Troubleshooting
Progressive Grease Systems: Avoiding Pressure Relief Valve Issues When a progressive grease system starts pushing grease out of the pressure relief valve, it's often a sign that something has gone wrong—most likely a blockage in the distribution line or contamination inside the block assembly. These issues lead to high pressure building up in the system, which can cause inefficient lubrication, damage to components, or even system failure. Properly diagnosing and fixing these problems can save time, reduce downtime, and keep your equipment running smoothly. A series progressive distribution block relies on the lubricant moving spool valves (pistons) in the block sections in a specific series to move the lubricant out of the block segment into the distribution line and out to the bearing. At LSL, we’ve seen many customers struggle with high pressure in their grease systems, and we’ve helped them resolve these issues by guiding them through a systematic troubleshooting process. To make it easy, we’ve put together this step-by-step troubleshooting guide that focuses on the most common causes of high pressure in progressive grease systems, along with practical solutions to fix the issue. Step-by-Step Guide: Troubleshooting High Pressure in a Progressive Grease System We understand your time is valuable, so here’s a quick reference table to help you locate and resolve blockages in your grease system.
Common Issues Explained In progressive grease systems, high pressure often indicates that a blockage is preventing the lubricant from moving through the system. This can happen in two main areas: at the end of a distribution line or inside the progressive block assembly itself. Here’s how to handle each situation: .
These types of blockages are usually caused by a broken line being capped after it has been broken in some manner. This is done because of the thought that the entire reservoir of grease may be pumped out of the broken line. With a series progressive type system (or a Parallel system such as the Groeneveld Singleline or Twin) a broken line will only lose the amount of grease designated to that line, all of the other points will get there designated amount of grease. If a broken line will cause an environmental hazard you can cable-tie a bag over the end of the broken line to collect the grease until the line can be repaired. Another rare cause of a blockage can be a crushed steel line or a rotated bushing, blocking the grease access hole.
To locate the blockage use the following procedure. When you loosened the inlet line there was a high pressure rush of grease out of the fitting indicating high pressure in the block assembly. Re-tighten the inlet line and press the extra lube button to start the pump and bring the system back up to pressure relief or fit a grease nipple to the inlet port of the block and pressurise with a manual grease gun. Then loosen each of the lines on the side of the block starting with the top left side. If you loosen all of the lines and no pressure is found then the blockage is inside of the block assembly, go to (Blockages inside of a Block Assembly). If you loosen a line on the outlet side of the block and you have pressure at that line, the blockage is at the bearing side of the line. Consult a block schematic or trace the line to locate the bearing end of the line and find out what is causing the blockage. Correct the line blockage then make sure that all lines are tight at the block, then press the extra lube button at the pump and test the system to make sure that there are no other blockages.
Blockages inside of Series Progressive Blocks are mainly caused by contamination in the grease. Particles as small as dust, that are blown into an open reservoir lid can cause an enormous amount of trouble. Grease Lubrication Systems should be treated with the same care as a hydraulic system. In-line filters are available and can be purchased for your system if contamination is a great concern.
To locate a blockage inside a block assembly use the following procedure. When you loosened the inlet line at the block assembly there was a high pressure rush of grease out of the fitting indicating high pressure in the block assembly. Re-tighten the inlet line and press the extra lube button to start the pump and bring the system back up to pressure relief or fit a grease nipple to the inlet port of the block and pressurise with a manual grease gun. Then loosen each of the lines on the side of the block starting with the top left side. If there is no pressure at any of the lines you have determined that the blockage is in the block assembly. After marking the lines to ensure that they are re-connected to the same outlets, remove the distribution lines and clean the block assembly. Remove the plugs (or caps) on both sides of the block to give access to the spool valves. Use the back end of a small drill to press the spool of each block segment back and forth until you locate the spool that is stuck. By pressing back and forth you may be able to free the spool and dislodge the piece of contamination. Even though you may be successful at freeing the spool you will want to order and replace the block segment that had the seized spool. It has been our experience that once a spool has seized it will do so again from the scoring of the spool. If you remove the spools from the block segment be sure to keep them in order and replace them into the same block segment. Each of the spools has been hand honed to that specific block segment even if they are the same number value.
Once repairs are made, running the system through a series of test cycles ensures that all blockages have been resolved and the system is lubricating as intended. We hope this guide helps you troubleshoot your progressive grease system and resolve high-pressure issues quickly. By following these steps, you can save time, reduce equipment downtime, and keep your system running smoothly. If you’re still experiencing issues or need parts and service, don’t hesitate to reach out to us at LSL. Our team of experts is here to help you keep your lubrication systems in top shape, ensuring your machinery runs efficiently with minimal interruptions. Contact us today—we’re always ready to assist! |
Trouble Shooting a Progressive Grease System