Lubricants in industrial gears

MDI-170-B-EN 12.01.2010

LUBRICANTS IN INDUSTRIAL GEARS

1. SIGNIFICANCE OF LUBRICATION ................................................................................... 2

2. LUBRICATION METHODS ................................................................................................. 2
2.1 BATH LUBRICATION ............................................................................................................ 2
2.2 SPLASH LUBRICATION ........................................................................................................ 2
2.3 GREASE LUBRICATION ....................................................................................................... 2
2.4 PRESSURE-FEED LUBRICATION ........................................................................................... 2
3. LUBRICATION IN EXTREME SITUATIONS....................................................................... 2
3.1 OIL HEATING ..................................................................................................................... 2
3.2 OIL COOLING ..................................................................................................................... 3
3.2.1 Bath and splash lubrication ......................................................................................... 3
3.2.2 Pressure-feed lubrication............................................................................................. 3
3.3 COLD START ..................................................................................................................... 4
4. HANDLING AND DISPOSING OF LUBRICANTS .............................................................. 4
5. APPROVED LUBRICANTS ................................................................................................ 5

Moventas Santasalo Oy 1(9)


1. SIGNIFICANCE OF LUBRICATION
To secure the appropriate lubrication of a gear
assembly, it is of primary importance that its
lubrication and the related observation and
maintenance tasks have been properly arranged.
The main task of lubrication is to form an oil film
between the working flanks of the gear teeth of a
gear wheel to prevent metal contact and to lubricate
the bearings and seals.
Other lubrication functions include:
reducing friction and the resultant power loss
transfer heat away from the tooth contact and
bearings
minimise wear and tear
prevent the entry of impurities into the lubricated
parts
move impurities and wear-down particles away
reduce vibration
protect the parts from corrosion
The thickness of the oil film depends for example on
the surface pressure of the gear tooth, the viscosity
of the oil and the pitch line velocity. If the oil film fails
repeatedly during operation, the working flank of the
tooth becomes damaged.
Information pertaining to the viscosity and amount of
the gear lubrication oil is presented per application
either in the plate attached to the gear and/or in the
dimensional drawing of the gear. Oil types approved
for use in industrial gears are presented in section 5.
When using oil types not presented in the above
appendix, consult with the gear manufacturer first.
2. LUBRICATION METHODS
2.1 Bath lubrication
In bath lubrication, the oil surface is raised high
enough to submerge the tooth contact and the rolling
elements of the bearings in oil. Bath lubrication is
suitable only for very slow-rotating gear wheels with a
low pitch line velocity.
2.2 Splash lubrication
In splash lubrication, the gear wheels are partially
submersed in oil. Tooth contact is lubricated with the
oil splashing from the gear wheels or conveyed with
the teeth. The bearings are lubricated with oil
splashing from the gear wheels. Splash lubrication is
suitable for relatively slow-rotating gear wheels.
2.3 Grease lubrication
The use of grease lubrication is limited almost solely
to the lubrication of bearings and seals if the bearing
structure of a gear assembly requires that.
Moventas Santasalo Oy
Lubricants in industrial gears
MDI-170-B-EN 12.01.2010
2.4 Pressure-feed lubrication
The structure, size, use and cooling requirement of
the gear may require pressure-feed lubrication. In
pressure-feed lubrication, the oil pipeline of the gear
is connected to a central lubrication system, or a
dedicated lubrication pump is located close to the
gear. The lubrication pump may be shaft-operated,
which means that it gets its operating power directly
from the gear shaft, or it may have a dedicated
electric engine.
The equipment level in pressure-feed lubrication is
determined by the demand level, supervision and
gear cooling requirements of the machine being
operated. It is also possible to connect a standard
lubrication unit to the gear and equip it with a water
or air cooling unit.
3. LUBRICATION IN EXTREME
SITUATIONS
3.1 Oil heating
If a gear is located outdoors or in a non-heated
location, the gear manufacturer must be notified of
this and of the temperature variations. The usual
problem at low temperatures is the supply of oil to the
item requiring lubrication because of the high
viscosity of the oil.
An oil heater is a resistor element located in the oil
compartment of the gear and thread-mounted in the
wall of the gear housing. If required, the resistor
element can be detached for cleaning. In this case,
the gear oil must be removed first.
There is a thermostat for controlling the oil heater.
The thermostat must be programmed in such a way
as to power on the oil heater if the temperature in the
gears falls below the pour point in bath or splash
lubricated gears or below the temperature listed in
Table 1 for pressure-feed-ubricated gears.
Table 1. Minimum temperatures (C) with different oil
qualities in pressure-feed-lubricated gears at or
above which the oil viscosity value <2000 cSt occurs.
ISO VG class 680 460 320 220 150 100
Mineral oil +25 +20 +15 +10 +5
Synthetic oil +15 +10 +5 0 -5
In pressure-lubricated gears, the viscosity of the
lubrication oil must be <2000 cSt at the start-up
temperature.
The high end of the thermostat is set to power the
unit off at a temperature of +8..+10 C above the
abovementioned power-on temperature.
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 Lubricants in industrial gears
MDI-170-B-EN 12.01.2010

Table 2 presents oil viscosity as a function of temperature.

Mineral oils Synthetic PAO oils

-25 -20-15-10 -7 Po ur poi nt [C]
-40 -40 - 35 -30 Pour point [C]

3000
3000 220 460
2000
2000 1 50 3 20 Viscosi ty i nde x
150 32 0 68 0 Vi scosity index
VI=90...100 VI=140...180
220 460 1000 ISO VG
1 000
ISO VG

500 500

200 200
150 150

1 00 100

40 40

Visc osity V iscosity

2
2
[mm / s] [mm /s]

10 10
-20 -10 0 10 20 30 40 50 60 70 80 90 1 00
-20 -10 0 10 20 30 40 50 60 70 80 90 100

Gear unit
s lubricating temperat ure of oil T L [C] Gear unit
s lubricating temperature of oil TL [ C]

Table 2
3.2 Oil cooling MPa (10 bar). The direction of flow of the water is
insignificant in the water cooling coil unit.
The gear manufacturer must be notified of above-
normal operating temperatures and temperature The flow amount of the water cooling coil unit must
variations. If the operating temperature of the oil is be adjusted so that the temperature of the oil
higher than the designed temperature, the oil compartment in the gear does not exceed +80 C.
viscosity falls too low. This may result in decreased There must be a thermometer in the oil compartment
lubrication film thickness, potential metal contact, of the gear for monitoring the temperature.
surface wear and damage. 3.2.2 Pressure-feed lubrication
3.2.1 Bath and splash lubrication The operating temperature of a gear with pressure-
The highest allowed operating temperature of bath feed lubrication is normally at most +80 C measured
and splash-lubricated gears is normally +90 C at the gears bearing housing.
measured at the gear s bearing housing. In special Gear cooling may be enhanced as follows:
cases the highest allowable operating temperature
use a water-cooled oil cooler
may be +100 C. If the gear s operating power
exceeds the thermal power, the above normal use an air-cooled oil cooler
operating temperature will be exceeded unless the An air-cooled oil cooler must be located in a dust-free
gear cooling is enhanced. environment.
Gear cooling may be enhanced as follows: The input side of a water-cooled oil cooler must have
a thermostat-controlled water valve. The greatest
place a water cooling coil unit in the gear
s oil
allowed operating pressure of the water is 1 MPa (10
compartment
bar). The direction of water flow marked in the oil
place one or two fans on the input shaft of the cooler must be adhered to.
gear In water-cooled oil coolers, the water volume must be
Fans are not recommended in dusty or humid adjusted with a thermostat so that the temperature of
environments. the oil entering the gear is +45..+55 C.
The input side of the water cooling coil unit must If the gear has an air-cooled oil cooler, it must be
have a thermostat-controlled water valve. The thermostat-controlled and control the operation of the
greatest allowed operating pressure of the water is 1

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fan engine so that the temperature of the oil entering
the gear is +45...+55 .
3.3 Cold start
In a cold start situation, the viscosity of the lubrication
oil must be <2000 cSt at the start-up temperature for
the pressure-feed-lubricated gears. For bath and
splash-lubricated gears, the start-up temperature
must be higher than the pour point of the lubrication
oil. If this is not the case, the seals, bearings and
gear wheels will not be lubricated at all.
If the viscosity of the selected oil exceeds the allowed
viscosity at the start-up temperature, the following
measures can be performed with the gear
manufacturer s permission:
4. HANDLING AND DISPOSING OF LUBRICANTS
Lubrication oils are hazardous waste and dangerous
to the environment. National laws and regulations
must be adhered to in their handling and disposal.
Moventas Santasalo Oy
Lubricants in industrial gears
MDI-170-B-EN 12.01.2010
use the closest matching oil of a thinner oil group
use different oil for winter and summer
environments
use an oil heater
use a synthetic polyalphaolephin-based (PAO)
oil
In case of a temporary start-up temperature decrease
(e.g., downtime), start-up problems in pressure-feed-
lubricated gear wheels can be reduced by allowing
the electric engine pump to run through the
downtime.
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 Lubricants in industrial gears
MDI-170-B-EN 12.01.2010

5. APPROVED LUBRICANTS
The lubricant table below lists the lubricants approved for Moventas Santasalo Oy
s industrial gear wheels.
Mineral oils
ISO VG AGMA Viscosity Pour point
Company Oil types
class number cSt / 40 C C
Aral Degol BG 150 plus 150 -12
BP Energol GR-XP 150 149 -12
Castrol Alpha SP 150 150 -21
Castrol Alpha MAX 150 150 -23
Castrol Optigear BM 150 150 -18
Castrol Tribol 1100/150 146 -27
150 4EP Chevron Meropa WM 150 150 -27
Fuchs Renolin CLP 150 150 -24
Fuchs Renolin CLP 150 PLUS 150 -24
Fuchs Lubritech Gearmaster CLP 150 150 -24
Klber Klberoil GEM 1-150 N 150 < -10
Lubrication 604 ALMASOL Vari- 150 -24
Engineers Purpose Gear Lubricant
Lukoil Steelo 150 150 -15
Mobil Mobilgear XMP 150 150 -27
Mobil Mobilgear 600 XP 150 150 -24
Neste Vaihteisto 150 EP 150 -21
Petro Canada Ultima EP 150 150 -33
Shell ------- -- --
Statoil Loadway EP 150 140 -27
Total ------- -- --
Total Carter XEP 150 150 -27
Aral Degol BG 220 plus 220 -15
BP Energol GR-XP 220 210 -9
Castrol Alpha SP 220 220 -21
Castrol Alpha MAX 220 220 -23
Castrol Optigear BM 220 220 -15
Castrol Tribol 1100/220 214 -24
220 5EP Chevron Meropa WM 220 220 -21
Fuchs Renolin CLP 220 220 -24
Fuchs Renolin CLP 220 PLUS 220 -24
Fuchs Lubritech Gearmaster CLP 220 220 -21
Klber Klberoil GEM 1-220 N 220 < -10
Lubrication 607 ALMASOL Vari- 220 -24
Engineers Purpose Gear Lubricant
Lukoil Steelo 220 220 -15
Mobil Mobilgear XMP 220 220 -24
Mobil Mobilgear 600 XP 220 220 -24
Neste Vaihteisto 220 EP 220 -24
Petro Canada Ultima EP 220 220 -27
Shell Omala F 220 220 -18
Statoil Loadway EP 220 225 -21
Total Carter VP/CS 220 220 -21
Total Carter XEP 220 220 -24
Aral Degol BG 320 plus 320 -9
BP Energol GR-XP 320 311 -9
Castrol Alpha SP 320 320 -21
Castrol Alpha MAX 320 320 -23
320 6EP Castrol Optigear BM 320 320 -15
Castrol Tribol 1100/320 331 -21
Chevron Meropa WM 320 320 -18
Fuchs Renolin CLP 320 320 -14

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 Lubricants in industrial gears
MDI-170-B-EN 12.01.2010

Fuchs Renolin CLP 320 PLUS 320 -18

Fuchs Lubritech Gearmaster CLP 320 320 -15
320 6EP Klber Klberoil GEM 1-320 N 320 < -10
Lubrication 605 ALMASOL Vari- 320 -18
Engineers Purpose Gear Lubricant
Lukoil Steelo 320 320 -15
Mobil Mobilgear XMP 320 320 -18
Mobil Mobilgear 600 XP 320 320 -24
Neste Vaihteisto 320 EP 320 -12
Petro Canada Ultima EP 320 320 -21
Shell Omala F 320 320 -15
Statoil Loadway EP 320 337 -18
Total Carter VP/CS 320 320 -18
Total Carter XEP 320 320 -18
Aral Degol BG 460 plus 460 -18
BP Energol GR-XP 460 432 -
Castrol Alpha SP 460 460 -6
Castrol Alpha MAX 460 460 -9
Castrol Optigear BM 460 460 -12
Castrol Tribol 1100/460 460 -21
460 7EP Chevron Meropa WM 460 460 -15
Fuchs Renolin CLP 460 460 -12
Fuchs Renolin CLP 460 PLUS 460 -14
Fuchs Lubritech Gearmaster CLP 460 460 -12
Klber Klberoil GEM 1-460 N 460 -10
Lubrication 608 ALMASOL Vari- 460 -15
Engineers Purpose Gear Lubricant
Lukoil Steelo 460 460 -15
Mobil Mobilgear XMP 460 460 -12
Mobil Mobilgear 600 XP 460 460 -15
Neste Vaihteisto 460 EP 460 -15
Petro Canada Ultima EP 460 460 -15
Shell Omala F 460 460 -9
Statoil Loadway EP 460 440 -12
Total Carter VP/CS 460 460 -12
Total Carter XEP 460 460 -12
Aral Degol BG 680 plus 680 -12
BP Energol GR-XP 680 710 -
Castrol Alpha SP 680 680 -6
Castrol ------- -- --
Castrol Optigear BM 680 680 -9
Castrol Tribol 1100/680 690 -18
680 8EP Chevron ------- -- --
Fuchs Renolin CLP 680 680 -10
Fuchs Renolin CLP 680 PLUS 680 -17
Fuchs Lubritech Gearmaster CLP 680 680 -12
Klber Klberoil GEM 1-680 N 680 -5
Lubrication 609 ALMASOL Vari- 680 -15
Engineers Purpose Gear Lubricant
Lukoil Steelo 680 680 -15
Mobil Mobilgear XMP 680 680 -9
Mobil Mobilgear 600 XP 680 680 -9
Neste Vaihteisto 680 EP 680 -12
Petro Canada Ultima EP 680 680 -15
Shell ----- -- --
Statoil Loadway EP 680 645 -9
Total Carter VP/CS 680 680 -9
Total Carter XEP 680 680 -9

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 Lubricants in industrial gears
MDI-170-B-EN 12.01.2010

Mineral oils for paper machine use

ISO VG AGMA Viscosity Pour point

Company Oil types
class number cSt / 40 C C
Esso Teresstic N 220 220 -12
BP Energol PM 220 220 -18
Mobil DTE PM 220 -6
220 5EP Neste-Exxon Paperikone 220D 220 -12
Petro Canada SEPRO XL 220 218 -21
Petro Canada ULTIMA EP 220 220 -27
Texaco PMO Premium 220 220 -18
Texaco PMO Ashless 220 220 -18

Synthetic polyalphaolephin-based oils

ISO VG AGMA Viscosity Pour point

Company Oil types
class number cSt / 40 C C
Aral Degol PAS 150 150 -39
BP Enersyn EP-XF 150 150 -48
Castrol Alphasyn EP 150 150 -48
Castrol ------- -- --
150 4EP Castrol Optigear Synthetic X 150 146 -39
Castrol Tribol 1510/150 155 -45
Fuchs Renolin Unisyn CLP 150 150 -45
Klber Klbersynth GEM 4 150 N 150 -40
Mobil Mobilgear SHC XMP 150 150 -48
Mobil Mobil SHC 629 150 -42
Neste Vaihteisto S 150 EP 150 -42
Petro Canada Enduratex Synthetic EP 150 150 -54
Shell Omala HD 150 150 -54
Statoil Mereta 150 150 -57
Total Carter SH 150 148 -45
Aral Degol PAS 220 220 -39
BP Enersyn EP-XF 220 220 -42
Castrol Alphasyn EP 220 220 -42
Castrol Optigear Synthetic A 220 210 -36
220 5EP Castrol Optigear Synthetic X 220 218 -33
Castrol Tribol 1510/220 220 -42
Fuchs Renolin Unisyn CLP 220 220 -42
Klber Klbersynth GEM 4 220 N 220 -40
Mobil Mobilgear SHC XMP 220 220 -45
Mobil Mobil SHC 630 220 -42
Neste Vaihteisto S 220 EP 220 -48
Petro Canada Enduratex Synthetic EP 220 223 -48
Shell Omala HD 220 220 -48
Statoil Mereta 220 220 -48
Total Carter SH 220 220 -45

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 Lubricants in industrial gears
MDI-170-B-EN 12.01.2010

Aral Degol PAS 320 320 -39

BP Enersyn EP-XF 320 320 -30
Castrol Alphasyn EP 320 320 -36
Castrol Optigear Synthetic A 320 330 -36
320 6EP Castrol Optigear Synthetic X 320 325 -33
Castrol Tribol 1510/320 330 -39
Fuchs Renolin Unisyn CLP 320 320 -42
Klber Klbersynth GEM 4 320 N 320 -35
Mobil Mobilgear SHC XMP 320 335 -38
Mobil Mobil SHC 632 320 -39
Neste Vaihteisto S 320 EP 320 -48
Petro Canada Enduratex Synthetic EP 320 323 -42
Shell Omala HD 320 320 -45
Statoil Mereta 320 320 -42
Total Carter SH 320 314 -42
Aral Degol PAS 460 460 -39
BP Enersyn EP-XF 460 460 -36
Castrol Alphasyn EP 460 460 -36
Castrol Optigear Synthetic A 460 463 -30
Castrol Optigear Synthetic X 460 459 -27
460 7EP Castrol Tribol 1510/460 460 -33
Fuchs Renolin Unisyn CLP 460 460 -39
Klber Klbersynth GEM 4 460 N 460 -30
Mobil Mobilgear SHC XMP 460 460 -36
Mobil Mobil SHC 634 460 -39
Neste Vaihteisto S 460 EP 460 -45
Petro Canada Enduratex Synthetic EP 460 501 -42
Shell Omala HD 460 460 -42
Statoil Mereta 460 460 -39
Total Carter SH 460 455 -30
ARAL ----- -- --
BP ----- -- --
Castrol ----- -- --
Castrol ----- -- --
Castrol ----- -- --
Castrol Tribol 1510/680 680 -30
Fuchs Renolin Unisyn CLP 680 680 -33
680 8EP Klber Klbersynth GEM 4 680 N 680 -30
Mobil Mobilgear SHC XMP 680 680 -30
Mobil Mobil SHC 636 68 -39
Neste Vaihteisto S 680 EP 680 -35
Petro Canada ----- -- --
Shell Omala HD 680 680 -39
Statoil Mereta 680 680 -39
Total Carter SH 680 676 -21

Synthetic polyalphaolephin-based oils for paper machine use

ISO VG AGMA Viscosity Pour point
Company Oil types
class number cSt / 40 C C
Castrol Optisynth HT 220 220 -39
Mobil SHC PM 220 225 -36
220 5EP
Neste Lamda 220 ZF 220 -45
Texaco Paper Machine Oil Premium

Moventas Santasalo Oy 8(9)

 Lubricants in industrial gears
MDI-170-B-EN 12.01.2010

Roller bearing greases

Operating temperature -30..+100 C NLGI 2 (EP)

Fluency point
Company Grease type Penetration
C
Aral Aralub HLP2 265/295 180
BP Energrease LS-EP 265/295 195
Castrol Tribol 3785/220-1,5 265/295 >180
Castrol Longtime PD 2 265/295 260
Castrol Tribol 4020/220-2 265/295 260
Chevron Dura-Lith EP2 265/295 185
Elf Epexa EP2 265/295 207
Exxon Beacon EP2 265/295 190
Gulf Gulfcrown EP 2 265/295 180
Klber CENTOPLEX 2EP 265/295 190
Mobil Mobilux EP2 265/295 190
Neste Allrex EP 2 265/295 198
Shell Alvania Grease EP2 265/295 180
Statoil Uniway EP2N 270/280 185
Teboil Multi-purpose EP 265/295 185
Texaco Multifak EP2 265/295 186
Total Multis EP2 265/295 190

Lubrication of hot-running cone bearings (>80 C) NLGI 2 (EP)

Fluency point
Company Grease type Penetration
C
Castrol Tribol 3785/220-1,5 265/295 >180
Castrol Tribol 4020/220-2 265/295 260
Castrol Tribol 4747/220-2 265/295 >250
Klber Klberplex BE 31-102 265/295 190
Shell Albida Grease EP2 265/295 260
Teboil Multi-purpose HT 265/295 260

Lubrication of slow-rotating, axial, spherical pressure bearings NLGI 0..1 (EP)

Fluency point
Company Grease type Penetration
C
Castrol Molub-Alloy 9141-1 310/340 >230
Castrol Olista Longtime 1 310/340 >180
Castrol Optipit 245/275 300
Castrol Tribol 3020/1000-1 265/295 260
Klber STABURAGS NBU 30 245/275 220
Klber Klberplex BEM 41-141 310/345 250

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