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I have been working on Open Gear automatic lubrication systems now for almost 30 years and have conducted over 150 open gears lubricant conversions in numerous countries. However there is one design failure that is present in almost all systems that I have come across. It does not seem to matter whether it is a BijurDelimon dual line system or a Single line progressive type or even a Single line injector system the delivery and return lines are typically sized too small. When designing an automatic lubrication system it is critical that the delivery lines from the pump to the distribution valve and the return line to the tank are of suitable size to enable free flow of lubricant under all operating conditions. My default minimum size for both is 1/2" ID, however most installed systems tend to have 3/8" as their delivery and 1/4" for the return line. While the line from the distribution valves to the spray nozzles is important it is getting the lubricant to the valves and back to tank which has the largest impact on lubrication system performance. The second design failure is to not use a three way air solenoid to deliver air to the pump, without a three way solenoid when the system is stopped the line remains full of air thereby leading to continued delivery of lubricant after the fact.