DOUBELL JUMBO SERIES OPERATIONS GUIDE

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Curtis Stanley
5 years ago
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1 Applicable Codes: JJM, JJMEVSP, JJMEV3P, JJMPV, JJMDV JJJM, JJJMEVSP, JJJMEV3P, JJJMPV, JJJMDV For any questions pertaining to this guide, contact us: TEL:

CONTENTS: 1 Setup... 4 1.1 Fit the Mould... 4 1.2 Adjust the Wheel Brackets... 5 1.3 Vibrator... 7 2 Operation... 8 2.1 Ready Machine... 8 2.2 Add Mixture... 8 2.3 Fill Mould... 8 2.4 Drop Tamper.

2 CONTENTS: 1 Setup Fit the Mould Adjust the Wheel Brackets Vibrator Operation Ready Machine Add Mixture Fill Mould Drop Tamper Compact Mix Raise Mould Move Machine Maintenance Start of Operation End of Operation Periodical Troubleshooting Machine-Related The handle won't stay down There is little vibration when button pushed There is one shaft that s not going up/down The mould is higher/lower than the machine The mould doesn't lift high enough to clear the bricks when done Handles are sticking Tamper doesn't fit into mould box smoothly Brick-Related Wider at the bottom than at the top Brick heights differ My brick height is too high Bricks are breaking Bricks behind are breaking

3 INTRODUCTION: Brick-making is a process. It begins with the raw materials brought in from a quarry, followed by the correct mixing of those materials in combination with cement, the compressing of those materials into bricks & ends with the curing of those bricks before transporting them. This guide strictly deals with the operation of the MACHINE. For mixing advice, please read the mixing guide. This manual has been created to acquaint you with the functioning of your machine. As you become familiar with the process, you will no longer need to keep referring to these steps & may even create your own shortcuts to increase efficiency. An important point to emphasise is to observe problems may arise any time, but if noticed quickly, can be rectified with minimal cost. When planning out your business costing & cash flow projections, ensure to budget for a period of initial learning. During this period there may be wastage before all workers involved are familiar with the machinery. 3

1 Setup Setting up the Jumbo MK II is a simple checklist procedure.

lower the tamper into the mould-box Loosen & remove the bolts of the carrier plate attaching the tamper Loosen & remove

4 1 Setup Setting up the Jumbo MK II is a simple checklist procedure. Before starting the brick-making operation, please ensure that your machine is at the "ready" position by following this checklist of tasks. 1.1 Fit the Mould If there is a mould fitted, remove it by doing the following: Release the arm catches & raise arms to lower the tamper into the mould-box Loosen & remove the bolts of the carrier plate attaching the tamper Loosen & remove the bolts of the mould bracket, attaching the mould-box Remove the rear wheel brackets (if necessary) Slide out the mould The new mould is fitted in reverse: Remove rear wheel brackets (if necessary) Slide in entire mould Raise mould arm to lower mould bracket into mould box 4

Raise tamper arm to lower the carrier plate onto the tamper Fit & tighten bolts on mould bracket attaching the mould box Adjust tamper left/right & forward/back until tamper footplates are not

tamper can be made by lifting the tamper up so that the footplates are level with the top of the mould box. If the tamper is not dead centre (i.e. the footplates are touching the mould box anywhere) then loosen the bolts attaching the carrier plate to the tamper, adjust the tamper accordingly & re-tighten the bolts.

The setting is correct when the mix bin is flush (aligned) with the top of the mould box.

5 Raise tamper arm to lower the carrier plate onto the tamper Fit & tighten bolts on mould bracket attaching the mould box Adjust tamper left/right & forward/back until tamper footplates are not touching the inside of the mould box Fit & tighten bolts on the carrier plate attaching the tamper Replace rear wheel brackets INCORRECT CORRECT DOES NOT SCRAPE SIDES WHEN LOWERED Adjustments to the tamper can be made by lifting the tamper up so that the footplates are level with the top of the mould box. If the tamper is not dead centre (i.e. the footplates are touching the mould box anywhere) then loosen the bolts attaching the carrier plate to the tamper, adjust the tamper accordingly & re-tighten the bolts. 1.2 Adjust the Wheel Brackets Different moulds have different heights. To cater for this, the machine height relative to the mould height must be adjusted. The setting is correct when the mix bin is flush (aligned) with the top of the mould box. The height of the machine is changed by taking the bolts out of the wheel brackets, sliding them up/down until the desired height is achieved & replacing the bolts. The front brake pedal will also need removing. A list of wheel height adjustments for the various moulds is included so no trial & error is necessary. Use a brick/block to steady the machine while changing the wheel mould bolts to the correct hole settings. 5

6 (SEE APPENDED WHEEL-MOULD HEIGHT ADJUSTMENT GUIDE) 6

7 1.3 Vibrator If your machine is fitted with a vibrator, ensure that oil & petrol/diesel levels are optimal. If there are electrical cords, make sure they do not cross any moving parts of the machine such as the mould. For electric vibrators with extension cables running to a power source, be careful than enough slack is given so that the cord never crosses the bricks/blocks & potentially damages them. Have the cord run along the side of the column of blocks if it must be run at the back of the machine. Alternatively, have the cord run from the front & shorten as bricks/blocks are laid. INCORRECT CORRECT 7

8 2 Operation The operation of the machine has been broken down into easy-to-follow steps. This instruction set will assume that mix is ready to use & the yard has enough operating space. The number of workers to conduct the machine is decided by you. Usually for optimal operations, it is advised to have 2 workers on the machine. 2.1 Ready Machine The "ready" position of the machine is achieved by making sure the following is set: The machine is clear of bricks/blocks laid Raise mould arms ( mould box on ground ) Locked tamper arms ( tamper raised above mould box ) 2.2 Add Mixture Assuming the mix is of the correct quality, tip the mix from the barrow into the mix bin in the front of the machine. 2.3 Fill Mould With the provided rake, push the mixture back into the open mould box. Continue pushing mix into the mould until all cavities are filled level to the top of the mould box. Remove excess mix for the top by pulling it back with the rake into the front bin. 8

9 2.4 Drop Tamper Place one foot onto the brake pedal to prevent the machine from moving about. Release the Tamper Arm catch to drop the tamper onto the mixture in the mould. 2.5 Compact Mix In a manual setting, the tamper is repeatedly raised & then dropped into the mould. This process is repeated until the mixture is compacted to the height correct height of the brick/block. When the shaft nut has been lowered to the top sleeve, the mix has been fully compacted. With a vibrator motor kit, a button pressed will vibrate & compact the mixture automatically & can be stopped when it is observed that the mix is compacted enough (watch the shaft nut until it touches top sleeve). In both scenarios remember to stand on the brake pedal to stop machine from moving off. MANUAL COMPACTION 9

WITH VIBRATOR MOTOR NOT COMPACTED ENOUGH SUFFICIENT COMPACTION TAKE NOTE: IF THE BRICK HEIGHT IS UNIFORMLY INCORRECT, ADJUST THIS NUT TO UP OR DOWN BY THE DIFFERENCE. (see troubleshooting) 2.

10 WITH VIBRATOR MOTOR NOT COMPACTED ENOUGH SUFFICIENT COMPACTION TAKE NOTE: IF THE BRICK HEIGHT IS UNIFORMLY INCORRECT, ADJUST THIS NUT TO UP OR DOWN BY THE DIFFERENCE. (see troubleshooting) 2.6 Raise Mould While the tamper is lowered, grip & pull only the mould box arm to raise both the mould box & the tamper. Lock this arm & release foot from brakes. 2.7 Move Machine Pull machine forward until there is a safe distance from the newly laid bricks/blocks. 10

3 Maintenance Maintenance is an important part to the

Without proper maintenance, poor quality bricks/blocks

day as well as a periodical check-up. 3.

following tasks: Grease the pillow blocks (bearings that

11 3 Maintenance Maintenance is an important part to the working day. Without proper maintenance, poor quality bricks/blocks could be manufactured & the lifetime of the machine severely reduced. Maintenance can divided into the start & end of the work day as well as a periodical check-up. 3.1 Start of Operation Before the day begins, perform the following tasks: Grease the pillow blocks (bearings that rotate the arms) Grease shafts Tighten carrier plate - shaft nut Tighten all visible nuts / bolts PILLOW BLOCK MOULD BRACKET ACCESS TO SHAFTS SHAFT TO GREASE 11

12 3.2 End of Operation To lengthen the life of the machine, care must be taken at the end of the work day. CLEANING After the day's work, the residual cement/mix should be cleaned from the machine bin & mould box. For hardened dirt, a metal scraping brush can be used. Hitting the tamper to remove dirt should be avoided as this may damage the legs over time & could affect the quality of the brick/blocks made. STORAGE When the machine is not in use, it should be stored away in a covered area, out of the way of rain or other adverse weather conditions. It is advisable to apply oil/grease to the mould box overnight to minor dirt from hardening. 3.3 Periodical Check springs are still tight enough Check handles & arm catches are not worn out Check for visible cracks in the frame/arms in cases of heavy long- term usage Check mould cavities are still shapely Check mounting rubbers 12

13 4 Troubleshooting As you become familiar with the machine, you will be able to identify causes to problems encountered & come up with solutions based on your experience & brick-making intuition. Until that time comes, you can refer to this troubleshooting guide for helpful insights. While some problems may have multiple possible causes, we have tried to group difficulties into 2 sections: Machine-Related & Brick-Related. 4.1 Machine-Related These are problems that relate to the brick-making machine The handle won't stay down The catch is broken or the spring is weak Replace catch part or install new springs There is little vibration when button pushed Electrical Fault Have an electrician check the vibrator unit Weight settings are incorrect Open vibrator & add/adjust weights. Ensure there is a offbalance There is one shaft that s not going up/down Shaft not secured Tighten screw in carrier plate attaching the shaft 13

14 4.1.4 The mould is higher/lower than the machine Wheel mould brackets are at an incorrect setting Raise/lower wheel brackets until The mould doesn't lift high enough to clear the bricks when done The arm-mould link is at the incorrect setting Adjust arm-mould link bolt to another setting Handles are sticking Pillow-blocks are sticking Grease handle shaft bearings Tamper doesn't fit into mould box smoothly Mould not aligned Loosen mould box & tamper nuts. Adjust until level & squared. Tighten bolts & nuts on the carrier plate & mould brackets. 14

15 4.2 Brick-Related These are problems that relate to the brick directly Wider at the bottom than at the top The mix is too liquid Add more aggregate/cement to dry the mix more Brick heights differ Carrier plate is not level Check the tamper plate holding the mould to the shaft is level. Adjust with screw on the shaft Mould tamper is not level If the tamper plate is level, use spacers when attaching the mould tamper to ensure that is level as well. Machine not level - Wheel height incorrect Adjust wheel height so machine is level My brick height is too high Insufficient compaction Compact for longer (if manual, more drops. If vibrator, longer cycle) 15

16 Pallet on static adaptor not thick enough Correct pallet size Machine's shaftstopper nut is at incorrect setting Readjust shaftstopper nut up/down for correct height Bricks are breaking Likely to be from not standing on the brake while vibrating / compacting Stand on brake while compacting Ground not level Lay concrete slab Mix too dry Add more water Bricks behind are breaking Vibration is transferred along the ground Thicker concrete slab or wider gap between drops 16

17 JUMBO WHEEL-MOULD ADJUSTMENTS: MOULD CODE: FRONT: REAR: AA, AB, AE, AR A14 : C8 A11 : C7 AAMXC, AAMXS A13 : C7 A11 : C7 BBM, BCM, BAM A7 : D1 B6 : D2 BA, BB, BC, RWBD A6 : C1 A5 : C1 PB, PG, PZ, Pavers (55mm) B16 : D11 B12 : D8 PB, PG, PZ, Pavers (65mm) A16 : D10 B11 : C9 PB, PG, PZ, Pavers (80mm) A15 : D9 A12 : C8 17

18 JUMBO ARM-MOULD ADJUSTMENTS: MOULD CODE: INNER: OUTER: AA, AB, AE, AR B-1 B-2 AAMXC, AAMXS B-1 B-2 BAM, BBM, BCM B-1 B-2 BA, BB, BC, RWBD B-1 B-1 PB, PG, PZ, Pavers (55mm) B-1 B-2 PB, PG, PZ, Pavers (65mm) B-1 B-2 PB, PG, PZ, Pavers (80mm) B-1 B-2 18

19 Outer Arm Handle Inner Arm Handle Top Sleeve Shaft Upper Catch Inner Arm Link Lower Catch Carrier Plate Outer Arm Link Mould Tamper Bottom Sleeve Mould Box 19

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DOUBELL JUMBO MK II OPERATIONS GUIDE DOUBELL JUMBO MK II OPERATIONS MANUAL DOUBELL JUMBO MK II

DOUBELL JUMBO MK II OPERATIONS GUIDE DOUBELL JUMBO MK II OPERATIONS MANUAL DOUBELL JUMBO MK II DOUBELL JUMBO MK II The world of brick-making can be likened to making a cup of coffee. Even when you have a coffee-machine, you still must adjust the strength until you get the coffee you want. Making