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Lubrication Technology Training Course (MP-10006)

Course Length: 16 hours

Purpose: This course provides a comprehensive discussion of the applications of Lubrication Technology (MP-10006) as they apply to the different components and systems involved with the lubrication of manufacturing equipment.

Hands-on training is accomplished through the use of components and tabletop trainers. This process allows the students to see lubrication systems in action and to perform equipment setups.

This course is taught by highly qualified instructors who are experts in this field. The course covers the basics of lubrication, lubricants, filtration, maintenance, failure analysis, and system design. This course is recommended for personnel involved in the maintenance, repair, and testing of lubrication systems and equipment.

Objectives: Upon completion of this course, and with the use of the training manual, participants will be able to:

  • Maintain and troubleshoot lubrication systems commonly found in a manufacturing environment such as manual greasing systems and automatic oiling systems
  • Understand lubrication specifications, lubrication systems and applications, PLC lube controllers, and mechanical timers
  • Interpret viscosity and consistency ratings
  • Operate common lubrication systems
  • Maintain system components including pumps, filters, valves, reservoirs, and manifolds, as well as different types of seals and their compatibility with different fluids
  • Monitor lubricant levels and conditions including common preventive maintenance items such as filter changes, sampling, and inspections and their frequencies

Table of Contents

1. BASICS OF LUBRICATION
Objectives
Introduction
Solid Friction
Six Basic Functions of Lubrication
Reduce Friction
Reduce Wear
Absorb or Dampen Shock
Reduce Temperature
Minimize Corrosion
Seal Out Contaminants
Lubrication of Rubbing Surfaces
Full Film
Elastohydrodynamic Film
Thin Film
Boundary Film
How to Lubricate
Overlubrication
Underlubrication
Summary

2. LUBRICANTS
Objectives
Introduction
Lubricating Oils
Mineral Oils
Synthetic Fluids
Compounded Oils
Fire-Resistant Fluids
Characteristics of Oils
Viscosity
SAE Viscosity Grades
ISO Viscosity Grades
Viscosity Index
Gravity
Flash/Fire Points
Color
Lubricity
Cloud and Pour Point
Pour Point
Additives
Rust Inhibitors
Extreme-Pressure Additives
Viscosity Improver
Pour Point Depressant
Oxidation Inhibitor
Metal Deactivator
Foam Inhibitor
Demulsifiers
Detergents/Dispersants
Fatty Oil Agents
Solid Additives
Greases
Characteristics of Greases
Viscosity of Greases
Consistency
Dropping Point
Texture
Solid Lubricants
Lube System Maintenance
Sources of Contamination
Changing Oil
Fluid Levels of Gear Units
Summary

3. TRIBOLOGICAL TESTS
Objectives
Introduction
Oil Analysis
Spectroscopy
Particle Analysis
Viscosity
Water
Infrared
Flash Points
Color
Neutralization Number
Precipitation Number
Foaming
Oxidation
Sampling Locations and Guidelines
Significance of Wear Particles
Summary

4. BEARINGS
Objectives
Introduction
Bearing Requirements
Load
Anti-Friction Bearings
Friction Bearings
Lubrication of Anti-Friction Bearings
Lubrication of Plain Bearings
High and Low Speed Limits
Surface Material Properties
Operating Characteristics
Allowances for Deflection in Plain Journal Bearings
Journal Bearings with Reciprocating Loads
Methods
Bearing Inspections
Removal and Disassembly
Grease Appearance
Load Distribution in a Bearing
Axial Loads
Axial and Radial Load
Pre-Loads
Out-of-Round Housing Bores
Load Zones with Misaligned Rings
Lubrication-Related Failures
Spalling
Thermal Softening and Discoloration
Glazing
Pulling
Smearing
Skid Smearing
Grooving
Broken Cage
Welded Rollers
Adhesive Wear
Surface Fatigue
Fretting
Particle and Droplet Erosion
Cavitation Erosion
Corrosive Wear
Avoiding Lubrication-Related Failures
Sufficient Elastohydrodynamic Oil Film
Good Boundary Lubrication
Clean Lubricants
Maintenance-Related Failures
True Brinelling
Abrasive Wear
Spark Erosion
Summary

5. OVERVIEW OF LUBRICATION SYSTEMS
Objectives
Introduction
Grease Lubrication
Oil Lubrication
System Types
Intermittent Lubrication
Manual Lubrication
Automatic Intermittent Lubrication
Self-Contained Lube Units
Orifice Control Systems
Pump-to-Point System
Single Line Parallel System
Two-Line Parallel System
Series Progressive Oil or Grease System
Two-Line Parallel with Series Progressive
Continuous Lubrication
Splash Lubrication
Drop Feed and Wick Oilers
Bottle Oilers
Ring Oiler
Continuous Greasing Devices
Force-Fed Lubrication
Mist System
Air/Oil System
Filtration Systems
Lubrication of Gears
Low-Speed Gear Units
High-Speed Gear Units
Selecting Gear Lubricants
Lubricating Oils
Additives
Summary

6. FILTRATION
Objectives
Introduction
Methods of Filtration
Filter Units
Levels of Filtration
Filter Rating
Beta Ratio
Special Considerations
Maintenance of Filtration Systems
Turbulence in Lubrication
Filter Status Indicators
Summary

7. SELF-CONTAINED LUBRICATION UNITS
Objectives
Introduction
SKF SYSTEM 24
Operation
SKF SYSTEM 24 Programming
Installation
Summary

8. SERIES PROGRESSIVE LUBRICATION SYSTEMS
Objectives
Introduction
Divider Valves
Valve Operation
Divider Valve Components
Valve Section
Twin Outlet Block Sections (Lubriquip)
Single Outlet Block Sections (Lubriquip)
Lubecraft Divider Valve Section
Cross-Porting
Bypass Section
Cycle Monitoring
Performance Indicators
Shunt Valve
Zero-Leak Shutoff
Timers and Controllers
Key Functions
Programming
Counter Mode
Timer Mode Prompts
Component Installation Guidelines
Pumps, Reservoirs, and Header Lines
Divider Valves
Check Valves
Installation/Replacement of Tubing, Pipes, and Hoses
Cleaning Tubing and Pipes
Filling System with Lubricant
Filling the Divider Valve
Filling Lines and Tubing
Troubleshooting
Locating a Blockage
Divider Valve Disassembly/Reassembly (Lubriquip, Inc.)
Summary

Appendix A Glossary
Appendix B Bearings
Appendix C Lab Exercises
Appendix D System Design




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