DJF2500 Block

How DJF2500 Progressive Metering Works

Grease or oil enters the inlet (first) slice and advances pistons slice by slice through the stack. Each working slice discharges a fixed volume through its T (twin) or S (single) outlets only after upstream sections complete their stroke—this is progressive (series) logic, not parallel PDI firing. One full movement of the cycle indicator pin (or one pulse from a type 8 electromechanical switch) confirms that every connected point on that stack received its dose for that pump run.

If one bearing line blocks, lubricant cannot pass and the chain stalls. Line pressure rises; the indicator stops; the host controller should alarm on missing cycle signal within the timeout window. That fail-safe behaviour is why machine-tool and industrial OEMs prefer progressive blocks over open header systems where a blocked point may go unnoticed.

Typical Plant Layout

1. Pump + controller — CS, CSK, FS, or electric grease station from Related Products.
2. Fill filter — 150 μm on grease fill; pair with grease filter in dusty environments.
3. Main line — typically Φ8 mm inlet tube (1.5–4.5 m) to the DJF2500 inlet section.
4. DJF2500 stack — inlet + 3–10 working slices + end section; cycle monitor on left or right face.
5. Branch lines — Φ6 mm outlet tube (1.2–3.5 m) to each bearing, slide, or pin.

One manifold assembly can serve up to 20 points; larger machines may use several stacks fed from one pump header or separate zones.

When to Choose DJF2500 (Not 1000, 2000, or 3000)

• Need 25 MPa with steel body and Viton for elevated ambient or hot machine frames.
• Require the finest twin doses in the DJF family—down to 0.08 ml/cycle on size-5 twin slices (finer minimum than DJF2000 at 0.16 ml).
• Dose per point falls in 0.08–1.28 ml/cycle—below heavy DJF3000 capacity (0.4–4.8 ml/cyc) but above compact DJF1000 pressure class (16 MPa).
• 3–20 outlets on one sequential header with modular slice replacement without full re-piping.

DJF2500 vs Other Metering Architectures

Not dual-line: DJF2500 is single-line progressive only. Do not mount on A/B reversing headers without full system redesign.

Sizing a DJF2500 Stack (5 Steps)

1. Point count & dose — list each bearing with ml/cycle from OEM chart or bearing calculator.
2. Size code — pick 5–40 and T vs S: twin slices feed two nearby points from one section; single feeds one side only.
3. Slice count — sum working slices (≤10) so total outlets ≥ point count; do not plug unused outlets—route or use correct S/T layout.
4. Pressure & tube — confirm pump delivers 25 MPa at the farthest Φ6 mm outlet with your NLGI grade; respect max 60 cyc/min with cycle pin installed.
5. Monitor — specify mechanical pin or electromechanical switch (250 VAC 1 A or 125 VAC 3 A) for PLC fault stop when pin motion stops.

Ordering Code Example

Example stack: DJF-2500 · 4 sections · indicator 8R (micro-switch, right face) · sequence such as 35T, 15SR, 10T with cross-port CF notation left/right per factory drawing (Section 2 sketch). Cross-port kit P/N 32265-3 (2500 series). Send machine layout for confirmed BOM.

Installation & Commissioning

• Mount with slice T/S markings visible; torque inlet/outlet fittings to spec—never block unused outlets.
• After first fill, bleed air at the highest outlet in the stack; verify one full pin stroke per pump cycle.
• Route tube through lubrication pipe and compression fittings; protect exposed runs near heat or impact zones.
• Log size codes and P/N (22500-xxT/S) in CMMS—when a slice is replaced, match original sequence exactly.

Troubleshooting Quick Reference

Hub pages: progressive manifold · grease distributor block · metering unit · commissioning service.

Before you buy: read our guide to how distributor blocks work.