How to reduce the probability of failure of ZJY106-11.2 gearbox through preventive maintenance measures

The following preventive maintenance measures can effectively reduce the probability of failure of ZJY160-11.2 gearbox:

Regularly check the lubricating oil

Oil quality inspection: Conduct oil quality testing at regular intervals (such as 2000-3000 hours), by observing the color and transparency of the oil, smelling its odor, and using professional oil quality testing equipment to detect impurities, moisture, acid value, and other indicators in the oil, to determine whether the oil quality has deteriorated. If the oil quality deteriorates, the lubricating oil should be replaced in a timely manner to ensure good lubrication and heat dissipation of the gearbox.

Oil level check: Check the oil level at least once a week to ensure that it is within the range specified by the oil gauge. Low oil level can lead to poor lubrication and accelerate the wear of gears and bearings; If the oil level is too high, it may cause problems such as oil temperature rise and oil seal leakage.

Monitoring operating temperature: During the operation of the gearbox, use a thermometer or temperature sensor to monitor its oil temperature and bearing temperature. Generally speaking, the oil temperature during normal operation of the gearbox should be between 30-70 ℃, and the bearing temperature should not exceed 80 ℃. If an abnormal increase in temperature is found, the machine should be stopped immediately for inspection, and the cause should be identified, such as excessive load, poor lubrication, poor heat dissipation, etc. The fault should be promptly eliminated to avoid equipment damage caused by high temperature.

Regular cleaning and fastening

Cleaning the exterior: Conduct external cleaning at least once a month to remove dust, oil stains, and debris from the surface of the gearbox, prevent excessive accumulation that affects heat dissipation, and also facilitate timely detection of equipment surface damage and leaks.

Tightening bolts: Conduct a tightening inspection of the foundation bolts, connecting bolts, etc. of the reducer once a quarter to ensure that the bolts are not loose. Loose bolts may lead to increased equipment vibration and even damage to connection parts, affecting the normal operation of the gearbox.

Check seals: Carefully inspect the seals of the gearbox, such as oil seals, sealing rings, etc., every time lubricating oil is replaced or regular maintenance is carried out. If aging, wear, deformation or leakage of the sealing components are found, they should be replaced in a timely manner to prevent lubricating oil leakage and ensure a clean and good lubrication environment inside the reducer.

Monitoring vibration and noise: During daily operation, pay attention to monitoring the sound of the gearbox and observing its vibration situation. Under normal circumstances, the gearbox operates smoothly and uniformly with minimal vibration. If there is abnormal noise such as piercing sound, impact sound, friction sound, or significant increase in vibration, it may indicate problems such as gear wear, bearing damage, and foreign objects inside. The machine should be stopped for inspection and maintenance in a timely manner.

Regular alignment inspection: Regularly (such as once every six months) inspect the alignment of the reducer with the motor, working machine, and other equipment. Misalignment can lead to uneven bearing force on the shaft, accelerate bearing and gear wear, and even cause equipment vibration and noise. By using tools such as laser centering instruments or dial indicators for centering detection, and adjusting them in a timely manner, the connection accuracy between devices is ensured.