course industrial & fleet lubricants - blue sky elearn of grease over oil: semi-solid lubricants...

Basic Products Course

Module 7: Industrial & Fleet

Lubricants

Contents We will cover Industrial & Fleet Lubricants in SIX steps:

This module will have some new information, as well as reemphasize some things discussed in earlier modules. In addition, there is a lesson on Product Application Manuals. Grease--What it is and how it is evaluated.

Gear Oils--What they are made of, which additives are used, and various grading/classification systems.

ATF--What it is, its uses, and grading/classification systems

Metalworking Fluids--What they are, their uses and types.

Hydraulic Fluids--Basic theory of hydraulics and what hydraulic fluids are.

Product Application Manuals--What they are, what they contain, and how they can be used to select products to meet the customer's needs.

This lesson covers All 6 sections.


Lubricants

Part 1: Grease

Industrial & Fleet Lubricants – Grease

As you’ve become accustomed to: Let’s kick this Module off with some questions to get you thinking about

the subject matter.


Grease has three main components.

QUICK QUESTION:

It contains a liquid lubricant, additives, and a __________ to make it into a semi-solid.

o Mineral Oil o Water o Thickener o Dry Lubricant


There are many specifically formulated lubricants. Each lubricant is formulated for the best performance under specific conditions.

QUICK QUESTION:

The type and amount of additives in a gear oil depend on the type of ________ it will be lubricating.

o Bearing o Automatic transmission o Metalworking piece o Gear


Sometimes a DYE is added to a lubricant or grease. It doesn't have any affect on the lubricant's performance.

QUICK QUESTION:

Why are Dyes added to some lubricants?

o To improve viscosity o To provide identification o To indicate age o To make you ask questions


QUICK QUESTION:

Lubricants are used during metalworking operations: cutting, grinding, shaping, punching. During metalworking operations, a lubricant has

two main functions. It must lubricate and ______ .

o Reduce operating temperatures. o Prevent metal to metal contact. o Increase working temperatures. o Prevent abrasion.


QUICK QUESTION:

There are some applications where lubricants do more than lubrication and cooling. In hydraulics, the lubricant is an energy

transfer medium. Hydraulics is the science of fluids. Whenever a fluid is stored, controlled, or _______, it involves hydraulics.

o Heated o Frozen o Moved o Evaporated


Because there are so many products, manufacturers provide manuals that summarize product application information. You can find typical product applications in a Product Application Manual. TYPICAL APPLICATIONS

Modern high pressure ( over 1200 psi ) hydraulic equipment. Older, lower pressure hydraulic systems. Air line lubrication.

QUICK QUESTION:

You can find typical product application in a Product Application Manual. What is one use of a Product Application Manual?

o Identified specific chemical formulas. o Match products to customer equipment applications. o Identify manufacturing procedures. o Determine retail price of products.


Now that you have an idea of what this Module is about ........LET' S GET STARTED..........

TOPICS

The following topics will be covered in this lesson on GREASE:

Grease Components. Advantage/Disadvantages of Grease over Oil. Evaluating Grease Quality and Performance.

Industrial & Fleet Lubricants – Grease Grease Components: Semi-solid lubricant (GREASE) is made up of three main components:

OIL + THICKENER + ADDITIVES = GREASE

THICKENERS: Also known as SOAPS. Thickeners act like sponges holding the lubricant. When the grease is worked or churned, lubricant is released; when the working stops, the oil returns to the thickener. Typical grease thickeners are:

– Lithium, Lithium Complex, Sodium – Calcium, Clay ( Bentone ), Aluminum Complex

The type of thickener used in a grease can affect its performance characteristics:

– Dropping Point:: The temperature at which oil first separates from the thickener.

– Water Resistance – Stability


ADDITIVES: Additives increase a grease's usefulness in specific applications. Extreme pressure and oxidation additives are two of the most common. The three main COMPONENTS OF GREASE are: Liquid lubricant, thickener and additives.

Industrial & Fleet Lubricants – Grease QUICK QUESTION:

What three MAIN grease characteristics are affected by the type of

thickener used in the grease?

o Dropping point, water resistance and stability. o Water resistance, stability and viscosity index. o Stability, water resistance and oiliness. o Dropping point, stability and molecular structure.

QUICK QUESTION:

What are the three main components of Greases?

o Thickener, oil and solid lubricant o Additives, liquid lubricant and thickener o Liquid lubricant, oil and additives o Solid lubricant, additives and thickener


Advantages/disadvantages of Grease over Oil: Semi-solid lubricants have many ADVANTAGES over liquid lubricants in certain applications. Three main advantages are:

Prolonged Service Intervals: Greases stay on the items they are lubricating longer than liquid lubricants do, so they need to be replaced less frequently. Less Complex Housings: Because grease stays on parts longer than liquid lubricants do, it does not need the complex housings, seal and delivery systems that liquid lubricants require. Self-Sealing: As grease is worked, it emerges from the bearing and forms a semi-solid collar, which keeps out dirt and moisture. The semi-solid nature of grease provides a seal for parts.


For some applications, grease performs better than liquid lubricants. But grease has some important DISADVANTAGES, like:

Poor Heat Transfer: Semi-solid grease, because it does not flow like liquid lubricant, it does not carry heat away from moving parts. Reduced Flushing: Also, because grease does not flow well, it cannot carry contaminants away from moving parts.


What are the main advantages that grease has over liquid type

lubricants?

o Dropping point, water resistance and stability. o Water resistance, stability and viscosity index. o Stability, water resistance and oiliness. o Prolonged Service, Easier delivery, and sealing ability.

QUICK QUESTION:

What are the two main disadvantages of grease?

o Reduced flushing and complex housing requirements. o Poor heat transfer and reduced flushing. o Reduced flushing and prolonged service intervals. o Self-sealing and poor heat transfer.


Evaluating Grease quality and performance: Because grease has specific applications, two types of tests are used to evaluate a grease:

INSPECTION TESTS: are used to evaluate the manufacturing quality of a grease. They are quality control tests, and do not indicate how grease will perform under operating conditions. PERFORMANCE TESTS: are used to predict how a grease will perform under operating conditions.


INSPECTION TESTS: The Production Quality of a grease is measured through the use of vary specific Inspection Tests. Two types of inspection tests are:

Penetration: A measure of the consistency of a grease ( its hardness or softness). It may also indicate something about the flow and dispensing properties of a grease. Dropping Point: At dropping point temperatures, thickeners begin to melt, and the grease cannot lubricate effectively.


PERFORMANCE TESTS: How a grease will perform in various applications is predicted through the use of PERFORMANCE TESTS. There are six main performance tests:

Stability: A measure of grease's resistance to changes in consistency while being churned or worked. If a grease softens or hardens during use, it can lead to leakage or poor lubricating. OxidationA measure of grease's tendency to combine with oxygen. The higher the operating temperature, the faster the rate of oxidation. Oxidation can cause a grease to harden or soften, which can prevent proper lubrication. Oil Separation: A measure of grease's resistance to separation of the oil from the thickener. During normal operation, oil must bleed from the thickener to provide lubrication. However, if the oil separates too readily from the thickener, a hard, concentrated residue may build up. This residue can clog devices and prevent flow of lubricant.


Water Resistance: A measure of a grease' s ability to resist washout under conditions where water is present. Also, the grease must be able to resist absorbing water, which may cause it to soften. Rust Protection: A measure of a grease's ability to provide rust/corrosion protection. EP/ Wear Prevention: A relative measure of a grease' s performance under extreme pressure and wear conditions. These tests often are not exactly the same as service performance, but are a cost efficient means of measuring these properties. (This is one of the most important performance tests.)


There are six basic PERFORMANCE TESTS used to predict how a grease will perform. Of the tests below, which is usually the most

important test? Water resistance o Viscosity index o Rust protection o EP/ wear prevention

QUICK QUESTION: One of the most important tests performed during the manufacturing

of a grease is EP/WEAR PREVENTION. What grease characteristics do EP/ Wear prevention tests measure?

o Resistance to wear. o Performance under extreme pressure and wear. o Resistance to changes in consistency. o Performance under extreme temperatures.


REVIEW Grease components: Liquid lubricant, thickener and additives. Advantages of grease: Prolonged service, less complex housing, and self sealing. Disadvantages of grease: Poor heat transfer and reduced flushing of contaminants. Type of inspection tests: Penetration and dropping point. Penetration tests: Relative hardness/softness of a grease. Dropping point tests: Temperature at which oil separates from thickener. Thickener type: Affects dropping point, water resistance and stability. Grease performance tests: One of the most important test is the EP/Wear Prevention test. EP/Wear Prevention tests: Relative measure of how a grease will perform under extreme pressure and wear applications.


THAT COMPLETES GREASE

Now it’s time for a quick BREAK!

Then go to GEAR OILS, Lesson 2 in this Module.


Lubricants

Part 2: Gear Oils

Industrial & Fleet Lubricants – Gear Oils

The following topics will be covered in this lesson on GEAR OILS:

Gear Oil Components Gear Oil Classification

Lubricating Enclosed Gears

Industrial & Fleet Lubricants – Gear Oils Gear Oil Components: A GEAR OIL is a lubricant that is specifically formulated for use with gears and gear sets. Specific formulation of a gear oil depends on the gear it lubricates ...

SPUR: A spur is the simplest type of gear. It is a disk with straight teeth that protrude outward from its edge. The teeth are evenly spaced around the entire edge of the disk. Two or more gears are used to transmit motion. As the gears rotate, one tooth meshes with one tooth of the second gear, and the second gear rotates.

Industrial & Fleet Lubricants – Gear Oils HELICAL: Helical gears are much like spur gears except the teeth on a helical gear are not straight- they are angled and twisted across the gear face. This difference provides smoother operation, and allows more than one tooth from each gear to mesh at the same time. BEVEL/SPIRAL BEVEL: Bevel gears are cone shaped gears, with straight teeth that run from the small end of the cone to the large end. Spiral bevel gear are bevel gears with angled or twisted teeth.


HYPOID: Hypoid gears, like spiral bevel gears, are cone shaped and have angled or twisted teeth. If spiral bevel gear shafts were extended, they would intersect. Hypoid gear shafts do not intersect. WORM: A worm gear is a straight toothed gear , or worm wheel, meshed with a corkscrew shaped shaft or worm. Worm gears are used when very high gear reductions are needed.

Industrial & Fleet Lubricants – Gear Oils The type of gear determines which ADDITIVES are used in a gear oil.

Lubrication of spur and helical type gears require few, if any additives. In some cases, plain mineral oil can be used. Helical gears sometimes use mild anti-wear additives.

Bevel gears can use mineral oil. Spiral bevel gear lubricants need anti wear additives.

Hypoid gears require the addition of EP additives to basic mineral oils.

Worm gears require high viscosity base oils with oiliness additives.

Industrial & Fleet Lubricants – Gear Oils QUICK QUESTION:

Spurs and helical gears operate with simple rolling motion. A basic lubricant for spur and helical gears contains?

o Only anti wear additives. o Only EP additives. o Plain mineral oil. o Plain reformates.

QUICK QUESTION: Bevel and spiral bevel gears operate with a little sliding motion.

Spiral bevel gears should be lubricated with mineral oil and ________ additives.

o No o Oiliness o Anti-wear o EP


Hypoid gears have lots of sliding motion. Hypoid gear lubricants must contain mineral oil with _________ additives.

o No o Oiliness o Oiliness & Anti-wear o EP

QUICK QUESTION: Worm gears operate with pure sliding motion.

Worm gears should be lubricated with high viscosity oil containing _________ additives.

o Oiliness. o Anti foam. o EP o AW


A GEAR OIL is a lubricant that is specifically formulated for use with gears and gear sets. Specific formulation of a gear oil depends on the gear it lubricates and some times, the gear housing.

Spur & Helical: Plain mineral oil sometimes mild AW. Bevel/Spiral bevel: Mineral oil + AW additives. Hypoid: Mineral oil + EP additives. Worm: High viscosity oil + oiliness additives

Enclosed gears present a special problem

Enclosed gears are gears that are contained in some box or structure which can reduce lubricant loss. Anti-foam additives are used to reduce the amount of foam generated during operation.


QUICK QUESTION:

What type of additives must be used in a gear oil that is intended for use in enclosed gear sets?

o EP o Anti-foam o Oiliness o Anti-wear


What type of lubricant is used by HYPOID gear ?

o Plain Mineral oil o Mineral Oil + Anti-wear Additives o Mineral Oil + EP Additives o High Viscosity Oil + Oiliness Additives

QUICK QUESTION:

What type of lubricant is used by BEVEL gear ?



What type of lubricant is used by SPUR gear ?


QUICK QUESTION:

What type of lubricant is used by WORM gear ?



What type of lubricant is used by ENCLOSED GEARS gear ?

o Plain Mineral oil o Mineral Oil + Anti-wear Additives o Mineral Oil + EP Additives o Lubricant + Anti-foam Additives

QUICK QUESTION:

What type of lubricant is used by HELICAL / SPIRAL BEVEL gear ?


Industrial & Fleet Lubricants – Gear Oils Gear Oil Classification: There are three basic classifications systems for gear oils: Two of the systems involve the measurement of the oil's VISCOSITY.

Viscosity is one of the most important characteristics of a gear oil. It's really a balance in performance. Today's gear lubricants must flow freely when components are cold, yet have enough viscosity to lubricate at operating temperatures. A gear oil must be able to flow upon startup, but still have the correct VISCOSITY during operation.


Viscosity is a measure of a liquid's

o Volatility. o Extreme pressure capacity. o Oiliness. o Resistance to flow.

QUICK QUESTION: There are three methods for classifying a gear oil. Two of the

methods indicate the viscosity of the lubricant. What are the three main types or methods used to classify a gear oil?

o AGMA, SAE Viscosity, EP. o SAE Viscosity, ISO, AGMA. o API Service, AGMA, SAE Viscosity. o Density, AGMA, SAE Viscosity.

Industrial & Fleet Lubricants – Gear Oils SAE VISCOSITY GRADES

The SAE viscosity grade system provides VISCOSITY RECOMMENDATIONS for AUTOMOTIVE GEAR OILS. Even though both crankcase oils and gear oils use SAE viscosity systems, the two are not the same...

Of the three methods used to classify gear oils, two methods measure viscosity.


Which of the three methods is used to classify gear oil used in

automobile gear sets?

o AGMA o SAE Viscosity. o API Viscosity. o None of the above.

QUICK QUESTION:

Are SAE Viscosity Grades for crankcase oils the same as SAE Viscosity Grades for gear oils?

o YES o NO


API SERVICE DESIGNATIONS API service classifications indicate the type of automotive service or application the gear oil was designed for. There are FIVE API service classifications GL-1, GL-2, GL-3, GL-4, GL-5. GL-1 was the first API service classification. Straight mineral oils meet GL-1 specifications. GL-1 oils were commonly used in automobile manual transmissions. Each subsequent API service classification represents an improvement to meet new equipment requirements. For example, the GL-5 classification represents oil requirements for moderate to severe service found in automobiles today. A GL-5 gear oil has several additives that adjust the oil's lubricating properties to the equipment and application. API Service classifications indicate typical applications for gear oils in AUTOMOTIVE gear sets. Now, a look at the applications for each API service classification...

Industrial & Fleet Lubricants – Gear Oils CLASS TYPE APPLICATION

GL-1 Straight mineral oil Automotive manual transmissions.

GL-2 Oiliness additives Worm gear drives/industrial gears.

GL-3 Mild EP additives Manual transmission and spiral bevel final drivers ( This class is not widely used ).

GL-4 Equivalent to obsolete MIL-L-2105 specification. Usually satisfied by 50% of GL-5 additives.

Manual transmissions, spiral bevel and hypoid gears in moderate service.

GL-5 Equivalent to present MIL-L-2105D specification.

Required for moderate and sever service in hypoid and all other gears. Also used in manual transmissions. This is the primary field service recommendation of most passenger car and truck builders worldwide.

MT-1 Addresses thermal degradation, component wear, and oil seal deterioration which is not provided by GL-5 oils.

Some heavy duty nonsynchronized manual transmissions.


QUICK QUESTION:

API Service designations are classifications that represent various improvements in oil formulation. The GL-5 specification is the most common specification today, althought the MT-1 specification is not

obselete either. API Service Classifications are applied to?

o Industrial gear sets. o Automotive gear sets. o All gear sets. o Exposed gear sets.


AGMA GRADES For industrial gears, viscosity recommendations are indicated by AGMA Grades. This grading system was developed by the American Gear Manufacturer' s Association. There are two AGMA Gear Lube Grade Classifications:

Industrial & Fleet Lubricants – Gear Oils Let's look at the differences....

For example: An SAE 90W gear oil is the equivalent of an AGMA 5 gear oil, or a 5EP oil, if it has extreme pressure additives.


QUICK QUESTION:

There are two classification systems that represent viscosity recommendations for gear oils: AGMA and SAE.

AGMA Grade Classifications represent viscosity recommendations for __________ gear oils.

o Industrial gear sets. o Automotive gear sets. o All gear sets. o Exposed gear sets.


QUICK QUESTION:

Match the following classifications to their correct applications:

A. AGMA B. SAE Viscosity Grades C. API Service

o Viscosity recommendations for automotive gear oils. o Application/use recommendations for automotive gear oils. o Viscosity recommendations for industrial gear oils.


Lubricating Enclosed Gears: Lubricants that are used in enclosed gears are subjected to severe service conditions like....

Churning: Churning occurs as a lubricant is thrown around. It forms a mist or spray which increases oxidation of the lubricant. Oxidation shortens the effective life of a lubricant. Heat Buildup: Heat build-up within the enclosed gear box results in increased oxidation. Sludge Building: When heat builds up in a gear box, sludge forms. This sludge can inhibit lubrication and thus cause damage.


To minimize the effects of severe service conditions, enclosed gear lubricants must have the following characteristics:

Correct viscosity at operating temperatures. Permit flow at startup: adequate low temperature fluidity. Good chemical stability ( minimized oxidation effects ). Permit rapid separation of water: good demulsibility. Anti-rust properties. Non-corrosive nature. Good foam resistance. In enclosed gear sets, the oil must resist foaming.


QUICK QUESTION:

To perform well at both startup and normal operating temperatures, a gear oil must have the proper

o Low temperature fluidity and viscosity. o Oiliness and low temperature fluidity. o Additives and all temperature fluidity. o Oiliness and additives.


REVIEW

Gear oil formulation is determined by the type of gear to be lubricated. There are three methods of classifying gear oils: SAE Viscosity Grades, API Service Designations, and AGMA Viscosity Grades. SAE Viscosity Grades and API Service Designations are used with Automotive gear sets. AGMA Grades are viscosity recommendations for industrial gear sets. A gear oil must be pumpable enough to flow at startup, but must also have the correct viscosity during operation.


THAT COMPLETES GEAR OILS

Now it’s time for a BREAK!

Then go to ATF, Lesson 3 in this Module.


Lubricants

Part 3: ATF

Industrial & Fleet Lubricants – ATF

The following topics will be covered in this lesson on ATF:

ATF Basics (Definition, properties and functions)

ATF Classifications Hydraulic Tractor Fluids


QUICK QUESTION:

Compared to an SAE 10w grade crankcase oil, ATF has exceptionally good:

o High temperature properties. o Low temperature properties. o Low viscosity properties. o Both A and B.

ATF Basics ( Definition, properties and functions ): ATF or Automatic Transmission Fluid is a complex lubricant that contains as many as fifteen components. ATF is blended to meet the unique requirements of automotive automatic transmissions, which produce high temperatures and violent churning. Drain intervals are much longer than they are for crankcase oils. ATF viscosity is similar to a SAE 10W grade crankcase oils, but ATF has a higher viscosity index and better oxidation resistance.

Industrial & Fleet Lubricants – ATF ATF contains some of the same types of additives as crankcase oils, but ATF typically has additional additives which are:

Special friction modifiers. Increased oxidation stability additives. Increased anti-foam additives

ATF is a lubricant especially designed for automotive automatic transmissions.

Because temperatures in automatic transmission can range from low at startup to high during operation, ATF must have a high viscosity index. Because automatic transmissions produce a great deal of churning, ATF must resist foaming and oxidation. Because drain intervals are long, AFT must be stable. For easy identification, ATF is usually dyed RED.

Industrial & Fleet Lubricants – ATF QUICK QUESTION:

ATF contains special additives to protect against foaming and oxidation. What is the characteristic color of ATF?

o Bright stock clear. o White. o Red. o Green.

QUICK QUESTION: ATF has special additives that provide a high viscosity index and

protect against oxidation and foaming. Which of the following additives does ATF contain?

o Glycol. o Oxidation promoters. o Friction modifiers. o Vasoline.

Industrial & Fleet Lubricants – ATF The primary use for ATF is in automatic transmissions. Six basic properties make it especially suited for automatic transmissions:

Wide temperature range: Automatic transmissions have very low tolerance for viscosity changes. ATF viscosity index is very high. High oxidation resistance: High operating temperatures and long drain intervals promote oxidation. ATF must be STABLE. Corrosion protection: Transmission valves have extremely small clearances. Valves will fail if they are pitted or corroded. Friction modifiers: Clutches and bands in automatic transmissions require friction modifiers to provide smooth shifting. Detergent/Dispersant Action: Finely machined parts can stick if the ATF dose not keep them clean. Rough shifting results. Good resistance to foam: Violent churning can produce foam. Foam causes erratic shifting and can force the fluid to leak.


QUICK QUESTION:

Six basic properties are required for ATF to function well in automatic transmissions:

ATF must have a wide temperature range, high oxidation resistance, good foam resistance, special friction modifiers, and…

o High viscosity and detergent/dispersants. o Detergent/dispersants and corrosion protection. o High viscosity and low viscosity. o Corrosion protection and low viscosity.

Industrial & Fleet Lubricants – ATF With the previously mentioned properties in mind, let's look at ATF' s four main functions:

Transmit drive power: Movement of the ATF in the torque converter transmits engine power to the driver train. Act as a hydraulic fluid: ATF under pressure moves control valves to control shifting. Lubricate gears and bushings: ATF lubricates and cools moving parts in the transmission. Transfer heat: Hot ATF circulates through a section of the radiator and releases heat to the atmosphere.

ATFs also Clean parts and disperse contaminants: Detergents/dispersants clean and protect transmission parts.


Which of the following is one of ATF’s 4 main functions?

o Act as a hydraulic fluid. o Increase friction. o Trap heat transfer. o Absorb contaminants.

QUICK QUESTION:

ATF circulates through the radiator to function as a

o High friction modifier. o Low viscosity lubricant. o 10W grade crankcase oil. o Heat transfer medium.


ATF Classifications: There are several main classifications of ATF:

DEXRON III: Dexron is a registered trademark of General Motors Corporation. Dexron III is typically used in GM and import automobile automatic transmissions. TYPE F: Types F is primarily used in older Ford vehicles. MERCON/MERCON V: Mercon is a registered trademark of the Ford Motor Company. Mercon V is specified for many newer models and may be used in place of Mercon. ATF +3/+4: ATF +3 and +4 are specified for most Chrysler-made vehicles. ATF+4 is required for many newer models, and may be used in place of ATF+3. Dexron VI & Mercon LV: newer products with slightly lower viscosities designed to meet needs of transmissions developed in the late 2000’s and 2010’s.

– Type F, and Mercon fluids are typically used in Ford automobile automatic transmissions. Which one depends on the year and model.


Which type of ATF is used in GM automatic transmissions?

o Dexrons. o Mercons. o Type F. o ATF +3/+4.

QUICK QUESTION:

Which type of ATF is used in Ford automatic transmissions?

o Dexrons. o Mercons. o Type F. o B & C.

U.S. Service Fill Specifications OEM Specification Name P66 Products

Chrysler MS-9602 ATF+4 VersaTrans® ATF *

Ford WSS-M2C938-A MERCON® V MERCON® SP WSS-M2C924-A Mazda M 5 WSS-M2C933-A ESW-M2C33-F

MERCON® LV MERCON® V MERCON® SP Premium ATF FNR5 ATF CVT Chain Type Type F ATF

VersaTrans® LV ATF MERCON® V ATF / VersaTrans® ATF None None VersaTrans® ATF None Type F ATF

GM GMN10060 DEXRON®-VI VersaTrans® LV ATF

* Not officially licensed


Hydraulic Tractor Fluids: are also transmission fluids. But in addition to lubricating transmissions, they are hydraulic fluids. A tractor or backhoe, for example, may use the same lubricant in the transmission and in the system that moves the scoop or bucket.

ATF formulated as hydraulic fluids can be used in: Industrial equipment ( Compressors ) Tractors Heavy equipment Hydraulic tractor fluids have many of the same additives as do ATFs. Some ATFs are suitable for use as hydraulic fluids.


QUICK QUESTION:

ATFs formulated as hydraulic fluids can be used in

o Industrial equipment. o Tractors and backhoes. o Heavy equipment. o All of the above.


REVIEW ATF is a complex lubricant. ATF additives include:

V.I. Improvers, Anti-foam, Oxidation inhibitors, Corrosion protection, Friction modifiers, Detergent / Dispersants.

ATF types include: Dexron III, Dexron VI, Type F, Mercon/Mercon V, Mercon LV, ATF+3/+4…

Transmission fluids can also be used as hydraulic tractor fluids. ATF is a complex lubricant that is primarily used in automotive automatic transmissions.


QUICK QUESTION:

ATF is different from an SAE 10W grade crankcase oil, because it has a

o Low viscosity index. o High pour point. o Low operating temperature. o Wider operating temperature range.


THAT COMPLETES ATF

Take a BREAK if you need it.

Then go to Metalworking Fluids, Lesson 4 in this Module.


Lubricants

Part 4: Metalworking Fluids

Industrial & Fleet Lubricants – Metalworking Fluid

TOPICS The following topics will be covered in this lesson on Metalworking Lubricants:

Metalworking Lubricants Basics – (definition, properties, and functions)

Metalworking Lubricant Types


Metalworking Lubricants Basics (definition, properties and functions ):

Metalworking lubricants are fluids that reduce the heat and friction associated with metalworking operations. Metalworking is a term that describes those industrial processes that involve CUTTING, GRINDING, STAMPING, FORGING and FORMING metal parts. The following images show some of the common metalworking processes.


All of these processes generate heat and wear, which can damage both equipment and the piece being worked on. Metalworking lubricants carry away heat and reduce friction between tools and workpieces. Metalworking lubricants have two main functions:

COOL: As the metalworking lubricant is applied, it cools both the cutting or grinding tool and the workpiece. LUBRICATE: This reduces the heat buildup, tool wear and equipment power consumption. It also improves the smoothness of the finished piece.


QUICK QUESTION:

Metalworking processes generate large amounts of friction: What are the two functions of metalworking lubricants?

o Lubricate and seal. o Cool and lubricate. o Cool and bond. o Lubricate and polish.


In addition to its two main functions, a metalworking lubricant also:

Protects surfaces against rust. Prevents welding of the metal tool to the workpiece.

Metalworking lubricants must also do all of this without:

Staining the workpiece. Smoking or misting. Having a disagreeable odor.


QUICK QUESTION:

Metalworking lubricants are fluids that reduce friction and heat normally generated during metalworking operations.

What else do metalworking lubricants do?

o Reduce misting and cooling. o Prevent contact between tool and workpiece. o Prevent welding and rust. o Both A and B.


Like other lubricants, metalworking lubricants are formulated with ADDITIVES. Typical additives are:

Extreme Pressure (EP) Additives Anti-wear (AW) Additives – EP/AW additives reduce friction and prevent

scoring, welding and seizure. This helps reduce equipment and workpiece wear.

Two common Extreme Pressure and Anti-wear additives are: – Sulfur – Chlorine


QUICK QUESTION:

What are the two main types of metalworking lubricant additives?

o Viscosity improvers and EP additives. o Anti-wear and quality-assurance additives. o Friction modifying additives. o EP additives and anti-wear additives.

Industrial & Fleet Lubricants – Metalworking Fluid Metalworking Lubricant Types: There are three types of metalworking lubricants:

Mineral Cutting Oils: Mineral oils provide both lubrication and cooling. They are often low viscosity oils. Straight mineral oils can be used in mild applications. In more severe applications, an EP additive may be required. Soluble Oils: These lubricants are oils that form milky emulsions when mixed with water. Because soluble oils contain water, they cool more efficiently than straight mineral oils do. Water releases heat faster than oil does. Soluble oils are easily contaminated by bacteria. If not handled carefully, they will turn rancid. Synthetic Metalworking Fluids: These fluids are a suspension of salts dissolved in water. They provide excellent cooling. Synthetic fluids contain NO mineral oils. Unlike soluble oils, they are not easily contaminated by bacteria. They are clear liquids, so workpieces are visible. Metal debris settles out of the working fluid quickly.


QUICK QUESTION:

What are the three main types of metalworking fluids?

o Synthetic fluids, mineral cutting oils and soluble oils. o Synthetic fluids, grinding oils and cutting oils. o Soluble oils, mineral cutting oils and EP oils. o Mineral cutting oils, AW oils and EP oils.


REVIEW Metalworking lubricants reduce heat and friction during various metalworking operations for example Cutting, Grinding, Stamping, Forging, Forming. There are three main types of metalworking lubricants:

Soluble Oils Synthetic Fluids

( Oil +Water) (No Mineral Oils)

Lubricating and cooling Mainly coolingMainly cooling and is More Stable

Mineral Cutting Oils (oil only )

Industrial & Fleet Lubricants – Metalworking Fluid QUICK QUESTION:

The two main functions of metalworking lubricants are to reduce friction and __________ tools and workpieces.

o Lubricate. o Cool. o Heat. o Oxidize.

QUICK QUESTION: There are two main additives used in metalworking lubricants: EP and

Anti-wear. Straight mineral oils have no additives. If the metalworking operation generates extremely high levels of heat

and friction, a __________ oil would be required

o Mineral. o Low viscosity. o High Viscosity. o Synthetic.


THAT COMPLETES Metalworking Fluid

Take a quick BREAK!!!

Then go to Hydraulic Fluids, Lesson 5 in this Module.


Lubricants

Part 5: Hydraulic Fluids

Industrial & Fleet Lubricants – Hydraulic Fluids

TOPICS

The following topics will be covered in this lesson on HYDRAULIC FLUIDS:

Overview of Hydraulics Hydraulic Fluids

Industrial & Fleet Lubricants – Hydraulic Fluids QUICK QUESTION:

Hydraulics is the science of fluids. Whenever a fluid is stored, moved or controlled, it involves hydraulics. Hydraulics are involved

whenever fluids are stored, __________ or _______ . o Moved, Solidified. o Controlled, moved. o Vaporized, moved. o Manufactured, controlled.

QUICK QUESTION: Hydraulic systems transmit MOTION and FORCE. EXAMPLE: Hoists

in a service station are hydraulic systems. Hydraulics are used in equipment like automatic transmissions, elevators and earth moving

equipment. Hydraulics are used to transmit _______ and ________ . o Force, Viscosity. o Motion, Temperature. o Force, Viscosity. o Motion, Force.


Hydraulic systems have FOUR essential elements: Reservoir: Hydraulic fluid is stored in the reservoir. Pump: The PUMP moves the fluid, under pressure, from the reservoir to other parts of the hydraulic system. Valve(s): The VALVE or VALVES control fluid movement. When the valves are open, fluid flows through the hydraulic system. Hydraulic Motor: The force of the fluid moving against or through the hydraulic motor, or ram, is converted into mechanical power. A hoist is pushed upward.


QUICK QUESTION:

What are the four main elements of a Hydraulic system?

o Reservoir, pump, valve(s) and hydraulic motor. o Pump, valve(s) hydraulic fluid and lines. o Hydraulic motor, pump, hydraulic fluid and additives. o Reservoir, pump, valve(s) and hydraulic additives.


Hydraulic Fluids: Any liquid can be a hydraulic fluid. Simple irrigation systems use water to provide force and motion. Complex machinery requires hydraulic fluids with these general characteristics:

Resistance to oxidation Wear protection Rust and corrosion resistance Good demulsibility Resistance to foam

Hydraulic fluids must have anti-wear, rust/corrosion, demulsibility, anti-foam and anti-oxidation characteristics.


QUICK QUESTION:

Which of these additives must a hydraulic fluid have?

o Emulsifiers. o Anti-oxidation additives. o Extreme Pressure additives. o Graphite.


Hydraulic fluids are blended from carefully selected base stocks, with appropriate additives. The additive package is determined by the

application. Hydraulic fluids are blended from selected __________ stocks and various _______ .

o Base, additives. o Synthetic, base stocks. o Additive, viscosity improvers. o Base, synthetic fluids.

QUICK QUESTION: The type and amount of additives in a hydraulic fluid are determined

by the o Kind of gears to be used. o Amount of water to be blended to the fluid. o Type of foam generated by gear operation. o Severity of the application.

Industrial & Fleet Lubricants – Hydraulic Fluids REVIEW

Hydraulics is the science of fluids. Hydraulic systems are use to transmit motion or force. Hydraulic systems have four main elements:

Reservoir: It stores hydraulic fluid. Pump: It moves the hydraulic fluid through the system. Valve(s): It controls the movement of hydraulic fluid. Hydraulic motor: The hydraulic motor or ram turns fluid motion into mechanical motion.

Hydraulic fluids are formulated to meet specific applications.


Of the four elements of a hydraulic system, which controls the

movement of hydraulic fluid through the system?

o Pump. o Hydraulic Motor. o Valve(s). o Reservoir.

QUICK QUESTION:

Of the four elements of a hydraulic system, which converts the fluid power into mechanical motion?

o Pump. o Hydraulic Motor. o Valve(s). o Reservoir.


THAT COMPLETES Hydraulic Fluids

That was too short for a BREAK.

Trudge on to Product Application Manuals, Lesson 6 in this Module.


Lubricants

Part 6: Product Application

Manuals

Industrial & Fleet Lubricants – App. Manuals

TOPICS

The following topics will be covered in this lesson on Product Application Manuals:

What is a Product Application Manual? Finding Information in Product Application Manuals.


What a Product Application Manual is: Product Application Manuals provide information that can be used to match specific products to specific applications. Customer equipment and operating requirements determine which product should be used. Product Application Manuals contain information sheets that outline specific product data, specifications and applications.


These information sheets are Product Application Sheets. Generally, all lubricants and greases are included in a Product Application Manual. Each type of product generally has its own section. – For example, Crankcase Oils , Industrial Oils, Gear

Oils, and Lubricating Greases may be some of the sections.


QUICK QUESTION:

What is the main purpose of Product Application Manuals?

o Match customer equipment to custom products. o Match products to specific areas of sales. o Match products to customer equipment requirements. o Match sales areas to customer bases.

Industrial & Fleet Lubricants – App. Manuals There are THREE types of information in a Product Application Manual:

General Reference Information: Typical product application manuals contain general product information, such as:

– A description of the product. – A description of areas of application

Product Test Information: Application sheets contain typical test data. Results of standard inspection and performance tests are listed here.

– EXAMPLE: ASH - The residue remaining after a sample has been burned.

Specific Production Application Information: Application information includes descriptions of the types of equipment and operating environments a product has been designed for.


QUICK QUESTION:

What are the three types of information in a Product Applications Manual?

o Detailed description, formulas, methods of manufacture. o General reference, customer evaluation, test results. o General reference, test results, product application

information. o Product application, customer evaluation, product formulas.


Each Product Application Sheet contains the following general information and data:

General description of the product. Detailed description of the product and its properties. Reference tables: Uses and typical inspection test data for the product. A discussion of typical product applications. A description or list of typical customers. A discussion of the major functional characteristics of the product.

This information/data is the basis for matching a particular product to a customer's equipment application requirements.


QUICK QUESTION:

Which of the following is not contained in a Product Application Sheet?

o Detailed properties. o Reference tables. o Typical customers. o Specific chemical formulas.

Industrial & Fleet Lubricants – App. Manuals Finding Information in Product Application Mannuals:

Product Application Manuals are very helpful in matching products to customer's requirements. It contains general information like: – Viscosity grade charts that compare ASTM, SAE, AGMA and ISO

values. – Explanations of test data and terminology (like Dropping Point).

Product Application Manuals also contain specific product information in the Product Application Sheets. Each major product type should have its own section, for example: Crankcase Oils, Industrial Oils, Gear Oils, Lubricating Greases. The Product Application Sheet in a section contains data and general information for a specific product.

Industrial & Fleet Lubricants – App. Manuals QUICK QUESTION:

An SF/CD oil could be used in:

o Summer weather and cold climates. o Cars and motorcycles only. o Trucks and buses only. o Gasoline and diesel engines.

QUICK QUESTION:

The API classifications are divided into S for __________ , and C for_____________ .

o Special service, common service o Service station, commercial o Service, commercial o Special service, commercial service


Now, let's look at a typical Product Application Sheet for a grease. (sample on the following page)

The Product Name is typically written to describe the applications the fluid is typically used for. The General information area gives an overall description of the product. Information about product formulation, typical features and advantages is contained in the Description area. Various charts and tables contains specific information, including typical inspection and performance test results. A list of typical applications is usually included. Specific functional characteristics or benefits of the product are usually given.

Industrial & Fleet Lubricants – App. Manuals REVIEW

Product Application Manuals are used to Match products to customer equipment application requirements. Product Application Manuals contain:

General Reference Information. Product Test Information. Product Application Sheets.

Product Application Manuals are divided into sections. Each section contains information about specific types of products For Example: Crankcase Oils, Lubricating Greases.

Industrial & Fleet Lubricants – App. Manuals REVIEW continued

Typical Product Application Sheets contain the following types of information:

General Description Specific Description Typical Inspection and Performance Test Results Typical Applications Descriptions of Typical Consumers Functional Characteristics

Why use a Product Application Manual (PAM)? This is used to find the best product that meets the customer's equipment application requirements and to be able to explain why it's the most appropriate product for the application.


THAT COMPLETES PRODUCT APPLICATION MANUALS

Now is a good time for a BREAK! At least 15 minutes!!!

Then on to the review for Module 7.

course industrial & fleet lubricants - blue sky elearn of grease over oil: semi-solid lubricants...

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