
Automatic lubrication systems provide many benefits to manufacturers by removing the need for manual lubrication, reducing the risk of over or under-lubrication, and helping prolong the lifespan of machinery components. However, the performance of a lubrication system can decline if it’s not properly maintained, leading to issues like improper application and lubricant contamination.
In this blog post, we’ll cover some of the most common issues you could experience with your system, what causes these issues, and how to resolve them.
Clogs
Clogs are some of the most common issues, and if left unresolved, they can impact equipment performance so much that the equipment could fail entirely. There are some visible and audible signs of clogs in a system, including unusual noises from bearings and residue or debris near lubrication points, but other signs can include uneven lubrication and high-pressure buildup within the system.
If you’re experiencing clogs, it’s mostly likely because the lubricant is contaminated by dirt, dust, or metal particles or the lubricant has degraded.
Troubleshooting Steps
- Inspect the lubrication points for blockages. Look especially for hardened grease or dirt buildup.
- Examine the filters and lines for clogs. Replace dirty filters or flush lines as needed.
- Test the lubricant for contamination or degradation. If it is contaminated or degraded, replace it with a manufacturer-recommended lubricant.
- Use a pressure gauge to detect pressure irregularities, then clean or replace components affected in high-pressure zones.
Prevention Tips
- Always use manufacturer-recommended lubricant.
- Regularly inspect and replace dirty filters. Your system manufacturer will have a specific frequency recommendation, but it’s usually every three to six months or every one to three months if the equipment is in a high-contamination environment.
- Annually flush the system(or bi-annually if in a high-contamination environment).
- Flush the system if you switch lubricant type or replace any major components.
Pump Malfunctions
Pump malfunctions can occur when contamination issues escalate. They can also be caused by air bubbles in the lubricant causing cavitation, worn seals and valves, misalignments or loose connections, and using incompatible lubricants.
If your pump is malfunctioning, you’ll most likely notice inconsistencies with lubricant flow, grinding or knocking sounds in the pump, pressure fluctuations, visible leaks around the pump housing or fittings, or overheating.
Troubleshooting Steps
- Inspect the pump for visible damage, loose connections, or leaks.
- Tighten fittings or replace damaged seals and gaskets.
- Check the lubricant for contamination and replace it if needed.
- Adjust the pump settings or replace faulty components.
- Bleed the system to remove trapped air.
- Remove debris or buildup in the pump and connected lines. If the contamination is widespread, then flush the entire system.
After each step, be sure to test the pump. Move on to the next step if the pump is still acting strange. Contact a service professional if the pump still operates incorrectly after performing all six steps.
Prevention Tips
- Always use the manufacturer-recommended lubricant.
- Schedule periodic component inspections to address worn components sooner rather than later.
- Perform regular inspections (as noted in the clogs section) of system filters.
Inconsistent Flow or Inconsistent Lubrication
Automatic lubrication systems are supposed to provide consistent lubrication to machinery components. If the system isn’t doing that, then there’s definitely a problem that needs to be addressed immediately.
The most obvious sign of inconsistent lubrication is when certain components are dry while others have excessive buildup, but you may also notice fluctuations in the system’s pressure or flow rates. Generally, many systems will have built-in alarms that will alert technicians when lubricant is being delivered irregularly.
These inconsistencies are often caused by clogs or blockages, pump malfunctions, degraded lubricant, or air bubbles.
Troubleshooting Steps
- Check all lines, nozzles, and filters for blockages, and clean or replace any components if necessary.
- Bleed the system to remove air.
- Test the lubricant for contamination or degradation.
If these steps don’t work, the pump may need to be repaired, or there are other components within your system that need to be replaced because they were improperly sized and installed.
Prevention Tips
- Perform periodic filter inspections and keep them clean.
- Regularly check lines, nozzles, and pressure levels.
- Always use the manufacturer-recommended lubricant.
Leaks
Leaks can be a fairly common, minor issue, but if left unaddressed, they could lead to lubrication inconsistencies and more wear due to increased friction between components.
If you have leaks, you’ll immediately notice lubricant beneath equipment or around system components. You may also notice the need to refill lubricant reservoirs constantly and hear squealing or grinding sounds from dry components.
Worn seals are often at fault here because they can crack, harden, and wear out over time, especially in heavy-duty environments (or if the system is over pressurized). If vibration is normal in your environment, that vibration can also loosen components over time. Contaminated or degraded lubricants can also damage seals.
Troubleshooting Steps
- Inspect hoses, fittings, seals, and reservoirs to identify the source of the leak.
- Replace worn seals or gaskets—ensure you get properly sized replacements!
- Tighten fittings, joints, and other connections if loose.
- Check the system pressure and adjust settings if needed.
- Test the lubricant for contamination or degradation, and flush and replace it if needed.
Prevention Tips
- Regularly inspect hoses, seals, and connections.
- Monitor and regulate system pressure to prevent over pressurization.
- Use the correct lubricant.
Contamination
Particularly dusty, dirty, or high-moisture environments can increase risks of contamination and lubricant degradation. If you’ve noticed cloudy or discolored lubricant, you need to replace it. More indirect signs may include excessive wear or visible rust on components (especially if water has contaminated the lubricant) or grinding, squealing, or knocking sounds from dry components. If seals are damaged, they can also allow contaminants to enter the system and impact the lubricant.
Troubleshooting Tips
- Inspect the lubricant for discoloration or foreign particles and replace it.
- Replace clogged/dirty filters.
- Flush the system to remove residual contaminants.
- Replace worn seals.
Prevention Tips
- Don’t mix lubricant types. If you’re switching a lubricant type, flush the system first.
- Keep lubricants stored properly to ensure they don’t degrade while in storage.
- Use oil analysis and particle counters to detect contamination early on.
- Visually inspect lubricant every few months for discoloration.
Incorrect Readings
While not as common as the issues listed above, incorrect readings can be an issue when integrated sensors are malfunctioning or not calibrated, if there are power fluctuations, or when dirt, debris, or moisture block sensors.
Troubleshooting Steps
- Perform manual readings and compare them to system readings to confirm inaccuracies.
- Check the sensors for damage or dirt, and clean or replace them if it’s needed.
- Recalibrate sensors per manufacturer specifications.
- Clean measurement points to ensure debris and moisture aren’t affecting the sensors.
- Verify that the software is up-to-date and configured.
Prevention Tips
- Install covers or filters over the sensors to shield them from contaminants.
- Clean, inspect, and test the sensors every few months to verify functionality.
Pressure Issues
Sudden spikes or drops in pressure levels, blockages or dry spots in lubrication points, excess lubricant escaping from seals, or unusual grinding and squealing noises can all be signs indicating pressure issues. Similar to flow and lubrication inconsistencies, automatic systems will alert technicians when the system is under or over-pressurized.
These pressure issues can be caused by clogs or blockages, pump malfunctions, leaks, and air bubbles/cavitation.
Troubleshooting Steps
- Inspect lines, nozzles, and filters for blockages. Clean or replace these components as needed.
- Check seals, hoses, and fittings. Replace damaged seals or tighten loose connections as needed.
- Bleed the system to remove any air bubbles.
Get Support From DropsA
DropsA helps manufacturers keep their systems up and running by engineering and selling high-quality replacement components like manifolds, pumps, reservoirs, filters, and lubricants, and by offering comprehensive support and maintenance services, including routine inspections and repairs.
Our experts can help troubleshoot challenging issues, create preventative maintenance programs for your system, and provide guidance on replacement part selection. Contact us today to speak with a team member.