Filling of open gear lubricant and its application in electric shovel lubrication

(1) Mastering scientific and rigorous open gear lubricant filling method
For any open gear lubricant, its fill level is critical to its performance. In fact, there is no way to ensure that the amount of oil added is just right with the filling interval. Every machine, every part and lubrication system has its own “personality”, so the lubricant film must always be monitored to ensure that the lubricant has full potential.
The practical experience of ExxonMobil engineers in working closely with global mining machinery manufacturers and mining companies includes:
During the preventive maintenance shutdown of the machine, the parts must be inspected in detail. In addition, the maintenance personnel/fuelers must continuously monitor the lubricant film status at least twice a day and perform the necessary operation adjustments according to the state of the machine at that time;
Adjustments to the amount of refill should be the team decision made by the maintenance team and their supervisor. Adjustments must be documented and shared within the team to ensure that they are not re-adjusted due to lack of communication. Only one or two people in the team are allowed to have the right to actually perform the refill adjustment.
Only make small adjustments, take into account all the components that will be affected in the system, and then allow the adjustment to have enough time to “appear” to determine if the adjustment is correct.
Recording of all repairs, oiler adjustments, timer adjustments, etc. is critical to ensuring the success of the lubrication management program
When replacing open gear lubricants, cross-contamination between different oils is strictly avoided as this will result in a poor lubricant film on the gear surface.
Climatic conditions, such as rain and snow, typhoons, sandstorms, extreme cold, extreme heat, etc., may affect the performance of open gear lubricants.
Appropriate fill levels allow the lubricant to perform exceptionally well. When the amount of lubricant is properly applied, it will look like a dark velvet and sticky. The entire lubricated surface should be evenly covered by the lubricant, which is difficult to wipe off with a gloved finger or rag.
When the lubricant is underfilled, the part will be exposed or the exterior will shine, and the lubricant may look dry or scaly.
When the lubricant is overfilled, it may cause loss of adhesion and cohesive properties. It is important that it may be "washed away" by itself. This will also cause the parts to be exposed. It is generally found that when a large amount of waste oil is present, it indicates an overfill.
(2) Lubrication application of open gear parts of electric forklift
Regular lubrication checks can identify problems associated with excessive lubrication, under-lubrication, lubrication systems, or problems that may be associated with lubricated parts. For example, an electric forklift widely used by mining companies, such as the lifting gear, the pushing gear, the ring gear/swing pinion, the cover roller and the bucket handle/rod, etc., need to be regularly inspected and periodically lubricated. Flux adjustment.
Lifting gears: Lifting gears are only used on Caterpillar/Bycelos electric shovel and earlier Marion electric shovel. The Mobil DegerTM 4000 is ideal for this heavy lifting gear set. Proper filling of the lubricant and frequent inspection of the gears will ensure the toughness of the lubricant film, providing excellent protection for the gear set. System separation and heat tracing measures are required on older models of electric shovel operating in cold climates. Close monitoring of the calibration of open gears is critical to maintaining a tough lubricant film on these gear surfaces.
Mechanical Room Roller Lubrication: The machine room roller is basically a cylindrical rolling element of an oversized bearing that rotates the turntable on top of the fixed body. It has an upper rail and a lower rail, and some machines have three rails for lubrication. They are lubricated by a drip tube or a fuel injection tube. The rod lubrication machine operates in an open gear lubricant bath, but the Caterpillar/Bicelos machine relies on a properly filled Mobil DegeTM gear oil to create a tough lubricant film on the mating surface.
Pushing gears: This open gear set uses two push pinions that carry the weight of the bucket by the flange of the pinion. The push pinion meshes with the round bar rack for advancement/extrusion. This open gear is exposed to the outside environment for all of the time and must be closely monitored in accordance with climatic conditions. Dust, rain, snow and temperature fluctuations can quickly adversely affect the coverage of the lubricant. In addition, the configuration of the drip tube is also critical to the proper filling of the lubricant on the gear teeth and flanges.
Rod Lubrication: On a rod lubrication machine, use two rectangular sticks. These sticks slide through a pair of saddles that are equipped with wear plates on the sides and top of the stick. The side of the stick is lubricated by an oil line that passes through the passage drilled in the wear plate. The top of the stick is lubricated by a drip tube at the top or bottom of the saddle (preferably at both locations). So again, proper configuration of the drip tube is critical to proper coverage of the lubricant on the top of the stick. This is usually the first component that is affected by environmental conditions or changes.
(3) Mechanical room roller lubrication
Ring Gear / Swing Pinion: The ring gear is mounted directly on the fixed fuselage and is a super large horizontal open gear exposed to the environment. The oscillating pinion is mounted on the turntable and driven by the oscillating transmission mechanism to effect the oscillating motion. The gear is lubricated by a large number of injectors, and the lubricant is preferentially applied directly to the meshing portion of the gear set. Depending on the machine manufacturer/model, 2, 3 or 4 oscillating pinions can be used. With proper refueling, this gear set will create a tough lubricant film on the teeth of the gears and pinions.
Ring gear / swing pinion
With its unique formulation, Mobil DegeTMTM greases enable mining companies to benefit from safe, environmentally friendly and efficient production while extending their life and equipment life:
Safety – Mobil DegeTMTM greases offer exceptional extreme pressure (EP) and anti-wear (AW) protection to help protect the mating surfaces in the contact area from wear and extend component life and avoid unplanned Maintenance and repair within, reducing the chance of contact between personnel and equipment, providing safer working conditions.
Environmentally friendly - Mobil DegeTMTM greases do not use carbon black in their formulations, reducing the health risks associated with carbon black.
Efficient – Mobil DegeTMTM greases offer excellent rust and corrosion protection and long-lasting protection for parts, helping to reduce maintenance associated with surface damage and increasing productivity.