Grease is an essential lubricant in many applications. Unlike oil, grease is thick and sticks to the component surface, providing longer-lasting lubrication. However, on its own, it is much harder to control during application. Grease guns provide a clean and controlled application method that moves grease directly from the gun through a grease fitting coupler to a grease fitting, where it is evenly dispersed into the application. Different types of grease guns have unique designs that help facilitate lubrication in a variety of applications, from high-volume manufacturing and commercial equipment to small, custom projects.

A grease gun is either a manual, battery-operated/electric, or pneumatic tool used to pump grease into an application that needs lubrication, typically ones with moving parts. It is used for precisely applying grease to grease fittings in various equipment types, ranging from passenger vehicles and lawn equipment to aircraft and aerospace applications. It usually features a cylindrical grease gun barrel to hold a grease cartridge, a trigger or plunger for pumping the grease out of the barrel, and a grease fitting hose, extension pipe, or nozzle.

There are many different designs and types of grease guns, each one suited for specific application needs. For example, manual grease guns - like lever-handle and pistol-grip guns - are easy to use but may not be as conducive to high-volume applications. On the flip side, pneumatic and cordless/electric grease guns are better suited for high-volume setting but tend to be a bigger investment.

The four most common types of grease guns are divided into two categories: manual and automatic. Within the manual category, lever-handle and pistol-grip pistols are the most popular options. As for automatic options, air-powered and battery-powered are the preferred choices. 

Manual grease guns tend to be the more economical choice, partly because they are hand operated and partly because they do not require additional equipment to work. These guns are ideal for low-volume applications like personal projects/equipment or repairs on older automotives. They are also better suited to applications that require more precise grease disbursement, as the handheld trigger or lever allows the user to control the grease flow. There are two main types of manual grease guns available: lever-handle guns and pistol-grip guns.

Automatic grease guns facilitate lubrication through an attached source of power. The two most common types of automatic grease guns are air-powered (pneumatic) and battery-powered, each of which provide significant pressure to discharge the grease without taxing the user, who only needs to pull the trigger. While these guns are more expensive and do not control the grease flow like a manual grease gun, they are well suited for high-volume and repetitive lubrication applications and often handle cold temperatures more efficiently than their manual counterparts.

As with any tool, care should be taken in selecting the right grease gun for the application. Over lubricating or using the wrong grease can damage the grease fitting, the gun, or both. Also, the grease itself can be a health concern if allowed to penetrate the skin. Below are some important points to consider when buying a grease gun.

First, define the use. Will the gun be used in commercial, industrial, or custom/small operations? How often will it be used? Does the grease flow need to be controlled? Will the gun need to operate under extreme temperatures? Is it far away from a power source? What kind of equipment will it service?

Suction Load

Suction load means the gun is filled manually from a bulk drum by inserting the end of the gun into grease and pulling up on the handle. This method is best suited for lighter grade grease, as it tends to be difficult to extract heavy grease.

Bulk Load

Bulk loading is the easiest, cleanest, and most cost effective method of reloading a grease gun. Using bulk loading to reload your gun will necessitate purchasing the following items:

GREASE FITTING COUPLERS

There are many types of grease gun tips – some are designed to fit specific zerk fittings, while others are designed to expand the gun’s versatility with features like angled attachments, swivels, etc. Grease gun couplers generally adapt to different zerk sizes of the same style, but that may vary depending on the components and application. You should always check the parts yourself to ensure a proper connection before use.

Three of the most common grease gun coupler types are standard, quick connect, and loader couplers. Four less common grease gun tips include button head, pin type, needle nozzles, and flush type couplers.

Download our Grease Gun Coupler and Mating Grease Fittings quick guide here.

The standard grease coupler (also called a hydraulic coupler) is designed to fit standard grease fittings or fittings with standard nipple profiles, which covers most of the common zerk fittings in use. The hydraulic option is a simple tip that attaches to the end of a hose or pipe extension to transfer grease on its own, but it can also act as a mount for other types of couplers. There are two subtypes of these components: conventional and special use .

Loader grease couplers are specifically designed for bulk lubrication loading systems, in which a grease gun is filled with grease from a bulk barrel rather than an individual cartridge. This works well in high-volume settings where it would be costly to use large amounts of cartridges or when environmental impact is a concern.

This is the only coupler that does not transfer grease from the gun to the application; it only moves it from the bulk barrel into the gun.

Button head couplers are designed to fit over the unique profile of button head zerk fittings. These fittings have a smooth, flat head with a low profile and a small grease nipple. The corresponding couplers feature slots on the bottom of the tip that fit over the zerk head and a threaded hole above it at a 90⁰ angle for grease gun attachment.

The pin type coupler is designed to be used with pin type grease fittings, a unique type of fitting that features a cross pin sticking out from the zerk head at a 90⁰ angle. This was one of the first zerk fitting designs ever manufactured, and they are now often used to restore antique vehicles or older machinery. The coupler uses a slot on the bottom of the tip to create a positive lock with the fitting, which makes for simple servicing.  

A needle nozzle is a long, skinny grease gun tip that reaches into awkward spaces where a bulky gun can’t fit. They are available in a variety of lengths, with some options featuring a rubber tip.  

Flush type couplers fit with flush type grease fittings, which have a low, concave profile and a sunken grease nipple so the zerk doesn't protrude from the mating surface. To reach the grease nipple, this coupler features a small, pointed tip to reach into the zerk. 

In most cases, couplers attach and detach in a similar, easy manner. To ensure a leak-proof seal and a clean removal between your coupler and zerk fitting, consider the following:

All-in-one coupler kits are collections of quick connect tips packaged in a pouch that are ideal additions to agricultural or maintenance tool kits.  

Grease gun couplers are available in a variety of styles to help you navigate a wide range of lubrication applications.

Some tips, like hydraulic or needle nozzle couplers, provide ways to get around tight spaces, awkward angles, or hard-to-reach areas. Others, like button head, pin type, and flush type couplers, are designed to work with specific grease fittings. Whatever type of grease gun you are working with, these components help you save time by expanding your gun’s versatility.

For more information on Huyett's selection of grease fittings, grease guns, and lubrication tools and accessories, visit our complete lubrication product line and tools or our FAQ page. You can also contact Sales today for questions and quotes.