TPM Autonomous Maintenance Step 4 Lubrication Module.

Part 1
Purpose of Lubrication
As shown in the figure, the lubricating fluid film between the two surfaces keeps the surfaces from making
direct contact. The very small particles of the lubricating fluid in the film move over each other reducing
the friction between the surfaces.

Training Objectives
o Describe the purpose of lubrication.
o List the types of lubricants used.
o Provide examples of the application of lubricants.
o Identify the lubrication receptacles.
o Outline the problems of over and under lubrication.
o Describe lubrication tools used.
o Identify the hazards of cross contamination.

Friction
o Any movement between solid materials, liquids and gases produces friction. Friction is the resistance to
motion between two surfaces in contact.
o Friction produces heat(loss of energy) and causes deterioration.
o Friction is very important! We need friction to walk, to drive, or to stop a car.
o During the operation of any machine, there is a metallic friction between components in motion
(chains, bearings, gears).
Why Do We Need to Lubricate?
Everyday Comparisons
Reducing the resistance of friction through lubrication decreases the wear to sliding and rotating surfaces.
To Achieve the CORRECT Lubrication, We Need:
o Stress that all these aspects of lubrication must be understood and followed correctly.
o Place (location) on the machine
o Amount (how much should you use with each application)
o Lubricant (which one should you use)
o Frequency (how often should you perform lubrication)
Viscosity
Viscosity means the resistance to the flow at a certain temperature.

Low viscosity oil = light oil, free flowing. This oil is used for high speed, low temperature and low pressure.
High viscosity oil = heavy oil, very slow flow.
This oil is used for low speed, high temperature and high pressure.

Viscosity can be related to density or thickness. (That’s not all viscosity is, but this is a good way for the
operators to begin to understand it.)

Imagine a styrofoam cup with a hole in the bottom. If you pour honey into the cup, you will find that the
cup drains very slowly. This is because honey’s viscosity is large compared to other liquids’ viscosities. If
you put coffee in the same cup, it will drain much more quickly.
Viscosity is the measure of a fluid’s resistance to flow. It describes the internal friction of a moving fluid. A
fluid with large viscosity resists motion because its molecular makeup gives it a lot of internal friction. A
fluid with low viscosity flows easily because its molecular makeup results in very little friction when it is in
motion.
If we pour out three oils with low, medium and high viscosity at the same speed, after a given time we will
have:

Types of Lubricants
A lubricant is a material placed between two moving surfaces to reduce friction and wear. Equipment
operating conditions determine the selection of lubricants. These conditions include:

o Temperature
o Surface materials
o Working load
o Speed
o Distance between surfaces
Temp – don’t use low temperature base adhesive in a high-speed bearing.
Surface materials – chain lube on chain NOT grease on chain because grease will attract dust and grit
and cause an abrasive surface.
Speed – Higher the speed, higher the temperature. Usually at >10,000rpm speed becomes a factor.
Working Load – example would be torque of gear box and load of weight on axle or shaft, shock load,
misalignment and starting and stopping.
Distance – the smoother the surfaces, the tighter the tolerances may be. There must be enough
clearance between to allow formation of lubricant.
Lubricants used in industrial applications may be classified as:
o Mineral or petroleum oils
o Animal or vegetable oils
o Synthetic liquids
o Greases (food grade)
Ask what type of lubricants do you use at home when cooking? (Example of vegetable oils.)

It is very important that the proper lubricant be used. Using the wrong type of lubricant can
cause damage to equipment.
Oils
Multi-grade oils contain additives that permit the oil to flow steadily across a large temperature range.

The viscosity of oil decreases as temperature increases. Therefore, oils are thinner and flow more easily at
high temperatures than at low temps. (Example of syrup in refrigerator and then heated in microwave.)

It is very important for oil to completely cover the surface it is lubricating. If the oil film between two
surfaces becomes too thin due to high temperature, friction and wear will increase.
Thicker oils would be used in high temperature conditions to ensure complete coating of the
surfaces. Most equipment manufacturers will designate the correct type of oil to be used and how often
the equipment should be lubricated.

o Lubricating oils come in a wide variety of grades and viscosities.

o Oils with a high viscosity number are thicker than oils with lower numbers. For instance, 20W (W stands
for weight) is thinner than a 40W that is much thicker.
Melt point
Grease melts at different temperatures . Melt Point means the temperature that the grease starts to
become liquid.
Water Resistance
Some types of grease need to work in presence of water, and because of this they need to have a water
resistance.
Stability
Stability indicates the period of time that the grease can keep its original consistency.

General:

Greases are mixtures of oil and a wax or soap base.

They range in concentrations from almost solid to a thick oil and are used more in slow operations and
when high temperatures are expected.
Some greases are made for special conditions and contain materials such as silicone, aluminum, graphite,
or lithium.

Greases are also used when the physical arrangement of the lubricated components makes it difficult to
keep the surfaces coated with oil.

Manual Lubrication
Gears, chains and gearboxes. Remember to clean the surface before lubrication. Apply the lubricant
directly on or in the surfaces in contact. Remove over lubrication!
Standards
Ask “What lubricant should be used on this machine for gear boxes? At what interval? What method is
used?”

Proper Lubrication Techniques

o Receptacles
o Lubrication amounts
o Tools used
o Hazards of cross contamination
Receptacles
o Zerk fittings
o Oilers
o In-Line Air Lubricators
Zerk fittings
It is very important to clean zerk fittings before adding grease because dirt on the fitting could be
forced inside, causing harm to lubricated parts. Remember to clean the fittings after adding grease, also!
Oilers
Oilers are small containers of oil located near the components to be lubricated. They continually lubricate
components by gravity flow from the reservoir. Gravity feed rates vary from one machine to the next.
When filling oilers check the following:

o Verify that you are using the correct oil.

o Clean off the glass bulb and area where oiler connects to machine to prevent contamination of oil.
o After filling, look for leaks.
Observe oiler over time and note amounts of oil used. If an oiler never seems to have to be filled or must
be filled more frequently than others, this may be a sign of a problem.

TPM Autonomous Maintenance Step 4 Lubrication Module. Part 2

In-Line Air Lubricators
These lubricators lubricate the air supply to air operated equipment. Do you work on any air operated
equipment? Drip rates can be adjusted using the adjustment knob on top of the lubricator.
Components Identified
Air lubricators cannot be filled while pressurized. Pressure must be removed by activating the air dump or
closing the isolation valve. Always remove the fill port cap “slowly” to remove the remaining pressure.
REMEMBER YOUR LOCK OUT/TAG OUT PROCEDURES!
Lubricant Amounts
2 potential problems:
o Too Much (over lubrication)
o Too Little (under lubrication)
Over Lubrication
Over lubrication occurs when the amount of lubricant exceeds the required amount to adequately
reduce the friction between moving parts.

Potential problems:
o Damage to machine seals
o Component leaks
o Undue stress and wear on motors/parts
o Contamination of product
o Increased friction
Under Lubrication
Under lubrication occurs when the amount of lubricant falls below the required level to prevent friction
between moving parts.
The main problem is machine parts seizing up and irreparable damage. Even if levels are low, friction on
moving parts will increase and cause damage over time.

o Follow machine documentation.

o Verify correct lubricant is used.
o Check levels and amounts used.
o Observe flow and amount where possible.
o Uses senses to observe undue friction (how?)
o Label lubrication points with type/amount (tags)
o Be aware of unusual changes in machine usage.
o Follow lubrication schedule!
Lubrication Effects
o Downtime for adjustment
o Frequency and seriousness of breakdown
o Product quality
o Percentage of product rework
o Cost of machine maintenance
o Equipment life cycle
o Reduced speed losses
o Reduced minor stoppages
Tools used for Lubrication
o Grease guns
o Pumps – oil cans or oil bottles
o Spray lubes
Grease Gun
Hand powered lubricators with special fittings on the end of hoses that connect to grease fittings on
equipment.
Guidelines for use
o Verify correct lubricant is used
o Verify grease is present in supply cylinder
o Check proper operation
o Wipe off zirc to prevent contamination
o Insert outlet fitting of gun on the zerk fitting
o Keep outlet tube straight on zerk fitting
o Verify transfer of greases by handle/lever pressure
o Watch for grease around outlet/zirc connection
o Do not over grease. (Follow Standard)
o Wipe off excess grease
Oil cans
Hand lubricators that are used to apply oil directly to machine parts such as chains and sprockets and to
fill local oilers.
Guidelines for use
o Verify correct oil is in can for parts to be lubricated
o Verify that can is operating properly
o Apply oil directly to parts only during shutdown to prevent oil from slinging onto associated equipment.
o Wipe up all excess oil
NEVER use the same oil can for two different types of oil. Even if the can is empty, the residue from the old
oil will contaminate the new oil.
Spray Lubes
Aerosol-pressurized cans that spray lubricants on the parts to be lubricated. Designed for chains, wide
surfaces and in hard-to-access areas.

Guidelines for use

o Verify correct type of lubricant
o Shake can vigorously
o Insert straw adapter if necessary
o Verify correct operation
o Direct spray at parts to be lubricated
o Do not over lubricate parts
o Clean any excess spray lubricant
o Return spray lubricant to proper storage
Hazards of Cross Contamination
Cross contamination is the mixing of different types and/or weights of lubricants.

o —Always verify the correct lubricant has been obtained

o —Always use lubricant specific containers
Lubrication Safety
o Always use LOTO, when specified
o Review HMIS – Hazardous Materials Identification System
o Minimize skin contact with used oil
o Clean up thoroughly
Hazardous Material Identification System Label

Don’t Forget about TAGGING!

o Abnormalities are potential problems
o Abnormalities accelerate deterioration of equipment
o Abnormalities are detected through cleaning and inspection
Remind them to tag, tag, tag! Now that operators are getting more and more AM Step 4 training, should
the number of blue tags vs. red tags be changing.
Lubrication Competency
Assess knowledge gained by associates by demonstrating skill with “Hands on” practical exercises on
physical models.