Troubleshooting Common Issues in Automatic Lubrication Systems

February 28, 2025
3 Minute Read

Automatic lubrication systems are designed to keep machinery running efficiently by ensuring a consistent supply of grease or oil to critical components. However, like any mechanical system, they can experience issues that require troubleshooting. Below, we cover some of the most common problems, their potential causes, and solutions to keep your system operating smoothly.

1. The Pump Isn't Dispensing Lubricant

Possible Causes

Empty or low lubricant reservoir
Clogged lines or fittings
Airlock in the pump
Power supply issues

Solutions

Check the lubricant level and refill if necessary
Inspect lines and fittings for blockages and clean as needed
Bleed air from the system following the manufacturer’s instructions
Verify power connections and ensure the pump is receiving the correct voltage

For pump-specific troubleshooting, refer to our Graco and Lincoln Troubleshooting Guide.

2. Too Much or Too Little is Being Dispensed

Possible Causes

Incorrect pressure or metering valve settings
Clogged or damaged metering valves
Worn-out pump seals or components

Solutions

Adjust the system settings to match the manufacturer’s recommendations
Inspect metering valves for blockages or wear and replace if needed
Check for leaks in the system that may be affecting pressure

3. System is Leaking Lubricant

Possible Causes

Faulty or blocked injectors
Broken or disconnected tubing
Control unit failure

Solutions

Tighten all fittings and replace any damaged hoses
Ensure the reservoir is filled only to the recommended level
Reduce system pressure if it exceeds manufacturer specifications

4. System is Running but not Lubrication

Possible Causes

Faulty or blocked injectors
Broken or disconnected tubing
Control unit failure

Solutions

Test and replace any clogged injectors
Inspect tubing for damage or disconnection and repair as needed
If the control unit is unresponsive, check wiring and error messages, or reset it

5. The System is Making Unusual Noises

Possible Causes

Air trapped in the system
Contaminated lubricant
Worn-out pump or motor components

Solutions

Bleed the system to remove air pockets
Drain and replace the lubricant if contamination is suspected
Inspect the pump and motor for wear and replace parts as necessary

Preventive Maintenance Tips

To reduce the likelihood of system failures:
Regularly check lubricant levels and top off when necessary

Keep lines and fittings clean to prevent clogging
Perform routine system inspections and address small issues before they escalate
Follow manufacturer-recommended maintenance schedules

If your issue persists, check out our Graco and Lincoln Troubleshooting Guide for brand-specific solutions.