Mill Lubrication

and
Clear Gear
Technology

Bel-Ray Mill Lubrication Program

Molylube Repair Compound

Molylube SF100 Semi-Synthetic OGL

Medium, Heavy, Extra Heavy

CompleteMill
GearProgram

(Repair)

Priming
Running In
Operational

Priming

Molylube Mill Gear Grease

Operational

RunningIn

Clear Gear Lubricant

Molylube Running In Compound

Priming-Get It Started Right

Priming
Get It Started Right

Priming-Get It Started Right

Priming:
Molylube SF100 Semi-Synthetic Open Gear
(Medium, Heavy, Extra Heavy)
Pre-coating a fresh contact surface to prevent tooth
damage on start up
Apply manually by:
Brush
Spatula

Priming-Get It Started Right

Priming Quantity:
55
50
45

900

800

35

700

30

600

25

500

20

400

15

300

10

200

3000

4000

5000

GearDiameter,mm

6000

7000

8000

ToothFlankWidth,mm

RequiredPrimingCompound,kg

40

0
2000

Example of Chart Use:

1000

Gear Diameter, mm: 7000

Flank Width, mm: 800
Required Priming Compound:
kg: 34
lb: 76

Running In-Smoothing the Roughness

Running In
Smoothing the Roughness

Running In-Smoothing the Roughness

What Is Running In?
In Situ resurfacing of mill gear teeth
using special non-abrasive compounds
Why Is Running In Beneficial?
New Pinion Roughness:
Average, RaBefore Run In=4.3
Average, RaAfter Run In=0.4 to 2.0

A Smoother Surface=Increased
Surface Contact Area=Reduce
Contact Pressure=Reduced
Wear=Longer Gear Life

Running In-Smoothing the Roughness

RunningInvs.AsperityHeight
5

AsperityHeight,microns

4.5
4
3.5
3
2.5

Molylube Mill Gear Grease:

Medium @ 2.37
Heavy @ 2.73

2
1.5
1
0.5
0

Competitor Grease OGL @ 1.70

Running In-Smoothing the Roughness

When to run in:

New gears or pinions

Turned gear or pinions
Uneven temperature
across flank

Typical Duration and Volume:

Running in requires up to 500 hours
Consumption: 8 g/cm/hr for the duration
of the process (double pinion mill)

Molylube Running In Cpd.

1.
2.
3.
4.
5.

Grease type OGL

Superior EP/AW
Non-abrasive
Heat Activated
Deactivates when run in is
complete

Running In-Smoothing the Roughness

Running In-Measures of Success
Consistent temperature across the
girth gear tooth widths and around
the circumference (~3oC)
Vibration patterns at the pinion
bearings improved

Running In-Smoothing the Roughness

Specifics of the Use of Molylube Running In
Compound
1. Use through standard lubrication system.
2. Duration: typically 500 hours
3. Consumption (grams/centimeter/hour):
Application(width,cm)

Consumption
g/cm/hr

Total Pounds
500hr

Singlepinion kiln(50)

275

Singlepinionmill(50)

330

Largesinglepinion millanddoublepinionkiln(100)

771

Doublepinionmill(100)

881

Operational OGL-Grease
Grease Type OGL
Disadvantages
1. Low base oil viscosity
2. Operates in boundary mode
3. Questionable fluidity of
spent lubricant

Molylube Mill Gear Grease

Advantages
1. Base oil selections following
ANSI/AGMA guidelines
2. Exceptional EP/AW
3. Readily flows to waste

Operational OGL-Grease
Molylube Mill Gear Grease & the Competition
Product

Base Oil Viscosity, cst @ 40oC*

ANSI/AGMA 9005-E02
-10oC to +5oC
+5oC to +20oC
+20oC to +50oC
Film Thickness @ 60oC,
microns

Molylube Mill Gear Grease

Medium and Heavy

Fuchs Ceplattyn
KG10 HMF 2500

Kluber Grafloscon
C-SG Ultra

1570 (L)
4630(M)
6440(H)

1000
2500

1000
2000

4140 cst @ 40oC, minimum

6120 cst @ 40oC, minimum
190 Cst @ 100oC, minimum
2.37(M)
2.73(H)

1.17 (1000)
1.65 (2500)

1.13 (1000)
1.65 (2000)

Operational OGL-Grease
Specifics in the Use of Molylube Mill Gear Grease
1. Use through standard lubrication system.
2. Duration: continuous during normal operation
3. Consumption (grams/centimeter/hour):
Application (width, cm)

Consumption
g/cm/hr

Pounds
Month

Drums
Year

Single-pinion kiln (50)

1.5

119

3-4

Single-pinion mill (50)

2.0

159

4-5

Large single-pinion mill and double-pinion kiln

(100)

2.5

397

12

Double-pinion mill (100)

3.0

476

14-15

BEL-RAY CLEAR GEAR:

Excellence in Open Gear Lubrication

Operational OGL-High Viscosity Synthetic

Bel-Ray Clear Gear General Data
Light

Medium

Standard

Heavy

Extra
Heavy

KinematicViscosity@ 40oC,cst

4,270

10,859

16,837

28,204

45,273

KinematicViscosity@100oC,cst

239.5

472.8

618.5

997.9

1354

ANSI/AGMA9005E02Recommendations
10oC to+5oC
+5oCto+20oC
+20oCto+50oC
ViscosityIndex
PourPoint,oC (oF)
FourBallWearTest,ASD*,mm
TimkenOKLoad,kg (lb)

4140cst@40oC,minimum
6120cst@40oC,minimum
190Cst@100oC,minimum
179

194

195

219

223

18(0)

6 (21)

0(32)

3(37)

3(37)

0.42
40.8(90)

FZG,ScuffingLoadStage (12max.)

>12

FZGWorkRelatedWear,mg/kWh

<0.2

Operational OGL-High Viscosity Synthetic

Bel-Ray Clear Gear Standard Grade: 60oC Film Thickness
RunningInvs.AsperityHeight
5
4.5

Clear Gear Standard @ 4.4

AsperityHeight,microns

3.5
3
2.5

Molylube Mill Gear Grease:

Heavy @ 2.73
Medium @ 2.37

2
1.5
1
0.5
0

Competitor Grease OGL @ 1.70

Operational OGL-High Viscosity Synthetic

The Technology of Clear Gear
Secret

Benefit

BaseOils

Fully syntheticfluidsselectedforveryspecific
propertiestoensurefilmformationand
maximumfilmthickness.

HighEndGearOilPackage

Providebasicproperties includingAW,EP,rust
andcorrosionprotection.

Friction ModifiersandPerformance Reducefriction leadingtosignificantlyreduced

Boosters
operatingtemperatureandvibration.

DO YOU REALLY THINK WERE GOING TO TELL YOU

THE SECRET TO CLEAR GEAR?....THINK AGAIN BUT
KNOW THAT IT WORKS AND ITS THE BEST.

Operational OGL-High Viscosity Synthetic

An Amazing Picture:
Gear and pinion completely
wrapped in a protective web
of Clear Gear.
Lubricating film across flank
renewed on every mesh.

Operational OGL-High Viscosity Synthetic

Specifics in the Use of Bel-Ray Clear Gear
1. Use through standard lubrication system.
2. Duration: continuous during normal operation
3. Consumption (grams/centimeter/hour):
Application (width, cm)

Consumption
g/cm/hr

Pounds
Month

Drums
Year

Single-pinion kiln (50)

1.0

79

2-3

Single-pinion mill (50)

1.3

103

3-4

Large single-pinion mill and double-pinion kiln

(100)

1.5

237

7-8

Double-pinion mill (100)

1.8

286

8-9

Bel-Ray Mill Gear Lubricants & Accessories

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