Gears 3 – Open Gear Lubricants

Open gears are critical components in heavy industries such as mining, cement, and power generation, where they drive large rotating equipment under extreme loads and harsh environmental conditions. Unlike enclosed gear systems, open gears are exposed to contaminants, varying temperatures, and high wear, making proper lubrication essential for their performance and longevity.

This course provides an in-depth understanding of open gear lubrication, covering gear design, lubrication principles, lubricant selection, and application methods. Participants will explore different types of open gear lubricants, including asphaltic, grease-based, and synthetic options, as well as specialized lubricants for priming, running-in, and repair applications. The course also covers key industry standards for open gear lubrication and best practices for ensuring effective lubricant application and gear protection.

Designed for maintenance professionals, lubrication engineers, and reliability specialists, this course equips participants with the knowledge and skills to optimize open gear lubrication, reduce wear and failure risks, and extend the service life of these critical components.

Course Modules:
Gears 03 01 – Open Gears
Understand the design, function, and operational challenges of open gears used in industrial applications, including mills, kilns, and draglines.

Gears 03 02 – Open Gear Teeth
Explore the different types of open gear teeth profiles, wear patterns, and failure modes, and how lubrication plays a role in reducing tooth damage and extending service life.

Gears 03 03 – Open Gear Lubrication
Learn the fundamentals of open gear lubrication, including film formation, load distribution, and the role of tackiness, viscosity, and extreme pressure (EP) additives.

Gears 03 04 – Open Gear Lubricant Standards
Review industry standards and OEM recommendations for open gear lubricants, including AGMA 9005, ANSI, and manufacturer-specific requirements.

Gears 03 05 – Asphaltic Lubricants
Understand the properties, advantages, and drawbacks of asphaltic-based lubricants traditionally used in open gear applications.

Gears 03 06 – Open Gear Greases
Explore grease-based lubrication for open gears, including the selection of thickeners, solid additives, and application techniques.

Gears 03 07 – Synthetic Open Gear Lubricants (OGLs)
Learn about the benefits of synthetic OGLs, including enhanced performance in extreme temperatures, reduced wear, and extended reapplication intervals.

Gears 03 08 – Priming Lubricants
Discover the role of priming lubricants in preparing new or reconditioned open gears for operation, ensuring proper adhesion and load distribution.

Gears 03 09 – Running-In Lubricants
Learn how running-in lubricants facilitate the smooth break-in of open gears, reducing asperity contact and wear during initial operation.

Gears 03 10 – Repair Lubricants
Understand the function of repair lubricants in restoring damaged gear surfaces, reducing pitting, and prolonging the life of worn open gears.

Key Learning Outcomes:

• Understand the function and challenges of open gear lubrication in heavy industry.
• Identify the different types of open gear lubricants and their appropriate applications.
• Learn best practices for applying and maintaining lubricants on open gears.
• Gain insight into industry standards and compliance requirements for open gear lubrication.
• Develop lubrication strategies to reduce wear, extend service life, and optimize maintenance costs.

This course is ideal for lubrication engineers, maintenance technicians, and reliability professionals responsible for the performance and longevity of open gear systems. By mastering open gear lubrication best practices, participants will be equipped to minimize failures, improve efficiency, and extend the operational life of critical gear-driven equipment.