Lubrication Requirements

for
825 Series Engines
 Module Contents
• Review of Basic Concept – Oil & Bearings
• 825 Series General Lubrication Requirements
• Oil Traveling Through The Engine

2
Bearings & Lubrication

A Review of the Basic

Concepts

3
What is the purpose of bearings?

• It provides shaft support.

• Maintains shaft alignment.
• Absorbs load transmission.
• Reduces Friction between
the Rotating and Stationary
parts.
4
 What is FRICTION?
• It is the resistance to relative motion
between two bodies in contact with
each other.
• When friction is present, heat is
produced.
• When friction is reduced, heat is reduced.

5
Never-Ending Battle Against Friction
• If it were not for friction,we would not
need lubricants.
• A film of oil between two sliding surfaces
can be described as:
 Oil molecules that tend to slide over
one another freely and;
 Oil molecules cling to the metal
surfaces more readily than to
each other.
6
 Molecule Relationship
Sliding Metal Surface
Journal

OIL
MOLECULES

Bearing

Stationary Metal Surface

7
What is the purpose of LUBRICATION?

• Reduces Friction
• Absorbs & Removes Heat

8
What can cause oil to Break Down?

• Heat
• Contamination
• Overloading

9
 Bearing Materials

Are chosen based upon that dissimilar

materials slide against each other with
less friction than similar materials.
• Babbitt: soft alloy of Lead, Antimony
and Tin (Pb, Sn, Sb).
• Sintered Copper-Lead (Cu, Sn, Pb).
• Aluminum (Al, Sn, Cu, Ni, Si, Cd).
• Cast Copper-Lead (Cu, Pb, Zn, Sn). 10
Desirable Material Properties

• Good Fatigue Strength.

• Corrosion and Wear Resistance.
• Tolerance for:
 Foreign Particles.
 Misalignment.
 High Temperature.

11
 Bearing Selection
Takes into account many factors,
some of them are:
• Rotating Speed.
• Load Capability.
• Lubrication System.
• Life Requirement.
• Shaft Material & Process Fluid.
• Operating Conditions.
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 Bearing Types

Journal Thrust
(Radial Load) (Axial Load)
13
 Tri-Metal Bearings

BABBITT

STEEL
F32 - (.004-.007 ) BACK
F62 - (.001-.0025)

BRONZE
F112- (.0015-.002)
BRONZE

NICKEL
DAM

Steel BABBITT
OVERLAY

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 Objective and Performance

• The bearing design objective is to

establish and maintain a oil film
between the surfaces in contact
under various load conditions.
• The bearing performance is greatly
improved by the addition of lubricant
between the moving parts and bearing
surface.
15
Bearing Damage

• Dirt (45%)
• Misassemble (15%)
• Misalignment (13%)
• Lack of Lubrication (11%)
• Overloading (10%)
• Corrosion (5%)
• Others (1%)
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 Bearing Oil Flow

Journal

Oil Flow

Bearing

Clearance Dirt Particles

17
Bearing Ingesting Trash
Displaced Babbit “healing”
Bearing Material over dirt particles

Journal

Bearing

18
 Journal Bearings
• Journal bearings depend on a film of
oil to keep shaft and bearing surfaces
separated
• The oil film is generated by shaft
rotation
• The oil wedge lifts the shaft off it’s
bearing and supports it during engine
operation
• With normal operating conditions and
a continuous supply of clean oil, the
shaft and bearing surfaces will remain
separated
• Bearings fail when the oil film breaks
down or when the bearing is
overloaded
• When bearing damage occurs, the
cause must be determined and
corrected before installing new parts
19
 At Rest At Start-up During Normal
Operation
.0002 - .0004 oil wedge

• At rest the shaft and bearing are in contact

• At start up the shaft rubs the bearing briefly.
• Tuning, the shaft pulls oil from the clearance space into the wedge shaped area between
the shaft and bearing
• The oil wedge lifts the shaft off it’s bearing and supports it during engine operation
• Continued rotation of the shaft maintains the oil wedge separating the shaft and bearing
• The oil wedge is typically only 0.0002” to 0.0004”
20
Normal Bearing wear
– A polished appearance
– Uniform wear pattern
over approximately 2/3
of the bearing surface
– Uniform wear pattern
across the bearing in the
axial direction

21
Accelerated wear
– Wall thickness
reduced from original
demension
– Bearing surface worn
and polished but not
smeared, torn, or
scored
– No evidence of heat or
foreign particle
contamination
• Cause
– Poor shaft surface
finish
– Wear in the presence
of adequate
lubrication is caused
by peaks in the shaft
that penetrate the oil
film
– Shafts should be
ground opposite to
direction of rotation
then polished in the
direction of rotation

22
Scoring
– Surface deeply
scratched and torn
• Cause
– Excessive foreign
particle contamination
– Poor shaft surface
finish
– Insufficient lubrication

23
Fretting
• Bearing back polished
from movement in Back of
housing Bearing
• Pock marks or build up
due to metal transfer
between bearing and
housing
• Cause
– Insufficient crush
– Oversize housing
– Bearing cap not
torqued properly
– Foreign object
between cap and
housing
– Overstressed cap
bolts

24
Corrosion
• Bearing surface is
darkened and spongy
• Babbit is etched by
chemical attack
• Cause:
– Acids in the oil
– Excessive operating
temperatures
– Excessive blow-by
– Coolant contamination
in the oil
– Use of high sulfur fuel
– Excessive oil change
interval

25
Overlay Fatigue
• Network of fine cracks in surface
layer of bearing
• Cause:
– Overloading, low speed and
high load
– Overfueling or detonation
– Localized concentration of
load due to misalignment
such as:
• Edge loading
• Bent rod
• Tapered, hourglass or
barrel shaped housing
or journal
– Note: Moderate overlay
fatigue in localized areas
are part of the break in
process.
– Severe overlay fatigue may
require special bearing
construction with a thinner 26
overlay
Fatigue
• Bearing surface cracked
• Areas of lining broken out leaving craters with ragged
edges
• Cause:
– Overloading (low speed, high load)
– Overfueling or detonation
– Bearing material inadequate for application
– Lining material weakened by corrosion
– Localized concentration of load from:
• Misalignment, Edge loading, Bent rod, Tapered,
hourglass, or barrel shaped housing or shaft
27
Oil Starvation
• Bearing surface streaked
or smeared
• Most damage in the center
of the bearing
• Heat discoloration
• May show bearing material
on shaft
• Will progress to Wiped or
Hot Short failure
• Cause
– Low oil level
– Oil pump failure
– Blocked oil hole or
passage
– Excessive oil dilution
– Lubrication system not
primed prior to start
– Overspeed
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Wiped
• Bearing surface
smeared, scratched
and/or torn.
• Bearing metal melted
and resolidified along
edges
• Cause:
– Lubrication system
not primed prior to
start
– Clogged oil
passage
– Oil pump failure
– Improper
installation (blocked
oil hole)
– Misalignment of
shaft and bearing
surface
– Insufficient bearing
clearance
29
Hot Short
• Bearing surface wiped and
torn
• Bearing surface blackened
from heat
• Patches of lining material
torn cleanly from shell
• Cause:
– Breakdown of
lubrication which
causes high heat from
friction
– wiping
– Dirt contamination
– Concentrated loading
– Misalignment
– Lead in overlay melts
allowing shaft to tear
away patches of lining
30
Dirt Embedment
• Bearing surface speckled
or cratered
• Surface darkened and may
have scratches
• Cause:
– Foreign particle
contamination
– Engine or components
not properly cleaned
during assembly
– Wear particles from
another engine
component
– Dirt entering system
during oil replacement
– Faulty air filtration
– Neglected or improper
oil filter replacement

31
Dirt on bearing back
• Concentrated area of
distress on bearing ID
with corresponding mark
on bearing OD
• Cause:
– Foreign particle
trapped between
bearing back and
housing
– Damaged bearing
housing
– Damaged bearing
back
– High spot on bearing
back or housing due
to fretting

32
Cap shift
• Wear or fatigue near
bearing parting lines
on opposite sides in
upper and lower
bearing halves.
• Cause:
– Mixed bearing
caps
– Reversed bearing
cap
– Poor doweling of
cap to housing
– Mating faces of
housing not flat
and parallel
– Housing not
machined and
assembled at the
same bolt torque
33
Distorted Crankcase
• Bearings show a progression
of damage when viewed as a
set
• Cause:
– Main bearing bore not
properly aligned
– Engine overheating
– Improper tightening of
engine components
– Improper engine support
– Stress on crankshaft
from external force such
as over tightened belt
driven accessories.

34
Bearing & Lubrication
Basic Concepts

Any Questions?

35
 General
Lubrication Requirements
for
Superior 825 Series
Engines

36
 General
Lubrication Requirements
Main Lubrication System
– ES-1001 – Oil Specifications
(Refer to ES-1007 for the Superior 1700 and 2400 series engines)
• SAE 40 – Recommended
• Pour point temperature must be maintained in cold
weather conditions
– Oil Change Requirement
• Oil & filters should be changed after 1st 400 hours
– New or overhauled
• 1000 hour intervals there-after (See SSB 229)
• Oil analysis program highly recommended
37
 General
Lubrication Requirements

Superior 825 Series Engine Capacities

Capacities in Gallons
# cylinders Oil Water
6 65 54
8 80 70
12 165 140
16 220 180

38
 General
Lubrication Requirements
Operating Pressures & Temperatures
System Normal Shutdown
Lube Oil Pressure 34 - 45 psi 18 psi
Lube Oil Temp - IN 150˚ - 180˚F
Lube Oil Temp - Max Out 210˚ F
Water Temp from Engine 170˚ - 180˚ F 195˚ F
Air Manifold Temp (Full Load) 128˚ - 132˚ F
Overspeed Shutdown 990 RPM

39
Lube Oil System – Skid mounted Cooler
40
Lube Oil System – Pump, Relief Valve and
Strainer Assembly 41
Lube Oil System – Pump, Relief Valve and
Strainer Assembly 42
 Back to Sump

To cooler

From Sump

Lube Oil System – Pump, Relief Valve and

Strainer Assembly 43
Lube Oil System –
Main Oil Gallery

44
Lube Oil System – Base – Passages to Main
Bearings
45
Lube Oil System – Crankshaft
46
 Connecting Rod

• Oil travels from the

crank pin to the wrist
pin via the internal
porting in the
connecting rod

47
 Connecting Rod

• Enters pin area

between the bushings
and flows to hole in
center of piston pin

48
 Piston Pin
• Pin is hollow
• Oil flows into pin though center hole and out to
the chamber below crown of piston through 6
holes on each end of the pin.
49
 Piston
• Through ports in piston
• One slot on each side 50
 Piston

• Directed from piston pin

to chamber below
piston crown
• 4 passages / 2 plugged
that drain back to sump

51
OIL FLOW - SUMMARY
• Oil Gallery
• Main bearing
• Crankshaft
• Crankpin
• Connecting rod
• Piston Pin
• Piston
• Sump
52
Lubrication System

Any Questions?

53