Obtain the Right Tools
To develop the program, acquiring the right equipment was essential. Flexible extensions were necessary for grease fittings that were difficult to reach with hard extensions.
Each Car Lift Repair Orlando grease gun was equipped with an SKF grease meter and a pressure gauge to accurately measure the grease and identify any line blockages (Figure 1).
Manual Grease Gun with Grease Meter
Manual Grease Gun with Grease Meter and Pressure Gauge
Additional equipment included a ladder, nipple kit, toolbox, customized grease gun carry bag (for ladder climbing), air compressor, hose reels with a grease pump, and digital grease guns.
The facility contains numerous large Car Lift Repair Orlando high-voltage drives (3,500 kilowatts), each requiring up to 200 grams of grease per month in each bearing. To streamline the greasing process, an air-powered digital grease gun was chosen for its ability to measure the grease amount. The grease pump and drum were contained in a separate compartment to prevent contamination in the dusty environment (Figure 2).
Grease Drum and Pump Compartment
Grease Drum and Pump Compartment
High-strength industrial rubber seals were used to minimize dust intake. A specialized trailer/skid (Figure 3) was designed in collaboration with Cooper-Standard Automotive Australia Tecalemit.
Greasing Trailer/Skid
Greasing Trailer/Skid
The trailer’s top skid could be unclipped, lifted off the frame, and placed on the back of a four-wheel-drive utility car for field-greasing applications. Weight and size restrictions were critical factors in the Car Lift Repair Orlando design.
The final design, optimized for weight and space, weighed 700 kg and measured 1,500 mm x 1,000 mm x 1,000 mm. Features included a roof rack for extra storage, hinged doors with industrial seals, gas struts for the rear service door, skid with forklift access, silent block mounts for compressor vibration dampening, a fuel fill point on top of the skid, and support legs.
5. Training
The final implementation step involved training personnel responsible for maintaining the Car Lift Repair Orlando program. This training, both practical and theoretical, was conducted by the lubricant supplier in cooperation with the equipment supplier and involved company staff to promote ownership and responsibility.
The training covered all theoretical aspects of grease application, with special attention to safety and troubleshooting. Job plans were validated during the training, using and updating actual job plans in the gas plant.
Training included a plant walk to identify safety concerns, such as exposed rotating shafts, faulty connections, incorrect grease applications, noisy or high-vibration equipment, and errors within job plans. Trainees integrated theory and practical knowledge, noting:
– Faulty connections to a gas engine cooling fan, preventing failure.
– Missing safety barriers around high-speed shafts, which could cause injury.
– High noise and vibration issues on critical electric motors, highlighting maintenance needs.
– High-pressure readings indicating blockage problems.
– Incompatible grease applications requiring line flushing.
These steps were crucial in creating an error-free program and facilitating a smooth handover to site staff.
Implementation
Developing and implementing the program took approximately six months and significant financial investment. Despite the costs, the benefits were substantial, ensuring a cost-effective and productive facility. The program quickly demonstrated its value by eliminating reactive maintenance due to grease-related failures, reducing operating costs.
End users were involved throughout the development stages, providing valuable input and ensuring strong support for the program. Their experience and ownership were key to the program’s success.
Responsibility for the program was recently transferred to the site maintenance supervisor, who now updates the program with new equipment, regularly inspects grease equipment, ensures the completion of job plans, and strives for continuous improvement.
This Car Lift Repair Orlando formal greasing program has significantly reduced equipment failures and maintenance costs. It was well-received by all staff and has become integral to the optimized operation of the Santos gas plant, serving as a model for lubrication program development at other company locations.
Exercise caution and prioritize safety when working around moving equipment and using a grease gun, especially near the shaft area.
When loading grease into the grease gun, take care to avoid introducing contaminants. If using a cartridge, be cautious when removing the metal lid to prevent metal slivers from entering the grease.
Ensure the dispensing nozzle of the grease gun is clean before use.
Verify that the grease drain (hole at the bottom of the grease box) is clear and unobstructed.
Clean dirt from all grease fittings before attaching the grease gun. Inspect and replace any damaged fittings. Clean the grease fitting again after applying grease.
Always use the correct type of grease at each grease point. Using the wrong grease can cause incompatibility issues that may quickly lead to bearing failure.
Do not rush the Car Lift Repair Orlando grease application process. Apply grease with constant force to avoid oil bleeding in the feed line. If applied too quickly, grease will leak at the labyrinth seals due to excessive pressure. After injecting every 15 grams of grease, wait 20 seconds before injecting the next supply. The newly injected grease pushes the used grease to the slinger ring, which expels it into the grease box.
Note: Only inject the full specified amount once the motor is running again. Do not close the work order until this is completed.
When finished, remove any excess grease from the area.
Regularly calibrate grease guns to ensure proper delivery volume.
Store grease guns unpressurized in a clean, cool, dry area and in a horizontal position to prevent oil from bleeding out of the grease. Cover the coupler to keep it free from dirt and contaminants.
Car Lift Repair Orlando Hydraulics will allow you to do so many things that you simply can’t do with your hands or conventional tools. Just like any workshop environment, you must strictly adhere to all safety precautions when working around hydraulics. Small oversights or falling into complacency can lead to serious physical injuries or even death for you, a team member, or the entire shop. Please do not skimp on reading and having your entire staff read and sign off on all the safety rules and regulations set forth by your manufacturer’s safety portion of their manuals. Have fun!