Lubrication, Maintenance, Service

for Open Gears

2

LUBRICANTS.
TECHNOLOGY.
PEOPLE.

FUCHS LUBRITECH –
Special Application Lubricants

Within the FUCHS Group, we at FUCHS LUBRITECH are the experts for highly specialised applications.
We develop, produce and distribute the world’s leading branded products of our own. Our employees
are committed to solving your challenges. We are there, with you and for you.
 CEPLATTYN High performance lubricants 3

Facts and figures

Company: FUCHS LUBRITECH GmbH, part of the FUCHS
Group, based in Kaiserslautern, Germany
LUBRITECH: the Special Application Lubricants Division of the
FUCHS Group
Product range: LUBRITECH GROUP offers a full range of more
than 1,000 special products, including food grade lubricants,
adhesive lubricants, lubricating fluids and greases, pastes, solid
film lubricants, concrete release agents, aerosols and metal-
forming lubricants
Certifications: ISO 9001: 2008, ISO 21469, Halal, Kosher

FUCHS has developed, produced, and sold lubricants and

related specialties for more than 80 years – for virtually all
applications and sectors. With over 100,000 customers
and 50 companies worldwide, the FUCHS Group is the
world’s leading independent lubricant supplier.

Within the FUCHS Group, FUCHS LUBRITECH is the

expert for Special Application Lubricants. A team of
more than 500 specialists around the world work to meet
your needs. However demanding the application, we
offer a specialised solution. Service is a crucial and
fundamental component of our offering. Our experts
offer on-site technical consultation to assure
performance, efficiency and process reliability.

FUCHS LUBRITECH special lubricants stand for the highest

performance and sustainability, safety and reliability as
well as efficiency and cost savings. They represent a
promise: technology that pays back.
4

HIGH-PERFORMANCE LUBRICANTS FOR

THE MOST DEMANDING APPLICATIONS

Expertise in Open Gear lubricants

With increasing size, the demands on the lubrication of Open Gears also increase. Wherever high
transmission of forces at low sliding speeds is required, we do everything we can to reduce the wear on
your technology to a minimum, thus maximising the reliability and safety of your equipment. Together
with gear and machinery manufacturers, we develop innovative adhesive lubricants for Open Gears in
kilns and mills. We always strive for the most application-specific solutions – and thus achieve running
times of 40 years and more.
CEPLATTYN High performance lubricants 5
 6

FUCHS LUBRITECH in motion – your realiable partner

in Open Gear lubrication

Large Open Gear drives constitute a mechanical method of transmitting move­

ment and force. The level of success ultimately achieved does not only depend
on the gear design and materials used but also on the lubricant quality, volume
of lubricant and the means of application. This is particularly true for large,
low-speed Open Gear drives where high torques are transmitted.

Demands grow with size Open Gear drives do the heaviest

The tolerances involved in the work in many branches of industry
manufacture and assembly of girth Open Gear drives are very common in
gear drives increase in proportion to the raw materials industry. The girth
the size of the gear train. Distortions gear drives that are used in tube mills,
developing under the influence of coolers, washing drums, kilns, calciners
load and tempera­ture also increase and other machines have to transmit
with size. It is not uncommon to see enormous torques‚ i.e. often up to
large gears with a diameter of 14 50,000 Nm. It is only natural that this
metres. Transmission ratios typically kind of force subjects the gear wheels
range between 1:8 and 1:12. Under to very high stresses. Such gears are
these conditions effective lubrication usually designed as spur or helical
is often only possible with difficulty gears with modified involute profiles.
because of the slow sliding speed of The materials used for the gearing
the working tooth flanks. A special, are usually CrNiMo tempered steel
correctly applied adhesive lubricant (pinion) and alloyed CrMo steel
will reliably prevent metal-to-metal casting or cast iron (girth gear).
contact of the tooth flanks. Lubricants
with a high proportion of solids and
with superior additives ensure safe
running properties in the area of
boundary friction. As a result a service
life exceeding 20 years can be
expected.
 CEPLATTYN High performance lubricants 7

Open Gears – where the mighty forces rule lubricants

play a crucial role

Open Gears transmit extreme forces. Their service life is subject to several
factors, one of them being the lubricants used. FUCHS LUBRITECH offers
the ideal lubricant range for this heavy-duty application. Our Multi-Phase-
Lubrication is the key to the efficiency and long life of your Open Gear.

The lubricant plays an important role The best solution has a name: CEPLATTYN
The purpose of all design and tribotechnical efforts is to Wherever lubrication is required on highly stressed or
ensure, in spite of the enormous stresses, long-term, pre-damaged gear drives, under arctic conditions or in high-
trouble-free operation. The primary cause of damaged temperature environments, FUCHS LUBRITECH offers the
gear wheels is not exclusively the problem of faulty right lubricant from the CEPLATTYN product range.
adjustment of the drives and radial and axial run-out, but CEPLATTYN adhesive lubricants are recommended by all
also the use of unsuitable lubricants, shortage of lubricant leading manufacturers of gears and machines.
and its incorrect application. Therefore an optimum load-
carrying capacity and smoothed gear teeth are to be Lubrication with the FUCHS LUBRITECH CEPLATTYN range
achieved. An extremely precise alignment of the gears of products fully meets the tough tribotechnical require­
combined with the correct running-in procedures is ments. The CEPLATTYN range was developed in the early
essential. For the lubrication of Open Gears adhesive 60s as the first sprayable non-asphaltic adhesive lubricants.
sprayable lubricants are most suitable. The brand name is a synonym for high-quality and reliable
adhesive lubricants.

The CEPLATTYN range includes more than 20 different

products and is approved by all major gear and machine
manufacturers in the raw materials industry.
8

MULTI-PHASE-LUBRICATION

Three lubrication steps to ensure a long

service life for the Open Gear

LUBRITECH MULTI-PHASE-LUBRICATION (M-P-L) is a sophisticated system for optimum lubrication and a

long lifetime. Once the drive is precisely aligned, the selection of the correct lubricant is the next step in
achieving a long service life.
 CEPLATTYN High performance lubricants 9

The most reliable method The best possible protection against wear
LUBRITECH MULTI-PHASE-LUBRICATION (M-P-L) is the most Optimum load transmission implies that the stress is evenly
reliable method of averting serious mistakes. The use of distributed across the full width and height of the teeth.
M-P-L is essential with new gears but it is also helpful after However, for Open Gear drives in particular, even state-of-
a repair of damaged gear tooth flanks or at any time the-art manufacturing techniques and the most precise
when the pinion or girth gear is changed. LUBRITECH alignment possible hardly permit this optimum state to be
M-P-L consists primarily of three components: priming, achieved. The consequences of inadequate load distribution
running-in and operating lubricants. These special M-P-L are excessive heating, scuffings, pitting and, in the worst
lubricants are the result of many years of research, and case, even tooth breakage. The operator can, however,
have proved themselves in practical applications have a significant influence on such damage type, and
all over the world. thus on the lifetime of the drive, by selecting the right
lubricant.

Priming
Priming lubricants prevent damage during initial operation
and are manually applied to the clean teeth of a new or
repaired gear. After the first rotations using an auxiliary
drive the gear will display the actual contact pattern. Any
corrections needed will be shown and can be implemented.

M-P-L
Running-in
Running-in is effected by our RN range of CEPLATTYN.
Working tooth flanks are smoothed in this process, which
is considered successful as soon as a load-carrying
proportion of at least 80% has been achieved.

Operational lubrication
Operational lubrication starts at the end of the running-in
process. It is not only subject to the condition and use of
the drive but also to environmental influences.

Reference table: the right lubricant for each lubrication step

M-P-L Lubricants
LUBRITECH M-P-L can only be applied to a limited extent
to drives that are not lubricated by an automatic spray
Priming CEPLATTYN 300 Initial lubrications system. FUCHS LUBRITECH Service Engineers will be
lubricants CEPLATTYN GT P Manual applications pleased to advise you on the running-in of gears, the
CEPLATTYN SF P operating lubrication of which is subsequently performed
Running-in CEPLATTYN RN Surface smoothing manually by dipping or circulation lubrication.
lubricants CEPLATTYN GT RN Automatic spray
CEPLATTYN SF RN systems
The best solution has a name: CEPLATTYN
Operational CEPLATTYN KG 10 HMF range Regular lubrication
lubricants CEPLATTYN GT range Automatic spray
CEPLATTYN SF range systems

On page 29 of this brochure you will find the complete product selection guide, which
shows the available lubricants for the different fields of applications.
 10

Priming

Priming is the first process step of Multi-Phase-Lubrication. Priming the

tooth flanks is necessary to provide initial lubrication during the first
revolution of the gears, in the course of assembly.

Priming lubricants prevent damage Priming and checking the contact pattern
Due to the surface finish of the gear teeth, priming is It is necessary to fully clean the tooth flanks before
crucial to prevent damage during initial operation. In the applying a lubricant for the first time. The whole tooth
context of FUCHS LUBRITECH Multi-Phase-Lubrication flank area should be thoroughly cleaned up to the bare
(M-P-L) priming or initial lubrication is effected with metal. The tooth flanks are then primed with CEPLATTYN
CEPLATTYN 300 / CEPLATTYN GT P / CEPLATTYN SF P 300 / CEPLATTYN GT P / CEPLATTYN SF P using a stiff-bristled
immediately after the assembly of the drive. brush or a spatula. Its application includes the working
flanks, tooth roots, back flanks and tips in order to avoid
corrosion and damage due to any movement during
assembly. After priming, turning the gears with the
auxiliary drive will result in the actual contact pattern
being projected onto the working tooth flanks. Any areas
devoid of lubricant must be primed again. The projection
facilitates any correction of the transmission gear that may
be required.

CEPLATTYN 300 / CEPLATTYN GT P / CEPLATTYN SF P

cannot be applied with automatic spray systems.

A layer of lubricant must be applied evenly and without air bubbles.

Quantity of CEPLATTYN 300 / CEPLATTYN GT P / CEPLATTYN SF P

60 9,000
8,000
50 7,000
6,000
40
5,000
4,000
30
3,000
2,000
20
Quantity [kg]

1,000
m x n [mm]

10
n = total number of teeth
m = module
0
100 200 300 400 500 600 700 800 900

Tooth width [mm]

 CEPLATTYN High performance lubricants 11

Various contact patterns and their causes

360° picture girth gear girth gear pinion

Contact pattern at the perimeter of the girth gear

when the pinion wobbles.   Check seating of pinion.

Contact pattern for wobble impact of the girth gear.

 
Check alignment and fixing of the girth gear.

Contact pattern due to edge loading. Axles not

sufficiently parallel.  
Realign pinion.

Circulating pressure point, resulting from manufacturing

fault or isolated thermal deformation (protuberances).

Contact pattern from pinion expanded on both

sides, resulting from incorrectly assembled ring
tensioning elements.

Contact pattern with opposing obliquity of the two halves

of the girth gear.  
Check the impact point bolting.

Contact pattern when one half of the gear is oblique.

 
Check assembly.

Radial run-out of the gear wheel. The contact pattern

appears weaker or stronger over half the perimeter of the
girth gear.  
Readjust.

Contact pattern when the girth gear has protuberances on

both sides, resulting from excessive frictional heating of
the jacket seals (often found in oil-lubricated drives).
 
Improve lubrication of seals. Check assembly of seals.
 12

Running-in
Running-in is the second process step of Multi-Phase-Lubrication or after Re-Con­
ditioning. The following case study offers a detailed overview of this process step.

Case study:
Better load-carrying pattern after Re-Conditioning in shape and assembly and significantly increasing the
Even after the drive has been correctly aligned, the initial contact area. The result: significantly enhanced gearing
load-carrying proportion often remains below 50–60 %. quality that provides the basis for a long service life.
The reason for this is the surface roughness arising in the
course of manufacture on the one hand and deviations of The running-in procedure
the flanks due to their shape and due to assembly on the The time required for running-in can only be assessed
other hand. This means that there is a very high risk that individually and is subject to the hardness of materials,
drives can be damaged at this early stage of initial manufacturing tolerances and the way in which a gear has
operation as a result of local overload. Such damage can been assembled. On average, the time required to effi­
be slight local scuffing or cracks that propa­gate in the ciently run in drives on ball mills and kilns in single load
form of pitting caused by fatigue damage during steps is 350 hours, during which the lubricant should be
subsequent operation. continuously applied to the extent possible.

Axial run-out deviations caused the contact pattern of a Values may vary in practical applications. The process must
cement mill drive to be only 40% in some areas. Since it be adapted to the given operating conditions. The state of
was not possible to achieve an improved contact pattern the tooth flanks should be checked throughout the
through alignment, the drive had to be submitted to a running-in process. This particularly applies to the change
forced running-in using RE-CONDITIONER. The load peaks of grinding charge, which should only be undertaken
that are obvious in the part marked red of the working when the load-carrying proportion given in the table has
tooth flanks (left-hand picture) were elimina­ted by Re- been reached. If the contact pattern is considerably worse,
Conditioning (right-hand picture). The pitch line covers the readjustment of the transmission gear will be required.
full width of the tooth (visible in the picture as a white Running-in can be considered complete as soon as, at
line on the working tooth flank). maximum charge or throughput, a load-carrying pro­
portion of at least 80 % has been achieved, and the
CEPLATTYN RN/CEPLATTYN GT RN/CEPLATTYN SF RN manufacturing roughness of the loaded teeth surface has
removes the manufacturing roughness and it smoothes been smoothed.
the working tooth flanks.
In cases where normal running-in does not result in a
The economical way to a higher gearing quality sufficient contact pattern or the drive has to be run in at
Controlled running-in with CEPLATTYN RN/CEPLATTYN GT full load, a forced running-in (the quick running-in method)
RN/CEPLATTYN SF RN running-in lubricants prevents represents the best solution. This forced running-in
damage in the course of initial operation. CEPLATTYN RN/ procedure is also suitable for achieving an optimum
CEPLATTYN GT RN/CEPLATTYN SF RN eliminates manu­ carrying capacity and surface finish if the load-carrying
facturing roughness and smoothes the load-carrying surfaces show scuffings, or under unfavourable circum­
surfaces of tooth flanks, thus overcoming slight deviations stances if old and new gears have been combined.

Before running-in Even load contact

Due to assembly and misalignments load peaks often occur when starting a new drive. After a selective running-in using CEPLATTYN RN/ CEPLATTYN GT RN/CEPLATTYN SF RN these
load peaks are eliminated and a good contact pattern across the flank width is achieved.
 CEPLATTYN High performance lubricants 13

Surface roughness profiles of tooth flanks

Load-carrying pattern before running-in approx. 50% Load-carrying pattern after running-in approx. 85%
0.8 mm

0.8 mm
Before running-in with After running-in with
CEPLATTYN RN CEPLATTYN RN
CEPLATTYN GT RN CEPLATTYN GT RN
CEPLATTYN SF RN CEPLATTYN SF RN

Quantity of CEPLATTYN RN / CEPLATTYN GT RN / CEPLATTYN SF RN

500

400 28

300 21
Quantity [kg/350h]

Quantity [kg/24h]

200 14

100 7

0
100 200 300 400 500 600 700 800 900

Tooth width [mm]

Mill double-pinion drive: 1.2 g/h • mm Kiln double-pinion drive: 0.9 g/h • mm
Mill single-pinion drive: 0.8 g/h • mm Kiln single-pinion drive: 0.6 g/h • mm
 14

Operational lubrication

Operational lubrication is the third process step of Mulit-Phase-Lubrication. The

selection of the right lubricant in the process step plays an important role in the
overall lifetime of the gear set.

Central lubricant supply with CEPLATTYN Changeover to operational lubrication

Once priming and running-in have been successfully In practice the changeover is achieved through a gradual
comple­ted, the next point to be considered is operational quantity reduction to a targeted minimum (see graph on
lubrication. Making the right selection here is very important the right). It is necessary to measure the quantity every
in terms of low wear, operation without damage, and time this value is reduced by the spray system. Small
lifetime of the Open Gear drive. The selection of the volumes frequently applied avoid phases in which the
lubricant depends on a large number of factors including drive is excessively saturated with lubricant, thus
stress on the working tooth flanks, rotary speed of the preventing fling-off. The short breaks between cycles
transmission gear, actual flank temperatures and condition prevent a lack of lubrication. Quantity guidelines for
of the drive. Environmental influences such as dust various drives are included in the diagram on the right.
contamination, humidity and very low or very high ambient
temperatures must also be considered.

On the safe side with CEPLATTYN

The changeover to operating lubrication starts at the end
of running-in. When changing to the operating lubricant a
cleaning procedure is not required. It is just the drum
container attached to the lubrication system that has to be
replaced. CEPLATTYN lubricants are adhesive lubricants
which are suitable for extremely high pressures. They are
resistant to water and approved by all leading gear and
machine manufacturers.
 CEPLATTYN High performance lubricants 15

Quantity reduction Note: The attainable minimum quantity

e.g. for a single-pinion drive is directly subject to the operating
conditions. Lubrication rates below the
1.0
minimum may create an increased risk of
Specific consumption [g/h × mm]

0.8 wear and damage on the tooth flanks.

0.6

0.4

0.2

0
24 48 72 96

Time [h]

Quantity of CEPLATTYN for operational lubrication Note: For double-pinion drives, please
calculate at a factor of 1.5.

500

400

300
Quantity [kg/350h]

200

100

0
100 200 300 400 500 600 700 800 900

Tooth width [mm]

Mill drives: 0.2–0.4 g/h • mm Kiln drives: 0.1–0.2 g/h • mm

16

TAILOR-MADE SERVICE AND MAINTENANCE

Our local experts contribute through their broad process-spanning expertise and on-site technical
consultation to the performance, efficiency and process reliability of your entire application. Whether­you
want specialist advice with a view to reducing your number of lubricants, longer lubrication intervals or
the perfect Open Gear services, we provide you with precisely the support you need to further optimise
your use of lubricants.
 CEPLATTYN High performance lubricants 17

FUCHS LUBRITECH Open Gear inspection procedure Running-in of new gears

Specially trained service engineers assist with the
Visual check of Open Gear and surrounding conditions
§§
commissioning and running-in of new gears. They ensure
Pinion and girth gear check
§§ that the drive is run-in optimally according to the principle
of the LUBRITECH MULTI-PHASE LUBRICATION (M-P L) with
Vibrations on the pinion bearings
§§
accurately defined application quan­tities of the appropriate
Temperature conditions on the pinion bearings
§§ CEPLATTYN lubricant.

Temperature conditions on the mill/kiln shell

§§

Check of the spray system

§§

Inspection of spray and pump equipment

§§

Temperature conditions across the tooth surfaces

§§
of the pinion and girth gears

Quantity determination of the lubricant

§§

Documentation of the result in the

§§
FLT INSPECTOR online system

 18

Service – inspection and repair

Regular inspection of Open Gears

For drive units that are lubricated with CEPLATTYN, our if necessary, reset it. In addition, the service engineer takes
service engineers carry out regular in­spections over the extensive measurements (oscillation speed, flank tempe­
entire service life. They make written notes of the general rature, etc.), which are recorded in the FLT INSPECTOR, a
operational status, ascertain the amount of wear on the modern documen­tation system, and are always available
load-carrying tooth flanks, check the spray lubrication and, to our customers.

Measuring vibrations of the pinion bearing Measuring the tooth flank temperature

Dynamic check of the contact pattern with a stroboscope Dynamic check by infrared video thermography
 CEPLATTYN High performance lubricants 19

Repair service
The repair of damaged tooth flanks on Open Gear drives is running-in and assistance with alignment of the
part of the extended service offered by FUCHS LUBRITECH. transmission gears. On heavily worn-out or damaged
Such repair work is primarily a matter of the mechanical tooth flanks FUCHS LUBRITECH can provide complete
treatment of the working tooth flanks by grinding pit­ reprofiling of the entire gear set.
tings or larger breakages, smoothing scuffings, forced

Tooth flanks before grinding During grinding process

Tooth flanks after grinding Older pitting and reworked pitting

 20

Tooth flank damage and its causes in Open Gears

Gears in a wide variety of designs provide movement throughout the industry.

If a gear wheel suddenly stops, the causes can differ considerably. Statistically
speaking, damaged tooth flanks account for about 60 per cent of gear drive
defects.

The correct lubricant eliminates many damage causes. be influenced to a large extent by the lubricant. A poor-
It does not matter whether a light oil or an adhesive quality lubricant also has a direct adverse effect on the
lubricant is under consideration. Nor does it matter occurrence of fretting corrosion, scoring and scuffings.
whether it is a high-speed vehicle gearing or a low-speed The consequences of a lack of lubricant usually include
Open Gear drive: whenever teeth mesh the appropriate increased wear or deformations such as the development
lubricant is one of the most important factors for smooth of rippling and hot or cold flow. The chart below gives a
operation. Scuffings and abrasive wear, for example, can basic overview of the problems that can be experienced.

Cracks Pittings/seizure

Deformations Tooth breakages

 CEPLATTYN High performance lubricants 21

The causes of tooth flank damage in Open Gears

Cracks Pittings Deformations Tooth Wear Corrosion Other types

breakage of damage
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
Cavitation
Cold flow

Scratches

Scuffings
Hot flow
Rippling
Spalling

Scoring

Erosion
Flaking

Cracks Pittings Deformations Tooth Wear Corro- Other types

break- sion of damage
age

Alignment errors      

Fixing of pinion    

Frequent load changes  

Overload         
Operational conditions/assembly faults

Impact/vibration stress        

Incorrect running-in  

Speeds too low/high    

Dust ingress       

Dynamic changes       

Shortage of lubricant     

Wrong consistency     
Lubrication faults

Inadequate quality     

Soiling with solids/liquids       

Incorrect application   
 22

Re-conditioning service

Forced running-in with RE-CONDITIONER

In cases where normal running-in does not result in a Re-Conditioning is used to reprofile the old girth gear
sufficient contact pattern or the drive has to be run in with the new profile of the pinion. Forced running-in
at full load, a forced running-in (the quick running-in involves a service lubricant known as RE-CONDITIONER
method) represents the best solution. This forced running- being manually applied to the working surfaces in
in procedure is also suitable for achieving an optimum addition to the regular CEPLATTYN RN lubricant during
load-carrying capacity and surface finish if the load- production. This RE-CONDITIONER effects a smoothing of
carrying surfaces show scuffings. In case a new pinion the working surfaces within in a shorter time, thus
is installed in combination with an old girth gear tremendously reducing the running-in time.

The use of RE-CONDITIONER

Before After

red = no contact complete tooth contact

 CEPLATTYN High performance lubricants 23

Case study: smoother running after Re-Conditioning

When restarting a helical, double-pinion cement mill small mission gear no improvement was achieved. The
deviations in axial and radial run-out of the girth gear had manufacturer of the machinery therefore initiated a
the effect of high vibration differences between the forced running-in. The application of RE-CONDITIONER for
pinion bearings. At the run-out pinion the vibration levels nine hours resulted in a carefully controlled redistribution
were well below 2 mm/s, but they were above 8 mm/s at of the load: the vibrations of both bearings were
the run-in pinion. The operator could not accept this large eventually below 2 mm/s. Result: a smooth operation.
difference. Even after several corrections of the trans­-

The material removal gen- Vibration monitoring

erated through using the
RE-CONDITIONER requires
specialised technical know­ 20.0
ledge. Forced running-in is
only carried out by FUCHS 15.0
LUBRITECH Service Engine­
ers. For gears under war- 10.0
ranty the machine or gear
manufacturer must agree 5.0
to this procedure being
conducted prior to the 0
start of the procedure. 13:00 01:00 13:00 01:00
2009-09-21 2009-09-22 2009-09-22 2009-09-23

run-in pinion run-out pinion

Extract from permanent vibration monitoring at the plant.

Reduction of vibrations during forced running-in.
 24

FLT INSPECTOR – online documentation

With the FLT INSPECTOR, FUCHS LUBRITECH is making a unique online

documentation database with an integrated, graphical trend analysis
available that enables the customer to retrieve all relevant information on
their system and the lubricants used at any time.

The open gear service, combined with the online provision Your benefits with the FLT INSPECTOR
of inspection reports, is a further step towards being able
Availability of all reports at a glance
§§
to operate open running drives reliably.
Online access at any time 
§§

Instant check via a 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

App solution for mobile devices

§§
 CEPLATTYN High performance lubricants 25

Sample report from our FLT Inspector

First part of the inspection report contains customer and system data, as well as images and comments. Measurements of values for temperatures and vibrations,
inclu­ding reference values relating to the previous inspec-
tion, can be found in this second part.

Tooth flank temperature run-in pinion Vibration run-out of pinion/fixed end

64 5

60 4
Vibration [mm/s] [m/s]*

56 3
Temperature [°C]

52 2

48 1

44 0
1 2 3 4 5 18 Feb. 11 May 23 Mar. 26 Jul.
2015 2015 2016 2016
Checkpoints accross the tooth width [mm]

Horizontal Vertical Axial

18 Feb. 2015 11 May 2015
23 Mar. 2016 26 Jul. 2016

Graphic trend analysis enables informative display

of temperatures and vibrations over time.
 26

Guide values for adjustment and assembly

The commissioning engineer of Open Gear drives is faced life of the drive. This is why it is usual for assembly
with extremely tough requirements when aligning or companies to prepare records of measurements of radial
correcting the drive. Careful alignment of girth and and axial run-outs, backlash and root clearance.
transmission gears is of critical importance for the service

Maximum concentric and axial run-out deviation of Adjustment of the tooth flank clearance
Open Gears as a function of girth gear diameter for mills and rotary kilns

10,000 5,000

8,000 4,000

6,000 3,000
Axial distance [mm]
Girth gear Ø [mm]

4,000 2,000

2,000 1,000

0 0
0.25 0.50 0.75 1.00 1.25 1.80 2.00 2.20 2.40 2.60 2.80 3.00

Tolerance value [mm] Backlash [mm]

Axial run-out Radial run-out Mills Kilns

If a gear set must be reversed because of wear, it will no

longer be possible to align the gears by means of the
backlash. The drive must be set up using the tip clearance.
A sui­t­able guide value for the tooth tip clearance is 0.25 to
0.3 times the module.
 CEPLATTYN High performance lubricants 27

Inspecting the spray system

The following points should be observed before The increased throughput of a running-in lubricant is
commending operation of the machinery: necessary in order to flush out any metallic particles due
to the removal of the rough surface peaks. The lubricant
must then flow freely and drain away to prevent blockages
Functional test
§§
and build-up of any waste.
Spray pattern and overlap
§§

Spray angle
§§

Nozzle distance
§§

Lubricant quantity
§§

30° mm
- 200
150 30°
00 mm
150 - 2

Inward running pinion Outward running pinion

 28

Complete solutions: the CEPLATTYN® ranges

FUCHS LUBRITECH offers three different CEPLATTYN ranges, thus always

providing our customers with the ideal lubricant for mill or kiln gears.

CEPLATTYN KG 10 HMF range CEPLATTYN SF range

The lubricants of the CEPLATTYN KG 10 HMF range include The CEPLATTYN SF range includes light-coloured, high-
black, graphite-containing greases suitable for any kind of viscosity fluids without solid lubricants. They are designed
Open Gear. The CEPLATTYN KG 10 HMF range provides for use in any kind of mill gear and are especially suitable
excellent wear and damage protection for mill and kiln for use on AGMA-designed gears for high-powered mills in
gears. Suitable grades for spray, bath and circulation the mining industry. The lubricants of the CEPLATTYN SF
application are available. range are mainly intended for spray application.

CEPLATTYN GT range
The CEPLATTYN GT range includes milk-coloured, white
solid lubricant-containing, high viscosity-fluids suitable for
all kinds of Open Gears. Like the graphite-containing
greases they provide optimum wear and damage
protection for mill gears and low-speed kiln gears. They
contain flame-retardant additives to prevent fire on kilns,
build up a suitable sealing layer to avoid the occurence of
oil leakages and are well pumpable. The CEPLATTYN GT
range comprises suitable viscosities for spray, bath and
circulation applications and can be used on AGMA and
DIN/ISO-designed gears.
 CEPLATTYN High performance lubricants 29

Open Gear CEPLATTYN® products and application

Product Description Field of application Method of application

CEPLATTYN® 300 Paste with a high graphite content, As primer for large Open Gears, Manually to clean surfaces; do not use
high-pressure additives gear racks and sliding surfaces in centralised lubrication systems!

CEPLATTYN® RN Sprayable running-in lubricants Can be applied to single- and Via automatic spraying systems.
for Open Gears double-pinion drives of any kind Spraying should be effected permanently and
of tube mills and kilns highest possible quality

CEPLATTYN® KG 10 Sprayable running-in lubricants Is used on Open Gear drives of tube Applied via standard spray lubrication sys-
HMF for large Open Gears mills and kilns, dryers and crushers tems

CEPLATTYN® KG 10 Sprayable, graphite-containing Is used for heavy-load applications Applied via standard spraying system
HMF-1000 adhesive lubricant for Open Gears because of its high base oil viscosity

CEPLATTYN® KG 10 Highly viscous, sprayable adhesive Suited for shock loads in heavy- Sparingly applied by commercially
HMF-2500 lubricant for Open Gear drives duty applications because of its high avail­able spraying systems
base oil viscosity and the resulting
good cushioning effect

CEPLATTYN® KG 10 Sprayable, extremely high- High base oil viscosity and thus good Applied economically via conventional spray
HMF LC viscos­ity adhesive lubricant damping character­istics make it espe- lubrication systems. At temperatures below
for Open Gears cially suitable for shock-loaded gear in +5°C / +40°F additional heating systems may
heavy-duty applications have to be used for spraying

CEPLATTYN® GT P Priming lubricant with white Is used as priming lubricant for Open By spatula, brush or non-fibre cloth onto pre-
solid lubricants Gears viously cleaned surfaces. Not suitable for
spray lubrication systems

CEPLATTYN® GT RN Sprayable running-in lubricant Is used to smoothen the tooth surface Via automatic spraying systems. The lubri-
for Open Gears of newly installed gear rims or pinions cant quantity should be 2–3 times higher
and for optimisation of the load- compared to operational lubricant quantities
carrying pattern

CEPLATTYN® GT 10 Light-coloured, high-viscosity adhe- Especially for Open Gears under critical Suitable for application in immersion
sive lubricant with white operating conditions, such as slow- baths, circulation lubrication and spraying
solid lubricants for Open Gears speed kiln drives with increased tooth systems
flank temperatures, mill drives with
extreme drive power, and drives which
are frequently operated under start-
stop conditions

CEPLATTYN® GT 3 Light-coloured, high-viscosity adhe- Especially for application on Open Suitable for the application in immersion
sive lubricant with white solid lubri- Gears under critical operat­ing bath and circulation lubrication systems
cants for Open Gears conditions

CEPLATTYN® SF P Priming lubricant for Open Gears Used as priming lubricant for Open By spatula, brush or non-fibre cloth onto pre-
with white solid lubricants Gears viously cleaned surfaces; caution: not suita-
ble for spray lubrication systems!

CEPLATTYN® SF RN Sprayable running-in lubricant Is used to smoothen the tooth surface Via automatic spraying systems. The lubri-
for Open Gears on newly installed gear rims or pinions cant quantity should be 2–3 times higher
and for optimisation of the load-carry- compared to operational lubricant quantities
ing pattern

CEPLATTYN® SF 10 Light-coloured, highly viscous adhe- Especially for heavy-duty, high-speed Via commercially available spraying systems
sive lubricant for Open Gears on open mill drives subject to high vibra-
mills tions

CEPLATTYN® SF 30 Sprayable, extremely high-viscos­ity Especially for extremely heavy-duty Via spray systems
lubricant for Open Gears Open Gear drives exposed to high
shock loads
30
CEPLATTYN High performance lubricants 31
FUCHS LUBRITECH – Special Application Lubricants

Innovative lubricants need

Experienced application engineers

Every lubricant change should be preceded by expert

consultation on the application in question. Only then
the best lubricant system can be selected. Experienced
LUBRITECH engineers will be glad to advise on products
for the application in question and also on our full range
of lubricants.

Contact:

Global Headquarters
FUCHS LUBRITECH GmbH
Werner-Heisenberg-Strasse 1
67661 Kaiserslautern/Germany
Tel.: +49 (0) 6301 3206-0
info@[Link]
[Link]/lubritech

The information contained in this product information is based on the experience and know-how of FUCHS LUBRITECH GmbH in the development and manufacturing of lubricants and
represents the current state-of-the-art. The performance of our products can be infl uenced by a series of factors, especially the specific use, the method of application, the operational
environment, component pre-treatment, possible external contamination, etc. For this reason, universally-valid statements about the function of our products are not possible. Our
products must not be used in aircrafts/spacecrafts or their components, unless such products are removed before the components are assembled into the aircraft/spacecraft. The
930116055 08/2016 1.0

information given in this product information represents general, non-binding guidelines. No warranty expressed or implied is given concerning the properties of the product or its
suitability for any given application. We therefore recommend that you consult a FUCHS LUBRITECH GmbH application engineer to discuss application conditions and the performance
criteria of the products before the product is used. It is the responsibility of the user to test the functional suitability of the product and to use it with the corresponding care. Our
products undergo continuous improvement. We therefore retain the right to change our product program, the products, and their manufacturing processes as well as all details of our
product information sheets at any time and without warning, unless otherwise provided in customer-specific agreements. With the publication of this product information, all previous
editions cease to be valid. Any form of reproduction requires express prior written permission from FUCHS LUBRITECH GmbH.

© FUCHS LUBRITECH GmbH. All rights reserved.