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Bel-Ray Specialty Lubricants: Tech Notes, Vol 4, Issue 6

August, 2013

MINING DIVISION

The Very Best EP Gear Oil: Bel-Ray 100 Gear Oil Extreme Pressure Gear Oil

Mining machine enclosed gears are subjected to some of the highest loads of any type of gearing. To overcome the tremendous interface loads the gears are subjected to you need gear oil that can provide the best Extreme Pressure protection available.

Extreme Pressure gear oil additive is an active metal protection system that prevents the asperities of contact surfaces from welding and scoring. The Extreme Pressure additive is only activated when exposed to extremely high temperatures, approximately 2000°F ( 1200°C), caused by high contact pressures up to 500,000 pounds per square inch. These temperatures and pressures are easily generated between the asperities of the surface finish of gears. When these temperatures and pressures are realized, the Extreme Pressure additive plates over the asperities and prevents them from welding together. Naturally, these Extreme Pressure additives are consumed in the process. The level of Extreme Pressure additive should be analyzed during the routine oil analysis to determine the oil’s additive level and if the oil should be changed due to Extreme Pressure additive depletion.

Without the Extreme Pressure protection the amount of wear metal will start to increase causing unacceptable wear rates and shorter life of the equipment. Bel-Ray 100 Gear Oil Extreme Pressure Gear Oil is available in ISO 100 through ISO 1500 and provides the maximum Extreme Pressure protection for enclosed gears. The useful life of oil is determined by routine oil analysis and under extreme operating conditions, mining machines have used the same charge of Bel-Ray 100 Gear Oil Extreme Pressure Gear Oil for tens of thousands of hours without significant oil degradation, additive depletion or lapse in gear and bearing protection. The life of the oil is dependent on the control of contaminants, temperature and water. Results will vary depending on machine age and contamination levels.

Bel-Ray 100 Gear Oil Extreme Pressure Gear Oil is formulated with paraffinic base oils. It is blended with proprietary advanced generation Extreme Pressure and anti-wear additives and friction modifier along with corrosion, rust, oxidation and foam inhibitors. Bel-Ray 100 Gear Oil Extreme Pressure Gear Oil provides maximum protection in an extremely cost-effective, high performance gear oil.

Typical performance test values for the Bel-Ray 100 Gear Oil Extreme Pressure Gear Oils:

Falex EP Test, ASTM D3233

  • Method A, Non-seizure Load, lbf..........4500
  • Method B, Non-seizure Load, lbf..........3500

4-Ball EP Test, ASTM D2783

  • Weld Load, kg.........................................400
  • Load Wear Index, kg.................................69

Timken EP Test, ASTM D2782

  • OK Load, kg (lb)........................................45.4 (100)

FZG Visual Test, ASTM D5182

  • Failure Load Stage....................................12+

Protect your equipment with the Best Extreme Pressure Gear Oil available: Bel-Ray 100 Gear Oil Extreme Pressure Gear Oil. Contact your Bel-Ray Mining Representative or call Technical Services at 732-378-4082.

Check out all the Bel-Ray Performance products on our web site belray.com.

INDUSTRIAL DIVISION

Important Tips for Control of Lubricant Cleanliness

Customers are responsible for protecting lubricants from contamination, whether they are stored inside or outside, as well as how they are transferred into machinery and maintained in service. Ask yourself this question: Can our lubricants storage area or storeroom become more efficient? Of course it can! A safe, clean, user-friendly lubricants storeroom leads to lubrication excellence and equipment reliability. Where do we begin and how do we maintain lubricant cleanliness? For starters, you begin with team commitment, lubrication management training and a plan.

Examine and evaluate your current lubricant storage and handling practices. Identify any possible source of contamination. Is there any way that dirt, dust or moisture could get into the lubricants from the day they are received to how they are stored and how they are transferred to the equipment/machine reservoirs? After your evaluation, concentrate on improvements. It helps to take before and after pictures that can be used for training purposes and SOP pictorial guidelines.

When new lubricants arrive at their destination, they should be immediately moved to the lubricants storage area, preferably inside. Do not remove the drum seal and/or the cap seal until it is time to open the drum for service. If the drums are left outside for any length of time, cover them with plastic/metal drum covers or a tarpaulin. If drums have dust, pallet splinters, sand and gravel, floor-dri, leaves, etc. on the drum head, use a soft bristled brush to remove the debris. Never use a water hose to rinse off the top of a drum and never let rain water or snow remain on top of a drum head. Before opening the drum take a shop towel, preferably a lint-free towel, and wipe the fine dust off. A car duster works very well to remove settled dust from drum heads. Do not blow dust off of lubricant packages. After opening the drum for use, immediately install a spigot, drum pump or molasses valve to extract the oil or grease. Always remember to reseal the bungs and also close spigots and valves. If drums will be in service using a drum pump, it is a good idea to place a drum top absorbent pad on each drum to aid in the control of drips and cleanliness.

When small package lubricant containers arrive they should be moved to the lubricant storeroom or parts cage and placed on clean shelves lined with absorbent pads. Shelving should remain uncluttered, no tools, rags, grease guns, paint, hand cleaner, mechanical parts, etc. A vented fireproof/safety storage cabinet is ideal for aerosol cans, grease cartridges (store upright) and pails.

Advice for Inside Storage of Lubricants to Prevent Contamination

Storing lubricants inside is always preferable. There is more to storing lubricants than finding an empty corner in the warehouse. If a specifically designed lube room is not in the budget, there are still guidelines to be followed for proper storage and maintaining ISO Cleanliness. In large plants, several strategically located storage areas improve efficiency and service.

Considerations for optimal interior storage:

  • The optimum temperature in the storage area should remain constant, without fluctuation. Ideal temperature is 68°F / (20°C). In other words, find an area away from high heat and severe cold. High heat can damage lubricants and extreme cold makes lubricants flow extremely slowly, especially gear oils.
  • Contamination such as blowing dust from a parking lot or dust from product production can be blown onto the drums if they are stored in the path of fork lift traffic or plant fans. Find a dust-free area or a closed storeroom.
  • Seal storeroom floor with a non-slip paint/sealant.
  • Lubricants should be stored in product groups with matching labels on the wall, racks or shelves. Incorporate color coding from storage, to transfer container, all grease guns, transfer carts and filter carts in use and all applications. Also color code small package lubricants.
  • Small package lubricants should be stored in cabinets or on shelves, not on the floor or on top of drums.
  • Floor-dri can be very dusty, therefore, store it away from new lubricants.
  • The lubricant storage area should be kept dry.
  • Oil spills should be cleaned up immediately.
  • Drums, kegs, pails and all lubricant packages should never be left open.
  • When using drum pumps absorbent drum top pads should be used to control the dripping oil from the pump. Most pumps are threaded at the end of the nozzle which allows for the use of a dust/drip cap to be used when out of service.
  • Do not store used/empty drums in the lube storage area. Find a separate location, preferably outside in a visibly marked contained area.
  • Post all rules, regulations and lubricant procedures for safety reasons. Have an eye wash system in or next to the lubricant storage area.
  • Train all personnel on using the lubricant storage area. Appoint someone to take ownership of the lube storage area.

NOTE: Never store used oil in the same location as new oil. Create a used oil storage area preferably outside in compliance with local regulations and easy access for the used oil carrier. Do not create the opportunity for used oil to be reintroduced to production equipment or to cross-contaminate new lubricants in storage.

POWERSPORTS DIVISION

JASO Oil Classification for Clutch Performance

When you are interested in getting the maximum performance from your motorcycle or ATV, then the level of clutch performance is a very important aspect of the performance oil you choose.

JASO stands for the Japanese Automotive Standard Organization that controls the friction testing and certification process for the JASO clutch performance rating.

Japan is one of the leading countries in the world producing motorcycle four-cycle engines. Prior to JASO, quality standards for motorcycle four-cycle oils were unavailable. The four-cycle oil standards such as API, ILSAC and ACEA are primarily for 4-wheel vehicles, not for motorcycles. Therefore there is a concern that four-cycle oils for 4-wheel vehicles may cause problems in drive-line components when used in motorcycles in which lubricating oil is used, commonly for the engine, clutch and transmission.

There are concerns that lower friction and lower viscosity four-cycle oils, which are strongly required recently for achieving better fuel economy of 4-wheel vehicles, may cause clutch slippage or poor gear durability in motorcycles. Field problems have actually been observed that are probably attributable to such problems.

The JASO approval process starts with the manufacturer of the oil providing a sample to JASO who assigns a sample number to it. The oil manufacturer purchases a clutch pack from JASO to be used for testing on the dynamometer. JASO ratings are MA, MA1, MA2 and MB. The JASO rating is based on the performance of the lubricant during three different types of tests.  The first test is the Dynamic Friction Test that starts with the clutch disengaged. When the dynamometer reaches a set rpm the clutch is engaged and the level of performance is recorded. Bel-Ray Four-Cycle Performance Products are certified JASO MA2 the highest performance standard.

The second test is the Static Friction Test that starts with the clutch engaged. When the dynamometer reaches a set rpm the performance level is recorded. Again all Bel-Ray Four-Cycle Performance Products are certified JASO MA2 the highest performance standard.

The third test is the Stop Time Index Test. The test starts with the clutch engaged and the dynamometer running at a set rpm. A brake is applied to the clutch pack to stop the rotation. The performance is recorded and again the Bel-Ray Four-Cycle Performance Products are certified JASO MA2.

Bel-Ray Four-Cycle Performance Products that are certified MA2:

  • EXS Synthetic Ester 4T Engine Oil
  • EXP Synthetic Ester Blend 4T Engine Oil
  • EXL Mineral 4T Engine Oil
  • Works Thumper Racing Synthetic Ester 4T Engine Oil
  • Thumper Racing Synthetic Ester Blend 4T Engine Oil
  • Scooter Synthetic Ester Blend 4T Engine Oil

When you are serious about getting the maximum performance from your bike or ATV choose:

Bel-Ray Performance Products Certified JASO MA2

There is one Bel-Ray product specifically formulated for ultra low friction, Bel-Ray Friction Modified Thumper Racing 4T Engine Oil, which is certified JASO MB or the lowest level of friction. This product is formulated for use in engine lubrication only and not used in wet clutch applications. It provides low coefficient of friction for maximum horsepower development but cannot be used in a unit-constructed engine with a wet clutch.

Check out our our web site at belray.com and review all the Bel-Ray Products.