INDUSTRIAL CASE|MINING|DRILL RIG · ROTARY GEARBOX
COMMISSION REPORT ON THE USE OF XADO COMPOUNDS
LPS-ZU rotary gearbox: at work instead of overhaul, parts found serviceable
PRODUCTXADO compoundsXADO grease compounds for friction units · consumption per unit 500 ml and 36 ml
TEST OBJECTRotary gearbox LPS-ZU No. 16drill rig of drilling and blasting section No. 6 · 11,000 operating hours, overall wear 70-80%
DOCUMENT TYPECommission report
of the Tishinsky mine, Kazzinc JSC
of the Tishinsky mine, Kazzinc JSC
What the full teardown showed
↓0new chips
chips on the rotor shaft splines and the housing rim teeth, 13 → 13 over 850 m of drilling
↓0.10mm
largest loss of tooth thickness over 850 m of drilling, 3.00 → 2.90 mm
| UNIT OF THE ASSEMBLY | CONDITION BEFORE TREATMENT | WHAT WAS MEASURED |
|---|---|---|
| Rotary gearbox LPS-ZU No. 16 | 11,000 operating hours, overall wear 70-80%, drive seized, submitted for major overhaul | Operating hours and drilling footage after treatment |
| Gear rims of the upper and lower housing parts | Chipping on 3 and 4 teeth, wear above the maximum permissible | Tooth thickness at a depth of 4.3 mm: 3 teeth × 3 points |
| Splined rotor drive shaft | Chipping on 6 splines, wear of the spline joints above the maximum permissible | Tooth thickness at a depth of 4.5 mm: 3 teeth × 3 points |
| Bearings No. 405, No. 118, No. 1605, No. 407, No. 211 and the loose-ball bearing | Wear of rollers and balls above the maximum permissible | Radial clearances, condition of races and rolling elements |
| Planet gears and planet bearings | Wear of the gearbox gears above the maximum permissible | Chipping and damage found at teardown |
Condition of the units at full teardown after 850 m of drilling
| UNIT | BEFORE TREATMENT | AFTER 850 M OF DRILLING |
|---|---|---|
| Splines of the rotor drive shaft | chipping on 6 splines | chipping on 6 splines, no new ones appeared |
| Gear rim of the lower housing part | chipping on 4 teeth | chipping on 4 teeth, no new ones appeared |
| Gear rim of the upper housing part | chipping on 3 teeth | chipping on 3 teeth, no new ones appeared |
| Bearings No. 405, No. 118, No. 1605, No. 407, No. 211 and the loose-ball bearing | wear of rollers and balls above the maximum permissible | after washing and control measurements of radial clearances, fit for further operation |
| Rolling elements of the housing loose-ball bearing | wear above the maximum permissible | show no one-sided wear, fit for further operation |
| Planet gears and planet bearings | wear of the gearbox gears above the maximum permissible | no additional chipping or damage, in working order |
Chips were counted at the full teardown on 18.05.2002 and compared with the inspection record of 05.12.2001. The friction surfaces show areas of a glossy mineral-ceramic coating.
Tooth thickness of the lower housing part gear rim, mm
| TOOTH | MEASUREMENT POINT | BEFORE TREATMENT | AFTER 850 M OF DRILLING | CHANGE |
|---|---|---|---|---|
| 1 | near end, 10 mm from the edge | 6.05 | 6.10 | +0.05 |
| 1 | middle | 5.95 | 5.90 | −0.05 |
| 1 | far end, 10 mm from the edge | 6.85 | 6.90 | +0.05 |
| 2 | near end, 10 mm from the edge | 5.75 | 5.70 | −0.05 |
| 2 | middle | 5.95 | 5.95 | 0 |
| 2 | far end, 10 mm from the edge | 5.75 | 5.70 | −0.05 |
| 3 | near end, 10 mm from the edge | 5.75 | 5.80 | +0.05 |
| 3 | middle | 5.70 | 5.60 | −0.10 |
| 3 | far end, 10 mm from the edge | 5.65 | 5.65 | 0 |
Measured at a depth of 4.3 mm at three points of the tooth — 10 mm from each edge and at the middle, on three teeth of the rim.
Tooth thickness of the splined part of the rotor drive shaft, mm
| TOOTH | MEASUREMENT POINT | BEFORE TREATMENT | AFTER 850 M OF DRILLING | CHANGE |
|---|---|---|---|---|
| 1 | 20 mm from the shaft | 3.40 | 3.35 | −0.05 |
| 1 | 30 mm from the shaft | 2.85 | 2.80 | −0.05 |
| 1 | 40 mm from the shaft | 2.55 | 2.50 | −0.05 |
| 2 | 20 mm from the shaft | 3.00 | 2.90 | −0.10 |
| 2 | 30 mm from the shaft | 2.90 | 2.85 | −0.05 |
| 2 | 40 mm from the shaft | 2.55 | 2.50 | −0.05 |
| 3 | 20 mm from the shaft | 3.10 | 3.05 | −0.05 |
| 3 | 30 mm from the shaft | 2.95 | 2.95 | 0 |
| 3 | 40 mm from the shaft | 2.85 | 2.80 | −0.05 |
Measured at a depth of 4.5 mm at three points by distance from the shaft — 20, 30 and 40 mm, on three teeth of the splined part.
Conclusion of the commission
The gearbox had been submitted for major overhaul: 11,000 operating hours, overall wear 70-80%. After 850 m of drilling, the commission of Kazzinc JSC dismantled the unit completely and recorded:
1. All bearings and units of the LPS-ZU No. 16 rotary gearbox, after washing, replacement of the rubber seals, cotton packings and the standard lubricant, are fit for further operation.
2. All spline and gear meshes, over 850 m of drilling length, acquired no additional chipping and no increased wear (more than 0.05 mm), are in working order and fit for operation.
3. On the friction surfaces of all interacting units and parts, clearly pronounced areas with a glossy, hard mineral-ceramic coating are visible, formed by interaction with the XADO compounds.
4. The commission recognises the use of XADO compounds for the repair and restoration of the LPS-ZU No. 16 rotary gearbox during its continuous operation as effective and expedient.
The results relate to the LPS-ZU rotary gearbox of a drill rig under underground mine conditions; with other units and operating modes the figures may differ. The original report of 18.05.2002 with signatures and stamps is published in full and available for download. The commission included staff of W.F.G. Corporation LLP, which carried out the treatment.
Current equivalent
- Revitalizant gel for gearboxesGearboxes · transmissions · gear drives
- Revitalizant gel for compressors and bearingsCompressors · bearings · spindles
How such units are treated: