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If you've had it for a few years, the bearings are probably getting bad (dry).
Always start a fan on high---then go to the speed you want, only the high speed windings will handle start-up.
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Sounds like you have covered all the bases already, but there is the small possibility that it is the housing vibrating. You can remove it and buffer the adjoining parts with electrical tape on the inside (so as to be hidden). Otherwise, you have a fan that hums (many just do). May need to exchange for a known quiet model like a Hunter or Panasonic.
Farmerbear at FixYa.com
its not the bearings sounds like you need to level the mount and that scraping it the fan blade mounting plate hitting the side of the 'case' that surrounds the motor assembly ive never heard of bearings in the motor going or needing lubrication other than what factory placed in them...remember Hampton Bay is the Yugo of electric appliances too
Although we do deal with Hampton Bay fans ourselves, here's a link to someone who does:Contact Mike Evans Website: www.eceilingfans.com Phone: 979-553-3260
18 gauge is a little light... should use 14. Are you sure it is a hum, or is it possibly the fan resonating due to imbalance of the blades. Watch to see if the fan is oscillating when it runs. Also, does changing the speed affect the frequency of the hum. If this is the case, you have to balance the blades using metal shims.
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