Determining the Application and Number of Spray Heads

The shape and size of the spray pattern are influenced by the tip angle and spray distance. The tip angle is the included angle of the spray pattern as it exits the spray tip, while the spray distance refers to the gap between the spray tip and the target surface. This distance affects both the spray width and the impact force, with increased distance leading to reduced impact force.

 Spray Pattern Components

The distance from the spray tip to the gear face should not exceed 18 inches. Air turbulence from moving gears can diminish the lubricant’s impact force and create inconsistent results. Reducing this distance decreases the spray pattern width. Smaller spray angle tips are available for applications needing a narrower spray pattern.

For larger gears, more than one airless spray valve may be necessary to adequately lubricate the surface. If one valve is insufficient, an additional valve can be added to extend the spray pattern width. A controller can manage two airless spray valves on a single machine.

 Spray Pattern Factors

The Car Lift Repair Orlando spray pattern is significantly influenced by the lubricant’s viscosity, specific gravity, type, and temperature. To ensure a consistent spray pattern, the airless spray system includes a heater to maintain the lubricant temperature, which helps control its viscosity across various atmospheric conditions. The lubricant is heated just before application to prevent solvent evaporation. Heating the lubricant in the drum is generally unnecessary unless in extremely cold conditions.

 Airless Spray Pattern

The system’s thermostat maintains the lubricant temperature between 120°F and 150°F (49°C and 66°C), suitable for most asphaltic- and petroleum-based greases. Some synthetic lubricants and greases might need higher temperatures, between 160°F and 175°F (71°C and 79°C), for an optimal spray pattern.

 Keeping the Lubricant Clean

For smooth operation, it is recommended to filter the Car Lift Repair Orlando lubricant before it enters the airless spray valves. Solid particles can clog the spray valve and tips, necessitating frequent maintenance. Maintaining clean lubricants in the reservoir helps, but does not entirely prevent contaminants from entering the system. A dual filter panel is available to reduce tip and valve clogging.

 Spray Nozzle Tips

Standard Car Lift Repair Orlando spray tips attach directly to the airless spray valve assembly’s outlet adapter. However, they are not recommended for lubricants prone to clogging the tip. Alternative tips are available that can be easily cleaned and replaced without tools, often featuring a rotating tip handle for flushing out with a lubrication cycle. Additionally, a swivel assembly is available to direct the spray without moving the entire valve assembly, which can be locked in place with a swivel lock nut.

 System Requirements

To effectively lubricate Car Lift Repair Orlando open gear and pinion assemblies in bull gear applications using a typical airless spray system, several key factors need to be determined:

– The number of airless spray valves needed to cover the gear face.

– The required film thickness of the lubricant.

– The specific area on the outside diameter of the gear where lubrication is applied.

– The capacity of the gear lubricant.

– The rotational speed of the gear and corresponding spray duration.

– The coverage area of the gear per spray cycle.

– The duration of pauses between spray cycles.

After initial calculations, the system should be configured and observed during operation. Any necessary adjustments to the application rate or pause time should be made based on performance evaluation.

 Pump and Size of Supply Lines

The standard pump should generate a pressure of 3,500 psig at the system connection point. Determine the optimal position for the pump and create a system sketch. It’s advisable to position the pump as close to the system as possible. Refer to the manufacturer for specific requirements regarding pump assembly, hose selection, and controller compatibility.

 Maintenance

Following Car Lift Repair Orlando installation and fine-tuning for the application, regular maintenance of filters and spray tips is essential. Clean, well-filtered lubricant minimizes tip and system maintenance, typically requiring only occasional tip cleaning. Lubricant contaminated with dust and dirt can lead to frequent tip clogging and potential spray valve issues.

Various factors can impact the spray pattern, including temperature fluctuations, viscosity changes, pressure variations, and tip wear. If the spray pattern deviates, such as spraying in a solid stream instead of fanning out, inspect the tip for any clogging or dried lubricant buildup.

Ensure the system filters remain clean to prevent filter bypass, which can introduce dirt and debris into the system. In severe cases, a clogged filter may burst, allowing filter media and contaminants to enter. Maintaining clean lubricant in the reservoir helps reduce filter maintenance. Utilize a follower and tightly sealed drum cover with no openings.

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Discoveries in Preventive Maintenance

During start-up, routine preventive maintenance (PM) checks consistently revealed abnormal heat levels in both gearboxes. Employing an infrared (IR) heat gun, we measured the temperatures while using VG 460 synthetic worm gear lube:

– At 40 percent speed, the temperature registered 110ºF.

– At 80 percent speed, the temperature rose to 167ºF.

It’s important to note that the actual oil temperature within the gearbox could be 15 to 20 degrees higher than the surface temperature.

What caused these elevated temperatures? One potential explanation was Car Lift Repair Orlando residual flushing solution from a seven-viscosity flushing procedure, which might have mixed with the VG 460 gear oil, possibly reducing its viscosity significantly. To investigate this, we sent an oil sample to the lab for analysis. The results indicated normal lubricant condition, but excessive copper levels suggested bronze gear wear.

Temperature Fluctuations

Following the original Car Lift Repair Orlando equipment manufacturer (OEM) recommendation, we switched to synthetic 680 lubricant. After draining one gearbox and filling it with 680, we noted the following temperature readings upon start-up:

These findings hinted at potential heat generation from viscous churning losses, indicating a need for a lower viscosity lubricant. To test this hypothesis, we replaced the 680 with 320 nontoxic synthetic worm gear lube. The subsequent results were as follows: