How to carry out targeted maintenance based on the fault performance of JS series reducers

Systematic troubleshooting and targeted maintenance are needed to address the different fault manifestations of JS gear reducers. The following are detailed repair steps and solutions for the four common types of faults:

1、 Targeted maintenance of abnormal noise and vibration

When abnormal noise occurs, do not disassemble blindly. It is recommended to first stop the machine and manually turn it to feel the resistance, and then locate and repair it through the following steps:

Troubleshooting gear issues: Open the observation hole and check the gear meshing status. If the excessive meshing clearance is caused by gear wear, precise adjustment can be made by adding or removing copper shims on the bearing cover (if the clearance is large, reduce the shims; if the clearance is small, add shims). If slight poor tooth contact is found, grinding paste can be used for running in; But if there are broken teeth, root cracks or severe pitting, the machine must be stopped immediately and the gears must be replaced in pairs to avoid damaging other components.

Troubleshooting of bearing failure: Use a stethoscope close to the bearing end cover. If you hear sharp friction sounds or obvious "clunking" impact sounds accompanied by high bearing seat temperature (>90 ℃) or abnormal vibration, it indicates that the bearing raceway or rolling elements have been damaged. It is necessary to replace the same type of bearing in a timely manner and ensure installation accuracy and preload.

Check for installation looseness: Check and re tighten the anchor bolts, bearing end caps, and gear compression nuts. Use laser centering instruments and other tools to recalibrate the coaxiality between the input/output shaft and the connected equipment (deviation should be controlled within 0.05mm/m).

2、 Targeted maintenance for high temperature (abnormal heating)

When the shell temperature exceeds 80 ℃, it is necessary to investigate and cool down in the following order:

Check the lubrication system: Observe the oil window. Excessive oil volume can cause stirring and heating, while insufficient oil volume can result in insufficient lubrication. The oil level should be adjusted to 1/2-2/3 of the oil window or dipstick. At the same time, check whether the oil has deteriorated and whether the viscosity matches. If necessary, thoroughly drain the old oil, clean the oil tank, and replace it with new lubricating oil that meets the standards.

Improve heat dissipation conditions: Clean the dust and oil stains on the heat sink and fan to ensure good ventilation. If the ambient temperature is too high or the operation is under heavy load for a long time, it may be considered to install cooling devices such as forced air cooling or water-cooled coils.

Control load and internal friction: Monitor motor current to ensure that the actual load is within the rated range of the gearbox. If both lubrication and heat dissipation are normal but still high temperature, it is necessary to stop the machine and check whether there are abnormal friction sources such as tight gear meshing or improper bearing assembly inside.