Troubleshooting Common Grease Related Issues

Are you concerned about the issues that occurred in your grease lubrication system? Applying and maintaining the health of your grease needs a lot of attention. To attain absolute longevity and smooth operation, there are several things that you need to follow. A major part of these considerations are related to lubrication. Proper lubrication plays an important role in your machinery and equipment life. However, sometimes the most reliable lubricants can encounter issues that can hinder their effectiveness.

Greases are the most common lubricant used in almost every machinery and equipment. Therefore, we must all experience common grease-related issues like clogs and overflow. Sometimes, when we attempt to start our car’s engine, it gives us trouble. Even after several tries, it still doesn’t cooperate. We don’t know the cause of these troubles and also the solutions. If your grease’s health is not up to the mark, such situations can occur frequently. Here, we are discussing the common grease-related issues and offering some practical solutions to avoid these problems.

Greases are the most common lubricant used in almost every machinery and equipment. Therefore, we must all experience common grease-related issues like clogs and overflow. Sometimes, when we attempt to start our car’s engine, it gives us trouble. Even after several tries, it still doesn’t cooperate. We don’t know the cause of these troubles and also the solutions. If your grease’s health is not up to the mark, such situations can occur frequently. Here, we are discussing the common grease-related issues and offering some practical solutions to avoid these problems.

Common Grease Related Issues 

Many grease-related problems can hinder the smooth operation of your machinery and equipment. Being aware of these problems can help you to take proper care of your grease lubrication system. Referring to your grease supplier’s suggestions about grease maintenance will also reduce the chances that these problems may occur. There are mainly three grease lubrication issues that you should avoid for the better health of your bearings.

Many grease-related problems can hinder the smooth operation of your machinery and equipment. Being aware of these problems can help you to take proper care of your grease lubrication system. Referring to your grease supplier’s suggestions about grease maintenance will also reduce the chances that these problems may occur. There are mainly three grease lubrication issues that you should avoid for the better health of your bearings.

1. Clogs – There are three lines in a grease trap; the incoming line, the outgoing line, and the crossover line. Certainly, the clogs occur in one of these lines. Clogs usually happen when dust, debris, or any other contaminants accumulate in any of these lines and prevent them from functioning properly. Sometimes, grease itself solidifies and is deposited in these lines. This will also become the cause of the clog.
A full cleaning of your grease can solve the issue of clogging. If the deposition of contaminants is hard and severe, you can adopt methods like hydrojetting. And following a regular grease flush and plumbing will help you to prevent contamination in the future.

2.Overflow – Sometimes, your grease lubrication system can overflow and create a huge mess in your machinery. And the mess will get worse until you fix the problem. It mainly occurs when excess grease accumulates, surpassing the system’s capacity. The improper setting of lubrication intervals and quantity can lead to overflow of the grease. Overflow can cause several damages to the machine or equipment including increased friction, heat generation, leakage, and contamination. 

Adhering to a proper grease maintenance schedule will help to prevent grease overflow. Following your grease manufacturer’s or grease supplier’s recommendations about lubrication maintenance can also prevent the overflow-related issues of your machinery. 

Identifying and Resolving Grease Contamination

One of the primary challenges faced by machines or equipment that use grease as their lubricant is its contamination. The contaminants that accumulate in grease change from dust, and debris to water and other chemicals. Therefore, detecting and resolving grease contamination at an early stage is crucial for the optimal performance of your machinery. 

Improper storage, handling, or faulty seals are the most common sources of contamination. A frequent inspection and regular grease analysis can help you in the early detection of these problems and resolve them accordingly. You can identify the contamination by discoloration, foul odour, change in texture, and the presence of foreign particles in the grease. 

Grease contamination can occur in several ways. Therefore, the preventive measure also involves several steps. The primary step is identifying and eliminating the source of contamination. Analyzing the storage conditions, making sure the seals are in good connection, and finding equipment problems can ensure the prevention of further contamination. After the inspection and elimination, cleaning the lubrication system and other components is a must. Then, refill the contaminated grease with fresh and clean grease. 

Opting for superior quality greases and following grease supplier’s recommendations are also considered preventive measures. Installing effective seals, regular grease maintenance checks, and adopting novel grease storage technologies will also prevent contamination.

Dealing with Grease Separation Issues

Grease separation causes potential damage to the machinery resulting in the decreased lifespan of your bearings. Grease separation, also known as oil bleeding, is the state, where the lubricating oil will separate from the thickening agents leaving a dry and ineffective lubricant. Oil bleeding mostly arises due to the improper formulation of greases, higher temperature conditions, and prolonged grease storage. 

Choosing higher-quality greases with the correct formulation is crucial for the efficient performance of the grease. Selecting greases that align with your operating conditions and specific applications can prevent the oil bleeding at a certain level. Water contamination is another reason for the grease separation. The accumulation of water in grease leads to emulsion formation resulting in compromised grease consistency. Regular inspections can prevent the ingress of water.

If you’re storing your grease in higher temperature conditions, it can result in its oxidation, leading to grease separation. Prolonged storage or usage can also be the reason behind the oxidation. Opting for greases with good quality anti-oxidants will be a better solution for this issue. 

Regular inspections will help you to find the oil bleeding in the early stage. But once the oil bleeding is confirmed, you can resolve it by stirring and agitating. But these are temporary solutions for oil bleeding. As a long-term solution, you can consult your grease supplier to find grease with suitable formulations for your machinery and equipment. 

Regular inspections will help you to find the oil bleeding in the early stage. But once the oil bleeding is confirmed, you can resolve it by stirring and agitating. But these are temporary solutions for oil bleeding. As a long-term solution, you can consult your grease supplier to find grease with suitable formulations for your machinery and equipment. 

Solving Overheating Problems Caused By Grease

Overheating is a common concern when it comes to the operation of machinery and equipment. There are several reasons for overheating but it can often be traced back to grease-related issues. However, if you’re planning to troubleshoot grease-related issues, then you cannot overlook the overheating problems of machines. 

Improper greasing, overgreasing, or undergreasing are the most common causes of overheating in machinery. Selecting non-suitable grease also can lead to friction, wear, and overheating. Therefore, selecting a suitable grease, regular checks, and adequate maintenance are crucial for preventing overheating in the machinery. 

Always remember to apply only a sufficient amount of grease to your machine. If you’re bearing is working in extremely high temperature conditions, then go for lubricants with excellent heat resistant properties. Consulting your grease manufacturer will help you to identify greases that can withstand elevated temperatures. 

After all, these troubleshooting tips are for controllable grease-related issues. If your machinery is experiencing severe grease–related problems, it is better to consult an expert like a grease manufacturer or grease supplier. You can even refer to the equipment manufacturer’s manual. Troubleshooting grease issues involves several steps and activities. However, the core practices for ensuring a trouble-free, effective, and longer machinery life include regular maintenance and proper grease selection. Therefore, always focus on these practices for a smoother and more efficient machinery operation.

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