Fuchs Mining Offer Tailor-made Service And Maintenance – Worldwide

You can rely on the strength of our technical and service excellence, and our global network of specialists in all key mining locations.
With our range of services, we ensure that our lubricants perform at the highest level and allow for your machine to run reliably and efficiently. Our expertise in this field contributes to longer maintenance intervals, reduced consumption, longer lifetimes of machines and, as such, to the sustainability and environmental strategies of mining operators.
Our local experts contribute to the performance, efficiency and process reliability of your entire application through their broad process-spanning expertise and on-site technical consultation. Whether you want specialist advice with a view to reducing your number of lubricants, longer lubrication intervals or the perfect Open Gear services, we provide you with precisely the support you need to further optimise your use of lubricants.
  • Running-in and repairs of Open Gears
  • Condition monitoring of gear drive bearings and other highly loaded parts
  • Grease and oil analysis
  • Extensive online reporting
  • Further services, such as the checking of lube systems, temperatures vibrations, and load patterns with infrared images and videos
Specially trained service engineers assist with the commissioning and running-in of new open gears. They ensure that the drive is run-in optimally according to the principle of the LUBRITECH MULTI-PHASE LUBRICATION (M-P L) with accurately defined application quantities of the appropriate CEPLATTYN adhesive lubricant.
  • Visual check of Open Gear and surrounding conditions
  • Pinion and girth gear check
  • Vibrations on the pinion bearings
  • Temperature conditions on the pinion bearings
  • Temperature conditions on the mill/kiln shell
  • Check of the spray system
  • Inspection of spray and pump equipment
  • Temperature conditions across the surfaces of the pinion and girth gears
  • Quantity determination of the lubricant
  • Documentation of the result in the FLT INSPECTOR online system

Service – Inspection and Repair

Regular inspection of Open Gears

For drive units that are lubricated with CEPLATTYN, our service engineers carry out regular inspections over the entire service life. They make written notes of the general operational status, ascertain the amount of wear on the load-carrying tooth flanks, check the spray lubrication and,
if necessary, reset it. In addition, the service engineer takes extensive measurements (oscillation speed, flank tempe- rature, etc.), which are recorded in the FLT INSPECTOR, a modern documentation system, and are always available to our customers.

Repair service

The repair of damaged tooth flanks on Open Gear drives is part of the extended service offered by FUCHS LUBRITECH. Such repair work is primarily a matter of the mechanical treatment of the working tooth flanks by grinding pit- tings or larger breakages, smoothing scuffings, forced
running-in and assistance with alignment of the transmission gears. On heavily worn-out or damaged tooth flanks FUCHS LUBRITECH can provide complete reprofiling of the entire gear set.

Tooth flank damage and its causes in Open Gears

Gears in a wide variety of designs provide movement throughout the industry. If a gear wheel suddenly stops, the causes can differ considerably. Statistically speaking, damaged tooth flanks account for about 60 per cent of gear drive defects.

The correct lubricant eliminates many damage causes. It does not matter whether a light oil or an adhesive lubricant is under consideration. Nor does it matter whether it is a high-speed vehicle gearing or a low-speed Open Gear drive: whenever teeth mesh the appropriate lubricant is one of the most important factors for smooth operation. Scuffings and abrasive wear, for example, can
be influenced to a large extent by the lubricant. A poor- quality lubricant also has a direct adverse effect on the occurrence of fretting corrosion, scoring and scuffings. The consequences of a lack of lubricant usually include increased wear or deformations such as the development of rippling and hot or cold flow. The chart below gives a basic overview of the problems that can be experienced.

Re-conditioning service

Forced running-in with RE-CONDITIONER

In cases where normal running-in does not result in a sufficient contact pattern or the drive has to be run in at full load, a forced running-in (the quick running-in method) represents the best solution. This forced running- in procedure is also suitable for achieving an optimum load-carrying capacity and surface finish if the load- carrying surfaces show scuffings. In case a new pinion is installed in combination with an old girth gear
Re-Conditioning is used to reprofile the old girth gear with the new profile of the pinion. Forced running-in involves a service lubricant known as RE-CONDITIONER being manually applied to the working surfaces in addition to the regular CEPLATTYN RN lubricant during production. This RE-CONDITIONER effects a smoothing of the working surfaces within in a shorter time, thus tremendously reducing the running-in time.

Case study: smoother running after Re-Conditioning

When restarting a helical, double-pinion cement mill small deviations in axial and radial run-out of the girth gear had the effect of high vibration differences between the pinion bearings. At the run-out pinion the vibration levels were well below 2 mm/s, but they were above 8 mm/s at the run-in pinion. The operator could not accept this large difference. Even after several corrections of the trans-
mission gear no improvement was achieved. The manufacturer of the machinery therefore initiated a forced running-in. The application of RE-CONDITIONER for nine hours resulted in a carefully controlled redistribution of the load: the vibrations of both bearings were eventually below 2 mm/s. Result: a smooth operation.

FLT INSPECTOR – online documentation

With the FLT INSPECTOR, FUCHS LUBRITECH is making a unique online documentation database with an integrated, graphical trend analysis available that enables the customer to retrieve all relevant information on their system and the lubricants used at any time.
The open gear service, combined with the online provision of inspection reports, is a further step towards being able to operate open running drives reliably. Your benefits with the FLT INSPECTOR
  • Availability of all reports at a glance
  • Online access at any time
  • Instant check via a traffic light system
  • Graphical trend analysis for temperatures and vibrations
  • Rapid transmission of data and reports
  • Individual access hierarchy
  • Optional extra information (attachments) for each inspection report
  • App solution for mobile devices