LUBRICATION

REQUIREMENTS

Unit
Fundamentals

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 Fundamentals

What is the purpose of bearings?

• Provides shaft support.
• Maintains shaft alignment.
• Absorbs load transmission.
• Reduces friction between the
rotating and stationary parts.

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 Fundamentals

What is FRICTION?
• It is the resistance to relative motion
between two bodies in contact with each
other.
• When friction is present, heat is produced.
• When friction is reduced, heat is reduced

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 Fundamentals

Mechanical Devices fight a

Continuous Battle Against Friction
 Because of friction,we need lubrication /
lubricants.
 There are two ways to describe a film of oil
between two sliding surfaces:
 Oil molecules that tend to slide over one
another freely and;
 Oil molecules that tend to cling to metal
surfaces more readily than to each other. 5
 Fundamentals

Oil to Bearing Relationship

Journal
SLIDING METAL SURFACE

OIL MOLECULES
TEND TO FLOW OVER
EACH OTHER, AND
STICK TO METAL
SURFACES

Bearing

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 Fundamentals

What is the purpose of LUBRICATION?

• Reduces Friction
• Absorbs & Removes Heat
• Provides a Cushion (wedge)

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 Fundamentals

What can cause oil to Break Down?

• Heat
• Contamination
• Overloading

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 Fundamentals

Bearing Materials
• Are chosen based upon dissimilar materials
ability to slide against each other with less
friction than similar materials.
– Babbitt: soft alloy of Lead, Antimony and
Tin (Pb, Sn, Sb).
– Sintered Copper-Lead (Cu, Sn, Pb).
– Aluminum (Al, Sn, Cu, Ni, Si, Cd).
– Cast Copper-Lead (Cu, Pb, Zn, Sn).

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 Fundamentals

Bearing Material Performance Requirements

 Load capacity
 Various Conditions

 Conformability
 Soft enough to adjust to minor irregularities

 Embedability
 Able to ingest small amounts of dirt

 Compatibility
 Slippery

 Corrosion resistant
 Sour Gas 10
 Fundamentals

Bearing Selection
• Some factors to consider:
–Rotating Speed.
–Load Capability.
–Lubrication System.
–Life Requirement.
–Shaft Material & Process Fluid.
–Operating Conditions.
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 Fundamentals

Bearing Types

Journal Thrust
(Radial Load) (Axial Load)
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 Fundamentals

Bearing
Objectives and Performance

• The bearing performance is greatly

enhanced by the addition of lubrication
between the moving parts and bearing
surfaces.
• The bearing design objective is to
establish and maintain an oil film
between the surfaces in contact under
various load conditions. 13
 Fundamentals

Journal to Bearing Relationship

At Rest At Start-up During Normal

Operation
.0002 - .0004 oil wedge

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 Fundamentals

Causes of Bearing Damage

 Categories of damage include:
– Dirt (45%)
– Misassemble (15%)
– Misalignment (13%)
– Lack of Lubrication (11%)
– Overloading (10%)
– Corrosion (5%)
– Others (1%)
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 Fundamentals

Journal

Oil Flow

Bearing

Clearance Dirt Particles

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 Fundamentals

Displaced Babbit “healing”

Bearing Material over dirt particles

Journal

Bearing

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Fundamentals

MISALIGNMENT

FATIGUE PATTERN

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 Fundamentals

FOREIGN PARTICLES

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Fundamentals

Any
Questions?

Basic Lubrication
& Bearing Concepts

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Fundamentals

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 Fundamentals

Points to Remember
 Cooper Compression & Ajax can not &
does not guarantee the quality or
performance of lubricating oils.
 However, our recommendations include:
 Use oils specially formulated for two cycle
gas engines.
 Ajax oils should exhibit ash contents per
ASTM D874, less than .1% by weight.

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 Fundamentals

Points to Remember
 General specifications are as follows:
Viscosity @ 100 ° F S.U.S. 450 - 650
@ 210 ° F S.U.S 58 - 70
@ 37.8 ° C cST. 97.0 - 140.2
@ 98.9 ° C cST. 9.64 - 12.96

Viscosity Index - Min. 70 ASTM D2270

Flash Point ° F (° C) - Min. 400 (204) ASTM D92
Pour Point ° F (° C) - Min. 10 (-12) ASTM D97

Note: SAE 30 or SAE 15W-40 are recommended for

normal conditions. Lower temps and certain
startups may require viscosity grades other than
this. Contact AJAX for recommendations.
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 Fundamentals

Oil Selection for Ambient Temperature

SAE 30

SAE 40

SAE 15W-40

0 20 40 60 80 100 24 120
Lowest Expected Temperature in ° F
 Fundamentals

Points to Remember

Caution

Crankcase oil temperature must be above the pour point

temperature before attempting to start the unit. Equipment
failure will result due to lack of lubrication when the oil
temperature is below pour point temperature. Where low oil
temperature starts are require, provisions should be made to
either heat the oil or use a multi-viscosity oil that meets the
preceding requirements.
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 Fundamentals

Low Overnight Temp Starting Chart

Number of Minutes
Overnight Low Ambient Minutes @ Ide Minutes Times Light Loaded
Temps (300 RPMs) Down Sequence to Before Full
be Done Loading
90° - 70°F (32° - 21°C) 20 0 1 15
69° - 50°F (20° - 10°C) 30 0 1 20
49° - 40°F (9° - 5°C) 45 0 1 20 Low Overnight
39° - 32°F (4° - 0°C)
5 5 3 No Load Temp Chart
40 0 1 30
3 3 3 No Load
31° - 18°F (-1° to -7°C) 7 7 3 No Load
50 0 1 30
3 3 5 No Load
17° - 0°F (-8° to -17°C) 7 7 4 No Load
60 0 1 45
2 2 3 No Load
-1° to -20°F (-18° to -28°C) 5 5 4 No Load
Refer to Paragraphs 4.1 & 15 15 3 No Load
4.2 of ES 1006 30 30 1 No Load
60 0 1 45
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 Fundamentals

Points to Remember

 Power cylinder lubrication rates based on 1 pint per

day for every 30 hp.
PINTS PER DAY = HORSEPOWER / 30
PINTS PER DAY = HORSEPOWER / 25 Break-in

 Compressor cylinder lubrication rates based on 1 pint

of oil per day for every two million square feet of
swept surface.
PINTS PER DAY = RPM x DIA. Of PISTON (inches) x STROKE (inches)
31,900 27
 Fundamentals

Points to Remember
 Recommended oil viscosity for various
compressor cylinder pressures.
 Offered as a guide ONLY!
PSIG @210 ° F @98.9 ° C
0 - 1000 55 - 75 8.77 - 14.26
1000 - 1500 75 - 95 14.26 - 19.18
1500 - 2000 95 - 115 19.18 - 23.83
2000 - 3500 115 - 150 23.83 - 31.68
3500 & up 150 minimum 31.68 minimum

Caution:
Due to material compatibility, synthetic lubricants should
not be used without contacting AJAX for
recommendations. 28
 Fundamentals

Points to Remember
 Initially, check crankcase oil level by measuring from the
top machined surface to the top of the oil with the # 1
throw in the oil. Once unit is running set the oil level
controller.

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 Fundamentals
• On DC-22 & 30, check oil level with the dip stick
when unit is stopped. Add oil as necessary through
the breather cap. When unit is at operating speed
the oil level can be monitored at the bulls eye and
should be centered.

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 Fundamentals

Checking Oil Level on C-42 & Larger Units

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 Fundamentals
Unit Size Distance “A” Inches Approx. Quantity
C-42 19-7/8 8 Gal.
DPC-60 22-1/2 17 Gal.
DPC-80A 26-7/8 23 Gal.
DPC-115 28 25 Gal.
DPC-120 22-1/2 25 Gal.
DPC-140 28 25 Gal.
DPC-162 22-1/2 25 Gal.
DPC-160A 26-7/8 30 Gal.
DPC-180 28 25 Gal.
DPC-230 28 30 Gal.
DPC-300 28 30 Gal.
DPC-360 28 30 Gal.
DPC-600 28 58 Gal.
DPC-800 28 95 Gal.
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Note: Add 1/2” for 440 RPM Units (27.5”)
 Fundamentals

Any Questions? 33
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Dipping oil from crankcase.

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 Fundamentals

Pouring Oil on Journals.

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 Fundamentals

Pouring oil on the tapered roller bearings.

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 Fundamentals

Pouring oil into the trays.

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 Fundamentals

To Compressor X-Head
Guides

To Engine X-Head
Guides

Twin Pre-lube System 39

 Fundamentals

To Compressor X-Head
Guides

To Engine X-Head
Guides

Three Cylinder Prelube System

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 Fundamentals
Four Cylinder Pre-lube System

To Compressor X-Head
Guides

To Engine X-Head
Guides

Four Cylinder Prelube System 41

 Fundamentals
Automatic Prelube System W/Pneumatic Motors

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 Fundamentals
Automatic Prelube System W/Pneumatic Motors

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 Fundamentals
Automatic Prelube System W/Pneumatic Motor

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 Fundamentals
Automatic Prelube W/Electric Motor

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 Fundamentals

l Oil to Control Box

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Fundamentals

Orifice

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 Fundamentals

2803 Bed

Oil Tray # 2

Rotate Crank to move crosshead to ensure lubrication.

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Fundamentals

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Fundamentals

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 Fundamentals

Oil Tray in Crosshead

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 Fundamentals

Prelube Systems

Questions?

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