Open Gear Lubrication

16
OPEN GEARS LUBRICATION + MAINTENANCE + SERVICE

description

lubrication

Transcript of Open Gear Lubrication

Page 1: Open Gear Lubrication

OPEN GEARS LUBRICATION + MAINTENANCE + SERVICE

Page 2: Open Gear Lubrication

2 FUCHS LUBRITECH GMBHOPEN GEAR LUBRICATION

CONTENTS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

MULTI-PHASE-LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

PRIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

RUNNING-IN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

OPERATIONAL LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SERVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

FLUIDS FOR OPEN GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SELECTION GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

■ WITH REFERENCE TO THE TECHNICAL BROCHURE: The

information in this brochure corresponds with the status of

our momentary development and knowledge. Subject to

alteration.

■ WITH REFERENCE TO THE PHOTOS: We thank all our

customers for the photos they put at our disposal, as well

as all the other companies who supported us with photo-

graphic material.

Page 3: Open Gear Lubrication

3OPEN GEAR LUBRICATIONFUCHS LUBRITECH GMBH

FOREWORD

IN MOTION■ LARGE OPEN GEAR DRIVES constitute a mechanical method of transmitting

movement and force. The level of success ultimately achieved does not only de-

pend on the gear design and materials used, but also on the lubricant, volume of

lubricant and the means of application. This is particularly true for large, slow-

running open gear drives where high torques are transmitted.

The demands grow with the size

The tolerances involved in the manufacture and assembly of girth gear drives

increase in proportion to the size of the gear train. The distortions that develop

under the influence of load and temperature also increase with size. It is not un-

common to see large gears having a diameter of 14 meters. Transmission ratios

are typically in the range of 1:8 to 1:12. Under these conditions hydrodynamic lu-

brication is often hardly possible because of the slow sliding speed at the work-

ing tooth flanks. A special, correctly applied adhesive lubricant will safely prevent

metal-to-metal contact between the tooth flanks. Greases with high proportion

of solid lubricant or fluids with superior additives ensure safe running properties

in the areas of boundary friction. As a result an operating life in excess of 20 years

can be expected.

Security with system

Lubrication with the FUCHS LUBRITECH CEPLATTYN range of products fully

satisfies the tough tribo-technical requirements. The CEPLATTYN range was

developed in the early 60's as the first sprayable adhesive lubricant. The name is

now as closely identified with these special lubricants as Aspirin is with pain killers.

The CEPLATTYN range includes more than 20 different products and is approved

by all major gear and machine manufacturers in the raw-materials industry.

Page 4: Open Gear Lubrication

4 FUCHS LUBRITECH GMBHOPEN GEAR LUBRICATION

INTRODUCTION

■ OPEN GEAR DRIVES are most often

used in the raw materials industry. The

girth gear drives that are used in tube

mills, coolers, washing drums, kilns and

calciners have to transmit enormous

torque – up to 50,000 Nm is by no

means rare. It is only natural that such

force subjects the gear wheels to very

high stresses. These gears are usually

designed as spur or helical gears and

with modified involute profiles. The ma-

terials that are utilized for the gearing

are usually CrNiMo tempered steel (pin-

ion) and alloyed CrMo steel casting

(girth gear).

The lubricant plays an important role

The purpose of all constructional

and tribotechnical measures is to en-

sure, in spite of the enormous stresses,

long-term, trouble-free operation. The

primary cause of damage to gear

wheels is not exclusively the problem

of faulty adjustment of the drives and

radial and axial run-out, but also the

use of unsuitable lubricants, shortage

of lubricant and incorrect application.

Therefore an optimum load carrying

capacity and smoothing of the gear

teeth are to be achieved, the most pre-

cise alignment of the gears coupled

with the correct running-in procedures

is essential. For the lubrication of open

gears adhesive sprayable lubricants are

most suitable. LUBRITECH MULTI-

PHASE-LUBRICATION (M-P-L) with the

range of CEPLATTYN adhesive lubricants

is widely accepted as one of the mar-

ket leaders in this area.

The best solution has a name – CEPLATTYN

Wherever lubrication is to be car-

ried out on highly stressed or pre-dam-

aged gear drives, FUCHS LUBRITECH can

offer the right lubricant from the

CEPLATTYN product range. Whether un-

der arctic conditions, or in high tem-

perature surroundings. CEPLATTYN

products, moreover, contain no heavy

metals, chlorine or solvents, and there-

fore do very little harm to the environ-

ment. As a result of more than 50 years

experience, CEPLATTYN adhesive lubri-

cants are recommended by the leading

manufacturers of gears and machines.

WHERE MIGHTY FORCES RULE

Krup

p Po

lysi

us A

G

Open gear drives do the heaviest work in many branches of industry.

IN DETAIL: GUIDE VALUES FORADJUSTMENT AND ASSEMBLY

The commission engineer of open geardrives is faced with toughest requirementswhen aligning or correcting the drive.Careful alignment of the girth gear and ofthe transmission gear is of critical impor-tance for the life of the drive. This is why itis usual for assembly companies to preparerecords of measurements of the radial andaxial run-outs, of the backlash, the rootclearance and of the free play.

Note: When a gear set must be turnedbecause of wear, it is no longer possible toalign the gears by means of the backlash.The drive must be set up by means of theroot clearance. A suitable guide value forthe tooth tip play is 0.25 to 0.3 times themodule.

1.80

2.00

2.20

2.40

2.60

2.80

3.00

500

1000

1500

2000

2500

3000

3500

4000

4500

Backlash [mm]

Axia

l dis

tanc

e [m

m]

7000

6000

8000

9000

5000

4000

3000

2000

1000

1.25

1.00

0.50

0.25

0.75

Tolerance value [mm]

Pitc

h ci

rcle

Ø [m

m]

Radial run-outRadial run-out

Axial run-outAxial run-out

Radial run-out

Axial run-out

MillsMills

KilnsKilns

Mills

Kilns

Heid

elbe

rger

Zem

ent A

G

Page 5: Open Gear Lubrication

5OPEN GEAR LUBRICATIONFUCHS LUBRITECH GMBH

MULTI-PHASE-LUBRICATION

■ AFTER THE CAREFUL ALIGNMENT of

the drive, the selection of the correct lub-

ricant is the next step to a long lifetime.

LUBRITECH MULTI-PHASE-LUBRICATION

(M-P-L) is the most secure method of

averting serious mistakes. The use of

M-P-L is essential with new

gears but it is also helpful

after repair work of

damaged gear tooth

flanks or at any

time when the

pinion or girth

gear is changed.

LUBRITECH M-P-L

consists primarily of

four components:

priming, running-in,

operating and special

(service) lubricants. The various

lubricants, and the combination of the

individual components, are the result of

many years of research, and have been

proven in practice all over the world.

The best possible protection from wear

Optimum load transmission im-

plies that the stress is evenly distributed

over the full width and height of the

teeth. However, for open gear drives in

particular, even the most careful man-

ufacturing techniques and the most pre-

cise alignment possible do not permit

this optimum state to be achieved. The

consequences of inadequate

load distribution are, in

the worst case, exces-

sive heating, scuffin-

gs, pitting and even

tooth breakage.

The operator can,

however, have a

significant influ-

ence on these types

of damages, and

thus on the lifetime of

the drive, through selec-

tion of the correct lubricant.

Note: LUBRITECH M-P-L can only

be applied in a restricted way to drives

that are not lubricated by an automat-

ic spray system. FUCHS LUBRITECH Ser-

vice Engineers will be pleased to advise

you about running in of gears whose

operating lubrication is subsequently

performed manually, by dipping or cir-

culation lubrication.

THE MULTI-PHASE-LUBRICATIONA cleverly devised system for optimum lubrication and long lifetime.

Checking the contact pattern when assem-bling with CEPLATTYN 300/CEPLATTYN SF-P.

IN PRINCIPLE: FOUR COMPONENTSFOR A LONG LIFETIME

Priming lubricant:• Initial lubrication• Manual application

Running-in lubricant:• Smoothes the surface• Automatic spray system

Operating lubricant:• Lubrication at intervals• Automatic spray system

Special lubricant:• Service lubricant• Only carried out by FUCHS LUBRITECH staff

* the selection guide on page 15 of this brochure gives an inital overview

Page 6: Open Gear Lubrication

6 FUCHS LUBRITECH GMBHOPEN GEAR LUBRICATION

MULTI-PHASE-LUBRICATION

Gears, in a wide variety of design,

provide movement throughout indus-

try. When a gear wheel suddenly stops,

the causes can be highly varied in na-

ture. Looked at it statistically, damaged

tooth flanks are the reason for about

60 percent of gear drive defects. The

chart on the next page gives a general

indication of the kind of problems that

can be experienced.

The correct lubricant eliminatesmany sources of damage

It doesn’t matter whether a light

oil or an adhesive lubricant is under

consideration. Nor does it matter

whether it is a fast-running vehicle gear-

ing or a slow running open gear drive:

whenever teeth mesh together, the ap-

propriate lubricant is one of the most

important factors for trouble-free op-

eration. Scuffings and abrasive wear,

for example, depend to a large extent

on the lubricant. Poor quality lubricant

also has a direct effect on the occur-

rence of fretting corrosion, scoring and

scuffings. The consequences of a short-

age of lubricant usually include in-

creased wear or deformations such as

the development of rippling, hot or cold

flow.

There are many causes of damage totooth flanks – nearly all can be avoided

IN DETAIL: THE CAUSES OF TOOTH FLANK DAMAGES IN OPEN GEARS

slag inclusions • • • •

forging folds • •

non-metallic inclusions •

unsuitable material pairing • •

inadequate dimensions • • • • •

incorrect tooth geometry • •

meshing faults •

incorrect tooth play • •

Forging faults •

Overheating during processing • •

Inappropriate heat treatment • • • • •

poor surface quality • • •

Alignment errors • • • • • •

Fixing of pinion • • • •

Frequent load changes • •

overload • • • • • • • • •

impact/vibration stress • • • • • • • •

incorrect running-in • •

Speeds too low/high • • • •

Dust ingress • • • • • • •

Dynamic changes • • • • • •

Shortage of lubricant • • • • • • •

Wrong consistency • • • • • •

inadequate quality • • • • • •

Soiling with solids/liquids • • • • • • •

incorrect application • • •

Nor

mal

wea

r

Abra

sive

wea

r

Inte

rfere

nce

wea

r

Scra

tche

s

Scor

ing

scuf

fings

Initi

al/d

estru

ctiv

e/fa

tigue

pitt

ing

flaki

ng

spal

ling

Ove

rload

bre

akag

e

fatig

ue b

reak

age

Grin

ding

cra

cks

hard

ness

cra

cks

mat

eria

l cra

cks

fatig

ue c

rack

s

inde

ntat

ions

rippl

ing

hot f

low

cold

flow

chem

ical

cor

rosio

n

fretti

ng c

orro

sion

cavi

tatio

n

eros

ion

oxid

isatio

n

over

heat

ing

Lubr

icat

ion

faul

tsO

pera

tiona

l con

ditio

nsAs

sem

bly

faul

tsM

anuf

actu

ring

faul

tsCo

nstru

ctio

nal

faul

tsM

ater

ial f

aults

Wear Pittings Tooth breakage CorrosionCracks Deformations Other types of damage

Pitting is fatigue damage resulting from over-loading. CEPLATTYN operational lubricants canprevent the damage from spreading.

Page 7: Open Gear Lubrication

7OPEN GEAR LUBRICATIONFUCHS LUBRITECH GMBH

PRIMING

Fuch

s Lu

brite

ch (A

ustr

alia

) Pty

.Ltd

.

PRIMINGInitial lubrication with CEPLATTYN 300/CEPLATTYN SF-P provides pro-tection on the first occasion at the teeth mesh and prevents corrosion.

■ PRIMING THE TOOTH FLANKS is nec-

essary to provide initial lubrication dur-

ing the first revolution of the gears dur-

ing the course of assembly. The surface

finish of the gear teeth makes it essen-

tial to prime to prevent damage during

initial operation. In the context of

LUBRITECH MULTI-PHASE-LUBRICATION

(M-P-L) the priming or initial lubrica-

tion takes place with CEPLATTYN 300/

CEPLATTYN SF-P immediately after as-

sembly of the drive.

Note: CEPLATTYN 300/CEPLATTYN

SF-P can not be applied with automat-

ic spray systems.

Priming and checking the contactpattern

It is necessary to fully clean the

tooth flanks before applying lubricant

for the first time. The whole tooth flank

area should be thoroughly cleaned to

bare metal. The tooth flanks are then

primed with CEPLATTYN 300/CEPLATTYN

SF-P using a stiff-bristled brush or

spatula. The application includes the

working flanks, tooth roots and tips in

order to avoid corrosion and damage

from any movement involved during

assembly. After priming, turning the

gears with the auxiliary drive will result

in the actual contact pattern being pro-

jected onto the working tooth flanks.

Any areas devoid of lubricant must be

primed again. The projection allows any

correction to the transmission gear to

be made more easily.

IN PRINCIPLE: FOUR COMPONENTS FOR A LONG LIFE

Contact pattern at the perimeter of the girthgear when the pinion wobbles. → Checkseating of pinion.

Contact pattern for wobble impact of thegirth gear. → Check alignment and fixing ofthe girth gear.

Contact pattern from edge loading. Axles notsufficiently parallel. → Realign pinion.

Circulating pressure point, resulting frommanufacturing fault or isolated thermaldeformation (protuberances).

Contact pattern from pinion expanded onboth sides, resulting from incorrectly assem-bled ring tensioning elements.

Contact pattern with opposing obliquity ofthe two halves of the girth gear. → Check theimpact point bolting.

Contact pattern when one half of the girthgear is oblique. → Check assembly.

Radial run-out of the gearwheel. The contactpattern appears weaker or stronger over halfthe perimeter of the girth gear. → Readjust.

Contact pattern when the girth gear has pro-tuberances on both sides, resulting fromexcessive frictional heating of the jacket seals(often found in oil-lubricated drives). →Improve lubrication of seals. Check assemblyof seals.

10

0

20

30

40

50

100 200 300 400 500 600 700 800 900

1000

20003000

40005000

6000

7000

8000

9000

Qua

ntit

y [k

g]

m x

n [m

m]

Face width [mm]

QUANTITY CEPLATTYN 300/CEPLATTYN SF-P

n = total number of teethm = modulus

The film of lubricant must be applied evenlyand without air-bubbles.

Page 8: Open Gear Lubrication

8 FUCHS LUBRITECH GMBHOPEN GEAR LUBRICATION

RUNNING-IN

■ EVEN AFTER THE DRIVE has been

carefully aligned, the initial load-carry-

ing proportion is often no more than

50 to 60 percent. The reason for this is

surface roughness, arising in the course

of manufacture, and deviations of the

flanks due to their shape and to as-

sembly. This means that there is a very

high risk, during initial operation, that

drives can be damaged at this early

stage as a result of localised overload.

These damages can be slight local scuff-

ing, or it can be cracks that spread in

the form of pitting during later opera-

tion as a result of fatigue damage.

The economical way to highergearing quality

Controlled running-in with

CEPLATTYN RN/CEPLATTYN SF-RN run-

ning-in lubricant allows damage from

initial operation to be avoided. Because

CEPLATTYN RN/CEPLATTYN SF-RN car-

ries away manufacturing roughness,

smooths the load-carrying surfaces of

tooth flanks, overcomes slight devia-

tions in form and assembly, and thus

significantly increases the contact area.

The result: gearing quality that is sig-

nificantly better, providing the basis for

long life operation.

The running-in procedure

The time required for running in

can only be assessed in individual cases

and has a relation to the hardness of

materials, manufacturing tolerances and

the way in which the gear has been as-

sembled. On average, the time required

to efficiently run in drives on ball mills

and kilns in single load steps is 350

hours and as far as possible the lubri-

cant should be continuously applied.

Depending on the running time, a

charging illustrated in the following

table have been found effective.

Note: Other values may vary in

practice. The process must be adapted

to the particular operating conditions.

The state of the tooth flanks

should be checked throughout the run-

ning-in process. This applies particular-

ly to the change of grinding charge. This

should only be undertaken when the

load-carrying proportion given in the

table has been reached. If the contact

pattern is considerably worse, read-

justment of the transmission gear is re-

quired. Running-in can be considered

complete when, with maximum charge

or throughput, a load-carrying propor-

tion of at least 80 percent is achieved,

and the manufacturing roughness of

loaded teeth surface has been

smoothed down.

RUNNING-INCEPLATTYN RN/CEPLATTYN SF-RN removes the manufacturing rough-ness, and it smooths working the tooth flanks.

Min. contactGrinding Running area to becharge time achieved

1. abt. 50-60 % abt. 70 h 50-60 %2. abt. 70-80 % abt. 120 h 70 %3. abt. 90-100 % abt. 160 h 80 %

abt. 350 h

IN PRINCIPLE: SURFACE ROUGHNESS PROFILES OF TOOTH FLANKS

Load-carrying patternbefore running-in about 50 %

Load-carrying patternafter running-in about 80 %

Before running-in with CEPLATTYN RN/CEPLATTYN SF-RN

After running-in with CEPLATTYN RN/CEPLATTYN SF-RN

0.8

mm

0.8

mm

100

200

300

400

5

10

15

20

30

25

100 200 300 400 500 600 700 800 900

Qua

ntit

y [k

g/35

0h]

Qua

ntit

y [k

g/24

h]

5

10

15

20

30

25

Qua

ntit

y [k

g/24

h]

Face width [mm]

■■ Mill double pinion drive 1,2 g/h·mm■■ Kiln double pinion drive 0,9 g/h·mm■■ Mill single pinion drive 0,8 g/h·mm■■ Kiln single pinion drive 0,6 g/h·mm

QUANTITY CEPLATTYN RN/CEPLATTYN SF-RN

Page 9: Open Gear Lubrication

INSPECTING THE SPRAY SYSTEMThe following points should be observedbefore commencing operation of themachinery:• Functional test• Spray pattern• Spray angle• Nozzle distance• Lubricant quantity (see diagrams

on page 8-10)The increased throughput of run-inlubricant is necessary in order toflush any metallic particles caused byremoving the peaks of the rough surface.The lubricant consumed must be allowedto flow without restriction out of thegear guard. Dredging in the lubricantsump must be avoided.

9OPEN GEAR LUBRICATIONFUCHS LUBRITECH GMBH

RUNNING-IN

In cases where normal running-in

may not result in a sufficiently high con-

tact pattern or the drive has to be run-

in under conditions of immediate full

load, forced running in (the quick run-

ning in method) represents the best so-

lution. This forced running in procedure

is also suitable for achieving optimum

carrying capacity and surface finish if

the load carrying surfaces show scuff-

ings, or under the unfavourable cir-

cumstances where pairing of old and

new gears has taken place.

The use of Reconditioner

Forced running-in involves a serv-

ice lubricant known as Reconditioner

being applied manually to the working

surfaces in addition to the normal

CEPLATTYN RN lubricant during the pro-

duction process. The Reconditioner has

the effect of causing smoothing of the

working surfaces in a shorter time. In

this way the running-in time is reduced

tremendously.

Note: The aggressive material re-

moval resulting from the use of Recon-

ditioner calls for specialised technical

knowledge. Forced running-in is there-

fore only be carried out by FUCHS

LUBRITECH Service Engineers. For gears

being under warranty, the machine

manufacturer must give its approval pri-

or du start of the procedure.

Example 1: Axial run-out devia-

tions caused the contact pattern of a

cement mill drive to be only 40 percent

in some areas. Since it was not possible

to achieve an improvement in the con-

tact pattern through alignment means,

the drive had to be run in using recon-

ditioner in a forced run-in. The load

peaks that can clearly be seen in the red

framed part of the working tooth flanks

(left picture) are no longer present af-

ter reconditioning (right picture). The

pitch line reaches over the full width of

the tooth (visible in the picture as a

white line on the working tooth flank).

Example 2: After the pinion was

changed on the drive of a tube mill, the

unfavourable combination of old girth

gear and new pinion resulted in dam-

age to the pinion after two months of

running (left picture). The damage was

caused by overloading, since the load-

carrying proportion did not reach over

the full height of the teeth. After using

Reconditioner for eight hours, the con-

tact pattern finally reached over the full

tooth height (right picture) and the

damaged areas on the working tooth

flanks had been removed.

Forced running-inwith Reconditioner

30°30°150 - 200 mm

150

- 200

mm

Inward running pinion Outward running pinion

SMOOTHER RUNNING FROM RECONDITIONERSmall deviations in axial and radial run-out at the girth gear had the effect of large differences inthe vibrations of the pinion bearings when restarting a helical, double pinion cement mill. At therunning-out pinion the vibration levels were well below 2 mm/s, but were above 8 mm/s at therunning-in pinion. The operator could not accept this large difference. Even several corrections tothe transmission gear brought no improvement. The manufacturer of the machinery therefore ini-

tiated forced running-in.The application of recondi-tioner for nine hours result-ed in a carefully controlledredistribution of the load:the vibrations at both bear-ings were at the end below2mm/s, so that on thewhole the operation wasvery smooth.

Inward running

pinion

[mm/s]

Time [h]

Outward running

pinion

Extract from permanent vibration monitoring at the factory.

Horizontaloverlap

Verticaloverlap

Overlapwith wide jet

nozzles

Page 10: Open Gear Lubrication

0.1

0.2

0.3

0.4

2

4

6

8

1010

100 200 300 400 500 600 700 800 900

Qua

ntit

y [k

g/h]

Qua

ntit

y [k

g/24

h]Q

uant

ity

[kg/

24h]

Face width [mm]

Mill Drives m

in. 0.2-0.4 g/h·mm

Kiln Drives min. 0.1-0.2 g/h·mm

QUANTITY CEPLATTYN KG 10 HMF

Heid

elbe

rger

Zem

ent A

G

10 FUCHS LUBRITECH GMBHOPEN GEAR LUBRICATION

OPERATIONAL LUBRICATION

■ ONCE PRIMING and running-in have

been successfully completed, the next

point to be considered is the opera-

tional lubrication. Making the right se-

lection here is very important for low

wear, for operation without damage,

and for the lifetime of the open gear

drive. The selection of the lubricant de-

pends on a large number of factors.

These include the stress on the working

tooth flanks, the rotary speed of the

transmission gear, the actual flank tem-

peratures and the condition of the

drive. Environmental influences such as

dust contamination, humidity, very low

or very high ambient temperatures

must also be considered.

On the safe side with CEPLATTYN

The changeover to operating lu-

brication starts at the end of running-

in. When changing to the operating lu-

bricant a cleaning procedure is not

needed. Just the drum container at-

tached to the lubrication system has to

be changed. CEPLATTYN lubricants are

adhesive lubricants without heavy met-

als, solvents or chlorine. They can sup-

port extremely high pressure, are re-

sistant to water, and are approved by

all leading gear and machine manu-

facturers.

Changeover to operating lubrication

In practice the changeover is

achieved through a staged reduction in

quantity towards a target minimum (see

graph on the left). It is necessary to

measure the quantity every time this

value is reduced by the spray system. In

practice, small volumes frequently ap-

plied avoid phases where the drive is

saturated with lubricant which can sub-

sequently fling. The short pause times

between cycles also avoid insufficient

lubrication. The minimum quantities

consumed by various drives can be

found from the diagram below.

Note: The minimum quantity that

can be aimed at depends directly on the

operating conditions. Lubrication rates

below the minimum creates an in-

creased risk of wear and damage to the

flanks. This can drastically reduce rated

life.

OPERATIONAL LUBRICATION

The lifetime of the gear set depends on the selection of the lubricant.

Central lubricant supply with CEPLATTYN KG 10 HMF.

24 48 72

time [h]

0.8

0.6

0.4

0.2

0spec

ific

cons

umpt

ion

[g/h

·mm

]

96

Quantity reduction for a single pinion drive.

Page 11: Open Gear Lubrication

11OPEN GEAR LUBRICATIONFUCHS LUBRITECH GMBH

SERVICES

Contactless temperature measurementwith an IR thermometer.

WORLD-WIDESERVICE

An outstanding product, fair andhonest consultation when pur-chasing, and comprehensive tech-nical service afterwards – that ishow FUCHS LUBRITECH definesservice.

■ IN MANY COUNTRIES and in many

parts of the world FUCHS LUBRITECH

are the market leaders with the

CEPLATTYN range of products. Their

success is not only based on the prod-

uct line but also by providing gear tech-

nology service and consultation. This

service is valued not only by end users,

but by machine manufacturers also.

FUCHS LUBRITECH offers this wide

range of technical service to all their

customers world-wide, and in the case

of the basic service inspection, this is

free of charge.

Comprehensive world-wide service

The specially trained FUCHS

LUBRITECH Service Engineers are in du-

ty at all times on every continent. The

services offered include consultation re-

garding the choice of product and, of

course, regarding the application. This

also includes assistance with drive as-

sembly and transmission gear alignment

and with the running-in of new open

gear drives. Corrections to transmission

gears and tooth flanks, and regular

checks of the drive and spray systems,

are performed on site by the Service

Engineer.

Satisfaction begins with consultation

The high performance lubricants

from the CEPLATTYN range are ideally

tailored for very varied operating con-

ditions. The best evidence for this is that

leading machine manufacturers do not

merely recommend CEPLATTYN adhe-

sive lubricants, but in some cases rigid-

ly prescribe them. To be on the safe side

when selecting the operating lubricant,

the operator should therefore always

consult the machine manufacturer, or,

contact FUCHS LUBRITECH directly (the

section guide on page 15 of this

brochure gives an initial overview).

FUCHS LUBRITECH engineers will then

inspect the machinery on site, and will

develop an optimum scheme jointly

with the operator. In many cases, both

the manufacturer and the operator call

for the presence of the Service Engineer

at commissioning or when repairs are

required, in order to be properly ad-

vised and supported from the very be-

ginning.

IN DETAIL: THE SERVICES• Consultation on product selection and

application• Assistance with drive assembly and trans-

mission gear alignment• Running-in open gear drives• Assistance with corrections to transmis-

sion gears and tooth flanks• Regular checking of the drive and spray

systems

Page 12: Open Gear Lubrication

tation (FLT-INSPECTOR) is pro-

vided (see page 13).

Skilled repair

The repair of damaged tooth

flanks on open gear drives is an ex-

tended service from FUCHS LUBRITECH.

This is primarily a matter of mechanical

treatment of the working tooth flanks,

grinding pittings or larger breakages,

smoothing scuffings, forced running-in

and assistance with alignment of the

transmission gears. On heavily worn out

or damaged tooth flanks FUCHS

LUBRITECH can provide a complete Re-

Profiling of the entire gear set.

12 FUCHS LUBRITECH GMBHOPEN GEAR LUBRICATION

SERVICES

Inspections are free of charge

The Service Engineers of FUCHS

LUBRITECH regularly check drives lu-

bricated with CEPLATTYN free of

charge. The checks cover the spray sys-

tem, assessment of the contact area and

the state of the tooth flanks, and meas-

urement of the vibrations of the trans-

mission gear bearings. In addition,

measurement of the temperature pro-

file across the width of the load-carry-

ing surfaces and documentation of the

condition of the tooth flanks (photo-

graphic, blue print...) are obligatory. To

complete the job, an online documen-

IN PRACTICE: THE INSPECTIONS• Checking the spray system• Assessment of the contact pattern and the

condition of the load-carrying surfaces• Measurement of the vibration of the pin-

ion bearings• Measurement of the temperature profile

across the tooth width• Documentation of the condition of the

flanks (photographic, blue print...)• Written documentation of the whole

inspection, including trending of themeasured values

IN PRACTICE: THE REPAIR SERVICE• Re-profiling of the working tooth flanks• Grinding pittings or larger breakages• Smoothing of scuffings• Forced running-in• Assistance with the alignment of the

transmission gear

Inspection, servicing andrepair are specialist jobs.

Check of spray pattern.

Measuring vibration ofthe pinion bearings.

Treatment of the working tooth flanks.

Dynamic check-ing of the con-tact patternwith a strobo-scope.

Page 13: Open Gear Lubrication

13OPEN GEAR LUBRICATIONFUCHS LUBRITECH GMBH

SERVICES

With the FLT-INSPECTOR, FUCHS

LUBRITECH is making a unique online

documentation available that enables

the customer to retrieve all relevant in-

formation on his system and the lubri-

cants used in at any time.

The open gear service, combined

with the online provision of inspections

reports, is a further step towards being

able to operate open running drives re-

liably.

Page 1 of the two-page report

contains customer and system data, im-

ages and comments (Fig. 1). Measured

values for temperatures and vibrations,

including reference values relating to

the previous inspection, can be found

in the second part (Fig. 2).

IN DETAIL: THE FLT-INSPECTOR• Availability of all reports at a glance• Online access at any time• Instant check via ”traffic light system”• Graphical trend analysis for temperatures

and vibrations• Rapid transmission of data and reports• Individual access hierarchy• Optional extra information (attachments)

for each inspection report

FLT-INSPECTOR – Online reporting withintegrated, graphical trend analysis

Graphic trend analysis en-ables informative displayof temperatures and vi-brations over time.

Focus on: Instant check via ”traf-fic light system”.

Fig. 1

Fig. 2

Critical measured valuesare highlighted in red.

Page 14: Open Gear Lubrication

▼FIELDS OF APPLICATION

Product code

Kind of machinery

Tube mill

Rotary kiln

Mixing drum, calcinating and rotary dryers

Crusher

Bucket-wheel excavator

Wire Ropes

Forging press

Portal crane, hoisting crane

Dragline

Slewing ring

Racks

Kind of application

Primary lubrication

Running-in lubrication

In-service lubrication

Low-consumption lubrication

Loading charge

Normal

High

Extreme

Extreme shock loading

Pre-damaged

Temperature

Low

Normal

High

Method of application

Manual

(Dip) bath lubrication

Automatic spray lubrication

Other criterion

Environmentally harmless

Cleanliness

14 FUCHS LUBRITECH GMBHOPEN GEAR LUBRICATION

FLUIDS

■ THE CEPLATTYN SF SERIES was de-

veloped to meet the requirements of

AGMA 9005 D 94, which refers to the

base oil viscosity. In order to make the

highly viscous lubricants sprayable, most

manufacturers make these products

with a high proportion of solvents even

today. Bitumen is partially still in use to

improve the adhesive strength. For en-

vironmental reasons and operator pro-

tection such products nowadays are

hardly acceptable. FUCHS LUBRITECH

developed the highly viscous CEPLATTYN

SF series (solvent and bitumen free) for

these applications. The aim of FUCHS

LUBRITECH for the CEPLATTYN SF series

was to offer a complete series consist-

ing of primer (CEPLATTYN SF-P), run-

ning-in lubricant (CEPLATTYN SF-RN)

and operational lubricants (CEPLATTYN

SF 10 and SF 30) which are suitable for

both AGMA and for DIN ISO-drives. But

because of the different structures of

both CEPLATTYN series there are dif-

ferences in application and practical use.

The characteristics of the SF series and

those of the KG 10 HMF series are

shown in the following table.

A CLEAN SOLUTIONSolvent-free adhesive lubricants - highly viscous and sprayable

PRODUCT COMPARISON:

Appearance

Composition

Application

Kind of application

Please see selection guide on page 15

CEPLATTYN SF range

light coloured

High viscous, synthetic oil with high performance additives

Open gears on mills in cement,lime, gypsum, sugar and miningindustry and power plants.Especially for open gears, designedaccording to AGMA design.

For spray, dip and circulating lubrication, depends on base oil viscosity

CEPLATTYN KG 10 HMF range

dark grey/black

Thickener with mineral oil,additives, 10 % graphite

Open gears on kilns and mills incement, lime, gypsum and miningindustry and power plants. Forsmaller open running gears, e.g. inthe construction industry, windpow-er plants, water-locks, draglines etc.

For spray and dip lubrication or manually by brush.

Page 15: Open Gear Lubrication

CEPL

ATTY

N 1

00 H

V

CEPL

ATTY

N 3

00

CEPL

ATTY

N B

L

CEPL

ATTY

N E

CO 3

00

CEPL

ATTY

N K

G 1

0 H

MF

CEPL

ATTY

N K

G 1

0 H

MF-

1000

CEPL

ATTY

N K

G 1

0 H

MF-

2500

CEPL

ATTY

N K

G 1

0 H

MF-

LT

CEPL

ATTY

N K

G 1

0 LC

CEPL

ATTY

N R

N

CEPL

ATTY

N S

F 10

CEPL

ATTY

N S

F 30

CEPL

ATTY

N S

F-P

CEPL

ATTY

N S

F-RN

CEPL

ATTY

N 3

00 S

PRAY

CEPL

ATTY

N E

CO 3

00 S

PRAY

1157

1119

1129

1161

1162

1153

1154

1106

2467

1179

3310

3330

3314

3316

1612

2162

15OPEN GEAR LUBRICATIONFUCHS LUBRITECH GMBH

SELECTION GUIDE

Page 16: Open Gear Lubrication

Headquarter:

FUCHS LUBRITECH GMBHWerner-Heisenberg-Straße 167661 Kaiserslautern/Germanywww.fuchs-lubritech.com

Regional Contact:

Phone +49 (0) 6301 3206-0Fax +49 (0) 6301 3206-940E-mail [email protected] 1’

KD

06/

10 0

6012

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Lubrication Technology