The grease gun is the workshop's most-used and most-abused lubrication tool. Pick the right one and your bearings last their design life; pick the wrong one and 15,000 psi of grease pressure blows past seals that are rated for 500 psi. This guide is the engineering and workshop reference — manual lever guns, pistol-grip Flexiguns, pneumatic air-operated, battery Li-Ion cordless, and specialty booster guns. AIMS stocks the Macnaught range (premium AU brand, including mining-spec variants) plus Alemlube, Lubemate and Samoa across 22+ grease guns. We don't stock Milwaukee/Makita/Dewalt/Ryobi cordless — those are battery-platform tied to their respective power-tool ecosystems and better-served by Bunnings, Sydney Tools and Total Tools. Honest scope below.
Grease cartridge sizes — AU standards and US variants — Quick Reference
Most grease guns are sized to match standard cartridge dimensions. Two cartridge formats dominate:.
| Cartridge size | Market | Common brands | AIMS guns that fit |
|---|---|---|---|
| 400g | AU/UK industry standard | Castrol, Penrite, Inox, Mobil AU, Shell AU | K32 Flexigun, K40 Levergun, all Alemlube + Lubemate standard guns |
| 450g | AU industry premium | Mobil HP, Macnaught compatible | K29 Flexigun, K45 Levergun, PG450 PowerGun |
| 14oz (397g) | US standard | Shell US, Mobil US, Mobile Aviation | Most guns will accept with tight fit; check manufacturer spec |
| 500cc (~450g) | European | Various Euro suppliers | Same chamber as 450g typically |
| Bulk fill (no cartridge) | Industrial — drum or pail | Penrite Drum, Mobil Drum, Castrol Drum | All guns accept bulk loading via filler tube |
Why grease gun choice matters — pressure vs seal rating
A grease gun's job sounds simple: push grease into a fitting. The reality is more nuanced. A standard manual lever grease gun can deliver up to 15,000 psi at the coupler. Most bearing lip seals are rated for 500 psi maximum, and many for less. The pressure differential is the single most common reason for "premature bearing failure" diagnoses: the seal got blown out long before the bearing wore out, contamination got in, and the bearing failed quickly afterwards.
The rule that prevents this: pump only until grease starts to purge from the seal, then stop. If you can't see the seal purge (greasing a blind fitting), pump only the number of strokes specified by the equipment manual — typically 2-3 strokes for a small bearing, 5-10 for a larger one. Don't pump until you "feel resistance" — by that point the seal is gone.
The other half of choice is matching the gun to the volume of work. Greasing one trailer once a month doesn't need a $608 battery gun. Greasing a fleet of mining equipment three times a week makes a $130 manual lever gun the bottleneck. Match tool to use intensity, not aspirational use case.
This guide assumes you've already chosen the grease — see the Grease Types Guide for NLGI grade selection, EP additives, and base oil compatibility. The grease itself matters more than the gun. For specialty greases see the Moly Grease Guide and the Industrial Lubricants Guide.
The five grease gun categories — decision matrix
Every grease gun in this guide belongs to one of five functional categories. Pick the category first, narrow on capacity and brand second.
| Category | Best for | Pressure | Speed | Price tier (AIMS) |
|---|---|---|---|---|
| Manual lever | Heavy stuck fittings, occasional/general workshop, max pressure when needed | Highest (up to 15,000 psi) | Slowest — one stroke = small shot | $45–$165 (entry to premium) |
| Pistol-grip / Flexigun | Multiple fittings, one-handed operation, fast workshop greasing | High (6,000–10,000 psi) | Fast — single hand | $33–$200 |
| Pneumatic (air-operated) | Production workshop, continuous greasing, fleet maintenance, requires air supply | High (4,500–7,000 psi typical, throttle-controlled) | Fastest — trigger and forget | $190–$402 |
| Battery Li-Ion | Mobile fleet maintenance, mining/agricultural field work, no air available | Medium-High (6,000–10,000 psi) | Fast + programmable shot counts | $507–$608 |
| Booster / Pressurite (specialty) | Stuck/blocked fittings, recovery work, pressure beyond manual lever reach | Highest (>15,000 psi) | Slow — recovery use, not production | $210–$280 |
Three-gun workshop minimum: a manual lever (for stuck fittings + occasional bench work), a pistol-grip Flexigun or pneumatic (for daily greasing), and either a booster or quick-release coupler kit (for recovery on seized fittings). This combination handles 95% of workshop scenarios.
The remainder of this article goes deep on each category, then covers pressure limits, cartridge sizing, couplers, priming (the #1 user issue), brand reality, and the AIMS supply across all five tiers. Browse the full range at /collections/grease-equipment.
Manual lever grease guns — workshop standard
The manual lever grease gun is the workshop's most-bought lubrication tool. A long handle drives a piston through a multi-stroke action; each lever stroke delivers approximately 1.0–1.5 g of grease at up to 15,000 psi. The high pressure is what makes lever guns the right tool for stuck or blocked fittings — when grease can't get past dried, crusted old grease in a Zerk fitting, the lever gun has the muscle to break through.
The trade-off is speed and effort. Greasing 30 fittings on a tractor with a lever gun is a sustained workout; the same job with a pneumatic or battery gun is two-minute work. Use lever guns when pressure matters more than speed.
AIMS manual lever range (Macnaught — AU industry standard):
- Macnaught K45 LEVERGUN 450g Grease Gun — $126.40. Workshop standard. Heavy-duty zinc and chrome plated steel construction. Adjustable for stiff or soft greases.
- Macnaught K45 LEVERGUN 450g — Underground Mining — $163.05. Anti-spark, dust-rated, complies with underground mining specifications.
- Macnaught K40 LEVERGUN 400g — $132.77. 400g cartridge variant. Same construction tier as K45.
- Samoa 400g Underground Lever Rigid Extension 400A — $44.29. Budget AU-import option with rigid extension nozzle for awkward-reach fittings.
- Lubemate Lever-Action Grease Gun — $68.46. Budget tier, heavy-duty steel body.
Lincoln 1134 reference: r/Tools (50+ comments) repeatedly cites the Lincoln 1134 as the US gold standard manual gun ("cast steel handle, not sheet metal like most"). AIMS doesn't stock Lincoln Industrial — the Macnaught K45 LEVERGUN is the AU industrial-tier equivalent in construction quality (zinc + chrome plated steel body, not sheet metal). Same workshop class.
Pistol-grip and Flexigun grease guns — fast workshop
Pistol-grip grease guns squeeze a trigger like a power drill — much faster than the multi-stroke lever action, and one-handed. Most pistol-grip designs run lower maximum pressure than lever guns (typically 6,000–10,000 psi) but deliver grease much faster per cycle.
Flexigun = pistol grip + flexible hose. Macnaught coined the Flexigun name in the 1960s. The flexible hose lets you reach fittings the rigid extension can't. For field maintenance — utes, trucks, agricultural machinery — the Flexigun is the most-used pattern in Australia.
AIMS pistol-grip / Flexigun range:
- Macnaught K29 FLEXIGUN 450g — $150.30. The flagship AU Flexigun. 450g cartridge, flexible hose, pistol-grip action.
- Macnaught K29 FLEXIGUN 450g — Underground Mining — $180.58. Mining-spec K29 with anti-spark certification.
- Macnaught K32 FLEXIGUN 400g — $152.96. 400g cartridge variant.
- Macnaught K29 Basic Greasing Kit — $195.86. K29 gun + standard couplers in a compact kit.
- Macnaught K29 FLEXIGUN Greasing Kit FGK1-01 — $356.51. Complete K29 kit with multiple couplers, hose, accessories.
- Lubemate Pistol-Grip Grease Gun Premium — $99.44. Budget pistol-grip option.
- Lubemate Mini-Pistol Grease Gun — $33.15. Small-cartridge pistol for tight-space work and occasional use.
- Alemlube 400g Trigger Action 220A — $114.56. Alemlube workshop pistol-grip.
- Alemlube 400g Clear Barrel Trigger Action 220ACB — $197.53. Clear-barrel variant so you can see grease level remaining.
For deeper detail on the Macnaught K29 specifically, see the legacy Macnaught K29 Flexigun product article.
Pneumatic (air-operated) grease guns — production speed
Pneumatic grease guns run off compressed air — connect a coiled air line, pull the trigger, grease pumps continuously while the trigger is held. Average shop air pressure (90 psi) drives grease pressure at the coupler to 4,500–7,000 psi typical (some guns higher with regulator turn-up). The advantage is sustained continuous operation without operator fatigue.
Pneumatic suits: production workshop greasing, fleet maintenance with multiple vehicles, fabrication shops where the compressor is already running. The downside: needs a compressor + air line, doesn't move with you to the field unless you have a portable compressor.
AIMS pneumatic range:
- Macnaught K53 POWERPISTOL Air-Operated — $402.11. Premium AU pneumatic grease gun. Steel construction, suits heavy workshop use.
- Alemlube 400g Air-Operated 480AN — $357.64. Workshop pneumatic gun with continuous grease delivery.
- Lubemate Air-Operated Grease Gun — $189.07. Budget pneumatic option for occasional production use.
Air pressure rule: don't crank the air regulator up to "make it pump faster" — the gun is rated for a specific shop pressure (typically 90–120 psi). Higher input pressure doesn't speed greasing materially (the bearing fitting limits flow), but it does shorten the gun's life and risks blowing fittings off coupler ends.
Battery / cordless Li-Ion grease guns — mobile fleet
Battery cordless grease guns are the modern workshop standard for mobile and fleet maintenance work. No air line, no manual fatigue, programmable shot counts on premium models. The trade-off is cost ($500–$608 typical for premium) and battery dependence — flat battery, no greasing.
Programmable shot counts matter: the Macnaught PG450 POWERGUN lets you set the number of shots per trigger pull. For a fleet of identical equipment (same bearing, same service interval, same shot count), this turns greasing into a repeatable timing-controlled task rather than a guess. Eliminates over-greasing.
AIMS cordless range:
- Macnaught PG450 POWERGUN High Performance Li-Ion — $608.27. Premium AU cordless. Programmable shot counts, heavy industrial construction.
- Lubemate 18V Lithium-Ion Rechargeable — $506.97. Mid-tier cordless. Standalone battery platform (not tied to Milwaukee/Makita).
- Lubemate Lithium-Ion Charger for L-BG18VLI — $58.36. Replacement charger.
Honest scope: Milwaukee M12/M18, Makita LXT, Dewalt 20V/XR, Ryobi One+ cordless grease guns are popular on US Reddit (r/Tools 80+ comments threads) — these are battery-platform tied to their respective cordless tool ecosystems. AIMS doesn't stock them — if you're already invested in a brand's battery platform, buy the matching grease gun from that brand's retailer (Sydney Tools, Total Tools, Bunnings). The AIMS-stocked Macnaught PG450 + Lubemate 18V are standalone-battery alternatives with their own chargers.
Booster guns and Pressurite — stuck fitting recovery
Booster guns and Pressurites are the specialty high-pressure recovery tools. When a Zerk fitting is so crusted with old grease that a standard manual lever gun can't break through, the booster gun's geometry delivers higher pressure than a standard lever gun — sometimes 20,000+ psi at the nozzle.
Used carefully and only as a recovery tool. The same high pressure that breaks through dried grease will also damage bearing seals if used on a clear fitting. Treat as a recovery tool, not production equipment.
AIMS booster range:
- Macnaught B2 Grease Booster Gun — $225.29. Zinc and chrome plated steel construction. The standard recovery booster.
- Macnaught B2 Grease Booster Gun with Safety Guard — $280.00. Same gun with a safety guard for higher-spec workshop compliance.
- Macnaught Pressurite Gun KR — $209.74. Pressurite-style recovery gun. Suits stuck or blocked fittings.
Underground mining grease guns — Macnaught mining-spec
Underground mining work in Australia is governed by strict equipment specifications. Coal-mine spec requires anti-spark construction; metalliferous mining typically requires dust-rated and impact-resistant tools. Macnaught manufactures dedicated mining-spec variants of the K29 Flexigun and K45 Levergun:
- Macnaught K29 FLEXIGUN 450g — Underground Mining — $180.58. Mining-spec K29 with anti-spark certification.
- Macnaught K45 LEVERGUN 450g — Underground Mining — $163.05. Mining-spec K45 manual lever.
- Samoa 400g Underground Lever Rigid Extension — $44.29. Budget underground option with rigid extension.
The mining variants cost a premium over standard models. If your work is in scope of NSW Resources or state mining regulator approval, the mining-spec variants are the compliance tier. If you're general workshop, the standard K29/K45 work fine.
Grease gun pressure vs bearing seal rating — the critical warning
This is the single most important section in the guide. A standard manual lever grease gun delivers up to 15,000 psi at the coupler. Most bearing lip seals are rated for 500 psi maximum, and some for less.
| Equipment | Typical seal rating | Standard gun pressure | Ratio |
|---|---|---|---|
| Standard bearing lip seal | 500 psi | 15,000 psi (manual lever) | 30:1 over-pressure |
| Heavy-duty automotive seal | 1,500 psi | 15,000 psi (manual lever) | 10:1 over-pressure |
| Industrial pillow block seal | 500–1,500 psi | 6,000 psi (pneumatic, regulated) | 4–12:1 over-pressure |
What this means practically: if you pump grease into a fitting until you "feel resistance," the seal has already been blown out before the resistance feedback reached your hand. Once the seal is gone, contamination enters the bearing, water and dust track in, and the bearing fails within months — well before its design life of years.
The rule that prevents this:
- Visible seal greasing: pump until grease starts to purge from the seal, then stop immediately.
- Blind fittings (can't see the seal): follow the equipment manufacturer's grease schedule — typically 2–3 strokes for small bearings, 5–10 for larger ones. Don't add "just one more" stroke.
- Programmable cordless (Macnaught PG450, Lubemate 18V) lets you set shots per trigger pull, making fleet greasing repeatable and over-greasing impossible.
- Pressure-relief fittings exist for high-precision equipment — these vent excess grease rather than blowing the seal. Use where specified by the equipment manufacturer.
From Machinery Lubrication magazine: "A high-pressure grease gun delivers pressure up to 15,000 psi. Most bearing seals will rarely handle more than 500 psi. A grease gun in the hands of an unaware operator is a more frequent cause of bearing failure than the bearing itself." This isn't a fringe view — it's the industry consensus.
See the Bearing Maintenance Guide for the wider context of bearing lubrication schedule and Rolling Bearings Guide for seal types.
Grease cartridge sizes — AU standards and US variants
Most grease guns are sized to match standard cartridge dimensions. Two cartridge formats dominate:
| Cartridge size | Market | Common brands | AIMS guns that fit |
|---|---|---|---|
| 400g | AU/UK industry standard | Castrol, Penrite, Inox, Mobil AU, Shell AU | K32 Flexigun, K40 Levergun, all Alemlube + Lubemate standard guns |
| 450g | AU industry premium | Mobil HP, Macnaught compatible | K29 Flexigun, K45 Levergun, PG450 PowerGun |
| 14oz (397g) | US standard | Shell US, Mobil US, Mobile Aviation | Most guns will accept with tight fit; check manufacturer spec |
| 500cc (~450g) | European | Various Euro suppliers | Same chamber as 450g typically |
| Bulk fill (no cartridge) | Industrial — drum or pail | Penrite Drum, Mobil Drum, Castrol Drum | All guns accept bulk loading via filler tube |
Sizing rule: match cartridge format to gun barrel. A 400g cartridge won't seat properly in a 450g barrel and vice versa. Always check the gun's specified cartridge size in the manual before buying cartridges in bulk.
Bulk loading vs cartridge — the trade-off:
- Cartridges — clean, fast, no contamination risk, slightly more expensive per gram (~$15–$30 per 400g cartridge)
- Bulk pail/drum loading — cheaper per gram (~$8–$15 per 400g equivalent), but contamination risk during filling, requires a suction filler or scoop, messier
For fleet/production work, bulk loading saves significant money. For occasional or precision work, cartridges are the right choice. Pair the gun with the appropriate grease selection — see the Grease Types Guide for NLGI grade and base oil matching.
Couplers and fittings — standard, quick-release, button head, needle
The coupler is the gun-end fitting that connects to the grease nipple (Zerk fitting) on the equipment. Different fitting types require different couplers; carrying a single coupler set covers most workshop needs.
| Coupler type | Application | Notes |
|---|---|---|
| Standard 3-jaw / 4-jaw | Standard hydraulic Zerk fitting (most common) | Click-on/screw-on. Three or four spring-loaded jaws grip the nipple. |
| Quick-release / Lock-N-Lube style | Any standard fitting — fast on/off without leaks | Premium upgrade. Reduces grease loss and saves time on multi-fitting greasing. r/Tools consensus: "I add a swivel and locking lube end to any gun I buy." |
| Button head | Hydraulic button-head fittings (Caterpillar, mining) | Specific to button-head Zerk variants. Won't fit standard nipples. |
| Needle nozzle | Sealed bearings with pin-hole grease entry | Sharp pin nozzle. Use with care — high pressure through tiny opening. |
| Right-angle / 90° adapter | Awkward-access fittings — between motor and base, behind brackets | Brass elbow. Fits between coupler and gun. |
| Swivel coupler | Reduces flex hose strain at the gun nozzle | Rotates 360° during use. Premium upgrade. |
| Rigid extension | Deep-recess fittings or long-reach applications | Steel tube extending the gun's reach. Common on mining variants. |
AIMS coupler range:
- Alemlube Quick Release Grease Gun Coupler — $40.42. The most-bought workshop coupler upgrade.
- Alemlube 1/8" BSP swivel MxF Grease Gun Swivel Coupler 14501 — $21.16. Swivel coupler to reduce hose strain.
The full coupler range is in /collections/grease-equipment — including standard 3-jaw, button head, needle nozzle and right-angle adapters. The forum-validated workshop standard (r/Tools 80+ comments): one quick-release coupler + one button head + one needle + one right-angle covers ~98% of fittings you'll meet in AU workshop and field work.
Priming the grease gun — the #1 user issue (airlock fix)
Air-lock is the most common reason for grease guns failing to pump — Google searches for "grease gun won't prime" significantly outnumber searches for the guns themselves. The cause: air pockets between the cartridge follower and the pump piston. Until the air is purged, the gun pumps air instead of grease.
The standard fix (works for ~80% of priming issues):
- Loosen the barrel from the head 2-3 turns — don't fully unscrew. This breaks the seal and lets trapped air escape.
- Push the follower rod against a hard surface — compress the rod into the barrel firmly. This forces air out past the loose head.
- Pump the handle 5-10 times with the head loose. Air bleeds out, grease moves forward.
- Re-tighten the barrel when grease starts coming through the head/coupler. Wipe excess grease.
- Test on a scrap fitting to confirm steady grease flow.
If that fails — the air-bleed valve method (guns with bleed valve fitted):
- Locate the air bleed valve on the gun head.
- Open the valve while pumping the handle.
- Pump until grease (not air) comes out the bleed valve.
- Close the valve immediately when grease comes through.
Cold-weather priming trick (AU farm machinery — Facebook Planting the Crop forum): if the cartridge is cold and stiff, place it on the ute dash with the heater running for 10 minutes before loading. Cold grease is much harder to prime — warming the cartridge reduces airlock incidence dramatically. Especially relevant for outdoor field work in winter.
Common priming failure causes (not all the gun's fault):
- Rusty grease nipple — the fitting itself is blocked, gun is fine. Spray with penetrating oil, work it loose, then re-grease.
- Empty cartridge mistaken for airlock — check the follower rod position before troubleshooting deeper.
- Damaged cartridge seal — the rubber cup at the back of the cartridge is collapsed or torn. Replace cartridge.
- Worn pump piston seals — gun is at end of life. Most manual guns have replaceable seals; check the manufacturer's parts list.
Brand reality — Macnaught, Alemlube, Lubemate, Lincoln, Milwaukee
The grease gun market has clear tier brands. Knowing them helps interpret price differences.
| Brand | Tier | Strength | AU availability |
|---|---|---|---|
| Macnaught | Premium AU manufacturer | Genuinely Australian (Sydney-based NSW manufacturing). Industrial workshop standard. Mining-spec variants available. Heavy chrome-plated steel construction. | AIMS deep range across all categories |
| Alemlube | Mid-premium AU | Comprehensive workshop and fleet range. Strong in trigger-action and air-operated. Wide coupler/accessory range. | AIMS multiple models + couplers |
| Lincoln Industrial | Premium US | Lincoln 1134 is the US-Reddit gold-standard manual gun. Cast steel handle quality. Not common in AU industrial supply. | Specialty importers. Not AIMS. |
| Milwaukee M12/M18 | Premium cordless | US-dominant cordless. Powerful battery platform. Programmable shot counts. Brand-platform tied to Milwaukee power tools. | Sydney Tools, Total Tools. Not AIMS. |
| Makita LXT, Dewalt 20V/XR, Ryobi One+, AEG | Premium cordless | Same category as Milwaukee — brand-platform tied to respective cordless tool ecosystems. | Bunnings, Sydney Tools, Total Tools. Not AIMS. |
| Samoa | Mid-budget | Spanish manufacturer. Budget AU import. Strong in basic lever and underground variants. | AIMS |
| Lubemate | Budget-mid | Budget workshop range. Multiple formats including standalone 18V cordless. | AIMS multiple models |
| Lock-N-Lube | Coupler specialty (US) | The quick-release coupler that became the brand-as-generic. Forum gold standard for fast on/off. | Specialty importers. AIMS Alemlube quick-release is equivalent tier. |
| Alemite | Premium US | Old-school American grease gun brand. Heavy industrial standard. | AIMS has Alemite 400g Delux Lever (currently out of stock — see Macnaught K45 equivalent). |
| Repco / Supercheap / Bunnings generic | Consumer DIY | Light-duty home and occasional use. Plastic-handled lever guns common. Will work, won't last. | Mass retail — not industrial supply. |
If you need a brand AIMS doesn't stock — call (02) 9773 0122. We can usually source through supplier network for specific brand requirements.
AIMS grease gun range — Macnaught dominant, Alemlube, Lubemate, Samoa
The complete AIMS grease gun range covers all five categories across 22+ active products at /collections/grease-equipment:
Macnaught (premium AU manufacturer — dominant range):
- Flexigun (pistol-grip + flexible hose): K29 450g, K29 Mining, K32 400g
- Levergun (manual lever): K40 400g, K45 450g, K45 Mining
- PowerPistol (air-operated): K53
- PowerGun (Li-Ion cordless): PG450
- Booster (high-pressure recovery): B2, B2 with Safety Guard, Pressurite KR
- Kits: K29 Basic Greasing Kit, K29 Flexigun Greasing Kit FGK1-01
Alemlube (workshop and fleet tier):
- 400g Trigger Action 220A
- 400g Clear Barrel Trigger Action 220ACB
- 400g Air Operated 480AN
- Quick Release Coupler, 1/8" BSP Swivel Coupler
Lubemate (budget-mid):
- Lever-Action, Pistol-Grip Premium, Mini-Pistol
- Air-Operated
- 18V Lithium-Ion Rechargeable + Li-Ion Charger
Samoa: 400g Underground Lever Rigid Extension 400A
Browse the full Grease Equipment collection (443 products) for couplers, hoses, cartridges, parts and accessories. Cross-reference grease selection with the Grease Types Guide.
Care, maintenance and troubleshooting
Grease guns last years with basic care. Three failure modes dominate:
- Worn pump piston seals — gun pumps but pressure drops over time. Most manual lever guns have replaceable seal kits. Check the manufacturer's parts list before replacing the whole gun.
- Damaged flex hose — kinks, cracks or burst hose at the gun-to-nozzle connection. Replace flex hoses showing cracks immediately; high-pressure grease leaking at the user end is messy and dangerous.
- Crusted grease nipple on the equipment — common cause of "gun won't pump" diagnoses that aren't actually the gun's fault. For oil dispensing (engine oil, gear oil, hydraulic oil from 20L/60L/205L drums) the equivalent workshop tool is the drum pump — see the Oil Pump & Drum Pump Guide covering lever, rotary, air-operated ratio pumps and the Macnaught BOP/OILMASTER/R-SERIES range. Spray fittings with penetrating oil, work them loose, replace if needed before troubleshooting the gun. See the Grease Nipple & Zerk Fitting Guide for blocked-nipple diagnostic workflow, broken-nipple removal, and thread-standard identification (1/8" BSP vs UNF vs NPT vs metric).
Routine care:
- Wipe the coupler and nozzle clean after each use
- Store with a partially loaded cartridge — empty barrel can dry out the pump seals
- Lubricate the lever pivot and pump piston annually with light machine oil
- Replace cartridges that have been opened more than 12 months — grease can separate and degrade
- For cordless: keep the battery on the charger when not in use; Li-Ion batteries last longer at 80% than at 0%
Common mistakes — 8 forum-validated errors
| Mistake | Why it fails | Fix |
|---|---|---|
| Pumping until "resistance" is felt | By the time you feel resistance, the bearing seal has already been blown out. The grease channel went past the seal, into the housing, then out the casing — but you didn't know. | Pump until visible seal purge, OR follow manufacturer stroke count for blind fittings. Stop earlier rather than later. |
| Cranking the air regulator on pneumatic guns | Higher input pressure doesn't speed greasing materially (the fitting limits flow) — it just stresses the gun and risks blowing fittings off couplers. | Run the gun at manufacturer-rated input pressure (typically 90 psi). If grease isn't flowing, check the fitting and coupler before the gun. |
| Using budget guns for fleet/production work | $30 mini-pistol guns work fine for the occasional trailer grease — they fail under daily-use workshop demand within months. | Match gun tier to use intensity. Production = Macnaught K53 air or PG450 cordless. Occasional = Lubemate mini pistol fine. |
| Mixing incompatible greases | Different thickeners (lithium, calcium, polyurea) can react in the cartridge or in the bearing. Lithium + calcium sulfonate complex = soap formation that blocks flow. | Check the Grease Types Guide for compatibility. When in doubt, drain and clean the housing before switching grease types. |
| Ignoring air-lock | Gun pumps air for first 5-10 strokes after cartridge change — operator thinks gun is broken. | Always prime after every cartridge change. See "Priming the grease gun" section above for the standard fix. |
| Wrong cartridge size in gun barrel | 400g cartridge in 450g barrel = follower rod doesn't seal properly. Grease leaks past, pressure won't build. | Match cartridge to gun spec (400g vs 450g). Check manufacturer manual before bulk-buying cartridges. |
| Single coupler for all fittings | Standard 3-jaw coupler doesn't fit button-head, needle, flush-type or 90° access fittings. Operator forces wrong coupler, damages the fitting. | Carry a coupler kit. Standard, quick-release, button head, needle and right-angle covers ~98% of fittings. |
| Storing empty grease guns | Empty barrel allows seals to dry out and crack. Next use, gun won't prime even when fresh cartridge installed. | Store with a partially loaded cartridge. Replace seals if gun has been stored empty for months. |
Frequently Asked Questions
What are the different types of grease guns?
Five main categories: manual lever (workshop standard, highest pressure, slowest), pistol-grip / Flexigun (one-handed, fast workshop), pneumatic air-operated (production speed, needs compressor), battery Li-Ion cordless (mobile fleet, programmable shots), and booster / Pressurite (high-pressure stuck-fitting recovery). AIMS stocks all five categories — Macnaught dominant across the range plus Alemlube, Lubemate and Samoa.
Is a pistol-grip or lever-action grease gun better?
Different jobs. Lever-action delivers the highest pressure (up to 15,000 psi) — the right tool for stuck or crusted fittings, but slow over many fittings. Pistol-grip / Flexigun is faster, one-handed, and easier on the wrist over multiple fittings, but typically lower maximum pressure (6,000–10,000 psi). Most AU workshops carry both — a lever gun for stuck fittings and a Flexigun for routine greasing.
How do I prime a grease gun (fix airlock)?
Standard fix: loosen the barrel from the head 2-3 turns, push the follower rod against a hard surface, pump 5-10 strokes to bleed air, re-tighten the barrel when grease starts coming through. For guns with a bleed valve: open the valve while pumping until grease (not air) comes out, then close immediately. Cold cartridges prime more easily if warmed on the ute dash for 10 minutes before loading.
What pressure does a grease gun produce?
Manual lever grease guns deliver up to 15,000 psi at the coupler. Pistol-grip and Flexigun guns typically 6,000–10,000 psi. Pneumatic guns 4,500–7,000 psi (regulated). Battery Li-Ion 6,000–10,000 psi. Booster guns can exceed 20,000 psi. Critically — most bearing seals are rated for only 500 psi, so over-pressurising during routine greasing is the #1 cause of premature bearing failure.
Can you over-grease a bearing?
Yes, and it's far more common than under-greasing. Pumping past the seal-rated pressure blows the lip seal, lets contamination into the bearing, and causes failure months before the bearing's design life. The rule: pump until visible seal purge (if you can see it), or follow the equipment manual's stroke count (if you can't). Don't pump "until resistance" — by then the seal is gone. Programmable cordless guns (Macnaught PG450, Lubemate 18V) make this repeatable.
What size grease cartridge does my grease gun take?
AU industry standard is 400g and 450g cartridges. 400g fits most Alemlube and Lubemate guns plus Macnaught K32 and K40. 450g fits Macnaught K29, K45 and PG450. 14oz (397g) is the US standard — usually fits AU 400g guns with minor adjustment. 500cc European cartridges fit 450g chambers. Check the gun's specified cartridge size before buying cartridges in bulk; mismatched cartridges seal poorly and cause priming issues.
What's the difference between 00 and 000 (NLGI) grease?
NLGI grade describes grease consistency, not chemistry. 000 (triple-zero) is nearly fluid — used in centralised lubrication systems and some gearboxes. 00 (double-zero) is semi-fluid. 0 is soft. 1 is moderately soft. 2 is standard workshop grease — what most cartridges contain. 3 is firm. 4 is very firm — specialty bearing only. Most grease guns work best with NLGI 1 or 2 grade grease. For full detail see the Grease Types Guide.
What is a Lock-N-Lube / quick-release coupler?
A quick-release coupler is an upgrade fitting that snaps on and off the grease nipple with minimal pressure release. Reduces grease loss at the fitting, saves time on multi-fitting greasing, and lets the operator switch between fittings without the standard coupler's wrestle. Lock-N-Lube is the original US brand that became the brand-as-generic term. AIMS stocks the Alemlube Quick Release Grease Gun Coupler ($40.42) as the equivalent — fits any standard grease gun thread.
What's the best grease gun for cold weather?
For occasional outdoor work in winter: any AU-industrial-tier manual lever gun (Macnaught K45 LEVERGUN $126) works fine if the cartridge is warmed first. For continuous cold-weather work: pneumatic or cordless models since manual lever pressure rises sharply as grease stiffens in cold. Cold cartridge tip: place the cartridge on the ute dash with the heater running for 10 minutes before loading — eliminates most cold-weather priming issues. AU farmers and outdoor mechanics swear by this.
How often should I grease my equipment?
Equipment-specific — follow the manufacturer's grease schedule. Typical examples: trailer wheel bearings every 10,000 km or 12 months whichever first; agricultural tractor PTO bearings every 50 hours; mining equipment grease points daily or per shift; bicycle bottom bracket every 5 years. The wrong answer is "as often as it looks dry" — over-greasing blows seals, while sticking to a schedule keeps bearings happy. When unsure, check the equipment manual or call the manufacturer.
What is a Macnaught grease gun?
Macnaught is an Australian-manufactured industrial grease gun brand based in Sydney, NSW. Their range includes the K29 and K32 Flexigun (pistol-grip flexible hose), K40 and K45 Levergun (manual lever), K53 POWERPISTOL (pneumatic), PG450 POWERGUN (Li-Ion cordless), and B2 Booster (high-pressure recovery). Macnaught is one of the few AU-manufactured industrial lubrication equipment brands and is the workshop standard across Australian industry — Macnaught K29 Flexigun is on a ute dashboard somewhere in every state right now. Available at AIMS across the full range including underground mining variants.
Pneumatic vs battery — which is faster?
Pneumatic is marginally faster in sustained continuous operation (no battery swap needed), but battery cordless wins on mobility. For workshop production with compressor already running, pneumatic. For fleet maintenance and field work where mobility matters, battery. Modern Li-Ion battery guns (Macnaught PG450, Lubemate 18V) hit 10,000+ psi continuously with programmable shot counts — they've closed the speed gap with pneumatic.
Can I use any grease in any grease gun?
Almost always yes — but check compatibility before switching grease types in the same gun. Different thickeners (lithium, calcium sulfonate complex, polyurea, calcium, aluminium complex) can react if mixed in the cartridge or in the bearing. Worst case: lithium + calcium sulfonate forms a soap that blocks flow. Best practice: clean the gun barrel and pump piston before switching to a different grease type. For most workshop work, sticking with one NLGI 2 lithium-complex grease (the AU standard) avoids compatibility questions entirely.
Why won't my grease gun pump grease?
Five most common causes: (1) Air-lock — use the priming procedure (loosen barrel, push follower, pump 5-10 strokes). (2) Empty cartridge — check the follower rod position. (3) Damaged cartridge seal — replace cartridge. (4) Worn pump piston seals — check manufacturer parts list for seal kits. (5) Crusted grease nipple on the equipment — the fitting is blocked, not the gun. Spray with penetrating oil and work the fitting loose before blaming the gun.
What's a Flexigun and how is it different?
Flexigun is Macnaught's brand name for their pistol-grip grease guns with a flexible hose at the nozzle end. The flexible hose lets you reach fittings that rigid extensions can't — behind brackets, around motor mounts, in confined ute and tractor service points. Different from a standard pistol-grip gun (which uses a rigid extension) and from a lever-action gun (which has no flex). The Macnaught K29 Flexigun 450g ($150) is the AU workshop standard; the K32 Flexigun 400g ($153) is the 400g cartridge variant.

