Common faults and troubleshooting methods for motors and reducers

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Common faults of motors and their troubleshooting methods
Fault cause | Troubleshooting method
Motor fails to start | Often due to wiring issues such as missing phases or broken wires. Check the power cables, overload protection devices, fuses, and control wires.
Excessive noise | High voltage. Check the wiring and supply voltage. Eccentric air gap. Send the motor to a professional manufacturer for repair.
Motor overheats | Overload, actual current (measured) exceeds the rated current value. Eliminate sources of excessive friction in the motor or load; reduce the load or replace it with a motor of higher capacity. Missing phase: Check the current in each phase (which should be roughly equal) and correct any errors.
Abnormal ventilation | Check that air flows properly through the cooling fans; clean debris accumulated on the motor.
Voltage imbalance | Check whether the voltages across each phase are equal.
Friction between rotor and stator | Check the air gap and bearings.
Overvoltage or undervoltage | Check the input voltage of the motor.
Open circuit in stator windings | Check whether the resistance of the stator windings is balanced across all three phases.
Windings grounded | Inspect the insulators and repair them as necessary.
Incorrect wiring | Check all power connection terminals, gaps, and mechanical strength; refer to the motor’s wiring diagram.
Bearings overheat | The motor and drive equipment are not aligned properly. Check and align the motor and drive equipment.
Belt too tight | Reduce the tension of the belt.
Excessive axial thrust | Reduce the axial thrust applied by the drive equipment.
Too much grease in bearings | Remove some of the grease so that only 3/4 of the bearing cavity is filled.
Bearings lack lubrication | Add lubricant.
Debris inside bearings | Clean the bearings and add lubricant.
Excessive vibration | The motor and drive equipment are not aligned properly. Check and align them.
Friction between rotor components and stator components | Eliminate the friction.
Rotor is unbalanced | Check the rotor’s balance; send it to the manufacturer for repair.
Resonance | Adjust the system or send it to the manufacturer for repair.
Excessive noise | Eccentric air gap or friction caused by foreign objects in the ventilation holes. Clean the rotor and remove foreign objects; reinstall the rotor. Check the overall insulation quality and clean the ventilation holes.
Windings grounded | Damaged bearings. Replace the bearings, clean all grease from the bearing cavity, and install new bearings