Greasing is the most basic and most frequently neglected maintenance task on heavy equipment. Missed grease points lead to dry bearings, seized pins and expensive component replacements that could have been avoided with 30 minutes of effort and a tube of grease.
This guide covers the full greasing procedure for excavators, loaders, dozers and similar mobile plant. The principles apply to most machines with zerk (grease nipple) fittings, but always check your OEM manual for the specific grease points, intervals and grease type for your model.
Before you start
Gather your grease gun (loaded with the correct cartridge), clean rags and PPE. Check the OEM manual for the grease specification. Most manufacturers call for a lithium-complex EP2 grease, but swing bearings, track adjusters and cold-climate applications may require different products.
Print or pull up the machine's grease point diagram from the manual. If your team uses a heavy equipment maintenance checklist, open it now so you can tick off each point as you go.
Step-by-step greasing procedure
1. Identify all grease points from the manual
The operator or service manual lists every grease point with a diagram. A typical 20-tonne excavator has 20 to 40 grease points across the boom, dipper, bucket linkage, swing bearing, track idlers and cab pivot. Map out a route so you work systematically and do not miss any.
2. Clean each grease fitting before connecting
Wipe dirt and debris from each zerk fitting with a clean rag before attaching the grease gun. This step is critical. Contaminated fittings push abrasive particles directly into the bearing, causing the exact damage you are trying to prevent.
- Replace any zerk fittings that are damaged, bent or seized
- Check that protective caps (if fitted) are in place after greasing
- Note any fittings that are hard to access for future reference
3. Attach the grease gun coupler
Press the grease gun coupler squarely onto the zerk until it locks. If using a pneumatic gun, set the pressure to the OEM-recommended level (often around 3,000-5,000 psi). A loose connection wastes grease and fails to pressurise the bearing properly.
4. Pump grease until fresh grease purges
Pump the handle steadily. Old, discoloured grease will exit the bearing seal first. Continue pumping until you see clean, fresh grease begin to purge. This confirms the new grease has displaced the old and fully packed the bearing. Stop as soon as fresh grease appears.
5. Wipe excess grease and move to the next point
Remove the coupler and wipe away any excess grease from the fitting and seal area. Leftover grease attracts dirt and can mask future leaks. Move to the next fitting and repeat the process.
6. Record the service in your maintenance log
Log the date, machine hours, operator name and any notes in your equipment maintenance log. Flag any fittings that did not accept grease (the passage may be blocked), any seized fittings that need replacement, or any abnormal grease colour (e.g. rust-coloured grease indicating water ingress).
Grease types and compatibility
| Grease type | Common use | Compatible with |
|---|---|---|
| Lithium-complex EP2 | General purpose, most grease points | Lithium, lithium-complex |
| Calcium sulphonate | Wet environments, marine, water resistance | Limited, check with manufacturer |
| Polyurea | Sealed-for-life bearings, electric motors | Polyurea only, not lithium |
| Molybdenum disulphide (moly) | High-load pins, swing bearings | Lithium-complex base compatible |
Never mix incompatible grease types. If you are unsure what is currently in the bearing, purge the old grease completely before switching products. Mixing lithium and polyurea, for example, can cause the grease to soften and lose its load-carrying ability.
Common mistakes to avoid
- Over-greasing: pumping past the point where fresh grease purges blows out seals and attracts contamination. Stop as soon as clean grease appears.
- Skipping hard-to-reach points: the fittings you cannot easily see are often the ones that fail first. Use extension hoses or needle adaptors for tight spaces.
- Not cleaning fittings: pushing dirt into a bearing with the grease gun defeats the purpose of the service.
- Wrong grease type: using general-purpose grease on a swing bearing that requires moly EP can lead to premature wear.
- No record-keeping: without a log, there is no way to prove the service was done or to track intervals accurately.
Greasing frequency by component
| Component | Typical interval | Notes |
|---|---|---|
| Bucket pins and bushes | Every 8-10 hours | High load, frequent movement |
| Boom and dipper pins | Every 8-10 hours | High load, constant cycling |
| Swing bearing | Every 50-100 hours | May require moly EP grease |
| Track idlers and rollers | Every 50-250 hours | Check OEM manual for sealed types |
| Door hinges and cab pivot | Every 250 hours | Low load, general-purpose grease |
Download a preventive maintenance schedule to set up interval-based reminders across your fleet.
Going digital with MapTrack
Tracking greasing across a fleet of 10 or more machines on paper is unreliable. With MapTrack, each machine carries a QR code label that operators scan to open the greasing checklist on their phone. The system records who serviced the machine, at what hours, and flags any points that were skipped or noted as faulty.
Managers get automated alerts when a machine is overdue for greasing, and the full service history is available in asset tracking for audits, warranty claims and resale documentation.
