Mechanical Drives 2 Lap 4

MECHANICAL
LEARNING
DRIVES 2 ACTIVITY
PACKET
LUBRICATION CONCEPTS
TM
B503-XC
LEARNING ACTIVITY PACKET 4
INTRODUCTION
Nearly every industry in the world uses a machine of some sort. In order for these
machines to function properly and last as long as they were designed to, component wear
and tear must be kept to a minimum. This is accomplished through proper lubrication.
In this LAP you will learn about the various types of lubricants and how they are
applied. The use of this information is vital in preventing the premature failure of any
type of machine.
ITEMS NEEDED
Needed Amatrol Supplied
Items
950-ME1 Mechanical Drives 1 Learning System

95-ME2 Mechanical Drives 2 Learning System
Amatrol or School Supplied

Assorted Hand Tools
FIRST EDITION, LAP 4, REV. B

Amatrol, AMNET, CIMSOFT, MCL, MINI-CIM, IST, ITC, VEST, and Technovate are trademarks or registered
trademarks of Amatrol, Inc. All other brand and product names are trademarks or registered trademarks of their
respective companies.
Copyright © 2006, 2005 by AMATROL, INC.
All rights Reserved. No part of this publication may be reproduced, translated, or transmitted in any form or by any
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recording or any information storage and retrieval system, without written permission of the copyright owner.
Amatrol,Inc., P.O. Box 2697, Jeffersonville, IN 47131 USA, Ph 812-288-8285, FAX 812-283-1584 www.amatrol.com
B503-XC LAP 4 LUBRICATION CONCEPTS

Copyright  2006 Amatrol, Inc. 2
TABLE OF CONTENTS
SEGMENT 1 LUBRICATION CONCEPTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

OBJECTIVE 1 Describe the six functions of a lubricant
OBJECTIVE 2 Describe four types of lubricants and give an application of each
OBJECTIVE 3 Describe the functions of nine types of lubricant additives
OBJECTIVE 4 Describe the operation of five types of lubrication application methods and give an example
SEGMENT 2 OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
OBJECTIVE 5 Describe three types of oils and give an application of each
OBJECTIVE 6 Define viscosity and give its unit of measure
OBJECTIVE 7 Describe the operation of a viscosimeter and give an application
SKILL 1 Use a viscosimeter to measure oil viscosity
OBJECTIVE 8 Describe how oils are specified
SKILL 2 Select an oil specification for a given application
SEGMENT 3 GREASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
OBJECTIVE 9 Describe four types of grease and give an application of each
OBJECTIVE 10 Describe how greases are specified
SKILL 3 Select a grease specification for a given application
OBJECTIVE 11 Describe the function and operation of a grease gun
Activity 1 Grease gun component identification
OBJECTIVE 12 Explain how to use a grease gun to lubricate a pillow block bearing
SKILL 4 Use a grease gun to lubricate a pillow block bearing
SEGMENT 4 LUBRICANT MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

OBJECTIVE 13 Describe five lubricant storage rules
OBJECTIVE 14 Describe the function of a material safety data sheet (MSDS)
SKILL 5 Read and interpret a material safety data sheet
OBJECTIVE 15 Describe the purpose of recycling lubricants
OBJECTIVE 16 Describe four methods used to recycle lubricants
OBJECTIVE 17 Describe how to dispose of spent lubricants

SEGMENT 1
OBJECTIVE 1 DESCRIBE THE SIX FUNCTIONS OF A LUBRICANT
his
dT A lubricant is a slippery substance placed between two moving solid
Rea
surfaces.
Lubricants provide six general functions:
• Reduce Friction Load
• Reduce Component Wear
• Dissipate Heat
• Absorb Shock Between Mating Components
• Prevent Corrosion
• Restrict Contamination
Each of these functions is described as follows:
Reduce Friction Load

Lubricants reduce friction by creating a slippery film between two
surfaces. This separates the two surfaces to keep them from rubbing
against each other, as shown in figure 1.
UNLUBRICATED
LUBRICATED
THIN
FILM
Figure 1. A thin film separates two surfaces.

Almost every type of bearing uses lubrication in some ways to
reduce friction. The simplest example is a plain bearing and shaft, as
shown in figure 2.
LUBRICATING
FILM
Figure 2. Lubrication of a Plain Bearing and Shaft

Reduce Component Wear
Component wear is caused by friction. If you reduce friction,
component wear will be reduced. Lubrication creates a thin film that
prevents machine components from coming in direct contact with each
other. This reduces the wear of components by reducing the grinding and
abrasion between them, as shown in figure 3.
LUBRICATED
UNLUBRICATED
Figure 3. Lubrication prevents wear of components.

Dissipate Heat
Many lubricants are supplied to a mechanical system in a bath or
continuous stream, as shown in the chain drive of figure 4. This serves as
a good cooling system because the heat is absorbed by the lubricant and
carried away to a cooler location where the heat can be dissipated.
Figure 4. Chain Drive Lubrication System
Bearings also often use continuous stream lubrication cooling

systems to absorb heat as well as lubricate. When the oil leaves the
bearing it is cooled, cleaned, and returned to the bearing.

Absorb Shock Between Mating Components
When gears, sprockets, and chains mesh with their components,
every connection is essentially a small collision, as shown in figure 5.
The thin layer of lubricant provides a buffer, or cushion, that acts as a
shock absorber for each of these collisions. This helps to dampen shock
and to keep the machinery running quieter and lasting longer.
Figure 5. The meshing of gears involves many small collisions.
Prevent Corrosion
Corrosion occurs when metals are attacked by oxygen or other
elements. Lubricants prevent corrosion by keeping these elements from
coming in direct contact with machine components.
Restrict Contamination
Contaminants can invade mechanical systems through small gaps.
These gaps can be filled with a lubricant, thus preventing contaminants
from entering. Re-lubrication also removes contaminants by forcing
them out or by acting as a wash.

OBJECTIVE 2 DESCRIBE FOUR TYPES OF LUBRICANTS AND GIVE
AN APPLICATION OF EACH
dT
his There are four types of lubricants:
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• Liquid
• Semisolid
• Solid
• Gas
Each of these types is described as follows:
Liquid Lubricants
The most versatile and best known lubricants are in liquid form.
Liquid lubricants include all types of oils, as shown in figure 6. Liquids
are ideal for use in most mechanical and all hydraulic applications. As a
liquid they can be poured, take the shape of the container they are in, and
occupy a definite volume of space which cannot be changed, except by
adding or removing some of the liquid. These properties help liquid
lubricants to completely coat mechanical surfaces.
Liquid lubricants are often used in applications where components
are lubricated by being dipped in an oil bath or where the oil is circulated
by some sort of pump.
Figure 6. Oils are a liquid lubricant.

Semisolid Lubricants
In many applications, liquid lubricants cannot be used because
mechanical components cannot retain the lubricant (they would leak) and
would require frequent lubrication. One example is high-speed
machinery which would churn and create bubbles within the oil. For
these types of applications, a semisolid lubricant, or grease, is used.
Greases are made by adding a thickener to a liquid lubricant, usually
oil. These thickeners are most often metallic soaps, which make the
liquid lubricant more solid, as shown in figure 7. The thickener serves as
a sponge, holding the oil and letting it slowly bleed out to lubricate
mechanical components.
Semisolid lubricants are used in applications where liquid lubricants
would leak out. These include many types of bearings and mechanical
joints.
Figure 7. Grease is a semisolid lubricant.

Solid Lubricants
Solid lubricants provide a dry film between moving surfaces. They
are mostly made from metals that are bonded or plated to the moving
surfaces to reduce friction. Solid lubricants are often used with oils or
greases that evaporate and leave the solid lubricant behind, but they can
also come in the form of powders or granules.
Solid lubricants are ideal for use in very cold temperatures that
would freeze liquid lubricants. They are also useful in extremely high
temperatures that would cause oils or greases to burn out and fail. One
application that requires the use of a solid lubricant is a roller press used
in a paper mill. The forces generated by the rollers are so great that
liquid and semisolid lubricants do not work.
Gas Lubricants
A gas serves the purpose of a lubricant by filling the gap between
two solids, preventing them from coming in contact with each other, as
shown in figure 8. Gas lubricants also serve as a coolant to moving parts.
Gas lubricants are most often used in applications which have high
rotational speeds and extreme temperatures.
GAS
FILLED
CHAMBER
ROTATING
SHAFT
Figure 8. A gas separates the two rotating parts of a gastatic bearing.

OBJECTIVE 3 DESCRIBE THE FUNCTIONS OF NINE TYPES
OF LUBRICANT ADDITIVES
dT
his Because there is such a broad range of mechanical applications
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which require lubrication, many types of lubricants are made, each
having different properties. This is accomplished mainly with additives.
An additive is anything added to a lubricant to enhance or change a
particular performance characteristic.
There are nine types of lubricant additives:
• Detergent
• Dispersant
• Extreme Pressure
• Foam Inhibitor
• Oxidation Inhibitor
• Pour Point Depressant
• Rust Preventive
• Viscosity Index Improver
• Water Repellent
Each of these additives is described as follows:
Detergent Additives
Detergent additives prevent the formation of deposits on the
surfaces. Used in oils, detergents break up and wash away deposits, as
shown in figure 9.
DEPOSITS BEING
CLEANED AWAY
BY DETERGENTS
IN OIL
BUILD-UP
INSIDE
OIL LINE
Figure 9. Detergents break up and wash away deposits.

Dispersant Additives
Another way to keep deposits from forming on mechanical
components is to keep them suspended in the lubricant. Dispersants hold
particles in suspension, or keep them floating in the lubricant, as shown
in figure 10.
DIRT PARTICLES
SUSPENDED IN
OIL RESERVOIR
Figure 10. Dispersants keep deposits suspended in the lubricant.
Extreme Pressure (EP) Additives

Extreme pressure additives are normally used in greases and oils to
increase the strength of the film that forms on components. The stronger
film is able to withstand greater pressures.
These additives are used to cushion the shock of moving parts
caused by high pressure and heavy loads.

Foam Inhibitor Additives
Foam inhibitors are used in oils to prevent bubbles from creating
foam, as shown in figure 11. This allows the oil to be used in high-speed
applications.
WITH WITHOUT
FOAM INHIBITOR FOAM INHIBITOR
Figure 11. Foam inhibitors prevent foaming.
Oxidation Inhibitor Additives

Just as oxygen combines with metals to cause corrosion, it can also
combine with lubricants. When a lubricant combines with oxygen, acids
are created. This can cause the lubricant to form a sludge that is harmful
to machinery. Oxidation inhibitors retard the oxidation process, even at
high temperatures where oxidation readily occurs.
Pour Point Depressant Additives

When an oil becomes cold, it gets thicker and can become unable to
pour under its own weight. This makes the oil useless in many
applications. Additives called pour point depressants are often used to
maintain an oil’s usefulness in reduced temperature applications.
Rust Preventive Additives

These are additives that prevent the corrosion of mechanical
components during equipment shutdown. Shutdown is a time when
many surfaces aren’t continuously coated with lubricant and are exposed
to corrosive elements.

Viscosity Index Improver Additives
The thickness of an oil is called its viscosity. An oil needs a certain
viscosity in order to function properly, but viscosity tends to decrease at
extremely high temperatures. A viscosity index improver additive
minimizes the oil’s viscosity change. You will learn more about
viscosity and viscosity index later in this LAP.
Water Repellent Additives

As you know, water and lubricants don’t mix, they repel each other.
If water penetrates an area that requires lubrication, it could prevent the
lubricant from getting to where it is needed. Many types of greases have
water-repelling additives that prevent water from penetrating in the first
place, as shown in figure 12.
Figure 12. Water repellents prevent the intrusion of water.

OBJECTIVE 4 DESCRIBE THE OPERATION OF FIVE TYPES OF LUBRICATION
APPLICATION METHODS AND GIVE AN EXAMPLE
his
dT There are five basic methods with which a lubricant can be applied
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to mechanical components. The method used depends on the application
for which the lubrication is being used. The five basic methods are:
• Manual Method
• Drip or Gravity Method
• Splash Method
• Bath Method
• Pressure Method
Each of these methods and the applications in which they are used is
described as follows:
Manual Method
In this method, lubricants are periodically applied with a brush or
drip can, as shown in figure 13. This method requires that the machinery
be shut down for safety.
Figure 13. Manual Lubrication

The manual method is used in slow speed applications where the
equipment can be periodically shut down. One application where
lubricants are applied manually is the lubrication of shop machines such
as drill presses and band saws.
NOTE
tic
e This The manual method of lubrication requires the shutdown of
No
equipment. It also requires an employee to remember to perform

the lubrication. For these reasons, other methods of lubrication
are used more often than manual lubrication.
Drip or Gravity Method

This method uses gravity to slowly drip lubricant onto the required
areas, as shown in figure 14. A reservoir holds a small volume of oil and
is allowed to slowly drip out of a port in the reservoir.
OIL CUP
DRIPS ON
DRIVE
Figure 14. Oil Drip Method
Sometimes a mesh wick is used to help gravity move the lubricant

from the reservoir. Here, one end of the wick is kept submerged in the oil
reservoir and the other end contacts the surface that requires lubrication.
Gravity and capillary action bring a constant supply of lubricants.
The drip or gravity method of applying lubrication is most often
used in machinery with slow operating speeds. One such application is in
the lubrication of a low-speed drive chain.
Splash Method
The splash method uses a slinger wheel that dips into a pool of oil.
As the slinger is rotated, it scoops up a small amount of oil and slings it
against a collection plate and trough, as shown in figure 15. The trough
then directs the flow of oil to where it is needed.
COLLECTION
PLATE
SLINGER
OIL LEVEL
Figure 15. Slinger Method of Lubrication
This method of lubrication is used in mechanical systems with high

operating speeds, such as a chain drive. The speed must be great enough
to sling the oil against the plate but not too fast that it creates foam in the
oil.

Bath Method
In the bath method, the machinery is partially submerged in a bath of
oil. As the components are rotated, the lubricant is applied to all of the
necessary parts, as shown in figure 16.
OIL LEVEL
Figure 16. Oil Bath Lubrication
This method is best used in applications that run at high speeds and
high temperatures. The bath helps to dissipate heat from the machinery.

Pressure Method
This method uses a pump and hose to distribute and spray the oil
onto the surfaces where it is needed, as shown in figure 17.
This method is used in high speed and high temperature applications.
Figure 17. A pump and hose spray oil onto machinery components.

SEGMENT 1
SELF REVIEW
r This
we
Ans
1. A lubricant is a slippery or smooth substance that lessens the
__________ between two moving solids.
2. Lubricants __________ premature failure of mechanical

components.
3. Dissipating heat, absorbing shock, reducing friction, and

preventing corrosion are all __________ of lubricants.
4. All types of oils are considered _________ forms of

lubricants.
5. Semisolid lubricants come in the form of ___________.
6. _______ lubricants work at high pressure to keep moving

surfaces from into contact with one another.
7. Any substance that is added to a lubricant to enhance or

change a particular characteristic is called a __________.
8. __________ break up and wash away deposits in a

lubrication system.
9. An additive that prevents the formation of deposits by

holding them in suspension is called a(n) __________.
10. __________ _________ __________ is an additive that

prevents oils from breaking down at higher temperatures.

SEGMENT 2
OILS
OBJECTIVE 5 DESCRIBE THREE TYPES OF OILS AND GIVE

AN APPLICATION OF EACH
his
dT By far, the most commonly used lubricant is oil. There are three
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categories of oils:
• Vegetable and Animal Oil
• Mineral Oil
• Synthetic Oil
Each of these oil categories is described as follows:
Vegetable and Animal Oil

These types of oils are extracted from plant and animal tissues. Lard
and fish oil are examples of animal oils, while olive oil and soybean oil
are examples of vegetable oils. These types of oils are created by
complicated processes and break down easily. Vegetable and animal oils
are not often used for lubrication of industrial machinery.
One application in which vegetable and animal oils are used is when
they are mixed with mineral oils to help them to better adhere to surfaces
of high speed machinery. Aside from mixing with mineral oils, vegetable
and animal oils are only used for cooking.

Mineral Oil
Mineral oils are the most common of all oils and is the type of oil
most often used to lubricate industrial machinery. They come from the
refining of crude oil from the world’s oil wells, as shown in figure 18.
These oils are not as complex as vegetable and animal oils, and do not
break down as easily.
REFINERY
OIL WELL
MINERAL OIL
CRUDE
Figure 18. Mineral Oil Production
Mineral oils can withstand extreme conditions under extreme

temperatures. This is why they are preferred for most industrial
applications. Mineral oils are used to lubricate bearings, chains, and
gears.
Synthetic Oil
Synthetic oils are artificial, man-made oils. Many are also used to
lubricate industrial machinery. These oils are either a combination of
synthetic products mixed with mineral oils or made completely of
synthetic components. Synthetic oils are made to be used in applications
that are too extreme for natural oils to withstand. One application where
synthetic oils are used is in space equipment and auto racing.

OBJECTIVE 6 DEFINE VISCOSITY AND GIVE ITS UNIT OF MEASURE
his
dT The single most important characteristic in an oil is its resistance to
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flow. Sometimes called fluid friction, this anti-flow characteristic is the
oils thickness, or viscosity.
The viscosity of a lubricant is extremely important in mechanical
systems. That is why machinery manufacturers base their lubrication
recommendations on viscosity. If the viscosity is too low, there will not
be enough protection between moving surfaces and excessive leaking
will occur, as shown in figure 19. If the viscosity is too high, the oil
doesn’t flow properly or not at all, as shown in figure 20. Both situations
can cause improper operation and premature failure of mechanical
components.
Figure 19. Viscosity that is too low can cause leaking.

CLOGGED
LINE
Figure 20. Viscosity that is too high can cause flow problems.

In the United States, the viscosity of an oil is measured in units
called Saybolt Universal Seconds (SSU or SUS), or in centistokes for
metric measurement. The viscosity of an oil is determined by heating it
to a specified temperature, either 100 or 210°F, and then measuring the
time it takes for the oil to flow out of a standard orifice and fill a 60
milliliter container, as shown in figure 21. A temperature of 100°F is
always used unless it takes longer than 1,000 seconds to fill the
container. If so, the oil is heated to 210°F and measured again.
CONTROL
THERMOMETER BOX
HEATER
OIL CONTAINER
OIL
BATH
OUTLET
OIL TUBE
SAMPLE
PLUG
PLUG
SAYBOLT
FLASK
Figure 21. Measuring Oil Viscosity
For example, if it takes an unknown oil 250 seconds to fill the 60

milliliter container at 100°F, it has a viscosity of 250 SUS @ 100°F.

A field approximation of an oil’s viscosity can be determined by
using a hand-held device known as a viscosimeter.
The temperature at which an oil’s viscosity is measured is very
important because temperature changes viscosity. Specifically, the higher
the temperature, the lower the viscosity.
The Society of Automotive Engineers (SAE) has standardized
certain ranges of viscosities and assigned a number, called an SAE
number, to each range. Figure 22 shows a table with an oil’s viscosity at
100°F and its associated SAE number.
VISCOSITY OF SAE LUBRICANTS AT 100°F

SAYBOLT VISCOSITY KINEMATIC VISCOSITY
LUBRICANT (SSU) (CENTISTOKES)
SAE 10 165 to 240 35.4 to 51.9
SAE 20 240 to 400 51.9 to 86.6
SAE 30 400 to 580 86.6 to 125.5
SAE 40 580 to 950 125.5 to 205.6
SAE 50 950 to 1600 205.6 to 352
SAE 60 1600 to 2300 352 to 507
SAE 70 2300 to 3100 507 to 682
Figure 22. SAE Number and Viscosity at 100°F
As you have learned, the viscosity of an oil changes with

temperature. The amount the viscosity changes due to temperature is
called the viscosity index. Oils with a high viscosity index change very
little with temperature. Oils with a lower viscosity index change quite
readily with changes in temperature.
Additives that raise the viscosity index of an oil are used in
applications that require operation through a wide range of temperatures.

OBJECTIVE 7 DESCRIBE THE OPERATION OF A VISCOSIMETER
AND GIVE AN APPLICATION
his
dT A viscosimeter is a device used for measuring the viscosity of an oil.
Rea
It has two tubes, each with a steel ball bearing in it, as shown in figure
23. One of the tubes is filled with an oil of known viscosity, a standard,
and the other tube is filled with the oil to be measured. The tubes lie next
to a scale whose markings are graduated in Saybolt Universal Seconds
(SUS).
Figure 23. Viscosimeter

To measure an oil’s viscosity, fill the empty tube with the oil whose
viscosity is to be determined. Once all air is removed from the system,
tip the viscosimeter over and observe the motion of the steel balls. When
the first ball reaches a certain point, observe the position of the other
ball. Its position relative to the graduations will indicate the approximate
viscosity of the oil, as shown in figure 24.
Figure 24. Measuring an Oil’s Viscosity Using a Viscosimeter
The viscosimeter does not give the precise measurement of an oil’s

viscosity. But, it is very useful in the field when approximating the
viscosity of an unknown oil. A viscosimeter is generally 95% to 99%
accurate.

SKILL 1 USE A VISCOSIMETER TO MEASURE OIL VISCOSITY
Procedure Overview
In this procedure, you will use a hand-held
viscosimeter to approximate the viscosity of three types of
oils.
This ❑ 1. Obtain the following items:

Do
• Hand-held viscosimeter
• Clean rag
• Empty can for oil spills and disposal
• 3 cans of oil samples (labeled A, B, and C) from your instructor
❑ 2. Perform the following substeps to clean the viscosimeter.
A. Dip the nozzle tip of the viscosimeter into the oil sample.
B. Draw oil into the sample chamber by pulling up on the plunger
knob, as shown in figure 25. The plunger works in exactly the
same manner as a syringe.
Figure 25. Drawing Oil Into the Viscosimeter
C. Eject the sample into the empty can and wipe the nozzle tip off
with the rag
In this way the plunger and oil cleans the inside of the sample
chamber.

❑ 3. Perform the following substeps to completely fill the viscosimeter
sample chamber.
A. Dip the nozzle tip into the oil and fill the chamber as was done
in the previous step.
B. Lift the nozzle out of the oil and hold the viscosimeter so that
its nozzle points straight up to allow any air bubbles to rise to
the top.
If any bubbles are stuck to the glass of the chamber, lightly tap
the viscosimeter with your finger to release them.
NOTE
e This
tic The reference chamber contains an air bubble that is used to
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compensate for the expansion and contraction of the oil due to

temperature. It does not affect the operation of the viscosimeter.
C. Eject the air bubbles from the sample chamber by holding the
meter straight up and slowly pushing in the plunger rod. Do
this until all of the air has been ejected and oil just begins to
ooze out. Wipe away spilled oil with the rag.
D. Re-insert the nozzle into the oil sample to finish filling the
sample chamber with oil.
E. Repeat substeps B - D until the sample chamber is completely
filled with oil and there is no sign of air bubbles.
F. While holding the viscosimeter as shown in figure 26, adjust
the syringe plunger to set the ball in the sample chamber to
zero. This is known as zeroing the meter.
Figure 26. Zeroing the Viscosimeter

❑ 4. Position the viscosimeter in the draft proof case with the syringe
plunger rod extending through the slot in the case. Be very careful
not to move the rod.
❑ 5. Close and lock the cover of the case, and allow several minutes to
pass.
The case is draft proof and will allow the oils in both chambers to
stabilize at identical temperatures.
❑ 6. Perform the following substeps to measure the viscosity of the oil
sample.
A. Once the oils have had a chance to reach identical
temperatures, hold the viscosimeter in a horizontal position
with the scale in the upright position.
B. Tilt the instrument, nozzle down to an angle of 30 - 45 degrees
and observe the motion of the two balls as they travel to the
left, as shown in figure 27.
Figure 27. Tilting the Meter to Begin Viscosity Measurement
C. As the leading ball approaches the 200 mark at the left of the
scale, gradually return the instrument to the horizontal position
to stop the lead ball on that mark.
D. Read the point of the scale next to the position of the other ball.
❑ 7. Perform Step 6 numerous times (at least 10 times) and record the
reading that most often occurs.
Viscosity of Sample A: ____________________________(S.U.S.)
❑ 8. Eject the oil sample into the waste oil can.
❑ 9. Perform Steps 2-8 in a similar manner to measure the viscosities of
the remaining two oil samples.
Viscosity of Sample B: ____________________________(S.U.S.)
Viscosity of Sample C: ____________________________(S.U.S.)
❑ 10. Make sure all oil is ejected from the viscosimeter and wipe it and
its case clean with a rag.
❑ 11. Return the meter to its case and return it to its proper storage.

OBJECTIVE 8 DESCRIBE HOW OILS ARE SPECIFIED
his
dT Oils are usually specified in two parts: the type of oil and its
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viscosity. You have already learned much about oil viscosity. Next, you
will learn about the different types of oils.
There are seven basic types of oils in use today.
• Circulating oils - For use in gear or crank case circulation
systems or systems that have a pump to circulate the oil. These
also include hydraulic oils.
• Gear oils - For use on gears. These oils are the heavier, high
viscosity oils that will form a film that is thick enough to dampen
shock.
• Internal Combustion oils - These oils are the ones that you will
find in use in many automobiles. They are formulated to withstand
extremely high operating temperatures and high pressure.
• Machine oils - These are inexpensive oils for use in applications
where the rate at which oil is lost is quite high. These oils are
commonly used on plain bearings in heavy-duty or outdoor
equipment.
• Refrigeration oils - Most refrigeration systems are very complex
and delicate. The formation of oil sludge would cause them to fail.
For this reason, refrigeration oils are designed to not dissolve into
the refrigerant gas, have very little wax, and are able to function in
both high and low temperatures.
• Spindle oils - These oils are formulated to be tacky enough to
cling to high-speed machine components without being slung off.
These oils are usually found in machine spindles, such as those
used on high-speed textile machines.
• Steam Cylinder oils - These oils are usually mixed with steam
just before entering a steam cylinder. Therefore, they must have a
viscosity low enough to be atomized, yet it must be high enough to
lubricate hot cylinder walls.
When specifying an oil, you need to know the application for which
the oil will be used and the viscosity required. Sometimes, an application
may require an oil with particular additives or an oil made from a given
base. When this information is needed, it is simply added to the oil
specification.
NOTE
e This Lubricants are almost always specified by the manufacturer of
tic
the equipment. It is important for you to know how they are
No
specified so that you will know what to use for each machine.
This will also help you to select a different lubricant, if operating
conditions change significantly.

SKILL 2 SELECT AN OIL SPECIFICATION FOR A GIVEN APPLICATION
Procedure Overview
In this procedure, you will be given an application
requiring oil lubrication. You will choose the best lubricant
from a list based on the information given in the
application.
This ❑ 1. Review each of the applications given below, choose the best
Do
lubricant from the following list.
VISCOSITY
OIL TYPE ADDITIVES
(SUS)
Extreme-pressure (EP)
A Gear Oil 1900 additives, Rust and corrosion
inhibitors, Water repellent
Water repellent, Rust and

corrosion inhibitors,
B Steam Cylinder Oil 150 Extreme-pressure (EP)
additives
Antifoam agents, Pour-point

C Refrigeration Oil 100 depressants, Viscosity-index
improver
Antifoam agents, Detergents,

D Machine Oil 600 Dispersants, Oxidation
inhibitors
Viscosity-index improver,
E Internal Combustion Oil 500 Detergents, Dispersants,
Antifoam agents
Viscosity-index improver, Rust

F Circulating Oil 300 and corrosion inhibitors,
oxidation inhibitors
Extreme-pressure (EP)
G Gear Oil 300 additives, Detergents
Antifoam agents, Detergents,

H Refrigeration Oil 200 Dispersants, Oxidation
inhibitors
Antifoam agents, Pour-point

depressants, Extreme pressure
I Internal Combustion Oil 100 (EP) additives, Viscosity-index
improver
Viscosity-index improver,
J Internal Combustion Oil 1100 Detergents, Dispersants,
Pour-point improver

❑ 2. Choose a lubricant for the following application. Use the table
from Step 1.
Application 1:
The lubricant that is required for an air conditioner compressor
must: have a low viscosity, be nonfoaming, be able to flow at low
temperatures, and be able to not break down at high temperatures.
The Lubricant to use is: ____.
from Step 1.
Application 2:
The lubricant that is required for a hydraulic system must: have a
fairly low viscosity, be stable in a wide range of temperatures, be
able to prevent rust and oxidation.
from Step 1.
Application 3:
The lubricant that is required for the gears of a toy car must: have a
fairly low viscosity, be able to withstand high pressure, and be able
to clean the system as it lubricates.
from Step 1.
Application 4:
The lubricant that is required for the engine of a small motorcycle
must: have a moderate viscosity, be able to clean and prevent dirt
buildup, withstand a wide range of temperatures, and not foam.
from Step 1.
Application: 5
The lubricant that is required for the gears that open and close a
drawbridge must: have an extremely high viscosity, be able to
withstand high pressure, prevent rust, and be able to repel water.
from Step 1.
Application 6:
The lubricant that is required to continuously lubricate a
high-speed bearing must: have a moderate viscosity, be
inexpensive, not foam, clean and prevent dirt buildup, and prevent
oxidation.

from Step 1.
Application 7:
The lubricant that is required to continuously lubricate a low-speed
bearing must: have a low viscosity, be inexpensive, not foam,
clean and prevent dirt buildup, and prevent oxidation.
from Step 1.
Application 8:
The lubricant that is required to lubricate the engine that runs an
emergency generator at a high RPM must: have an extremely high
viscosity, withstand a wide range of temperatures, clean and
prevent dirt buildup, and be able to flow in cold temperatures.
from Step 1.
Application 9:
The lubricant that is required to lubricate the steam catapult aboard an
aircraft carrier must: have a low viscosity, be water repellent, prevent
rust and corrosion, and be able to withstand high pressures.
from Step 1.
Application 10:
The lubricant that is required for an industrial freezer compressor
must: have a low viscosity, be nonfoaming, be able to flow at low
temperatures, withstand high pressure, and be able to not break
down at high temperatures.
❑ 12. Check your answers:
APPLICATION OIL
1 C
2 F
3 G
4 E
5 A
6 D
7 H
8 J
9 B
10 I

SEGMENT 2
SELF REVIEW
r This
we
Ans
1. The most commonly used of all types of lubricants are
__________.
2. The three categories of oils are __________ oil, vegetable

and animal oil, and ____________ oil.
3. The measure of an oil’s resistance to flow is called

__________.
4. An oil that flows easily has a ____ ____________.
5. Oil viscosity is measured in units of ___________

___________ ___________ or ________________.
6. The viscosity of an oil can be determined by using a

______________.

SEGMENT 3
GREASES
OBJECTIVE 9 DESCRIBE FOUR TYPES OF GREASE AND

GIVE AN APPLICATION OF EACH
dT
his There are many applications in which the liquid nature of an oil is
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not well suited. Applications where components can’t retain the oil and
would require frequent re-lubrication or high-speed applications that
would create bubbles and foam in an oil are just a few. For these types of
applications, semisolid lubricants known as greases must be used.
Greases are categorized by the soaps that are used to form their
semisolid bases. There are four basic types of grease. They are:
• Aluminum
• Calcium
• Lithium
• Sodium
These categories of grease vary only with the soap that is used to
make the thickening base. As you have learned earlier, a grease is made
up of a soap that holds an oil. For different applications, greases have
different oils with their own lubricating properties imbedded into them.
Since greases are most often used on bearings, the applications for
which they are used depends on the temperature and the loads placed on
the bearing.
Aluminum
Aluminum greases are most often found on bearings that operate in
all kinds of loads and at all temperatures.
Aluminum greases are excellent general-purpose greases.
Calcium
Calcium greases are usually limited to mild bearing loads and low
temperatures around 150°F.
Lithium
The most often used grease is lithium grease because it not only
provides excellent lubrication under moderate loads, but also at high
temperatures and speeds. Lithium grease is widely used in automobiles.

Sodium
Sodium greases are reserved for special applications such as
appliances and hand-held tools.
OBJECTIVE 10 DESCRIBE HOW GREASES ARE SPECIFIED
dT
his There are three qualities used when specifying a grease.
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• Type of soap
• Hardness
• Dropping point
You have already learned about the types of soap used in most
greases. You will now learn about the other two qualities used to specify
grease.
Hardness
The hardness of a grease affects its ability to be pumped. Hardness is
determined by using a device known as a penetrometer, as shown in
figure 28.
DIAL
CONE
GREASE
SAMPLE
TABLE A
Figure 28. Grease Penetrometer

To determine the hardness of a grease sample, the penetrometer uses
a cone-shaped weight which is allowed to sink into the grease. The
distance it sinks provides a measure of the hardness of the grease, as
shown in figure 29.
DIAL
CONE GREASE
SAMPLE
TABLE A
Figure 29. Hardness measurement of Grease
There are nine categories of grease hardness, as determined by the

National Lubricating Grease Institute (NLGI) ranging from 000 to 6.
Each category is assigned a number, called an NLGI number. The top 7
categories are shown, along with a qualitative description in figure 30.
GREASE CATEGORIES
NLGI NUMBER QUALITATIVE DESCRIPTION
0 Partly fluid, similar to dish soap or honey
1 Extremely soft, but still semisolid
2 Soft, similar to hair gel
3 Medium soft, like toothpaste
4 Medium, like jelly
5 Medium hard. Similar to stick butter
6 Hard, like the lead of a pencil
Figure 30. Table of NLGI Numbers and Their Descriptions

Dropping Point
Another important factor in specifying a grease is its dropping point.
This is the temperature at which the semisolid soap in the grease breaks
down and becomes a liquid. Greases can be put into categories ranging
from low temperature greases (dropping point around 300°F/149°C) to
extremely high temperature greases (dropping point around 450°F/232
°C).
In most applications, all that you will need to specify a grease is the
soap base and the NLGI number. Remember, lubrication specifications
are normally determined by the manufacturer of the equipment. It is
important for you to know what the terms mean to ensure that you use
the proper lubricant.
SKILL 3 SELECT A GREASE SPECIFICATION FOR A GIVEN

APPLICATION
Procedure Overview
In this procedure, you will be given an application
requiring lubrication with grease. You will choose the best
lubricant from a list based on the information given in the
application.
This ❑ 1. Choose the best lubricant for the following application from the
Do
following list.
Application 1:
A manufacturer specifies that a soft lithium grease with a high
dropping point be used.
The Lubricant to use is: _____.
DROPPING
GREASE TYPE NLGI NUMBER POINT (°F)
A Lithium 4 550°
B Calcium 2 200°
C Lithium 1 350°
D Aluminum 2 500°
E Lithium 2 450°
F Sodium 6 350°
G Calcium 5 200°
H Aluminum 2 190°
I Calcium 2 550°
J Sodium 3 350°

❑ 2. Choose the best lubricant for the following application from the
list of greases in Step 1.
Application 2:
A manufacturer specifies that a soft calcium grease with a low
Application 3:
A manufacturer specifies that a medium lithium grease with a high
Application 4:
A manufacturer specifies that a soft aluminum grease with a high
Application 5:
A manufacturer specifies that a hard sodium grease with a
moderate dropping point be used.
Application 6:
A manufacturer specifies that a very soft lithium grease with a
moderate dropping point be used.
❑ 7. Check your answers:
APPLICATION GREASE
1 E
2 B
3 A
4 D
5 F
6 C

OBJECTIVE 11 DESCRIBE THE FUNCTION AND OPERATION
OF A GREASE GUN
his
dT Lubrication with grease is often accomplished through the use of a
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grease gun, similar to the one shown in figure 31. This is a manual
method of supplying grease to a machine.
Figure 31. A Typical Grease Gun
A grease gun comes with a coupler that is designed to snap onto a

special grease fitting, often called a zirk fitting. The coupler creates a
tight seal between the grease gun and the fitting. The operator then
pumps the handle of the grease gun. This builds pressure within the
grease gun that forces grease to flow through the coupler and grease
fitting into the component.
Grease guns can be filled by a grease cartridge or they can be filled
with grease from a large barrel. Since even the smallest amount of dirt in
a mechanical system can cause premature failure, it safer to use grease
cartridges. Loading a grease gun from a barrel is not recommended,
especially for bearings.

Activity 1. Grease Gun Component Identification
Procedure Overview
In this procedure, you will examine the grease gun and
identify the location and function of each of its main
components.
This ❑ 1. Select a grease gun from the tool crib. It should look similar to the
Do
one shown in figure 32.
HEAD
CAP GREASE
PLUNGER HOSE
ROD BARREL
GREASE
COUPLER
PUMP
HANDLE
Figure 32. The Components of a Grease Gun

❑ 2. Locate the Plunger rod.
The plunger rod has a T-shaped handle and a rod that enters the
rear of the grease gun. Inside the barrel is the plunger which is
used to force grease from the cartridges.
❑ 3. Locate the Barrel.
The barrel houses the grease cartridges and the plunger.
❑ 4. Locate the Pump Handle.
The pump handle works just like any other hand-operated pump. It
is used to build up enough pressure within the grease gun barrel to
force grease through the grease hose.
❑ 5. Locate the Head Cap.
The head cap is located on the top of the grease gun. Attached to it
are the pump handle and the grease hose.
❑ 6. Locate the Grease Hose.
The grease hose provides an extension between the grease gun and
the grease coupler. Many grease guns have a rigid extension, but
the hose allows work to be performed in areas where space is
limited.
❑ 7. Locate the Grease Coupler.
The grease coupler is designed to make a perfect fit with a grease
(zirk) fitting, as shown in figure 33. When a connection is made, a
very tight seal exists that allows grease to flow from the coupler
and into the fitting.
Figure 33. A grease coupler is designed to fit onto a grease fitting.

OBJECTIVE 12 EXPLAIN HOW TO USE A GREASE GUN TO LUBRICATE
A PILLOW BLOCK BEARING
dT
his Most pillow block bearings have a zirk fitting built into them for the
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purpose of re-lubrication. This fitting has spring-operated ball valve that
allows grease to flow in, but not out, as shown in figure 34. It is very
important that the grease fitting be wiped off with a clean rag before
coupling the grease gun to the fitting. This removes any dirt that could
be forced into the bearing during the lubrication operation. Once the
fitting has been wiped off, the coupler is pressed onto the grease fitting.
Figure 34. Zirk Fitting

When coupled, a spring within the coupler maintains a tight seal, as
shown in figure 35.
COUPLER
ZIRK
FITTING
Figure 35. A Grease Gun Coupler/Grease Fitting Connection

Once the connection is made, the user then slowly pumps the handle
of the grease gun. This forces grease to flow through the coupler and into
the fitting. New grease is pumped into the fitting until old grease begins
to flow out of the bearing in the pillow block, as shown in figure 36.
Figure 36. Lubricating a Pillow Block Bearing
There are some types of bearings that don’t require any lubrication
during their operating lifetime. In these cases, the manufacturer lubricates
the bearing at the factory. They also install seals or shields to keep the
lubricant from leaking out. You should be aware of these types of bearings,
since any attempt to lubricate them could damage their seals or shields.
tion
u
CAUTION
Ca
CAUTION
Do not lubricate a sealed bearing.

SKILL 4 USE A GREASE GUN TO LUBRICATE A PILLOW BLOCK
BEARING
Procedure Overview
In this activity, you will load a grease gun with a grease
cartridge and then couple the grease gun to a fitting on a
pillow block bearing to lubricate the bearing.
This ❑ 1. Obtain the following items:

Do
• Grease gun
• Cartridge of grease
• Pillow block bearing
❑ 2. Perform the following substeps to load the grease gun and prepare
it to lubricate a pillow block bearing.
A. Pull back on the plunger rod until it is full extended, then turn
it so the rod teeth are engaged with the key-hole slot, as shown
in figure 37.
Figure 37. Locking the Plunger Rod in Place

B. Remove the head cap by holding the grease gun barrel in one
hand and turning the cap with the other.
C. Remove both of the end caps from the grease cartridge.
D. Insert the large open end of the cartridge into the barrel of the
grease gun.
E. Replace the head cap, being careful not to over tighten it.
F. Pull the pump handle away from the barrel of the grease gun,
and unlock the plunger rod, as shown in figure 38.
HEAD
CAP
PLUNGER
ROD BARREL
GREASE
HOSE
GREASE
PUMP COUPLER
HANDLE
Figure 38. Pump Handle Operation
G. Push the plunger rod until grease begins to ooze out of the
grease coupler. This purges all air out of the grease gun, a
process known as priming.

❑ 3. Perform the following substeps to engage to grease gun to a pillow
block bearing and lubricate the bearing.
A. With the clean rag, wipe off the grease fitting of the bearing to
remove any dirt that might be on it. This is a very important
step.
B. While holding the grease gun barrel in one hand, press the
coupler onto the grease fitting, as shown in figure 39. You
should press the coupler onto the fitting until you feel it snap
into place.
NOTE
tic
e This It is very important to keep the coupler directly in line with the
No
fitting. The coupler will remain securely fastened to the fitting

unless it is pulled too far to one side. This will weaken the
connection and could cause grease to flow out around the fitting.
Figure 39. Engaging the Coupler to the Grease Fitting
C. Slowly pump the grease gun until a teaspoon of grease has

oozed out of the pillow block bearing.
D. Slightly pull back on the pump handle to release any pressure
within the grease gun.

E. Disengage the coupler by pulling to one side of the grease
fitting until the two separate, as shown in figure 40.
Figure 40. Disconnecting the Coupler from the Grease Fitting
F. Use the clean rag to wipe away the old grease that has oozed
out of the pillow block bearing.
❑ 4. Return all materials to their proper storage. Ask your instructor
where to dispose of the rag.

SEGMENT 3
SELF REVIEW
r This
we
Ans
1. Greases are a combination of a lubricating oil and some form
of thickening _________.
2. The two most important qualities used in specifying a grease

is the ________ of soap used and the ____________ of the
grease.
3. ___________ ________ is the temperature at which a grease

turns from a semisolid to a liquid.
4. A _______________ is used to test the hardness of a grease.
5. The ________ number is used to specify the relative

hardness of the grease.
6. Another quality that is less often used in specifying a grease

is its ________________.
7. A __________ _____ is often used to lubricate with greases.
8. The ___________ of a grease gun makes a secure

connection with a grease _________ for the purpose of
lubrication.

SEGMENT 4
LUBRICANT MANAGEMENT
OBJECTIVE 13 DESCRIBE FIVE LUBRICANT STORAGE RULES
dT
his Whether it is simply a shelf to store a few grease cartridges or a shed
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containing many barrels of oil, nearly every industry that uses machinery
needs a place to store lubricants.
A lubricant storage area has two functions: to safely store lubrication
materials and to keep them clean. In order for a storage area to fulfill
these functions, there are several rules that should be followed. They are:
• Store in a Clean and Orderly Manner
• Protect from Environment
• Prevent Fire
• Use Fire Suppression Equipment
• Provide Safety
Each of these is described as follows:
Store in a Clean and Orderly Manner

One of the easiest ways to ensure that lubricants remain clean is to
have good housekeeping in any lubricant storage area. Lubricant
containers should be stored upright, and in a manner where labels can
easily be read.
Any spills should be cleaned up immediately. Remember, most
lubricants are petroleum products. They not only pose a health risk, but
they are also a fire hazard.

Protect from Environment
A lubricant storage area must be able to protect lubricants from the
effects of weather. Wind can bring dirt and other contaminants, direct
sunlight can create a fire hazard, and rain can ruin most lubricants. A
good lubricant storage area eliminates all of these factors, as shown in
figure 41.
Figure 41. Lubricant Storage Area

Prevent Fire
The best way to keep fire from destroying anything is not to have a
fire in the first place. As you well know, the petroleum base in most
lubricants can be very flammable, if not explosive. Below are some items
that can be helpful in preventing fires:
• Keep products out of direct sunlight.
• Prohibit smoking in or around the area.
• Use proper containers.
• Use explosion proof lighting, as shown in figure 42.
• Do not store lubricants with other flammable materials.
These techniques can greatly reduce the risk of fire.
NO SMOKING
WITHIN
50 FEET
Figure 42. Fire Prevention Techniques

Use Suppression Equipment
Even if every fire prevention technique is used, accidents can still
happen. It is, therefore, very necessary to have fire suppression
equipment available in or around a lubricant storage area, as shown in
figure 43. Some of the more effective items are:
• Automatic sprinkler system
• Fire extinguishers
• Water Hoses
• Area made of fire proof construction
FIRE
FIRE
Figure 43. Fire Suppression Techniques

Provide Safety
Not only should the lubricant storage area be a safe place to store
lubricants, but it should also be a safe place for people to work. This
means that the area should have proper ventilation and lighting. The
work area should be clean, and all the equipment and information needed
to safely handle all stored materials must be made available. This
includes Material Safety Data Sheets and any personal protective
equipment, as shown in figure 44.
Figure 44. Personal Protective Equipment

OBJECTIVE 14 DESCRIBE THE FUNCTION OF A MATERIAL SAFETY
DATA SHEET (MSDS)
his
dT A Material Safety Data Sheet (MSDS) is a document that specifies
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any hazards or special precautions that must be taken with a specific
material. Oils, as well as other chemicals, which are used in the plant
must have an MSDS filled out and available for anyone who will use the
material.
tic
e This NOTE
No
All MSDS are supplied as examples only. Refer to an actual

MSDS for product safety.
MSDS PAGE 1 OF 2
MATERIAL SAFETY DATE 3/17/94
DATA SHEET
I. PRODUCT IDENTIFICATION
Mobilith AW-2 Telephone No. 412-345-8000

Emergency No. 412-234-7000
II. HAZARDOUS INGREDIENTS
Material
Based On The U.S. OCCUPATIONAL SAFETY AND HEALTH ACT OF 1970, This
product should not be considered hazardous
III. PHYSICAL DATA
Boiling Point, Greater than (316°-600°F) Percent Volatile

Vapor Pressure: N/A By Volume (%): Less
Than 0.4
Melting Point: >160°C (320°F) Evaporation Rate
Specific Gravity (H20 - 1): 0.88-0.92 (Butyl Acetate - 1): N/A
Appearance: Green Grease
IV. FIRE AND EXPLOSION HAZARD DATA
Flashpoint: Greater than 204°C Extinguishing Media: Water,

(400°F) Foam, Carbon Dioxide, Or Dry
Autoignition Chemical
Temperature: Greater than 357°C
(675°F)
Figure 45. Example of a Material Safety Data Sheet

The rules for using MSD sheets are determined by each country. In
the United States, the Hazard Communication Standard (HCS) governs
the use. In Canada, the Workplace Hazardous Materials Information
System (WHMIS) is used. These standards specify that an employee or
anyone working with a material has a right to know any hazards that they
are exposed to when working with a material. This allows a person to
determine what protective measures should be taken to prevent adverse
effects from occurring.
Material Safety Data Sheets are needed because not all materials
used in industry are safe if used without special precautions. Many
materials are highly flammable, or can cause skin irritation, cancer, and
other serious health hazards. If you are working with a chemical
material, such as plastics, you should be supplied with an MSDS from
the supplier to make sure you understand any hazards. In countries, such
as Canada, that have more than one official language, suppliers must
develop an MSDS in each language.
Currently, there is not a specified format for the material safety data
sheets in the United States. However, in the United States, the
Occupational Safety and Health Administration (OSHA) has developed a
non-mandatory format, OSHA Form 174. This form is shown in figures
46 and 47.

Material Safety Data Sheet U.S. Department of Labor
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May be used to comply with Occupational Safety and Health Administration

OSHA’s Hazard Communication Standard, (Non-Mandatory Form)
29 CFR 1910.1200 Standard must be Form Approved
consulted for specific requirements. OMB number 1218-0072
IDENTITY (As Used on Label and List) Note: Blank spaces are not permitted. If any item is not applicable or no
information is available, the space must be marked to indicate that
Section I
Manufacturer’s Name Emergency Telephone Number
Address (Number, Street, City, State, and Zip Code) Telephone Number For Information
Date Prepared
Signature of preparer (optional)
Section II - Hazardous Ingredients/Identity Information

Other Limits
Hazardous Components (Specific Chemical Identity; Common Name(s) OSHA PEL ACGIH TLV Recommended % (optional)
Section III - Physical/Chemical Characteristics

Boiling Point Specific Gravity (H0
2 = 1)
Vapor Pressure (mm Hg) Melting Point
Vapor Density (Air = 1) Evaporation Rate

(Butyl Acetate = 1)
Solubility in Water
Appearance and Odor
Section IV - Fire and Explosion Hazard Data

Flash Point (Method Used) Flammable Limits LEL UEL
Extinguishing Media
Special Fire Fighting Procedures
Unusual Fire and Explosion Hazards
(Reproduce locally) OSHA 174, sept. 1985
Figure 46. OSHA Form 174 (Page 1)

Section V - Reactivity Data
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Unstable Conditions to Avoid

Stability
Stable
Incompatibility (Materials to Avoid)
Hazardous Decomposition or Byproducts

Hazardous May Occur Conditions to Avoid
Polymerization
Will Not Occur
Section VI - Health Hazard Data

Route (s) of Entry Inhalation? Skin? Ingestion?
Health Hazards (Acute and Chronic)
Carcinogenicity NPT? IARC Monograph? Osha Regulated?
Signs and Symptoms of Exposure
Medical Conditions
Generally Aggravated by Exposure
Emergency and First Aid Procedures
Section VII - Precautions for Safe Handling and Use

Steps to Be Taken in Case Material is Released or Spills
Waste Disposal Method
Precautions to Be taken in Handling and Storing
Other Precautions
Section VIII - Control Measures

Respiratory Protection (Specify Type)
Ventilation Local Exhaust Special
Mechanical (General) Other
Protective Gloves Eye Protection
Other Protective Clothing or Equipment
Work/Hygenic Practices
Page 2
Figure 47. OSHA Form 174 (Page 2)

SKILL 5 READ AND INTERPRET A MATERIAL SAFETY DATA SHEET
Procedure Overview
In this procedure, you will learn how to read and
interpret a material safety data sheet. This skill is
extremely important because this will allow you to
recognize hazardous conditions.
NOTE
Canada specifies that an MSDS must contain nine sections.
However, like the United States, the exact format is not specified
as long as each section is presented. These sections include:
• Product information
e This • Hazardous ingredients
tic
• Physical data
No
• Fire and explosion hazard

• Reactivity data
• Toxicological properties (health properties)
• Preventive measures
• First aid measures
• Preparation information
e This
tic NOTE
No
This activity will use the United States’ OSHA form 174.
This
❑ 1. Locate the Title Block of the MSDS, shown in figure 46.
Do
It is located at the top left corner of the form. It identifies this as a

material safety data sheet. Notice that it also specifies that this
form can be used to comply with OSHA's Hazard Communication
Standard (HCS) 29 CFR 1910.1200.
❑ 2. Perform the following substeps to review a typical MSDS format.
A. Locate the Identity block of the form.
This block is used to identify the material covered by this data
sheet.
B. Locate Section I.
This section specifies the manufacturer's name, address, various
telephone numbers, the date the sheet was created, and the
signature of the person that prepared the sheet. This gives you
the information you will need in case you have questions that
are not answered on the MSDS.

C. Locate Section II.
This section contains the hazardous ingredients/identity
information. If a material is made from several components,
any hazardous ones must be listed and properly identified.
D. Locate Section III.
This section contains the various physical and chemical
characteristics of the material.
E. Locate Section IV.
This section contains information about the fire and explosion
hazard data for the material. Notice that areas are provided to
list the extinguishing media and special fire fighting
procedures.
When working with a material, it is good practice to make sure
the correct type of fire extinguisher is nearby in case a fire
occurs.
F. Locate Section V.
This section contains the reactivity data. This section contains
information about the stability of the material. Some materials
can undergo chemical changes under certain conditions that
could be hazardous.
G. Locate Section VI.
This section contains the health hazard data for the material.
This section includes signs and symptoms of exposure. It also
contains emergency and first aid procedures.
H. Locate Section VII.
This section contains information on the safe handling of the
material. This information would include precautions to be
taken during handling and storage. Another important piece of
information is the method of waste disposal.
I. Locate Section VIII.
This section contains the control measures for the material.
This includes protective equipment that should be worn. This
equipment may include protective gloves, respiratory masks,
and eye protection.
❑ 3. Perform the following substeps to read an MSDS sheet created in a
different format as shown in figures 48 and using a different
format. You must be able to locate the necessary information
regardless of the format. Knowing the format that OSHA
recommends will provide a standard which you can compare to
other formats.
WARNING
ning
ar The following MSDS is a sample used for training only. Do not
W
rely on information contained in the following figures for any

material or process.

MATERIAL SAFETY DATA SHEET MSDS PAGE 1 OF 2
DATE 3/17/94
I. IDENTIFICATION
PRODUCT: Mobilith AW-2

CHEMICAL FAMILY: Lithium Complex Grease, Petroleum
II. INGREDIENTS
HAZARDOUS COMPONENTS APPROX. WT. PERCENTAGE

None <0.3%
NONHAZARDOUS COMPONENTS
Hydrotreated Heavy Naphtheml Petroleum <0.7%
Butene, Homopolymer <1%
Octo Decanoil Acid
Borated Esthers <0.9%
III. HEALTH INFORMATION
GENERAL: normal handling with general ventilation would not expose operators to safety or health hazards
EYE CONTACT: May cause mechanical irritation
INHALATION: No inhalation hazards anticipated with normal use.
SKIN CONTACT: None Known

INGESTION: Biologically Inert
MEDICAL CONDITIONS AGGRAVATED: None Known
IV. OCCUPATIONAL EXPOSURE LIMITS
EXPOSURE LIMITS: None

Normal handling would involve only minimal exposure.
PEL (OSHA): None 3-hour twa
V. EMERGENCY FIRST AID PROCEDURE
EYES: Irrigate with water to wash out any particles.

INHALATION: None Expected
SKIN: Wash with soap and water to remove particles.
INGESTION: Notify medical personnel
Figure 48. MSDS Page 1 of 2 (Example Only)

MATERIAL SAFETY DATA SHEET MSDS PAGE 2 OF 2
DATE 3/17/94
VI. PHYSICAL DATA
BOILING POINT: N/A

VAPOR PRESSURE: N/A
MELTING POINT: Softens at 300°F TO 320°F
SPECIFIC GRAVITY: (H20 = 1): 1.04 - 1.06
APPEARANCE: Green grease
VOLATILE BY VOLUME: N/A
EVAPORATION RATE: N/A
VII. FIRE AND EXPLOSION HAZARDS
FLASH POINT: 400°F (204°C)

EXTINGUISH MEDIA: Water, Fog, Carbon Dioxide, or Dry Chemical
SPECIAL FIRE FIGHTING INSTRUCTIONS: None
UNUSUAL HAZARDS: None
VIII. REACTIVITY
STABILITY: Stable
HAZARDOUS POLYMERIZATION: None
HAZARDOUS DECOMPOSITION: Carbon Monoxide, Carbon Dioxide, Carbon, Water
IX. EMPLOYEE PROTECTION
RESPIRATORY PROTECTION: Not required under normal operating conditions.

SKIN PROTECTION: None under normal conditions.
EYE PROTECTION: ANSI-Approved safety glasses with side shields.
X. ENVIRONMENTAL HAZARDS AND PROTECTION
ENVIRONMENTAL HAZARDS: None

DISPOSAL METHOD: Recycle, incinerate or landfill per local and state regulations.
MOBILE OIL CORPORATION
Figure 49. MSDS Page 2 of 2 (Example Only)

A. Identify the material listed on the MSDS.
Material: ___________________________________________
In this case, the material is Mobilith AW2.
B. Locate the name of the manufacturer.
Manufacturer: _______________________________________
The manufacturer of this product is Mobile Oil Corporation.
C. Identify the hazardous ingredients.
Ingredients: _________________________________________
__________________________________________________
__________________________________________________
This information is contained in section II. There are no
hazardous materials in this product.
D. Locate the physical data for the material and identify the
section in which it is contained.
Section: ____________________________________________
This information is contained in section VI. As you can see, the
format does not follow the recommended format. However, the
information is presented.
E. Locate the section that contains information about fire and
explosion hazards for this material.
Section: ____________________________________________
This information is contained in section VII. If these fields
where left blank, the person reading this information could not
be positive that some critical information had not been left out.
Therefore, fields on a MSDS are never left blank.
F. Locate the section that contains the information about reactivity
data.
Section: ____________________________________________
This information is contained in section VIII. Notice that this
material is listed as stable.
G. Locate the section that contains the information on any health
hazards associated with the material.
Section: ____________________________________________
This information is contain in section III. By placing this
information in an earlier section, this information may be easier
to locate quickly.
H. Locate the section that contains the information how the safe
handling of the material.
Section: ____________________________________________
This information is contained in section IX.

OBJECTIVE 15 DESCRIBE THE PURPOSE OF RECYCLING LUBRICANTS
dT
his Many industrial plants operate large machines 24 hours a day. These
Rea
types of operations can cost a fortune in lubrication alone. One way to
reduce the cost of lubrication is to recycle the lubricants. In many cases,
oil can be removed from a machine, cleaned of all impurities, and put
back into the system, as shown in figure 50.
DIRTY
OIL
RECYCLING
=
CLEAN
OIL
Figure 50. Recycling lubricants can save money.
e This NOTE
tic
No
Only oils are recycled. It is too difficult and not very cost
efficient to try to remove impurities from grease.
In larger operations, lubricant recycling systems are built directly

into the lubrication system. Lubricant recycling extends the service life
of the lubricant, thus greatly reducing the amount of money spent on
lubrication.

OBJECTIVE 16 DESCRIBE FOUR METHODS USED TO RECYCLE LUBRICANTS
dT
his There are four common methods used to recycle oil. They are:
Rea
• Gravity Separation
• Straining
• Filtering
• Centrifuge
Each of these is described as follows:
Gravity Separation
This is one of the most simple, but slowest of the four recycling
processes. Gravity separation is capable of removing water and any
contaminants that do not mix well with oil.
Recycling using the gravity separation method is accomplished by
heating the oil to reduce its viscosity. It is then put into a tank, similar to
the one shown in figure 51.
DIRTY OIL INLET
CLEAN OIL
OUTLET
OIL
WATER
DIRT
Figure 51. A Simple Separation Tank
Due to gravity, water and other contaminants will sink to the bottom
of the tank. Clean oil can then be drawn off the top and returned to use.
These tanks normally have some means of removing the contaminants
that have been removed from oil.
An oil separation tank can be as simple as the one shown in the
figure above, or it can be more complex.

Straining
Another simple means of recycling oil is straining. This process
removes solid contaminants by forcing the oil to flow through a screen or
mesh, called a strainer. The contaminants are then stopped by the strainer
while the oil passes through, as shown in figure 52. These strainers are often
rotated to allow a stationary scraper to remove excess contaminants.
CLEAN OIL
OUTLET
HOUSING
STRAINING
DISKS
STATIONARY
SCRAPING
BLADE
DIRTY OIL
INLET
Figure 52. Operation of a Typical Strainer
There are several types of strainers, but they all function in nearly
the same way. Some of the more common ones are shown in figure 53.
COFFEE-TYPE
WIRE MESH
STRAINER
SCREEN PERFORATED
Figure 53. Some of the More Common Types of Strainers

Filtering
The process of filtering is not too much different from that of
straining. The primary difference is that a filter has many layers through
which the oil must pass so that it can trap smaller particles inside its
body, as shown in figure 54.
DIRT TRAPPED
THROUGHOUT
FILTER NOT
JUST ON
OUTSIDE
Figure 54. A filter traps contaminants on its surface and inside its body.

Centrifuge - A centrifuge is a mechanical method of recycling oil.
In this method, oil is pumped into a spinning chamber of the centrifuge,
as shown in figure 55. The rotation of the chamber causes all
contaminants that are heavier than the oil to move to the outside of the
chamber.
Figure 55. Contaminants are thrown to the outside of a spinning drum.
Clean oil, which weighs less than most of the other materials, tends
to remain around the center of the centrifuge, where it can be drawn out
and returned to a lubrication system.

OBJECTIVE 17 DESCRIBE HOW TO DISPOSE OF SPENT LUBRICANTS
dT
his As you know, many of the lubricants used in today’s industries are
Rea
petroleum based. These products are potentially harmful to the
environment. Therefore, the disposal of lubricants is controlled by the
Environmental Protection Agency (EPA).
The EPA has established a set of federal guidelines that outline how
disposed lubricants must be handled. Each state has then established
their own disposal procedures based on the federal guidelines.
According to these guidelines, no amount of lubricant is to be
dumped or thrown away. Instead, waste lubricants are to be collected by
a local environmental service. These companies will heat treat the waste
to make products that can be sold to asphalt manufacturers. The waste
that isn’t used for asphalt is converted into fuels that are used to run
various types of machines in different industries.
Most facilities that use lubricants will store waste oils and greases in
approved containers until it can be picked up by their local
environmental service. Often these containers are kept in the lubrication
storage area. Other facilities may even have underground storage tanks.
In any case, if you must dispose of waste lubricants, determine where the
waste storage is and put them in their proper containers.

SEGMENT 4
SELF REVIEW
r This
we
Ans
1. The two primary functions of a lubricant storage area are to
__________ store the materials and to keep them
___________.
2. The easiest way to ensure that lubricants are kept clean is to

apply the rules of good _________ - __________.
3. ___________ should be prohibited in or around a lubrication

storage area.
4. A ______________ storage area should be made of ______

- __________ materials.
5. MSDS stands for M__________ S__________ D________

S____________.
6. Saving __________ is the primary reason for recycling

lubricants.
7. A __________ __________ tank is a device that uses

gravity to recycle oil.


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Mechanical Drives 2 Lap 4

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MECHANICAL

950-ME1 Mechanical Drives 1 Learning System

Amatrol or School Supplied

FIRST EDITION, LAP 4, REV. B

B503-XC LAP 4 LUBRICATION CONCEPTS

SEGMENT 1 LUBRICATION CONCEPTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SEGMENT 4 LUBRICANT MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

B503-XC LAP 4 LUBRICATION CONCEPTS

OBJECTIVE 1 DESCRIBE THE SIX FUNCTIONS OF A LUBRICANT

Reduce Friction Load

Figure 1. A thin film separates two surfaces.

B503-XC LAP 4 LUBRICATION CONCEPTS

Figure 2. Lubrication of a Plain Bearing and Shaft

B503-XC LAP 4 LUBRICATION CONCEPTS

Figure 3. Lubrication prevents wear of components.

B503-XC LAP 4 LUBRICATION CONCEPTS

Figure 4. Chain Drive Lubrication System

Bearings also often use continuous stream lubrication cooling

B503-XC LAP 4 LUBRICATION CONCEPTS

Figure 5. The meshing of gears involves many small collisions.

B503-XC LAP 4 LUBRICATION CONCEPTS

Figure 6. Oils are a liquid lubricant.

B503-XC LAP 4 LUBRICATION CONCEPTS

Figure 7. Grease is a semisolid lubricant.

B503-XC LAP 4 LUBRICATION CONCEPTS

Figure 8. A gas separates the two rotating parts of a gastatic bearing.

B503-XC LAP 4 LUBRICATION CONCEPTS

Figure 9. Detergents break up and wash away deposits.

B503-XC LAP 4 LUBRICATION CONCEPTS

Figure 10. Dispersants keep deposits suspended in the lubricant.

Extreme Pressure (EP) Additives

B503-XC LAP 4 LUBRICATION CONCEPTS

Figure 11. Foam inhibitors prevent foaming.

Oxidation Inhibitor Additives

Pour Point Depressant Additives

Rust Preventive Additives

B503-XC LAP 4 LUBRICATION CONCEPTS

Water Repellent Additives

Figure 12. Water repellents prevent the intrusion of water.

B503-XC LAP 4 LUBRICATION CONCEPTS

Figure 13. Manual Lubrication

B503-XC LAP 4 LUBRICATION CONCEPTS

equipment. It also requires an employee to remember to perform

Drip or Gravity Method

Figure 14. Oil Drip Method

Sometimes a mesh wick is used to help gravity move the lubricant

Figure 15. Slinger Method of Lubrication

This method of lubrication is used in mechanical systems with high

B503-XC LAP 4 LUBRICATION CONCEPTS

Figure 16. Oil Bath Lubrication

B503-XC LAP 4 LUBRICATION CONCEPTS

B503-XC LAP 4 LUBRICATION CONCEPTS

2. Lubricants __________ premature failure of mechanical

3. Dissipating heat, absorbing shock, reducing friction, and

4. All types of oils are considered _________ forms of

5. Semisolid lubricants come in the form of ___________.

6. _______ lubricants work at high pressure to keep moving

7. Any substance that is added to a lubricant to enhance or

8. __________ break up and wash away deposits in a

9. An additive that prevents the formation of deposits by

10. __________ _________ __________ is an additive that

B503-XC LAP 4 LUBRICATION CONCEPTS

OBJECTIVE 5 DESCRIBE THREE TYPES OF OILS AND GIVE

Vegetable and Animal Oil

10. ______ _ ______ is an additive that

4. An oil that flows easily has a ________.