An automatic lubrication system is a pump, a controller, a network of lines and a set of distributor blocks that divide the grease between the points. The pump almost never fails silently; the parts that do are the distributor blocks, the lines and the grease itself. In a progressive system one blocked outlet stops the whole block cycling, so every point downstream of it starves while the pump continues to run and the reservoir continues to fall. That is why the service check is not a level check: it is a count of pump cycles against the controller, a look at the indicator pins on each distributor, and an inspection of every line for chafe, crush and heat damage. Points that need grease by hand between services are the ones the system is not reaching.
What you will notice
| Symptom | What it usually points to |
|---|---|
| Reservoir empties faster than the interval predicts | Grease is going somewhere. A burst line under the machine or a distributor dumping through a failed seal is the usual answer. |
| One group of pins wears while the rest are fine | A distributor block has stopped cycling, so every point it feeds is dry. Grease on the outside of the joint proves nothing. |
| Controller shows a fault or a cycle count that has stopped rising | The pump is not running: supply, pressure switch, motor or controller. Nothing downstream is being lubricated while it shows this. |
| Grease weeping from a distributor or a hose end | A seal or a fitting has failed, which drops system pressure and starves the points beyond it. |
| Joints squealing in cold weather only | Grease that is too stiff for the line diameter and the temperature. The pump cannot push it and the distributor cannot cycle. |
Most likely causes
| Cause | How to confirm it |
|---|---|
| Blocked or crushed grease line | The most common single fault. A line pinched against the frame, hardened at a hot manifold or plugged at a fitting stops its point and, in a progressive block, everything after it. |
| Failed distributor block | Wear or contamination stops the piston from cycling. The indicator pin stops moving and the block's outlets receive nothing. |
| Air in the system after a reservoir ran dry | The pump compresses air instead of grease and the cycle count looks normal while nothing is delivered. Purge at the furthest point until solid grease appears. |
| Incompatible grease mixed in the reservoir | Two thickener types can thicken into a gel that will not pass a line. The system then blocks progressively from the pump outward. |
| Controller settings wrong for the ambient temperature | Cycle time and pump run time set for a warm climate deliver too little in winter and the fault looks mechanical. |
Diagnosing by where the grease stops
| What you find | What it means |
|---|---|
| No grease at any point, pump not cycling | Electrical or controller fault. Nothing downstream is being lubricated. |
| No grease at any point, pump cycling | Air lock, empty reservoir or a blocked main line at the pump outlet. |
| One block's pin not moving | That block is blocked or worn. All of its points are dry. |
| Block cycles, one point dry | The line or the fitting to that point. Trace and clear it. |
| Grease at the surface but the pin still dry | The point is accepting grease around a worn fitting instead of into the joint. Replace the fitting. |
How to confirm it
- Compare cycles against the controller's own record
Most controllers log cycle count or fault codes. A count that has not moved since the last service means the pump is not running, and the fault is electrical: supply, fuse, pressure switch or motor. Check that before looking at any hydraulic or mechanical cause.
- Watch each distributor block cycle
With the pump commanded to run, watch the indicator pin on every block. Each block must complete a full cycle and the pin must return. A pin that does not move identifies the blocked block, and the point it feeds is the place to start looking for the obstruction.
- Inspect every line end to end
Follow each line by hand and eye from the block to the point: chafe against a frame, crush at a clamp, hardening near the exhaust, a fitting that has been cross-threaded. A line that has been replaced with a longer one and looped has a trap where grease will separate.
- Test delivery at the furthest point
Disconnect at the most distant fitting, run a cycle and confirm grease arrives. This single test separates a pump and distributor problem from a line problem, and it is the test most often skipped because it means lying under the machine.
- Purge the system after any interruption
After a reservoir has run dry or a line has been opened, run cycles until solid grease appears at every furthest point. Air in a grease system does not clear itself and the controller will happily report cycles that delivered nothing.
- Confirm the grease grade suits the season and the lines
Use one product family across the machine and change to the grade the manual specifies for low ambient. Record what went in and when, because a mixed reservoir is a blockage waiting for the first cold morning.
What to do about it
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Parts you may need, by grade
| Part | Grades commonly quoted |
|---|---|
| Distributor blocks | Genuine or OEM-quality with the same outlet count and division ratio. A block with the wrong ratio starves the points that need the most grease. |
| Grease lines and fittings | OEM-quality to the original diameter and pressure rating. Line diameter is part of the system design, not a convenience. |
| Pump assembly and controller | Genuine or OEM-quality matched to the system voltage and reservoir size. Controller settings must be transferred, not assumed. |
Need the parts this covers?
Send the machine model, serial number and the part numbers you need. We confirm fitment before payment and state the grade of every line — genuine, OEM-quality or aftermarket.
Request a quoteFrequently asked
How do I know the auto-lube system is actually working?
Cycle count plus indicator pins plus one physical delivery test at the furthest point. The reservoir falling proves only that grease left the pump, and a progressive block that has stopped cycling will let the pump run and the reservoir fall while every point it serves runs dry.
Can I grease the machine by hand as well as with the system?
Yes, and on many machines it is the right thing to do at the points the system does not reach, but do not over-grease a sealed joint that the system is already feeding: excess grease blows the seal and takes the grease with it. The better fix is finding why the system is not reaching that point.
Why does the system fail in cold weather?
Grease stiffness rises sharply as temperature falls, and the pump and the blocks were sized for a warmer figure. Use the low-temperature grade the manual specifies, keep lines away from cold frame members where they harden, and check the controller's cycle settings for the season.