Northwest Automatic Lubrication, Inc.
Beka-Max MX-F series Progressive Block
Trouble shooting guide:
this Trouble Shooting Guide when the lubrication system is in pressure relief.
High pressure in the distribution
system can be caused by a blockage at the end of a distribution line or by contamination within the distribution block. Follow the procedure listed to determine the location and type of blockage.
A series progressive distribution
block relies on the lubricant moving spool valves in the block sections in a specific series to move the lubricant out of
a block segment in to the distribution line to the bearing. If a blockage occurs
at the end of a distribution line or in a block segment the next spool in the series cannot move and hydraulic back pressure
builds eventually going over the pressure relief valve.
The system pressure
relief should be between 4,500 and 5,000 psi. If the pump is equipped with a
gauge the pressure relief setting can be determined by checking the gauge, if not install a pressure gauge in-line to make
sure the pressure relief is set at the correct level.
To locate the blockage loosen
the inlet fitting at the distribution block farthest from the primary distribution block.
Always start at the block farthest from the primary block. The primary block is the block that is connected to the pump and has lines connected
to the secondary blocks. The primary block may in some cases feed both secondary
blocks and bearings, but will always be the block connected to the pump.
If when the fitting is loosened
at the block farthest away from the primary block and there is a high pressure release of grease, the blockage is in that
block assembly. If there is not high pressure at the block inlet there is not
a problem in that block assembly. Move to the next block assembly closer to the
primary block and perform the same test.
There are two
basic types of blockages in series progressive systems.
Blockages at the end of a distribution line:
These types of blockages
are usually caused by a broken line being capped after it has been broken in some manner.
This is done because of the thought that the entire reservoir of grease may be pumped out of the broken line. With a series progressive type system a broken line will only lose the amount of grease
designated to that line, all of the other points will get there designated amount of grease.
If a broken line will cause an environmental hazard you can tie strap a bag over the end of the broken line to collect
the grease until the line can be repaired. Another rare cause of a blockage can
be a crushed steel line or a rotated bushing, blocking the grease access hole.
To locate the blockage use
the following procedure. When you loosened the inlet line there was a high pressure
rush of grease out of the fitting indicating high pressure in the block assembly. Re-tighten
the inlet line and press the extra lube button to start the pump and bring the system back up to pressure relief. Then loosen each of the lines on the side of the block starting with the top left side. If you loosen all of the lines and no pressure is found then the blockage is inside of the block assembly,
go to (Blockages inside of a Block Assembly). If you loosen a line on the outlet
side of the block and you have pressure at that line, the blockage is at the bearing side of the line. Consult a block schematic or trace the line to locate the bearing end of the line and find out what is
causing the blockage. Correct the line blockage then make sure that all lines
are tight at the block, then press the extra lube button at the pump and test the system to make sure that there are no other
Blockages inside of Series Progressive Block Assembly:
Blockages inside of Series
Progressive Blocks are mainly caused by contamination in the grease. Particles
as small as dust, that are blown into an open reservoir lid can cause an enormous amount of trouble. Grease Lubrication Systems should be treated with the same care as a hydraulic system. In-line filters are available and can be purchased from your system supplier if contamination is a great
To locate a blockage inside
a block assembly use the following procedure. When you loosened the inlet line
at the block assembly there was a high pressure rush of grease out of the fitting indicating high pressure in the block assembly. Re-tighten the inlet line and press the extra lube button to start the pump and bring
the system back up to pressure relief. Then loosen each of the lines on the side
of the block starting with the top left side. If there is no pressure at any
of the lines you have determined that the blockage is in the block assembly. After
marking the lines to ensure that they are re-connected to the same outlets, remove the distribution lines and clean the block
assembly. Remove the 9mm caps on both sides of the block to give access to the
spool valves. Use the back end of a small drill to press the spool of each block
segment back and forth until you locate the spool that is stuck. By pressing
back and forth you may be able to free the spool and dislodge the piece of contamination.
Even though you may be successful at freeing the spool you will want to order and replace the block segment that had
the seized spool. I t has been our experience that once a spool has seized it
will do so again from the scoring of the spool. If you remove the spools from
the block segment be sure to keep them in order and replace them into the same block segment.
Each of the spools has been hand honed to that specific block segment even if they are the same number value.
After you have repaired the
block assembly, install a grease zerk into the inlet of the block assembly and use a hand grease gun to test the block. Then re-install on the machine making sure to re-connect the distribution lines to
their correct ports. Press the extra lube cycle button on the pump and run it
through several cycles to check the distribution system.