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CECW-ET Engineer Manual 1110-2-1424 Department of the Army U.S. Army Corps of Engineers Washington, DC 20314-1000 EM 1110-2-1424 28 February 1999 Engineering and Design LUBRICANTS AND HYDRAULIC FLUIDS Distribution Restriction Statement Approved for public release; distribution is unlimited. DEPARTMENT OF THE ARMY EM 1110-2-1424 U.S. Army Corps of Engineers CECW-ET Washington, DC 20314-1000 Manual No. 1110-2-1424 28 February 1999 Engineering and Design LUBRICANTS AND HYDRAULIC FLUIDS 1. Purpose. This manual provides guidance on lubricants and hydraulic fluids to engineering, operations, maintenance, and construction personnel and other individuals responsible for the U.S. Army Corps of Engineers (USACE) civil works equipment. 2. Applicability. This manual applies to all USACE commands having civil works responsibility. 3. Discussion. This manual is intended to be a practical guide to lubrication with enough technical detail to allow personnel to recognize and easily discern differences in performance properties specified in manufacturers’ product literature so that the proper lubricant for a particular application is selected. It describes basic characteristic properties of oils, hydraulic fluids, greases, solid lubricants, environmentally acceptable lubricants, and their additives. It examines the mechanics of hydrodynamic, boundary, extreme pressure, and elastohydrodynamic lubrication to protect against surface deterioration. Separate chapters are devoted to lubricant specification and selection, and requirements of lubricants for equipment currently in use at USACE civil works facilities. Because conscientious adherence to lubrication schedules is the best prescription for longevity of component parts, operation and maintenance considerations are also addressed. 4. Distribution Statement. Approved for public release, distribution is unlimited. FOR THE COMMANDER: 2 Appendices (See Table of Contents) ALBERT J. GENETTI, JR. Major General, USA Chief of Staff DEPARTMENT OF THE ARMY EM 1110-2-1424 U.S. Army Corps of Engineers CECW-ET Washington, DC 20314-1000 Manual No. 1110-2-1424 28 February 1999 Engineering and Design LUBRICANTS AND HYDRAULIC FLUIDS Table of Contents Subject Paragraph Page Chapter 1 Introduction Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-1 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-1 Distribution Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1-1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1-2 Chapter 2 Lubrication Principles Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-1 Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-4 Lubrication and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2-6 Hydrodynamic or Fluid Film Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2-6 Boundary Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2-8 Extreme Pressure (EP) Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2-9 Elastohydrodynamic (EHD) Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2-9 Chapter 3 Lubricating Oils Oil Refining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1 Types of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-2 Characteristics of Lubricating Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3-4 Oil Classifications and Grading Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3-7 Chapter 4 Hydraulic Fluids Purpose of Hydraulic Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1 Physical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4-1 Quality Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4-2 Use of Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4-4 Types of Hydraulic Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4-4 Cleanliness Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4-6 i EM 1110-2-1424 28 Feb 99 Subject Paragraph Page Chapter 5 Grease Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5-1 Grease Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5-2 Fluid Lubricants Soap Thickeners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 5-5 Complex Soap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 5-6 Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 5-6 Types of Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5-6 Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5-8 Grease Application Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 5-8 Chapter 6 Nonfluid Lubrication Solid Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1 Self-Lubricating Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6-6 Self-Lubricating Bearings for Olmsted Wicket Gates Prototype Tests . . . . . . . . . . 6-3 6-7 Chapter 7 Lubricant Additives General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-1 Surface Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7-1 Performance-Enhancing Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 7-3 Lubricant Protective Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7-3 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 7-4 Chapter 8 Environmentally Acceptable Lubricants General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8-1 Definition of Environmentally Acceptable (EA) Lubricants . . . . . . . . . . . . . . . . . . 8-2 8-1 Biodegradation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 8-2 Toxicity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 8-3 EA Base Fluids and Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 8-3 Properties of Available EA Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 8-6 Environmentally Acceptable Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 8-8 Changing from Conventional to EA Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 8-8 Survey of Corps Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 8-9 USACE Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 8-10 Chapter 9 Gears General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9-1 Gear Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9-1 Gear Wear and Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 9-2 Gear Lubrication . . . . . . . . . . . . . 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