En Open Gear GB
En Open Gear GB
The lubricants harmonise so that cleaning after each individual process is not necessary. For the treatment of special tooth ank problems tailor-made products are available on request.
The required quantity BERULIT 443 can be calculated by the following diagram. For a double pinion drive the quantity is to
be multiplied by 1,15.
The gear cover should already be mounted to prevent dust from sticking on the tooth flanks before applying the priming
the auxiliary drive the real contact pattern can be seen as a projection of the priming lubricant on the opposite wheel.
BERULIT 443 must not to be applied in automatic spraying systems!
60
1.000 900
50 800 700 600 30 500 400 20 300 200 10 100 0 1000,0 2000,0 3000,0 4000,0 5000,0 6000,0 7000,0 8000,0 9000,0
40
The duration of the running-in process depends on the type of drive and factors such as mounting, material and production quality. In general, 300 to 500 operating hours are necessary. For drives to be lubricated manually or by immersion special running-in procedures are provided by BECHEM technicians.
Flanks of the Kiln drive after 7 days running-in with BERULIT EL 420
During the running-in process the load has to be increased in stages. Running-in under full load can lead to tension peaks and as a consequence to initial damages. The following stages are appropriate for ball mills:
The change into the next load stage is only recommended if a contact pattern of at least 60 % in stage 1 and 70 % in stage 2 has been achieved. The running-in process should only be nished after the
80 to 110 h at 60 - 70 % lling 100 to 150 h at approx. 80 % lling 150 to 200 h at 90 - 100 % lling
The values stated are intended as a guide. They can vary considerably according to conditions. The condition of the tooth anks and the contact pattern achieved are basis for the decision regarding further proceeding.
surface roughness has been smoothened and a contact pattern of at least 80 % at full nominal load has been achieved. The condition of the tooth anks as well as the contact pattern has to be checked permanently during the runningin process. In case of possible damages or a negative development of contact pattern the manufacturer of the lubricant and the supplier of the drive should be contacted.
Flanks of the drive after finishing the running-in with BERULIT EL 420
The diagram at the bottom of the page helps to determine the minimum quantity with regard to the type of gear drive. Values below the minimum increase the risk of wear and damage and can reduce the life time of the drive. The values have always to be increased for unfavourable operating conditions. Under normal service conditions and undamaged tooth anks the application of BERULIT GA 400 as service lubricant is sufcient from a tribological point of view. Under high service temperatures, extreme loads, unfavourable contact conditions and/or damaged tooth anks we recommend the application of BERULIT GA 800 or
BERULIT GA 2500. These products have a higher base oil viscosity and thus a more stable lubricating lm. On Open Gear drives with increased requirements on the lubricant lm life time due to very long spray intervals, BERULIT GA 800 or BERULIT GA 2500 should also be used. Depending on service conditions and sprayability a reBERULIT GA 2500 is applied. The operation of a gear drive with such small quantities requires, however, permanent checking and regular cleaning of the spraying system.
1,0
B very small single pinion mill drives C medium single pinion kiln drives D medium single pinion mill drives E large single pinion mill drives F double pinion kiln drives G medium double pinion mill drives H large double pinion mill drives
0,8
0,6
0,4
0,2
0 A B C D E F G H
Factor
Spray Systems
The condition and the operation of an installed spray system should be checked prior to the application of BERULIT or BERUGEAR Open Gear Lubricants. The check should include a functional test, nozzle adjustment, spray pattern and applied lubricant quantity. Special attention should be paid to an overlapping of the spray patterns of the singular nozzles. Gaps in between these singular spray patterns may easily lead to initial damages.
Running-out pinion
The spray nozzles should be adjusted in a way that they spray on the anks of the pinion in an angle of 30. The distance between the outlet of the nozzles and the tooth ank surface should be approximately 200 mm. A clean spray system is prerequisite to prevent spray problems caused by ingressed foreign particles. Special care has to be taken when changing the lubricant drum or relling the container. Transfer pumps in combination with an additional lubricant lter reduce the danger of contaminated lubricant in the spray system signicantly. The lubricant lter of the spray system needs to be cleaned regularly. Especially with lubricants of very high viscosity there is a tendency for some components to settle down in
the lter. When using lubricants with high base oil viscosity we recommend cleaning the lubricant lter every 3 weeks at least. For drives equipped with a spray system a permanent dredging of the tooth anks in the used lubricant in the impurities. Therefore the used product needs to be removed regularly from the gear guard. The BERULIT and BERUGEAR Open Gear lubricants are well sprayable in all common spray systems taking the application temperature into consideration. Respective spray test results are available. sump should be prevented. It may contain abrasive foreign
Since not product performance only but also service quality decide about life time of the machinery the service component is highly rated by the equipment manufacturers. The excellent service, provided by BECHEM, convinced leading equipment manufacturers to recommend BECHEM open gear lubricants.
The service operations are planned and prepared in our Service Centres around the world. The coordination is managed in our headquarters in Hagen. There also the central reporting system and the training of the service staff are organised.
BECHEM offers a complete service package for open gear drives to all customers. Based on agreements this package can include:
a lubrication management with selection of the most suitable (technical and economical) product and optimisation of consump-
across the anks and a vibration measurement at the pinion bearings, the assessment of contact pattern, gear ank condition and possible damages as well as a complete check of the lubricant application system
a detailed written report with appropriate documentation
requirement
repair services such as grinding of pitting marks and
plant staff
Discussion of the drive condition of a Ball Mill in a cement plant
The package with exception of repair services is provided free of charge to customers using BECHEM open gear lubricants over a longer period of time at their drives.
Inspection of the contact pattern of a Bucket Wheel Excavator slewing gear
ThatSpecial!
A tradition we are proud of since 1834. This is still today demonstrated by our trademark: the Rhus Flower. After permanent development, BECHEM is today a Global Player. BECHEM special lubricants, industrial lubricants, metal working fluids and solutions for forming technology are based on our extensive experience in the development of special chemistry and on the latest tribologic knowledge. Our know-how with regard to friction, wear and lubrication always takes account of our customers requirements for economical and ecological optimisation. We feel obliged to tradition and progress. ThatSpecial! Besides the headquarter in Hagen, BECHEM has two other production sites in Germany in Mieste and Kierspe. In addition to that, our worldwide distribution network allows us to develop markets all over the world. With daughter companies in France, India and Switzerland, as well as Joint Ventures in the USA, South Africa, Sweden and China, BECHEM shows its international presence. It is our target to supply our customers with high-quality products and to simultaneously meet the corresponding international standards. The quality of our products is guaranteed by our quality management system in accordance with the automotive standard ISO/TS 16949. All our production sites are systematically controlled by internal audits and regular external inspections by the certification association TV NORD CERT GmbH. Audits which are regularly carried out by our customers confirm the compliance with our high quality requirements. Further information material is available either direct from us or at www.bechem.com
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CARL BECHEM GMBH, Weststrae 120, 58089 Hagen, Germany Phone +49 2331 935-0, Fax +49 2331 935-1199, E-Mail: [email protected], www.bechem.com
7902809015/0211/165815
Special lubricants
Industrial lubricants
Metal working
Forming technology