Radial Shaft Seals - Troubleshooting 2016

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Content
Content
Leakage Troubleshooting
Leakage according to DIN 3761
Basic Steps in Analyzing Sealing
System Failures
Proper Seal Measurement
Common Sealing Problems
Leakage Analysis
Sealing System Check List
2 Service & Repair 2/12/17

Leakage
Leakage
Leakage
Leakage
1. an act of leaking; leak.
2. something that leaks in or out.
3. the amount that leaks in or out.

Troubleshooting
Troubleshooting

Troubleshooting
Troubleshooting
Follow a sequence of steps that should lead you
to the problem.
1. What was the seal supposed to do?
How well has it done the job in the post?
2. Was it the right seal?
Check the seal's part number and look up its
recommended applications.
3. Pinpoint the source of the leak.
It may be either an I.D. leak or an O.D. leak.
Also, find out when the leak first occurred and see
if this relates to a change in maintenance or
operating procedures.
4. In the case of exceptional seal wear, what is
the cause of this wear?
To find out requires failure analysis.
Basic Steps in Analyzing
Basic Steps in Analyzing
Sealing System Failures
Sealing System Failures

Basic Steps in Analyzing Sealing System
Failures
Failures
Follow these steps in determining why a seal has failed:
1. Inspect the seal before removal to check the
condition of the area, note the amount of
leakage that has occurred, and determine the
source of the leakage
The following definitions should assist:
Sealed
Moist
Wet
Measurable leakage
Short-term leakage
Apparent-leakage
Taconite sealing systems, used grease emerges from the
sealing gap due to the principle of operation. This apparent
leak is not a fault.
Transport damage to the gear unit, or gear unit
components may result from leakage of lubricants.
Failures
Failures
Follow these steps in determining why a seal has failed:
2. Wipe the area clean and inspect to determine
if:
There are nicks on the bore chamfer,
The seal is cocked in the bore,
The seal was installed improperly, There is shaft-to-
bore- misalignment,
The seal is loose in the bore,
The seal case is deformed, and / or
There is paint on the seal.
3. Rotate the shaft to determine if there is

excessive end-play or excessive run-out.

Definition of leakage according to DIN 3761 and its appropriate use
Term Explanation Shaft sealing ring in IEC adapter Housing joint Venting
No moisture No reason for No reason for No reason for No reason for
Sealed
apparent complaint complaint complaint complaint
Moisture film
No reason for No reason for No reason for No reason for
Damp, Moist locally restricted
complaint complaint complaint complaint
(not an area)
Moisture film
No reason for No reason for Repair if No reason for
Wet beyond the extent
complaint complaint necessary complaint
of the component
Repair
Measurable Recognisable Repair Repair Repair
recommende
leakage stream, dripping recommended recommended recommended
d
Temporary
malfunction of the
Temporary No reason for No reason for Repair if No reason for
sealing system or
leakage complaint complaint necessary complaint
oil leak due to
transport [1]
Apparent leakage,
e.g. due to soiling,
Apparent No reason for No reason for No reason for No reason for
sealing systems
leakage complaint complaint complaint complaint
which can be re-
lubricated
[1] Previous experience has shown that moist or wet radial shaft sealing rings stop leaking later.

Failures
Failures
If the leakage cannot be located, follow this procedure:
1. Add ultraviolet dye to the sump or spray the area with
white powder.
2. Operate for 15 minutes.
3. Use ultraviolet or regular light to check for leakage.
4. Mark the seal location at 12 o'clock and remove it
carefully.
1. Check for nicks on the bore chamfer.
2. With the seal removed, check for:
1. Rough bore surface.
2. Shaft cleanliness (is it clean and free of carbon?)
3. Coked lube on the shaft.
4. Shaft damage.
5. Flaws or voids in the bore.
6. Shaft corrosion.
7. Shaft discoloration.
3. Identify the seal style and materials. Then inspect it for:
1. Primary lip wear.
2. Primary lip condition.
3. Seal O.D. wear / damage.
4. Spring damage.
Two of a seal's measurements are its outer diameter
(O.D.) and its inner diameter (I.D.)
To deter these, follow these procedures:
1. To measure the O.D. of a seal, take three measurements

equally spaced around the outside of the seal. The
average of the three is the seal's O.D..
2. A metal O.D. seal is generally 0.13mm to 0.41mm larger
than the bore, for press fit.
3. A rubber O.D. seal is generally 0.20mm to 0.51mm
larger than the bore, for press fit.
4. The inner diameter is more difficult to measure. Take
about five I.D. readings, average them and add an
interference figure to the lip I.D. to reach the
approximate shaft I.D.
5. Alternatively, use the shaft O.D. as the seal I.D.

Measuring the O.D. of a seal

Common Sealing
Common Sealing
Problems
Problems

Hammer Damage
Hammer Damage
Some obvious signs of hammer damage include visible
dents on the seal back, a distorted sealing element, or a
garter spring that pops out.
Causes
o Using a steel hammer on the seal housing during
installation.

Shaft-to-Bore-Misalignment
Dynamic Run-Out
Dynamic Run-Out
Early lip leakage, excessive (uneven) lip wear on one
side of the seal, and / or
Excessive but consistent lip wear all around are
symptoms of shaft-to-bore-misalignment or dynamic
run-out.
Shaft-to-bore misalignments (Right) and dynamic run-out (Left) both

cause early lip leakage
The seal lip will appear worn on one side and relatively untouched
on the other. Shaft alignment should always be checked before
installing a new seal.
Causes
o Shaft-to-bore-misalignment (STBM) is a condition of
excessive misalignment created by:
o Inaccurate machining,
o Shaft bending,
o Lack of shaft balance or
o Worn bearings
Dynamic Run-Out
Dynamic Run-Out
The seal lip will be severely worn around the entire diameter.
Causes
o A similar condition where the shaft does not rotate
around its true center.
o Is the result of
o A bent,
o Unbalanced or
o Misaligned Shaft

Lip Wear
Lip Wear
[A] New Seal
[B] Normal wear
[C] Excessive wear
Causes
Look for clues in the sealing member of the seal.
o A small cut
o Nick or
o Abrasives continually laying at lip / shaft interface.
o Wear pattern of the lip

Outer Case Damage
Outer Case Damage
A "curled" or rolled edge of the seal metal case
indicates damage.
The damaged zone may feel rough.
No Chamfer
The beveled edge (chamfer)
on the leading edge of the
bore provides a ramp for
starting the seal straight.
Without it, it is virtually
impossible to get the seal
installed correctly.
Causes
The housing bore may have
o A square corner,
o Not have had a proper lead-in chamfer, or
o The bore diameter and tolerance are incorrect.
Out - of - Round Shaft
Out - of - Round Shaft
Early lip leakage is also a symptom that the shaft is out-
of-round.
An out-of-round shaft
can also cause seal
leakage
Causes
o Inspect the shaft to see if it is out-of-round.
o Flat spots on the shaft can also cause early lip leakage.

Garter Spring Damage
Garter Spring Damage
Causes
Garter Spring may be:
o Loose
o Out of seal
o Pop out
o Damage the mechanical components
o Missing
Cut Seal Lip
Cut Seal Lip
Ever-so-slight seal leakage is evidence that may be a small
nick or cut in the sealing lip.
A nicked seal lip

also causes lip
leakage
Causes
It may have been caused by
o A burr on the keyway,
o Spline or shaft end.
Lube Breakdown
Lube Breakdown
Sludge or varnish-like deposits on the seal lip and / or
shaft are symptoms of lube breakdown.
Sludge deposits
on the seal lip
indicate lube
breakdown
Causes
Sometimes heat is high enough to break down the oil, but
not enough to harden the lip. In this case, sludge
accumulates and is deposited on the seal lip.

Heat Checking
Heat Checking
This may be evidenced by a hardened seal lip or fine
cracks that show up in the seal lip surface.
Fine cracks in the

seal lip are visible
signs of excess
heat or pressure
Causes
o Operating temperature greater than the lip material
maximum.
o Excessive surface speeds or insufficient lubrication at
the seal lip.

Pressure Blow-Out
Pressure Blow-Out
Ruptured or inverted seal lip.
Too much
pressure can
rupture the seal
lip
Causes
o Pressure exceeding seal design limitations can cause
seal rupture, inverted lips and resultant lip leakage.

Pressure Lip Wear
Pressure Lip Wear
Signs of excessive pressure include extreme lip wear and
lip leakage.
Extreme lip wear [B]

is a sign of excess
pressure. Note the
lip with pressure [A]
Causes
Excess pressure can
o Crush the lip against the shaft. Heavy friction will
eventually force the garter spring through the lip.
o Blow the lip completely off.

Chemical Swelling
Chemical Swelling
A swollen, distorted appearance of the seal rubber element
combined with "soft" feel can indicate incompatibility
between the lip compound and the media being retained or
excluded.
Chemical Swelling
Incompatibility between the lip material
and the operating media, including
lubricants, can produce major swelling of
the seal material.
Before [1] and after [2] example of the

gross damage from chemical
incompatibility.
Causes
o The rubber is experiencing swell and increase in
volume.
o The rubber may dissolve completely.
Leakage
Leakage
Analysis
Analysis

Where potential problems could arise
Where potential problems could arise
The sealing system is broken down in several
area
Each of these areas can contribute to seal failure if they
are not manufactured and / or finished properly.
Main sealing system components:
Bore
Seal
Others
Seal Lip
Case and O. D.
Spring
Shaft
Oil
Seal Failure
Seal Failure
Bore
Nicks on Bore Chamfer
Looseness in Bore
Bore Diameter
Bore Chamfer
Flaws or Voids in Housing
Tool Withdrawal Marks on Bore
Scratches or Galling Marks on Bore

Seal Failure
Seal Failure
Seal
Contaminants Packed in the Seal Area
Paint Spray on Seal Lip
Seal Cocking
Proper Installation and Orientation Relative
to Assembly
O. D. Leakage
Case Defomation (dishing or damage)

Seal Failure
Seal Failure
Other
Bolt Holes
Gaskets
Axial Shaft End Play
Excessive Shaft Run-out
Shaft to Bore Misalignment
Obtain Oil or Sealed Lubricant Sample
If Wear Sleeve is used, Between Shaft and
Sleeve
If Assembled Seal, Between Clamped
Elements
Seal Failure
Seal Failure
Seal Lip
Lack of Wear
Coked Oil on Lip
Excessive Wear
Eccentric Wear
Nicks, Scratches or Cuts at Lip Contact Area
Tears or Separations in Lip area
Hardening or Cracking of Rubber
Softening or Swelling
Inverted Lip

Seal Failure
Seal Failure
Seal Case and O.D.
Wrong Seal
Scratches on Seal O.D.
Peeled Rubber on Seal O.D.
Hardened Rubber on Seal O.D.
Non Fills / Cut on Seal O.D.

Seal Failure
Seal Failure
Spring
Missing Spring
Corroded Spring
Wrong Spring
Multiple Spring
Separated Spring

Seal Failure
Seal Failure
Shaft
Wrong Shaft size
Shaft Surface Roughness
Shaft Corrosion
Wrong Orientation of Seal
Scratches or Nicks at Lip Contact Area
Excessive Shaft Wear
Wide Shaft Wear Band
Shaft Discoloration or Coked Oil on Shaft
Machine Lead
Shaft Hardness
Shaft Chamfer
Shaft Material
Wear Sleeve Fit
Seal Failure
Seal Failure
Oil
Contaminants in Oil
Composition of Lubricant

Check List
Check List







Thank you for your attention!

Radial Shaft Seals - Troubleshooting 2016

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SEW-EURODRIVE

Driving the world

1 Service & Repair 2016 2/12/17

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3. Rotate the shaft to determine if there is

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1. To measure the O.D. of a seal, take three measurements

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Shaft-to-bore misalignments (Right) and dynamic run-out (Left) both

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[A] New Seal

[B] Normal wear

[C] Excessive wear

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A nicked seal lip

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Fine cracks in the

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Extreme lip wear [B]

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Before [1] and after [2] example of the

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