OPEN GEARS

LU BRI CATI ON + M A I N TEN A N CE + SERV I CE

2 FUCHS LUBRITECH GM BH OPEN 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 al l our
customers for the photos they put at our disposal, as well
as all the other companies who supported us with photo-
graphic material.
3 OPEN GEAR LUBRICATION FUCHS LUBRITECH GM BH
FOREWORD
IN M O TIO N
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
sati sfi es the tough tri bo-techni cal requi rements. 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.
4 FUCHS LUBRITECH GM BH OPEN 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
cal ci ners have to transmi t enormous
torque up to 50,000 Nm i s by no
means rare. It is only natural that such
force subjects the gear wheels to very
hi gh stresses. These gears are usual l y
desi gned as spur or hel i cal gears and
with modified involute profiles. The ma-
terials that are utilized for the gearing
are usually CrNiMo tempered steel (pin-
i on) and al l oyed CrMo steel casti ng
(girth gear).
The lubricant plays an
important role
The purpose of all constructional
and tri botechni cal measures i s to en-
sure, in spite of the enormous stresses,
long-term, trouble-free operation. The
pri mary cause of damage to gear
wheels is not exclusively the problem
of faulty adjustment of the drives and
radi al and axi al run-out, but al so the
use of unsuitable lubricants, shortage
of lubricant and incorrect application.
Therefore an opti mum l oad carryi ng
capaci ty and smoothi ng of the gear
teeth are to be achieved, the most pre-
ci se al i gnment of the gears coupl ed
with the correct running-in procedures
is essential. For the lubrication of open
gears adhesive sprayable lubricants are
most sui tabl e. 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 ri ght l ubri cant from the
CEPLATTYN product range. Whether un-
der arcti c condi ti ons, or i n hi gh tem-
perature surroundi ngs. 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.
W H ERE M IG H TY
FO RC ES RU LE
K
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P
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Open gear drives do the heaviest
work in many branches of industry.
I N DETAI L: GUI DE VALUES FOR
ADJUSTM ENT AND ASSEM BLY
The commi ssi on engi neer of open gear
dri ves i s f aced wi t h t oughest requi rement s
when al i gni ng or correct i ng t he dri ve.
Caref ul al i gnment of t he gi rt h gear and of
t he t ransmi ssi on gear i s of cri t i cal i mpor-
t ance f or t he l i f e of t he dri ve. Thi s i s why i t
i s usual f or assembl y compani es t o prepare
records of measurement s of t he radi al and
axi al run-out s, of t he backl ash, t he root
cl earance and of t he f ree pl ay.
Not e: When a gear set must be t urned
because of wear, i t i s no l onger possi bl e t o
al i gn t he gears by means of t he backl ash.
The dri ve must be set up by means of t he
root cl earance. A sui t abl e gui de val ue f or
t he t oot h t i p pl ay i s 0.25 t o 0.3 t i mes t he
modul e.
1
.
8
0
2
.
0
0
2
.
2
0
2
.
4
0
2
.
6
0
2
.
8
0
3
.
0
0
500
1000
1500
2000
2500
3000
3500
4000
4500
Backl ash [ mm]
A
x
i
a
l

d
i
s
t
a
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e

[
m
m
]
7000
6000
8000
9000
5000
4000
3000
2000
1000
1
.
2
5
1
.
0
0
0
.
5
0
0
.
2
5
0
.
7
5
Tol erance val ue [ mm]
P
i
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h

c
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c
l
e

[
m
m
]
Radial run-out
Axial run-out
Radial run-out
Axial run-out
M ills
Kilns
M ills
Kilns
H
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A
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5 OPEN GEAR LUBRICATION FUCHS LUBRITECH GM BH
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) i s the most secure method of
averti ng seri ous mi stakes. The use of
M-P-L i s essenti al wi th new
gears but it is also helpful
after repai r work of
damaged gear tooth
fl anks or at any
ti me when the
pi ni on or gi rth
gear i s changed.
LUBRITECH M-P-L
consists primarily of
four components:
pri mi ng, runni ng-i n,
operati ng and speci al
(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
f rom wear
Opti mum l oad transmi ssi on i m-
plies that the stress is evenly distributed
over the ful l wi dth and hei ght 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 i nadequate
l oad di stri buti on are, i n
the worst case, exces-
sive heating, scuffin-
gs, pitting and even
tooth breakage.
The operator can,
however, have a
si gni fi cant i nfl u-
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.
TH E M U LTI-PH A SE-LU BRIC ATIO N
A cleverly devised system f or optimum lubrication and long lif etime.
Checking t he cont act pat t ern when assem-
bling wit h CEPLATTYN 300/ CEPLATTYN SF-P.
I N PRI NCI PLE: FOUR COM PONENTS
FOR A LONG LI FETI M E
Pri mi ng l ubri cant :
Ini t i al l ubri cat i on
Manual appl i cat i on
Runni ng-i n l ubri cant :
Smoot hes t he surf ace
Aut omat i c spray syst em
Operat i ng l ubri cant :
Lubri cat i on at i nt erval s
Aut omat i c spray syst em
Speci al l ubri cant :
Servi ce l ubri cant
Onl y carri ed out by FUCHS LUBRITECH st af f
* t he sel ect i on gui de on page 15 of t hi s brochure gi ves
an i ni t al overvi ew
6 FUCHS LUBRITECH GM BH OPEN 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 dri ve defects. The
chart on the next page gives a general
indication of the kind of problems that
can be experienced.
The correct lubricant eliminates
many sources of damage
It doesnt matter whether a light
oi l or an adhesi ve l ubri cant i s under
consi derati on. Nor does i t 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-
erati on. Scuffi ngs and abrasi ve wear,
for example, depend to a large extent
on the lubricant. Poor quality lubricant
al so has a di rect effect on the occur-
rence of fretting corrosion, scoring and
scuffings. The consequences of a short-
age of l ubri cant usual l y i ncl ude i n-
creased wear or deformations such as
the development of rippling, hot or cold
flow.
There are m any causes of dam age to
tooth flanks nearly all can be avoided
I N DETAI L: THE CAUSES OF TOOTH FLANK DAM AGES I N OPEN GEARS
sl ag i ncl usi ons
f orgi ng f ol ds
non-met al l i c i ncl usi ons
unsui t abl e mat eri al pai ri ng
i nadequat e di mensi ons
i ncorrect t oot h geomet ry
meshi ng f aul t s
i ncorrect t oot h pl ay
Forgi ng f aul t s
Overheat i ng duri ng processi ng
Inappropri at e heat t reat ment
poor surf ace qual i t y
Al i gnment errors
Fi xi ng of pi ni on
Frequent l oad changes
overl oad
i mpact /vi brat i on st ress
i ncorrect runni ng-i n
Speeds t oo l ow/hi gh
Dust i ngress
Dynami c changes
Short age of l ubri cant
Wrong consi st ency
i nadequat e qual i t y
Soi l i ng wi t h sol i ds/l i qui ds
i ncorrect appl i cat i on
N
o
r
m
a
l

w
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A
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M
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Wear Pi t t i ngs
Toot h
breakage
Corrosi on Cracks Def ormat i ons Ot her t ypes of damage
Pit t ing is f at igue damage result ing f rom over-
loading. CEPLATTYN operat ional lubricant s can
prevent t he damage f rom spreading.
7 OPEN GEAR LUBRICATION FUCHS LUBRITECH GM BH
PRIMING
F
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(
A
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P
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.
PRIM IN G
Initial lubrication with CEPLATTYN 300/CEPLATTYN SF-P provides pro-
tection on the f irst 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
i ni ti al operati on. In the context of
LUBRITECH MULTI-PHASE-LUBRICATION
(M-P-L) the pri mi ng or i ni ti al l ubri ca-
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 contact
pattern
It i s necessary to ful l y cl ean 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 usi ng a sti ff-bri stl ed brush or
spatul a. The appl i cati on i ncl udes the
working flanks, tooth roots and tips in
order to avoid corrosion and damage
from any movement i nvol ved duri ng
assembl y. After pri mi ng, turni ng 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.
I N PRI NCI PLE: FOUR COM PONENTS FOR A LONG LI FE
Cont act pat t ern at t he peri met er of t he gi rt h
gear when t he pi ni on wobbl es. Check
seat i ng of pi ni on.
Cont act pat t ern f or wobbl e i mpact of t he
gi rt h gear. Check al i gnment and f i xi ng of
t he gi rt h gear.
Cont act pat t ern f rom edge l oadi ng. Axl es not
suf f i ci ent l y paral l el . Real i gn pi ni on.
Ci rcul at i ng pressure poi nt , resul t i ng f rom
manuf act uri ng f aul t or i sol at ed t hermal
def ormat i on (prot uberances).
Cont act pat t ern f rom pi ni on expanded on
bot h si des, resul t i ng f rom i ncorrect l y assem-
bl ed ri ng t ensi oni ng el ement s.
Cont act pat t ern wi t h opposi ng obl i qui t y of
t he t wo hal ves of t he gi rt h gear. Check t he
i mpact poi nt bol t i ng.
Cont act pat t ern when one hal f of t he gi rt h
gear i s obl i que. Check assembl y.
Radi al run-out of t he gearwheel . The cont act
pat t ern appears weaker or st ronger over hal f
t he peri met er of t he gi rt h gear. Readj ust .
Cont act pat t ern when t he gi rt h gear has pro-
t uberances on bot h si des, resul t i ng f rom
excessi ve f ri ct i onal heat i ng of t he j acket seal s
(of t en f ound i n oi l -l ubri cat ed dri ves).
Improve l ubri cat i on of seal s. Check assembl y
of seal s.
10
0
20
30
40
50
100 200 300 400 500 600 700 800 900
1000
2000
3000
4000
5000
6000
7000
8000
9000
Q
u
a
n
t
i
t
y

[
k
g
]
m

x

n

[
m
m
]
Face w i dt h [mm]
QUANTI TY CEPLATTYN 300/ CEPLATTYN SF-P
n = t ot al number of t eet h
m = modulus
The f ilm of lubricant must be applied evenly
and wit hout air-bubbles.
8 FUCHS LUBRITECH GM BH OPEN 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
fl anks due to thei r shape and to as-
sembly. This means that there is a very
high risk, during initial operation, that
dri ves can be damaged at thi s earl y
stage as a result of localised overload.
These damages can be slight local scuff-
i ng, or i t can be cracks that spread i n
the form of pitting during later opera-
tion as a result of fatigue damage.
The economical way to higher
gearing quality
Control l ed runni ng-i n wi th
CEPLATTYN RN/CEPLATTYN SF-RN run-
ning-in lubricant allows damage from
initial operation to be avoided. Because
CEPLATTYN RN/CEPLATTYN SF-RN car-
ri es away manufacturi ng roughness,
smooths the load-carrying surfaces of
tooth fl anks, overcomes sl i ght devi a-
ti ons i n form and assembl y, 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 rel ati on 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 ki l ns i n si ngl e l oad steps i s 350
hours and as far as possible the lubri-
cant shoul d be conti nuousl y appl i ed.
Dependi ng on the runni ng ti me, a
chargi ng i l l ustrated i n the fol l owi ng
table have been found effective.
Note: Other val ues may vary i n
practice. The process must be adapted
to the particular operating conditions.
The state of the tooth fl anks
should be checked throughout the run-
ning-in process. This applies particular-
ly to the change of grinding charge. This
shoul d onl y be undertaken when the
load-carrying proportion given in the
table has been reached. If the contact
pattern i s consi derabl y 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 manufacturi ng roughness of
l oaded teeth surface has been
smoothed down.
RU N N IN G -IN
CEPLATTYN RN/CEPLATTYN SF-RN removes the manuf acturing rough-
ness, and it smooths working the tooth f lanks.
Mi n. cont act
Gri ndi ng Runni ng area t o be
charge t i me achi eved
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
I N PRI NCI PLE: SURFACE ROUGHNESS PROFI LES OF TOOTH FLANKS
Load-carryi ng pat t ern
bef ore runni ng-i n about 50 %
Load-carryi ng pat t ern
af t er runni ng-i n about 80 %
Bef ore runni ng-i n wi t h
CEPLATTYN RN/CEPLATTYN SF-RN
Af t er runni ng-i n wi t h
CEPLATTYN RN/CEPLATTYN SF-RN
0
.
8

m
m
0
.
8

m
m
100
200
300
400
5
10
15
20
30
25
100 200 300 400 500 600 700 800 900
Q
u
a
n
t
i
t
y

[
k
g
/
3
5
0
h
]
Q
u
a
n
t
i
t
y

[
k
g
/
2
4
h
]
Face w i dt h [mm]
Mi l l doubl e pi ni on dri ve 1,2 g/ h mm
Ki l n doubl e pi ni on dri ve 0,9 g/ h mm
Mi l l si ngl e pi ni on dri ve 0,8 g/ h mm
Ki l n si ngl e pi ni on dri ve 0,6 g/ h mm
QUANTI TY CEPLATTYN RN/ CEPLATTYN SF-RN
I NSPECTI NG THE SPRAY SYSTEM
The f ol l owi ng poi nt s shoul d be observed
bef ore commenci ng operat i on of t he
machi nery:
Funct i onal t est
Spray pat t ern
Spray angl e
Nozzl e di st ance
Lubri cant quant i t y (see di agrams
on page 8-10)
The i ncreased t hroughput of run-i n
l ubri cant i s necessary i n order t o
f l ush any met al l i c part i cl es caused by
removi ng t he peaks of t he rough surf ace.
The l ubri cant consumed must be al l owed
t o f l ow wi t hout rest ri ct i on out of t he
gear guard. Dredgi ng i n t he l ubri cant
sump must be avoi ded.
9 OPEN GEAR LUBRICATION FUCHS LUBRITECH GM BH
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-
i ngs, or under the unfavourabl e ci r-
cumstances where pai ri ng of ol d and
new gears has taken place.
The use of Reconditioner
Forced running-in involves a serv-
i ce l ubri cant known as Recondi ti oner
being applied manually to the working
surfaces i n addi ti on 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 onl y be carri ed out by FUCHS
LUBRITECH Service Engineers. For gears
bei ng under warranty, the machi ne
manufacturer must give its approval pri-
or du start of the procedure.
Exampl e 1: Axi al run-out devi a-
ti ons 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-
di ti oner i n a forced run-i n. The l oad
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 (vi si bl e i n the pi cture as a
white line on the working tooth flank).
Exampl e 2: After the pi ni on 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 hei ght (ri ght pi cture) and the
damaged areas on the working tooth
flanks had been removed.
Forced running-in
w ith Reconditioner
30
30
1
5
0
- 2
0
0
m
m
1
5
0

-

2
0
0

m
m
Inward runni ng pi ni on Out ward runni ng pi ni on
SM OOTHER RUNNI NG FROM RECONDI TI ONER
Smal l devi at i ons i n axi al and radi al run-out at t he gi rt h gear had t he ef f ect of l arge di f f erences i n
t he vi brat i ons of t he pi ni on beari ngs when rest art i ng a hel i cal , doubl e pi ni on cement mi l l . At t he
runni ng-out pi ni on t he vi brat i on l evel s were wel l bel ow 2 mm/s, but were above 8 mm/s at t he
runni ng-i n pi ni on. The operat or coul d not accept t hi s l arge di f f erence. Even several correct i ons t o
t he t ransmi ssi on gear brought no i mprovement . The manuf act urer of t he machi nery t heref ore i ni -
t i at ed f orced runni ng-i n.
The appl i cat i on of recondi -
t i oner f or ni ne hours resul t -
ed i n a caref ul l y cont rol l ed
redi st ri but i on of t he l oad:
t he vi brat i ons at bot h bear-
i ngs were at t he end bel ow
2mm/ s, so t hat on t he
whol e t he operat i on was
very smoot h.
Inward
runni ng
pi ni on
[ mm/s]
Ti me [ h]
Out ward
runni ng
pi ni on
Ext ract f rom permanent vibrat ion monit oring at t he f act ory.
Hori zont al
overl ap
Vert i cal
overl ap
Overl ap
wi t h wi de j et
nozzl es
0.1
0.2
0.3
0.4
2
4
6
8
10
100 200 300 400 500 600 700 800 900
Q
u
a
n
t
i
t
y

[
k
g
/
h
]
Q
u
a
n
t
i
t
y

[
k
g
/
2
4
h
]
Face w i dt h [mm]
M
ill D
riv
e
s m
in
. 0
.2
-0
.4
g
/ h
m
m
Kiln Drives min. 0.1-0.2 g/ hmm
QUANTI TY CEPLATTYN KG 10 HM F
H
e
i
d
e
l
b
e
r
g
e
r

Z
e
m
e
n
t

A
G
10 FUCHS LUBRITECH GM BH OPEN GEAR LUBRICATION
OPERATIONAL LUBRICATION
ONCE PRIMING and running-in have
been successfully completed, the next
poi nt to be consi dered i s 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 l arge number of factors.
These include the stress on the working
tooth fl anks, the rotary speed of the
transmission gear, the actual flank tem-
peratures and the condi ti on of the
drive. Environmental influences such as
dust contamination, humidity, very low
or very hi gh ambi ent temperatures
must also be considered.
On the saf e side with CEPLATTYN
The changeover to operating lu-
brication starts at the end of running-
in. When changing to the operating lu-
bri cant a cl eani ng procedure i s not
needed. Just the drum contai ner 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 extremel y hi gh pressure, are re-
sistant to water, and are approved by
al l l eadi ng gear and machi ne manu-
facturers.
Changeover to operating
lubrication
In practi ce the changeover i s
achieved through a staged reduction in
quantity towards a target minimum (see
graph on the l eft). It i s necessary to
measure the quanti ty every ti me thi s
value is reduced by the spray system. In
practice, small volumes frequently ap-
pl i ed avoi d phases where the dri ve i s
saturated with lubricant which can sub-
sequently fling. The short pause times
between cycles also avoid insufficient
l ubri cati on. The mi ni mum quanti ti es
consumed by vari ous dri ves can be
found from the diagram below.
Note: The minimum quantity that
can be aimed at depends directly on the
operating conditions. Lubrication rates
bel ow the mi ni mum creates an i n-
creased risk of wear and damage to the
flanks. This can drastically reduce rated
life.
O PERATIO N A L LU BRIC ATIO N
The lif etime of the gear set depends on the selection of the lubricant.
Cent ral lubricant supply wit h CEPLATTYN KG 10 HM F.
24 48 72
t i me [ h]
0.8
0.6
0.4
0.2
0
s
p
e
c
i
f
i
c

c
o
n
s
u
m
p
t
i
o
n

[
g
/
h

m
m
]
96
Quant it y reduct ion f or a single pinion drive.
11 OPEN GEAR LUBRICATION FUCHS LUBRITECH GM BH
SERVICES
Cont act less t emperat ure measurement
wit h an I R t hermomet er.
W O RLD -
W ID E
SERVIC E
An outstanding product, f air and
honest consultation when pur-
chasing, and comprehensive tech-
nical service af terwards that is
how FUCHS LUBRITECH def ines
service.
IN MANY COUNTRIES and i n many
parts of the worl d FUCHS LUBRITECH
are the market l eaders wi th the
CEPLATTYN range of products. Thei r
success is not only based on the prod-
uct line but also by providing gear tech-
nol ogy servi ce and consul tati on. Thi s
service is valued not only by end users,
but by machi ne manufacturers al so.
FUCHS LUBRITECH offers thi s wi de
range of techni cal servi ce to al l thei r
customers world-wide, and in the case
of the basi c servi ce i nspecti on, thi s i s
free of charge.
Comprehensive
world-wide service
The speci al l y trai ned 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 fl anks, and regul ar
checks of the drive and spray systems,
are performed on si te by the Servi ce
Engineer.
Satisf action 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
secti on gui de on page 15 of thi s
brochure gi ves an i ni ti al overvi ew).
FUCHS LUBRITECH engineers will then
inspect the machinery on site, and will
devel op an opti mum scheme joi ntl y
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
requi red, i n order to be properl y ad-
vised and supported from the very be-
ginning.
I N DETAI L: THE SERVI CES
Consul t at i on on product sel ect i on and
appl i cat i on
Assi st ance wi t h dri ve assembl y and t rans-
mi ssi on gear al i gnment
Runni ng-i n open gear dri ves
Assi st ance wi t h correct i ons t o t ransmi s-
si on gears and t oot h f l anks
Regul ar checki ng of t he dri ve and spray
syst ems
tation (FLT-INSPECTOR) is pro-
vided (see page 13).
Skilled repair
The repai r of damaged tooth
fl anks on open gear dri ves i s 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 assi stance wi th al i gnment of the
transmission gears. On heavily worn out
or damaged tooth fl anks FUCHS
LUBRITECH can provide a complete Re-
Profiling of the entire gear set.
12 FUCHS LUBRITECH GM BH OPEN GEAR LUBRICATION
SERVICES
Inspections are f ree of charge
The Servi ce Engi neers of FUCHS
LUBRITECH regul arl y check dri ves l u-
bri cated wi th 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-
mi ssi on gear beari ngs. In addi ti on,
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-
I N PRACTI CE: THE I NSPECTI ONS
Checki ng t he spray syst em
Assessment of t he cont act pat t ern and t he
condi t i on of t he l oad-carryi ng surf aces
Measurement of t he vi brat i on of t he pi n-
i on beari ngs
Measurement of t he t emperat ure prof i l e
across t he t oot h wi dt h
Document at i on of t he condi t i on of t he
f l anks (phot ographi c, bl ue pri nt ...)
Wri t t en document at i on of t he whol e
i nspect i on, i ncl udi ng t rendi ng of t he
measured val ues
I N PRACTI CE: THE REPAI R SERVI CE
Re-prof i l i ng of t he worki ng t oot h f l anks
Gri ndi ng pi t t i ngs or l arger breakages
Smoot hi ng of scuf f i ngs
Forced runni ng-i n
Assi st ance wi t h t he al i gnment of t he
t ransmi ssi on gear
Inspection,
servicing and
repair are
specialist jobs.
Check of spray pat t ern.
M easuring vibrat ion of
t he pinion bearings.
Treat ment of t he working t oot h f lanks.
Dynamic check-
ing of t he con-
t act pat t ern
wit h a st robo-
scope.
13 OPEN GEAR LUBRICATION FUCHS LUBRITECH GM BH
SERVICES
Wi th 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).
I N DETAI L: THE FLT-I NSPECTOR
Avai l abi l i t y of al l report s at a gl ance
Onl i ne access at any t i me
Inst ant check vi a t raf f i c l i ght syst em
Graphi cal t rend anal ysi s f or t emperat ures
and vi brat i ons
Rapi d t ransmi ssi on of dat a and report s
Indi vi dual access hi erarchy
Opt i onal ext ra i nf ormat i on (at t achment s)
f or each i nspect i on report
FLT-IN SPEC TO R O nline reporting w ith
integrated, graphical trend analysis
Graphic t rend analysis en-
ables inf ormat ive display
of t emperat ures and vi-
brat ions over t ime.
Focus on: I nst ant check via t raf -
f ic light syst em .
Fig. 1
Fig. 2
Crit ical measured values
are highlight ed in red.

FIELDS OF APPLICATION
Product code
Kind of machinery
Tube mi l l
Rot ary ki l n
Mi xi ng drum, cal ci nat i ng and rot ary dryers
Crusher
Bucket -wheel excavat or
Wi re Ropes
Forgi ng press
Port al crane, hoi st i ng crane
Dragl i ne
Sl ewi ng ri ng
Racks
Kind of applicat ion
Pri mary l ubri cat i on
Runni ng-i n l ubri cat i on
In-servi ce l ubri cat i on
Low-consumpt i on l ubri cat i on
Loading charge
Normal
Hi gh
Ext reme
Ext reme shock l oadi ng
Pre-damaged
Temperat ure
Low
Normal
Hi gh
Met hod of applicat ion
Manual
(Di p) bat h l ubri cat i on
Aut omat i c spray l ubri cat i on
Ot her crit erion
Envi ronment al l y harml ess
Cl eanl i ness
14 FUCHS LUBRITECH GM BH OPEN GEAR LUBRICATION
FLUIDS
THE CEPLATTYN SF SERIES was de-
vel oped to meet the requi rements 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-
tecti on such products nowadays are
hardl y acceptabl e. 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-
i ng of pri mer (CEPLATTYN SF-P), run-
ni ng-i n l ubri cant (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 seri es there are di f-
ferences in application and practical use.
The characteristics of the SF series and
those of the KG 10 HMF seri es are
shown in the following table.
A C LEA N SO LU TIO N
Solvent-f ree adhesive lubricants - highly viscous and sprayable
PRODUCT COM PARI SON:
Appearance
Composi t i on
Appl i cat i on
Ki nd of appl i cat i on
Pl ease see sel ect i on gui de on page 15
CEPLATTYN SF range
l i ght col oured
Hi gh vi scous, synt het i c oi l wi t h
hi gh perf ormance addi t i ves
Open gears on mi l l s i n cement ,
l i me, gypsum, sugar and mi ni ng
i ndust ry and power pl ant s.
Especi al l y f or open gears, desi gned
accordi ng t o AGMA desi gn.
For spray, di p and ci rcul at i ng
l ubri cat i on, depends on base oi l
vi scosi t y
CEPLATTYN KG 10 HMF range
dark grey/bl ack
Thi ckener wi t h mi neral oi l ,
addi t i ves, 10 % graphi t e
Open gears on ki l ns and mi l l s i n
cement , l i me, gypsum and mi ni ng
i ndust ry and power pl ant s. For
smal l er open runni ng gears, e.g. i n
t he const ruct i on i ndust ry, wi ndpow-
er pl ant s, wat er-l ocks, dragl i nes et c.
For spray and di p l ubri cat i on
or manual l y by brush.
C
E
P
L
A
T
T
Y
N

1
0
0

H
V
C
E
P
L
A
T
T
Y
N

3
0
0
C
E
P
L
A
T
T
Y
N

B
L
C
E
P
L
A
T
T
Y
N

E
C
O

3
0
0
C
E
P
L
A
T
T
Y
N

K
G

1
0

H
M
F
C
E
P
L
A
T
T
Y
N

K
G

1
0

H
M
F
-
1
0
0
0
C
E
P
L
A
T
T
Y
N

K
G

1
0

H
M
F
-
2
5
0
0
C
E
P
L
A
T
T
Y
N

K
G

1
0

H
M
F
-
L
T
C
E
P
L
A
T
T
Y
N

K
G

1
0

L
C
C
E
P
L
A
T
T
Y
N

R
N
C
E
P
L
A
T
T
Y
N

S
F

1
0
C
E
P
L
A
T
T
Y
N

S
F

3
0
C
E
P
L
A
T
T
Y
N

S
F
-
P
C
E
P
L
A
T
T
Y
N

S
F
-
R
N
C
E
P
L
A
T
T
Y
N

3
0
0

S
P
R
A
Y
C
E
P
L
A
T
T
Y
N

E
C
O

3
0
0

S
P
R
A
Y
1
1
5
7
1
1
1
9
1
1
2
9
1
1
6
1
1
1
6
2
1
1
5
3
1
1
5
4
1
1
0
6
2
4
6
7
1
1
7
9
3
3
1
0
3
3
3
0
3
3
1
4
3
3
1
6
1
6
1
2
2
1
6
2
15 OPEN GEAR LUBRICATION FUCHS LUBRITECH GM BH
SELECTION GUIDE
Headquarter:
FUCHS LUBRITECH GMBH
Werner-Heisenberg-Strae 1
67661 Kaiserslautern/Germany
www.fuchs-lubritech.com
Regional Contact:
Phone +49 (0) 6301 3206-0
Fax +49 (0) 6301 3206-940
E-mail info@fuchs-lubritech.de
1

K
D

0
6
/
1
0

0
6
0
1
2
0
9
Lubrication Technology