What to Do When a Gearbox Leaks Oil? When using a gearbox, we sometimes find that it's leaking oil. What should we do then? Don't worry, the editor is here to teach you how to handle a leaking gearbox.
1. Enhanced breathable caps and inspected cover plates
One of the primary causes of oil leakage in gearboxes is the internal pressure exceeding atmospheric pressure. By equalizing the pressure inside and outside the machine, oil leakage can be prevented. Although all gearboxes are equipped with breathers, the vent holes are too small and easily clogged with coal dust and oil residue. Additionally, each time oil is added, the inspection cover must be opened, increasing the likelihood of leakage each time. This can cause even areas that were not previously leaking to begin to do so. To address this, a cup-type breather cap has been designed, replacing the original thin inspection cover with one that is 6mm thick. The cup-type breather cap is then welded to the cover, featuring a 6mm diameter vent hole for better ventilation and pressure equalization. Filling oil is now done through the oil cup, eliminating the need to open the inspection cover and reducing the chance of oil leakage.
2. Seamless Flow
To prevent excess lubricating oil from accumulating at the shaft seal due to the gear's action on the bearing, it is necessary to ensure that the excess oil flows back to the oil sump in a specific direction, achieving a smooth flow. The specific method involves creating a sloping return oil channel at the center of the bearing housing, and also opening a notch at the straight end cap, aligning it directly with the return oil channel. This allows the excess oil to flow back to the oil sump through the notch and the return oil channel.
3. Enhanced shaft seal structure
Improvement of Half-Axis Reduction Gear Seal: The output shafts of most equipment such as belt conveyors, spiral unloaders, and impeller coal feeders are halfshafts, making the modification convenient. Disassemble the reducer, remove the coupling, take out the reducer shaft seal end cover, machine a groove on the outer side of the original end cover according to the size of the supplied frame oil seal, install the frame oil seal with the spring side inward. During reassembly, if the end cover is more than 35mm away from the inner face of the coupling, a spare oil seal can be installed on the shaft outside the end cover. In case the oil seal fails, the damaged seal can be removed, and the spare oil seal can be pushed into the end cover, thereby eliminating the time-consuming and labor-intensive procedures of disassembling the reducer and removing the coupling.
2) Improvement of Output Shaft Seals for Whole Shafts in Gearboxes: Gearboxes with whole shaft transmission have no couplings on their output shafts. If改造 according to Plan 2.3.1, the workload is too great and unrealistic. To reduce workload and simplify the installation process, a separable end cover design has been developed, and an attempt has been made with an open-type oil seal. The separable end cover has lathe-cut slots on the outer side, where the spring is first removed during the oil seal installation. The oil seal is then sawed to form an open shape, and the seal is slipped onto the shaft from the opening. The open ends are bonded together using an adhesive, with the opening facing upwards. Afterward, the spring is reinserted, and the end cover is pushed into place.
4. Employing new sealing materials
For gear reducer static seal point leaks, a new high polymer repair material can be used for sealing. In case of oil leakage at the static seal point during the gear reducer's operation, a surface engineering oil surface emergency repair agent (adhesive-high polymer 25551 and 90T composite repair material) can be applied to block the leak, thereby eliminating the oil leakage.
5. Adhere to the maintenance and inspection procedures meticulously
During the reducer maintenance, strictly follow the process regulations. Do not reverse the oil seal, avoid damaging the lip, prevent deformation of the outer edge, ensure the spring does not fall off, clean the mating surface, apply the sealant evenly, and do not overfill beyond the oil level marker.
6. Wipe
Through treatment, static seal points of reducers can generally achieve no leakage. However, due to reasons such as aging of sealing parts, poor quality, improper assembly, and high roughness of the shaft surface, some dynamic seal points still have minor leaks. Due to poor working conditions, coal dust sticks to the shaft, making it look greasy. Therefore, it is necessary to wipe off the oil污 from the shaft after the equipment stops running.
Don't worry if the gear reducer is leaking oil; just follow the six points mentioned by the editor above, and you'll be fine. Overall, it's essential that everyone thoroughly inspect the machines and perform regular maintenance in their daily work.
