CONTENTS

CONTENTS
ICONS 1
GLOSSARY 3
1. HEALTH AND SAFETY 5
1.1 Personal Safety 6
1.2 Spillages 6
1.3 Storage Precautions 7
1.4 Fire Fighting Procedures 8
1.5 Importance of PPE (Personal Protective Equipment) 8
2. LOCK-OUT 11
2.1 What is a Lock-Out? 12
2.2 The Purpose behind Lock-out 12
2.3 Different Types of Lock-out Devices 13
2.4 Safe Lubrication during Lock-out 14
3. INTRODUCTION TO LUBRICATION 15
3.1 What is Lubrication? 16
3.2 Main Functions and Effects of Lubrication 17
3.3 Comparison of the Application of Oil and Grease 17
3.4 History 18
3.5 Friction 19
3.6 Viscosity 21
3.7 Importance of Lubrication 23
3.8 Grades of Lubrication 23
3.8.1 Food Grade Lubricants 23
3.8.2 Normal Grade Lubricants 24
3.9 Types of Lubricants 24
3.9.1 Solid Lubricants 24
3.9.2 Semi Solid Lubricants (Grease) 25
3.9.3 Liquid Lubricants (Oil) 26
3.9.4 Spray Lubricants 26
CONTENTS

4. LUBRICATION SYSTEMS 27
4.1 Different Lubrication Systems 28
4.1.1 Total Loss System 28
4.1.2 Sealed System 29
4.1.3 Open System 29
4.1.4 Immersed System 30
4.1.5 Gravity Feed System 30
4.1.6 Force or Pressure Feed System 31
4.1.7 Splash Lubrication System 32
4.1.8 Electronically Automated Systems 33
5. LUBRICATION APPLICATIONS 35
5.1 Liquid Lubrication Applications 36
5.1.1 Oil Can 36
5.1.2 Needle Valve / Sight Feed 37
5.1.3 Pneumatic Sight Feed Lubricator 37
5.1.4 Wick-feed Lubricators 38
5.1.5 Bottle Oiler 38
5.1.6 Oil Bath 39
5.2 Semi Solid Lubrication Applications 40
5.2.1 Grease Gun 40
5.2.2 Grease Cup 41
5.2.3 Screw-Piston Lubricator 41
5.2.4 Spring Feed Grease Lubricators 42
5.2.5 Measured-Shot Grease Lubricators 42
5.3 Lubrication with Compressed Air 43
5.4 Visual Inspection 45
5.5 Level Indication 48
5.6 Roller Chain Lubrication 49
6. PREPARE AND CARE FOR LUBRICATION TOOLS 51
6.1 Prepare Lubrication Tools 52
6.1.1 Filling a Grease Gun 52
6.1.2 Filling an Oil Can 54
6.2 Housekeeping & Care of Tools 57
6.2.1 Returning Unused Goods 59
6.2.2 The Importance of Storing Tools & Equipment 59
6.2.3 Cleaning After Lubrication 60

7. USE OF LUBRICATION TOOLS 61

7.1 Using a Grease Gun 62
7.1.1 Lubricating a Bearing Using a Grease Gun 62
7.1.2 The Purpose of a Grease Gun Nozzle 63
7.1.3 Lubricating Components Using a Grease Gun 64
7.2 Using an Oil Can 65
7.2.1 Lubricating Chains Using an Oil Can 65
7.2.2 Lubricating a Component Using an Oil Can 66
7.3 Quantity of Lubricants 66
7.3.1 Oil 68
7.3.2 Grease 68
7.4 Manual Lubrication 69
7.4.1 Packing a Plummer Block with Grease 69
7.4.2 Topping Up A Gearbox 71
8. MALFUNCTIONING OF LUBRICATION TOOLS 75
8.1 Grease Gun 76
8.2 Oil Can 77
9. FAULT FINDING 79
9.1 Faults 80
9.2 Inspecting a Lubrication System 80
9.3 Corrective Action Procedures 81
9.4 Replacing Parts Procedures 81
9.5 Importance of Procedures 82
9.6 Inspection After Maintenance 82
9.7 Results of Poor Lubrication 83
9.8 Fault Finding Table 84
CONTENTS
ICONS
The following icons can be found in this module:

Highlights important information.

Highlights information pertaining to safety.

Highlights helpful learning tips.

 GLOSSARY

GLOSSARY
The following list is a description of terms referred to in this training module:

TERM DESCRIPTION

Bearing A device that supports, guides and reduces the friction of motion
between fixed and moving machine parts
Contaminant Dirt or compounds that affect the quality of a product
Demulsibility The resistance of a lubricant to mix with water.
Force Strength or energy as an attribute of physical action or movement
Friction The action of one surface or object rubbing against another
Grease A semi-solid compound lubricant
Grease Gun A tool used to apply grease to equipment
Isolated To stop the supply of electricity to a machine or component
Liquid Running liquid-type compound
Lubricant A compound that is used to lubricate equipment
Oil A liquid-based lubricant
Oil Can A tool used to apply oil to equipment
Prolong Increase the life span
Resistance The act or power of resisting, opposing or withstanding.
Semi-Solid Soft and shape-changing compound
Solid Hard compound
Viscosity The thickness of a substance

2
 HEALTH & SAFETY

SECTION 1
HEALTH & SAFETY

SECTION OUTCOMES
After working through this section you will be able to explain the
following:

 Personal safety.
 Spillages.
 Storage precautions.
 Fire fighting procedures.
 The importance of personal protective equipment.


5
LUBRICATION TRAINING MODULE

When working with lubricants, lubrication systems and lubrication tools there
are certain health and safety precautions that must be adhered to. This must
be done to prevent possible injury to yourself and possible hazardous situations
from happening. When health and safety precautions and procedures are
followed, the risk of danger can be minimised or eliminated.

1.1 Personal Safety

Excessive or prolonged skin contact with
any mineral oil or synthetic fluid product
may remove the natural fats from the skin.
This can, in turn, cause dryness and
subsequent irritation of the skin, as
illustrated in Fig 1.1. Low viscosity products
have a greater tendency to do this, so
particular care is necessary in handling used
products which may be diluted because of
contamination.

1.2 Spillages Fig 1.1

It is of extreme importance to immediately
clean up oil spillages. Lubricant can
penetrate and contaminate floors and
surfaces which are exposed to an oil
spillage. An Oil Spill Kit, as illustrated in
Fig 1.2, must be available on site to clean
and sanitise the spillage area. The oil spill
kit is equipped with; sawdust, sand, rags,
gloves and waste bags. Lubricant spills
must be covered with either sand or saw
dust to absorb the lubricant. Once the
majority of the lubrication is absorbed, the
sand or sawdust can be collected and
disposed of. The surface area can then be
treated to remove any penetrated lubricant.

Fig 1.2

6
 HEALTH & SAFETY

1.3 Storage Precautions

Lubricant is normally stored on-site in an oil
store as illustrated in Fig 1.3. The oil store is
normally situated away from the factory in the
maintenance workshop, or in a low-heat
conducting area. This is done because of flash
point and the flammable nature of lubricants.
Lubrication stores must be locked to control
the access and to prevent unauthorised
people from entering them.
The following is a list of precautions that must be adhered to:
Fig 1.3
 Do not store lubricants in open or unlabelled containers.
 Where necessary, grease should be brought to a satisfactory dispensing
temperature just before being put into service.
 Use the oldest grease container first and keep containers tightly covered.
 Wipe off the edges of the container before opening it to avoid intrusion of
dirt.
 Clean grease-handling tools (such as spatulas, drum pumps, etc.) before
using them.
 To prevent air-pockets being formed in a grease container, ensure that the
surface of the grease is smooth and level before and after every
application.
 Store grease in a cool, dry area where airborne debris is at a minimum, as
illustrated in Fig 1.4.

Fig 1.4

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LUBRICATION TRAINING MODULE

1.4 Fire-fighting Procedures

Lubricants must be extinguished with either carbon dioxide, dry chemical or
foam. Never use water on an oil fire as this could cause the fire to spread and
ultimately cause more damage. Fire-fighters should use a self-contained
breathing apparatus, which should be readily available at different points in the
factory.
Fire-fighting Signs and Symbols

Fire Hose and Fire Direction and

Location Extinguisher Location
and Location

Water Sprinkler Pump Connection Fire

Control Valve and and Location Hydrant
Location and
Location
1.5 Importance of PPE (Personal Protective Equipment)
Maintaining lubricating systems involves working with potentially hazardous
and slippery lubricants and heavy equipment. There are, therefore, inherent
dangers present in carrying out this type of work, and protective clothing must
be worn in order to minimise the risk of accidents and fatalities occurring in the
workplace.
Once again, you need to familiarise yourself with the specific PPE procedures
relevant to your workplace. The OHS act is the ‘Occupational Health and Safety
Act’. It lays out all the statutory requirements that should be adhered to in
order to ensure safety in the work environment. Your workplace procedures will
adhere to this act.

8
 HEALTH & SAFETY

Overalls
Protects the body from products and spillages

Safety Boots
Used to protect your feet from falling objects

Gloves
Used to protect your hands from harmful substances

Safety Glasses
Used to protect your eyes from dust

9
LUBRICATION TRAINING MODULE

10
 LOCK-OUT

SECTION 2
LOCK-OUT
SECTION OUTCOMES
After working through this section you will be able to explain the
following:

 What Lock-out is.

 The purpose behind lock-out.
 Different types of Lock-out devices.
 Safe lubrication during Lock-out.

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LUBRICATION TRAINING MODULE

2.1 What is a Lock-out?

There is always a danger when working on any machine, whether it is in the
factory or at home. Always consider safety before rushing your way into
lubricating, fixing, stripping or maintaining a machine.
You could categorise working safely into two categories; one being electrical
and the other mechanical. Locking-out a machine would require one to switch
off the electricity to the machine, but also might require turning off the air or
steam supply, depending on the type of machine that has to be locked-out, and
removing any potential energy that might be present.
More often than not, the one cannot go without the other. A machine needs to
be isolated and locked- out prior to any maintenance being performed, as
illustrated in Fig 2.1.

Fig 2.1
2.2 The Purpose behind Lock-out
This ensures that the machine is not operational and that no one will be able to
use it whilst the maintenance procedure is taking place. Each workplace will
have its own procedures with regard to lock-out and isolation. The process
usually involves:
 A padlock and key. In some cases more than one padlock and key can be
used (please refer to your own company’s lock-out procedure).
The key must be kept in a safe place by the responsible person (usually a lock-
out supervisor).

12
 LOCK-OUT

You need to ensure that you are familiar with the procedures relevant to your
workplace for your own safety as well as your fellow workers.

2.3 Different Types of Lock-out Devices

 Padlock on machine, Fig 2.2
 Lock-Out Calliper, Fig 2.3 and Fig 2.4

Fig 2.2

Fig 2.3 Fig 2.4

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LUBRICATION TRAINING MODULE

2.4 Safe Lubrication during Lock-out

Machine lubrication can only be performed in two ways:
 While the machine is running, or
 While the machine is switched off.
To lubricate a machine while it is working, as illustrated in Fig 2.5, you should
adhere to a number of safety regulations. These can include the following:
 No person should remove a machine guard to lubricate a machine while the
machine is in motion or operating.
 Any person lubricating moving machinery must be wearing the correct PPE.
 Lubricating a moving machine can only be done under supervision of
trained personnel (please refer to your own company’s procedures).

Fig 2.5 Fig 2.6

Running Machine
The safest way to lubricate a machine is when theIsolated
machine Machine
has been switched
off and locked-out, as illustrated above in Fig 2.6. The following safety
regulations should be in place before lubricating a stationary machine:
 Ensure that the company lock-out procedure has been followed.
 Ensure that all your PPE is worn.
 Lubricate the machine by using the correct tools provided.
 When the maintenance or lubrication on the machine has been completed,
leave the work area clean.
 Replace all guards, and then check that all the emergency stops are
functioning after switching on the machine.
 Document what you have lubricated on the maintenance schedule, if
applicable.

14
 INTRODUCTION TO LUBRICATION

SECTION 3
INTRODUCTION TO
LUBRICATION

SECTION OUTCOMES
After working through this section you will be able to explain the
following:

 The main functions and effects of lubrication.

 The history of lubrication.
 Friction.
 Viscosity.
 The importance of lubrication.
 The different grades of lubrication.

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LUBRICATION TRAINING MODULE

3.1 What is Lubrication?

A lubricant (sometimes referred to as "lube") is a substance (often a liquid)
introduced between two moving surfaces to reduce the friction between them,
improve efficiency and reduce wear. It may also have the function of dissolving
or transporting foreign particles, and of distributing heat.
Lubrication is an essential part of any
moving machinery. It is important to know
how and why lubrication is used.
In this module you will learn the theory
and application of the different lubricants
you may use in your work area. It is
important to know which lubricants are
used for specific jobs.
Common parts of machines that require lubrication are bearings, gears, sliding
flat surfaces and cylinders. These parts consist of surface-to-surface contact.
These parts are commonly made of:
 Non-ferrous metals.
 Ferrous metals.
 Engineering plastics.
The role of the lubricant is to create a film or layer between moving surfaces to
reduce contact between them and, at the same time, prevent them from over-
heating.

16
 INTRODUCTION TO LUBRICATION

Lubricants have been developed and improved over time and have inherited
new properties, as illustrated in the tables below:
3.2 Main Functions and Effects of Lubrication
MAIN FUNCTION EXPLANATION
Reduces Friction Lubrication of contact parts prevents wear and power loss by
reducing friction.
Cools Lubrication reduces heat in parts, which prevents seizing and
breakdowns.
Removes
Contamination Lubrication washes out carbon deposits, dirt, etc.
Prevents Rust and Lubrication prevents rusting and corrosion of metal surfaces, by
Corrosion adhering to the surfaces.
Relieves Stress Lubrication distributes the forces on the surfaces, by forming a film
of oil.
Sealing Agent Prevents penetration of water and dust.

In a broad sense, we can define Lubrication as:

Specifying the lubricant, understanding it,
storing it properly, ordering, and tracking its
3.3 Comparison of the Application of Oil
performance and and Grease
quality.

APPLICATION OIL GREASE

Cooling High No
Washing Yes No
Rust Prevention Yes Yes
Rotation Speed Medium to High Low to Medium
Contaminant Seal No Yes
External Leakage High Small
High Load Conditions Possible with certain types Medium
Filtering Easy Difficult
Replacement Easy Difficult
Performance Excellent Good

While the immediate goal of lubrication is to reduce friction, we can consider

that its main objective is to minimise wear.

3.4 History
Lubricants are not Industrial Age products; their ancestors are several million
years old. Humanity has always wanted to slide an object over another in order
to reduce the effort to move it, as illustrated in Fig 3.1.
The earliest manifestation of
lubrication, which we know of, was
found in Egypt. Animal fat residue was
actually found in the axle of a carriage
buried in the tomb of Yuaa and Thiu,
dating from around 1400 b.c.
The fight against friction has therefore
existed since man has needed to move
Fig 3.1 bulky objects.
To solve this problem, it was realised that using lubricants ultimately reduce
the friction, form a film that would protect the machine from wear, and would
increase the parts' working life. Nowadays, the production of lubricants is a

17
LUBRICATION TRAINING MODULE

specialised industry, which classified and standardised it according to scientific

studies for various industries’ different needs.

The act of lubrication can be misinterpreted as simply supplying a point of

lubrication.
It is necessary that before this, the Lubrication is planned and then controlled,
so that it has answers for the questions that inevitably arise:

 Where to Lubricate?
 How to Lubricate?
 What to Lubricate with?
 When?
 In what quantity? etc.

18
 INTRODUCTION TO LUBRICATION

3.5 Friction
When two surfaces come into contact with each other, as illustrated in Fig 3.2,
the coarser the surface area, the quicker the build up of heat and the greater
the wear will be, until it is finally worn down. Filing a piece of metal in the
workshop is known as friction in action. To reduce friction a lubricant is
used, which will reduce heat and wear of a component.

Fig 3.2
For Example:
If you tried to move a boat resting on sand, you would experience a
considerable force acting against you to prevent the boat from moving, as
illustrated in Fig 3.3. This resistive force is called ‘friction’. It would be much
easier to move the boat if it were floating on water, as illustrated in Fig 3.4,
since there would be a lubricant (water) underneath the boat that effectively
reduced the resistance. This is the basic principle behind lubrication.
When a force is applied to a stationary body, whose surface is in contact with
that of another body, a force resisting the applied force is generated. The
applied force must be stronger than the resistive force to make the body move
and must remain stronger than the resistive force to keep it moving. This
resistive force is referred to as frictional force.

Fig 3.3 Fig 3.4

With the sliding of one surface over another, the force of resistance or friction
that opposes the sliding motion causes heat, and at the contact points
temperature will increase. As the sliding speed increases, the temperature
increases to the point where fusion of the two metals will occur, as illustrated
with the red circles in Fig 3.5.

Fig 3.5
Contact Points
Wherever there is friction there will be wear, which is the loss of material and
the displacement of particles when peaks are broken. In more extreme cases,
fusion could cause moving parts to seize.
Static friction arises between two objects that are not in motion with respect to
each other, for example between the wheels of a car and the surface of the
road. The static friction force must be overcome by an applied force before an
object can move. An example of static friction is the force that prevents a car
wheel from slipping as it rolls on the ground. This is illustrated in
Fig 3.6.

19
LUBRICATION TRAINING MODULE

With the start of the movement, the friction force between the surfaces usually
decreases, so a smaller force, to maintain the uniform motion, will be
necessary. The force acting between surfaces in motion is known as dynamic
friction, as illustrated in Fig 3.7.

Fig 3.6 Fig 3.7

Static Friction Dynamic
Stationary Vehicle Friction
Moving Vehicle

20
 INTRODUCTION TO LUBRICATION

3.6 Viscosity
Viscosity can be defined as follows: a measure of a lubricant’s resistance to
flow. A lubricant with a high viscosity resists flow, whereas a lubricant with low
viscosity flows easily.
Viscosity is a characteristic of lubricants because it is directly related to the
flow ability of the lubricant, i.e. the thicker the lubricant, the higher the
workload supported.
We can observe the influence of viscosity in four tubes with oil, as illustrated in
Fig 3.8, or fluids with different viscosities flowing through a trough, as
illustrated in Fig 3.9. Example: the low viscosity flows easier than the higher
viscosity, which has a thicker consistency.

Fig 3.8

HIGH
LOW
VISCOSITY
VISCOSITY

Fig 3.9

21
LUBRICATION TRAINING MODULE

The viscosity of a lubricant is not constant; it strictly depends on the

temperature. At a high temperature, it must match a lubricant with lower
viscosity.
The thicker the lubricant, the greater its viscosity and the higher its yield
strength. The working speed is an important factor for choosing the viscosity of
a specific lubricant.
In industry, viscosity is measured in flow rate (mm/s), using a device called a
viscometer, as illustrated in Fig 3.10.

It is very important
to know the
working
temperature and
speed for proper
selection of a
lubricant.
Fig 3.10

As illustrated in Fig 3.11, the lubricant’s viscosity changes when it is subjected

to temperature variations.
Changes in viscosity due to temperature are very different, depending on the
various types of oils.

Fig 3.11

22
 INTRODUCTION TO LUBRICATION

3.7 Importance of Lubrication

If lubricating systems are not well maintained,
machinery, which depends upon this lubricating
system, could cause failure or rapid wear, as
illustrated in Fig 3.12. The machine may also not be
operating at its maximum output capacity if its
lubricating system is not being properly maintained.
Fig 3.12
From past breakdown records, it should be evident that the implications of not
maintaining a lubricating system can have far-reaching consequences for an
organisation. This is particularly emphasised in the more streamlined approach
to manufacturing that most companies are tending to adopt these days; eg:
TPM and JIT systems, where very little stock is held.
Worn and damaged machines lead to unexpected downtime, which in turn
leads to lower outputs for the company. This will mean the company cannot
meet their targets as per the plan, and can even lead to market and profit loss.
Therefore, it is of great importance that equipment is lubricated properly and
that lubrication is an on-going exercise on equipment.

3.8 Grades of Lubrication

In the manufacturing industry the machines and supporting equipment use a
lot of parts that need to be lubricated on a regular basis. Lubrication can either
be grease or oil. In each of these two different lubrication types you get
different grades of lubrication. In the food and beverage industry most
lubricants used are food grade to prevent poisoning.

3.8.1 Food Grade Lubricants

Food grade lubricants are made and supplied to be used in food and beverage
industries, where there is a high possibility that lubricant may come into
contact with the product. These lubricants are food grade; therefore it is not
poisonous if consumed.

23
LUBRICATION TRAINING MODULE

3.8.2 Normal Grade Lubricants

Normal lubricants are everyday lubricants, such as crude-based lubricants,

which are used in most engineering and maintenance equipment.
Food and beverage industries still use these lubricants, but only on equipment
that do not come in direct contact with the products produced. And therefore, it
will not be consumed by humans.
3.9 Types of Lubricants
There are 4 main types of lubricants that are used in industry. These can be
classified as follows:

 Solid.
 Semi Solid.
 Liquid.
 Spray Can.

3.9.1 Solid Lubricants

Several types are used, such as: graphite, white lead, talc or soapstone, mica,
etc. Graphite, as illustrated in Fig 3.13, is the most widely used as it is not
affected by acid or heat. It can be effective in temperatures of up to about
600oC and is considered as a high temperature lubricant. The flaky nature of
graphite imparts a lubricating effect as the flakes slide over one another when
in motion. Graphite can be used dry, or mixed with oil or grease, where high
thermal stability is required.

Solid lubricants are employed in

bearings or parts of machinery, which
are more prone to be neglected from a
lubrication point of view. It is also used
on those machines which operate at low
pressures and low speeds.
Fig 3.13
Solid Lubricant
(GRAPHITE)

24
 INTRODUCTION TO LUBRICATION

3.9.2 Semi-solid Lubricants (Grease)

Grease, as illustrated in Fig 3.14, unlike oil, resists draining away from
bearings, especially when the load is at the top half of the bearing. Grease is,
therefore, widely used in rolling bearings because of its ability to form a
lubricating and protective film that resists draining away. During operation of a
plain bearing, grease tends to work its way out through the end clearances,
forming a seal, which thus prevents the dirt from entering and damaging the
bearing. Grease, therefore, has an advantage over oil in dusty atmospheric
conditions. It is suggested that grease should mostly be used in special
conditions, e.g.:
 In cement mills, collieries, etc., where there is dust and dirt.
 It is used where splattering or leakage is undesirable, such as in food or
sweet factories.
 It is used on slow-running bearings under heavy loads.
 Rough, heavy machinery.
 Grease is also preferred to oil when the bearing works under stop/start
conditions.

Fig 3.14
Semi-solid Lubricant
(GREASE)

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LUBRICATION TRAINING MODULE

3.9.3 Liquid Lubricants (Oil)

Oil is liquid-based, as illustrated in Fig 3.15, and has a very specific application.
Oils are commonly used for chains, shafts, motors and gearboxes. The main
characteristics, which stand between efficient lubrication and failure, are of
great importance and are listed below:

 Correct viscosity (fluidity).

 High chemical stability.
 Good demulsibility (prevents contamination by water).
 High film strength.
 Anti-rust qualities.

Fig 3.15
Liquid Lubricant
(OIL)
3.9.4 Spray Lubricants
Spray Lubricants are supplied in pressurised aerosol
cans, as illustrated in Fig 3.16. They are commonly
used for the lubrication of chains and shafts.

Fig 3.16
Spray Lubricant
(OIL)

26
 LUBRICATION SYSTEMS

SECTION 4
LUBRICATION SYSTEMS

SECTION OUTCOMES
After working through this section you will be able to explain the
following:

 The different types of lubrication systems.



27
LUBRICATION TRAINING MODULE

4.1 Different Lubrication Systems

A lubrication system supplies the required lubricant to the necessary parts of a
machine, eg: oil to bearings. Essentially the lubricating system is a sub-system,
which supports the core mechanical system.
To illustrate this point, think of a car. The core mechanical system is the
engine, which ensures that the car can be driven. The lubricating system within
the engine is there to support the pistons, bearings, etc., in order to ensure
that the core mechanical system can operate properly.
To ensure the efficiency of lubrication and the correct application of the
lubricant, there are several application methods directly related to the
lubrication system available in the equipment.
Typically, manufacturers provide the following types of systems:

4.1.1 Total Loss System

This form of application is done through greasers, burettes, drop oilers or

mechanic oilers, as illustrated in Fig 4.1. There is no recovery of the lubricant
in this type of system. The quantity of lubricant is controlled and the supply
can be continuous or intermittent.

Fig 4.1
Total Loss System
(EYE DROPPER CUP)

28
 LUBRICATION SYSTEMS

4.1.2 Sealed System

This is an application system, through which you reuse the oil, i.e., it is
continuously reused, as illustrated in Fig 4.2. The main difference with this
system in relation to the total loss system is that it allows for prolonged usage
of the lubricant, as long as there is no leakage. Because there are no losses, it
should be protected from outside contact. An oil change is necessary after a
certain period of time since the additives lose their properties and become
ineffective.

Fig 4.2
Sealed System
4.1.3 Open System
An open system is when fresh oil is continuously consumed, as illustrated in Fig
4.3. Open systems are relatively rare, as contamination of the lubricant can
easily take place because dust and dirt penetrate the system. The lubricants in
this type of system must be changed regularly to prevent damage to the
components because of contamination.

Fig 4.3
Open System
(AUTO LUBE FEED)

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LUBRICATION TRAINING MODULE

4.1.4 Immersed System

Also known as the oil bath system, components are immersed in the lubricant,
as illustrated in Fig 4.4, to ensure that components are constantly covered in
lubricant.

Fig 4.4
Immersed System
(GEARBOX)

4.1.5 Gravity Feed System

As the name suggests, this lubricating method uses the force of gravity to drip-
feed the system; this is mostly applied in components requiring a low oil
supply. The oil gravity feeds down from the tray through the pipe, as
illustrated in Fig 4.5.

Fig 4.5
Gravity Feed
System

30
 LUBRICATION SYSTEMS

4.1.6 Force or Pressure Feed System

In this lubrication system, the lubricant is forced onto the bearing surfaces, as
illustrated in Fig 4.6. The method can be manual (e.g. using a grease gun) or
mechanical by means of a pump. For manual operation the application is only
efficient at low speeds.
Oil pumps are employed to maintain a continuous delivery of oil, under
pressure, to the points of application. These systems are of infinite variety,
ranging in scale from small units containing only a few litres of oil to those
serving complex heavy machinery, requiring an oil charge of 50 tons or more.
The full-pressure lubricating system lubricates the vital parts of the engine
under full pressure from the oil pump.

Fig 4.6
Mechanical
Pump

31
LUBRICATION TRAINING MODULE

4.1.7 Splash Lubrication System

In this form of lubrication a stream of oil is continually splashed round the parts
requiring it. Splash lubrication is generally used in the following ways:

 Oil Ring Lubrication, as illustrated in Fig 4.7.

 Splash Feed Lubrication, as illustrated in Fig 4.8

Fig 4.7 Fig 4.8

Oil Ring Lubrication Splash Feed Lubrication

This method of lubrication is often employed in small, high-speed machines

which do not require large volumes of oil, such as:
 Compressors.
 Boiler Feed Pumps.
 Multi Stage Pumps.
Elements rotating with the crankshaft are dipped into the oil during each
revolution and they throw up a spray of oil.

32
 LUBRICATION SYSTEMS

4.1.8 Electronically Automated Systems

These lubrication systems, as illustrated in Fig 4.9, are becoming more
common as the trend in industry moves towards automation. They are
commonly referred to as ‘Computer Numerically Controlled’ systems. The
lubrication process is electronically monitored and automatically carried out by
the machine, when required, for example, after a specified period of operating
time.

Fig 4.9
Electronically Automated System
(COMPUTER NUMERICALLY CONTROLLED SYSTEM)

33
LUBRICATION TRAINING MODULE

34
 LUBRICATION APPLICATIONS

SECTION 5
LUBRICATION
APPLICATIONS

SECTION OUTCOMES
After working through this section you will be able to explain the
following:

 Different liquid lubrication applications.

 Different semi-solid lubrication applications.
 Lubrication with compressed air.
 Visual inspection.
 Where CILT fits in to the lubrication process.
 Level indicators.


35
LUBRICATION TRAINING MODULE

Each lubrication application has its own specific tool for which it is intended. It
is important that each lubrication tool’s purpose is understood.
When a task must be performed the correct tools are crucial, as using the
wrong tool can cause damage to the component, and lead to risk of injuries to
yourself and others.
For example, the purpose of a grease gun is to ensure that the grease can be
pumped into the parts of the machine that are difficult to reach or lubricate.

5.1 Liquid Lubrication Applications

5.1.1 Oil Can
The oil can is made with a long spout to squirt
the oil into places where it would be difficult to
get to by any other means, as illustrated in Fig
5.1. Oil cans are small in size, designed to be
mobile and hand-held.
The oil is squirted out from the can through the
supply pipe to the components, by pressing the
feeding handle up and down.
Fig 5.1
The handle should never be pumped too much as this will lead to over-
lubrication and result in spillages.
The oil can is only used to apply liquid-based oil to components like:
 Chains.
 Linear bush bearings.

36
 LUBRICATION APPLICATIONS

5.1.2 Needle Valve / Sight-feed

This is a gravity feed device and also known
as a sight-feed lubricator. A glass, plastic or
metal cylinder is mounted on a metal base
with a hole, as illustrated in Fig 5.2.
A tapered needle extends into the hole to form
a needle-valve. When the shaft moves, it
vibrates the needle and the oil runs down the
clearance onto the shaft. The oil supply is
controlled by the position of the needle when
the valve is open.
Adjustment is possible, with reasonable
accuracy, to approximately one drop per
minute. The sight glass shows the rate of flow
of the lubricant.
Fig 5.2
5.1.3 Pneumatic Sight Feed Lubricator
This device operates on a similar principle to the manual needle valve device;
however, the oil flow starts and stops with the operation of the machine.
For example, a needle-valve is opened and closed by pressure from the
compressor against a spring-loaded piston. A sample of a pneumatic sight-
feed lubricator is illustrated in Fig 5.3.

Fig 5.3

37
LUBRICATION TRAINING MODULE

5.1.4 Wick-feed Lubricators

These are gravity feed devices. They are

manufactured in various shapes and classified
according to the action of the wick. A sample
is illustrated in Fig 5.4
The wick soaks up oil and the excess oil drips
onto the part being lubricated. Vibration and
gravity cause the oil to drip off. The wick can
be adjusted to regulate the flow and to
accommodate hot or cold weather.
Fig 5.4

5.1.5 Bottle Oiler

A glass or plastic reservoir, that looks like an
inverted bottle, is fitted to a metal base which
contains a closely fitting movable pin as
illustrated in Fig 5.5.
The pin rides lightly on the shaft, and as the
shaft rotates, the pin vibrates slightly and
causes oil to flow down.
The main advantage of this device is that oil is
only supplied when it is required; starting and
stopping with the motion of the shaft.

Fig 5.5

38
 LUBRICATION APPLICATIONS

5.1.6 Oil Bath

This is normally used with gears and bearings. Half of the gear/bearing is
immersed in oil and as it turns it splashes oil onto them, as illustrated in Fig
5.6. When the machine is stationary, no lubrication takes place.
Each part of a machine, which has an oil bath, has a different location from
which the oil can be drained and the parts dismantled and each component
cleaned. New oil is then added.
The oil bath application is suitable for oils with a very high viscosity and for
bearings operating at low speeds.

Fig 5.6

39
LUBRICATION TRAINING MODULE

5.2 Semi Solid Lubrication Applications

5.2.1 Grease Gun

A grease gun is a tool that fits onto a grease nipple on a machine to ensure
that grease is pumped into the moving part of a machine.
When you see a grease nipple on a machine this will be a good indicator of
where the greasing points of a machine is.
The grease gun, as illustrated in Fig 5.7, is used to apply semi-solid-type
lubricants to components, such as:
 Bearings.
 Machine Components.
 Bushes
 Slides.

Fig 5.7

40
 LUBRICATION APPLICATIONS

5.2.2 Grease Cup

A basic screw-cup is made up of a closed

cylindrical container, as illustrated in Fig
5.8.
It is threaded around its inner
circumference and fitted onto a screwed
base in which there is a hole leading to the
bearing. The cup is filled by hand with
grease and screwed down onto the base,
forcing grease into the bearing.
The grease is applied by simply turning the
handle, which forces the grease into the
component being lubricated. Grease cups
are usually used with thicker grades of
grease.
Fig 5.8
5.2.3 Screw-piston Lubricator
A threaded piston, capable of exerting greater pressure on the grease, is
normally used when a lubricator cannot be mounted directly onto the bearing
housing but is placed some distance away and connected to it by means of a
lubrication pipe. A sample is illustrated in Fig 5.9

Fig 5.9

41
LUBRICATION TRAINING MODULE

5.2.4 Spring-feed Grease Lubricators

Spring-feed lubricators are sometimes used in
place of ordinary grease cups to avoid
dependence of an attendant. The cup must
be filled by hand. The grease reservoir
contains a plunger under load from a
compression spring. This maintains continuous
pressure and thus continuous feed as
illustrated in Fig 5.10.
The flow of grease can be regulated by means
of an adjusting screw in the outlet tube and
the dispensing is done by a spring-loaded
piston or plate. These cups are normally used
with thinner grades of grease.
Fig 5.10
5.2.5 Measured-shot Grease
Lubricators
These are similar to spring-feed lubricators, but are not automatic and deliver a
measured shot of grease through manual activation of the pump by pulling or
pushing the handle, as illustrated in Fig 5.11.

Pump
Handle
Storage
Container

Fig 5.11

42
 LUBRICATION APPLICATIONS

5.3 Lubrication with Compressed Air

Pneumatic components (cylinders, valves, etc.) have moving parts that require
continuous lubrication. This is done by adding a small amount of oil to the air
which then lubricates the working parts.
The pneumatic air service unit consists of three components:
 Filter
 Pressure Regulator
 Lubricator
The following maintenance task must be carried out:
 Filter
- The level of condensed water should be checked regularly, as the
height marked on the indicator cup should not be exceeded. The
condensed water can be dragged by the compressed air pipe
inside.
- To drain the condensed water, you must open the drain screw on
the bottom of the indicator cup.
- The filter cartridge, when dirty, should also be cleaned or replaced.

Water Trap Filter Water

Drain Plug Reservoir

Fig 5.12

43
LUBRICATION TRAINING MODULE

 Pressure Regulator
- When there is a compressed air filter in front of the regulator, it
does not require maintenance. An example of a pressure regulator
is illustrated in Fig 5.13.

Pressure
Regulator
Pressure
Gauge
Fig 5.13
 Lubricator
- Control the oil level in the reservoir, as illustrated in Fig 5.14. If
necessary, add oil until it reaches the required level as indicated on
the reservoir.
- The reservoir should be cleaned only with kerosene.
- Only low-viscosity mineral oil (maximum 20°E) should be used.

Lubricator

Oil
Reservoir

Fig 5.14

44
 LUBRICATION APPLICATIONS

5.4 Visual Inspection

The identification of lubricants used on equipment should be done through
painting, or labelling the equipment or parts of it. It should indicate the type of
lubricant to be used. This is done to ensure that throughout the entire plant
the same standard is used. Fig 5.15 is an example of labelling equipment.

Lubrication
Labels

Gearbox
Fig 5.15
The CIL (Cleaning, Inspection and Lubrication) process is being implemented
into factories because of the reduction in breakdowns and wear on equipment.
CIL focuses around labelling equipment in the factories with colour-coded CIL
icons. Each icon represents frequency of tasks to be carried out and the colour
indicates the action to be carried out.
Bearing
The following table is an example of CIL icons and colour coding charts that can
be used.

45
LUBRICATION TRAINING MODULE

FREQUENCY ACTION

SHIFTLY

DAILY

WEEKLY

MONTHLY

BLUE = LUBRICATION
QUARTERLY

GREEN = CLEANING

RED = INSPECTION

INDICATES MONTHLY LUBRICATION

46
 LUBRICATION APPLICATIONS

Below is an example of a lubrication standard:

AUTONOMOUS MAINTENANCE STANDARD

Checked By Approved By Date Ref No

Line: Machine:

5
2/
2
1
44
2

FREQUENCY
LUBE COLOUR

RESPONSIBLE
QTY INPUTS
LUBETYPE

PERSON

STATUS
CODE

MACHINE

MONTHLY
NO METHOD

SHIFTLY

YEARLY
COMPONENT
DAILY

1 Cross feed chain Oil Oil Can 2 X Artisan L/O

2&3 Deep groove roller Grease Grease gun 1 X Artisan RUN
bearing
2 Cross feed gearbox Oil Oil Can 2 X Artisan L/O
4 Pneumatic system Oil Container 3 X Artisan RUN
5 Swivel bushes Oil Oil Can 2 X Artisan RUN

5
2
1
2
4
3

47
LUBRICATION TRAINING MODULE

5.5 Level Indication

The purpose of a lubrication level indicator is to indicate the minimum and
maximum level of lubricant for a specific piece of equipment, as illustrated in
Fig 5.16. A visual check icon should be placed on or next to all lubricant
reservoirs where it is necessary to monitor the level of lubricants, as illustrated
in Fig 5.17. The frequency of visual checks is determined by specific company
standards.

Fig 5.16

Visual Check
Icon

Fig 5.17

48
 LUBRICATION APPLICATIONS

5.6 Roller Chain Lubrication

Roller chain drives are efficient, economical and versatile. In every phase of
industry, chains will be found transmitting power and conveying raw materials
or finished goods with efficiency and dependability.
The dependability of chain operation depends upon the basic principles of good
installation, proper lubrication and maintenance. Some examples of different
roller chains are illustrated in Fig 5.18.

5.6.1 Lubricating Roller Chains

There are different areas on a roller chain that must be lubricated; they are
illustrated in Fig 5.19. Some roller chains have hooks that need to be
lubricated.
Fig 5.18
Between the
side bars to the
pin.
Inside the roller

Fig 5.19

49
LUBRICATION TRAINING MODULE

The lubrication of the pin and bush surfaces, which articulate with each other
while the chain is under full load, is vital to maintenance of the chain.
Lubrication is also required between the rollers and bushes. To reach all of
these surfaces, the lubricant is applied to the upper edges of the link plates on
the lower strand of the chain shortly before the chain engages a sprocket.
Then, as the chain travels around the sprocket, the lubricant is carried by
centrifugal force into the clearances between the pins and bushes. Spillage
over the link plates supplies lubricant to the interior and the end surfaces of
the rollers.

5.6.2 Characteristics of Chain Lubricants

Chain lubricants should have the following characteristics:

 Sufficiently low viscosity to reach the internal surfaces.

 Sufficient film strength to maintain the lubricating film under the bearing
pressures.
 Freedom from corrosive ingredients.
 Ability to maintain lubricating qualities under different temperatures,
moistures, etc.


50
 PREPARE & CARE FOR LUBRICATION TOOLS

SECTION 6
PREPARE & CARE FOR
LUBRICATION TOOLS

SECTION OUTCOMES
After working through this section you will be able to explain the
following:

 Preparing lubrication tools.

 Filling a grease gun.
 Filling an oil can.
 Housekeeping and care of tools.
 The importance of storing tools and equipment.

51
LUBRICATION TRAINING MODULE

6.1 Prepare Lubrication Tools

Lubrication tools are used almost daily in the industry, therefore it is of great
importance that tools are prepared, cared for and stored correctly. This is done
to prolong the life of the tool, to ensure that the tool is used correctly for its
purpose and that the tools are readily available when required to be used.

The preparation process for each lubrication tool is specially put in place to
ensure that the tools are prepared properly and ready for use. When a
component needs to be lubricated, it saves time if the lubrication tool is
properly prepared.

6.1.1 Filling a Grease Gun

 Clean the outside of the grease gun before opening the gun, as illustrated
in Fig 6.1 and 6.2. Remove all external contaminates so particles cannot
enter the cartridge tube.

Fig 6.1 Fig 6.2

52
 PREPARE & CARE FOR LUBRICATION TOOLS

 Unscrew the top end cover of the grease gun to open, as illustrated in Fig
6.3. Remember to inspect the condition of the rubber seal inside the
plunger cap of the grease gun.
 Use a spatula to scoop grease out of the container and force-feed it into the
open end of the grease gun, as illustrated in Fig 6.4.

Fig 6.3 Fig 6.4

 Wipe the thread area to remove any excess grease, as illustrated in Fig 6.5.
 Wipe any grease from the body of the grease gun and replace the pump
handle section, as illustrated in Fig 6.6.

Fig 6.5 Fig 6.6

53
LUBRICATION TRAINING MODULE

 Test the flow of grease by pumping the handle until the grease comes out
of the nozzle, as illustrated in Fig 6.7. This will remove any air pockets in
the delivery tube.
 Ensure that the nozzle moves back and goes securely over the nipple
before pumping the handle. This is done to prevent spillages, as illustrated
in Fig 6.8.

Fig 6.7 Fig 6.8

6.1.2 Filling an Oil Can

 Clean the outside of the oil can before opening it. Remove all external
contaminates so particles cannot enter the oil can dispenser, as illustrated
in Fig 6.9a & 6.9b.

Fig 6.9a Fig 6.9b

54
 PREPARE & CARE FOR LUBRICATION TOOLS

 Unscrew the plunger from the can dispenser and remove it carefully,
without causing damage to the internal plunger unit, as illustrated in Fig
6.10.
 Inspect the plunger unit for signs of damage or excessive wear, as
illustrated in Fig 6.11.
 Check flexible pipe and nozzle for damages and blockages (some oil cans
are fitted with rigid pipes).

Fig 6.10 Fig 6.11

 Ensure that the correct oil is dispensed into the can by pouring the oil
carefully without spilling it, as illustrated in Fig 6.12.
 Wipe any excess oil from the rim of the oil can, using a clean cloth, as
illustrated in Fig 6.13.

Fig 6.12 Fig 6.13

55
LUBRICATION TRAINING MODULE

 Once the required amount of oil has been filled into the oil can dispenser,
proceed to fit the plunger unit into the can, as illustrated in Fig 6.14.
 Screw the plunger unit tightly in place, without over-tightening the unit, as
illustrated in Fig 6.15.

Fig 6.14 Fig 6.15

 Once the plunger unit is securely tightened, clean the outer housing of the
can as well as the plunger unit, as illustrated in Fig 6.16.
 Squeeze the handle to see if the pump is functioning. If no oil comes out,
ask an artisan to assist you.

Fig 6.16

56
 PREPARE & CARE FOR LUBRICATION TOOLS

6.2 Housekeeping & Care of Tools

Your work environment should be treated in the very same way that you would
treat your home environment.
A neat and tidy work environment promotes a healthy attitude and a pleasant
and less frustrating place to work. Sometimes, in order to achieve this level of
housekeeping, an effective housekeeping strategy needs to be implemented.
When developing an effective housekeeping strategy, the initial step is to
correct any immediate problems. Contaminated machines and a dirty working
area need to be effectively cleaned through proper planning by dealing with
one area at a time.
Justifications, such as “it has always been this way” or “it was like this
when I got here” are often true; however, they do not change the necessity
for action.
Once the areas have been effectively cleaned, they must be maintained.
Without some degree of diligence, it would be quite easy for things to quickly
return to their previous level of disorganisation. This task is as simple as
everyone cleaning up after themselves, wiping down machines after an oil
change, or cleaning up spillages.
Oil storage areas should be kept clean and hazard-free at all times, as
illustrated in Fig 6.17 & 6.18.

Fig 6.17 Fig 6.18

57
LUBRICATION TRAINING MODULE

However, it may require design changes to the equipment or process areas.

The use of items, such as passive shields or guards, can protect machinery
from process material, which may continuously fall from above.
There are other measures that should be taken to maintain machine
cleanliness.
Painting machines and resurfacing floors on a routine basis is another good
way to support maintainability.
Caring for tools, by ensuring that they are in good working order and are stored
in the correct place, can also relieve pressure and frustration in a working
environment.
A clean and well-ordered workshop environment, as illustrated in Fig 6.19,
creates a more psychologically-healthy workplace, which in itself can boost
morale and productivity

Fig 6.19

58
 PREPARE & CARE FOR LUBRICATION TOOLS

6.2.1 Returning Unused Goods

Lubricants can amount to a significant cost loss to an organisation. It is,

therefore, important that any lubricants that are not used during the
maintenance process are returned to the stores.
It is not good or safe working practice to leave unused or spent oil, or other
consumables, lying around the workplace. Your workplace will, therefore, have
procedures that need to be followed when returning lubricants to the stores
department. Make yourself aware of these procedures.

6.2.2 The Importance of Storing Tools & Equipment

Not only is it frustrating not being able to find a tool, but it can also be
potentially hazardous to leave equipment, tools or consumables lying around.
Tools and equipment used for lubrication must be cleaned and properly stored
to ensure that the tools do not get misplaced or lost. Lubrication tools lying
around can cause contamination and, in the wrong hands, can cause damage
to components on machines and equipment.
The storage of tools and equipment forms part of good housekeeping. “A
place for everything and everything in its place” attitude must be
adopted to ensure smooth operation for any organisation.

59
LUBRICATION TRAINING MODULE

6.2.3 Cleaning After Lubrication

On completion of any maintenance task it is important that you clean up

properly. Each company will have its own procedures in this regard, but some
of the more common ones include the following:
 Oily rags should be disposed of with other dirty rags into designated bins,
as illustrated in Fig 6.20.
 In most companies, separate bins are allocated for these rags to ensure
that they don’t get mixed up with other items.

Old oil should always be decanted into a container or drum specifically made
for the disposal of used oils.

As illustrated in Fig 6.21, the drums are standing on a grid-like structure. This
structure prevents any possible contamination occurring by oil spilling into the
ground, drains, etc.

Fig 6.20 Fig 6.21

Oil Rags Waste Lubrication
Disposal Disposal Storage
Area

60
 USE OF LUBRICATION TOOLS

SECTION 7
USE OF LUBRICATION
TOOLS

SECTION OUTCOMES
After working through this section you will be able to explain the
following:

 Using a Grease Gun.

 Using an Oil Can.
 The correct quantity of lubricants.


61
LUBRICATION TRAINING MODULE

The right tool for the right job is very important to prevent damage to
components and yourself. Using the tool in the correct way is just as
important. This will allow you to know how to utilise the tool in the way it was
designed to, and to also ensure that the job is done properly. Lubrication
methods can either be by the use of a specific tool or manually. These are
done using the following applications:
 Grease Gun.
 Oil Can.
 Hand Application.

7.1 Using a Grease Gun

A grease gun is a cylinder-shaped tool that is filled with grease, as illustrated in
Fig 7.1. The grease gun is used to lubricate bearings or specific components.
The grease gun is designed to fit onto a grease nipple that will supply or guide
the lubricant to the desired location.

When grease starts

to appear from the
side of the bearing,
the lubrication is
more than
sufficient. Bearings
should be lubricated
Fig 7.1 to +-1/4 of the
bearing housing
7.1.1 Lubricating a Bearing Using a volume.
Grease Gun
 Always carry a clean rag whenever greasing a bearing.
 Clean the end of the grease gun and the grease nipple on the bearing.
 Contaminants can flow through to the bearing if the fittings are not cleaned
properly.
 Pay attention to the amount of grease being dispensed during the
application process.

62
 USE OF LUBRICATION TOOLS

 Place the tip of the grease gun nozzle over the grease nipple.
 Pump the handle on the grease gun to start forcing grease through the
grease nipple.
 Do not allow grease to exit from under the bearing seal. This can introduce
contaminants to the bearing area.
 Remove excess grease, as illustrated in Fig 7.2, using a clean rag after each
application.
 Store grease guns in a horizontal position, as illustrated in Fig 7.3. Oils can
leak from the grease gun if stored vertically.
 Keep grease guns in a dry, clean and cool storage area.

Fig 7.2 Fig 7.3

7.1.2 The Purpose of a Grease Gun
Nozzle
 To secure the grease gun to the nipple.
 It controls the flow of the grease.
 The nozzle is made up of various parts, as illustrated in Fig 7.4.
Tension Nipple Clamps
Spring

Nozzle
Nozzle Front
Rear

Spring Seat Clamp

Washer Housing

Fig 7.4

63
LUBRICATION TRAINING MODULE

7.1.3 Lubricating Components Using a Grease Gun

Centralised grease lubrication systems are widely used in industrial and heavy-
duty equipment to lubricate multiple points on a machine.
The design parameters of centralised grease systems include the volume and
frequency of grease required at each point, the number of points requiring
grease, operating conditions, pump pressure, line diameter and distance to the
grease points. When used and maintained properly, centralised grease systems
can enhance artisans’ productivity and simplify equipment maintenance
processes.
Components can also be difficult to reach and extension lubrication pipes can
be fitted to lead to an easy accessible point, as illustrated in Fig 7.5.

Fig 7.5
Grouping of
Grease
Nipples

64
 USE OF LUBRICATION TOOLS

7.2 Using an Oil Can

This is a manual application of oil where
lubricant is applied by means of an oil can. Oil
cans are used on specific equipment where
the tool is designed to apply squirts of oil onto
a component.
The extension pipe is designed to lubricate
difficult-to-get-to components on a machine
without getting your hands and fingers caught
in moving parts, as illustrated in Fig 7.6.
Fig 7.6
7.2.1 Lubricating Chains using an Oil Can
 Always carry a clean rag to wipe off any oil
spillages.
 Wipe away any oil from the oil can before
lubrication. Be careful not to
 Be careful when applying oil. allow the spout to
 Apply squirts of oil to the chain, running get caught up in
the spout along the chain. the chain unit if it
 Do not waste oil by over-lubricating. is in motion.
 Wipe any oil spillages immediately.

65
LUBRICATION TRAINING MODULE

7.2.2 Lubricating a Component Using

an Oil Can
 Always carry a clean rag to wipe off any oil
spillages.
 Wipe any oil from the oil can before
lubrication.
 Be careful when applying oil.
 Apply squirts of oil to the shaft or linear
bearing, running the spout along the
component, as illustrated in Fig 7.7.
 Ensure that oil flows into the component.
 Do not waste oil by over-lubricating.
 Wipe any oil spillages immediately.

7.3 Quantity of Lubricants Fig 7.7

When lubricating using grease or oil, it is important to remember to apply the

correct amount (refer to site specific standards). Under-lubrication can lead to
equipment running dry, which can lead to breakdowns and damage to
components.
Over-lubrication can lead to spillages and contamination. Over-lubrication can
also cause damage to the components.
To maintain efficient lubrication, one must meet the following requirements:
 Use the proper lubricant.
 Apply the lubricant in the correct location.
 Supply the lubricant in the exact quantity.

66
 USE OF LUBRICATION TOOLS

Effective Lubrication
 Specification of origin (manufacturer) is
correct;
The component receives correct
 Lubricant quality is controlled;
lubrication when:  There are no application errors;
 The product being used is appropriate;
 The system of handling, storage and
stocking are correct.
 There is a program to perform the
lubrication services;
The correct location is reached
 The predicted periods are correct;
when:  The manufacturer recommendations are
correct;
 The lubrication team is correctly
dimensioned.
 Lubricator (lubrication man) is qualified and
capable;
 Centralised systems are properly designed,
The exact quantity will be reached maintained and regulated;
when:  Implementation procedures are developed,
implemented and adhered to;
 There is a permanent and regular inspection
of the reservoirs.
 There is an execution plan for the
lubrication services.
 The predicted periods are correct.
The exact moment will be reached  The manufacturer's recommendations are
when: correct;
 Whoever does the lubrication is properly
trained.
 Centralised systems are properly regulated;

67
LUBRICATION TRAINING MODULE

7.3.1 Oil
The amount of oil should be such that its level at rest coincides with half the
diameter of the rolling element that is located on the lowest part of the
bearing.

7.3.2 Grease
The amount of grease used in the bearing housing should be a quarter to a
third the volume of the bearing housing.
The amount of lubricant in the bearing housing is very important as excess
lubricant is as harmful as the lack thereof, as illustrated in Fig 7.8.

Fig 7.8
Too Little Correct Too Much
Lubrication Lubrication Lubrication

68
 USE OF LUBRICATION TOOLS

7.4 Manual Lubrication

Manual lubrication is an application of lubricant by hand, e.g. packing a
bearing, lubricating drive chains or sprockets. When using your hands to apply
lubricant it is always advisable to use gloves as lubricant can damage your
skin. Some industries will also supply hand-barrier cream that will protect your
bare hands while handling lubricant.

7.4.1 Packing a Plummer Block with Grease

 Clean all dirt from the outside of the plummer block.
 Make a clear mark on the top cover of the plummer block.
 Remove the top cover and inner bearing, as illustrated in Fig 7.9 and 7.10.

Fig 7.9 Fig 7.10

 Remove the used lubricant from the housing and bearing by hand, or with a
clean lint-free cloth.
 Clean the bearing by washing it in cleaning solvent using a bearing washer.
If a bearing washer is not available, use a small stiff brush with no loose
bristles.

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LUBRICATION TRAINING MODULE

 Dry the bearing thoroughly with absorbent lint-free cloth, and re-fit the
bearing into the housing, as illustrated in Fig 7.11. Do not use
compressed air on the bearing.

Fig 7.11
 Turn the shaft and apply grease to the bearing with your fingers, as
illustrated in Fig 7.12.
 Ensure that the internals of the bearing are fully-packed with grease.

Fig 7.12

The over-greasing of bearings accounts for more failures than any

other factor. Excess grease in a bearing cavity increases internal
friction, which in turn raises the bearing temperature above the
dropping point of the grease. Ensure that the grease cavity is
only one-third full.

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 USE OF LUBRICATION TOOLS

Remove the seals and inspect them to see if they have not been contaminated
or have not hardened, which would prevent them from sealing against the
shaft.
 If the seals are in good working condition, dip them into oil and press them
firmly into the plummer block seal grooves.
 Wipe the top cover of the plummer block and coat the inside of the cover
with a thin layer of grease to prevent rusting.
 Replace the top bearing cover, so that the marks made previously
correspond.

7.4.2 Topping up A Gearbox

A Gearbox is a sealed unit that is lubricated with specific gearbox oil. The
gearbox is normally fitted with a sight glass to indicate the level of oil, while
some are fitted with a dipstick to check the level of oil in the gearbox.
When topping up gearbox oil it is important to use the correct grade of oil as
stipulated in the manufacturer’s manual. This is to avoid damaging the gears
inside the gearbox and also for maintaining warranty purposes.
 Always have a clean rag to wipe any spillages.
 Inspect the sight glass of the gearbox or check the dipstick (if available) to
check the level of oil in the gearbox, as illustrated in Fig 7.13.

Fig 7.13

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LUBRICATION TRAINING MODULE

 Ensure that the correct type and grade of oil is on site.

 Open the plug on the top of the gearbox, as illustrated in Fig 7.14.

Fig 7.14
 Ensure that no foreign material enters the gearbox.
 Place a filling spout into the top-up hole to prevent spillages, as illustrated
in Fig 7.15.
 Pour the gearbox oil into the gearbox until it becomes visible on the sight
glass and to ensure the correct level is achieved.

Be careful not
to over-fill
the gearbox
when topping
up!

Fig 7.15

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 USE OF LUBRICATION TOOLS

 On completion, wipe any excess oil using a clean rag.

 Replace the top-up plug and secure tightly, as illustrated in Fig 7.16.

Be sure to check
the oil level after 2
hours of operation
to allow for the
settling of the oil!
Fig 7.16

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LUBRICATION TRAINING MODULE

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 MALFUNCTIONING OF LUBRICATION TOOLS

SECTION 8
MALFUNCTIONING OF
LUBRICATION TOOLS

SECTION OUTCOMES
After working through this section you will be able to explain the
following:

 Maintenance of a Grease Gun.

 Maintenance of an Oil Can.

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LUBRICATION TRAINING MODULE

Lubrication tools are used daily. Sometimes tools will not function properly or
supply the lubricant as required. Lubrication tools must be inspected regularly
to ensure that they are in good working order at all times.

8.1 Grease Gun

The grease gun is not a sealed unit and can be dismantled when not
functioning properly.
When a grease gun is faulty, report it to the maintenance department for
repairs immediately.
The following maintenance can be done:
 Clean the grease gun with a rag.
 Unscrew the cap of the grease gun, as illustrated in Fig 8.1.

Fig 8.1 Fig 8.2

 Check that the nozzle is not blocked with old grease or dirt.
 Ensure that the seal is in a good working condition to prevent leakage, as
illustrated in Fig 8.2.
 Ensure that the lever is not bent or broken.
 Ensure that the screw thread is not damaged and that the grease gun seals
properly.

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 MALFUNCTIONING OF LUBRICATION TOOLS

8.2 Oil Can

The oil can is also not a sealed unit. It can be dismantled and inspected for
damage and malfunctioning. When the oil can does not supply oil or is
malfunctioning, report it to the maintenance department immediately.
The following maintenance can be done:
 Clean the oil can with a rag, as illustrated in Fig 8.3.
 Unscrew the cap of the oil can.

Fig 8.3 Fig 8.4

 Drain any remaining oil into a suitable container.
 Check that the nozzle is not blocked with old oil or dirt, as illustrated in Fig
8.4.
 Ensure that the seal is in a good working condition, to prevent leaking.
 Inspect the seal for damage or wear, as illustrated in Fig 8.5

Fig 8.5

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LUBRICATION TRAINING MODULE

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 FAULT FINDING

SECTION 9
FAULT FINDING
SECTION OUTCOMES
After working through this section you will be able to explain the
following:

 What a fault is.

 Inspect a lubrication system.
 Corrective action procedures.
 The importance of procedures.
 Inspection after maintenance.
 Typical faults and possible solutions.

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LUBRICATION TRAINING MODULE

9.1 Faults
Common faults tend to cause malfunctions which lead to breakdowns in
machines regularly. It is important to be able to identify common faults as this
can save a lot of time and frustration in trying to identify what is wrong with a
specific machine.
When a machine does not function correctly, it is always advisable to focus on
the most common fault first before investigating the more complex fault.

9.2 Inspecting a Lubrication System

In the same way that you would be dissatisfied if your vehicle required
refuelling more frequently than specified by the manufacturer’s guide, your
organisation will not be satisfied if a certain machine is not operating according
to manufacturer specifications.
Some examples of these manufacturers’ operating specifications you may find
for the factory machines could include:
 Number of items produced per hour.
 Speed of operation.
 Efficiency of operation.
 Percentage of wastage expected.
 Consumption of consumables such as oil and fuel.
 Heat that a machine generates.
 Unusual noises coming from the machine and equipment.
 Excessive vibrations on specific components and parts.

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 FAULT FINDING

9.3 Corrective Action Procedures

When a fault is diagnosed, it is important to follow the procedures laid out by
the company in order to report and correct the fault. Often the first step in the
process is to inform someone who is usually the supervisor or foreman.
Due to production pressures, it may be tempting to rush into a repair,
especially if you believe that you have already identified the problem. This,
however, may lead to further complications down the line if the problem
becomes worse or has a knock-on effect on other operations in the machine.
Procedures for corrective action also serve to protect you from injury.
If you fail to follow the required procedures laid down by your company, you
may find yourself in a disciplinary hearing.

9.4 Replacing Parts Procedures

Should a repair require the replacement of parts or components, your company
will have specific procedures in this regard. Make yourself aware of these
procedures. For example, you may have to request certain parts from the
stores, which will then need to be documented to ensure that the stock records
for the stores are maintained.
Replacing components may also require certain steps or checks to ensure that
you are able to correctly replace the defective parts without causing damage to
the machines and/or harm to yourself. Procedures may also be called “Works
Instructions”, which should be displayed in an area where they are easy to
refer to.

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LUBRICATION TRAINING MODULE

9.5 Importance of Procedures

In previous sections of the module, mention was made of the importance of
knowing the relevant procedures to repairing lubricating systems. Some of the
implications of not following these procedures were also mentioned; they are:
 Accidents occurring.
 Time wastage and frustration.
 Task not being completed satisfactorily, or at all.
 Stock control issues.
 Further knock-on effects or breakdowns.
There are many implications of not following proper lubrication repair
procedures, which could impact the organisation at all levels.

9.6 Inspection After Maintenance

During the maintenance procedure of a defective cylinder seal, where the seal
has been replaced, it would be necessary to ensure that the machine is
operating correctly, without any further leaks.
The machine should be operated for 5 or 10 minutes under observation to
ensure that all repairs done are successful and that the machine is operating
efficiently and smoothly.

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 FAULT FINDING

9.7 Results of Poor Lubrication

Poor lubrication can result is breakdowns and damages, as illustrated in Fig’s
9.1, 9.2 and 9.3.

Fig 9.1
Damaged
Bearing Casing

Fig 9.2
Taper roller
Bearing

Fig 9.3
Damaged
Helical Gear

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LUBRICATION TRAINING MODULE

9.8 Fault Finding Table

The following table can be used to identify faults, their possible causes and
possible actions:
FAULT CAUSE ACTION

Missing grease nipple Vibration of machine Replace

Grease does not flow into the Blocked grease nipple Notify maintenance, to clear
grease nipple the blockage or replace nipple

Broken lubrication supply pipe Notify maintenance, to repair

or replace lines
Seal broken Notify maintenance, to
replace the seal
Grease gun lever faulty Notify maintenance, to repair
Lubrication not reaching the or replace the grease gun
required components Remove the nozzle and clear
Nozzle blocked the blockage
Grease gun empty Fill the grease gun with
grease
Grease is old and Remove and replace the
contaminated grease with new grease

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 FAULT FINDING

FAULT CAUSE ACTION

Seal is broken Notify maintenance, to
replace the seal
Manual pump is broken Notify maintenance, to repair
or replace the oil can pump
Nozzle blocked Remove the nozzle and pipe,
Oil can is not supplying oil clear the blockage
Oil can empty Fill the oil can with oil
Oil is contaminated Drain old oil and fill with new
oil
Oil can supply pipe is leaking Replace the oil can pipe
Lubricant leaking from Notify maintenance of the
component Component is badly damaged component that needs to be
inspected and replaced
Notify maintenance of the
Component not receiving Oil/Grease pump faulty fault.
lubricant
Check if the pump is running.

85