1. Stop the machine immediately and cut off the power supply
Once the reducer is found to be overloaded (such as abnormal noise, severe vibration, excessive temperature rise, etc.), it must be stopped immediately and the power supply cut off. It is strictly prohibited to continue operating under high temperature or overload conditions to prevent more serious damage such as worm gear bonding or motor winding burnout.
2. Troubleshoot and eliminate sources of overload
In the shutdown state, check in detail whether there is a fault on the load side, such as whether the equipment is stuck, whether the material is blocked, etc. Only after the direct cause of the overload is confirmed and eliminated can restarting be considered.
3. Check the condition of lubricating oil
Overloading is often accompanied by severe heating. It is necessary to check whether the lubricating oil level of the reducer is sufficient and whether the oil quality has deteriorated. If the oil becomes thinned, emulsified or contains a large amount of impurities due to high temperature, it is necessary to replenish or replace the lubricating oil that meets the specifications in time to restore good lubrication status.
4. Check the wear of mechanical parts
Overload can easily cause damage to internal transmission components. Focus on checking the meshing status of the worm gear (whether there is severe wear, pitting or "gnawing" abnormal noise) and whether the bearing is damaged. If serious wear or damage is found, professional maintenance personnel must repair or replace relevant parts. Do not disassemble without permission.
5. Improve heat dissipation and ventilation conditions
Overload will cause the temperature of the reducer to rise sharply. After troubleshooting, ensure there is sufficient ventilation space around the reducer and clean the dust and oil on the surface of the cooling fins; if the ambient temperature is too high or it is in a confined space, you should consider installing an external cooling fan or other forced heat dissipation device.
6. Re-evaluate load and ramp up
After confirming that the equipment is back to normal, do not directly increase the load to the maximum when restarting. It is recommended to gradually increase the load and closely monitor operating current and temperature. If the actual working load exceeds the rated torque of the reducer for a long time, you should consider replacing a larger size reduction motor or optimizing the process to spread the load.
