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Whitmore SURTAC 2000 Guide: How Multiservice Lubricants Protect Draglines

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Heavy surface mining equipment like draglines operates under extreme pressures and harsh environments. Protecting expensive components such as open gears, swing racks, house rails, and rollers requires high-performance, specialized chemistry. Traditional asphalt-based lubricants can be difficult to pump and lack clean environmental profiles. Whitmore SURTAC 2000 represents a significant technological shift as a multiservice lubricant that provides heavy-duty wear protection without asphalt, solvents, or lead.

How does Whitmore SURTAC 2000 minimize gear-to-gear wear?

Whitmore SURTAC 2000 relies on a specialized chemical formulation containing graphite and molybdenum disulfide (MoS2) solid lubricants. These solid components bond directly to the metal surface under load. This process forms a dense, gray-colored protective film that physically separates mating gear teeth.

By establishing this robust physical barrier, the lubricant minimizes direct metal-to-metal contact even during boundary lubrication phases. According to field data, replacing traditional asphaltic fluids with SURTAC 2000 reduces overall lubricant consumption by approximately 50%, while successfully lowering operating temperatures to extend gear life.

What are the physical characteristics and extreme pressure limits of SURTAC 2000?

To withstand severe shock loading on mining machinery, a lubricant must offer exceptional extreme pressure (EP) performance and high base oil viscosity. The base oil viscosity for all SURTAC 2000 grades without diluent is a highly viscous 48,000 cSt at 40%C (and 380 cSt at 100%C under ASTM D-445). This heavy oil film is supported by a non-melt bentonite clay thickener that maintains physical stability on hot surfaces, such as high-temperature kiln open gears.

The formulation exhibits a high extreme pressure capacity, as proven by the ASTM D-2596 Four Ball EP test, achieving a weld point of 620 kg across all four grades. Corrosive resistance is also verified through ASTM D-4048 (Modified), with every grade achieving a 1B rating during a 3-hour test at 212%F (100%C).

How do the four SURTAC 2000 grades compare in low temperature pumpability?

While the base oil viscosity and weld point are identical across the product line, the NLGI consistency grades and low-temperature performance vary. Choosing the correct grade depends on your regional climate and central lubrication system design. The low-temperature pumpability is measured utilizing the standard Lincoln Ventmeter test at 400 psi:

  • Surtac 2000 (NLGI <000): Pumpable down to -30%F (-34%C). Ideal for extreme sub-zero operations.
  • Surtac 2000 RD (NLGI 000): Pumpable down to -20%F (-29%C). Designed for standard cold-weather climates.
  • Surtac 2000 HD (NLGI 00): Pumpable down to 15%F (-9%C). Engineered for mild temperate environments.
  • Surtac 2000 XD (NLGI 0): Pumpable down to 35%F (2%C). Formulated for warm climates or operations requiring a thicker grease consistency.

Where should you apply Surtac 2000 on mining and heavy industrial equipment?

Because Surtac 2000 is a true “multiservice” lubricant, it allows operations to consolidate their lubricant inventories. It can be applied across several distinct machine components rather than requiring a dedicated grease for every point. Specifically, it does not damage the seals or packaging materials used in automated pumping systems and injectors.

Appropriate application areas include swing racks, house rails, rollers, wire ropes, and drum laggings on draglines. It is also suitable for heavily loaded bushings (including pneumatic hammers) and slow-moving bearings operating at or below a speed factor of 150,000 DN. For crawler tracks, the standard grade is suitable for sealed pins and bushings.

Summary of Whitmore SURTAC 2000 Performance

  • EP Load Carrying: Achieves a 620 kg weld point on the ASTM D-2596 Four Ball test.
  • Solid Additives: Combines graphite and MoS2 solids to form a gray boundary film.
  • Consumption Savings: Lowers lubricant consumption by approximately 50% compared to asphaltic open gear lubricants.
  • Temperature Stability: Utilizes a non-melt bentonite thickener capable of handling high-heat applications like kilns.
  • Corrosion Resistance: Maintains a 1B rating on ASTM D-4048 copper strip testing.

Step-by-step

  1. Select the appropriate grade of Whitmore Surtac 2000 based on the regional ambient temperature using the Lincoln Ventmeter limits.
  2. Ensure the automated pumping system or manual grease injector is free of incompatible chemical thickeners before introducing the bentonite-based lubricant.
  3. Shake Surtac 2000 aerosol cans thoroughly at room temperature before applying to open gear teeth or wire ropes.
  4. Monitor the gear face to confirm the formation of a dense, gray-colored protective solid film.
  5. Consult with your Whitmore distributor to adjust lubrication cycles and target a 50% reduction in lubricant volume compared to previous asphaltic lubricants.

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