Lubricants Technical Training Program Course Outline

Agendas can be customized to fit your specific needs.

The following training manual outline compromises the basis of a hands on training course dealing with lubrication. Many classroom training props are used to reinforce instructional materials. Students will have the opportunity to examine bearings, gears, engine components, compressor valves and operate a hydraulic system that is used to demonstrate aeration and cavitation. Oil analysis, filtration and documentation techniques are review.

The 5 day class is conducted at our Newark, DE facility which is conveniently located 1 mile off of I-95. Air access is available through the Philadelphia airport (31 miles) or the Baltimore airport (65 miles).

The cost of the course is $1,495 per student which includes the training manual (approximately 400 pages), breaks and lunch.

Available Course Dates can be found on the Course Registration Form

Call Jim Spring at 610-869-0370 or send and e-mail to JimSpring@verizon.net. should have any additional questions.

Chapter 1

Course Introduction

  • 1.1 How Important is Price
  • 1.2 Participant Questionnaire
  • 1.3 Test on Fundamentals
  • 1.4 Viscosity-Temperature Charts

Chapter 2

Petroleum Chemistry

  • 2.1 Chemistry Fundamentals
  • 2.2 Refining Process
  • 2.3 Refining Terms
  • 2.4 Refining Slide Presentation
  • 2.5 Industry Data
  • 2.6 Annual Sales of Lubricants
  • 2.7 Base Stocks

Chapter 3

Additives

  • 3.1 Definitions
  • 3.2 Oil Additive Exercise
  • 3.3 Snake Oil by Fred Rau
  • 3.4 AW and EP Exercise

Chapter 4

Grease

  • 4.1 NLGI Film on Grease
  • 4.2 Lab Exercise on making Grease
  • 4.3 Discussion Issues
  • 4.3.1 Lubricant Selection
  • 4.3.2 General Trends
  • 4.4 Class Exercises
  • 4.4.1 Trabon Centralized Grease System
  • 4.4.2 Greased Bucket Pins
  • 4.4.3 Furnace Reheat Door

Chapter 5

Synthetics

  • 5.1 Types and Properties
  • 5.2 Applications
  • 5.3 Comparative Temperature Limits
  • 5.4 Synthetic Engine Oil Exercise
  • 5.5 Synthetic Cost Savings
  • 5.5.1 Engine Oil Drain Savings
  • 5.5.1.1 Cost Comparisons

Chapter 6

Fundamentals of Lubrication


  • 6.1 Friction
  • 6.2 Lubricant Film Definitions
  • 6.2.1 Thick Film Lubrication
  • 6.2.2 Thin Film Lubrication
  • 6.2.3 Solid Film
  • 6.3 Lubricant Films
  • 6.4 Terms

Chapter 7

Machine Elements

  • 7.1 Bearings
  • 7.1.1 Slide Show Presentation
  • 7.1.2 Cement Mill Grease Exercise
  • 7.1.3 Lab Exercises
  • 7.1.3.1 Bearing Identification Exercise
  • 7.1.4 Bearing Review
  • 7.1.5 Bearings
  • 7.1.5.1 Bearing Types Defined
  • 7.1.5.2 Bearing Characteristics
  • 7.1.5.2.1 Oil Viscosity Lubrication Selection
  • 7.1.5.3 Grease Re-Lubrication Period
  • 7.1.5.4 Relubrication Guidelines for Bearings
  • 7.1.5.5 How much grease is enough?
  • 7.1.7 Viscosity Selection for Rolling Element Bearings
  • 7.1.8 Oil Viscosity Selection for Plain Bearings
  • 7.2 Gears
  • 7.2.1 Slide Show Presentation
  • 7.2.2 Gear Quiz
  • 7.2.3 Gear Maintenance Concepts
  • 7.2.3.1 Air Padding
  • 7.2.3.2 Removing Wear Metals
  • 7.2.3.3 Gear Tooth Terminology
  • 7.2.4 Class Exercises
  • 7.2.4.1 Marion Hoist Gear
  • 7.2.4.2 Steel Mill Lubricant Recommendation Exercise
  • 7.2.5 Lab Exercises
  • 7.2.5.1 Gear Identification
  • 7.2.7 Lubricant Considerations for Gearboxes
  • 7.2.7.1 Gearboxes
  • 7.2.7.2 AGMA Lubricant Designations
  • 7.2.7.3 Sae Gear Oil Classifications
  • 7.3 Misc. Machine Elements
  • 7.3.1 Chains, Coupling, Wire Rope, Pistons and Other Components Slide Show

Chapter 8

Internal Combustion Engine

  • 8.1 Internal Combustion Engine Parts Slide Show
  • 8.2 Lab Exercise with Internal Combustion Engine
  • 8.3 Lab Exercise with Engine Parts
  • 8.4 Engine Oil Consumption Concepts
  • 8.5 Engine Clearances and Tolerances Slide Show
  • 8.6 Engine Exercises
  • 8.6.1 Exercise 1
  • 8.6.2 Exercise 2
  • 8.6.3 Exercise 3

Chapter 9

Power Train

  • 9.1 Chassis Components Slide Show
  • 9.2 Lubricants for Non-Driven Axles>

Chapter 10

Hydraulics

  • 10.2 Hydraulics Slide Show
  • 10.3 Hydraulic System Basics
  • 10.3.1 Guidelines for Vane Pumps
  • 10.3.3 Temperature/Viscosity Exercise
  • 10.3.4 Article
  • 10.3.4.1 How to detect and prevent hydraulic pump cavitation - G. R. Jordan
  • 10.4 Lab Hydraulic System Demonstration
  • 10.5 Lab Hydraulic Pump Exercises
  • 10.6 Class Exercises
  • 10.7 Article Discussion
  • 10.7.3.2 Converting old ACFTD particle sizes to NIST Sizes
  • 10.7.3.3 ACFTD vs. NIST Calibration
  • 10.7.3.4 Beta Ratios Comparing ACFTD vs. NIST vs. MTD Multi-Pass
  • 10.7.4 Clearing Up Hydraulic Fluid Myths
  • 10.8 Filtration Concepts
  • 10.8.1 ISO Particle Count Classification
  • 10.8.2 Typical Hydraulic Component Cleanliness Requirements
  • 10.8.5 Napa Micron Rating for Fluid Filters
  • 10.9 Vickers Target Cleanliness Ratings
  • 10.10 Plant Hydraulic Study Outline

Chapter 11

Compressors

  • 11.1 Introduction
  • 11.2 Slide Show Insert
  • 11.3 Discussion Issues
  • 11.4 Air Compressor Analysis (Trouble Shooting)
  • 11.4.1 Reciprocating Air Compressor Operating Data
  • 11.4.2 Rotary Type Compressor Operating Data

Chapter 12

Turbines

  • 12.1 Slide Show
  • 12.2 Steam Turbine Slide Show Insert
  • 12.3 Gas Turbine Slide Show Insert
  • Trouble Shooting Problems in EHC Control Fluid Hydraulic Systems - The Austin Group

Chapter 13

Machine Tools and their Operations

  • 13.1 Slide Show

Chapter 14

Oil Analysis - Are you wasting money?

  • 14.1 Oil Analysis Terms
  • 14.2 Reasons for Oil Analysis Program Failures
  • 14.3 On-Site Oil Analysis Program
  • 14.3.1 Filter Patch Interpretation Guide
  • 14.4 Slide Show Laboratory Oil Analysis for Off-Highway Equipment
  • 14.5 Oil Analysis Interpretation Tips
  • 14.6 Engine Oil Analysis Interpretation Guide
  • 14.7 Diesel Engine Oil Analysis Check List
  • 14.8 Class Exercise, Oil Analysis Questions
  • 14.9 Donaldson Oil Analysis General Guidelines
  • 14.10 Oil Analysis Sheets

Chapter 15

Trouble Shooting

  • 15.1 Recognizing Cost Reduction Opportunities

Chapter 16

Benefit Selling (For Sales Personnel Only)

  • 16.1 The Product Sell
  • 16.2 Benefit Selling

Chapter 17

Developing Benefit Areas

  • 17.1 Cost of Leaks
  • 17.2 Mobile Equipment - Typical Data
  • 17.2.1 Mobile Equipment - Typical Data
  • 17.2.2 Contractor Fuel and Lubricant Requirements
  • 17.3 Construction and Mining Industry Overview
  • 17.3.1 Earth Moving Lubricant Consumption Guidelines
  • 17.3.2 Strip Mining Lubricant Consumption Guidelines for Eastern Coal
  • 17.3.3 Crushed Stone Industry Cost Data
  • 17.3.4 Surface Mining Requirements (Lubricants)
  • 17.3.5 Underground Mining Requirements (Lubricants)
  • 17.4 Exercises
  • 17.4.1 Justification of Synthetic Lubricants in Fleets
  • 17.4.2 Dragline Hoist Gear Exercise
  • 17.5 Heavy Equipment Cost Benefit Areas
  • 17.6 Developing Cost Saving Benefits for Industry
  • 17.6.1 General - What are Suffering Points
  • 17.6.2 Finding Suffering Points
  • 17.6.3 Air Compressors
  • 17.6.4 Air Intake Systems (Compressors and Diesel Engines)
  • 17.6.5 Conveyor Systems
  • 17.6.6 Cement or Ready Mix Trucks
  • 17.6.7 Electric Motors
  • 17.6.8 Forklift Truck Maintenance
  • 17.6.9 Gearboxes
  • 17.6.10 Hydraulic Systems
  • 17.7 Lubricant Storage and Handling
  • 17.7.1 Storage and Handling Slide Show
  • 17.7.2 Savings on Lubricant Storage and Handling with Bulk Oil

Chapter 18

Proposal Writing

  • 18.1 Writing Workshop
  • 18.2 Ten Principles of Clear Writing
  • 18.3 Report Techniques

Chapter 19

Forms

  • 19.1 Storage and Handling
  • 19.2 Lubrication Survey Form
  • 19.3 Abbreviations used in Lube Surveys
  • 19.4 Plant Hydraulic Study
  • 19.5 Hydraulic System Inspection Report
  • 19.6 Hydraulic Fluid Inspection
  • 19.7 Hydraulic System Inspection Checklist
  • 19.8 Mobile Equipment Inspection Form

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