FLS OGL Specifications

Engineering Documentation
Installation, Operation, and Maintenance Instructions

Issued by: P. Debrah Dept: 2-26
Level III Number: 70.736.019 Rev: 2 Page: 1 of 13
Subject: Gear Set Lubrication Guidelines
1.0 Introduction
1.1 FLSmidth Minerals ring gears are the highest quality gears available for use on
Cylindrical Grinding Mills, Kilns, Coolers and Dryers. To fully realize the
advantages of this high quality, the gears must be properly installed and properly
maintained.
1.2 To achieve their individual design lives, gears and pinions must be properly
lubricated with a clean, dry lubricant of the proper viscosity and film strength.
Furthermore, the set must be properly aligned and operated within its rated
capacity.
2.0 Scope
2.1 This document defines the types of lubricants and lubrication systems to be used
for gears designed and manufactured to FLSmidth Minerals specifications and
intended for use in the above mentioned applications.
2.2 This document does not recommend lubricants by trade name.
2.3 The lubricants and lubrication systems described in this document each have a
long history of successful use in the applications for which they were employed.
Other lubricants and systems will be included once they have demonstrated their
ability to successfully protect, over extended time periods, the equipment to
which they have been applied.
3.0 Reference(s)
3.1 ANSI/AGMA 9005-D94 Industrial Gear Lubrication
3.2 AGMA 251.02 Lubrication of Industrial Open Gearing
3.3 Portions of this document are extracted from ANSI/AGMA 9005-D94, Industrial
Gear Lubrication and AGMA 251.02, Lubrication of Industrial Open Gearing with
the permission of the publisher, the American Gear Manufactures Association,
1500 King Street, Suite 201, Alexandria, Virginia 22314.
3.4 ED 70.736.014 Inspection of Mill Gear Mesh Temperature, for a Single

Rotation and Single Pinion Drive.
Print Date: 02 May 2017 Copy Not Automatically Updated FLSmidth Inc.
Number: 70.736.019 Revision: 2 Page: 2 of 13
4.0 Types of Lubricants
4.1 All lubricants shall meet all the requirements of ANSI/AGMA 9005-D94.
4.2 Extreme Pressure (EP) Lubricants:
4.2.1 Extreme pressure gear oils are petroleum-based lubricants containing

special chemical additives, which produce a protective film that provides
anti-scuffing properties.
4.3 Residual Compounds-Diluent Type:
4.3.1 Residual compounds are straight mineral or EP oils in the heavier grades
mixed with a diluent for ease of application. The evaporation of the diluent
allows the lubricant to adhere to the gear tooth flanks and form a high
strength film to protect the teeth against wear.
4.3.2 It is recommended that compounds have a Timken film strength of 33 lbs

as measured by the US Steel Retention Test Method. Lubricant samples to
be tested should include diluent in the same proportions found in the
drums.
4.4 Synthetic Gear Lubricants:
4.4.1 Synthetic oils differ from petroleum based liquids in that they are not
found in nature, but are manufactured chemically with special properties
to enhance performance or accommodate severe operating conditions.
Generally, synthetic oils have higher viscosity indices than mineral oils
which means a smaller viscosity change in response to a given
temperature differential.
4.5 Greases and Special Compounds:
4.5.1 In most of these lubricants, the components include a base oil, a thickener,
and in some cases, a solid lubricant such as graphite or molybdenum
disulfide. Generally, the thickener does not contribute to the lubrication
except to hold the oil and solid lubricant in place.
4.5.2 The specification of these lubricants and their accompanying lubrication

systems is beyond the scope of this document. FLS Minerals will work
with customers, on a case by case basis, to select a lubricant and design a
system to meet their needs.
5.0 Methods of Application
5.1 Intermittent Mechanical Spray Systems:
5.1.1 With these systems, the lubricant is sprayed on the working flanks of the
gear at regular, predetermined time intervals. The lubricant should be such
that it remains on the gear teeth during the interval between spray periods.
5.1.2 These systems have historically been used on grinding mills, and they are
increasingly being used on kilns and like equipment.
5.2 Idler Immersion Systems:
5.2.1 This is the simplest method of lubricating gears. The lubricant is drawn
from the gear guard sump and delivered to the gear or pinion by a partially
submerged oiling idler.
5.2.2 These systems have historically been used on kilns and like equipment.
They are not suitable for grinding mills because of speed limitations.
5.3 Continuous Pressure Lubrication Systems:
5.3.1 These are circulating systems that employ a pump to provide a continuous
spray of lubricant to the gear or pinion.
5.3.2 This is the preferred method of lubricating gears. Satisfactory systems can
be designed regardless of equipment or operating conditions.
6.0 Intermittent Mechanical Spray Systems
6.1 Residual compound-diluent type lubricants are to be used with these systems.
Guidelines for lubricant selection are shown in Table 1.
6.2 The lubricant shall be applied to the working flanks of the gear teeth immediately
after mesh to afford the diluent time to evaporate. Spraying the tooth flanks of the
pinion is not recommended.
6.3 The spray shall be activated automatically at regular timed intervals.
6.4 The spraying period should equal the time for one or preferably two revolutions
of the gear to ensure complete coverage.
6.5 Usually, the spray period is followed by an air purge or after blow for
approximately 30 seconds to assist in keeping the spray nozzles clean.
6.6 Spray nozzles shall be sufficient in number and properly spaced to provide
adequate lubricant across the entire face width of the gear.
6.7 The spray nozzles shall be positioned to direct the lubricant at the working flanks
of the gear teeth and should be located a minimum distance of 6 inches and a
maximum distance of 8 inches from the tooth surfaces.
6.8 The recommended total quantity of lubricant (all nozzles) is given by the
following:
Q = [(0.6 x D) + (0.15 x F) 4.8] x T
Q = total quantity of lubricant per application, ounces.

D = gear diameter, feet. If D < 10 feet, then set D = 10 feet.
F = gear face width, inches. If F < 8 inches, then set F = 8 inches.
T = time interval between applications, hours.
6.9 The suggested time interval between applications of lubricant is 0.25 hours. One
hour is the maximum interval permitted. More frequent application of smaller
quantities is preferred.
6.10 The recommended quantities of lubricant are tabulated in Tables 4 and 5,

Appendix A from the above equation. The total quantities shown in Tables 4 and 5
are in ounces and cubic centimeters, respectively.
6.11 The quantities of lubricant applied may, with experience, be reduced. However,
any adjustment will necessitate observing the lube film through three or four
applications to insure that the film remains intact between applications. The
quantities of reduced lubricant shall not be less than the typical values shown in
Tables 6 and 7 Appendix A, and are in ounces and cubic centimeters, respectively.
6.12 Periodic inspections should be made to ensure that sufficient lubricant is being
applied to give proper protection.
6.13 The spray pattern should be inspected frequently since the spray nozzles have a
tendency to become partially or fully clogged.
6.14 The gear and pinion should be thoroughly cleaned once a year. Special care
should be taken to remove the lubricant that has built up or caked in the roots of
the teeth. In severe cases, this caked lubricant can interfere with the proper
meshing of the gear teeth.
6.15 Protective devices are strongly recommended to warn of failure of timers, heaters,
air pressure and lubricant supply.
Table 1 - Viscosity Ranges for Intermittent Mechanical Spray Systems
Residual Compounds - Viscosity Range Metric Equivalent Viscosity

Diluent Type Range
AGMA Lubricant SSU at 210 Degrees Fahrenheit cSt at 100 Degrees Celsius
Number
15R 4,000 to 8,000 857 to 1714
NOTES
1) Viscosities of AGMA Lubricants Number 13 and above are specified at 100C (210F) as
measurement of viscosity of these heavy lubricants at 40C (100F) would not be
practical.
2) Residual compounds-diluent type, commonly know as solvent cutback, are heavy oils
containing a volatile, non-flammable diluent for ease of application. The diluent
evaporates leaving a thick film of lubricant on the surface of the gear teeth. Viscosities
listed are for the base compound without diluent.
CAUTION: These lubricants may require special handling and storage procedures.
Diluent can be toxic or irritating to the skin. Do not use these lubricants
without proper ventilation. Consult lubricant suppliers instructions.
7.0 Idler Immersion Systems
7.1 Petroleum based or synthetic gear oils are to be used with these systems.
Guidelines for lubricant selection are shown in Table 2.
7.2 Idler immersion systems are limited to pitch-line velocities below 300 feet per
minute.
7.3 It is preferred that the oiling idlers be driven by the pinion rather than by the gear, as
this more effectively lubricates the working flanks of both the pinion and gear.
7.4 Maximum oil sump temperatures have been established for the various types of
lubricants. They are limited to the temperature values above which many of these
lubricants become unstable.
7.4.1 The maximum oil sump temperature for petroleum based gear oils is
200F.
7.4.2 The maximum oil sump temperature for synthetic gear oils is 225F.
7.5 Under normal operating conditions, the lubricant should be changed every 2500
operating hours or six months, whichever occurs first.
7.5.1 Conditions that may require more frequent lubricant changes include:
- Ambient conditions of extreme dust, dirt, moisture and/or chemical

fumes.
- Sustained lubricant sump temperature approaching 200F.
- Ambient conditions causing large and rapid temperature changes.
7.5.2 The lubricant change interval can be extended by continuously draining oil
from the sump, passing it through a filter, and pumping it back to the
sump, at a location remote from the drain.
7.6 When ambient temperatures are low, the use of sump heaters is strongly
recommended to promote proper circulation of the lubricant and to prevent
channeling.
Table 2 Viscosity Ranges for Idler Immersion Systems

Petroleum Base Extreme Pressure Viscosity Range Metric Equivalent
or Gear Lubricants Viscosity Range
Synthetic Gear Oils
AGMA Lubricant AGMA Lubricant SSU at 210 cSt at 100
Number Number Degrees Fahrenheit Degrees Celsius
11 or 12, 11S or 12S 11EP or 12EP 400 to 500 86 to 109
8.0 Continuous Pressure Lubrication Systems
8.1 Petroleum based or synthetic gear oils are to be used with these systems.
Guidelines for lubricant Selection are shown in Table 3.
8.1.1 The choice of lubricant viscosity varies for each individual gear set.
Selection depends upon such things as pitch-line velocity, gear and pinion
rotational speed, transmitted power and tooth surface finish.
8.2 There are no speed limitations for these systems.
8.3 The lubricant is sprayed through nozzles onto the working flanks of the pinion or
gear teeth immediately prior to mesh.
8.4 Spray nozzles shall be sufficient in number and properly spaced to provide
adequate lubricant across the entire face width of the gear.
applied to give proper protection.
8.6 Oil that runs off or is thrown from the gears flows down the gear guard to a
recovery sump. The sump is typically protected with screens and magnets.
8.7 Level switches in the recovery sump control a return pump, which pumps the oil
back to the reservoir. The returning oil flows through filters to remove
contamination particles. Dual filters are typically employed.
8.8 Protective devices are strongly recommended to warn of failure of coolers or

heaters, inadequate lubricant supply and dirty filters.
8.9 When ambient temperatures are low, the use of sump and line heaters is strongly
recommended to promote proper circulation of the lubricant and to prevent
channeling.
Table 3 Viscosity Ranges for Continuous Pressure Lubrication Systems

Petroleum Base Extreme Pressure Viscosity Range Metric Equivalent
or Gear Lubricants Viscosity Range
Synthetic Gear Oils
AGMA Lubricant AGMA Lubricant SSU at 100 cSt at 40
Number Number Degrees Fahrenheit Degrees Celsius
7 or 7S 7EP 1919 to 2346 414 to 506
8 or 8S 8EP 2837 to 3467 612 to 748
9 or 9S 9EP 6260 to 7650 1350 to 1650
10 or 10S 10EP 13350 to 16320 2880 to 3520
11 or 11S 11EP 19190 to 23460 4140 to 5060
12 or 12S 12EP 28370 to 34670 6120 to 7480
9.0 Inspections
applied to gear set.
9.2 Periodically inspect the lubricant for possible contamination. If contaminated,

replace the lubricant and thoroughly clean both gear and the pinion.
9.3 Once every month, wipe the lubricant off several teeth of the gear and pinion.
Inspect the tooth surfaces for any sign of abnormal wear or insufficient
lubrication. An infrared temperature profile should be made prior to this
inspection and the results recorded.
9.3.1 The monthly temperature profiles should be kept in a readily accessible

location for comparison and trending purposes.
9.4 Once every year, thoroughly clean the gear set and the internals of the gear guard.
10.0 Appendix A
Table 4 FLSM Recommended Total Quantities of Lubricant

in Ounces
Automatic Spray System

Gear Application in Ounces
Diameter Face Width In Inches
in Feet 8 16 24 32 40
10 0.6 0.9 1.2 1.5 1.8

12 0.9 1.2 1.5 1.8 2.1
14 1.2 1.5 1.8 2.1 2.4
16 1.5 1.8 2.1 2.4 2.7
18 1.8 2.1 2.4 2.7 3.0
20 2.1 2.4 2.7 3.0 3.3
22 2.4 2.7 3.0 3.3 3.6
24 2.7 3.0 3.3 3.6 3.9
26 3.0 3.3 3.6 3.9 4.2
28 3.3 3.6 3.9 4.2 4.5
30 3.6 3.9 4.2 4.5 4.8
34 4.2 4.5 4.8 5.1 5.4
36 4.5 4.8 5.1 5.4 5.7
38 4.8 5.1 5.4 5.7 6.0
40 5.1 5.4 5.7 6.0 6.3
42 5.4 5.7 6.0 6.3 6.6
44 5.7 6.0 6.3 6.6 6.9
46 6.0 6.3 6.6 6.9 7.2
NOTES:
The spraying time should equal the time for 1, and preferably 2 revolutions of the
gear to ensure complete coverage. Periodic inspections should be made to ensure that sufficient
lubricant is being applied to give proper protection.
The suggested time interval between applications of lubricant is 0.25 hours. One hour is the
maximum interval permitted. More frequent application of smaller quantities is preferred.
For a difference in gear proportions from those shown, the quantities of lubricant can be obtained
by interpolation.
Table 5 FLSM Recommended Total Quantities of Lubricant in

Cubic Centimeters

Gear Application in Cubic Centimeters
in Feet 8 16 24 32 40
10 17.7 26.6 35.5 44.4 53.2
12 26.6 35.5 44.4 53.2 62.1
14 35.5 44.4 53.2 62.1 71.0
16 44.4 53.2 62.1 71.0 79.8

18 53.2 62.1 71.0 79.8 88.7
20 62.1 71.0 79.8 88.7 97.6
22 71.0 79.8 88.7 97.6 106.5
24 79.8 88.7 97.6 106.5 115.3
26 88.7 97.6 106.5 115.3 124.2
28 97.6 106.5 115.3 124.2 133.1
30 106.5 115.3 124.2 133.1 142.0
34 124.2 133.1 142.0 150.8 159.7
36 133.1 142.0 150.8 159.7 168.6
38 142.0 150.8 159.7 168.6 177.4
40 150.8 159.7 168.6 177.4 186.3
42 159.7 168.6 177.4 186.3 195.2
44 168.6 177.4 186.3 195.2 204.1
46 177.4 186.3 195.2 204.1 212.9
NOTES:
by interpolation.
Table 6 FLSM Recommended Quantities of Reduced Lubricant

in Ounces

Gear Application in Ounces
in Feet 8 16 24 32 40
10 0.2 0.3 0.4 0.5 0.5
12 0.3 0.4 0.5 0.5 0.6
14 0.4 0.5 0.5 0.6 0.7
16 0.5 0.5 0.6 0.7 0.8
18 0.5 0.6 0.7 0.8 0.9
20 0.6 0.7 0.8 0.9 1.0
22 0.7 0.8 0.9 1.0 1.1

24 0.8 0.9 1.0 1.1 1.2
26 0.9 1.0 1.1 1.2 1.3
28 1.0 1.1 1.2 1.3 1.4
30 1.1 1.2 1.3 1.4 1.4
34 1.3 1.4 1.4 1.5 1.6
36 1.4 1.4 1.5 1.6 1.7
38 1.4 1.5 1.6 1.7 1.8
40 1.5 1.6 1.7 1.8 1.9
42 1.6 1.7 1.8 1.9 2.0
44 1.7 1.8 1.9 2.0 2.1
46 1.8 1.9 2.0 2.1 2.2
NOTES:
by interpolation.
The above recommended quantities of reduced lubricant are tabulated from equation:
Q = [(0.18 x D) + (0.05 x F) 1.45] x T
Q = total quantity of lubricant per application, ounces (oz).
Table 7 FLSM Recommended Quantities of Reduced Lubricant
in Cubic Centimeters

Gear Application in Cubic Centimeters
in Feet 8 16 24 32 40
10 5.3 8.0 10.7 13.4 16.0
12 8.0 10.7 13.4 16.0 18.7
14 10.7 13.4 16.0 18.7 21.4
16 13.4 16.0 18.7 21.4 24.1
18 16.0 18.7 21.4 24.1 26.7
20 18.7 21.4 24.1 26.7 29.4
22 21.4 24.1 26.7 29.4 32.1
24 24.1 26.7 29.4 32.1 34.7
26 26.7 29.4 32.1 34.7 37.4

28 29.4 32.1 34.7 37.4 40.1
30 32.1 34.7 37.4 40.1 42.8
34 37.4 40.1 42.8 45.4 48.1
36 40.1 42.8 45.4 48.1 50.8
38 42.8 45.4 48.1 50.8 53.4
40 45.4 48.1 50.8 53.4 56.1
42 48.1 50.8 53.4 56.1 58.8
44 50.8 53.4 56.1 58.8 61.5
46 53.4 56.1 58.8 61.5 64.1
NOTES:
by interpolation.
The above recommended quantities of reduced lubricant are tabulated from equation:
Q = [[(0.18 x D) + (0.05 x F) 1.45] x T] x 29.57353
Q = total quantity of lubricant per application, cubic centimeters (cc).

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Engineering Documentation

Installation, Operation, and Maintenance Instructions

Subject: Gear Set Lubrication Guidelines

2.2 This document does not recommend lubricants by trade name.

3.1 ANSI/AGMA 9005-D94 Industrial Gear Lubrication

3.2 AGMA 251.02 Lubrication of Industrial Open Gearing

3.4 ED 70.736.014 Inspection of Mill Gear Mesh Temperature, for a Single

4.0 Types of Lubricants

4.2 Extreme Pressure (EP) Lubricants:

4.2.1 Extreme pressure gear oils are petroleum-based lubricants containing

4.3 Residual Compounds-Diluent Type:

4.3.2 It is recommended that compounds have a Timken film strength of 33 lbs

4.4 Synthetic Gear Lubricants:

4.5 Greases and Special Compounds:

4.5.2 The specification of these lubricants and their accompanying lubrication

5.0 Methods of Application

5.1 Intermittent Mechanical Spray Systems:

5.2 Idler Immersion Systems:

5.3 Continuous Pressure Lubrication Systems:

6.0 Intermittent Mechanical Spray Systems

6.3 The spray shall be activated automatically at regular timed intervals.

Q = [(0.6 x D) + (0.15 x F) 4.8] x T

Q = total quantity of lubricant per application, ounces.

6.10 The recommended quantities of lubricant are tabulated in Tables 4 and 5,

Table 1 - Viscosity Ranges for Intermittent Mechanical Spray Systems

Residual Compounds - Viscosity Range Metric Equivalent Viscosity

15R 4,000 to 8,000 857 to 1714

7.0 Idler Immersion Systems

- Ambient conditions of extreme dust, dirt, moisture and/or chemical

Table 2 Viscosity Ranges for Idler Immersion Systems

8.0 Continuous Pressure Lubrication Systems

8.2 There are no speed limitations for these systems.

8.8 Protective devices are strongly recommended to warn of failure of coolers or

Table 3 Viscosity Ranges for Continuous Pressure Lubrication Systems

8 or 8S 8EP 2837 to 3467 612 to 748

9 or 9S 9EP 6260 to 7650 1350 to 1650

10 or 10S 10EP 13350 to 16320 2880 to 3520

11 or 11S 11EP 19190 to 23460 4140 to 5060

12 or 12S 12EP 28370 to 34670 6120 to 7480

9.2 Periodically inspect the lubricant for possible contamination. If contaminated,

9.3.1 The monthly temperature profiles should be kept in a readily accessible

Table 4 FLSM Recommended Total Quantities of Lubricant

Automatic Spray System

10 0.6 0.9 1.2 1.5 1.8

Table 5 FLSM Recommended Total Quantities of Lubricant in

Automatic Spray System

16 44.4 53.2 62.1 71.0 79.8

Table 6 FLSM Recommended Quantities of Reduced Lubricant

Automatic Spray System

22 0.7 0.8 0.9 1.0 1.1

Automatic Spray System

26 26.7 29.4 32.1 34.7 37.4

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