White Paper

Gear oil change and flushing procedure

Improve gear longevity with proper oil change and flushing procedures.

–– Reasons for an oil change/flush include:

Oxidation or varnish build-up, contamination, lifetime of the oil has been met or changing to a different oil type.

–– Guidelines on properly flushing a gearbox and changing the oil.

Oil Changes for Increased Reliability Flushing Gears with Deposits

Oil-lubricated gears may require an exchange of lubricant when A bigger problem is more
the oil changes its characteristics more than what is acceptable profound contamination in
due to the working and ambient conditions, e.g., ageing, abrasion the form of deposits caused
and contamination. There are numerous factors that will dictate by strongly aged oil. In such
when oil should be changed. Proper oil analysis, regular change cases (Figure 2), it is inevitable
intervals as recommended by the gearbox OEM, or the limitations that the gears are cleaned
of the oil as summarized in the oil lifetime chart (Figure 1), can all by means of cleaning oil and
indicate when it is time for the oil to be changed. The objective of manual cleaning, as far as Figure 2: Heavy deposits on
gear housing.
the oil exchange is to ensure continued reliable lubrication. accessible (Figure 3).

Figure 1: Common oil

change intervals for
A recommended oil for
different types of oil. cleaning gears is
Klüberplus Z 03‑30 US, which
quickly dissolves varnish
residues and carbon build up
when added at a concentration
of 10%. At first, approximately
10% of the gear oil fill is drained,
and then the same quantity
of Klüberplus Z 03‑30 US is
added. After 24 to 48 hours Figure 3: The appearance of a clean
When operating conditions change and a different type of oil must of operation, the oil can be gear after flushing
be used, one should take caution to reduce the interaction between drained. Any remaining residues can be removed mechanically. For
the old and new types of oil. When an oil change of this type is situations where viscosity and loading conditions are a concern, the
performed, some residual amount of old oil will always remain in the higher viscosity Klüberplus Z 03‑30 US can be used to reduce the
gearbox. In many cases, these residues cannot be tolerated, and influence on the overall viscosity of the gear oil.
some way of removing them must be found. The simplest method
is flushing the gears. If possible, the old gear oil is drained while Changing Over from Mineral to Synthetic
still warm, i.e., immediately after the gears are stopped. Draining
is followed by flushing to remove residues. The oil container and Every changeover from mineral oil to synthetic oil should be
inside walls of the gearbox can also be cleaned by nonfraying performed with great care. It may not be enough to simply drain
cloth — do not use cleaning wool — and/or a rubber wiper. the used mineral oil and fill in the new synthetic oil.

White Paper Gear Oil Flushing

18.04 Edition KLUSA
 White Paper

Gear oil change and flushing procedure

Improve gear longevity with proper oil change and flushing procedures.

Oil Change and Flush Procedures for Different Types of Gear Conditions

Clean Gears Contaminated Gears Strongly Contaminated Gears

Follow this procedure if simply Follow this procedure if changing oil Follow this procedure if there is a
performing an oil change using types, brands, or for contamination significant amount of varnish, build up,
similar oils and the condition of the that can easily be flushed: or contamination:
gearbox is clean: 1. Drain oil while warm 1. Drain approximately 10% of total oil
1. Drain oil while warm 2. Fill with flushing oil fill while warm
2. Inspect teeth 3. Operate gears for 30–60 minutes 2. Top up with cleaning oil,
3. Replace filters Klüberplus Z 03‑30 US
4. Drain flushing oil
4. Fill new oil 3. Operate gears for 24–48 hours
5. Inspect teeth
5. Put gears into operation; stop 4. Drain oil while warm
6. Replace filters
again 5. Fill with flushing oil, if required
7. Fill new oil
6. Check oil level 6. Operate gears, unloaded, for
8. Put gears into operation; approximately 30–60 minutes
7. Take reference oil sample, stop again
if required 7. Drain flushing oil
9. Check oil level
8. Inspect teeth
10. Take reference oil sample,
if required 9. Replace filters
10. Fill new oil
11. Put gears into operation; stop again
12. Check oil level
13. Take reference oil sample,
if required

Older gears, in particular, can be assumed to contain oil
residues in the casing, the oil lines, etc., which might be
dissolved by synthetic oils. If such residues are not removed,
they may cause problems during operation. Oil lines and filters
may be clogged; seals, pumps and teeth may be damaged.
To prevent such damage, the gears or lubricant circulation
system should be flushed with the new synthetic oil after the
old oil has been drained (ideally at operating temperature).
The synthetic oil that was used for flushing must not be
used for lubrication afterwards; however, it can be kept for
further flushing operations. Prior to filling the fresh synthetic
oil, oil filters or filter elements should be replaced.
For more information, please contact Klüber Lubrication
at marketing@us.kluber.com.

Klüber Lubrication, N.A. / 32 Industrial Drive / Londonderry, NH 03053 / Toll-free: 1-800-447-2238 / Phone: 603-647-4104 / Fax: 603-647-4106

Innovative tribological solutions are our passion. Through personal contact and consultation, we help our customers to be successful worldwide, in all industries and markets. With our ambitious
technical concepts and experienced, competent staff we have been fulfilling increasingly demanding requirements by manufacturing efficient high-performance lubricants for more than 80 years.