Gearboxes with oil filtration

The procedure applies to gearboxes and transmissions whose lubrication system provides oil filtration and (or) oil moisture separation, as well as to gearboxes with hydraulic system elements in a common oil bath. The treatment is carried out without shutting down for repair and without changing the oil, in order to restore the working surfaces of the gear wheels and protect them against wear.

Units covered by the method

Reduction gearboxGearboxGear driveHydraulic systemPump

82 cases on these unitsAll methods →

05Method

What is treated

• Serviceable gearboxes having no parts with 100% wear and no macromechanical damage
• Gearboxes whose lubrication system is of a design that provides oil filtration and (or) oil moisture-separating devices
• Gearboxes having additional hydraulic system elements (hydraulic pumps, hydraulic directional valves, hydraulic motors) operating in the same oil bath
• Transmissions specified in this procedure

Preparation

• Eliminate oil leaks
• Flush or replace the filter elements
• Remove condensate from the oil moisture-separating devices
• Before starting the treatment, take measurements of the main technical performance characteristics of the gearbox and of the gear wheel parameters

What is measured before and after

What the reports on these components showed

1. Increased electric power consumption32 cases · median 10 %, 55 values
2. Loss of compression9 cases · median 14 %, 15 values
3. Elevated vibration31 cases · median 35 %, 17 values
4. Increased fuel consumption7 cases · median 12 %, 6 values
5. Increased clearances and backlash34 cases · median 11 %, 18 values
6. Elevated operating temperature10 cases · median 8 %, 2 values
7. Oil pressure drop10 cases · median 48 %, 2 values

Consolidated register of the evidence base →

Dosage rates

Treatment stages

1. Pour a small amount of the standard oil heated to 40 - 60°C into a separate vessel (at the rate of 1 part of the gel being dissolved to 5 - 10 parts of oil), add the calculated amount of gel (1.8 ml per 1 litre of the standard oil for one stage), and mix thoroughly until the mixture is uniform. With the equipment shut down, open the hatch or the oil filler opening of the gearbox, introduce the mixture by any convenient means into the working cavity of the gearbox or directly onto the working surfaces of the gear wheels, close and secure the hatch, and start the unit in operation8 -12 hours of total gearbox running time
2. Carried out in the same way as the first stageafter 8 -12 hours of total running time
3. Carried out in the same way as the first stageafter 8 -12 hours of total running time
4. Carried out in the same way as the first stageafter 8 -12 hours of total running time
5. Carried out in the same way as the first stageafter 8 -12 hours of total running time

After treatment

• The treatment of the gearbox is considered complete after 500 hours of total running time counted from the beginning of the first treatment stage
• After completing the full treatment cycle, measurements of the main technical performance characteristics of the gearbox and of the gear wheel parameters are taken again (vibration, noise, power or current consumption of the electric motor, oil temperature, gear wheel tooth thickness, condition of the contact patterns of the marked teeth)

Points to watch

• Only serviceable gearboxes are subject to treatment; if there are parts with 100% wear and macromechanical damage, the treatment is not carried out
• Before starting the treatment, it is mandatory to eliminate oil leaks, flush or replace the filter elements, and remove condensate from the moisture-separating devices
• The mixture is introduced with the equipment shut down; after introduction, the hatch must be closed and secured
• Measurements of the electric motor power (current) consumption must be taken at the same oil temperature

Instruction appendices

• Tooth Thickness Measurement Diagram

Compounds for these units

• Revitalizant gel for gearboxesIndustrial gearboxes, final and central drives, truck and tractor gearboxes, open gear and chain drives.
• Revitalizant gel for hydraulic systemsHydraulic systems of industrial and special equipment, pumps, motors and valves; gearboxes with oil filtration.

Methods for specific machines

• Extruder Drive GearboxA gearbox with dedicated oil filtration and water separation — this feature also changes the formulation: not the gel for gearboxes, but the gel for power steering.
• Main marine gearboxBoth the gear trains and the hydraulic components run in the same oil sump — this determines the choice of formulation.

Reports on this unit

1. Zaporozhstal OJSC · 2013↑ 0.05-0.15mm — gearbox tooth thickness, 5.8 → 5.9 and 6.0 → 6.15 mm
2. ArcelorMittal Kryvyi Rih · 2011↓ 2.8–3.1% — power drawn by the drive under load, 2578–2692 → 2506–2609 kW
3. Khabarovsk TETs-1 · 2008↓ 8.6% — current drawn by the electric drive, 3.5 → 3.2 A
4. Gavrilenko V.D. Farm Enterprise · 2008↑ 12.5–24% — compression across the cylinders, 25–28 → 31–32 kgf/cm²
5. Tomakovskiy Expanded Clay Gravel Plant · 2007↑ 0.1-0.5mm — tooth thickness over the constant chord on all four gear rims of both gearboxes
6. 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

All 82 in the catalogue →

Source: Instruction for the use of XADO revitalizant gels IE-24.6-25612000-005-2008, pages 13–14.