OPEN GEARS

LUBRICATION + MAINTENANCE + SERVICE

. . . . . . . . .CONTENTS FOREWORD . . . . . . . 2 OPEN GEAR LUBRICATION FUCHS LUBRITECH GMBH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 MULTI-PHASE-LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INTRODUCTION . . . . . . . . . . . 11 FLUIDS FOR OPEN GEARS . . . Subject to alteration. . . . . 14 SELECTION GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SERVICES . . . . 15 ■ WITH REFERENCE TO THE TECHNICAL BROCHURE: The information in this brochure corresponds with the status of our momentary development and knowledge. . . . . . . . . . . . . . . . . . . . . . . ■ WITH REFERENCE TO THE PHOTOS: We thank all our customers for the photos they put at our disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 PRIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 OPERATIONAL LUBRICATION . . . . . . . . . . . . . . . 7 RUNNING-IN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . as well as all the other companies who supported us with photographic material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

As a result an operating life in excess of 20 years can be expected. volume of lubricant and the means of application. slowrunning open gear drives where high torques are transmitted.FOREWORD IN MOTION ■ LARGE OPEN GEAR DRIVES constitute a mechanical method of transmitting movement and force. 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. but also on the lubricant. This is particularly true for large. The level of success ultimately achieved does not only depend on the gear design and materials used. Transmission ratios are typically in the range of 1:8 to 1:12. The distortions that develop under the influence of load and temperature also increase with size. It is not uncommon to see large gears having a diameter of 14 meters. correctly applied adhesive lubricant will safely prevent metal-to-metal contact between the tooth flanks. FUCHS LUBRITECH GMBH OPEN GEAR LUBRICATION 3 . A special. 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. Under these conditions hydrodynamic lubrication is often hardly possible because of the slow sliding speed at the working tooth flanks. Greases with high proportion of solid lubricant or fluids with superior additives ensure safe running properties in the areas of boundary friction. The CEPLATTYN range was developed in the early 60's as the first sprayable adhesive lubricant. Security with system Lubrication with the FUCHS LUBRITECH CEPLATTYN range of products fully satisfies the tough tribo-technical requirements.

00 2. The drive must be set up by means of the root clearance. CEPLATTYN adhesive lubricants are recommended by the leading manufacturers of gears and machines.80 3.20 2.50 0. coolers.25 to 0. contain no heavy metals.40 2. washing drums.INTRODUCTION WHERE MIGHTY FORCES RULE IN DETAIL: GUIDE VALUES FOR ADJUSTMENT AND ASSEMBLY The commission engineer of open gear drives is faced with toughest requirements when aligning or correcting the drive. The materials that are utilized for the gearing are usually CrNiMo tempered steel (pinion) and alloyed CrMo steel casting (girth gear). 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. the root clearance and of the free play.60 2.75 1. For the lubrication of open gears adhesive sprayable lubricants are most suitable. The girth gear drives that are used in tube mills. As a result of more than 50 years experience. long-term. A suitable guide value for the tooth tip play is 0. It is only natural that such force subjects the gear wheels to very high stresses. trouble-free operation. Note: When a gear set must be turned because of wear. FUCHS LUBRITECH can offer the right lubricant from the CEPLATTYN product range. and therefore do very little harm to the environment. The best solution has a name – CEPLATTYN Wherever lubrication is to be carried out on highly stressed or pre-damaged gear drives. Therefore an optimum load carrying capacity and smoothing of the gear teeth are to be achieved. Krupp Polysius AG Axial distance [mm] 4500 4000 3500 3000 2500 2000 1500 1000 500 1. kilns and calciners have to transmit enormous torque – up to 50. it is no longer possible to align the gears by means of the backlash.25 0. These gears are usually designed as spur or helical gears and with modified involute profiles. or in high temperature surroundings. in spite of the enormous stresses. The lubricant plays an important role The purpose of all constructional and tribotechnical measures is to ensure.00 1. chlorine or solvents.3 times the module. shortage of lubricant and incorrect application. CEPLATTYN products. ■ OPEN GEAR DRIVES are most often used in the raw materials industry. moreover. the most precise alignment of the gears coupled with the correct running-in procedures is essential. Whether under arctic conditions.25 Mills Kilns Backlash [mm] Pitch circle Ø [mm] 9000 8000 7000 6000 5000 4000 3000 2000 1000 0.000 Nm is by no means rare. LUBRITECH MULTIPHASE-LUBRICATION (M-P-L) with the range of CEPLATTYN adhesive lubricants is widely accepted as one of the market leaders in this area. of the backlash. This is why it is usual for assembly companies to prepare records of measurements of the radial and axial run-outs. Careful alignment of the girth gear and of the transmission gear is of critical importance for the life of the drive.80 2. but also the use of unsuitable lubricants. Open gear drives do the heaviest work in many branches of industry.00 Axial run-out Radial run-out Heidelberger Zement AG Tolerance value [mm] 4 OPEN GEAR LUBRICATION FUCHS LUBRITECH GMBH .

However. ■ AFTER THE CAREFUL ALIGNMENT of the drive. in the worst case. running-in. for open gear drives in particular. scuffings. even the most careful manufacturing techniques and the most precise alignment possible do not permit this optimum state to be achieved. pitting and even tooth breakage. IN PRINCIPLE: FOUR COMPONENTS FOR 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 FUCHS LUBRITECH GMBH OPEN GEAR LUBRICATION 5 . The consequences of inadequate load distribution are. The operator can. the selection of the correct lubricant is the next step to a long lifetime. The various lubricants. have a significant influence on these types of damages. through selection of the correct lubricant. however. Checking the contact pattern when assembling with CEPLATTYN 300/CEPLATTYN SF-P. LUBRITECH M-P-L consists primarily of four components: priming. by dipping or circulation lubrication. are the result of many years of research. and thus on the lifetime of the drive. Note: LUBRITECH M-P-L can only be applied in a restricted way to drives that are not lubricated by an automatic spray system. excessive heating. The best possible protection from wear Optimum load transmission implies that the stress is evenly distributed over the full width and height of the teeth. and the combination of the individual components.MULTI-PHASE-LUBRICATION THE MULTI-PHASE-LUBRICATION A cleverly devised system for optimum lubrication and long lifetime. FUCHS LUBRITECH Service Engineers will be pleased to advise you about running in of gears whose operating lubrication is subsequently performed manually. operating and special (service) lubricants. LUBRITECH MULTI-PHASE-LUBRICATION (M-P-L) is the most secure method of averting serious mistakes. and have been proven in practice all over the world. 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.

Pitting is fatigue damage resulting from overloading. The correct lubricant eliminates many sources of damage It doesn’t matter whether a light oil or an adhesive lubricant is under consideration. in a wide variety of design. the appropriate lubricant is one of the most important factors for trouble-free operation. Nor does it matter whether it is a fast-running vehicle gearing or a slow running open gear drive: whenever teeth mesh together. IN DETAIL: THE CAUSES OF TOOTH FLANK DAMAGES IN OPEN GEARS Wear Pittings Tooth breakage Overload breakage Cracks Deformations Corrosion Other types of damage chemical corrosion Initial/destructive/ fatigue pitting Interference wear fretting corrosion fatigue breakage hardness cracks Grinding cracks material cracks Abrasive wear fatigue cracks Normal wear indentations Material faults 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 • • • • • • • • • • • • • • • • • • Constructional faults Manufacturing faults • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Assembly faults Alignment errors Fixing of pinion Frequent load changes Operational conditions overload impact/vibration stress incorrect running-in Speeds too low/high Dust ingress Dynamic changes Lubrication faults Shortage of lubricant Wrong consistency inadequate quality Soiling with solids/liquids incorrect application 6 OPEN GEAR LUBRICATION FUCHS LUBRITECH GMBH overheating oxidisation cavitation Scratches cold flow scuffings hot flow spalling rippling Scoring erosion flaking • . damaged tooth flanks are the reason for about 60 percent of gear drive defects. hot or cold flow. Looked at it statistically. provide movement throughout industry.MULTI-PHASE-LUBRICATION There are many causes of damage to tooth flanks – nearly all can be avoided Gears. for example. scoring and scuffings. The consequences of a shortage of lubricant usually include increased wear or deformations such as the development of rippling. the causes can be highly varied in nature. depend to a large extent on the lubricant. Poor quality lubricant also has a direct effect on the occurrence of fretting corrosion. When a gear wheel suddenly stops. The chart on the next page gives a general indication of the kind of problems that can be experienced. CEPLATTYN operational lubricants can prevent the damage from spreading. Scuffings and abrasive wear.

→ Readjust. Check assembly of seals. The whole tooth flank area should be thoroughly cleaned to bare metal. The projection allows any correction to the transmission gear to be made more easily. The contact pattern appears weaker or stronger over half the perimeter of the girth gear. → Check the impact point bolting. → Check alignment and fixing of the girth gear. → Check seating of pinion. Contact pattern for wobble impact of the girth gear. → Improve lubrication of seals. Ltd. After priming. resulting from excessive frictional heating of the jacket seals (often found in oil-lubricated drives). The tooth flanks are then primed with CEPLATTYN 300/CEPLATTYN SF-P using a stiff-bristled brush or spatula. Axles not sufficiently parallel. The application includes the working flanks. → Realign pinion. In the context of LUBRITECH MULTI-PHASE-LUBRICATION (M-P-L) the priming or initial lubrication takes place with CEPLATTYN 300/ CEPLATTYN SF-P immediately after assembly of the drive. PRIMING Initial lubrication with CEPLATTYN 300/CEPLATTYN SF-P provides protection on the first occasion at the teeth mesh and prevents corrosion.PRIMING Fuchs Lubritech (Australia) Pty. resulting from manufacturing fault or isolated thermal deformation (protuberances). Contact pattern when the girth gear has protuberances on both sides. resulting from incorrectly assembled ring tensioning elements. The surface finish of the gear teeth makes it essential to prime to prevent damage during initial operation. Any areas devoid of lubricant must be primed again. Contact pattern when one half of the girth gear is oblique. turning the gears with the auxiliary drive will result in the actual contact pattern being projected onto the working tooth flanks. FUCHS LUBRITECH GMBH OPEN GEAR LUBRICATION 7 . tooth roots and tips in order to avoid corrosion and damage from any movement involved during assembly. Radial run-out of the gearwheel. → Check assembly. Note: CEPLATTYN 300/CEPLATTYN SF-P can not be applied with automatic spray systems. IN PRINCIPLE: FOUR COMPONENTS FOR A LONG LIFE Contact pattern at the perimeter of the girth gear when the pinion wobbles. QUANTITY CEPLATTYN 300/CEPLATTYN SF-P 9000 50 Quantity [kg] 40 30 20 10 0 100 200 300 400 500 600 700 800 900 8000 7000 m x n [mm] 6000 5000 4000 3000 2000 1000 Contact pattern from edge loading. Contact pattern with opposing obliquity of the two halves of the girth gear. Face width [mm] n = total number of teeth m = modulus Contact pattern from pinion expanded on both sides. ■ PRIMING THE TOOTH FLANKS is necessary to provide initial lubrication during the first revolution of the gears during the course of assembly. Priming and checking the contact pattern It is necessary to fully clean the tooth flanks before applying lubricant for the first time. Circulating pressure point. The film of lubricant must be applied evenly and without air-bubbles.

350 h Note: Other values may vary in practice. 90-100 % Running time abt. This means that there is a very high risk. or it can be cracks that spread in the form of pitting during later operation as a result of fatigue damage. and deviations of the flanks due to their shape and to assembly. The process must be adapted to the particular operating conditions. 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. readjustment of the transmission gear is required. providing the basis for long life operation. smooths the load-carrying surfaces of tooth flanks. Running-in can be considered complete when. This applies particularly to the change of grinding charge. 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 lubricant should be continuously applied. The reason for this is surface roughness. IN PRINCIPLE: SURFACE ROUGHNESS PROFILES OF TOOTH FLANKS QUANTITY CEPLATTYN RN/CEPLATTYN SF-RN 30 400 Quantity [kg/350h] 300 200 100 20 15 10 5 100 200 300 400 500 600 700 Face width [mm] 800 900 Quantity [kg/24h] 25 Load-carrying pattern before running-in about 50 % 0. that drives can be damaged at this early stage as a result of localised overload.RUNNING-IN RUNNING-IN CEPLATTYN RN/CEPLATTYN SF-RN removes the manufacturing roughness. and thus significantly increases the contact area. The economical way to higher gearing quality Controlled running-in with CEPLATTYN RN/CEPLATTYN SF-RN running-in lubricant allows damage from initial operation to be avoided. The result: gearing quality that is sig- nificantly better. Min. Because CEPLATTYN RN/CEPLATTYN SF-RN carries away manufacturing roughness. ■ EVEN AFTER THE DRIVE has been carefully aligned. The state of the tooth flanks should be checked throughout the running-in process. 50-60 % 2.2 g/h·mm Kiln double pinion drive 0. 70-80 % 3. 70 h abt. overcomes slight deviations in form and assembly. and the manufacturing roughness of loaded teeth surface has been smoothed down.8 g/h·mm Kiln single pinion drive 0. a charging illustrated in the following table have been found effective.9 g/h·mm Mill single pinion drive 0. This should only be undertaken when the load-carrying proportion given in the table has been reached. arising in the course of manufacture. abt. abt. contact area to be achieved 50-60 % 70 % 80 % Grinding charge 1.8 mm Load-carrying pattern after running-in about 80 % Before running-in with CEPLATTYN RN/CEPLATTYN SF-RN After running-in with CEPLATTYN RN/CEPLATTYN SF-RN ■ ■ ■ ■ Mill double pinion drive 1. a load-carrying proportion of at least 80 percent is achieved. 160 h abt. These damages can be slight local scuffing. with maximum charge or throughput. 120 h abt. manufacturing tolerances and the way in which the gear has been assembled. On average. If the contact pattern is considerably worse. and it smooths working the tooth flanks. the initial load-carrying proportion is often no more than 50 to 60 percent. abt. Depending on the running time.6 g/h·mm 8 OPEN GEAR LUBRICATION 0.8 mm FUCHS LUBRITECH GMBH . during initial operation.

Forced running-in with Reconditioner In cases where normal running-in may not result in a sufficiently high contact pattern or the drive has to be runin under conditions of immediate full load. 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 damage to the pinion after two months of running (left picture). After using Reconditioner for eight hours. Dredging in the lubricant sump must be avoided. forced running in (the quick running in method) represents the best solution. For gears being under warranty. The damage was 150 Overlap with wide jet nozzles 0 mm 30° 150 . Note: The aggressive material removal resulting from the use of Reconditioner calls for specialised technical knowledge. Since it was not possible to achieve an improvement in the contact pattern through alignment means. The load peaks that can clearly be seen in the red framed part of the working tooth flanks caused by overloading. The operator could not accept this large difference. Forced running-in is therefore only be carried out by FUCHS LUBRITECH Service Engineers. In this way the running-in time is reduced tremendously. At the running-out pinion the vibration levels were well below 2 mm/s. [mm/s] The application of reconditioner for nine hours resultInward running ed in a carefully controlled pinion redistribution of the load: the vibrations at both bearings were at the end below Outward running 2mm/s. the drive had to be run in using reconditioner in a forced run-in. The manufacturer of the machinery therefore initiated forced running-in.2 00 mm Inward running pinion Outward running pinion FUCHS LUBRITECH GMBH OPEN GEAR LUBRICATION 9 . so that on the pinion whole the operation was very smooth. The Reconditioner has the effect of causing smoothing of the working surfaces in a shorter time.20 Horizontal overlap Vertical overlap (left picture) are no longer present after reconditioning (right picture). 30° . The lubricant consumed must be allowed to flow without restriction out of the gear guard. INSPECTING THE SPRAY SYSTEM The following points should be observed before commencing operation of the machinery: • Functional test • Spray pattern • Spray angle • Nozzle distance • Lubricant quantity (see diagrams on page 8-10) The increased throughput of run-in lubricant is necessary in order to flush any metallic particles caused by removing the peaks of the rough surface. but were above 8 mm/s at the running-in pinion. This forced running in procedure is also suitable for achieving optimum carrying capacity and surface finish if the load carrying surfaces show scuffings. or under the unfavourable circumstances where pairing of old and new gears has taken place.RUNNING-IN SMOOTHER RUNNING FROM RECONDITIONER Small deviations in axial and radial run-out at the girth gear had the effect of large differences in the vibrations of the pinion bearings when restarting a helical. The use of Reconditioner Forced running-in involves a service lubricant known as Reconditioner being applied manually to the working surfaces in addition to the normal CEPLATTYN RN lubricant during the production process. Example 1: Axial run-out deviations caused the contact pattern of a cement mill drive to be only 40 percent in some areas. The pitch line reaches over the full width of the tooth (visible in the picture as a white line on the working tooth flank). Time [h] Extract from permanent vibration monitoring at the factory. since the loadcarrying proportion did not reach over the full height of the teeth. double pinion cement mill. Even several corrections to the transmission gear brought no improvement. the machine manufacturer must give its approval prior du start of the procedure. the contact pattern finally reached over the full tooth height (right picture) and the damaged areas on the working tooth flanks had been removed.

They can support extremely high pressure.6 0. and are approved by all leading gear and machine manufacturers.1 Mil l Dr ive s 0.2 -0. Environmental influences such as dust contamination.4 0. QUANTITY CEPLATTYN KG 10 HMF 0. The short pause times between cycles also avoid insufficient lubrication. min 4 2 K ves m iln Dri in. The selection of the lubricant depends on a large number of factors. ■ ONCE PRIMING and running-in have been successfully completed.4 g/h ·mm 10 8 6 -0.2 0 24 48 72 96 sistant to water. Central lubricant supply with CEPLATTYN KG 10 HMF. humidity. the rotary speed of the transmission gear. The minimum quantities consumed by various drives can be found from the diagram below. When changing to the operating lubricant a cleaning procedure is not needed. the actual flank temperatures and the condition of the drive. 0.OPERATIONAL LUBRICATION Heidelberger Zement AG OPERATIONAL LUBRICATION specific consumption [g/h·mm] The lifetime of the gear set depends on the selection of the lubricant. 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). solvents or chlorine. are re- 0. Lubrication rates below the minimum creates an increased risk of wear and damage to the flanks.4 Quantity [kg/h] 0.3 0.2 0. and for the lifetime of the open gear drive. Making the right selection here is very important for low wear. very low or very high ambient temperatures must also be considered. These include the stress on the working tooth flanks.8 0. On the safe side with CEPLATTYN The changeover to operating lubrication starts at the end of runningin.1 100 200 300 400 500 600 700 Face width [mm] 800 900 10 OPEN GEAR LUBRICATION FUCHS LUBRITECH GMBH Quantity [kg/24h] . the next point to be considered is the operational lubrication. small volumes frequently applied avoid phases where the drive is saturated with lubricant which can subsequently fling. for operation without damage. In practice. It is necessary to measure the quantity every time this value is reduced by the spray system. Note: The minimum quantity that can be aimed at depends directly on the operating conditions. This can drastically reduce rated life. Just the drum container attached to the lubrication system has to be changed.2 g /h·mm . time [h] Quantity reduction for a single pinion drive. CEPLATTYN lubricants are adhesive lubricants without heavy metals.

Satisfaction begins with consultation An outstanding product. both the manufacturer and the operator call for the presence of the Service Engineer at commissioning or when repairs are required. ■ IN MANY COUNTRIES and in many parts of the world FUCHS LUBRITECH are the market leaders with the CEPLATTYN range of products.SERVICES WORLDWIDE SERVICE IN DETAIL: THE SERVICES • Consultation on product selection and application • Assistance with drive assembly and transmission gear alignment • Running-in open gear drives • Assistance with corrections to transmission gears and tooth flanks • Regular checking of the drive and spray systems also includes assistance with drive assembly and transmission gear alignment and with the running-in of new open gear drives. this is free of charge. of course. FUCHS LUBRITECH offers this wide range of technical service to all their customers world-wide. In many cases. but by machine manufacturers also. This service is valued not only by end users. To be on the safe side when selecting the operating lubricant. Their success is not only based on the product line but also by providing gear technology service and consultation. and comprehensive technical service afterwards – that is how FUCHS LUBRITECH defines service. regarding the application. or. contact FUCHS LUBRITECH directly (the section guide on page 15 of this brochure gives an initial overview). in order to be properly advised and supported from the very beginning. and in the case of the basic service inspection. are performed on site by the Service Engineer. Comprehensive world-wide service The specially trained FUCHS LUBRITECH Service Engineers are in duty at all times on every continent. FUCHS LUBRITECH engineers will then inspect the machinery on site. and will develop an optimum scheme jointly with the operator. Contactless temperature measurement with an IR thermometer. The services offered include consultation regarding the choice of product and. and regular checks of the drive and spray systems. This The high performance lubricants from the CEPLATTYN range are ideally tailored for very varied operating conditions. but in some cases rigidly prescribe them. the operator should therefore always consult the machine manufacturer. The best evidence for this is that leading machine manufacturers do not merely recommend CEPLATTYN adhesive lubricants. FUCHS LUBRITECH GMBH OPEN GEAR LUBRICATION 11 . fair and honest consultation when purchasing. Corrections to transmission gears and tooth flanks.

servicing and repair are specialist jobs. smoothing scuffings. Measuring vibration of the pinion bearings... Skilled repair The repair of damaged tooth flanks on open gear drives is an extended service from FUCHS LUBRITECH. an online documentation (FLT-INSPECTOR) is provided (see page 13). Inspections are free of charge The Service Engineers of FUCHS LUBRITECH regularly check drives lubricated with CEPLATTYN free of charge. 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 pinion bearings • Measurement of the temperature profile across the tooth width • Documentation of the condition of the flanks (photographic. In addition. assessment of the contact area and the state of the tooth flanks. 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 Treatment of the working tooth flanks. measurement of the temperature profile across the width of the load-carrying surfaces and documentation of the condition of the tooth flanks (photographic. This is primarily a matter of mechanical treatment of the working tooth flanks. forced running-in and assistance with alignment of the transmission gears. The checks cover the spray system. including trending of the measured values Check of spray pattern. 12 OPEN GEAR LUBRICATION FUCHS LUBRITECH GMBH .SERVICES Inspection.. To complete the job. blue print.) are obligatory.. Dynamic checking of the contact pattern with a stroboscope. blue print. and measurement of the vibrations of the transmission gear bearings.) • Written documentation of the whole inspection. grinding pittings or larger breakages. On heavily worn out or damaged tooth flanks FUCHS LUBRITECH can provide a complete ReProfiling of the entire gear set.

1). Graphic trend analysis enables informative display of temperatures and vibrations over time. Focus on: Instant check via ”traffic light system”. FUCHS LUBRITECH GMBH OPEN GEAR LUBRICATION 13 . combined with the online provision of inspections reports. can be found in the second part (Fig. images and comments (Fig. including reference values relating to the previous inspection. The open gear service. graphical trend analysis Fig. Page 1 of the two-page report contains customer and system data. is a further step towards being able to operate open running drives reliably. 2 With the FLT-INSPECTOR.SERVICES Fig. 1 FLT-INSPECTOR – Online reporting with integrated. 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 Critical measured values are highlighted in red. Measured values for temperatures and vibrations. FUCHS LUBRITECH is making a unique online documentation available that enables the customer to retrieve all relevant information on his system and the lubricants used in at any time.

In order to make the highly viscous lubricants sprayable. designed according to AGMA design. running-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. draglines etc. water-locks. which refers to the base oil viscosity. gypsum and mining industry and power plants. FUCHS LUBRITECH developed the highly viscous CEPLATTYN SF series (solvent and bitumen free) for these applications. For spray. Bitumen is partially still in use to improve the adhesive strength. Product code Kind of machinery Tube mill Rotary kiln Mixing drum. The aim of FUCHS LUBRITECH for the CEPLATTYN SF series was to offer a complete series consisting of primer (CEPLATTYN SF-P). The characteristics of the SF series and those of the KG 10 HMF series are shown in the following table. calcinating and rotary dryers Crusher Bucket-wheel excavator Wire Ropes Forging press Portal crane. Especially for open gears.highly viscous and sprayable FIELDS OF APPLICATION ▼ ■ THE CEPLATTYN SF SERIES was developed to meet the requirements of AGMA 9005 D 94. But because of the different structures of both CEPLATTYN series there are differences in application and practical use. dip and circulating lubrication.FLUIDS A CLEAN SOLUTION Solvent-free adhesive lubricants . depends on base oil viscosity CEPLATTYN KG 10 HMF range dark grey/black Thickener with mineral oil. e. For spray and dip lubrication or manually by brush. windpower plants. synthetic oil with high performance additives Open gears on mills in cement. sugar and mining industry and power plants. hoisting crane Dragline PRODUCT COMPARISON: CEPLATTYN SF range Appearance Composition Application light coloured High viscous. in the construction industry. gypsum. lime. For environmental reasons and operator protection such products nowadays are hardly acceptable. lime.g. most manufacturers make these products with a high proportion of solvents even today. For smaller open running gears. 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 Kind of application Please see selection guide on page 15 14 OPEN GEAR LUBRICATION FUCHS LUBRITECH GMBH . 10 % graphite Open gears on kilns and mills in cement. additives.

1157 CEPLATTYN 100 HV FUCHS LUBRITECH GMBH 1119 CEPLATTYN 300 1129 CEPLATTYN BL 1161 CEPLATTYN ECO 300 1162 CEPLATTYN KG 10 HMF 1153 CEPLATTYN KG 10 HMF-1000 1154 CEPLATTYN KG 10 HMF-2500 1106 CEPLATTYN KG 10 HMF-LT 2467 CEPLATTYN KG 10 LC 1179 CEPLATTYN RN 3310 CEPLATTYN SF 10 3330 CEPLATTYN SF 30 3314 CEPLATTYN SF-P 3316 CEPLATTYN SF-RN 1612 CEPLATTYN 300 SPRAY SELECTION GUIDE OPEN GEAR LUBRICATION 2162 CEPLATTYN ECO 300 SPRAY 15 .

fuchs-lubritech.de 1’ KD 06/10 0601209 Headquarter: .com Phone +49 (0) 6301 3206-0 Fax +49 (0) 6301 3206-940 E-mail info@fuchs-lubritech.Lubrication Technology Regional Contact: FUCHS LUBRITECH GMBH Werner-Heisenberg-Straße 1 67661 Kaiserslautern/Germany www.