Professional Road Roller Gearbox Maintenance Guide

1. Standardized Quarterly Gearbox Deep Cleaning Procedure

Regular cleaning removes metal wear debris and maintains a clean lubrication system. Follow this verified standard procedure:

Step 1: Warm-up & Oil Drainage
After operation, while the gearbox is still hot, park the roller. Unscrew the drain plug on the gearbox side and completely drain the old lubricating oil into a dedicated container.

Step 2: Kerosene Circulation Flushing

1. Re-tighten the drain plug. Pour an appropriate amount of kerosene into the housing through the filler opening.

2. Crucial Note: Do NOT engage travel. Start the diesel engine only, allowing the gearbox input shaft to rotate the gears at low speed for 2-3 minutes, enabling the kerosene to flush internal components thoroughly.

3. Stop the engine and immediately drain all the kerosene completely. It is essential to ensure no kerosene residue remains, as it would dilute the new lubricant and compromise its effectiveness.

Step 3: Refilling with New Lubricant
After cleaning and reinstalling the drain plug, refill with dedicated SAE 20 Gear Oil until the oil level reaches the marked range on the dipstick.

2. Five Core Daily Maintenance Points

Point 1: Standardized Lubricant Selection
The gearbox must use SAE 20 Gear Oil (equivalent to API GL-5 grade 85W-90). Its viscosity-temperature characteristics and extreme pressure anti-wear properties are designed specifically for heavy-duty construction machinery gearboxes. Never substitute with regular engine oil.

Point 2: Control Linkage Inspection & Adjustment

• Periodically check the positioning devices (e.g., springs, ball detents, lock pins) of the gear shift and directional control linkages.

• Ensure gears are fully engaged in each position to prevent disengagement accidents caused by failed positioning.

• Adjust the control lever travel for clear and precise operation.

Point 3: Sealing System Monitoring

• Visually inspect all gearbox joints and shaft end seals for oil stains weekly.

• If leaks are detected, replace the oil seals or gaskets promptly to prevent gear wear due to oil loss.

Point 4: Critical Connection Point Tightening

• Monthly, check the tightness of the gearbox-to-frame mounting bolts using a torque wrench.

• Vibration can cause loosening. Timely tightening prevents structural damage and unusual noises.

Point 5: Establish a Preventive Maintenance Log
We recommend creating a maintenance checklist to record each cleaning, oil change, inspection, and anomaly. This enables traceable maintenance and early identification of potential failures.

3. Common Consequences of Neglecting Gearbox Maintenance

• Poor Lubrication: Degraded or insufficient oil leads to gear pitting and bearing seizure.

• Disengagement Risk: Failed control linkages cause sudden gear slip, affecting safety and compaction quality.

• Premature Failure: Damaged seals allowing water or dirt ingress significantly shorten the gearbox's overhaul interval.

Implementing the above standardized quarterly cleaning and daily checks will significantly enhance your road roller's gearbox reliability, reduce unplanned downtime, and is key to protecting your project schedule and economic returns.

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