Industrial Lubrication Field Application Engineer
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In this article, a case will be made for automatic lubrication as a true necessity, rather than an option. Here are just five of many reasons why automatic lubrication is so valuable.
Proper maintenance of equipment prolongs the life of components, increasing performance and productivity and reducing repair costs. Accurate, dependable lubrication is the most critical preventive maintenance step in preserving the life and productivity of any fleet.
Automatic lubrication systems provide consistent lubrication on a more frequent basis than manual lubrication. Too little lubrication creates heat and wear, while too much can create drag, heat and wear, and damaged seals.
“The effects of under-lubrication are well known – increased component wear, premature failure, higher energy usage, and increased operating and maintenance costs,” says Charles Hartl, Industrial Lubrication Sales Manager at Graco’s Lubrication Equipment Division. “But the effects of over-lubrication are just as harmful. It wastes lubricant, leads to excess heat buildup, puts stress on lube points and increases downtime. The solution is obvious: optimal lubrication.”
Ideal machine and vehicle performance requires maintaining a minimal lube film to separate the moving surfaces under all speeds and loads. For most grease applications, the volume of grease required is equal to an average thickness of 0.001 inch (1/ inch) of the surface area, applied every four hours. For oil applications, the same thickness is applied hourly. Even with an acceptable variance of +/- 20 percent, achieving this film thickness with manual application is next to impossible. However, for metering devices in modern automatic lubrication systems, this is an easy task.
Environmental concerns are another factor. First, a well-lubricated machine is more energy efficient. This benefits the environment as well as the bottom line. Second, most lubricants are derived from the same crude oil used to produce fossil fuels, so using less lubricant is better for the environment. Automatic lubrication applies less lubricant more frequently, reducing waste and therefore protecting the environment.
Reliability is always a concern. A manual lubrication plan can result in points being missed occasionally or forgotten entirely until something breaks. With automatic lubrication, you can trust that the right amount of lubricant is reaching critical pivots, bearings and joints at the right frequency. Automatic lubrication systems also offer system monitoring options, alerting you to a problem with the lubrication supply.
In many operating conditions, there are natural contaminants present, which can negatively impact lubrication points and cause more wear and tear, especially when manual lubrication methods are used. Most often, lubrication points are not properly cleaned prior to manually lubricating, and the coupler used to attach to the point is often dirty too. Contaminants such as chemicals, rocks, sand and other particles are then forced into the lubrication point. With automatic lubrication, the grease is pumped through a filter before it enters the reservoir of the lubricator, limiting the penetration of contaminants into these lubrication points.
The optimal time to lubricate a bearing is while it is moving, which is an unsafe condition for the people applying the lubricant. Lubricant points are also often in very hard-to-reach locations, which can cause technicians or operators to put themselves in risky situations. In general, automatic lubrication provides a safer method of supplying the required lubrication.
Modern automatic lubrication products – such as those offered by Graco – help equipment owners overcome the cost penalties of conventional manual lubrication. By applying the right amount of clean lubricant at frequent intervals and monitoring lube system performance, optimum lubrication is ensured.
Protect your equipment and your employees by utilizing automatic lubrication in your operation.
Grease gun basics can mean the difference between success and failure. Therefore, it helps to know how to use the gun properly. But what exactly do we mean by grease gun basics? And what are some of the different types of grease guns? Below we answer such important questions pertaining to the topic.
Grease gun basics are defined as the set of fundamental information about grease guns that prospective gun owners need to know before purchasing or using them. So let’s begin with some relevant facts about grease guns that make a valuable piece of equipment for DIY home owners, hobby farmers, trailer owners, boat owners, and small business owners such as, landscaping and construction companies.
When you look at a basic grease gun, it is designed with a tub, plunger, spring, barrel, follower rod, and follower handle. It also includes a lever, hydraulic coupler and flexible type hose. These parts are the basic components. In terms of the grease gun types, know that you can use any one of the several types of guns that are available. However, for the most optimum handling and use, it’s highly recommended to make your selection based on your comfort and level of use.
The most widely used grease gun types are: pistol-grip, hand-grip, lever, battery-operated and air-powered. However among these, pistol grip is the most popularly used gun and it’s also the most economical of all.
When it comes to grease gun basics, you can operate a gun manually or by air or electricity. If the gun is operated by air, it is called a pneumatic grease gun. Therefore, when this type of gun is used then, it is operated by using compressed air and a pistol-type grip. The air flows through the gun when the user pulls the trigger.
As the name suggests, manual or hand-operated types of grease guns are operated with a hand pump or pistol grip. If the gun has a pistol grip, you can operate the gun with one or both of your hands.
Another grease gun type is a battery-operated model. These grease guns are also configured with a pistol grip. This type of gun works very much like a gun powered with air. Because the guns are battery operated, they do not feature an electric cord.
Needless to say, when you know how a grease gun is used, you are more likely to realize successful results in the running of your machines.
Adapters are considered main grease gun accessories. For instance, some applications require lubrication in a restricted space. In this case a 90-degree adapter is used for lubrication. On the other hand, a needle-end adapter is used when grease is used in confined spots and you want to employ a precise amount of grease.
Whether you elect to use a flexible hose or a fixed tube on your gun depends on the grease gun type. For example, a gun with a lever would be better adapted to the use of fixed tubes. However, a hose is better suited for lubricating difficult-to-access spots.
The fitting for a grease gun is normally called a Zerk fitting of nipple. A hydraulic fitting is frequently used for lubrication, and is employed in vertical or angled designs. If you wish to supply grease in a tight space then, it is better to select a flush fitting. However, if you plan to use more grease, then a button-head type of fitting will suffice. To avoid damaging a seal, opt for a fitting that is designed for pressure relief.
If you want to know how a grease gun is used correctly, you have to consider the pressure that is applied as well. For instance, if you are lubricating a bearing seal, you should not use any more pressure than 500 psi. Too much pressure can lead to some damage that can prove to be expensive. So, you need to be a master of the grease gun if you want to make the most of its use.
Again, it cannot be overstated – when you know how a grease gun is used, you can ensure the continual operation of your machinery. Some basic tips should be followed along the way. For example, make sure you protect the pressure assembly on the gun by applying a layer of grease. Do this before inserting the gun’s plunger inside the barrel.
Also, be careful when you use any of the grease gun attachments. This is because attachments are used to grease openings that are exceptionally small in size. Needles attachments, too, can cut into the skin. So, you want to make sure that you handle these accessories with the utmost care. Any grease that seeps into a cut can lead to a serious infection.
Make sure you clean the nozzle before you use the gun. In addition you want to ensure that the right type of grease is used. Then squirt a very small bit of grease from the nozzle. Clean up the nozzle with a cloth before you attach it to a fitting.
While the use of grease gun is often discussed, it does not hurt to review the basics from time to time. Sometimes we forget about some of the risks involved in using a grease gun. That is why it is always essential to make sure you understand how to correctly use the tool.
Contact us to discuss your requirements of Grease Gun Nozzles. Our experienced sales team can help you identify the options that best suit your needs.
Equipment that is regularly serviced and maintained with a grease gun includes the lawn mower, automobile engine, chain saw, and factory-type machinery.
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aidanlong
Grease gun anatomy is a science unique to mechanics and machinists. If you need to use a grease gun for a repair or in your job, it helps to know the make-up of the tool. In order to understand the gun’s construction, the tool needs to be dissected and the types of guns reviewed.
Grease guns are featured in three types of styles with respect to use. Guns can be powered by hand, air, or electricity. Manual or hand-operated guns are made with a pistol or lever grip. The gun you use then depends on the application and personal preference. One major difference in grease gun use is how the gun is loaded. Guns are filled with lubrication by suction fill, bulk, or cartridge.
Manual Grease Guns
The manual grease gun is the most commonly used type of gun. It supplies about 1.28 grams of grease for each pump. The grease is transmitted into an aperture from a hand pump. The manual gun with a pistol grip can be operated by one or two hands. This type of gun provides about .86 grams for each pump.
Pneumatic Grease Guns
The pneumatic grease gun uses a pistol grip and compressed air. The air is directed inside the gun with a hose using a trigger.
Battery-Powered Guns
Grease guns powered by a battery feature a pistol-grip design. Guns of this type work similarly to pneumatic guns. This type of gun is manufactured without a cord.
Understanding grease gun anatomy is essential to using grease as the material clings to engine parts or components without leaking away. Therefore, proper grease gun use should be fully understood. When a technician or mechanic fully understands grease gun anatomy and use, machines and bearings work better as well as last longer.
A grease gun normally comes with a standard hydraulic coupler. Adapters may be used as well in the following configurations:
The choice to use a fixed tube or adaptable hose depends on a machine’s ease of location and the type of gun used. For instance, a hard-to-reach area would benefit from the use of a hose while a lever-style gun would work better with a fixed tube.
Meters for grease guns can be retrofitted into a gun to maximize lubricant use. The use of plastic caps prevent debris and corrosion. Color-coding the caps can help prevent cross-contamination. Sonic and ultrasonic devices are also available for use.
Fittings for grease guns go by a number of names, including grease nipple, Alemite fitting, or Zerk fitting. The fitting represents the point where the grease connector is attached. The mostly commonly used fitting is the hydraulic grease fitting, which is featured in an angled or upright design. If a large amount of grease is added, a button-head fitting is advised. Flush type fittings are preferred in restricted spaces. A pressure-relief vent fitting is recommended to prevent higher pressures that can lead to damaged seals.
Part of grease gun anatomy involves knowing the proper amount of pressure to apply. A high-pressured manually operated gun delivers from 2,000 to 15,000 psi. Bearing seals should be greased with no more than 500 psi of pressure. So, be careful about applying pressure as too much force leads to collapsed shields on bearings and environmental and safety problems.
It is essential to know the precise measure of grease needed for greasing applications. Damaged motor windings and seals, fluid friction, and higher energy consumption result from over-greasing. Increased contamination and fiction wear surface when parts are under-greased.
Manual Designs
In manual designs, the lever of a grease gun is used for hand-pumping the grease from the gun’s barrel into a tube or hose. The trigger and handle are used in manual grease guns in the same way. The barrel of the gun is the exoskeleton of the gun and contains the grease tub or grease that is derived from bulk storage. The grease tube or cartridge is a type of housing that is replaced when the grease has been used.
Operational Fittings
The hydraulic connector or coupler of the gun is a linking point that holds a fixed tube or hose that is affixed to the grease gun’s head. The filler nipple represents the grease injection point from a filler pump. An air-release nipple permits the escape of air after the lubricant has been added to the gun and pumped into its head. The spring on the gun supplies the pressure onto the plunger.
Rods and Handles
The follower rod assists the plunger maintain a uniform direction as it holds pressure on the bottom part of the tube of grease. The rod is also used to pull back the spring before the insertion of a new tube. The follower handle offers holding power when the follower rod or plunger rod is pulled before tube insertion. A fixed tube may be used interchangeably with a hose to ease the use and positioning of a coupler or connector. Fixed tubes are inflexible forms of hoses.
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