How to deal with abnormalities during the trial operation of ZQ250-31.5-4 gear reducer

If an abnormality occurs during the trial operation of the ZQ250-31.5-4 gear reducer, it should be stopped immediately for investigation. The root cause of the problem should be systematically diagnosed according to the principle of 'from outside to inside, from simple to complex' and dealt with in a targeted manner to avoid equipment damage or safety accidents.

1. Safety measures to be taken immediately

‌Cut off the power supply‌: Cut off the power supply to the motor and control system as soon as possible, and hang a 'no closing' warning sign to prevent misstarting.

‌Release energy‌: Confirm that the brake has been powered off and released, the inverter has completed discharge, and the equipment is completely stationary.

‌Record Phenomenon‌: Record abnormal phenomena (such as abnormal noise, vibration, temperature rise, stuck, etc.) in detail to facilitate subsequent analysis.

2. Common exception types and processing steps

1. Abnormal noise or noise occurs

Possible causes include poor gear meshing, damaged bearings, impurities in the lubricant, or improper gear clearance.

Check the condition of the lubricating oil: take a sample to see if metal shavings, moisture or impurities are mixed, and replace the gear oil that meets the standard if necessary.

Check the gear meshing: open the observation hole cover, check whether the tooth surface is corroded, peeled, scratched or abnormally worn, and adjust the tooth side clearance to the specified range (usually 0.15~0.3mm).

Check the status of the bearing: listen for irregular 'clicking' sounds or continuous high-frequency noise to determine whether it is caused by bearing damage or too small a gap.

2. Excessive vibration

Vibration often results from installation problems, worn components, or misalignment.

Check whether the anchor bolts are loose, whether the foundation is solid, and whether there are any cracks or settlement in the concrete.

Check the coupling alignment accuracy: use a dial indicator to measure the radial and axial deviation to ensure ≤0.05mm.

Check whether the input/output shaft is bent and whether the bearings are worn or damaged and replace if necessary.

3. The temperature is too high

The temperature of the box or bearing parts rises rapidly during trial operation, which may be caused by improper lubrication, overloading or poor exhaust.

Check the oil level: The oil level should be at the center line of the oil mark. Too high or too low will lead to poor heat dissipation.

Confirm whether the lubricant model matches the working conditions. Especially in low temperature environments, low pour point gear oil (such as L-CKD 150# or synthetic oil) is required.

Check whether the exhaust valve is blocked and ensure that the pressure in the box is released normally.

4. The reducer does not rotate or is stuck (the motor is normal)

If the motor is running but the reducer has no output, the power transmission path needs to be checked.

Disconnect the load-side coupling and manually turn the machine to check whether the reducer body is stuck.

If it can rotate easily, the problem may be at the load end (such as being stuck by materials); if it cannot rotate, the internal gear or bearing needs to be disassembled and inspected for damage.

Check whether the brake is not fully released or whether the connection between the input shaft and the motor is loose.