120L/16 Gallon Pneumatic Grease Pump

Overview The 120L / 16 Gallon Pneumatic Grease Pump is a heavy-duty air-operated lubrication system designed for industrial maintenance environments requiring high-volume, high-pressure grease delivery. Mounted on a mobile cart and driven by standard workshop compressed air, this pump converts pneumatic pressure into hydraulic force through a 50:1 ratio mechanism, delivering up to 7,500 PSI at the pump and 10,000 PSI at the dispensing gun with booster. Engineered for 120 lb (55 kg) / 16-gallon standard grease drums, the system handles industrial lubricating greases up to NLGI Grade 2 consistency. The 13 ft high-pressure hose provides reach around large equipment without drum repositioning, while the mobile cart allows single-operator transport across factory floors, fleet bays, and construction sites. Available in 50:1 standard configuration with optional 55:1 and 60:1 ratios for higher viscosity or colder-temperature applications. Intermittent-duty and continuous-duty motor configurations are offered to match your operational intensity. Operating Principle The pump operates on pneumatic force amplification. Compressed air enters a large-bore air motor piston that acts on a small-diameter grease plunger. The differential cross-sectional area produces proportional pressure gain: Output Pressure = Air Supply PSI × Pump Ratio At the optimal air pressure of 87 PSI (6 bar), a 50:1 pump generates approximately 4,350 PSI at the discharge port. At maximum air input of 150 PSI, output reaches 7,500 PSI. A booster gun further amplifies this to 10,000 PSI for penetrating seized fittings and long hose runs. Technical Specifications Parameter Specification Container Size 120 lb / 16 gallon / 55 kg (standard drum) Pump Ratio 50:1 (standard); 55:1 and 60:1 (optional) Max Pump Pressure 7,500 PSI (517 bar) Max Gun Pressure 10,000 PSI (689 bar) with booster gun Air Pressure Range 60–150 PSI (4–10 bar) Optimal Air Pressure 87 PSI (6 bar) Air Consumption 120–165 L/min at 6–8 bar (4.2–5.8 SCFM) Grease Output Up to 16 oz/min (460 g/min) Grease Compatibility Up to NLGI Grade 2 Hose Length 13 ft (4 m) Hose Diameter 1/4 inch (6 mm) Air Inlet Connection 1/4″ NPT (Female) Grease Outlet Connection 1/4″ NPT (Female) Noise Level 77–92 dB during operation Materials of Construction Zinc, chrome-plated steel, brass, NBR seals, PTFE seals Minimum Compressor Size 3 CFM (0.08 m³/min) sustained output Pump Weight 4–8.4 kg (configuration dependent) Mounting Mobile cart with casters Duty Cycle Intermittent (standard); continuous (heavy-duty option) System Configurations Standard Intermittent-Duty System The standard configuration is optimized for workshop and fleet maintenance with periodic lubrication cycles. The air motor is rated for intermittent operation with cooldown intervals between extended use periods. Includes pump head, 13 ft hose, control gun, drum cover, follower plate, and mobile cart. Suitable for shops servicing 5–20 machines per shift. Continuous-Duty Heavy-Duty System Engineered for high-volume service bays, centralized lubrication supply, and production-line environments where the pump runs for extended periods without shutdown. Features hardened fluid section components, precision-ground bores, and a rebuildable air motor with standard service kits. The continuous-duty motor eliminates overheating and extends service intervals in demanding 24/7 operations. High-Pressure Booster Gun Option The booster gun accessory increases dispensing pressure from 7,500 PSI to 10,000 PSI. This is essential for penetrating corroded or seized grease fittings, forcing thick NLGI Grade 2 grease through long hose runs, and overcoming back-pressure in centralized divider valve systems. The booster mechanism uses an inline hydraulic intensifier that requires no additional air supply beyond the base pump. Key Engineering Advantages High Pressure Delivery: The 50:1 ratio generates sufficient pressure to force grease into tight bearings, sealed joints, and long supply lines where manual guns fail. High Flow Rate: At 16 oz/min (460 g/min), the pump delivers grease approximately 4 times faster than manual lever guns, reducing maintenance cycle time. Air-Powered Efficiency: The pneumatic motor eliminates operator fatigue and provides consistent output regardless of grease viscosity or temperature. Complete Penetration: High pressure forces grease into bearing cavities and fitting internals, displacing old lubricant and contaminants more effectively than low-pressure methods. Rugged Construction: Zinc and chrome-plated steel housing resists corrosion in workshop environments. Brass internal components and NBR/PTFE seals provide chemical compatibility with standard petroleum and synthetic greases. Mobility: The cart-mounted design with industrial casters allows single-operator positioning on rough concrete, gravel, and uneven factory floors. Extended Reach: The 13 ft high-pressure hose eliminates the need to reposition the drum when servicing large equipment such as excavators, presses, and conveyor systems. Low Maintenance: The pre-lubricated air motor requires no in-line oiler, reducing maintenance variables and preventing oil contamination of the grease supply. Applications by Industry Manufacturing and Production Used for lubricating production line equipment, conveyor bearings, assembly machinery, and stamping presses. The high flow rate supports preventive maintenance schedules in plants with high machine counts and limited maintenance windows. Automotive and Fleet Service Standard equipment in heavy-duty truck bays, bus depots, and fleet maintenance facilities. The pump services chassis lubrication points, wheel bearings, fifth wheels, and suspension components on commercial vehicles. The mobile cart allows movement between service bays. Construction and Heavy Equipment Specified for backhoes, bulldozers, cranes, loaders, and articulated trucks. The system operates in outdoor and semi-environments where electrical lubrication systems are impractical. The rugged cart and corrosion-resistant finish withstand dust, moisture, and temperature variation. Mining and Quarrying Used for drilling equipment, crushing machinery, conveyor systems, and loaders in abrasive environments. The sealed air motor and hardened plunger resist contamination from dust and particulate-laden greases common in mining operations. Agriculture Applied to tractors, harvesters, balers, and irrigation systems. The pump handles the thick, tacky greases required for agricultural equipment exposed to moisture, dust, and crop residue. The mobile cart allows transport between farm buildings and fields. Shipping and Material Handling Used in container yards, ports, and warehouses for forklifts, reach stackers, and loading equipment. The long hose provides access to elevated lubrication points without repositioning the drum. Compressor Requirements Proper compressor sizing is critical for reliable operation. The pump requires both adequate pressure (PSI) and sustained volume (CFM/SCFM) to prevent motor stall and short-cycling. Application Minimum Compressor Recommended Compressor Light intermittent use 3 HP, 60-gallon tank, 8 SCFM @ 90 PSI 5 HP, 80-gallon tank, 12 SCFM @ 90 PSI Standard shop duty 5 HP, 80-gallon tank, 12 SCFM @ 90 PSI 7.5 HP, 120-gallon tank, 16 SCFM @ 90 PSI Continuous/heavy duty 7.5 HP, 120-gallon tank, 16 SCFM @ 90 PSI 10 HP, 160-gallon tank, 22 SCFM @ 90 PSI Undersized compressors will run continuously without tank recovery, causing moisture accumulation in the air supply and accelerated motor wear. Install a coalescing filter and regulator upstream of the pump to remove moisture and particulate contamination. Installation and Operation Drum Mounting: Secure the pump to the drum lid via the bung adapter. Ensure the follower plate is seated squarely on the grease surface with no air gaps. An improperly seated follower plate causes cavitation and priming failure. Air Connection: Connect the 1/4″ NPT air inlet to a filtered, regulated compressed air supply. Set the regulator to 87 PSI (6 bar) for optimal performance. Do not exceed 150 PSI input pressure. Priming: Before connecting the hose and gun, cycle the pump with the discharge open to purge air from the fluid section. This prevents dry-running wear and ensures immediate grease delivery. Hose Handling: Route the 13 ft hose to avoid kinks and sharp bends. Use the integrated hose reel or hanger to prevent damage to the high-pressure braid. Do not drag the hose across abrasive surfaces. Pressure Adjustment: Increase air pressure for thick greases, cold environments, or long hose runs. Decrease pressure for thin greases or close-proximity dispensing to prevent fitting damage from over-pressurization. Maintenance: Inspect the follower plate seal and inlet check valve every 500 operating hours. Replace air motor seals at the first sign of grease contamination in the exhaust. The fluid section is rebuildable with standard seal kits. How to Order To receive an accurate quotation, please provide the following information: Pump ratio: 50:1, 55:1, or 60:1 Duty cycle: Intermittent or continuous Configuration: Pump-only or complete system kit (pump, hose, gun, cart, follower plate) Grease grade: NLGI 2 standard, or NLGI 3 (requires higher ratio confirmation) Operating environment temperature range Air compressor specifications: HP, tank size, sustained SCFM at operating pressure Required accessories: Booster gun, additional hose length, metering valve Quantity and delivery schedule Our engineering team will confirm pump ratio suitability, compressor compatibility, and accessory requirements, and provide a detailed quotation within 24 hours. Frequently Asked Questions How much air pressure do I need to operate this grease pump? The pump requires 60–150 PSI (4–10 bar) compressed air, with 87 PSI (6 bar) being the optimal operating pressure for balanced flow and motor longevity. Most standard workshop compressors delivering 8–12 SCFM at 90 PSI are adequate for intermittent use. For continuous-duty operation, a compressor capable of 16–22 SCFM sustained output is recommended. Will this pump fit my grease drum? Yes. The pump is designed for standard 120 lb (55 kg) / 16-gallon grease drums, which are the most common industrial drum size. The bung adapter mounts directly to the standard 2-inch drum opening. The follower plate is matched to the drum internal diameter to maintain vacuum and prevent air ingestion. What type of grease can I use with this pump? The pump is compatible with industrial lubricating greases up to NLGI Grade 2 consistency. This covers the vast majority of standard petroleum-based and synthetic greases used in automotive, industrial, and fleet applications. For NLGI Grade 3 grease or cold-environment operation below 10°C, the 55:1 or 60:1 ratio option is recommended to overcome increased viscosity. How far can the pump deliver grease? The standard system includes a 13 ft (4 m) high-pressure hose that provides reach around large equipment without drum repositioning. The pump generates up to 7,500 PSI at the discharge port, which is sufficient to push grease through longer hose runs and elevated lubrication points. For distances exceeding 20 ft or centralized systems with multiple divider valves, the booster gun or higher-ratio pump is recommended. Does the pump require special maintenance? The pre-lubricated air motor requires no in-line oiler, minimizing routine maintenance. Standard maintenance includes: inspecting the follower plate seal for proper drum contact, checking the inlet check valve for contamination, and verifying air filter/regulator function. The fluid section is rebuildable with standard seal kits. Replace seals immediately if grease appears at the air motor exhaust. How loud is the pump during operation? The noise level during operation ranges from 77 dB to 92 dB, depending on air pressure and pump cycle rate. This is comparable to a busy industrial workshop or heavy machinery environment. Hearing protection is recommended for operators during extended use periods. Installing an air muffler on the exhaust port can reduce noise by 5–10 dB. Are replacement parts available? Yes. We supply complete replacement parts including follower plates, inlet check valves, piston seals, air motor repair kits, high-pressure hoses, control guns, and couplers. Rebuild kits containing all wear components for the fluid section and air motor are available. Provide your pump ratio and serial number when ordering spare parts to ensure compatibility. Will the pump work in cold conditions? Yes, with considerations. Standard 50:1 pumps handle NLGI Grade 2 grease effectively at temperatures above 15°C (60°F). In cold shops or outdoor environments below 10°C, grease viscosity increases significantly and may cause motor stall. For cold-climate operation, specify the 55:1 or 60:1 ratio option, or use a cold-weather grease formulation. The air motor is designed to operate without icing at normal humidity levels. What is the difference between the intermittent-duty and continuous-duty models? The intermittent-duty model is designed for standard workshop cycles with rest periods between use, typically servicing 5–20 machines per shift. The continuous-duty model features hardened fluid section components, a heavy-duty air motor, and precision-ground bores rated for sustained operation without thermal overload. Choose continuous-duty for production lines, 24/7 fleet facilities, and centralized lubrication supply systems. Can I use this pump with a centralized lubrication system? Yes. The pump can supply centralized progressive or parallel divider valve systems. For systems with more than 8–10 outlet points or long supply lines, the 55:1 or 60:1 ratio with booster gun is recommended to maintain adequate pressure at all dispensing points. Confirm the total system back-pressure and hose length when specifying the pump for centralized applications. Related: Grease Pump hub — types, selection guides, and troubleshooting.