Preventive maintenance 2009

Preventive
Maintenance
PE80

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 Preventive maintenance 2009

Caution.
Before any service actions depressurize and turn off power supply. If the machine has
been running, then allow it to return to ambient temperature before performing service

PE80 maintenance check list: 3 month

ID Description Guideline ref. No. Comments

no.
1. Inspection of extrusion dies PE-SG-9006
2.
3.
4.
5.
6.
7.
8.
9.
10.

Estimated time consumption: 15 min.

PE80 maintenance check list: 6 month

ID Description Guideline ref. No. Comments Inspec. Repair

no. Min. Min.
1. Inspection of liquid CO2 inlet filter 8.6 - PE80 owners 10 10
man.
2. Check oil level main oil pump 8.3 - PE80 owners 5 5
man.
3. Oil level reduction gear 8.4 owners man. 5 5
4. Inspection of gas separator 8.7 + 8.8 owners man. 10 15
5. Inspection of extrusion filters PE-SG-09000 15 60
6. Inspection of valve heads injection 8.5 owners man. 25 30
7. Inspection of valve heads valve PE-SG-09001 * *
arrangement
8. Inspection of extrusion plates 6.3 owners man. 15 15
9.
10. 85 min. 140 min.

Estimated time consumption: 85 to 140min.

* Combined with pos. 6

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 Preventive maintenance 2009

Caution.
Before any service actions depressurize and turn off power supply. If the machine has
been running, then allow it to return to ambient temperature before performing service

PE80 maintenance check list: 12 month

ID Description Guideline ref. No. Comments Inspec. Repair

no. Min. Min.
1. All inspections and replacements All guidelines fro 6 85 140
from 6 months service months service
2. Oil change main oil pump PE-SG-9002 10 10
3. Oil change reduction gear PE-SG-9003 20 20
4. Replacement of all valve heads if PE-SG-9001 Leave 2 sets 25 30
needed on site
5. Function test of motor protection PE-SG-9004 10 10
devises
6. Function test of automatic fuses PE-SG-9004 * *
7. Replace slider bearing with oil wiper Parts id page PE80005 120 120
+ PE80006
8. Replace front slider bearing Parts id page PE80005 ** **
+ PE80006
9.
10. 270 min. 330 min.

Estimated time consumption: 270 to 330 min.

* Combined with pos.6
** Combined with pos.7

PE80 maintenance check list: 24 month

ID Description Guideline ref. No. Comments Inspec. Repair

no. Min. Min.
1. All inspections from 6 and 12 All guidelines from 12 270 330
months months service
2. Inspection of all wire connections PE-SG-9005 10 10
3. Inspection of all Pipe/hose PE-SG-9006 5 5
connections
4. Inspection of liquid CO2 hose PE-SG-9007 5 5
5.
6.
7.
8.
9.
10. 290 350

Estimated time consumption: 290 to 350 min.

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 Preventive maintenance 2009

Maintenance guidelines: 3 months

PE-SG-9006 Inspection of extrusion dies:

The condition of the extrusion dies is very important for the safe operation of the equipment and the quality
of the pellets/nuggets. To insure good operation and quality the cutting side of the dies has to be intact.
Broken edges will overload the system and result in poor performance

• The cutting edges have to be intact.

NOTE !
Always keep the extrusion dies clean, dry and intact. Only use original Triventek dies in the PE80 or PE45.
None Triventek manufactured dies can damage the equipment.

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 Preventive maintenance 2009

Maintenance guidelines: 6 months

8.6 Inspection and renewal of inlet filter

For protection of the interior mechanical parts in the Pelletizer a

filter (see 1) is mounted on to the hose for liquid CO2 supply. The
filter is mounted together with a check valve to prevent CO2 flowing
out of the Pelletizer.

Procedure for cleaning and inspection of the inlet

filter:

1. The hose for liquid CO2 supply must be empty and

depressurized before inspection.

2. Dismantle the filter and hose from the Pelletizer.

3. The lid of the filter is locked by a circlip. Use a pair of proper

circlip pliers: be careful, not to damage the retaining ring.

4. The filter can be pulled out of the housing unit (it is a tight
friction fit). The filter is made of sintered bronze, therefore dirt
and grease can build up both on the inside and outside of the
filter.
The dirt and grease found on the outside of the filter can be cleaned off quite easily using a soft cloth.
To remove dirt and grease on the inside of the filter try and blow through the filter. If this works the
filter can be reused, if the filter is still blocked after doing this, it will have to be replaced with a new
one.

5. The screw in the end of the filter is dismantled in order to

change the sintered bronze.
6. Renew the O-ring if necessary.
7. Add a thin layer of oil or grease to the outer of the O-ring.
This will ease the refitting of the filter in the housing and
give some protection of the o-ring.
8. Put the filter back into the housing unit. Make sure that the
retaining ring is pressed in place. If the retaining ring is not
properly mounted the filter, then the filter will separate
when pressurized. This can be dangerous for people
standing nearby.

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 Preventive maintenance 2009

8.3 Checking oil level (main oil pump)

Oil level is monitored by the PE80 controller but should be
checked at least once or twice a year.

Oil level during

stand still

Oil level during

operation can vary

8.4 Checking oil level (gearbox)

An oil expansion vessel (picture 10), serving the gearbox, is located at the rear left
side of the Pelletizer. It should be possible to see some oil within the transparent
tube leading to the expansion vessel when the engine has obtaining working
temperature, approx. 50º C/122º F

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 Preventive maintenance 2009

PE-SG-09000 : Inspection of Extrusion filters

The three extrusion filters inside the extrusion chamber are made out of sintered bronze and are defined as
a wear part due to the fact that they are exposed to friction from the piston going back and forth.

• In order to inspect the filters the extrusion die bracket and pellet breaker has
to be removed

• All three cylinders/chamber are now visible. Depending on the position of the
piston the filter will more or less visible. Move the pistons by turning the fan
on the electrical motor. Use a flashlight for inspection

• Check for cracks and deformation of the filter. Also extensive wear
visible as burnished spots/areas on the inner surface of the filter

If the filters are showing signs of damage or wear they have to be replaced.

Intact filter surface

Before reassembly check the backside of the extrusion dies for damage to
the edges. If damaged replace with new dies.

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 Preventive maintenance 2009

PE-SG-09001: Inspection of valve heads and nozzles in the valve arrangement

In order to maintain safe operation of the PE80 all the valves and nozzles has to be inspected for wear or
damage. Malfunction of the valve will disturb the operation and can damage the equipment.

• Valves in the valve arrangement from left to right:

AV209 – AV208 – AV390 - AV266

• Valves in the main head from top down:

AV220 – AV221 – AV222

• Clip off the solenoid coil with a screwdriver.

• Loosen the valve head with a 27mm alloy ring key

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 Preventive maintenance 2009

PE-SG-09001: Inspection of valve heads and nozzles in the valve arrangement

• Caution when taking out the head. The plunger can fall out
and be damaged

• Check valve seat for wear or damage. The seat will show
signs of working against the nozzle. If these marks are
deep into the seat replace the head

• Check the plunger and spring for damage. The spring has
to be positioned in the groove at the front of the plunger

• Check the nozzle for wear. Also check that the nozzle is
tightened properly and with 1 copper washer underneath

NOTE !
Before reassembly of the valves the aluminium sealing ring has to
be checked for damage and that there is only 1 ring underneath
the valve head

The guidelines above are the same for valves AV220 to 222

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 Preventive maintenance 2009

Maintenance guidelines: 12 months

PE-SG-9002 Oil change main oil pump:

To ensure long lifetime operation the oil in the main lubrication system has to be changed within the
specified intervals.

• Pump motor and console

• Oil tank

Before draining off the oil run the PE80 for at least one hour. This will heat up
the oil and get most of the oil drained out of the crankshaft housing. Drain the
oil off while it is still warm.

• Loosen the tank clips on both sides of the tank.

• Carefully remove the tank and drain out the oil. Put some paper or
container under the pump during refilling to avoid spilling.

Oil data:
Oil type: Castrol Tribol MA140/460
Quantity: 1,7 litres / 0,37 gallons (UK)

CAUTION !

Before replacing the tank make sure that the o-ring on top of the tank is positioned correctly.

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 Preventive maintenance 2009

PE-SG-9003 Oil change reduction gear:

The reduction gear between crankshaft and motor is filled with oil and has to be changed once a year. Unlike
the main oil pump this system has no actual circulation and the operation temperature is significant higher. It
is very important to follow the guidelines for oil change intervals and oil type.

• Loosen the drain plug show at the picture. Put some sort
of tray under the drain hole in order to avoid spilling.

• When all the is drained put the plug back and tighten

• Remove the venting valve at the top of the oil expansion

tank.

• Fill the reduction gear trough the hole

Oil data
Ambient temp.: -20 to +10°C -5 to +35°C +20 to +50°C Quantity
Viscosity ISO VG 100 150 220
AGIP Blasia 100 Blasia 150 Blasia 220 1,3 litres / 0,285 gal. (uk)
Castrol Alpha SP100 Alpha SP150 Alpha SP220 -
Esso Spartan 100 Spartan 150 Spartan 220 -
FINA Giran 100 Giran 150 Giran 220 -
Mobil None Mobilgear 629 Mobilgear 630 -
Q8 Goya 100 Goya 150 Goya 220 -
Shell Omala EP100 Omala EP150 Omala EP220 -
Texaco Meropa 100 Meropa 150 Meropa 220 -

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 Preventive maintenance 2009

PE-SG-9004 Function test motor protection devises:

In order to insure safe operation of the motor protection devises these devises has to be activated manually
once a year.

• In standby mode turn the black knob by hand

until it trips by it self

• The knob will trip into position by it self and stay

there. Check the display for error message.
Reset the device and clear the error in the
display (see manual PE80)

• Automatic fuse functions test also has to be

carried out manually. Activate the fuse during
standby mode.

• All the control voltage will now be shut of. Reset

the automatic fuse by hand. Check that the
system is powered up again.

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 Preventive maintenance 2009

PE80005 + PE80006 Replacement of slider bearings with oil Wiper:

The function of the slider bearing with oil viper build in is the support the piston and to wipe of any oil sticking
to the piston and guide it into the oil drain housing.

• Replace all three bearings with oil

wiper. The bearing comes as a
complete replacement set. Part id
PE809901 x 3

Pos Part no Description

1 02150303
2 41232020
3 02150202
4 02150302
5 41212530
6 33462002
7 41212530
8 02150301
33273202
Slider bearing front
Bronze bearing 20x20
Insulation pipe
Slider bearing oil separation
Bearing 25x30
Oil wiper
Bearing 25x30
Slider bearing cranckshaft
O-ring slider bearing

• Replace the three front main head bearings.

Replacement part id PE809902 x 3

Pos Part no Description

1 02150402 Oil separation housing
2 02150302 Slider bearing with oil wiper
3 02150202 Insulation pipe
4 02150303 Slider bearing main head
5 Locking screw M5x6 hex. key
6
7
8
9
10
11

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 Preventive maintenance 2009

PE80005 + PE80006 Replacement of slider bearings with oil Wiper:

To get access to the bearings and oil wipers it is necessary to remove the main extrusion head.

Disassembly steps:

1. Disconnect all pipes and hoses

2. Disconnect coils and cable plugs
3. Remove the die bracket
4. Pull the main head off

The pistons and bearings are now visible and can be

replaced with new parts.

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 Preventive maintenance 2009

Maintenance guidelines: 24 months

PE-SG-9005 Inspection of wire connections:

All wire connections in terminals etc. has to be inspected for damage, loose connection to avoid “hotspot”
and risk of electrical short circuit due to melting cable insulation.

• Check that all wire connections are properly

tighten
• Check the insulation on cable in hazards
areas such as all cable outside the electrical
box.
• Check for unauthorized use of components
and wires

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 Preventive maintenance 2009

PE-SG-9006 Inspection of pipe and hose connections:

Inspect all pipe and hose connections within the 24 month period to insure safe operation and prevent risk of
pipe or hose burst that can lead to critical damage of the equipment.

• Make sure that pipe connections are tight

and intact
• Make sure that hoses does not show signs
of burst and wear
• Hose clamps are positioned correctly and
tight
• That the oil lubrication hoses are not leaking

Caution !

Materials used for repair of pipe work or hose connections have to be suited for pressure and temperature.

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 Preventive maintenance 2009

PE-SG-9007 Inspection of liquid CO2 hose:

Check the liquid CO2 hose supplied with the PE80 for sharp bends, flat spots, burst and signs of damage.
Damaged hoses are a high risk area and can course injury or damage to the equipment.

• Sharp bends or flat spot can course poor liquid

CO2 supply and low production rate.
• If the hose is damaged replace it. Do not try to
repair. The hose is under high pressure.
• The insulation of the hose should also be checked
to insure good insulation and reduce heat
loos/heat impact.

Caution !

DO NOT use hoses not approved for the specified pressure and medium.

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 Preventive maintenance 2009

Servicelog:

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