The 911MPE-TM-T is a Jaw Crushers for Coarse Primary Crushing and Mid Range Primary Crushing. This jaw crusher is equipped with a 5 HP motor and a 5” X 7″ jaw cavity that will produce a discharge crushed product of under <1mm.
Well proven single toggle, high reduction Jaw Crushers. The crushing capacity and the end-fineness of the sample material depends on the type of crusher and on the breaking characteristics of the sample material. Designed for laboratory applications and for operating environments and accepts soft to hard ores, drill cores, rocks, alloys, slags, soils, ceramics and similar hard and brittle materials.
The Jaw Crusher 911MPE-TM-T is used for the rapid, effective crushing and pre-crushing of medium-hard, hard, brittle and tough materials. Its variety of materials offered, including heavy-metal free steel, its efficiency and safety makes it ideal for sample preparation in laboratories and industrial plants. For small amounts of sample the 911MPE-TM-T is used batchwise; for larger amounts it can be operated continuously. Control of the gap width and zero point adjustment allow for reproducible results.
This performance jaw crusher can be inline unit (within your process) or stand-alone. With inline units we need to provide a control box, often also a different frame and inlet. Depending on the application stand-alone units can also need a different frame and/or inlet.
Thanks to the modular construction of housing and frame this jaw crusher is suitable for a wide range of applications. Jaw Crusher engineered for pre-crushing of extremely hard up to brittle materials.
Quick and easy to clean
Easy exchange of jaw plates and side liners
Modular in-feed hopper: removable, with splash back protection, batch loader or dosing plunger
External control box with start/stop
Powerful 7 kW- motor
Low installation height
Contamination free crushing
Specialty liners for your specific needs
cement & clinker
industrial brittle waste
high crushing ratio
front door facilitates cleaning
infinite/continuous gap width setting
wide range of materials for contamination free grinding
no-rebound custom feed hopper, removable
custom sample collector with safety switch
collecting receptacle with outlet for continuous operation
connector for dust extraction
Quick and easy to clean
Easy exchange of manganese jaw plates and side liners
External control box with start/stop
End-fineness: 1 mm
Powerful 5 HP motor (7.5 HP Optional)
Low installation height
Jaw Crusher is designed for batch or continuous pre-crushing of middle hard, hard brittle and tough materials for the following fine grinding.
Jaw Crusher Principle of Operation
The 911MPE-TM-T Jaw Crusher is used by laboratories and processing companies to crush solid materials such as rocks or soil and ores. The material to be processed falls into the crushing chamber of the 911MPE-TM-T Crusher via a guide chute and is crushed by crushing action of a static and a dynamic jaw plate until it passes the pre-selected gap of the crusher.
Easy cleaning and operation
The 911MPE-TM-T jaw crusher can be used for small volumes batchwise or in a continuous mode for bigger volumes. You can easily change the movable and static jaw plates as well as the side liners.
The desired gap can set up easy and reproducible by spacer.
Possible Jaw plates / side liners material compositions
Heavy metal free steel
Polyurethane & Ceramic
Features and benefits
Better crushing performance due to 7500 Watt
Optimum crushing results
Easy adjustment of gap setting
Removable infeed hopper
High precision solid steel underframe (available with castor wheels lockable)
Solid and spacious sample collector with castor wheels
The AUTOLUBE system of this Jaw Crusher is programmed to be active for one minute every sixty minutes regardless of how many times you start and stop the machine!
To prevent your machine from trembling or moving from its set position, place the supplied rubber mat underneath it.
FOR SHIPPING PURPOSES THE JAW CRUSHER IS NOT MOUNTED ON THE STAND (if supplied with your order) LIFT IT UP WITH AN OVERHEAD CRANE AND HOOKS AS SHOWN BELOW:
If the dust collecting hopper was ordered, it should be installed between the bottom of the machine and stand, in the back, with the two (2) screws in the sides already in place. Remove the screws, insert them in the eyes of the hopper, and tighten.
One Year Limited Warranty
This Jaw Crusher is warrantied against defective materials or workmanship for one year from date of original purchase. This warranty is void if the product has been damaged by accident, unreasonable use, neglect, improper service, by not following the instructions in this owner’s manual, or other causes not arising out of defect in material or workmanship.
ANY ALTERATIONS, RE-WIRING OR MODIFICATIONS TO BE DONE ON THIS MACHINE WHILE UNDER WARRANTY, MUST BE AUTHORIZED BY THE MANUFACTURER OTHERWISE ALL WARRANTIES BECOME VOID.
The lubrication system is set to grease the correct amount every 60 minutes irrespective of whether the machine is continuously operated or if it is stopped and started many times. Check regularly to refill it when the grease reservoir is at a very low level.
As grease, we recommend Lubriplate 1200-2 or any equivalent of the following heavy duty, non-corrosive extreme pressure, water resistant greases possibly containing molybdenum disulphides (N.L.G.I. No.2)
THIS MACHINE IS NOT SUITABLE FOR WET GRINDING. IT WILL CREATE SEIZING OF MATING PARTS AND POSSIBLE FAILURE OF BEARINGS AND OTHER PARTS.
The transparent purge lines will not show grease exiting from the machine simultaneously. That is, because there are different size cavities within the machine that will allow the grease to accumulate for a long time before it is eventually forced to come out.
The air deflector plate (JCT144G) with time might become obstructed with grease and rocks accumulation. It is advisable to detach the duct from fan cover to rear duct (JCT006A) and through the opening remove all the air flow obstructing material.
Should the clamp JCT095J, with time show slippage from the set position, that might be caused by grease that has percolated where it grips. By spraying paint thinner or similar solvent that dilutes the grease and blowing it away, this can be easily corrected. In the worse cases the clamp needs to be removed and cleaned along with the cover of the bottom shaft (JCT087A).
Also, when setting the opening with the moving jaw it is essential to have the moving jaw bottom edge, below the one of the stationary jaw. If the moving jaw bottom edge is set above the stationary bottom edge, under heavy crushing conditions, the jaws will have the tendency to open up.
If your machine is supplied with a dust enclosure, the recommended air suction for dust extraction is 150cfm, although variation may be needed upon the mass of dust produced. It is recommended to have an air regulating (Butterfly) valve installed, since it is highly unlikely a dust extraction system will generate the proper volume.
Instructions For Releasing Clamp
The clamp is released with the adjustment Lever (JCT095Y) shown to the right.
Slide holed side of the adjustment bar (JCT133) on to the lever (JCT095Y) and pull it to release the clamp (JCT095J).
Before adjusting jaws, the nut and bolt must be released entirely as shown in the image below.
The opening between jaws can then be adjusted to the desired amount using the adjustment key shown to the right.
when finished, release lever, and tighten the nut and bolt.
Parts Description – Jaw Crusher
(Quantities in brackets indicated quantity required per machine. When ordering please specify quantity required as all parts are priced each.)
JCT003 Motor Guard JCT006 Flywheel/Fan Guard JCT006A Duct from fan cover to rear duct JCT007 Retaining screws for flywheel locking plate (2 pcs.) JCT008 Locking screw for flywheel JCT009 Locking plate for flywheel JCT010 Retaining plate for flywheel JCT011-1 Flywheel JCT011A Screw to hold fan blade (10 pcs) JCT011B Fan blade (10 pcs) JCT011C Nut to hold fan blade (10 pcs) JCT012 Retaining screws for flywheel locking plate (2 pcs.) JCT013 Locking screw for flywheel JCT014 Locking plate for flywheel JCT015 Retaining plate for flywheel JCT016-1 Drive pulley JCT017 Key for drive pulley JCT018 Lock nut for eccentric shaft JCT019 Lock washer for eccentric shaft JCT020 Key for flywheel JCT021 Lock nut for eccentric shaft JCT022 Lock washer for eccentric shaft JCT023 Retaining screws for flange cover plate (4 pcs.) JCT025 Felt for cover plate JCT026 Ring for flange cover plate JCT027 Bearing for main frame flange (hub) JCT028 Felt for main frame flange (hub) JCT030 Flange mounting screws (4 pcs.) JCT031 Lock washer for flange mounting screws (4 pcs.) JCT032 Flange for main frame excentric shaft. Stamped B. JCT033B Spacing ring (Must be mounted with same flange where it was removed and with chamfer toward centre of shaft as shown). Stamped B. JCT034 Retaining screws for flange cover plate (4 pcs.) JCT036 Felt for cover plate JCT037 Ring for flange cover plate JCT038 Bearing for main frame flange (hub) JCT039 Felt for main frame flange JCT041 Flange mounting screws (4 pcs) JCT042 Lock washer for flange mounting screws (4 pcs.) JCT043 Flange for main frame excentric shaft. Stamped A. JCT044A Spacing ring (Must be mounted with same flange where it was removed and with chamfer toward centre of shaft as shown). Stamped A. JCT045 Bolts for pusher cover plate (6 pcs) JCT046 Felt for pusher cover plate JCT047 Pusher cover plate JCT048 Pusher cover plate spacing ring JCT049 Pusher bearing JCT049A Pusher auxiliary bearing JCT049C Bearing large spacer JCT049D Bearing small spacer JCT050 Screws for pusher cover plate (6 pcs) JCT051 Felt for pusher cover plate JCT052 Pusher cover plate JCT053 Pusher cover plate spacing ring JCT054 Pusher bearing JCT054A Bearing small spacer JCT055 Eccentric shaft JCT057 Pusher (must be sold with JCT059) JCT057A Barbed purge fitting (3 pcs) JCT057B Clamp for purge line hose JCT057C Purge line hose JCT058 Screws for Pusher retaining cover (8 pcs) JCT059 Pusher retaining covers (must be sold with JCT057) (2 pcs) JCT062 Moving jaw top shaft JCT062A Outer bearing (2 pcs) JCT062B Middle bearing (2 pcs) JCT062C Inner bearing (2 pcs) JCT062D Ring for bottom shaft (2 pcs) JCT062E Ring (grooves) for bottom shaft (2 pcs) JCT063 Block (bearing housing) cover (2 pcs) JCT063A Seal (2 pcs) JCT063B Seal (Wiper) (2 pcs) JCT063C O-Ring (2 pcs) JCT063D Block cover screws (16 pcs) JCT064A Clamp for purge line hose JCT064B Purge line hose JCT065 Moving jaw JCT065A Moving jaw cover (2 pcs) JCT065B Moving jaw cover screws (8 pcs total) JCT065C Seal (2 pcs) JCT065D Seal (Wiper) (2 pcs) JCT065R Purge line hose JCT065T Clamp for purge line hose JCT065U Rubber curtain retainer screws (2 pcs) JCT065V Rubber curtain retainer JCT065W Rubber curtain JCT105 JCT066A Holding screws of moving jaw (2 pcs) JCT067A Lockwasher for holding screws of moving jaws (2 pcs) JCT069A Clamp for moving jaw JCT108 JCT077 Bottom shaft of moving jaw (pivoting shaft) JCT109 JCT077A Bottom shaft offset sleeve side A (must be purchased with JCT077B) JCT110 JCT077B Bottom shaft offset sleeve side B (must be purchased with JCT077B) JCT111 JCT079 Key for bottom shaft of moving jaw (2 pcs) JCT112 JCT113 JCT080-1 Housing for offset sleeve side A JCT081A Cover for bottom shaft side A JCT114 JCT082 Screws to hold cover (4 pcs) JCT086-1 Housing for offset sleeve side B JCT115 JCT087-1 Cover for bottom shaft side B JCT116 JCT088A Screws to hold cover for bottom shaft side B (2 pcs) JCT117 JCT118 JCT088-1 Screws to hold cover for bottom shaft side B (2 pcs) JCT119 JCT095A Pivot bar for adjusting mechanism JCT120 JCT095B Bolt and nut JCT095C Threaded rod JCT095D Washer for adjusting rod JCT095E Nut for adjusting rod JCT095F Screw JCT095G Screw JCT095H Lockwasher JCT095J Adjustment holding clamp JCT095K Dowel pin for guide block (4 pcs) JCT095L Screws to hold guide blocks (2 pcs) JCT095M Guide block (2 pcs) JCT095N Clamp pivoting/sliding bar JCT095P Hexagon capscrew to hold support plate (longer)(2 pcs) JCT095N Flathead capscrew to hold support plate JCT095T Support plate JCT095U Dowel Pin JCT095V Guard for adjustment holding clamp JCT095W Screws to hold guard (2 pcs) JCT095X Flat disc (washer) JCT095Y Clamp releaser JCT095Z Hexagon capscrew to hold support plate (shorter) JCT105 Moving Jaw (serrated or smooth) Alloy 2 JCT106 Stationary Jaw (serrated or smooth) Alloy 2 JCT107 Clamp for stationary jaw JCT108 Lockwashers for holding screws of stationary jaw clamp (2 pcs) JCT109 Flat washers for holding screws (2 pcs) JCT110 Holding screws for stationary jaw (2 pcs) JCT111 Side wearing plate (left) JCT112 Side wearing plate (right) JCT113 Side wearing plate holding screws (2 pcs) JCT114 Side wearing plate flat washers (2 pcs) JCT115 Cotter pins (2 pcs) JCT116 Motor plate shaft JCT117 Motor plate JCT118 Motor plate tensioner JCT119 Retaining screw for motor plate tensioner to main frame JCT120 Nut and washer for bolt retaining motor plate tensioner to main frame JCT121 Bottom nut motor plate tensioner JCT122 Bottom angular retaining spacer JCT122A Upper angular retaining spacer JCT123A Top angular retaining spacer (2 pcs.) JCT124 Top nut of motor plate tensioner JCT125 Hopper JCT126 Hopper main frame side clamp JCT127 Hopper cover clamp JCT130 Drawer JCT131 Stand JCT132A Wrench JCT132B Adjustment key JCT133 Bar for Adjustment key JCT134 Cover for bearing flange of main frame eccentric shaft JCT138 Lockwashers for pusher cover (8 pcs) JCT139 Belts (specify 50 or 60 hertz, 5 or 7.5HP motor) (2 pcs) JCT143-1 Front part of JCT frame JCT143A Bar with rubber and hardware JCT144 Back part of JCT frame JCT144B Washer for autolube mounting frame (2 pcs) JCT144C Screw for autolube mounting frame (2 pcs) JCT144D Auto lube mounting frame JCT144E Screws and washers to hold duct (4 pcs) JCT144F Duct inlet JCT144G Air deflector plate (Vent) JCT145-2 Left side of JCT frame JCT145E Motor mounting plate’s yoke JCT145F Motor mounting plate’s yoke screw JCT145G Motor mounting plate’s yoke hardware JCT145J Support plate hardware (2 pcs) JCT145K Support plate JCT146-2 Right side of JCT frame JCT146A Insert for right side of frame JCT146B Screws for insert (2 pcs) JCT146C Dowel pins for insert (2 pcs) JCT146D Screws to hold strip (8 pcs) JCT146E Strip for holding side wearing plate (2pcs) JCT148A Seals (2 pcs) JCT151 Nuts for hopper bolts (4 pcs) JCT152 Hopper bolts (2 pcs) JCT153 Hinge brackets for hopper (4 pcs) JCT154 Lockwashers for hopper brackets (8 pcs) JCT155 Screws for hopper hinge brackets (8 pcs) JCT157 Screws for hopper main frame side clamp (3 pcs) JCT158 Frame/Leg screws (18 pcs) JCT158-2 Sockethead screws (2 pcs) JCT159 Lockwashers for frame/leg screws (22 pcs) JCT160 Frame legs (4 pcs). If ordering please specify front right (F.R.) front left (F.L), rear right (R.R.), rear left(R.L.) JCT161 Dowel pins for frame (8 pcs) JCT162 Cross bars (2 pcs) JCT165 Motor JCT165A Motor shaft key JCT165B Rock shield JCT173 Frame Leg Screw (4 pcs) JCT174 Screw for Stand (4 pcs) JCT175 Rubber pad (4 pcs) JCT176 Nylock Nut (4 pcs) JCT188 Cover for bearing flange of main frame eccentric shaft JCT238 Protective rubber rings for grease line (2 pcs) JCT280 Pulley (specify 50 or 60 hertz) JCT281 Bushing (specify 50 or 60 hertz) JCT351 Seal for offset sleeve side A and B Housing (2 pcs) JCT352 Seal for bottom shaft side B cover JCT374A Bar for Rubber (short hoppers) JCT374B Lockwasher JCT374C Screw JCT374D Bar for Rubber (tall hoppers) JCT374-S Rubber strips (short hoppers) JCT374-T Rubber strips (tall hoppers) JC-MAT Rubber Mat JCBAL2-1 Screw (6pcs) JCBAL4-1 Washer (6pcs) JCBAL9ABalancing block flywheel side JCBAL9B Balancing block Pulley side
Parts Description – Autolubrication System
(Quantities in brackets indicated quantity required per machine. When ordering please specify quantity required as all parts are priced each.)
JCT057A Barbed purge fitting (3 pcs.) JCT057B Clamp for purge line hose JCT064A Clamp for purge line hose JCT064B Purge line hose JCT065R Purge line hose JCT065T Clamp for purge line hose JCT230A Straight grease fitting (8 pcs.) JCT230B Fitting for main grease line JCT231A Check valve (3 pcs.) JCT233 Screws to fit manifold to Jaw Crusher (2 pcs.) JCT234 Fitting for main grease line to nmanifold JCT235 Fitting for main grease line to manifold JCT237 Lock washer for screw to hold manifold to Jaw Crusher (2 pcs.) JCT239A-1 Electric motor JCT240A 90 degree grease fitting (12 pcs.) JCT258 Grease unit main frame JCT260-4 Connector, wiring and plug JCT264 Straight adaptor for pipe JCT265-1 Control panel box JCT266 Grease line from one point lubrication to manifold JCT267 ¼” pipe adaptor JCT271A Pump speed reducer (sold only together with JCT239A-1) JCT272-1 Grease container JCT272-2 Screw (4pcs) JCT275-2 Cap (top part) JCT275-3 Cap (bottom part) JCT275-4 Screw (3pcs) JCT273A Grease pump primer nipple JCT276A Pressure check valve JCT279 Tube Compression Ring JCT282 Double Cone Compression Ring JCT288 ½” Non-metallic clamp for cable JCT289 ¾” Non-metallic clamp for cable (2 pcs) JCT292 Transformer for autolube JCT295-1 Grease Manifold JCT295A Grease Fitting (10pcs) JCT315 Grease Line JCT316 Grease Line JCT317 Grease Line JCT318 Grease Line JCT319 Grease Line JCT320 Grease Line JCT321 Grease Line JCT322 Grease Line JCT323 Grease Line JCT324 Grease Line JCT350 Grease pump bleeder screw JCT350-1 Grease pump bleeder screw larger JCT353-1 Lubricator Housing JCT353B Bottom cover plate JCT353C Screw (12pcs) JCT353D Side cover JCT353E 90 Degree connector and cable JCT353F Inner cover plate JCT353G Clear cover plate JCT353H Screw (8pcs) JCT353J Screw (6pcs) JCT353K Drain plug JCT353L Screw (3pcs) JCT354 Metal Sensor and hardware JCT356-2 Lubrication Monitor JCT357 Bridge Rectifier
Jaw Crusher Automatic Lubrication Motor 1
To remove the motor (JCT165):
Remove motor guard (JCT003).
Release tensioned belts by undoing nuts on motor plate tensioner (JCT118).
Remove belts (JCT139).
Remove motor (JCT165) by undoing bolts holding it to motor plate (JCT117).
Removing flywheel (JCT011) (same procedure for drive pulley (JCT016)):
Remove flywheel guard (JCT006).
Open up locking plate lips (JCT009) for all screws (JCT007 & JCT008).
Remove screw (JCT008), loosen up screws (JCT007) enough to allow insertion of a small plate and a ½” NC nut between the retaining plate of flywheel and the flywheel itself. Use a ½” bolt screwed in the nut through the hole in the retaining plate (JCT010) to force out the flywheel from the main excentric shaft (JCT055).
Disconnecting the pusher (JCT057) from the moving jaw (JCT065):
Remove grinding jaws (JCT105/106).
The moving jaw (JCT065) has the appropriate holes in the face for one to insert a ½” socket wrench and allen drive to start undoing bolts (JCT058). Afterwards, a bondus socket wrench in combination with a ratchet will speed up the process considerably (see Picture #1).
Moving jaw (JCT065) removal:
To remove moving jaw from the machine, remove cover (JCT081A) by undoing screws (JCT082) with a normal socket wrench and pipe (see picture #2).
Fasten the extractor/offset hub puller across offset sleeve (JCT077A) by using the threaded holes in the face (see Note 1). The bar will have two threaded holes ½” NC in line with the ones used, clearing the hub’s diameter. Now one can thread two bolts through the bar against the JC frame and pull out the hub. Make sure also to remove the pivoting shaft key (JCT079). By loosening the adjustment clamp one can now slide out the bottom shaft from the machine and remove the moving jaw.
To pull out bottom shaft (JCT077) from cover (JCT087-1), first remove the two screws (JCT088A) and two screws (JCT088-1) from it. Then screw in two through the cover on the shaft’s face with at least ½” thread into the shaft and clearance of ½” between cover and screw’s head. Make sure that screws are protruding from cover’s surface at least the same amount. Set shaft vertically with cover up supported at the lower edge. If a press is available press down on the screw’s head that had previously been mounted on the shaft’s end. Otherwise, by using the same set up and a flat plate set onto the screw’s head, hammer them down thereby freeing the cover from the shaft.
Now using a similar method one can press out the shaft from the offset sleeve.
Disassembling the moving jaw (JCT065):
All bearings, top and bottom, are precision pressed in line into the moving jaw. The same procedure will be used to press them out.
To replace old ones with new ones, proceed by pressing the top ones into the seats, one on each side and at the bottom two from each side.
Removing the pusher (JCT057):
Prying out the frame’s insert (JCT146A) will greatly facilitate the pusher removal. Therefore, first remove flange A (JCT043) and then undo screws (JCT030) from flange B (JCT032). (See Note 1.) The insert will come out by: 1) Removing support plate (JCT145K) by removing screws (JCT145J & JCT145F). 2) Insert two round bars (½” diameter by 2-3/8″ long) into threaded holes ¾” NC on part JCT146A (see Picture #3) 3) Screw in ¾” minimum thread screws. (For this purpose, custom made bolts are available from the factory without the need of ½” dia. x 2-3/8″ bars. Also read Note 1.) This will pry out the insert. Now the pusher can slide out from JC frame.
Pusher (JCT057) disassembling:
Set the excentric shaft (JCT055) vertically and supports under cover side A. The shaft can be pressed out all the way since it has no shoulders. Remove covers. Press out first bearing on side A. Rotate pusher. Use a bar slightly smaller than the big diameter of the center’s bearing inner ring and press out side B bearing. Central bearing will be removed by pressing onto the bearing roller.
Flange A (JCT043) and B (JCT032) are conventional bearing housings: If bearing replacement is necessary press them out, replace and re-pack with grease. At the reassembling stage, two important things to keep in mind: 1) Reassemble pusher and press onto it excentric shaft (JCT055) and also flange B (JCT032). Slide assemblies into JC frame. Fasten flange B to frame with two 3/8″ NC bolts. This allows one to mount flange A on the opposite side in an easy manner, particularly when one has two longer 3/8″ NC bolts that will drive the flange into the frame’s seat. (See Note #1). 2) The moving jaw must be re-assembled (if bearing replacement was needed) before being re-assembled into the JC. Being a relatively heavy piece some auxiliary lifting device might be necessary to lower it within the frame. All machines purchased and delivered before May 31, 2004 had been equipped with a sealing system made of parts JCT148, 149, & 150. After that date, a new improved seal (JCT148A) has been installed and it is fully interchangeable with all previous machines and is available for replacement. When replacing seals, first slide them onto covers (JCT065A) and then proceed in lowering the moving jaw within the JC frame until it has the lower bearing’s hole in line with housing’s 077B, 087, & 088 will be slid through the bearings and secured tightly with clamp (JC095J). Now, one can insert key (JCT079) onto the bottom shaft on the opposite side and by using a plastic mallet, hammer into place offset sleeve (JCT077A). Please note that in order to have the bottom shaft staying in place rigidly when assembling this offset sleeve it is sufficient to tighten the adjustment clamp on the opposite side.
Pusher installation and positioning:
With everything bolted in place, that is, insert (JCT146A) and flanges (JCT032 & JCT043) it is very important to tighten first locknut (JCT018) on side A and then the locknut (JCT019) on side B. In both processes, it is advisable to screw on old ½” NC hexagon head bolt, preferably with same heavy duty washers, in between at the opposite end of the excentric shaft and hammer onto it while tightening the locknuts. One will notice the shaft’s lateral displacement until it will no longer happen and therefore the shaft will be correctly positioned.
Two customized accessory kits are available that will facilitate enormously the disassembling/assembling of this machine.
Kit Two: All items in Kit One plus: – Disk to remove spherical roller bearings in pusher – Disk to press in pusher’s bearings – Disk to press in & out moving jaw bottom bearings – Riser to support moving jaw to press in or out bottom shaft bearings – Disk to remove bearings (bushings) in top of moving jaw – Bar to press in & out rings for bottom shaft – Disk to press bearings into flanges A & B – Disk to press bearings (bushings) in top of moving jaw in their seat
Autolubrication System Maintenance and Troubleshooting Information
Number of Devices Involved in the Pumping Process: From 1 to 3 Discharge/Cycle with Adjustable Pumping Element: 0.01 – 0.16 cc RPM: 22 Motor: 24 V dc – 30 W – 1.5 A Reservoir Capacity: 2 kg Maximum Working Pressure: 275BAR (3993 PSI) Recommended Lubricants: Grease Max. NLGI – 2 Temperature: From -20°C to +80°C Discharge Outlet: ¼”G
Overall Dimensions (in millimetres):
Single Line Progressive Dividers DPM Features:
Discharge/Stroke: 0.10cc – 0.15cc – 0.20cc Operating Pressure: From 15 bar to 275 bar Operating Temperature: From -20°C to +80°C Body Distributor: Galvanized Steel Number of Cycles/Minute: Maximum 250 Inlet: 1/8″ Outlet: M10x1 Mounting Screws: M5x40 Lubricants: Grease Max. NLGI – 2 Control Elements: Visual and Electric for Cycle and Overpressure indication Main Lines: Tube O.D. 10-8-6 Secondary Lines: Tube O.D. 6-4
Overall Dimensions (in millimetres):
Single Line Progressive Dividers Flow Diagram:
Pressure supply through internal passages moves piston “A” left while holding pistons “B” and “C” fixed. A measured quantity of grease discharges from Outlet 4.
Piston “A” reaches end of stroke. It opens internal passages directing pressure supply to right end of piston “B”. Grease discharges from Outlet 1.
Piston “B” reaches end of stroke. It opens internal passages directing pressure supply to right end of piston “C”. Grease discharges from Outlet 2.
Piston “C” reaches end of stroke. It opens internal passages directing pressure supply to left and end of piston “A” which returns on its initial position as grease discharges from Outlet 3.
Black – Pressure supply acting
Dots – Grease being dispensed to bearing White – Static, no pressure
Layout of Centralized Lubrication System with Single Block Progressive DPM Series
Starting Up the System
Fill the grease lines with clean grease. An air driven pump works well for filling long grease lines. Fill the discharge line from the valve manifold to the bearings and also lubricate the bearings with a hand grease gun if possible.
Fill the reservoir with clean grease.
Loosen the grease lines at all valve manifold inlet outlets as well as at bearing injection points.
Before starting the motor, check the following: ♦ System power requirements – voltage, phase, AC or DC, etc.
Start up the system pump and progressively purge all parts of the system of air. Tighten the inlet fitting at the primary valve manifold. When the pump to the primary valve manifold line is free of air, repeat the operation at the bearing injection points.
After the system has run for a while, check all connections for leaks.
Observe normal system operating pressure, check if there is any excessive pressure peaks or dips which may indicate a tight bearing or valve manifold being distorted in mounting, or a loose or disconnected fitting.
To check if the auto lubrication system is functional
Simply disconnect main grease line (235) from the grease reservoir or manifold and let the machine operate for more than one hour. There will be a teaspoon of grease protruding from the opening.
Be aware that the pump operates only one minute every hour regardless how many times one starts and stops the machine. Therefore, if ever circumstances arise where there is doubt that the lubrication occurs, repeat the above operation to ascertain the situation.
How to Prevent Problems:
Keep reservoir filled. A pump operating with an empty reservoir may force air into the system causing difficulty in building pressure or preventing the pump from priming.
Use clean grease because foreign matter may clog pump filler screen. Keep filler screen and filler connection assembly clean.
Inspect entire system regularly including all grease lines. Replace if damaged. Connections should be tight and a small amount of grease should be at the edge of each bearing.
How to Locate and Correct Problems:
If there is air in the reservoir it is likely because the pump fails to build pressure. Correct this by cleaning out reservoir, adding a small amount of oil (this helps prime and purge system of air), and filling it with clean grease. To ensure that the system is free of air, cycle it several times and then open the lines at the valve manifold inlet outlets to bleed out the air. Note: Remember that a fully pressurized grease system capable of operating properly is conditional to having removed all air and filled it with grease!
Locate blocked points as follows: A. Open the pressure line at the inlet outlet to the manifold to check for blockage of the line to this point with pump operating. Grease should flow without the pressure opening the pressure check valve and releasing grease. B. Disconnect lines in an alternative sequence at the manifold. Grease should eject from each of the discharge outlets. If any of the outlets does not let out grease, the manifold is not functioning. C. If the manifold is O.K., reconnect the grease lines and check at the bearing connections that grease reaches them. With a manual grease gun and a grease nipple one can check each passage at the bearing grease outlets that there is no blockage causing the grease not to flow. If all checks out O.K., reconnect all lines and start the autolube system.
If the Autolube System Operates but does not pump grease:
Pump Operates but Unable to Build Pressure or Operate System:
Other Possible Problems:
Autolube – Troubleshooting Wiring Connections
If the autolube system is not operational, it is possible that there is a wiring connectivity issue. Test wiring for continuity as shown in the steps below:
First remove the bottom cover plate from the autolube system (JCT353B). With the cover removed, unplug the motor cable connector as shown.
Start by testing the cable connector on the side that leads to the motor. The two white wires on the end need to be checked for continuity as shown below. If there is continuity between these wires, this connection is not the cause of the issue. Proceed to the next step.
Next test the connections on the corresponding cable connector that leads out the side of the autolube housing. Both of these wires need to be checked for continuity. See pictured below:
If testing is successful proceed to the next step.
Next test the cable that leads from the autolube system to the control panel. The two wires that need to be checked for continuity are the White (7) and green (6). See pictured below.
If all of the previous tests are successful, the last connection to check is the one at the PLC. Open the control panel and confirm that the white wire shown below is properly connected to the 12 port in the top of the PLC controller.
If all of the wires covered in this instruction set are tested successfully, it is likely that the PLC controller is faulty.