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.
Procedure for treating with XADO revitalizant gel the gearboxes whose lubrication system is of a design that provides oil filtration and (or) oil moisture-separating devices, as well as gearboxes having additional hydraulic system elements (hydraulic pumps, hydraulic directional valves, hydraulic motors) operating in the same oil bath
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
When treatment is not performed
- Gearboxes having parts with 100% wear and macromechanical damage are not subject to treatment
- The specified gearboxes and transmissions are treated only with "XADO revitalizant gel for power steering (industrial)"
- The treatment is carried out without changing the oil
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
| Parameter | Instrument | How and when |
|---|---|---|
| Vibration level (vibration acceleration, vibration velocity, vibration displacement) | Vibrometers | At fixed points (bearing supports are recommended), in the vertical, horizontal and axial directions; before starting the treatment and after completing the full treatment cycle |
| Noise level | Sound level meter | At fixed points; before starting the treatment and after completing the full treatment cycle |
| Power consumption (or current consumption) of the electric motor | Electric energy meters, clamp meters, wattmeters or a multimeter | In no-load mode and under a fixed load, at the same oil temperature |
| Oil temperature conditions | Liquid-filled thermometer or non-contact pyrometer | Before starting the treatment and after completing the full treatment cycle |
| Gear wheel tooth thickness | 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 patterns of the marked gearbox gear wheel teeth (presence and size of damage) | Visually or using a camera | Before starting the treatment and after completing the full treatment cycle |
Dosage rates
| Compound | Rate | How and when |
|---|---|---|
| XADO revitalizant gel for power steering (industrial) | in 5 stages without changing the oil | The formulation with which, according to clause 5.3, the gearboxes and transmissions specified in the procedure are treated |
| XADO revitalizant gel for transmissions and gearboxes | 1.8 ml per 1 litre of the standard oil for one stage | The calculated amount of gel introduced at each stage (the name of the formulation is given this way in clause 5.3.1) |
| Standard oil for diluting the gel | 1 part of the gel being dissolved to 5 - 10 parts of oil | The oil is heated to a temperature of 40 - 60°C, mixing is done in a separate vessel |
Treatment stages
- 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
- Carried out in the same way as the first stageafter 8 -12 hours of total running time
- Carried out in the same way as the first stageafter 8 -12 hours of total running time
- Carried out in the same way as the first stageafter 8 -12 hours of total running time
- 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
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.
Source: Instruction for the use of XADO revitalizant gels IE-24.6-25612000-005-2008, pages 13–14.