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California Pellet Mill

PELLET MILL MAINTENANCE


Maintenance
• Die Failure Causes/Prevention
• Die Care
• Pellet Mill maintenance
• Trouble shooting
• Maintenance Affecting Production
• Maintenance Schedule
Die Mounting
• Clean Clamps
• Clean quill Flange
• Coat mating surfaces with anti-seize
compound
• Check for die clamp/Quill Flange wear
using gauge
• Check Die Driving Key for wear
Die Clamps

• Torque bolts to 350 Ft. Pounds


• Tighten in Star Pattern
• Re-check new die after one shift (heat
cycle)
Worn Die Clamp was touching the OD of die
Wear Groves –
5/8 deep.
Maximum
adjustment on
roller eccentric
Roll Adjust

• Clean die/rolls
• Adjust rolls counterclockwise to the die
• Adjust to skip touch or sometimes no
touch
• Avoid metal to metal contact or running
the pellet mill w/o feed for extended
periods
Wipers
• Purpose: To take feed from the rear of the
die and spread it back onto die surface

• Check for wear (should be very close to


quill flange – 1/8 inch)
Deflectors
• Purpose: To take feed off the feed cone
spreading it evenly across the die face

• Ideally – each roll gets equal feed resulting


in even wear of rolls and smooth operation
of pellet mill and pellet mill amps
• Adjust 1/8 to ¼ inch away from feed cone
• Replace when adjustment can not be
made
Feed Cone Fasteners – 3 of 6 being used-
feed cone will move and hit deflector or build
up feed
Photo is looking into a pellet chamber with pellet mill door open: Dust Seal Ring should
be adjusted to 1/8 inch from feed cone to prevent fines from bypassing the die and going
straight to cooler – check once a year or with new feed cone
GEARBOX , SEAL
AND
DIE CLAMP MANAGEMENT
Shear Pins
• Bushings – check for cracks when
replacing shear pins. Cracked bushing will
result in shear pin fatigue/failure
• Check that shear pin groove is in center.
(Keepers holding pin)
Shear pin not secured, has moved, not in shear position –
main gear could be damaged
Gearbox
• Oil Temperature – 170 degrees or less
• Oil Filter – change every 2000 hours
(approx every 3 months)
• Oil Level – check sight glass
• Magnet – clean during every oil change
• Bull gear/Pinion- check wear/teeth yearly
or anytime unusual noise is heard
GEAR - TROUBLE SHOOTING
• BROKEN TEETH
STARTING OF PELLET MILL with
TOO LARGE OF SHEAR PINS, SOFT
START TOO FAST RAMP TIME, SHEAR
PINS MOVED- NOT IN SHEAR POSITION
• PITTING
OVER HORSE POWERED
• WEAR
DIRTY OIL
OIL BREAKDOWN
IMPROPER OIL
NOT CHANGING OIL AT PROPER
INTERVALS
MAINTENANCE OF GEAR-DRIVE
PELLET MILLS
LUBRICATION SYSTEM
PERFORMANCE (gearbox)
• PRESSURE 20-80 PSI (forced lube)
• TEMPERATURE
-140° NORMAL OPERATION
-170° MAXIMUM
OIL PRESSURE ALARM SWITCH
• SET AT 20 PSI
• TEST MONTHLY
-ADJUST PRESSURE RELIEF TO LESS
THAN 20 PSI
-ALARM SHOULD TRIP
WATER TO OIL COOLERS
• WATER PRESSURE 100 PSI MAXIMUM
• REQUIRES UP TO 19 GPM
• THERMOSTATICALLY CONTROLLED
VALVE FOR FLOW OF COOLING
WATER
AIR TO OIL COOLER
• MAXIMUM PRESSURE 100 PSI
• FIN TYPE
• THERMOSTATICALLY CONTROLLED
FAN
• REQUIRES SEMI-CLEAN
ENVIRONMENT
OIL FILTERS
• DUAL ELEMENT
• INTERNAL PRESSURE RELIEF
VALVE SET AT 18 PSI
DIFFERENTIAL
• REPLACEMENT SCHEDULE:
-2000 HOURS
-MORE THAN 18 PSI
DIFFERENCES
LUBRICATING OIL
SPECIFICATIONS
• HIGH OXIDATION STABILITY
• RUST INHIBITING
• FOAM INHIBITING
• DOES NOT ATTACH COPPER OR COPPER
ALLOYS
• COMPATABLE WITH BUNA-N RUBBER
• HIGH DEMULSIBILITY
• ANTI-WEAR ADDITIVE (EP?)
• VISCOSITY EQUIVALENT TO ISO GRADE 220
(APPROX. AGMA 5)
• VISCOSITY INDEX OF 90 OR BETTER
• TIMKEN OK LOAD OF 60 LB OR BETTER
FACE SEALS
• CHECK SEAL HOLDERS FOR
WEAR AND CORROSION
• FIT HALF OF SEAL IN EACH
HOLDER
• DURING MAINSHAFT ASSEMBLY
-DO NOT BUMP SEAL FACES
-KEEP SEAL FACES CLEAN
DIE CLAMPS AND CLAMPING
SURFACES OF DIES AND QUILL
FLANGES
• USE WEAR GAUGE TO CHECK FOR WEAR
• CHECK FOR NICKS AND DENTS
• CHECK FOR CRACKS
• LUBRICATE ALL CONTACT SURFACES WITH
NICKEL ANTISEIZE COMPOUND
• TIGHTEN BOLTS TO RECOMMENDED
TORQUE (generally 350 ft. pounds)
GEAR TROUBLE SHOOTING
• BROKEN TEETH
Over HP, Over torqued motor, No soft start
• PITTING
OVER HORSE POWERED
• WEAR (premature)
DIRTY OIL
OIL BREAKDOWN
IMPROPER OIL
NOT CHANGING OIL AT PROPER
INTERVALS
Maximizing Capacity
• Die Spec
• Proper Die feeding
• Feed Rate (amp load)
• Particle Size
• Remove Tramp metal
• Conditioning
Daily
Clean Feeder Magnet

Clean Temperature Probe

Check Roller Setting

Lubricate Rolls every 2-4 hours*

Check Die for Tramp Metal

Check Gear Box Oil Level

Check Oil Pressure

Check Oil Temperature


Lubricate Mainshaft Bearing (if applicable)
Weekly
Check Oil level in feeder drive
Check Deflectors and Wipers
Grease Feeder bearings*
Drain condensation from
Gearbox
Inspect Die face wear
Test Safety interlocks
Grease roller shaft bushings
(PM)
Check cooler bed level
Monthly

Check all chain drives for wear, tension, lubrication

Check all Belt drives for wear and tension

Check oil level in all gearboxes

Check cooler pan chain for tension

Grease Crumbler shaft bearings (if applicable)*

Clean fins on Air Cooler

Check flow control switch or pressure switch


Die Change

Inspect die hoist cable prior to use


Inspect/measure quill flange and die clamps with wear
gauge

Check die driving key

Check quill wear insert

Check Feed cone for cracks or oblong holes

Torque Die clamp bolts to 350 ft. pounds or per manual


Pellet Mill Oil

Every 2000 Hours

Change PM Gearbox Oil

Clean Magnet
Questions?