Common faults and solutions of CJY180-280-5.5KW shaft mounted reducer

Common faults and solutions of CJY180-280-5.5KW shaft mounted reducer
1. Bearing damage

Fault manifestations: abnormal bearing noise (high-frequency "sizzling sound" or periodic "clattering sound"), intensified vibration (amplitude ≥ 0.1mm), and temperature rise (shell surface ≥ 80 ℃).

Reason: Poor lubrication (insufficient oil quantity or deteriorated oil quality), overload operation, installation misalignment (coaxiality error>0.05mm).

Solution:

Replace damaged bearings (such as NU2308 cylindrical roller bearings) and ensure that the clearance of the new bearings meets the standard (0.03-0.05mm).

Check the lubrication system, use ISO VG 220 extreme pressure gear oil, and replace it every 2000 hours.

Adjust the coaxiality of the motor and reducer (≤ 0.05mm), and tighten the bolts (torque in diagonal order).

2. Gear wear or broken teeth

Fault manifestations: Irregular noise (500-1500Hz) during operation, decreased transmission efficiency, and stuck output shaft.

Reason: Long term overload, lubrication failure, tooth surface pitting or fatigue fracture.

Solution:

Replace worn gears (check the reduction in tooth thickness, if it exceeds 10%, it needs to be replaced).

Improve lubrication conditions to avoid mixing or contamination of oil products.

Check if the load exceeds the limit (rated torque ≤ 2800N · m).

3. Lubrication system malfunction

Fault manifestations: high oil temperature (>90 ℃), abnormal oil level, oil leakage.

Reason: Insufficient oil quantity, deterioration of oil products, seal failure (such as aging of skeleton oil seals).

Solution:

Fill the oil to the specified level (centerline of the oil dipstick) and replace the ISO VG 220 gear oil.

Clean or replace clogged exhaust valves and check seals (such as O-rings).

4. Axis misalignment or bending

Fault manifestations: obvious vibration, worn coupling, and inflexible rotation of output shaft.

Reason: Installation deviation and impact load caused shaft deformation.

Solution:

Adjust the coaxiality using a laser alignment instrument (error ≤ 0.05mm).

Replace the bent input/output shaft (repair if the shaft diameter wear exceeds 0.1mm).

5. Failure of connection between motor and reducer

Fault manifestations: Motor idling but gearbox not rotating, abnormal coupling noise.

Reason: worn keyway, loose coupling bolts, or broken elastic components.