A comprehensive list of common faults in cutting machine reducers

The common faults of cutting machine reducers mainly focus on abnormal noise, oil leakage, overheating, vibration, and transmission failure. Mastering the manifestations, causes, and handling methods of these faults can indeed help you quickly troubleshoot problems and save unnecessary repair costs. The following is a list of common faults and targeted maintenance guidelines for cutting machine reducers:
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1、 Abnormal noise fault

1. Abnormal noise fault phenomenon: Irregular or continuous metal friction, impact, or buzzing sounds occur during the operation of the gearbox.

2. Analysis of the causes of abnormal noise:

Bearing issues: Internal damage, insufficient clearance, or foreign objects embedded in the bearing.

Gear problems: insufficient gear oil, abnormal wear on the tooth surface, poor contact, or foreign objects embedded in the tooth surface.

Loose connection: Loose bolts and other connecting components cause relative displacement and impact of the parts.

3. Symptomatic repair for abnormal noise:

Disassemble and inspect the bearing. If it is damaged, replace it. If it is a foreign object, clean and adjust the clearance.

Add gear oil to the specified oil level to improve the contact condition of the tooth surface; If the gear is severely worn, it needs to be replaced with a new gear.

Tighten all connecting bolts and add anti loosening washers if necessary.

2、 Oil leakage fault

1. Oil leakage fault phenomenon: Lubricating oil leakage occurs at the joint surface of the gearbox and the seal of the input/output shaft.

2. Analysis of Oil Leakage Causes:

Seal aging: The oil seal is damaged or aged, losing its sealing effect.

Excessive oil volume: The internal pressure rises, causing lubricating oil to overflow from the sealing gap.

Joint surface issue: The joint surface of the box is impacted, embedded with foreign objects, or the fastening bolts are loose.

Other components damaged: loose/damaged oil drain valve, damaged oil level gauge, or blocked exhaust valve.

3. Targeted repair for oil leakage:

Replace damaged and aged oil seals and sealing components.

Drain the oil to the specified level (usually kept in the middle of the sight glass or at 1/3-1/2 of the gear tooth height).

Flatten the joint surface, remove foreign objects, reapply sealant, and evenly tighten the bolts.

Tighten or replace the oil drain valve and oil level gauge, and clean the blocked exhaust valve (respirator).

3、 High temperature fault

1. High temperature fault phenomenon: The temperature of the gearbox housing rises abnormally (normal oil temperature is generally ≤ 80 ℃).

2. Analysis of the causes of high temperature:

Lubrication issues: Insufficient/excessive gear oil, deteriorated oil quality, or improper selection of lubricant type.

Component damage: Improper bearing fit or bearing damage.

Operation and environment: Equipment overload operation, blocked exhaust valve, or high ambient temperature.

3. Symptomatic repair for high temperature:

Add oil or drain oil to the standard level, and replace gear oil that has deteriorated or does not match the model in a timely manner.

Adjust the bearing clearance or replace the damaged bearing directly.

Reduce the operating load of the equipment, clean the exhaust valve, and if necessary, add cooling devices or improve ventilation to lower the ambient temperature.