Master 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:
• Parts must be inspected in detail during preventive maintenance downtime of the machine. 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.
• Make only minor 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.
· Climate 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.