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Improvements to prevent gearbox oil leakage

Release date:

2022-03-21

A company provides on-site equipment lubrication services, and during inspections, several areas within the plant were identified as problematic. Specifically, some of the equipment is used to lift steel ladles weighing 80 to 120 tons, featuring relatively large bearings under extremely harsh operating conditions. As a result, gearboxes in these systems exhibit varying degrees of oil leakage—a common headache for most steel plants. Below, we’ll analyze the root causes of the gearbox oil leaks and outline steps for improvement.

A company provides on-site equipment lubrication services, and during the investigation, several areas within the factory were identified. Since some of these applications involve lifting steel ladles weighing 80 to 120 tons, the bearings are relatively large and operate under extremely harsh conditions— Gearbox Oil leaks of varying degrees are present, which is also a major headache for most steel plants. Below, we will discuss Gearbox Analyzing and improving the oil leak.

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All Gearbox They all use universal gear oil, which has excellent fluidity, but after a period of use… Gearbox Leakage of varying degrees may occur. Once the mechanical seal ages, oil leakage can quickly escalate—just as shown in the image above. If not detected promptly, this could lead to equipment damage, severely impacting the lifespan of the gears. In addition to using seals with excellent compatibility, it’s also crucial to choose a high-quality liquid grease for lubrication. Gears lubricated with liquid grease will experience significantly improved performance in preventing oil leaks, ultimately extending their service life.

Thanks to the unique sealing performance of grease, we can observe that if there’s a sealing issue, it won’t leak out quickly. Moreover, since the pressure difference between the inside and outside of the reducer isn’t significant, the grease effectively acts as an additional seal at the sealing gap, ensuring smooth operation of the equipment while preventing external contaminants from entering the gearbox.

Using standard gear oil, the gear surfaces remain relatively dry, revealing visible damage to the tooth flanks. The equipment is typically stationary during operation, and failures often occur precisely at startup. At the moment the gears engage during startup, the oil film on the tooth surfaces may not be thick enough, leading to a relatively high impact load as the gears begin to mesh. As a result, the damage to the equipment tends to be significant at this critical instant. As shown on the right side of the image above, Gearbox It is lubricated with liquid grease, and the oil film on the gear surfaces exhibits excellent adhesion, effectively preventing gear surface wear that typically occurs during startup.

Gearbox Widely used in industries such as mining, metallurgy, chemical processing, building materials, papermaking, lifting, and power generation, the quality requirements for these products are steadily increasing. Not only must they possess excellent internal qualities, but they also need to boast a visually appealing appearance. Gearbox During operation, oil leakage frequently occurs, leading not only to waste but also to environmental pollution and compromising the integrity of the entire equipment. Therefore, addressing oil leakage issues is a key indicator of the gearbox's overall quality.

Gearbox Common causes of oil leaks:

1. Damaged seals or incorrect installation leading to loose sealing at the joint surface:

2. Due to prolonged use or excessive wear of the parts, the clearance has become significant;

3. The casting for the box exhibits defects such as porosity and sand holes;

4. Operating temperature too high or lubricant viscosity too low;

5. Lubrication oil lines are deformed or cracked, resulting in oil leaks and fluid loss.

Gearbox Methods for Preventing and Repairing Oil Leaks:

When Gearbox When there are no leaks, strict inspections and tests can effectively address sealing issues. Be sure to purchase equipment from reputable manufacturers to ensure high-quality materials and performance, and always choose the right type of lubricant for optimal results. If a leak does occur, we recommend using Hendico polymer composite material—perfect for on-site leak repairs without the need for disassembly. This versatile polymer compound is ideal for tackling both internal and external leaks, saving time and effort while delivering immediate, long-lasting solutions. Its exceptional adhesion properties and outstanding oil resistance make it highly effective, even in challenging conditions like gear box vibrations. Plus, it’s easy to apply and cures quickly, making it an efficient choice for any repair job.


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