How to avoid leakage faults in ZQD series gearbox housing

1、 Build a strong defense line for the sealing system

Shaft end seal upgrade: Choose oil resistant and wear-resistant FKM double lip oil seals to replace ordinary nitrile rubber oil seals, adapt to temperature changes, and extend service life; Install a labyrinth seal on the outer side under dust conditions to prevent impurities from wearing the lip.

Sealing of box joint surface: Before assembly, thoroughly clean the residual old glue and oil stains, evenly apply anaerobic sealant such as Loctite 587, and apply the glue in diagonal order to avoid any gaps or fractures.

Special treatment for leakage prone points: Regularly replace the FKM oil resistant sealing ring at the sight glass, replace the ordinary breathing valve with a two-stage filter screen, clean the filter screen every six months to prevent oil from being squeezed out due to high pressure inside the box.

2、 Standardize lubrication management

Strictly control the oil level and oil products: The refueling amount is strictly controlled within the range of 1/2~2/3 of the oil standard to avoid oil splashing and leakage during operation due to high oil level; PAO synthetic gear oil is selected for high temperature conditions, and the water content of the oil is controlled below 0.1%.

Regular testing and filtering: Check the viscosity and impurities of lubricating oil every quarter, and replace the oil promptly if the viscosity fluctuates by more than 15%; Install a magnetic oil filter inside the fuel tank to absorb iron filings and impurities, reducing particle wear on the seals.

3、 Control assembly and installation accuracy

Precision assembly of core components: Use a dial gauge to detect the radial runout of the shaft neck, with a deviation controlled within 0.05mm. Minor wear is repaired with low-temperature chrome plating; Freeze the oil seal at -40 ℃ for 2 hours in advance, and press it vertically with a special fixture to ensure concentricity and avoid eccentric wear.

Standard tightening of box bolts: Use a torque wrench to tighten the box bolts in diagonal order to ensure uniform force on the joint surface and prevent local deformation and gaps.

Equipment alignment and leveling: During installation, ensure that the reducer is aligned with the transmission center axis of the working machine, and the error does not exceed the compensation amount of the coupling; Fixed on the basis of horizontal stability, reduce the impact of operational vibration on the sealing components.

4、 Strengthen daily operation and maintenance

Working condition control: Overloading operation is strictly prohibited, and an oil temperature alarm device should be installed to trigger a warning at 75 ℃, in order to avoid accelerated aging of seals due to soaring oil temperature; Reduce frequent start stop and minimize the impact of shaft vibration on the seal.

Regular inspection and fastening: Use an infrared thermal imager to detect the temperature of the sealing area every month. If the temperature difference exceeds 15 ℃, promptly identify potential sealing failure hazards; Tighten the end caps and anchor bolts every 3 months to prevent looseness and gaps.

Dust environment protection: Install dust covers in dusty scenes such as mines, clean the surface dust of the shaft seal and box every week, and prevent particles from damaging the sealing surface.