SERVICE ADVISORY Date: June 14, 2011 Bucyrus International, Inc. P.O. Box 500 - 1100 Milwaukee Avenue South Milwaukee, Wisconsin, 53172-0500, USA 414.768.4000 / Fax: 414.768.4570
Advisory No.: 11-005 Revision No.: 0
MANDATORY Compliance with this advisory should be perf ormed at the next convenient maintenance opportunity.
SUBJECT: OPEN GEAR LUBRICANT (OGL) SPECIFICA SPECIFICATION TION UPDATE -- SD4713 SD47 13 NOTE: IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY MEASURES SUCH AS THOSE SET FORTH IN THE APPLICABLE MACHINE MAINTENANCE MANUAL ARE FOLLOWED FOLLOWED DURING THE PERFORMANCE OF THIS WORK. MODELS AFFECTED: 495HD, 495HR, 495HF, 295HR, 295HD, 182M MACHINES AFFECTED S/N’s: 141136, 141141, 141142, 141143, 141146, 141148, 141149, 141156, 141157, 141197, 141231, 141244, 141260, 141272, 141322, 141344, 141358, 141431, 141457,
141161, 141162, 141163, 141164, 141167, 141176, 141177, 141178, 141179, 141185, 141186, 141198, 141207, 141208, 141209, 141214, 141215, 141224, 141227, 141228, 141229, 141230, 141232, 141233, 141234, 141235, 141236, 141237, 141238, 141240, 141241, 141242, 141243, 141245, 141246, 141247, 141252, 141253, 141254, 141255, 141256, 141257, 141258, 141259, 141261, 141262, 141263, 141264, 141265, 141266, 141267, 141268, 141269, 141270, 141271, 141310, 141311, 141312, 141313, 141314, 141316, 141317, 141318, 141319, 141320, 141321, 141323, 141324, 141325, 141326, 141327, 141328, 141329, 141330, 141332, 141333, 141343, 141345, 141346, 141347, 141350, 141351, 141348, 141349, 141352, 141353, 141354, 141356, 141359, 141409, 141410, 141411, 141412, 141420, 141421, 141422, 141423, 141425, 141430, 141433, 141439, 141440, 141442, 141444, 141446, 141449, 141451, 141454, 141455, 141456, 141460
ISSUE: The specification for open gear lube (OGL) prescribes a viscosity viscosity based on ambient temperature at the point of application. appl ication. Particularl Particularly y in cold climates, some some customers have selected selected seasonal seasonal lubricants with minimal viscosity allowing it to be pumped to external components. However, under certain conditions these lubricants lubrica nts may not meet the viscosity requirements requireme nts of the th e hoist pinions and bull gear gear (located in in the heated machinery room) and could provide marginal lubrication which could lead to premature distress on the gear teeth. 1 OF 3
ISO 9001: 2000 Registered Firm
ACTION: To meet the specification, a solvent cut-back (non-chlorinated diluent type) lubrican t or a pumpable high viscosity grease or compound may be required for cold weather applications. If the owner/operator chooses, a split lube system may be adapted that will allow the specified open gear lubricant to be utilized year round for the hoist pinions and hoist drum gear, and a seasonal low viscosity open gear lubricant for external components. To obtain a quotation for split lube system components please contact our Aftermarket Service Parts Group.
The high viscosity of the OGL may provide difficulty pumping in cold weather applications. The factory supplied systems have heat sources designed for pumpability during cold start ups. It is recommended to effectively plan refill intervals to avoid transport and refills during the coldest times of the year.
OPEN GEAR LUBRICANT
The new specification clarifies the viscosity requirement of the lubricant for the hoist pinions and hoist drum gear. Lubricant viscosities for systems other than the hoist will remain as before. The OGL viscosity requirements for the electric mining shovel equipment are as follows:
PROPERTY
REFERENCE
REQUIREMENT
Minimum Fluid Viscosity at Ambient Temperature All - Except Electric Mining Shovel Hoist Drum Gear °C -50 to +10 -20 to +40 +10 to +50
(°F) (-58 to +50) (-4 to +104) (+50 to +122)
ASTM D 445 680 cSt at 40°C 1860 cSt at 40°C 3600 cSt at 40°C
Minimum Fluid Viscosity at Ambient Temperature Electric Mining Shovel Hoist Drum Gear °C +10 to +35 +25 to +50
(°F) (+50 to +95) (+77 to +122)
ASTM D 445 3600 cSt at 40°C 5000 cSt at 40°C
Note : The ambient temperature shall be the temperature at the point of lubricant application. The Electric Mining Shovel Hoist Drum Gear is enc losed in a heated machinery room which should not be be low 10°C (50°F).
Included in the specification is the requirement that the lubricant contain molybdenum disulfide at a minimum of 2% to protect the gear surfaces during low speed – high load conditions which are common in the hoist system. Also included is a clarification to the lubricating solids particle size. Attached please find the new OGL Specification SD4713. 2 OF 3
ISO 9001: 2000 Registered Firm
Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/local regulatory requirements. Lubricants shall be certified by their manufacturers as complying with this specification. The use of lubricants not meeting this specification may invalidate the Bucyrus International, Inc. product warranty obligation.
If you have any questions on the above, please contact: Bucyrus International, Inc. Engineering Services & Technical Support 1100 Milwaukee Avenue South Milwaukee, WI 53172 414.768.4000
3 OF 3
ISO 9001: 2000 Registered Firm
Specification Data
SCOPE: 1. This specification covers “Open Gear Lubricant”. 2. Materials furnished under this specification are primarily intended to lubricate open gears, but may also be used to lubricate racks, bushings, rails, rollers, dipper handles and propel mechanism components. 3. The material furnished under this specification must be dispensable through the distribution lines of a centralized lubrication system to the most remote application point, at the lowest anticipated operating temperature. It must not plate or plug components of the centralized lubrication system such as injectors, metering blocks, or spray nozzles. 4. This specification covers open gear lubricants that may be applied in service at temperatures ranging from -50°C (-58°F) to the highest ambient temperatu re conditions. The particular grade or consistenc y selected must perform within the specific temperature range in which it is utilized. The temperature may vary significantly between external components in cold climates and components located within heated enclosures and must be considered during lubricant selection.
PHYSICAL CHARACTERISTICS: 1. Materials furnished under this specification are produced with highly fortified blends of viscous fluids combined with additives to form stable, long lasting, high load carrying, wear resistant films that lubricate under mixed film and boundary conditions. Lubricants addressed under this specification may be defined by AGMA 6014-A06 Annex D as (1) Residual [asphaltic (bitumen)] compounds, (2) High viscosity oils, (3) Compounds or (4) Greases. 2. Open gear lubricants supplied under this specification must have excellent adhesive and cohesive qualities, must not chip or throw off, and must provide sufficient film thickness and scuffing resistance to prevent metal to metal contact between applications of the lubricant under all operating conditions. Therefore: (2) High viscosity oils are NOT recommended due to performance characteristics at relatively slow speeds and frequent stop/start application; and (4) Greases inherently provide marginal film thicknesses at low speed which requires properly designed additive packages and thickener selection, stringent break in procedures and more frequent lubricant intervals. 3. Various grades or consistencies of open gear lubricants may be required to provide proper lubrication and application properties over a wide range of ambient temperatures. The consistency of the lubricant as applied must be appropriate for the method of application, and the in-service consistency shall be appropriate for the lubricant to meet or exceed the minimum performance requirements listed in the “MINIMUM PERFORMANCE REQUIREMENTS” section.
TITLE:
OGL – OPEN GEAR LUBRICANT
APPROVALS:
Director of Engineering :
Richard Morrell
DATE:
Initiator:
June 2011
Page 1 of 4
SD 4713
Timothy Vail
This document is the property of Bucyrus International, Inc. Subject matter herein is private, confidential and restricted. Do not use, reproduce, copy, distribute or disclose except with, and only to the extent of, prior written consent of Bucyrus International, Inc. Persons receiving this document a re respon sible for restricting di sclosure, excep t as abso lutely necessary consistent with the intended use. When such use is completed, return immediately to Bucyrus Internationa l, Inc. © 2011 Bucyrus International, Inc. All rights reserved.
Specification Data
4. Viscosity, a fluid’s resistance to flow, is the principal physical characteristic of a fluid in terms of its ability to produce a lubricating film between two interfacing surfaces. All lubricating fluids possess a natural viscosity that may be altered (enhanced) by additives such as resins or polymers. Some “viscosity enhancers” are shear sensitive, which could result in insufficient protection of the lubricated components under high load, elevated temperatures and/or high shear conditions. The viscosity of the fluids utilized in the open gear lubricants shall be sufficient under operating conditions for the product to meet or exceed the performance requirements listed in the “MINIMUM PERFORMANCE REQUIREMENTS” section. 5. Open gear lubricants supplied under this specification must be specifically formulated to protect surfaces, reduce wear, and provide satisfactory service life under all anticipated operating conditions. 6. Open gear lubricants supplied under this specification must have excellent water tolerance and rust preventive qualities, as well as minimal dripping qualities for operation over wide temperature ranges. 7. Should the material furnished under this specification contain a diluent to improve dispensability, special care must be exercised to ensure its compatibility with all centralized lubrication system components, i.e., gaskets, o-rings, vent valves, etc., and oil seal lip materials (Nitriles, Viton). Reference ASTM D 4289-03. 8. For extended use in low temperature areas, open gear lubricants supplied under this specification should be capable of slumping in containers and should be pumpable through lube lines without the aid of heat tracing. In order to minimize compatibility problems, it is desirable that the thickener and additive system be compatible with the additional grades that are suitable for the other ambient temperatures.
TITLE:
OGL – OPEN GEAR LUBRICANT
APPROVALS:
Director of Engineering :
Richard Morrell
DATE:
Initiator:
June 2011
Page 2 of 4
SD 4713
Timothy Vail
This document is the property of Bucyrus International, Inc. Subject matter herein is private, confidential and restricted. Do not use, reproduce, copy, distribute or disclose except with, and only to the extent of, prior written consent of Bucyrus International, Inc. Persons receiving this document a re respon sible for restricting di sclosure, excep t as abso lutely necessary consistent with the intended use. When such use is completed, return immediately to Bucyrus Internationa l, Inc. © 2011 Bucyrus International, Inc. All rights reserved.
Specification Data
MINIMUM PERFORMANCE REQUIREMENTS: PROPERTY
REFERENCE
Flash point of product as applied, minimum (base product with diluent) Ambient Temperature (See Note #1) -50°C(-58°F) to + 10°C (50°F) Above +10°C(50°F)
REQUIREMENT
ASTM D92 / ISO 2592 61°C (142°F) 80°C (176°F)
Flash point of base fluid(s), minimum
ASTM D92 / ISO 2592
140°C (284°F)
ASTM D 1743
Pass
Copper strip corrosion Maximum rating o o 24hr. @ 100 C (212 F)
ASTM D 4048
2a
Four ball EP test weld point, minimum kgf (base product without diluent)
ASTM D 2596
Load wear index (LWI), minimum (base product without diluent)
ASTM D 2596
Four ball wear test 60 minutes @ 40 kgf. Maximum scar, mm (base product without diluent)
ASTM D 2266
Rust protection
Adhesive properties
800
120
0.7
Must adhere to surfaces at the lowest anticipated ambient temperature. (See Note #1)
Minimum Base Fluid Viscosity ASTM D 445
Ambient Temperature (See Note #1) All - Except Electric Mining Shovel Hoist Drum Gear °C (°F) -50 to +10 (-58 to +50) -20 to +40 (-4 to +104) +10 to +50 (+50 to +122)
680 cSt at 40°C 1860 cSt at 40°C 3600 cSt at 40°C
Minimum Base Fluid Viscosity ASTM D 445
Ambient Temperature (See Note #1) Electric Mining Shovel Hoist Drum Gear °C (°F) +10 to +35 (+50 to +95) +25 to +50 (+77 to +122)
3600 cSt at 40°C 5000 cSt at 40°C To vent from 1800 psi (127 kgf/cm^2) to less than or equal to 600 psi (42 kgf/cm^2) within 30 seconds at the lowest anticipated ambient temperature.
Pumpability, Lincoln Ventmeter
TITLE:
OGL – OPEN GEAR LUBRICANT
APPROVALS:
Director of Engineering :
Richard Morrell
DATE:
Initiator:
June 2011
Page 3 of 4
SD 4713
Timothy Vail
This document is the property of Bucyrus International, Inc. Subject matter herein is private, confidential and restricted. Do not use, reproduce, copy, distribute or disclose except with, and only to the extent of, prior written consent of Bucyrus International, Inc. Persons receiving this document a re respon sible for restricting di sclosure, excep t as abso lutely necessary consistent with the intended use. When such use is completed, return immediately to Bucyrus Internationa l, Inc. © 2011 Bucyrus International, Inc. All rights reserved.
Specification Data
Molybdenum Disulfide
2% Minimum
Lubricating Solids (Molybdenum Disulfide, Graphite, Etc.) Particle Size
15 Micron Nominal 44 Micron Maximum
NOTE: 1. Ambient Temperature – The ambient temperature shall be the temperature at the point of lubricant application. The Electric Mining Shovel Hoist Drum Gear is enclosed in a heated mac hinery room which shou ld not be below 1 0°C (50°F).
LUBRICANTS: Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/local regulatory requirements. Lubricants shall be certified by their manufacturers as complying with this specification. Quality Control Documentation may be requested pertaining to viscosity, weld point and scar per batch to validate properties. The use of lubricants not meeting this specification may invalidate the Bucyrus International, Inc. product warranty obligation.
SPECIFICATION REVISIONS: This specification is subject to change without notice. Please contact the following for the latest specification: Bucyrus International, Inc. Engineering Services & Technical Support 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone (414) 768-4000
TITLE:
OGL – OPEN GEAR LUBRICANT
APPROVALS:
Director of Engineering :
Richard Morrell
DATE:
Initiator:
June 2011
Page 4 of 4
SD 4713
Timothy Vail
This document is the property of Bucyrus International, Inc. Subject matter herein is private, confidential and restricted. Do not use, reproduce, copy, distribute or disclose except with, and only to the extent of, prior written consent of Bucyrus International, Inc. Persons receiving this document a re respon sible for restricting di sclosure, excep t as abso lutely necessary consistent with the intended use. When such use is completed, return immediately to Bucyrus Internationa l, Inc. © 2011 Bucyrus International, Inc. All rights reserved.
ANEXO V
HOJA TECNICA MOBILTAC 275 (PETRON OGL 595)
ENGINEERED INDUSTRIAL LUBRICANTS & METALWORKING PRODUCTS
