RX97-2.64-22KW-M1 emergency treatment steps for reducer grease failure, core principles: first stop the machine to stop damage and prevent the fault from expanding, then perform emergency measures to ensure temporary operation, and finally make thorough rectifications to prevent recurrence, adapting to on-site sudden lubrication failure handling.
1. Stop the machine immediately and stop the loss (the first step is to prevent core components from being scrapped)
1. Emergency shutdown and power outage, hang a 'no closing' warning sign to prevent mis-starting; if accompanied by abnormal noise, high temperature, or jamming, forced start and stop is strictly prohibited to avoid gear teeth breaking and bearing sintering.
2. Let it cool down until the temperature of the reducer shell drops below 40°C (to prevent burns from hot oil and oil splashing) before proceeding with subsequent operations. Disassembly is strictly prohibited in high temperature conditions.
3. Preliminary investigation of failure symptoms: observe whether there is oil or grease leakage, whether there are cracks in the casing, whether the feet are loose, listen to see whether the cranking is stuck after stopping, and record the fault phenomena (abnormal noise, temperature, vibration) to provide a basis for subsequent processing.
2. Emergency troubleshooting (remove expired grease to avoid secondary damage)
1. Drain the expired grease: Find the oil drain plug at the bottom of the box, place the oil basin underneath, unscrew the plug and completely drain the expired grease/oil in the box. Shake the box (slightly) when draining to ensure that all the expired grease, metal debris, and impurities remaining at the bottom of the box are drained out.
2. Simple cleaning of the box: If the expired grease is accompanied by a large amount of metal debris and floc, use the same type of clean thin oil (such as 220# gear oil) to flush the inside of the box 2-3 times. After each flush, let it sit for 10 minutes before draining the oil until the discharged oil has no obvious impurities (if there is no special flushing oil, filtered new oil can be used as an emergency)
3. Check the seal protection: Quickly check the joint surface of the shaft end oil seal and the box body. If the oil seal is aged and damaged or the gasket leaks, temporarily seal it with sealant (emergency) to prevent subsequent new grease from being contaminated; if the oil filling port and oil drain port of the dust cap are missing, temporarily seal them with a clean rag.
3. Emergency filling (adapted to emergency resumption of production and ensure temporary operation)
1. Accurately select emergency grease: This model is a hard-tooth surface helical gear reducer. The gears are preferably L-CKC 320# medium-load closed gear oil (normal temperature) and L-CKC 460# (high temperature and heavy load). For separate grease injection of the bearings, choose LGMT 3# extreme pressure lithium-based grease. It is strictly forbidden to use inferior oil or mix different types of oil.
2. Standard filling: Wipe the oil filling port before filling, filter the new oil with a filter (≥100 mesh), and slowly add it through a funnel; the gear oil level is controlled between the upper and lower limits of the oil level gauge, and the bearing grease injection amount is 1/2-2/3 of the bearing inner cavity. Over or under is strictly prohibited
3. Exhaust running-in: After the filling is completed, tighten the oil filling and oil drain plugs, start the machine and run without load for 5-10 minutes, so that the new grease can fully cover the gear tooth surface and bearing raceway, and discharge the internal air; during this period, observe whether there is leakage or abnormal noise, stop the machine and let it sit for 2 minutes to recheck the oil level. If it is insufficient, add it to the standard level.
4. Emergency operation control (limited temporary resumption of production, strict risk control)
1. Strictly control working conditions: Overload operation is strictly prohibited after an emergency, and the load must not exceed 90% of the rating. Avoid frequent starts and stops, rapid acceleration and deceleration, and reduce gear bearing impact.
2. High-frequency monitoring: Check the oil temperature every 15-30 minutes during operation (normal ≤80°C, stop immediately if it exceeds 90°C), vibration (no violent tingling in the hand), abnormal sound (no sharp whistling, metal impact sound), and stop the machine immediately if any abnormality is found
3. Limited operating time: emergency treatment is only applicable to temporary resumption of production, the longest continuous operation
