Coal shearer gearbox
A dedicated calculation for a set of two shearer gearboxes. Treatment is carried out without taking the machine out of the face.
Coal shearer gearboxes: two machines with a 60 l oil bath each
The rate matches the class standard — 3.0 ml per litre; the cycle is shortened to 400 hours against 450 in the class procedure. Industrial reducers and transmissions →
What is treated
- A serviceable gearbox with no parts at 100 % wear and no macromechanical damage.
- Oil leaks have been eliminated — otherwise the concentration of the compound will not hold.
What is measured before and after
| Parameter | Instrument | How and when |
|---|---|---|
| Vibration level at the bearing supports | vibrometer | Vibration acceleration, vibration velocity, vibration displacement in three directions. |
| Noise level at fixed points | sound level meter | — |
| Power consumption or current of the electric motor | current clamps, wattmeter | At no load and at a fixed load, at the same oil temperature. |
| Oil temperature conditions | liquid-in-glass thermometer or pyrometer | — |
| Tooth thickness of the gear wheels | gear tooth caliper with a scale division no coarser than 0.05 mm | Over the constant chord; chord height h = 0.748·m, where m is the tooth module. |
| Condition of the contact patterns on the marked teeth | visually or with a camera | — |
Dosage rates
| Compound | Rate | How and when |
|---|---|---|
| Gel for transmissions and gearboxes | 3.0 ml per 1 litre of the standard oil per stage | 60 l bath: 180 ml per stage (20 tubes), 540 ml per gearbox, 1080 ml for two machines. |
Treatment stages
- Dilute the gel in the standard oil heated to 40–60 °C (1 part gel to 5–10 parts oil) and introduce it with the equipment shut down through the inspection hatch or the oil filler opening.Start of the operating time count
- The second stage is performed in the same way as the first.After 8–12 hours of total operating time
- The third stage is performed in the same way as the first.After another 8–12 hours
After treatment
- The treatment is complete after 400 hours of total operating time.
Points to watch
- Gearboxes without oil filtration and without hydraulic system elements may be treated by applying the gel directly onto the gear teeth.
- Tooth thickness is measured with a gear tooth caliper with a scale division no coarser than 0.05 mm.
Where coal shearer gearbox has already been treated
- Gavrilenko V. D. Peasant Farm · 2008↑ 1.6-5.1% — compression in all six cylinders, 29.5-30.5 → 31.0-31.5 kgf/cm²
Source: XADO applied procedure, lead engineer I. N. Sharaikin. Class standard — instruction IE-24.6-25612000-005-2008, method No. 4. Analysis: state/DRIVE_METHODS.md.