OPEN GEARS

LUBRICATION + MAINTENANCE + SERVICE

 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 ■ WITH REFERENCE TO THE PHOTOS: We thank all our
information in this brochure corresponds with the status of customers for the photos they put at our disposal, as well
our momentary development and knowledge. Subject to as all the other companies who supported us with photo-
alteration. graphic material.

2 OPEN GEAR LUBRICATION FUCHS 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.

FUCHS LUBRITECH GMBH OPEN GEAR LUBRICATION 3

 INTRODUCTION

WHERE MIGHTY IN DETAIL: GUIDE VALUES FOR

ADJUSTMENT AND ASSEMBLY
The commission engineer of open gear

FORCES RULE drives is faced with toughest requirements

when aligning or correcting the drive.
Careful alignment of the girth gear and of
the transmission gear is of critical impor-
tance for the life of the drive. This is why it
is usual for assembly companies to prepare
records of measurements of the radial and
axial run-outs, of the backlash, the root
clearance and of the free play.

Note: When a gear set must be turned

because of wear, it is no longer possible to
align the gears by means of the backlash.

Krupp Polysius AG
The drive must be set up by means of the
Open gear drives do the heaviest
root clearance. A suitable guide value for
work in many branches of industry. the tooth tip play is 0.25 to 0.3 times the
module.

■ OPEN GEAR DRIVES are most often primary cause of damage to gear
used in the raw materials industry. The wheels is not exclusively the problem

Axial distance [mm]

girth gear drives that are used in tube of faulty adjustment of the drives and
4500
mills, coolers, washing drums, kilns and radial and axial run-out, but also the
calciners have to transmit enormous use of unsuitable lubricants, shortage 4000
torque – up to 50,000 Nm is by no of lubricant and incorrect application. 3500
Mills
means rare. It is only natural that such Therefore an optimum load carrying 3000
force subjects the gear wheels to very capacity and smoothing of the gear
2500
high stresses. These gears are usually teeth are to be achieved, the most pre-
designed as spur or helical gears and cise alignment of the gears coupled 2000
Kilns
with modified involute profiles. The ma- with the correct running-in procedures 1500
terials that are utilized for the gearing is essential. For the lubrication of open 1000
are usually CrNiMo tempered steel (pin- gears adhesive sprayable lubricants are
500
ion) and alloyed CrMo steel casting most suitable. LUBRITECH MULTI-
(girth gear). PHASE-LUBRICATION (M-P-L) with the
1.80
2.00
2.20
2.40
2.60
2.80

3.00
range of CEPLATTYN adhesive lubricants
The lubricant plays an is widely accepted as one of the mar- Backlash [mm]
important role ket leaders in this area.
Pitch circle Ø [mm]

The purpose of all constructional The best solution has a name –

9000
and tribotechnical measures is to en- CEPLATTYN
8000
sure, in spite of the enormous stresses, Axial run-out
long-term, trouble-free operation. The Wherever lubrication is to be car- 7000
ried out on highly stressed or pre-dam- 6000
aged gear drives, FUCHS LUBRITECH can
5000
offer the right lubricant from the
CEPLATTYN product range. Whether un- 4000
Radial run-out
der arctic conditions, or in high tem- 3000
perature surroundings. CEPLATTYN
2000
products, moreover, contain no heavy
1000
metals, chlorine or solvents, and there-
fore do very little harm to the environ-
Heidelberger Zement AG

0.25

0.50

0.75

1.00

1.25

ment. As a result of more than 50 years

experience, CEPLATTYN adhesive lubri- Tolerance value [mm]
cants are recommended by the leading
manufacturers of gears and machines.

4 OPEN GEAR LUBRICATION FUCHS LUBRITECH GMBH


THE MULTI-PHASE-LUBRICATION
A cleverly devised system for optimum lubrication and long lifetime.
■ 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
FUCHS LUBRITECH GMBH
MULTI-PHASE-LUBRICATION
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. Checking the contact pattern when assem-
bling with CEPLATTYN 300/CEPLATTYN SF-P.
The operator can,
however, have a
significant influ- IN PRINCIPLE: FOUR COMPONENTS
ence on these types FOR A LONG LIFETIME
of damages, and Priming lubricant:
thus on the lifetime of • Initial lubrication
• Manual application
the drive, through selec-
tion of the correct lubricant. Running-in lubricant:
• Smoothes the surface
Note: LUBRITECH M-P-L can only • Automatic spray system
be applied in a restricted way to drives Operating lubricant:
that are not lubricated by an automat- • Lubrication at intervals
ic spray system. FUCHS LUBRITECH Ser- • Automatic spray system
vice Engineers will be pleased to advise
Special lubricant:
you about running in of gears whose • Service lubricant
operating lubrication is subsequently • Only carried out by FUCHS LUBRITECH staff
performed manually, by dipping or cir-
* the selection guide on page 15 of this brochure gives
culation lubrication. an inital overview
OPEN GEAR LUBRICATION 5
 MULTI-PHASE-LUBRICATION

There are many causes of damage to

tooth flanks – nearly all can be avoided

Gears, in a wide variety of design, consideration. Nor does it matter

provide movement throughout indus- whether it is a fast-running vehicle gear-
try. When a gear wheel suddenly stops, ing or a slow running open gear drive:
the causes can be highly varied in na- whenever teeth mesh together, the ap-
ture. Looked at it statistically, damaged propriate lubricant is one of the most
tooth flanks are the reason for about important factors for trouble-free op-
60 percent of gear drive defects. The eration. Scuffings and abrasive wear,
chart on the next page gives a general for example, depend to a large extent
indication of the kind of problems that on the lubricant. Poor quality lubricant
can be experienced. also has a direct effect on the occur-
rence of fretting corrosion, scoring and
The correct lubricant eliminates scuffings. The consequences of a short-
many sources of damage age of lubricant usually include in-
creased wear or deformations such as
It doesn’t matter whether a light the development of rippling, hot or cold Pitting is fatigue damage resulting from over-
loading. CEPLATTYN operational lubricants can
oil or an adhesive lubricant is under flow. prevent the damage from spreading.

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

Tooth
Wear Pittings Cracks Deformations Corrosion Other types of damage
breakage
Overload breakage

chemical corrosion
Initial/destructive/
Interference wear

fretting corrosion
fatigue breakage

hardness cracks
Grinding cracks

material cracks
Abrasive wear

fatigue pitting

fatigue cracks
Normal wear

indentations

overheating
oxidisation
cavitation
Scratches

cold flow
scuffings

hot flow
spalling

rippling
Scoring

erosion
flaking

slag inclusions • • • •
Material faults

forging folds • •
non-metallic inclusions •
unsuitable material pairing • •
inadequate dimensions • • • • •
Constructional

incorrect tooth geometry • •

faults

meshing faults •
incorrect tooth play • •
Forging faults •
Manufacturing

Overheating during processing • •

faults

Inappropriate heat treatment • • • • •

poor surface quality • • •
Assembly

Alignment errors • • • • • •
faults

Fixing of pinion • • • •
Frequent load changes • •
• • • • • • • • •
Operational conditions

overload
impact/vibration stress
incorrect running-in
Speeds too low/high
Dust ingress
Dynamic changes
Shortage of lubricant
Lubrication faults
• • • • • • • •
• •
• • • •
• • • • • • •
• • • • • •
• • • • • • •

Wrong consistency • • • • • •
inadequate quality • • • • • •
Soiling with solids/liquids • • • • • • •
incorrect application • • •

6 OPEN GEAR LUBRICATION FUCHS LUBRITECH GMBH

 PRIMING

Fuchs Lubritech (Australia) Pty. Ltd.

PRIMING
Initial lubrication with CEPLATTYN 300/CEPLATTYN SF-P provides pro- primed with CEPLATTYN 300/CEPLATTYN
tection on the first occasion at the teeth mesh and prevents corrosion. SF-P using a stiff-bristled brush or
spatula. The application includes the
■ PRIMING THE TOOTH FLANKS is nec- Note: CEPLATTYN 300/CEPLATTYN working flanks, tooth roots and tips in
essary to provide initial lubrication dur- SF-P can not be applied with automat- order to avoid corrosion and damage
ing the first revolution of the gears dur- ic spray systems. from any movement involved during
ing the course of assembly. The surface assembly. After priming, turning the
finish of the gear teeth makes it essen- Priming and checking the contact gears with the auxiliary drive will result
tial to prime to prevent damage during pattern in the actual contact pattern being pro-
initial operation. In the context of jected onto the working tooth flanks.
LUBRITECH MULTI-PHASE-LUBRICATION It is necessary to fully clean the Any areas devoid of lubricant must be
(M-P-L) the priming or initial lubrica- tooth flanks before applying lubricant primed again. The projection allows any
tion takes place with CEPLATTYN 300/ for the first time. The whole tooth flank correction to the transmission gear to
CEPLATTYN SF-P immediately after as- area should be thoroughly cleaned to be made more easily.
sembly of the drive. bare metal. The tooth flanks are then

IN PRINCIPLE: FOUR COMPONENTS FOR A LONG LIFE

Contact pattern at the perimeter of the girth Contact pattern with opposing obliquity of
gear when the pinion wobbles. → Check the two halves of the girth gear. → Check the
seating of pinion. impact point bolting.

Contact pattern for wobble impact of the Contact pattern when one half of the girth
girth gear. → Check alignment and fixing of gear is oblique. → Check assembly.
The film of lubricant must be applied evenly the girth gear.
and without air-bubbles.
Radial run-out of the gearwheel. The contact
Contact pattern from edge loading. Axles not pattern appears weaker or stronger over half
QUANTITY CEPLATTYN 300/CEPLATTYN SF-P
sufficiently parallel. → Realign pinion. the perimeter of the girth gear. → Readjust.
9000

50 8000
7000
40 Circulating pressure point, resulting from Contact pattern when the girth gear has pro-
Quantity [kg]

6000
m x n [mm]

30 5000
manufacturing fault or isolated thermal tuberances on both sides, resulting from
4000 deformation (protuberances). excessive frictional heating of the jacket seals
20 3000 (often found in oil-lubricated drives). →
2000
10 Improve lubrication of seals. Check assembly
1000
Contact pattern from pinion expanded on of seals.
0 100 200 300 400 500 600 700 800 900 both sides, resulting from incorrectly assem-
Face width [mm] n = total number of teeth bled ring tensioning elements.
m = modulus

FUCHS LUBRITECH GMBH OPEN GEAR LUBRICATION 7

 RUNNING-IN

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

■ 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 higher
gearing 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. The state of the tooth flanks
Depending on the running time, a should be checked throughout the run-
charging illustrated in the following ning-in process. This applies particular-
table have been found effective. ly to the change of grinding charge. This
should only be undertaken when the
Min. contact load-carrying proportion given in the
Grinding Running area to be
charge time achieved table has been reached. If the contact
pattern is considerably worse, read-
1. abt. 50-60 % abt. 70 h 50-60 %
2. abt. 70-80 % abt. 120 h 70 % justment of the transmission gear is re-
3. abt. 90-100 % abt. 160 h 80 % quired. Running-in can be considered
abt. 350 h complete when, with maximum charge
or throughput, a load-carrying propor-
Note: Other values may vary in tion of at least 80 percent is achieved,
practice. The process must be adapted and the manufacturing roughness of
to the particular operating conditions. loaded teeth surface has been
smoothed down.

IN PRINCIPLE: SURFACE ROUGHNESS PROFILES OF TOOTH FLANKS QUANTITY CEPLATTYN RN/CEPLATTYN SF-RN

30
400
Quantity [kg/350h]

25
Quantity [kg/24h]

300 20

15
200
Load-carrying pattern Load-carrying pattern
10
before running-in about 50 % after running-in about 80 % 100
5

100 200 300 400 500 600 700 800 900

0.8 mm

Before running-in with Face width [mm]

CEPLATTYN RN/CEPLATTYN SF-RN
■ 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
0.8 mm

After running-in with

CEPLATTYN RN/CEPLATTYN SF-RN ■ Kiln single pinion drive 0,6 g/h·mm

8 OPEN GEAR LUBRICATION FUCHS LUBRITECH GMBH


Forced running-in
with Reconditioner
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.
FUCHS LUBRITECH GMBH
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, double pinion cement mill. At the
running-out pinion the vibration levels were well below 2 mm/s, but were above 8 mm/s at the
running-in pinion. The operator could not accept this large difference. Even several corrections to
the transmission gear brought no improvement. The manufacturer of the machinery therefore ini-
[mm/s] tiated forced running-in.
The application of recondi-
Inward tioner for nine hours result-
running ed in a carefully controlled
pinion
redistribution of the load:
the vibrations at both bear-
Outward
ings were at the end below
running 2mm/s, so that on the
pinion
whole the operation was
Time [h] very smooth.
Extract from permanent vibration monitoring at the factory.
Note: The aggressive material re- caused by overloading, since the load-
moval resulting from the use of Recon- carrying proportion did not reach over
ditioner calls for specialised technical the full height of the teeth. After using
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.
Reconditioner for eight hours, the con-
tact pattern finally reached over the full
tooth height (right picture) and the
Example 1: Axial run-out devia- damaged areas on the working tooth
tions caused the contact pattern of a flanks had been removed.
cement mill drive to be only 40 percent
in some areas. Since it was not possible INSPECTING THE SPRAY SYSTEM
to achieve an improvement in the con- The following points should be observed
tact pattern through alignment means, before commencing operation of the
the drive had to be run in using recon- machinery:
• Functional test Horizontal
ditioner in a forced run-in. The load overlap
• Spray pattern
peaks that can clearly be seen in the red • Spray angle
framed part of the working tooth flanks • Nozzle distance
• Lubricant quantity (see diagrams
on page 8-10)
The increased throughput of run-in
Vertical
lubricant is necessary in order to overlap
flush any metallic particles caused by
(left picture) are no longer present af- removing the peaks of the rough surface.
The lubricant consumed must be allowed
ter reconditioning (right picture). The
to flow without restriction out of the
pitch line reaches over the full width of gear guard. Dredging in the lubricant
the tooth (visible in the picture as a sump must be avoided. Overlap
with wide jet
white line on the working tooth flank). nozzles
30°
- 200 mm
150 30°
Example 2: After the pinion was
00 mm
changed on the drive of a tube mill, the
150 - 2
unfavourable combination of old girth
gear and new pinion resulted in dam-
age to the pinion after two months of Inward running pinion Outward running pinion
running (left picture). The damage was
OPEN GEAR LUBRICATION 9
 OPERATIONAL LUBRICATION

Heidelberger Zement AG
OPERATIONAL LUBRICATION

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

specific consumption [g/h·mm]

0.8
■ ONCE PRIMING and running-in have sistant to water, and are approved by
0.6
been successfully completed, the next all leading gear and machine manu-
point to be considered is the opera- facturers. 0.4

tional lubrication. Making the right se- 0.2

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-
Changeover to operating
lubrication 0 24 48 72 96
time [h]
Quantity reduction for a single pinion drive.
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 Central lubricant supply with CEPLATTYN KG 10 HMF.
found from the diagram below.
Note: The minimum quantity that
QUANTITY CEPLATTYN KG 10 HMF
can be aimed at depends directly on the
10
operating conditions. Lubrication rates 0.4
Quantity [kg/24h]
Quantity [kg/h]

·mm 8
tached to the lubrication system has to below the minimum creates an in- 0.3 -0.4
g/h
. 0.2
be changed. CEPLATTYN lubricants are creased risk of wear and damage to the s min 6
ive
l Dr
0.2 Mil
adhesive lubricants without heavy met- flanks. This can drastically reduce rated /h·mm
4
-0.2 g
in. 0.1
0.1 ves m
als, solvents or chlorine. They can sup- life. Kiln Dri 2

port extremely high pressure, are re-

100 200 300 400 500 600 700 800 900
Face width [mm]

10 OPEN GEAR LUBRICATION FUCHS LUBRITECH GMBH


WORLD-
WIDE
SERVICE
An outstanding product, fair and
honest consultation when pur-
chasing, and comprehensive tech-
nical service afterwards – that is
how FUCHS LUBRITECH defines
service.
Contactless temperature measurement
with an IR thermometer.
FUCHS LUBRITECH GMBH
■ 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
SERVICES
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
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.
OPEN GEAR LUBRICATION 11
 SERVICES
Inspection,
servicing and
repair are
specialist jobs.
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-
Measuring vibration of
the pinion bearings.
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.
Dynamic check-
ing of the con-
tact pattern
with a strobo-
scope.
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 the
measured values
Check of spray pattern.
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.
FUCHS LUBRITECH GMBH

FLT-INSPECTOR – Online reporting with
integrated, graphical trend analysis
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
FUCHS LUBRITECH GMBH
Fig. 1
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).
Graphic trend analysis en-
ables informative display
of temperatures and vi-
brations over time.
Critical measured values
are highlighted in red.
SERVICES
Fig. 2
Focus on: Instant check via ”traf-
fic light system”.
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
OPEN GEAR LUBRICATION 13
 FLUIDS

FIELDS OF APPLICATION
A CLEAN SOLUTION ▼
Solvent-free adhesive lubricants - highly viscous and sprayable

■ 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
PRODUCT COMPARISON:
CEPLATTYN SF range
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- Product code
ning-in lubricant (CEPLATTYN SF-RN) Kind of machinery
and operational lubricants (CEPLATTYN Tube mill
SF 10 and SF 30) which are suitable for
Rotary kiln
both AGMA and for DIN ISO-drives. But
because of the different structures of Mixing drum, calcinating and rotary dryers
both CEPLATTYN series there are dif- Crusher
ferences in application and practical use.
Bucket-wheel excavator
The characteristics of the SF series and
Wire Ropes
those of the KG 10 HMF series are
shown in the following table. Forging press
Portal crane, hoisting crane
Dragline
Slewing ring
CEPLATTYN KG 10 HMF range Racks

Appearance light coloured dark grey/black Kind of application

Composition High viscous, synthetic oil with
high performance additives
Application Open gears on mills in cement,
lime, gypsum, sugar and mining
industry and power plants.
Especially for open gears, designed
according to AGMA design.
Kind of application For spray, dip and circulating
lubrication, depends on base oil
viscosity
Please see selection guide on page 15
Thickener with mineral oil, Primary lubrication
additives, 10 % graphite
Running-in lubrication
Open gears on kilns and mills in
In-service lubrication
cement, lime, gypsum and mining
industry and power plants. For Low-consumption lubrication
smaller open running gears, e.g. in
the construction industry, windpow- Loading charge
er plants, water-locks, draglines etc.
Normal
For spray and dip lubrication
High
or manually by brush.
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 OPEN GEAR LUBRICATION FUCHS LUBRITECH GMBH

 1157 CEPLATTYN 100 HV

1119 CEPLATTYN 300

FUCHS LUBRITECH GMBH

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

2162 CEPLATTYN ECO 300 SPRAY

OPEN GEAR LUBRICATION

SELECTION GUIDE

15
Lubrication Technology

Regional Contact:

Headquarter:
1’ KD 06/10 0601209

FUCHS LUBRITECH GMBH

Werner-Heisenberg-Straße 1 Phone +49 (0) 6301 3206-0
67661 Kaiserslautern/Germany Fax +49 (0) 6301 3206-940
www.fuchs-lubritech.com E-mail info@fuchs-lubritech.de