil film, resulting in direct metal contact), high-viscosity oil (poor fluidity, difficult to penetrate into the tiny gap between the bearing raceway and the rolling element), or failure to use 'extreme pressure anti-wear gear oil' (hard-tooth surface reducer load is heavy, ordinary lubricating oil is easily crushed, and cannot form an effective Read More