Conveyor gear reducers leaking 3

[Dandem19]

At my facility we have numerous gear boxes that are leaking oil either from the shaft seal or from the red vent plug. This facility has only been operating for about 2 years. Why would we have so many leaking and what would be the reason for it. Is it because of the high temp they all have I mean some I can't even put my hand on it its so hot. Is it because the techs are adding to much tension. Improper filling . What would be all the reason for the leaking in 2 years of operating.

 

[3DDave]

First guess - overfilled causing too much churning that causes heat to build and oil to expand. When you write "red vent plug," it should have a breather, not a plug, otherwise any air and oil expansion from the heat will increase the internal pressure and cause leaks and can rupture the seals.

High loads will initially cause bearing failures or fatigue failures of shafts, not leaks.

 

[TugboatEng]

A red plug is usually a plastic shipping plug. It's only meant to keel debris out until the gearbox is installed.

 

[BrianE22]

Leaking out of shaft seals or static gaskets?

 

[EdStainless]

Common issue.
Often wrong oil in the wrong amount.
More isn't better, there is a correct amount.
Both of these can cause a gearbox to run hot and shorten the life.
The heat also kills the seals.
Find the manuals, check actual temps, and look at maintenance records.
There should be a written procedure for this work, and it is often part the document where they record that they did it.

= = = = = = = = = = = = = = = = = = = =
P.E. Metallurgy, consulting work welcomed

 

[BrianPetersen]

Also, are these good quality gearboxes selected appropriately from a reputable manufacturer that stands behind their product and who has a local sales rep who you can (and should) call?

Or were they the cheapest gearboxes someone could find. Probably worm gear with terrible efficiency and that's why they're running hot.

 

[geesaman.d]

I'd look into whether these gear drives were specified based on continuous operation in the environment in which they are actually operating. And are the conveyors within their weight and speed rating.

Gear drives can tolerate some heat - too hot to touch can still be normal - but if the seals are leaking significantly then maybe they're overheating. I agree with a temp gun unless the drive manufacturer can offer a better way (ideally there would be a safe place to insert a temperature probe and directly measure the oil temperature). The gearboxes I work with are kept below 180F oil temp, which you don't want to lean against.

Excess belt tension would likely kill the output shaft bearings, but that doesn't always generate a lot of heat. But it can liberate metal particles that embed in the oil seals, score the shafts, and persistently leak.

 

[Dandem19]

Let me add some info to this. So we have about 200 work orders out of them 44% are gear reducers that are leaking. Either from the outlet shaft or inlet shaft or from the posivent fitting. Why would so many be leaking. Also we do conveyance like v-belts accuglides and belted conveyors. Is it wrong size over filled under filled to much tension or misaligned

 

[MintJulep]

Your gearboxes are leaking because something is wrong.

Without further relevant information, that's all anyone can offer.

Your best next action might be here:

https://www.bostongear.com/contact

 

[TugboatEng]

460 centistokes is about as thick as gear oils get so that is going to cause it to run hotter. I doubt an incorrect oil specification would increase the temperature much beyond that.

But! It's ok for gearboxes to run hot with the right seals. If it's too hot to touch by hand that just means it's above 150°F. Gearboxes will easily tolerate temperatures up to 250°F but will require special seals to do so for continuous operation. What seal material was specified for your gearbox? Viton and silicone are superior at high temps but don't have good wear properties. Engine manufacturers use PTFE seals as their operating temperatures are normally 210°F. Viton and silicone will tolerate those temps as well but lack wear resistance.

 

[BrianPetersen]

That's a worm-gear reducer. They have terrible efficiency. They run hot. Still ... they shouldn't leak.

Call Boston Gear and ask for technical support.

 

[Jboggs]

Like Mintjulep suggested - have you contacted the manufacturer? They know their product, and the most common problems, better than anyone. They also have a staff of full time application engineers whose only job is to help you succeed with their product. Of course you want to download any information, but you also want to speak to a live human being. I feel safe in saying there is nothing wrong with the gearboxes, and probably nothing wrong with the way they are installed. I'm very confident the problem lies in how they have been maintained.

 

[CWB1]

1. Draw the Ishikawa/fishbone diagram.
2. Include every possible root cause.
3. Use that as a checklist to confirm the root cause.

You'd prob be surprised how often I've been contracted to do that after an internal "expert" ran out of guesses. Analyze, dont guess.