Industrial reducers and transmissions
The procedure describes the treatment of industrial reducers, manual gearboxes and transmission units of trucks and special-purpose vehicles with XADO revitalizant gel without shutting down for repair and without changing the oil. The purpose of the treatment is to restore the working surfaces of the gear wheels and to protect them from further wear.
Units covered by the method
04Method
What is treated
- Serviceable reducers that have no parts with 100% wear and no macromechanical damage (cl. 4.1).
- Reducers and gearboxes — treatment with “XADO revitalizant gel for reducers” in 3 stages without changing the oil (cl. 4.4).
- Manual gearboxes and transmission units of vehicles with an engine displacement of up to 9.0 l — single-stage treatment by introducing the gel once into the oil filler hole of the gearbox, transfer case or axle reducer (cl. 4.6).
- New reducers or reducers with minor wear (up to 10%) — treatment in 2 stages (note to table 4.1).
When treatment is not performed
- Reducers having parts with 100% wear and macromechanical damage are not subject to treatment.
- Treatment is not started until oil leaks have been eliminated.
- The mixture is introduced only when the equipment is not running.
Preparation
- Eliminate oil leaks before starting the treatment of the reducer or transmission unit (cl. 4.2).
- Before the start of the treatment, take measurements of the gear wheel geometry and of the main technical performance characteristics of the reducer (cl. 4.3).
- In a separate vessel prepare the mixture: a small amount of the standard oil heated to a temperature of 40 - 60°C, at a ratio of 1 part of the gel being dissolved to 5 - 10 parts of oil, with the calculated amount of gel added.
- Mix the components thoroughly until a homogeneous mixture is obtained.
- With the equipment not running, open the hatch or the oil filler hole of the reducer.
What is measured before and after
| Parameter | Instrument | How and when |
|---|---|---|
| Vibration level (vibration acceleration, vibration velocity, vibration displacement) | Vibrometers | At fixed points of the reducer in the vertical, horizontal and axial directions; before the start of the treatment and after completion of the full cycle. |
| Noise level | Sound level meters | At fixed points; before the start of the treatment and after completion of the full cycle. |
| Power consumption (or current consumption) of the electric motor | Electricity meters, clamp meters, a wattmeter or a multi-parameter instrument for determining electrical parameters | In the no-load mode and at a fixed load on the output shaft at the same oil temperature. |
| Oil temperature regime | Liquid-in-glass thermometer or non-contact pyrometer | Before the start of the treatment and after completion of the full cycle. |
| Tooth thickness of the gear wheels | Gear tooth calipers of any type with a scale division no coarser than 0.05 mm | See appendix 3 of this instruction. |
| Technical condition of the contact patches of the marked gear wheel teeth (presence and size of damage) | Visually or with a camera | Before the start of the treatment and after completion of the full cycle. |
What the reports on these components showed
- Increased electric power consumption28 cases · median 9 %, 49 values
- Loss of compression9 cases · median 14 %, 15 values
- Elevated vibration27 cases · median 56 %, 11 values
- Increased fuel consumption7 cases · median 12 %, 6 values
- Increased clearances and backlash32 cases · median 11 %, 18 values
- Elevated operating temperature8 cases · median 8 %, 2 values
- Oil pressure drop8 cases · median 48 %, 2 values
Consolidated register of the evidence base →
Dosage rates
| Compound | Rate | How and when |
|---|---|---|
| XADO revitalizant gel for gearboxes and reducers | 3.0 ml per 1 litre of standard oil for one treatment stage | Reducers and gearboxes, treatment in 3 stages without changing the oil. |
| XADO revitalizant gel for gearboxes and reducers (preparation of the mixture) | 1 part of the gel being dissolved to 5 - 10 parts of oil heated to a temperature of 40 - 60°C | Proportion for diluting the gel in a separate vessel before introduction. |
| XADO revitalizant gel for reducers | at the rate given in table 3.1: unit oil bath volume 1–2 l — 1 pc; 2–5 l — 2 pcs; 5–8 l — 3 pcs, treatment scheme — single dose | Manual gearboxes and transmission units of vehicles with an engine displacement of up to 9.0 l; number of tubes or aerosol cans. The table is captioned “Table 4.1”. |
| XADO revitalizant gel for gearboxes and reducers | 3.0 ml of gel per 1 treatment stage (2 stages) or, in cases of a single introduction, 6.0 ml of gel per 1 litre of standard oil | New reducers or reducers with minor wear (up to 10%). |
Treatment stages
- Pour into a separate vessel a small amount of the standard oil heated to 40 - 60°C (1 part of the gel being dissolved to 5 - 10 parts of oil), add the calculated amount of XADO revitalizant gel for gearboxes and reducers (3.0 ml per 1 litre of standard oil), mix thoroughly until a homogeneous mixture is obtained. With the equipment not running, open the hatch or the oil filler hole, introduce the mixture by any convenient method into the oil system of the reducer or directly onto the working surfaces of the gear wheels, close and secure the hatch, put the unit into operation.total reducer operating time 8 - 12 hours
- The second treatment stage is carried out in the same way as the first.after 8 - 12 hours of total operating time
- The third treatment stage is carried out in the same way as the first.after 8 - 12 hours of total operating time
After treatment
- The treatment of the reducer is considered completed after 450 hours of total operating time, counted from the start of the first treatment stage.
- The full treatment cycle for gearboxes and transmission units of vehicles with an engine displacement of up to 5.0 litres is at least 50 hours of operating time or a minimum of 1500 km of mileage.
- The full treatment cycle for transmission units of vehicles with an engine displacement of 5.0 - 9.0 l is at least 150 hours of operating time or a minimum of 3500 km of mileage.
- After completion of the full treatment cycle, measurements of the gear wheel geometry and of the main technical performance characteristics of the reducer are taken again in order to determine the effectiveness of the use of XADO formulations: vibration level, noise level, power consumption (current) of the electric motor, oil temperature regime, tooth thickness of the gear wheels, condition of the contact patches.
Points to watch
- Only serviceable reducers are subject to treatment; if there are parts with 100% wear and macromechanical damage, the treatment is not carried out.
- Before starting the treatment of the reducer or transmission unit, oil leaks must be eliminated.
- The treatment is carried out without changing the oil.
- The mixture is introduced with the equipment not running; after introduction, close and secure the hatch.
Instruction appendices
Compounds for these units
- Revitalizant gel for gearboxesIndustrial gearboxes, final and central drives, truck and tractor gearboxes, open gear and chain drives.
Methods for specific machines
- Reduction gear of a mine hoisting machineThe largest oil bath among the reduction gears analysed — 1400 litres. The dosage is calculated for the whole bath at once.
- Coal shearer gearboxA dedicated calculation for a set of two shearer gearboxes. Treatment is carried out without taking the machine out of the face.
- Crawler construction craneThe entire machine is treated, not a single unit: oil-filled gearboxes with gel, couplings and the slewing mechanism with grease. The crane's service life is over 20 years, wear up to 90 %.
Reports on this unit
- Zaporozhstal OJSC · 2013↑ 0.05-0.15mm — gearbox tooth thickness, 5.8 → 5.9 and 6.0 → 6.15 mm
- ArcelorMittal Kryvyi Rih · 2011↓ 2.8–3.1% — power drawn by the drive under load, 2578–2692 → 2506–2609 kW
- Khabarovsk TETs-1 · 2008↓ 8.6% — current drawn by the electric drive, 3.5 → 3.2 A
- Gavrilenko V.D. Farm Enterprise · 2008↑ 12.5–24% — compression across the cylinders, 25–28 → 31–32 kgf/cm²
- Tomakovskiy Expanded Clay Gravel Plant · 2007↑ 0.1-0.5mm — tooth thickness over the constant chord on all four gear rims of both gearboxes
- UKROLIIA LLC · 2007↑ 0.2-0.5mm — tooth thickness of stage I and II gear drives, 4.0–6.9 → 4.3–7.2 mm
Source: Instruction for the use of XADO revitalizant gels IE-24.6-25612000-005-2008, pages 11–13.