Dont lose your bearings

Klber special lubricants for plain bearings The right choice made easy

Lubrication is our World

Contents
Plain bearings and lubricants The selection of operating lubricants 1. Lubricating oils 2. Lubricating greases 3. Dry lubricants Selection of lubricants for running-in and repair lubrication Cleaning bearings and determination of oil ageing Product survey Technical Questionnaire Plain Bearings 3 4 4 10 14

17

20 22

30

Plain bearings and lubricants

High loads call for high performance
Plain bearing bearing consisting of stationary bearing shells in which a rotating journal slides (supported by an oil film) What the dictionary does not mention is the loads a plain bearing can be exposed to: breathtakingly high speeds, extreme temperatures from 180 to + 450 degrees centigrade and the effects of aggressive media operating conditions like these take their toll. Proper lubrication of the bearing helps to improve wear resistance, corrosion protection, performance and, consequently, the bearings service life. For all plain bearings whether dry sliding bearings, sintered bearings, hydrodynamic or hydrostatic bearings the lubricant must be accurately tuned to the individual requirements of the application and the bearing design in order to become effective before the bearings vital functions are put at risk. Klber Lubrication has developed a wide range of high-quality special lubrication products to cover all aspects of up-to-date plain bearing lubrication. This range encompasses high-performance greases for extreme loads as well as food-grade lubricants for the food-processing and pharmaceutical industries and rapidly biodegradable lubricants for applications in agriculture, forestry and the water resources industry.

Lubricants as design elements

For plain bearings to offer maximum performance throughout their nominal service life, it makes sense to regard the selection and specification of the lubricant as an integral part of the design process. Only if lubricants are conceded the full worth of design elements can the potential of the manufactured component be fully utilised. With appropriate lubrication, plain bearings allow lowwear operation over a long time, in the mixed friction regime at high loads and/or low sliding speeds, as well as with fluid friction at high speeds.

Klber the right choice

Depending on the design and the type of application, plain bearings are lubricated by oils, greases, bonded coatings, solid lubricants or their combinations (see diagram). The Klber product range can be divided into two categories: J Operating lubricants J Running-in lubricants This classification makes for easy orientation in lubricant selection.

Is the old lubricant still fit for its job?

However, selecting the right lubricant is of importance not only when designing new plain bearings. Higher transmitted power, higher speeds or changing ambient temperatures in existing machines, plants or vehicles may make a modification or even replacement of the lubricant necessary. Changing ecological requirements, or situations where the lubricant may come into contact with foodstuffs, are further factors that require the lubricant to be adjusted to the individual application. As a supplier of special lubricants, Klber offers tailor-made up-todate solutions for any task on hand.

The selection of operating lubricants

1. Lubricating oils
For oil-lubricated plain bearings to offer full performance and attain their specified service life, a lubricant must be chosen that ensures low-wear continuous operation and minimum friction during starting and slowing down. However, wear can be reduced to a minimum only if journal and bushings are completely separated by a lubricant film under operating conditions (operating load, temperature, speed, etc.) such that the surfaces of the friction bodies are not in contact, i.e. the bearing must operate in the hydrodynamic range. The formation of a load-bearing lubricant film separating the friction bodies depends largely on the oils viscosity. This is why the determination of the appropriate viscosity is a central aspect in the selection of the plain bearing oil. Tables 1 to 3, pages 6 to 8, are to help in quickly and reliably selecting the right lubricating oil. Proceed as follows:

a) Determination of requirements
1. Determining values for:
K Mean bearing load
pm = F (N/mm2) DB

2. Determination of additional requirements:

K Lubricating oils for standard applications, table I, page 6. Lubricating oils especially designed for longterm use, table II, page 7 for applications where long oil change intervals bring about major savings in oil quantities and oil disposal quantities as well as in costs for maintenance and repair, production loss and organisation of disposal. Lubricating oils with USDA-H1 approval for the food-processing and pharmaceutical industries (food-grade lubricants), table III, page 8 for applications where there may be an incidental, technically unavoidable contact between the lubricant and the food product. Rapidly biodegradable lubricating oils / lubricating oils of water hazard class 1, table IV, page 8 for applications where lubricating oils may be released into the environment, e.g. the water or the soil, under normal operating conditions.

Sliding speed

v = d n (m/s)

K Operating temperature of bearing

(C)

b) Oil selection
1. Selection based on additional requirements. 2. Selection of lubricating oil suitable for the operating conditions (pm, v, ). 3. Accurate calculation of required oil viscosity.
(Calculations could be made for one bearing type only to give a rough idea of the viscosity range. Accurate calculations of the plain bearing functions have to be made prior to series application.) Based on the values found for K K K surface pressure, sliding speed and bearing operating temperature, The viscosity grade, which is indicated by the product name e.g. ISO VG 150 in the case of Klbersynth GH 6-150 was obtained by means of a generally recognised plain bearings computing program (see box on page 6). Not every individual bearing application could be taken into account for these tables, so the viscosities given are to be regarded as orientation values only. Most of the products listed are available in a wide range of viscosities. To ensure reliable operation in all bearing applications, users are advised to carry out their own calculations based on recognised methods. Of course, our application engineers will be glad to assist you.

as well as the other criteria listed above, a suitable lubricating oil can be selected.

Lubricant selection depending on sliding speed

Grease lubrication Lubricating paste Bonded coating

Solid-film lubrication
0 0.01 0.5 1.0

Oil lubrication
for circulation lubrication (ISO VG > 460)

Oil lubrication

1.5

2.0

2.5

Sliding speed v (m/s)

Lubricating oils
for standard applications
Operating temperatures Operational bearing temperature [C]
/

Product recommendation

Sliding speed v = 2 up to 4 m/s

mean bearing load pm < 3 N/mm2

up to 50 Almost constant up to 70
up to 90

LAMORA HLP 32 LAMORA HLP 68 Klberoil GEM 1-150 N

mean bearing load pm = 3 up to 7 N/mm2

Sliding speed v = 2 up to 4 m/s

up to 50 Almost constant up to 70 up to 90
Sliding speed v > 4 m/s /

LAMORA HLP 68 Klberoil GEM 1-220 N Klberoil GEM 1-460 N

mean bearing load pm < 3 N/mm2

up to 50 Almost constant up to 70 up to 90
Sliding speed v > 4 m/s /

LAMORA HLP 32 LAMORA HLP 46 Klberoil GEM 1-100 N

mean bearing load pm = 3 up to 7 N/mm2

up to 50 Almost constant up to 70 up to 90

LAMORA HLP 68 Klberoil GEM 1-150 N Klberoil GEM 1-320 N

The viscosity data in the tables for lubricating oil selection were determined by means of the ASSIG PC system (assistance system for the design of hydrodynamic plain bearings). This program was developed by the Department of Mechanical Engineering, Machine Elements and Design of the Engineering and Business Polytechnic in Zwickau, in cooperation with the Research Association for Power Transmission Engineering FVA in the years 1991 to 1994. The calculations are based on the following data: K plain bearing acc. to DIN 31 690, size 9 K shaft diameter D = 90 mm K bearing width B1 = 60 mm K proj. of load-bearing surface: B1 x D = 5 400 mm2 K housing surface: 0.416 m2 K 360 bearing

providing excellent long-term resistance

Operating temperatures Operational bearing temperature [C]
/

II

Product recommendation

Sliding speed v = 2 up to 4 m/s

mean bearing load p m < 3 N/mm2

up to 50 Almost constant up to 70 up to 90 up to 120 Varying 20 up to 60 20 up to 90 Low start-up and service temperatures 45 up to 50 60 up to 30

/

Klber Summit SH 32 Klber Summit SH 68 Klbersynth GH 6-80 Klbersynth GH 6-150 Klber Summit SH 46 Klber Summit SH 100 Klber Summit SH 32 ISOFLEX PDP 38
mean bearing load pm = 3 up to 7 N/mm2

Sliding speed v = 2 up to 4 m/s

up to 50 Almost constant up to 70 up to 90 up to 120 Varying 20 up to 60 20 up to 90 Low start-up and service temperatures 40 up to 40 55 up to 60

/

Klber Summit SH 68 Klbersynth GH 6-100 Klbersynth GH 6-150 Klbersynth GH 6-320 Klbersynth GH 6-80 Klbersynth GH 6-150 Klber Summit SH 46 ISOFLEX PDP 65

Sliding speed v > 4 m/s

mean bearing load pm < 3 N/mm2

up to 50 Almost constant up to 70 up to 90 up to 120 Varying 20 up to 60 20 up to 90 Low start-up and service temperatures 55 up to 50 65 up to 40

/

Klber Summit SH 32 Klber Summit SH 46 Klber Summit SH 100 Klbersynth GH 6-100 ISOFLEX PDP 48 Klber Summit SH 100 ISOFLEX PDP 40 ISOFLEX PDP 38

Sliding speed v > 4 m/s

mean bearing load pm = 3 up to 7 N/mm2

up to 50 Almost constant up to 70 up to 90 up to 120 Varying 20 up to 60 20 up to 90 Low start-up and service temperatures 40 up to 40 50 up to 60

Klber Summit SH 68 Klbersynth GH 6-100 Klbersynth GH 6-150 Klbersynth GH 6-220 Klber Summit SH 100 Klbersynth GH 6-100 Klber Summit SH 46 ISOFLEX PDP 65

Lubricating oils
for the food-processing and pharmaceutical industries
Operating temperatures Operational bearing temperature [C]
/

III

Product recommendation

Sliding speed v = 2 up to 4 m/s

mean bearing load pm < 3 N/mm2

up to 50 Almost constant up to 70 up to 90 Low start-up and service temperatures

Sliding speed v = 2 up to 4 m/s /

Klber Summit HySyn FG-32 Klber Summit HySyn FG-68 Klber Summit HySyn FG-100 Klber Summit HySyn FG-32

45 up to 50

mean bearing load pm = 3 up to 7 N/mm2

up to 50 Almost constant up to 70 up to 90 Low start-up and service temperatures

Sliding speed v > 4 m/s /

Klber Summit HySyn FG-68 Klberoil 4 UH1-150 N Klberoil 4 UH1-220 N Klber Summit HySyn FG-46

40 up to 40

mean bearing load pm < 3 N/mm2

up to 50 Almost constant up to 70 up to 90 Low start-up and service temperatures

Sliding speed v > 4 m/s /

Klber Summit HySyn FG-32 Klber Summit HySyn FG-46 Klber Summit HySyn FG-100 Klber Summit HySyn FG-32

45 up to 50

mean bearing load pm = 3 up to 7 N/mm2

up to 50 Almost constant up to 70 up to 90 Low start-up and service temperatures 40 up to 45

Klber Summit HySyn FG-68 Klber Summit HySyn FG-100 Klberoil 4 UH1-220 N Klber Summit HySyn FG-46

Rapidly biodegradable lubricating oils falling under water pollution category 1

Sliding speed v = 2 up to 10 m/s / mean bearing load pm = 0.1 up to 7 N/mm2

IV

up to 60 Almost constant up to 90 up to 110 Low start-up and service temperatures 25 up to 40

Klberbio CA 2-100 Klbersynth GEM 2-220 Klberbio CA 2-460 Klberbio C 2-46

Selection example for lubricating oils

In a tabletting machine producing fondant sweets, the screw conveying the heated sugar mass runs in two oil-lubricated plain bearings. Since it is technically unavoidable that small lubricant quantities may occasionally leak through the seals and into the sugar mass, a food-grade lubricant certified in line with NSF-H1 requirements is indispensable for lubricating these bearings.

Bearing data / operating conditions:

Inner of bearing Width of bearing: Bearing material: D = 40 mm B1 = 38 mm B2 = 50 mm red bronze
1 1

3. Selection according to additional requirements

Selection table to be used: Table III (page 8)

4. Selection of required lubricating oil

Speed of conveyor screw: n = 4000 min = 66.6 s Load force: Measured bearing operating temperature F = 500 N = approx. 70 C, constant

Table III is divided up into four sections. The section in which to look is determined by the calculated sliding speed v and the mean bearing load pm. Sliding speed v: 8.4 m/s; this value belongs to section v > 4 m/s pm = 0.33 N/mm2 this value belongs to section p < 3 N/mm2

Selection of required lubricating oil

1a. Calculation of mean bearing load pm

Bearing load p:

p =
m

F (N/mm2) DB

p =
m

500 40 38

= 0.33 N/mm2

Result: For a constant operating temperature of approx. 70 C, the appropriate lubricating oil would be Klber Summit HySyn FG-46. The recommended oil has a kinematic viscosity of 50 mm2/s at 40 C.

1b. Calculation of sliding speed v

v = d n (m/s) v = 0.04 3.14 66.6 v = 8.4 m/s

When making an accurate calculation for this bearing application, one will find that the viscosity of Klber Summit HySyn FG-32 is also sufficient. This is due in particular to the sliding speed above 8 m/s. This calculation is based on the viscosity data given in the product survey (page 22/23). The lubricant selection can be checked against the product data given on page 22/23.

2. Determination of additional requirements

(see under 2, page 4)

For this application, a food-grade lubricant with NSF-H1 certification is required.

The selection of operating lubricants

2. Lubricating greases
Klber offers a comprehensive range of products for grease-lubricated metal and plastic plain bearings. The products suitability for the lubrication of plain bearings has been tested in practice-oriented tests (bench tests on bearings with different surface designs: smooth, perforated or with holes). The task of deciding which lubricant to use for a plain bearing is made easy by the selection tables V, VI and VII, page 12/13. Please observe the following criteria to ensure maximum performance of the bearings throughout their service lives:

K K

Operating motion: rotating or oscillating Sliding speed range for grease lubrication: v = 0.01 to 2.5 m/s (see diagram on page 5) Permissible bearing load: Depends on bearing material and bearing geometry (note: high surface pressures at low speeds e.g. during starting and slowing down lead to mixed friction. Under conditions like these, the special lubricants shown in table V enable low wear and a long lubricant and bearing life.) Resistance to and sealing against media: To compare the different lubricating greases, they are tested for water resistance acc. to DIN 51 807 pt. 1, 3 h/90 C (page 25). The lower the test result, the better the greases water resistance (i.e. 0 = best). Service temperature range: The service temperatures given in the tables are orientative values assuming the grease is used in a plain bearing; they depend on the individual operating conditions.

In the following you will find the areas of application that are of interest for you: K K General machinery, plants, equipment and vehicles: lubricating grease selection in table V (page 12/13) Machinery, plants and equipment in food-processing and pharmaceutical industries: lubricating grease selection in table VI (page 12/13) Machinery, plants, equipment and vehicles where contact between lubricant and the environment is possible (e.g. agricultural and forestry machines, hydroelectric power plants): lubricant selection in table VII (page12/13)

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Selection example for lubricating greases

The grease required is to lubricate the plain bearings of calender rollers used in a rubber production plant. What is difficult about this application is that the rollers rotate at very slow speeds while loads acting on the bearings and bearing temperatures are very high.

Bearing specifications / operating conditions:

Bore diameter: Bearing width: Running surface: Bearing material: Operating speed: Radial bearing load: Bearing temperature: Resistance to media: Lubrication method: D = 295 mm B = 320 mm smooth bronze n = 4 min1 F = 685.7 kN = 145 C sodium hydroxide solution continuous lubrication by means of automatic lubricant dispenser

Selection of lubricating grease:

The calender rollers are pieces of general machinery. Selection table to be used: table V (page 12/13), section: sliding speed < 1 m/s, maximum surface pressure approx. 100 N/mm2, operating temperature range1) 20 to 160 C
Result: Suitable lubricating grease: Klberlub BVH 71-461

Please note: All plain bearing greases listed in tables V and VI are high-performance lubricants. Friction measurements made on test bearings at room temperature (25 C) have shown that a low friction coefficient and low temperatures can be obtained even under difficult operating conditions, e.g. v = 0.01 m/s, p = 50 N/mm2.

Sliding speed v

v = d n (m/s) v = 0.295 x 3.14 x 0.066 = 0.061 m/s Permissible sliding speed range for grease lubrication = 0.01 bis 2.5 m/s, i.e. in this range grease lubrication is possible.

Mean pressure pm

pm =

F (N/mm2) DB

pm =

686 700 295 320

= 7.27 N/mm2

This is clearly below the permissible maximum of 100 N/mm2.

1)

see page 30

11

Lubricating greases
General machinery, plants, equipment and
Mode of operation Sliding speed [m/s] Max. surface pressure [N/mm2] Service temperature1) [C]
20 up to 160 20 up to 140 oscillating / rotating <1 approx. 100 30 up to 180 40 up to 260 40 up to 150 30 up to 140 mainly rotating mainly rotating 1 2 approx. 10 approx. 1 50 up to 150 50 up to 130

Food-processing and pharmaceutical industries

oscillating / rotating <1 1 approx. 100 20 up to 160 5 up to 150 mainly rotating approx. 10 40 up to 120

Machinery, plants, equipment and vehicles where the

oscillating / rotating mainly rotating <1 1 approx. 100 approx. 10 40 up to 120 40 up to 120

Dry lubricants
Tribo-system materials
rotating / oscillating <1 approx. 50 40 up to 180

Bonded coatings
40 up to 230 rotating / oscillating depending on coated part 180 up to 450 40 up to 300

1)

see page 30

12

vehicles
Product proposal Notes

Klberlub BVH 71-461 Klberlub BE 41-542 PETAMO GHY 441 Klberalfa BHR 53-402 POLYLUB GLY 501 Klberlub BEM 41-122 POLYLUB GLY 151 Klbersynth LR 44-21

Plain bearing lubricant for long service life and long relubrication intervals, NLGI 1 Alternative product, NLGI 2 Alternative product for higher ambient temperatures High-temperature and long-term lubricant which is almost neutral to many materials (metals, plastics) Especially for plastic plain bearings For pivoting bearings (steelsteel)

VI
Klberlub BVH 71-461 Klbersynth UH1 64-1302 Klbersynth UH1 14-151
NSF H2 lubricant for the food-processing and pharmaceutical industries NSF H1 lubricant for the food-processing and pharmaceutical industries NSF H1 lubricant for the food-processing and pharmaceutical industries

lubricant may get into the environment

Klberbio BM 72-501 Klberbio M 72-82

VII

Rapidly biodegradable if lubricant gets into contact with environment Rapidly biodegradable if lubricant gets into contact with environment

VIII
Klberdur KM 02-854
For bronze plain bearings with lubricating holes

IX
FLUOROPAN 340 N A/B UNIMOLY C 220 Klbertop TG 05-371
Thermosetting Hygrosetting Suitable for ultra-high-vacuum applications Thermosetting

13

The selection of operating lubricants

3. Dry lubricants
Dry lubrication is of advantage in applications where, due to low sliding speeds, no load-bearing lubricant film can form, so the friction bodies are not sufficiently separated. A layer separating the two sliding surfaces can therefore only be obtained by interposing a bonded coating or a self-lubricating layer in these cases, there is a lubricating film right from the start of the motion. Dry lubricants, i.e. bonded coatings or tribo-system materials, offer maintenancefree permanent lubrication especially for plain bearings running under high loads at low speeds. This includes oscillating motions. Even under extreme operating conditions, e.g. at very high temperatures, in a vacuum or when exposed to chemicals, these dry lubricants help to reduce wear significantly. Dry lubricants are particularly useful in applications where the use of lubricating oils or greases is problematic, where lubricant dripping off the friction point may contaminate the product or where bearings cannot be maintained. And whats more: dry lubrication by means of bonded coatings or tribo-system materials makes sense not only economically but ecologically as well!

a) Bonded coatings
Bonded coatings consist of three different components: solid lubricant, binder and solvent. The lubricity of a bonded coating depends on the type and quantity of solid lubricant it contains, while its service life and abrasion resistance are influenced by the binder. The solvent serves for applying and spreading the bonded coating on the friction bodies sliding surfaces. Upon application, the solvent evaporates and has no further effect on the friction and wear behaviour of the bonded coating. Bonded coatings are frequently used for lifetime lubrication which requires special testing but also for running-in or correction purposes.

(see table IX, page 12/13) A variety of bonded coatings are available for use in plain bearings. They contain solid lubricants that are particularly suitable for dry lubrication and wear-resistant organic binders. Which bonded coating contains the best suitable dry lubricant component for a particular application is determined by the operating conditions, i.e. temperature, sliding speed, load and the surrounding atmosphere. Other criteria are the special requirements to be met by the bonded coating, for instance use in a vacuum or a very low friction coefficient. For further information, please refer to the following brief product descriptions and tables VIII and IX, page 12/13. Adhesion and service life of bonded coatings depend primarily on the pretreatment of the parts to be coated, the application method used for the coatings, the care dedicated to hardening and the subsequent use of the parts. Before using a bonded coating, please observe the information in the product information leaflet, which we will be pleased to send you on request.

14

FLUOROPAN 340 N A/B

Solid lubricant: Characteristics: polytetrafluoroethylene (PTFE) good wear resistance long service life low friction coefficient good corrosion protection good resistance to chemicals and oils2)

Suitable for metal/metal or metal/plastics material pairings. Recommended especially for very low sliding speeds: v < 0.05 m/s

UNIMOLY C 220
Solid lubricant: Characteristics: molybdenum disulphide (MoS2) good pressure resistance low friction coefficient good wear resistance good resistance to chemicals and oils2)

Suitable for metal/metal friction pairings (especially where high pressures forbid the use of PTFE bonded coatings). Also well suitable for use in a vacuum. Not suitable for applications in a moist atmosphere.

Klbertop TG 05-371
Solid lubricant: Characteristics: graphite wide operating temperature range long service life and good wear resistance low friction coefficient good resistance to chemicals and oils2) good lubricity also when exposed to moisture

Suitable for metal/metal or metal/plastics friction pairings. Especially suitable also for plain bearings that are normally lubricated by oil (e.g. for supporting lubrication when starting motors until the operating lubricant reaches the friction point).

2)

see page 30

15

b) Tribo-system materials
Klberdur KM 02-854

(see table VIII, page 12/13)

This product is a two-component system and contains a solid lubricant component consisting primarily of graphite with incorporated lubricating oil.

The two components i.e. the resin and the hardening agent are mixed to form a paste-like mass, which is then filled into the bore holes of plain bearing bushings. Once Klberdur KM 02-854 has hardened and, thanks to its good adhesion, is firmly fixed inside the lubricating holes, the plain bearings can be subjected to high loads without requiring wet lubrication or maintenance.

The friction bodies are lubricated by a permanent transfer of dry lubricant from the lubricating holes in the bushings. However, there is also constant minor wear to the inside metal surfaces. The service life of plain bearings containing Klberdur in lubricating holes does not, therefore, depend on the supply of solid lubricant but on the maximum permissible internal clearance of the bearing.

Klberdur KM 02-854 is oil- and grease-resistant, which allows combined lubrication (dry lubricant together with oil or grease) if required. New bearings can additionally be filled with grease for running-in or to facilitate assembly. This additional one-time lubrication helps to prevent boundary and mixed friction until the solid lubricant is distributed throughout the bearing. However, this kind of priming lubrication is not obligatory.

3)

see page 30

16

Selection of lubricants for running-in and repair lubrication

1. Running-in lubrication
The surfaces of new plain bearing elements always show a certain degree of surface roughness, which can be more or less pronounced depending on the finishing method used. By applying a bonded coating or a lubricating paste, the roughness peaks can be smoothened during the running-in process without scoring or scuffing the surfaces. If two friction components have very smooth surfaces, mixed friction (partial contact of the surfaces) only occurs under very adverse conditions, even with very thin lubricating films. Bonded coatings or pastes used for running-in also protect the friction points in the case of starved lubrication during normal operation, e.g. during the start-up and slow-down of a machine, when low sliding speeds prevent the formation of a load-bearing and coherent grease or oil film. Hint: to ensure a perfect surface finish, we recommend running in bearings at reduced load (approx. one third of the rated load and one third of the rated speed).

2. Repair lubrication
In many cases, scoring and scuffing marks on functional surfaces of plain bearings can be eliminated by means of a so-called repair lubrication: by the application of a bonded coating or a lubricating paste on the damaged bearing surfaces followed by a running-in process (at reduced sliding speed and load), scores and scratches can be smoothed considerably thus restoring the surface characteristics. Additional advantage: the emergency lubricating properties of dry lubricants used in subsequent operation for repair purposes protect the bearings from the effects of starved lubrication and reduce the risk of new surface damage.

17

Selection example: Running-in of truck engine bearing with bonded coating and operational lubricant
For the camshaft bearing in a truck diesel engine, a bonded coating is needed which K together with the operational lubricant (engine oil) improves the bearing run-in and prevents the formation of initial damage to the sliding surfaces during the run-in phase, supports lubrication during the start-up phase until engine oil has reached the friction points to form a hydrodynamic lubricating film.

Selection example: Running-in of a conveyor screw bearing with lubricating paste

A lubricating paste is required to run in and smooth the functional plain bearing surfaces of a screw conveyor of a soft candy making machine. The paste has to be physiologically safe and comply with relevant regulations, as a contact between the food product and the lubricant cannot be completely excluded. The criteria of an NSF H1 approval have to be met as well. For the operational lubrication of the bearings, a lubricating oil is used (see selection example for lubricating oils, page 9).

Bearing data / operating conditions:

Selecting the suitable lubricating paste

The bearings are to be run in with a lubricating paste. For product selection, please refer to table XI, page 19.
Result: the suitable lubricating paste for this application is Klberpaste UH1 84-201. Bearings should be run in at reduced speed in order to ensure proper smoothing of the surfaces. After the running-in process, and provided the lubricants are compatible, it is possible to immediately switch to operational oil lubrication without prior cleaning of the bearings. Please consult our application engineers as far as the compatibility of lubricants is concerned.

Bearing shell, ID Width: Material pairing:

50 mm 32 mm St/St

Operating temperature: 40 to 120 C Load p: oscillating or impact load, 6 ... 8 N/mm2

Selecting the suitable bonded coating:

Running-in of bearings by means of bonded coating in combination with the operational lubricant. For product selection, please refer to table XII, page 19.
Result: an excellent bonded coating for bearing shells made of steel is Klbertop TG 05-371, offering long service life, wear protection and resistance to lubricating oils. It contains graphite as solid lubricant.

Hint: in normal operation, the solid lubricant particles on the functional bearing surfaces protect the friction points in case of starved lubrication, e.g. during the start-up and slow-down of a machine.

18

Lubricants for running-in and repair

Lubricating pastes General machinery, plants, equipment and vehicles
Material of the bearing bushing
Aluminiumalloy Copper alloy, steel

X
Consistency NLGI grade

Service temperature1) [C]

15 up to 150 40 up to 140 15 up to 150 40 up to 150 40 up to 230 40 up to 200 (10004) )

Product proposal

Klberpaste ME 31-52 DUOTEMPI PMY 45 Klberpaste ME 31-52 Klberpaste 46 MR 401 UNIMOLY RAP Klberpaste HEL 46-450

3/2 2/3 3/2 1/2 3/2 1

Lubricating pastes Food-processing and pharmaceutical industries

Material of Approval the bearing bushing
Aluminiumalloy Copper alloy, NSF H1 steel NSF H2 40 up to 200 (12004) ) 40 up to 140 Klberpaste UH1 96-402 DUOTEMPI PMY 45 2 2/3 NSF H1

XI
Consistency NLGI grade

Service temperature1) [C]

45 up to 120

Product proposal

Klberpaste UH1 84-201

Bonded coatings for the running-in lubrication in conjunction with the operational lubricant
Material of the bearing bushing
Aluminium, copper alloy, steel Steel MoS2 180 up to 450 UNIMOLY C 220 Hygrosetting, suitable for ultra-high-vacuum applications, available as aerosols

XII

Solid Service lubricant temperature1) [C]

Graphite 40 up to 300

Product proposal

Notes

Klbertop TG 05-371

thermosetting

1)

and 4) see page 30

19

Cleaning bearings and determination of oil ageing

1. Concentrated conditioner: Klber-Summit Varnasolv
The use of mineral-based lubricating oils in plain bearings may lead to varnish and carbon buildup in the entire lubrication system, especially at high bearing temperatures. Such residues can damage bearing components or clog oil lines and filters. Starved lubrication, or even bearing failure, may occur, resulting in high maintenance and repair costs. Klber-Summit Varnasolv puts an end to expensive maintenance and repair works.

Hint: Klber-Summit Varnasolv is a concentrated conditioner fluid which dissolves varnish and carbon residues during operation. When using this product prior to an oil change, it is no longer necessary to dismantle bearings and lubrication systems for cleaning purposes.

Application notes:
As the cleaning agent dissolves buildups and residues, the system does not have to undergo expensive flushing processes before switching to the new product. Klber-Summit Varnasolv is added to the existing plain bearing oil at a ratio of 10% (i.e. add 1 litre of Klber-Summit Varnasolv to 9 litres of lubricating oil). For this purpose, enough lubricating oil has to be drained. After filling the conditioner into the bearings, let them run for an additional 40 to 60 hours at service temperature to dissolve all varnish and carbon residues. Drain the unit while the oil is still hot in order to prevent the dissolved residues from settling. Then exchange the oil filters and refill with the synthetic oil.

Material compatibility:
According to our knowledge, a 10% concentration of Klber-Summit Varnasolv in mineral oil is compatible with all materials resistant to mineral oil.

20

2. Test kit, also for plain bearing oils: Klber Summit T.A.N. Kit
The Klber Summit T.A.N. Kit is a simple and rapid way of checking the ageing condition of lubricating oils. This Kit can be used to test all conventional mineral and synthetic lubricating oils that have an initial T.A.N. of less than 2. This applies to all oils mentioned in this brochure.

Application notes:
K Draw a small sample of the used oil to be tested to the 1 ml mark of the graduated pipette. Wipe off the excess oil on the outside of the tube with the provided cloth, and add the contents of the pipette to the glass vial. Draw the solution in the vial into the pipette and squeeze it back several times in order to completely transfer all of the oil into the vial. Replace the vial cap and shake the contents for a few seconds. Observe the solution colour. a blue colour means: a green colour means: the lubricant condition has not changed significantly the lubricant has suffered slight ageing, but can still be used; repeat oil ageing test at short intervals the oil has to be changed.

K K

a brown/orange colour means:

When using the test kit, please observe the material safety data sheet. Avoid contact with clothing and skin. Do not get in eyes. The Kit consists of: K K K Plastic bag containing glass vial with test solution Pipette Cloth

21

Product survey
Lubricating oils
Klber product ISO VG DIN 51 519 Service temperature range1) [C] approx. Density DIN 51 757 [g/cm3] at 20 C approx. Kinematic viscosity DIN 51 562, part 1 [mm2/s] at 40 C 100 C approx. approx.

Mineral oils
Klberoil GEM 1-100 N Klberoil GEM 1-150 N Klberoil GEM 1-220 N Klberoil GEM 1-320 N Klberoil GEM 1-460 N LAMORA HLP 32 LAMORA HLP 46 LAMORA HLP 68 100 150 220 320 460 32 46 68 5 up to 100 5 up to 100 5 up to 100 0 up to 100 0 up to 100 25 up to 120 20 up to 120 15 up to 120 0.85 0.88 0.85 0.85 0.85 0.87 0.88 0.88 100 150 220 320 460 32 46 68 11.0 15.0 19.0 25.0 25.0 5.4 7.0 8.8

Synthetic hydrocarbon oils

Klber Summit SH 32 Klber Summit SH 46 Klber Summit SH 68 Klber Summit SH 100 32 46 68 100 45 up to 145 40 up to 145 40 up to 145 30 up to 145 0.85 0.86 0.88 0.87 32 46 62 100 6.0 7.8 10.0 12.0

Food-grade lubricants
Klberoil 4 UH1-150N Klberoil 4 UH1-220N Klber Summit HySyn FG- 32 Klber Summit HySyn FG- 46 Klber Summit HySyn FG- 68 Klber Summit HySyn FG-100 150 220 32 46 68 100 25 up to 120 25 up to 120 45 up to 135 40 up to 135 40 up to 135 35 up to 135 0.85 0.85 0.83 0.84 0.83 0.84 150 220 33 46 70 95 19.0 26.0 6.1 7.9 9.9 12.7

Polyglycol oils
Klbersynth GH 6- 80 Klbersynth GH 6-100 Klbersynth GH 6-150 Klbersynth GH 6-220 Klbersynth GH 6-320 100 150 220 320 35 up to 160 35 up to 160 35 up to 160 30 up to 160 30 up to 160 1.05 1.05 1.05 1.06 1.05 80 100 150 220 320 16 20 28 42 58

Ester oils
ISOFLEX PDP 38 ISOFLEX PDP 40 ISOFLEX PDP 65 65 up to 100 50 up to 100 50 up to 100 0.92 0.92 0.92 12 19 68 3.2 5.0 17.0

Rapidly biodegradable lubricating oils

Klberbio C 2- 46 Klberbio CA 2-100 Klberbio CA 2-460 Klbersynth GEM 2-220 46 100 460 220 40 up to 80 30 up to 110 15 up to 110 30 up to 130 0.93 0.94 0.95 0.95 46 100 460 220 10 15 50 27

22

Dynamic viscosity mPa s at 40 C approx. 100 C approx.

Viscosity index DIN ISO 2909 (VI)

Flash point DIN ISO 2592 [C]

Pour point DIN ISO 3016 [C]

85.0 132.0 187.0 272.0 391.0 27.5 39.9 59.0

9.4 13.2 16.1 21.3 21.3 4.4 5.8 7.3

approx. 90 approx. 90 approx. 90 approx. 90 approx. 90 approx. 100 approx. 100 approx. 100

200 200 200 200 200 > 200 > 210 > 220

approx. 15 approx. 10 approx. 10 approx. 10 approx. 10 approx. 30 approx. 30 approx. 25

27.1 38.1 53.8 70.2

5.0 6.5 8.3 9.9

approx. 140 approx. 140 approx. 145 approx. 140

> 230 > 240 > 240 > 240

approx. 50 approx. 45 approx. 45 approx. 35

125.8 184.5 27.0 40.9 57.9 78.5

15.3 20.8 4.8 6.2 7.8 10.0

> 150 > 150 approx. 130 approx. 130 approx. 125 approx. 130

> 220 > 220 > 230 > 240 > 240 > 240

approx. 30 approx. 30 approx. 50 approx. 45 approx. 45 approx. 40

82.0 103.0 154.0 227.0 330.0

15.7 19.7 27.5 40.3 57.1

> 190 > 190 > 200 > 220 > 220

> 280 > 280 > 280 approx. 250 > 280

< 35 < 35 < 35 approx. 35 < 30

11.0 17.2 61.7

3.1 4.3 14.7

approx. 150 approx. 230 > 245

approx. 200 approx. 200 approx. 200

approx. 70 approx. 55 approx. 55

42.1 91.7 431.0 206.1

8.7 13.1 46.7 24.2

> 140 > 160 approx. 150

> 200 > 200 > 220 approx. 270

< 30 < 30 < 20 < 30

For details as to the application and compatibility of lubricants please refer to the product information leaflets 1) see page 30

23

Product survey
Lubricating greases
Klber product Base oil / thickener Consistency5) DIN 51 818 Worked penetration DIN ISO 2137 [0.1 mm] approx. Service temperature range [C] approx.

Klberalfa BHR 53-402

Perfluorinated polyether oil/ Na complex soap Ester oil/ calcium soap Ester oil/ polyurea

265 295

40 up to 260

Klberbio GM 32-2200 Rapidly biodegradable Klberbio M 72-82 Rapidly biodegradable

0 / 00

370 410

40 up to 120

265 295

40 up to 140

Klberlub BE 41-542

Mineral oil/special lithium soap Mineral oil/special lithium soap Mineral oil/synth. hydrocarbon oil/ polyurea Mineral oil/synth. hydrocarbon oil/ spec. lithium soap Synth. hydrocarbon oil/ silicate Synth. hydrocarbon oil/aluminium complex soap Ester oil/ polyurea Mineral oil, synth. hydrocarbon oil/ spec. lithium soap Mineral oil, synth. hydrocarbon oil/ spec. lithium soap

265 295

20 up to 140

Klberlub BEM 41-122

265 295

30 upp to 140

Klberlub BVH 71-461 Special lubricating grease with NSF H2 approval Klbersynth LR 44-21

0/1

340 370

20 up to 160

310 340

50 up to 130

Klbersynth UH1 64-1302 Food-grade lubricant with NSF H1 approval Klbersynth UH1 14-151 Food-grade lubricant with NSF H1 approval PETAMO GHY 441

265 295

10 up to 150

310 340

40 up to 120

310 340

30 up to 180

POLYLUB GLY 151

310 340

50 up to 150

POLYLUB GLY 501

310 340

40 up to 150

24

Base oil viscosity DIN 51 757 DIN 51562 part 1 [g/cm3] at [mm2/s] 20 C at approx. 40 C 100 C approx. approx.
1.82 400 40

Density

Drop point DIN ISO 2176 [C] approx.

Apparent viscosity Klber DIN 51 807 viscosity part 1 grades 3h/90 C see below 6)

Water resistance

Colour

not measurable

white

0.89

220

28

> 130

0 up to 40

E/L

lightbrown reddish brownbeige brown

0.94

100

28

> 220

L/M

0.93

540

32

> 230

0/1

1.1

130

15

> 190

yellow

0.90

490

34.5

> 240

0/1

lightbrown

0.85

20

4.5

> 220

EL

beige

0.99

1300

100

without

0/1

beige

0.92

150

22

> 250

L/M

beige

0.97

435

36

> 250

L/M

beige

0.85

150

18

> 220

beige

0.88

500

40

> 250

0/1

L/M

beige

1) 5)

and 6) see page 30

25

Product survey
Lubricating pastes
Klber product Base oil/ thickener Service temperature range1) [C] approx. Density at 20 C [g/cm3] approx. Base oil viscosity DIN 51562 part 1 [mm2/s] at 40 C approx.
55

DUOTEMPI PMY 45 NSF H2 approval

Mineral oil/synth. hydrocarbon oil/ spec. Li soap/ solid lubricants Ester oil/ polyglycol oil/ solid lubricant Mineral oil/ calcium complex soap/ solid lubricant Polyglycol oil/ lithium soap/ solid lubricant mixture Synth. hydrocarbon oil/PTFE, solid lubricant Polyglycol oil/ silicate, solid lubricant Paraff. mineral oil/ silicate/ solid lubricant MoS2

40 up to 140

1.2

Klberpaste HEL 46-450

40 up to 1000
> 200 C dry lubrication

1.43

42

Klberpaste ME 31-52

15 up to 150

1.38

46

Klberpaste 46 MR 401

40 up to 150

1.23

360

Klberpaste UH1 84-201 NSF H1 approval

45 up to 120

1.13

200

Klberpaste UH1 96-402 NSF H1 approval

30 up to 1200
> 200 C dry lubrication

1.58

360

UNIMOLY RAP

10 up to 450
> 150 C dry lubrication

1.6

70

26

Drop point DIN ISO 2176 [C]

Four ball tester, welding load DIN 51 350 part 4 [N]

Flow pressure DIN 51 805 at C [mbar]

Consistency DIN 51 818

Colour

> 190

> 3200

at 35 C < 1400

2/3

beige

> 250

> 5000

at 35 C 500

1/0

black

> 170

> 4000

3/2

beige

> 185

> 4400

at 40 C < 1600

1/2

whitish

> 240

> 3000

at 45 C < 1400

white

> 250

> 2400

at 40 C < 1400

white

> 2400

3/2

black

1)

see page 30

27

Product survey
Bonded coatings
Klber product Service temperature range1) [C] approx. Colour Solid lubricant Drying or baking conditions

FLUOROPAN 340 N A/B

40 up to 230

black

Polytetrafluoroethylene (PTFE)

dry: 5 min/100 C burning-in: 15 min/250 C dry: 5 min/100 C burning-in: 15 min/220 C dry: 5 min/20 C hardening: 30 min/20 C

Klbertop TG 05-371

40 up to 300

greyishblack

Graphite (C)

UNIMOLY C 220

180 up to 450

grey

Molybdenum disulphide (MoS2)

Tribo-system materials
Klber product Service temperature range1) [C] approx.
40 up to 200

Colour

Chemical composition

Klberdur KM 02-854 Two-component tribo-system material

dark grey

Component A: epoxy resin, solid lubricant mixture, ester oil; Component B: special hardening agent, graphite, ester oil

28

Yield [m2/l] with a layer thickness of 10 m

Friction coefficient (Tannert 20 C) approx., Vmax = 0.243 mm/s, F = 300 N

17

0.04

18

0.06

0.10

Friction coefficient acc. to Tannert linear contact against steel Vmax = 0.243 mm/s, 30 N/mm approx.
20 C 0.05
no stick-slip

120 C 0.18
no stick-slip

1)

see page 30

29

Notes
1) Service temperatures are guide values which depend on the lubricants composition, the intended use and the application method. Lubricants change their consistency, apparent dynamic viscosity or viscosity depending on the mechano-dynamical loads, time, pressure and temperature. These changes in product characteristics may affect the function of a component.

2)

Especially if series application is planned, we recommend checking the compatibility of the materials to be coated (our results were obtained in tests made on random samples and do not release the user from the obligation to perform his own tests).

3)

Especially if series application is planned, we recommend checking the compatibility of the chemicals to be in contact with the material (our results were obtained in tests made on random samples and do not release the user from the obligation to perform his own tests).

4)

Dry lubricants

5)

Consistency DIN 51 818 (NLGI)

000 00 0 1 2 3 4 5 6

Worked penetration DIN ISO 2137 [0.1 mm]

445 up to 475 400 up to 430 355 up to 385 310 up to 340 265 up to 295 220 up to 250 175 up to 205 130 up to 160 85 up to 115

Texture

fluid almost fluid extremely soft very soft soft moderate stiff very stiff extremely stiff

6)

Klber viscosity grade

EL L M S ES

Definition

Extra light lubricating grease for extremely low torques, e.g. smooth running grease Light lubricating grease for low torques or high speeds in rolling bearings, e.g. high-speed grease Medium lubricating grease for standard requirements in the whole range of grease lubrication Heavy lubricating grease for applications subject to high loads or fluids, e.g. high-pressure/sealing greases Extra heavy lubricating grease for applications requiring high torques or securing effect, e.g. ocular grease or grease for valves and fittings

30

Publisher and Copyright: Klber Lubrication Mnchen KG Reprints, total or in part, are permitted if source is indicated and voucher copy is forwarded. 9.28 e Edition 04.08, replaces edition 05.01 The data in this technical brochure is based on our general experience and knowledge at the time of printing and is intended to give information of possible applications to a reader with technical experience. It constitutes neither an assurance of product properties nor does it release the user from the obligation of performing preliminary tests with the selected product. We recommend contacting our Technical Consulting Staff to discuss your specific application. If required and possible we will be pleased to provide a sample for testing. Klber products are continually improved. Therefore, Klber Lubrication reserves the right to change all the technical data in this technical brochure at any time without notice.

31

We are where you are.

Klber Lubrication the world market leader in speciality lubricants

subsidiaries in over 30 countries more than 1,700 staff products available worldwide
Klber Lubrication offers expert tribological solutions. Through our worldwide presence, we meet customers needs reliably and on time. We supply tailor-made speciality lubricants to customers from nearly all branches of industry and around the world oils, greases, bonded coatings, pastes and many more. Over 75 years of experience, industry-specific know-how, and exceptional test facilities all help to optimise our solutions.

Klber Lubrication Mnchen KG A company of the Freudenberg Group

www.klueber.com