Automatic Grease Lubrication Solutions - Dean Industrial
Automatic Grease Lubrication Solutions - Dean Industrial
Automatic Grease Lubrication Solutions - Dean Industrial
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<strong>Automatic</strong> <strong>Grease</strong> <strong>Lubrication</strong> Systems<br />
for the Solid Waste Industry
<strong>Automatic</strong> <strong>Grease</strong> <strong>Lubrication</strong> <strong>Solutions</strong><br />
• Purpose<br />
– Benefits of <strong>Automatic</strong> Lube Technology and the use<br />
of #2 Grade <strong>Grease</strong>!<br />
– How these systems provide value!<br />
– Proper Installation is the key!<br />
– Lincoln’s superior customer support network!
<strong>Automatic</strong> <strong>Grease</strong> <strong>Lubrication</strong> <strong>Solutions</strong><br />
• Based in St. Louis, Mo. since 1910<br />
• Four plants worldwide<br />
• World leader in grease lubrication<br />
dispensing systems
<strong>Automatic</strong> <strong>Grease</strong> <strong>Lubrication</strong> <strong>Solutions</strong><br />
On the road or in<br />
the field, Lincoln<br />
helps Industry<br />
by protecting their<br />
Mobile equipment<br />
investment<br />
• Over-The-Road Trucking<br />
• Off Road<br />
• Agricultural Equipment<br />
• Mining<br />
• Construction<br />
• Solid Waste<br />
• Military<br />
• Municipal
<strong>Automatic</strong> <strong>Grease</strong> <strong>Lubrication</strong> <strong>Solutions</strong><br />
Why use Automated <strong>Lubrication</strong> Systems?<br />
Daily lubrication is a “required<br />
maintenance practice” that’s vital<br />
to the life of pins and bushings<br />
Automated systems lubricate while<br />
the machine is in motion
Why use Automated <strong>Lubrication</strong> Systems<br />
Poor lubrication<br />
methods cause<br />
premature component<br />
failure<br />
Improper lubrication on landfill equipment can<br />
negatively impact productivity and increase<br />
maintenance costs… line boring can be as<br />
high as $2,500 per bushing
<strong>Automatic</strong> <strong>Grease</strong> <strong>Lubrication</strong> <strong>Solutions</strong><br />
Poor lubrication methods cause<br />
premature component failure with<br />
• slack adjusters<br />
• king pins<br />
• steering drag links<br />
• brake cams<br />
• shackle pins<br />
resulting in equipment downtime and<br />
high repair costs
<strong>Automatic</strong> <strong>Grease</strong> <strong>Lubrication</strong> <strong>Solutions</strong><br />
Why is a Heavy Body #2 Grade <strong>Grease</strong> important?<br />
Pins and bearings that are<br />
subject to high load or high<br />
duty cycle benefit from a<br />
heavy body #2 Grade <strong>Grease</strong>
<strong>Automatic</strong> <strong>Grease</strong> <strong>Lubrication</strong> <strong>Solutions</strong><br />
Choosing the right lubricant is important!<br />
#2 <strong>Grease</strong> acts as a<br />
constant seal, keeping out<br />
contamination<br />
Note: Competitive systems promote the use of<br />
heavy oil/fluid grease (00 to 000) as the lubricant<br />
These products have a tendency to run out of the<br />
bearing when faced with vibration, load, and motion,<br />
leading to environmental problems and lubricant<br />
waste.
<strong>Automatic</strong> <strong>Grease</strong> <strong>Lubrication</strong> <strong>Solutions</strong><br />
Why is a Heavy Body Lubricant important?<br />
Most major component manufacturers and lubricant formulators will<br />
recommend a heavy body grease for protection against:<br />
• High Load<br />
• Contamination<br />
• Water/Moisture<br />
NLGI <strong>Grease</strong> Viscosity Index Comparison – Heavy to Lightest Viscosity Range<br />
#2 - Heavier Body<br />
#1 - Heavy Body<br />
#0 - Light Body<br />
#00 - Lighter Body<br />
#000 - Lightest Body
<strong>Automatic</strong> <strong>Grease</strong> <strong>Lubrication</strong> <strong>Solutions</strong><br />
#1 or #2 Heavy Body Grade <strong>Grease</strong> offers the following<br />
advantages over #0, 00, or 000 fluid grease<br />
• Use up to three times less grease – acts as a grease seal<br />
• Designed to perform under high load bearing applications<br />
• Won't "drip" lubricant in high ambient temperature locations
Why Pins and Bushings Fail...<br />
In a study conducted by a major bearing manufacturer,<br />
over 50% of failures are the result of improper lubrication.<br />
Storage and Handling<br />
Errors (2.8%)<br />
Other (18.6%)<br />
Inadequate<br />
<strong>Lubrication</strong> (34.4%)<br />
Overload (6.9%)<br />
<strong>Lubrication</strong> Related<br />
Failures: 54%<br />
Installation Errors (17.7%)<br />
Contamination (19.6%)
<strong>Automatic</strong> <strong>Grease</strong> <strong>Lubrication</strong> <strong>Solutions</strong><br />
COMPARISON OF MANUAL AND AUTOMATED LUBRICATION<br />
Manual lubrication<br />
Automated lubrication<br />
Too much lubricant - wasted lubricant - messy<br />
- excess lubricant contaminates environment -<br />
excess lubricant creates additional heat in<br />
bearing<br />
Just the right amount of lubricant - maintains<br />
lubricant film - maintains positive lubricant<br />
seal to bearing<br />
Too little lubricant - lubricant film breakdown<br />
allows bearing wear - loss of lubricant seal<br />
allows contamination to enter bearing<br />
Metal to metal contact - severe bearing damage<br />
<strong>Lubrication</strong> intervals (weeks)<br />
<strong>Lubrication</strong> intervals (hours)
Automated <strong>Lubrication</strong> <strong>Solutions</strong> for #2 Grade <strong>Grease</strong><br />
Primary supply<br />
line<br />
Master Divider<br />
Valve<br />
Secondary Divider<br />
Valves<br />
Feed line<br />
Lincoln<br />
203 Pump<br />
w/Integrated<br />
Controller<br />
System operation<br />
1) The pump is actuated automatically by an adjustable on/off controller.<br />
2) The #2 Grade <strong>Grease</strong> is delivered to the divider valves through the supply line.<br />
3) The divider valve dispenses lubricant in measured amounts directly to the<br />
bearing through the feed line. Visual indication of cycle pin assures that all<br />
points are lubricated.
Quicklub® values ensure the right amount grease is delivered<br />
to each bearing point according to their requirements<br />
Quick plug in<br />
connections<br />
throughout entire<br />
system, up to 5,000<br />
psi<br />
No replacement<br />
errors possible<br />
Precision piston tolerances<br />
ensure exact amounts of grease<br />
are delivered to each bearing<br />
Proximity switch<br />
sends signal back to<br />
pump when valve<br />
has completed cycle<br />
High pressure<br />
feedline hose - 4,000<br />
psi<br />
Proper system<br />
function is monitored<br />
by a proximity switch<br />
-22°F to +212°F<br />
Operating Temperature<br />
No gaskets or O rings to<br />
leak
<strong>Automatic</strong> <strong>Grease</strong> <strong>Lubrication</strong> <strong>Solutions</strong><br />
• Pumps have 2, 4, or 8 liter reservoirs<br />
• Capable of handling #2 <strong>Grease</strong><br />
• Optional low-level and system operation<br />
alarm indicators on dashboard<br />
• Reservoir can be refilled through a grease<br />
fitting to prevent contamination<br />
• High pressure capability to ensure grease is<br />
delivered to each bearing<br />
• System can detect a blocked lube point<br />
• Optional electronic control and monitoring<br />
functions can communicate with the<br />
machine's onboard computer to integrate<br />
lubrication into the onboard service and<br />
status monitoring system<br />
Lighted push button<br />
mounted in the cab<br />
flashes when lubricant<br />
reservoir is low or if the<br />
system needs service
Installation Techniques - Refuse Bodies<br />
Use of guarding to protect lube<br />
lines and fittings
Installation Techniques – Refuse Body Side Arm<br />
<strong>Grease</strong> lines run with hydraulic<br />
lines and out of the way of<br />
impact zones<br />
Manual grease fitting<br />
override feature<br />
Guarding for hoses, divider<br />
blocks and valves
Typical On-Road Chassis Installation<br />
<strong>Automatic</strong> System Operation<br />
• The electric pump feeds a primary valve which distributes lubricant to four secondary valves that<br />
deliver the grease to each bearing/bushing<br />
• The pump operates on a timed basis, typically set to operate every six hours for six minutes
Installation<br />
<strong>Grease</strong> lines are<br />
armored to<br />
minimize<br />
exposure to<br />
road hazards<br />
Valve Block<br />
installed on<br />
chassis frame
Landfill Machines
Installation Techniques – Wheel Loader<br />
• Feed lines are protected<br />
in high impact zones with<br />
metal guarding<br />
• Note the grease sealing<br />
the pins, which keeps out<br />
contamination
Installation Techniques - Landfill Equipment<br />
Articulating End Dumps
Installation Techniques - Excavators<br />
• A Quicklub® metering valve located on the<br />
“H” link is guarded with a 3/8” steel plate.<br />
• Pump is typically located in the in the<br />
engine compartment or behind the cab.<br />
• Lube Lines are well protected.
Key OEM Accounts<br />
Some Major Equipment Manufacturers who offer Lincoln<br />
Lube Systems as OEM or Authorized Dealer Supplied<br />
Caterpillar<br />
Al Jon<br />
Bomag<br />
LaBrie<br />
Heil<br />
International<br />
Oshkosh<br />
McNeilus<br />
Komatsu<br />
Terex<br />
Mack<br />
Peterbilt
<strong>Automatic</strong> <strong>Grease</strong> <strong>Lubrication</strong> <strong>Solutions</strong><br />
Return on Investment – <strong>Automatic</strong> Side Arm<br />
Average annual costs<br />
– Manual labor cost to lubricate side arm<br />
(one man, 20 minutes/day, 6 days/week, $25.00 hr.) $ 2,600.00<br />
– Cost of rebuilt (labor and materials) side arm due to normal wear 4,333.00<br />
(assumes total $13,000 replacement cost and in service for three years)*<br />
Average annual savings<br />
Total yearly lubrication related costs $ 6,983.00<br />
– Manual Labor is eliminated by 90% $ 2, 340.00<br />
– Reduction in repair costs by 50% 2, 166.00<br />
Total yearly savings with auto lube $ 4, 506.00<br />
* $13,000 replacement cost could occur within first year if lubrication is neglected
<strong>Automatic</strong> <strong>Grease</strong> <strong>Lubrication</strong> <strong>Solutions</strong><br />
Return on Investment – <strong>Automatic</strong> Side Arm<br />
• System cost and return on investment<br />
– Average Field Installed Quicklub® System Cost : $ 4,000.00<br />
• Return on Investment with Labor<br />
System Cost X 12 Months = R.O.I.<br />
Annual Savings<br />
$ 4,000.00 X 12 Months = 11 Months Pay Back<br />
$ 4,506.00
Return On Investment Data – Landfill Equipment<br />
Annual costs to manually lubricate equipment<br />
Labor<br />
30 minutes per 8 Hr. shift<br />
X $ 20/ Hour X 250 days $2,500.00<br />
Lost Production<br />
30 minutes per 8 Hr. shift<br />
X $75 / Hour X 250 days $9,375.00<br />
Manual <strong>Lubrication</strong> Cost $11,875.00<br />
Annual costs to repair failed components<br />
Replacement Pins and Bushings<br />
2 Pins X $400.00 Each $ 800.00<br />
Repair Labor<br />
One Person X $45.00 X<br />
2 Repairs X 6 Hours Each $ 540.00<br />
Lost Production<br />
2 Repairs X 6 Hours Ea. X $75.00/HR. $ 900.00<br />
Repair Cost $2,240.00<br />
Total Annual Manual <strong>Lubrication</strong> Cost: $14,115.00
Estimated Savings with <strong>Automatic</strong> <strong>Lubrication</strong><br />
System – Landfill Equipment<br />
Savings Factor<br />
Savings<br />
Labor and Lost 95% $ 11,281.00<br />
Production to<br />
Manually Lubricate<br />
Parts, Labor and Lost 50% $ 1,120.00<br />
Production to Repair<br />
Failed Components<br />
Total Annual Savings $ 12,401.00<br />
System Cost and Return on Investment<br />
Typical Installed Quicklub® System Cost (excavator) $ 6,000.00<br />
Return on Investment<br />
System Cost X 12 Months = R.O.I.<br />
Annual Savings<br />
$ 6,000.00 X 12 Months = 6 Months Pay Back<br />
$12,401.00
<strong>Automatic</strong> <strong>Grease</strong> <strong>Lubrication</strong> <strong>Solutions</strong><br />
Return on Investment – Class 8 Tractor<br />
Manual <strong>Lubrication</strong> Costs<br />
• Cost of Manual Lube over 5 yrs. $ 1,200.00<br />
• Component replacement costs, 5 yrs. 11,860.00<br />
King Pins Total Cost $ 13, 060.00<br />
Tie Rod Ends<br />
Steering Drag Links<br />
Slack Adjusters<br />
Brake Cams<br />
Spring Pins<br />
Savings due elimination of manual labor and reduction of replacement parts<br />
• 75 % Savings factor per year $ 1,659.00<br />
System cost<br />
• Assume System Cost of $2,000 (32 points)<br />
• $2,000/$1,659 x 12 months = Payback 14 month payback
Why Automated <strong>Lubrication</strong> Systems<br />
are a good investment!<br />
• Increase daily productivity by lubricating “on the fly”<br />
• Increase bushing and bearing life - The cost to replace one pin and<br />
bushing can pay for a Quicklub® System<br />
• Reduce labor repair costs and downtime<br />
• Reduce labor for lubrication by up to 95%<br />
• Increase machine reliability<br />
• No more safety issues in reaching inaccessible lubrication points
Lincoln Distributor Network<br />
Unmatched in the Industry -<br />
More than 100+ service and parts<br />
centers located across North America<br />
• Stocking replacement<br />
parts center<br />
• Provides field, shop,<br />
service and installation<br />
services<br />
• Warranty service center
<strong>Automatic</strong> <strong>Grease</strong> <strong>Lubrication</strong> <strong>Solutions</strong><br />
2525 South East Ave<br />
Fresno, CA 93706<br />
Phone 559 233-4222<br />
Fax 559 233-7633<br />
info@deanindustrial.com<br />
www.deanindustrial.com<br />
“<strong>Lubrication</strong> Method Specialists”
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