Lesson 1Standards and terminology: ISO cleanliness codes, ASTM, NLGI, DIN/ISO references relevant to maintenanceThis section explains key lubrication standards and terminology used in industry, including ISO cleanliness codes, ASTM and DIN/ISO test methods, and NLGI classifications, enabling consistent communication and specification in maintenance programmes.
ISO particle cleanliness code structureASTM test methods for lubricantsDIN and ISO viscosity classificationNLGI grease consistency numberingReading lube labels and data sheetsLesson 2Lubrication regimes: boundary, mixed, elastohydrodynamic, hydrodynamicThis section describes boundary, mixed, elastohydrodynamic, and hydrodynamic lubrication regimes, linking film thickness to surface roughness, load, and speed, and showing how regime identification guides lubricant selection and operating practices.
Stribeck curve and key parametersBoundary lubrication characteristicsMixed lubrication in real contactsEHL in rolling element bearingsFull hydrodynamic film conditionsLesson 3Lubricant base stocks: mineral, PAO, ester, PAG — properties and selection criteriaThis section reviews major lubricant base stock types, including mineral, PAO, ester, and PAG fluids, comparing their physical and chemical properties, oxidation stability, seal compatibility, and cost to support informed selection for different industrial services.
API mineral base oil groupsPAO synthetics: strengths and limitsEster fluids: benefits and cautionsPAG fluids and water-mixable typesMatching base stocks to applicationsLesson 4NLGI consistency for greases and how consistency affects pumpability and film formationThis section explains NLGI grease consistency grades, how cone penetration relates to hardness, and how consistency influences pumpability, channelling, and film formation in bearings and centralised systems under varying temperatures and speeds.
Cone penetration and NLGI gradesConsistency vs pumpability in linesChanneling and grease distributionEffect on film thickness in bearingsTemperature impact on consistencyLesson 5Contamination effects: particulate, water, and incompatible lubricants — consequences and limitsThis section examines how particulate matter, water, and incompatible fluids degrade lubricants and components, describing failure modes, cleanliness targets, water limits, and practical methods to monitor, prevent, and correct contamination in service.
Particle-induced wear mechanismsWater contamination sources and limitsEffects of mixing foreign lubricantsCleanliness targets and ISO codesFiltration and dehydration practicesLesson 6Viscosity fundamentals: viscosity, viscosity index, ISO VG, SAE grades, temperature effectsThis section develops a solid understanding of viscosity behaviour, viscosity index, ISO VG and SAE grading systems, and temperature–viscosity relationships, showing how to select and verify the correct viscosity for bearings, gears, and hydraulic systems.
Dynamic vs kinematic viscosityViscosity index and its significanceISO VG grades and selection rulesSAE engine and gear oil gradesTemperature–viscosity charts and toolsLesson 7Additives: anti-wear (ZDDP), EP, antioxidants, rust/corrosion inhibitors, anti-foam, detergentsThis section details common lubricant additive families, including anti-wear, EP, antioxidants, rust and corrosion inhibitors, anti-foam agents, and detergents, explaining their functions, limits, and how they influence lubricant selection and life.
Anti-wear and EP chemistry basicsOxidation control and antioxidantsRust and corrosion inhibitor rolesAnti-foam and air release additivesDetergent and dispersant actionsLesson 8Basic lubricant compatibility and mixing rules (base oil and thickener compatibility)This section covers lubricant compatibility principles, focusing on base oil families and grease thickener systems, how to interpret compatibility charts, risks of mixing, and safe changeover procedures to avoid sludge, softening, or seal damage.
Base oil family compatibility basicsGrease thickener compatibility matrixRisks of mixing incompatible lubricantsFlushing and changeover best practicesUsing OEM and supplier guidanceLesson 9Principles of friction, wear, and lubrication mechanismsThis section introduces the fundamentals of friction and wear, describing adhesive, abrasive, and fatigue wear, and explaining how different lubrication mechanisms form protective films that separate surfaces and extend component service life.
Types of friction in machine elementsAdhesive, abrasive, and fatigue wearSurface roughness and contact areaRole of lubricant films in protectionRelating wear modes to field symptomsLesson 10Types of lubricants: oils, greases, solid lubricants, and their general usesThis section classifies oils, greases, and solid lubricants, explaining how their structures differ, where each type is typically used, and how application method, speed, load, and environment influence the choice of lubricant form in industrial equipment.
Liquid oils and circulation systemsGreases for bearings and couplingsSolid lubricants: MoS2 and graphiteDry-film and boundary lube coatingsSelecting form based on duty cycle
