DJF3000 Progressive Distributor Block

How DJF3000 Progressive Metering Works

Grease or oil enters the inlet (first) slice of the DJF3000 stack and advances pistons slice by slice. 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 injector firing. One full movement of the cycle indicator pin (or one pulse from a type 8 electromechanical switch rated 250 VAC 1 A / 125 VAC 3 A) confirms that every connected point on that stack received its dose for that pump run.

DJF3000 slices are sized for heavier per-point delivery: even the smallest twin size 25 delivers 0.4 ml/cycle—higher than the maximum twin dose on DJF2500 (0.64 ml on size 40 twin). Size 150 single outlets reach 4.8 ml/cycle for large plain bearings, way covers, and open gears fed through progressive branches.

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 steel-mill OEMs prefer progressive blocks over open header systems where a blocked point may go unnoticed until failure.

Typical Plant Layout

1. Pump + controller — BSB, FS, or electric grease station from Related Products; size for 25 MPa at farthest outlet.
2. Fill filter — 150 μm on grease fill; pair with grease filter in dusty steel or foundry environments.
3. Main line — typically Φ10 mm inlet tube (1.8–5.5 m) to the DJF3000 inlet section.
4. DJF3000 stack — inlet + 3–10 working slices + end section; cycle monitor on left or right face.
5. Branch lines — Φ8 mm outlet tube (1.5–4.5 m) to each bearing, slide, or pin; respect max 60 cyc/min with cycle pin installed.

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

When to Choose DJF3000 (Not 1000, 2000, or 2500)

• Each point needs ≥0.4 ml/cycle on twin layout—or up to 4.8 ml/cycle on single size 150—for large bearings, way lubrication, or open gear branches.
• Plant requires 25 MPa with carbon steel body and Viton on hot machine frames or steel-mill ambient.
• Dose per point exceeds DJF2000 (0.16–1.12 ml/cyc) and DJF2500 (0.08–1.28 ml/cyc) capacity without stacking excessive slices.
• 3–20 outlets on one sequential header with modular slice replacement without full re-piping.
• Machine-tool OEM wants progressive logic with larger Φ8 mm outlet runs than compact 1000-series Φ4 mm branches.

DJF3000 vs Other Metering Architectures

Not dual-line: DJF3000 is single-line progressive only. Do not mount on A/B reversing headers without full system redesign.

Sizing a DJF3000 Stack (5 Steps)

1. Point count & dose — list each bearing with ml/cycle from OEM chart or bearing calculator.
2. Size code — pick 25–150 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 Φ8 mm outlet with your NLGI grade; heavier grease may need shorter runs or warmer fill.
5. Monitor — specify mechanical pin or electromechanical switch for PLC fault stop when pin motion stops; add crossport kit 32266-4 when drawing requires line crossover.

Ordering Code Example

Example stack: DJF-3000 · 4 sections · indicator 8R (micro-switch, right face) · sequence such as 100T, 75SR, 50T with cross-port CF notation left/right per factory drawing (Section 2 sketch). Cross-port kit P/N 32266-4 (3000 class). 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 (3000-xxT/S, outlet 20730-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 · project cases.

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