SPROUT-MATADOR MODEL 21-250 PELLET MILL INSTRUCTION MANUAL ®@OPERATION @ PARTS LIST KEEP YOUR EQUIPMENT UNDER WARRANTY USE ANDRITZ INC. ORIGINAL PARTS FOR PARTS CALL: Telephone: (570)546-5811 1-800-446-8629 Fax: (570)546-1306 NOTE: EMERGENCY SERVICE AVAILABLE 24 HOURS PER DAY, 7 DAYS PER WEEK MEMBER OF THE ANDRITZ GROUPSPROUT-MATADOR MODEL 21-250 PELLET MILL USE COMMON SENSE SAFETY PRECAUTIONS Sprout-Matador can assume no responsibility for damage or injury resulting from use of the equipment. SERIALNO.: INSTALLATION DWG. NO.: DIESPEED: ___ DRIVE MOTOR: ‘SPROUT-MATADOR ORDER NO.: CUSTOMER: __ DATE PREPARED: pie IMPORTANT DO NOT FILE AWAY This manual must be read immediately and proper action taken before any unit is received. Also, this manual must be referred to before installing, handling, starting, or operating any component.GENERAL SAFETY INSTRUCTIONS WARNING: To avoid hazardous situations that may result in serious injury and / or death, it is extremely important that you understand and follow all of the safety instructions listed below. DO NOT operate or conduct maintenance on the equipment if you do not understand these instructions. Read and understand the Equipment Operation and Maintenance Manual. Adhere to all local company or site operating safety rules, practices, directions, and posted notices, Do not operate the equipment until all guards and covers are mounted in their proper location and all doors are closed. Do not open doors or remove covers while the equipment is running Do not insert hands, feet, tools or any other foreign objects into the equipment or while it is running. Any of these actions could result in bodily harm or death. De-Energize and Lockout/Tagout equipment before performing maintenance. Equipment motor disconnects andlor circuit breakers must be locked in the open (off) position. Shut-off, de-energize (bleed off pressure) and lock out all pneumatic and hydraulically operated components, steam systems and electrical circuits supplying power to control functions. De-pressurize all vessels and chambers associated with or connected to the equipment. Rotating elements and other moving parts must be firmly blocked to prevent unintended motion. Individuals or the group supervisor responsible for the safety of the individuals performing the maintenance or inspection shall personally place key-style padlocks on the equipment disconnects. Locks shall be utilized in a manner to guarantee the de-energized condition. Lock keys shall be retained only by the person placing the lock on the disconnect equipment. A“DANGER-PERSONNEL WORKING’ notice shall be securely attached in a ‘conspicuous place on or near the lock. The padlock must never be removed by anyone other than the person who placed it on the equipment disconnects. If maintenance or inspection is required inside a confined space, two or more persons must work as a team with at least one person outside of the confined area at all times. ‘The person located outside of the confined area shall never leave while someone is in the unit Feed Technolo SNES rears eee 570-546-5811 SPROUT-MATADORSAFETY MESSAGE DEFINITIONS The Equipment Operation and Maintenance Manual contains important safety messages preceded by one of four standard Signal Words. Danger, Waming, Caution, and Note are used as Signal Words. Signal Words are assigned according to the likelihood of occurrence and severity of injury or damage. The Signal Words and messages are defined as follows: DANGER: DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This Signal Word is limited to the most extreme situations of equipment operation and maintenance. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe operation or maintenance practices. \ IMPORTANT: IMPORTANT is used to emphasize the importance of an operation or maintenance instruction. IMPORTANT is not used to indicate a hazardous situation. Fed Technology 00.146 8629 FoF. Parts) 988 570-546-5811 SPROUT-MATADORSAFETY WARNINGS AND CAUTION NOTICES IT 1S IMPORTANT THAT: (1) SAFETY WARNINGS BE OBSERVED TO PREVENT INJURY OR DEATH. (2) CAUTION NOTICES BE FOLLOWED TO AVOID EQUIPMENT DAMAGE. The following Safety Warnings and Caution Notices appear in this manual: and Pages WARNING: BEFORE PERFORMING MAINTENANCE OR REPAIR WORK, DISCONNECT THE ELECTRICAL SWITCH AND SECURE IT IN THE "OFF" POSITION WITH PADLOCK. EACH PERSON WORKING ON THE MACHINE SHOULD ACCOMPLISH THIS LOCKOUT WITH HIS OWN LOCKOUT DEVICE AND SHOULD RETAIN KEY WHILE WORK IS BEING PERFORMED. Page C=1 CAUTION: OTL LEVEL IN THE PELLET MILL GEARBOX MUST BE MAINTAINED AFTER THE PELLET MILL HAS STARTED. AUXILIARY EQUIPMENT WILL HOLD LUBRICANT WHICH RESULTS IN A DECREASED OIL LEVEL IN TBE GEARBOX. CHECK LEVEL WHILE PELLET MILL IS OPERATING AND ADD OIL AS REQUIRED. SEE RECOMMENDED OIL TO ASSURE PROPER LUBRICATION (SECTION F). Page C-2 CAUTION: IF MILL TS EQUIPPED WITH MECHANICAL VARIABLE SPEED DRIVE, ADJUST VART-DRIVE SPEED ONLY WHILE MOTOR IS RUNNING. Pages Del, Do4 and E-1 WARNING: MAKE ABSOLUTELY SURE THE POWER IS OFF! Page E-7 CAUTION: DO NOT OVERTIGHTEN WHEN ADJUSTMENT IS MADE TO BEARING SETTING. THE ROLL MUST BE TURNED SEVERAL REVOLUTIONS TO SEAT THE TAPERED ROLLS IN THE RACES. 21-250 Pellet Mill Safety, Caution April, 1984Page CAUTION: ALWAYS CLEAN GREASE FITTINGS AND GREASE GUN HEAD BEFORE SERVICING BEARINGS. KEEP ALL GREASE CANS COVERED TO AVOID CONTAMINATION. Form 1863 CAUTION: DO NOT OVERGREASE! Page CAUTION: IF THE OTL TEMPERATURE IS LESS THAN 40° F., WE RECOMMEND THE USE OF AN OIL HEATER TO BRING THE TEMPERATURE TO AT LEAST 50° - 60° F. BEFORE STARTING THE PELLET NILL. Page WARNING: TO ASSURE MAXIMUM SAFETY DURING THE RAPID CARTRIDGE CHANGE, THE FLOOR IN THE AFFECTED AREA MUST: (1) SUPPORT 3,400 POUNDS OF ROLLING WEIGHT WITHOUT SAGGING (1,000 POUNDS ON EACH FRONT WHEEL AND 700 POUNDS ON EACH CASTER WHEEL); (2) BE SMOOTH SURFACED TO AVOID DESTRUCTIVE SHOCK LOADS ON CART; AND (3) BE LEVELED. Page WARNING: WHEN CARTRIDGE IS BEING REMOVED FROM THE MILL WITH THE DIE OR PART OF THE CARTRIDGE ASSEMBLY REMOVED, SECURE PELLET MILL MAIN SHAFT T0 THE DIE HOUSING BEFORE REMOVING SPINNER NUT FROM THE MAIN SHAFT. A MAIN SHAFT RETAINER (SEE FORM 2013C) HAS BEEN FURNISHED FOR THIS PURPOSE AND SHOULD BE USED AS DESCRIBED ON PAGE F-12. IF THIS PROCEDURE IS NOT FOLLOWED, THE MAIN SRAFT WILL BECOME LOOSE WHEN THE SPINNER NUT IS REMOVED AND COULD FALL OUT OF THE PELLET MILL, CAUSING SERIOUS INJURY OR DEATH. ‘THE NEVER-SEEZ COATING SHOULD BE SPREAD TO A VERY THIN LAYER WITH A CLEAN RAG, ANY BUILD-UP OF LUBRICANT SHOULD BE AVOIDED. CHECK THE TAPERED BORE IN THE PELLET MILL TO BE SURE IT IS WIPED CLEAN BEFORE EACH CARTRIDGE INSTALLATION. 21-250 Pellet Mill Safety, Caution Aprily 1986Page F-12 WARNING: THE MATN SHAFT RETAINER MUST BE USED WHEN REMOVING A CARTRIDGE WITH THE DIE OR PART OF THE CARTRIDGE ASSEMBLY REMOVED. FAILURE TO USE THE RETAINER MAY RESULT IN SERTOUS INJURY OR DEATH. Page F-15 WARNING: THE MAIN SHAFT MUST BE SUPPORTED BEFORE THE SPINNER NUT TS REMOVED. THE KEYED END OF THE SHAFT MUST ALSO BE SUPPORTED BEFORE IT 1S TOTALLY REMOVED FROM THE DIE HOUSING. NOT SUPPORTING THE SHAFT AT BOTH ENDS ALLOWS THE KEYED END TO DROP AS IT EXITS THE DIE HOUSING. Page F-16 WARNING: SUPPORT SHAFT AT KEYED END BEFORE COMPLETE REMOVAL. Page Fo17 WARNING: THE MAIN SHAFT MUST BE SUPPORTED WHILE INSERTING INTO DIE HOUSING UNTIL THE SPINNER NUT SECURES SHAFT INTO CARTRIDGE. SUPPORT THIS LARGE SHAFT AT ALL TIMES TO PREVENT THE SHAFT FROM DROPPING. Page F-17 CAUTION: THE SHAFT MUST BE CAREFULLY GUIDED INTO PLACE TO AVOID DAMAGING THE LIP SEALS. MAKE SURE THE KEYWAYS ON THE MAIN SHAFT ARE IN THE RIGHT POSITION BEFORE SLIDING THE SHAFT INTO THE SHEAR PIN HUB. 21-250 Pellet Mill Safety, Caution April, 1984I Section vy 11 Section » 2) 3) TIT Section »y 2) IV Section v 2) 3) 4) 5) 6) 7” 8) 9) 10) Vv Section ay 2) 3) VI Section »v 2) 3) 4) 5) 6) GIRDEXS A ~ Introduction Foreword B - Installation General Plumbing Connections Electrical System © - Operation Pre-Start Check Initial Start-Up D ~ Dies General Die Removal Wear Ring Replacement Die Replacement Selection and Care of Pellet Mill Dies Die Life and Wear Adjusting Feed Plow Determining Die Wear Sample Procedure for Measuring Dies Die and Bolt Breakage E ~ Rolls Installing Rolls Adjusting Roll Settings Rebuilding Rolls F - Maintenance Remote Manual-Type Lubrication System Recommended Lubricant (Grease) Gear Drive Lube System and Controls Recommended Lubricant (011) Recommended Oil Change Suggested Maintenance Timetable Page No. Bl Bel Bel 21-250 Pellet Mill ‘Index April, 1984VI Section F - 7) 8) 9” 10) M1) VII Section G 1) 2) 3) 4) 5) 6) D 8) 9” 10) 11) VIII Section # IX Section 1 INDEX ~ continued Maintenance - continued Rapid Change Pelleting Cartridge Main Shaft Retainer Shear Pin Hub Assenbly Center Bearing Replacement Gear Drive Assembly - Parts List Ordering Instructions Recommended Spare Parts Roll Assembly - Standard Width Roll Assembly - Wide Rolls Only Gear Drive and Housing Assembly Cartridge Pelleting Assenbly Shear Pin Hub Assenbly Hinged Die Casing with Cut-Off Knives 011 Lube System Centrifeeder Tools Furnished with 21" Pellet Mills ~ Manufacturers’ Descriptive Sheets ~ Drawing Sheets F-9 F-12 P-13, FS, F-l7 en G12 21-250 Pellet Mill Index April,- 1984INTRODUCTION FOREWORI This manual has been prepared to help you obtain trouble-free performance from the Sprout-Waldron Model 21-250 Pellet Mill, a quality-built, precision machine representing hundreds of hours of careful workmanship. If you follow the instructions outlined herein, your pellet mill will give long and profitable performance. Failure to read and understand the information in this manual may result in damage to the equipment from improper installation and/or initial start-up. Such mistreatment or damage may void the warranty of the equipment, or could result in serious personal injury. DO NOT FILE THIS MANUAL. See that it is placed in the hands of installation, operating and service personnel. For best results, the operation and maintenance of the pellet mill should be assigned only to qualified personnel. Whenever possible, this responsibility should be assigned to one man. Systematic and planned maintenance will assure continuous service and lowest pelleting costs. Follow lubrication instructions carefully and regularly. Keep all bolts tight. Use, but don't abuse! We are proud of our reputation as the design leader in the pelleting field, and we are anxious to do what ve can to help to get top performance from this precision machine. Improvements in machinery are being made constantly to bring industry increased value for its equipment investment. Consequently, there may be minor variations between the equipment you receive and the details as described in this manual. If any problems arise which this manual does not cover adequately, contact our district sales representative in your area or division headquarters in Muncy, PA. 21-250 Pellet Mill Introduction Page A-1 April, 1984GENERA Thie pellet mill is completely assembled and fitted in our shop, but for the ease of handling, it is usually shipped in three parts: mill, conditioner and centrifeeder. Install pellet mill on a level, vibration-free surface, preferably on concrete, We recommend the use of a vibration-dampening material or device between pellet mill and the mounting surface. Oak planks bolted between the floor and pellet mill are the reconmended vibration dampening material. Install the coupling on the main drive motor as outlined on the Instruction Sheet 428-810 in Section H of this manual. Install the main drive motor and align the coupling as outlined on the Instruction Sheet 428-110 in Section H. On the two-speed mill, check and realign, if necessary, the coupling between the mill and the transmission prior to motor installation. IMPORTANT: Align couplings after the pellet mill has been securely bolted in place. When the coupling alignment is completed, pin the motor (and transmission on two-speed mill) to base with two 1/2" diameter pins spaced across. PLUMBING CONNECTIONS: Connect all the plumbing (steam piping, liquid addition system, cooling water, etc.) to mill in such a way that the adjustable controls can be easily reached by the mill operator. The proper piping diagrams are included in this manual (Section I). ELECTRICAL SYSTEM: ‘The electrical interlock system should be such that the finished pellet carry-off equipment should start first, then the main pellet mill motor, centrifeeder, and finally, the conditioner and feeder. Wiring diagram, Form 2022A, shows the recommended connections for the electrical interlocks and safety devices for automatic shutdown of the pellet mill. If your pellet mill is to be equipped with a feeder- conditioner controlled with an A.C. frequency drive, refer to Form 2143 for proper wiring. 21-250 Pellet Mill Installation Page F-1 April, 1984Within the pellet mill, there are two electrical safety switches: The shear pin limit switch and the oil pressure switch. These must be connected in the control circuit of the pellet mill main motor. This motor must stop when there is a loss of oi] pressure or shear pin failure to prevent damage to the pellet mill. The shear pin limit switch and oil pressure switch are connected into the motor starter control circuit through relay contacts. To start the main motor, the "start" pushbutton must be held in until the oil pressure switch contact closes, operating the relay contacts in the motor starter control circuit to keep the main motor running after the "Start" pushbutton is released. ‘The exact type of starting and controlling equipment is generally a customer preference. Local electrical codes and specifications should be carefully studied for proper electrical wiring. NOTE: ‘An ammeter of proper size should be located in such a position that it is readily seen by the operator when adjusting the pellet mill feeder and the steam controls. This will make possible proper loading of the pellet mill to its optimum output capacity. 21-250 Pellet Mill Installation Page B-2 April, 1984usvac conTROL VOLE eee agane ae 3 2 eeay eter GeO Ht . ae ree eee g ae ane rm "3 ae ey. ee sate, a Otte ie a a re ee By sso sau i mt ron ss ma yA om, omnes ot SUGGESTED ELECTRICAL WIRING, DIAGRAM 2\'& 26° PELLET MILLS (with mechanical-type variable speed feeder drive) FORM 2022A (Ref. B2100-013)ALOHA GATIOWINOD @ATHC XONaNDRA ATEvIUVA *O°Y HLIM STW JATTAd ZE ONV 97 ‘aT? “WWYOVIG ONTUIN GaLsa9ons - EyTZ WHOTOPERATION WARNING: BEFORE PERFORMING MAINTENANCE OR REPAIR WORK, DISCONNECT THE ELECTRICAL SWITCH AND SECURE IT IN THE "OFF" POSITION WITH PADLOCK. EACH PERSON WORKING ON THE MACHINE SHOULD ACCOMPLISH THIS LOCKOUT WITH HIS OWN LOCKOUT DEVICE AND SHOULD RETAIN KEY WHILE WORK IS BEING PERFORMED. TAI CHECK: Check the drive coupling alignments (both couplings on the two-speed mill), It should be within 0.008" max. radial run-out. Realign if necessary as described on Page B-1 and relubricate them prior to the drive guard installation. Lubricate all motors, gearmotors, etc., and fill all gearboxes to the appropriate level. CAUTION: OTL LEVEL IN THE PELLET MILL GEARBOX MUST BE MAINTAINED AFTER THE PELLET MILL HAS STARTED. AUXILIARY EQUIPMENT WILL HOLD LUBRICANT WHICH RESULTS IN 4 DECREASED OIL. LEVEL IN THE GEARBOX. CHECK LEVEL WHILE PELLET MILL 1S OPERATING AND ADD OIL AS REQUIRED. SEE RECOMMENDED OILS TO ASSURE PROPER LUBRICATION (SECTION F). Lubricate the three pelleting rolls and the center main bearing as described on Pages P-I through P-3 and illustrated on Form 1849. Adjust the three pelleting rolls as described on Page F-. Check all die bolts on both sides (housing and cover) for the proper tightness of 150 ft.-Ib. torque. Check electrical interlock on all of the associated equipment (see "Installation", Section B). Check the rotation of all units. The pellet mill must rotate with the die turning clockwise when facing the front of the mill. Check for proper interlock of pellet mill oil pressure switch by breaking connection to switch. Pellet mill should run while start switch is depressed but stop upon its release. Reconnect connection and check for proper operation of the oil pressure switch by connecting an ohmmeter across the rear connector wires on the switch. Reading should show high resistance. Start 21-250 Pellet Mill Operation Page C-1 April, 1984pellet mill and reading should show low resistance. Stop pellet mill and observe pressure gauge when reading returns to high resistance. Gauge should read approximately 10 PSI. 9. Remove the two shear pins and rotate the shear pin hub manually approx. 45° in order to trip the magnetic limit switch due to dislocation of the steel activator plate. An attempt to start pellet mill should result in failure if the switch is properly connected. Install shear pins (see Page F-13). INITIAL START-UP: It is recommended to run some feedstock through all bins and supply conveying equipment and then run this material out on the floor, rather than attempting to pellet immediately. This is done in an attempt to remove all scrap metal, velding rod stubs, nuts, bolts., etc., that can accumulate in these systems during the construction process. One does not want to get this tramp metal in the pelleting chamber. Discard this material. You are now ready for start-up. 1, Set the "HAND-AUTO" switch on "HAND" position. Start the main motor. Start the centrifeeder and conditioner. Start the feeder making cure it is set at its minimum feed rate. CAUTION: IF MILL IS EQUIPPED WITH MECHANICAL VARIABLE SPEED DRIVE, ADJUST VARI-DRIVE SPEED ONLY WHILE MOTOR 1S RUNNING. 5. Watching the ammeter so as not to overload the main motor, you can begin to increase the feed rate if the pellet mill accepts the initial feed without plugging. (Definition of plugging: when the material being fed to the die is not being extruded and begins to build up in the pelleting chamber ahead of the rolls.) If the pellet mill plugs, shut down and clean the pelleting chamber immediately to avoid hardening of feed. 6. Motor load. For maximum output, the motor should be run as close to full load as possible. Draw a line on the ammeter to indicate a point at which full load is obtained. ‘The full load amperage of the main motor will be found on the motor name plate. 21-250 Pellet Mill Operation Page C-2 April, 1984Bring the load up on the motor by gradually increasing the feed rate. To reduce the load on the main motor, you must add more steam or liquid to the conditioner to the extent which your pelleting requirements dictate. Generally speaking, the pellet mill will have its greatest capacity when the mash temperature in the conditioner approaches 180°=200° F. NOTE ON STEAM SYSTEN: The steam system must be "blown down" (clearing ‘any water or condensation) before full steam pressure is released into the system. (When this is not done, the hot steam causes a thermal shock when it comes in contact with the water which could be trapped in the strainer and possibly break it.) 21-250 Pellet Mill Operation Page C-3 April, 1984DIES Reference: Exploded View, Form No. F-1917B. (A11 numbers ineluded in parentheses in this section are piece numbers on the above exploded view, unless otherwise noted.) GENERAL: Net production from this pellet mill depends greatly upon the precision machined die. Years of research and experience have gone into the design of this die and high speed automatic machine is used in its manufacture. To get maximum results and service, certain precautions must be observed. ‘The hardened wear ring (31) is pressed into the die housing (30) and tack welded to the housing prior to receiving the die. When mounting the die, it is imperative that everything be as clean as possible to insure proper fits. The die must be started into the wear ring squarely or the rings (31) may be severely damaged and require replace- ment mich sooner than they would with normal wear. The fit between a new die and a new wear ring will be snug to quite tight. When a loose Fit develops, new wear rings must be installed to insure proper operation or bolt breakage can develop. See detailed instructions for replacing wear rings. NOTE: An old die may still be loose in a new wear ring as the old die shoulder may be worn undersize. Also, when checking the fit of the die, both the die and the housing must be the same temperature because a cold die will fit quite loosely in a hot housing, due to the expansion of the housing from heat. DIE REMOVAL: WARNING: MAKE ABSOLUTELY SURE ALL POWER TS OFF! This pellet mill is equipped with the "Rapid Cartridge Change" feature, (see Section B) which makes it possible to change the die in a matter of minutes by simply changing cartridges with pre-mounted dies. This type of die change offers many advantages: Reduced downtime (under 10 minutes) Increased die life (due to mated die with rolls) Increased capacity (due to mated die with rolls) Smoother operation (due to mated die with rolls) The actual die replacement (in the cartridge) could be done while the cartridge is mounted on the pedestal (servicing stand), or on the pellet mill. In either case, proceed with the die replacement as follows: 21-250 Pellet Mill Dies Page D-1 April, 1984Remove the four bolts (38) holding the die cover (37). Remove die cover, Next remove all the die bolts (33) holding the die stiffener ring (36) to the die. Using the jack screws (35) furnished, push the die stiffener ring off the die shoulder. Use the screws alternately to bring the die stiffener ring (36) off evenly to prevent binding of the die shoulder in the wear ring. When the stiffener ring is free, be careful to turn the screws back into the casting so as not to hinder replacement of the stiffener ring on the die shoulder. Failure to do this can also break the stiffener ring. Before removing the die, the rolls will have to be backed away from the face of the die. First, remove the square head set screws (9) holding the roll adjusting segments (4). Remove segments. Now place the supplied roll adjusting wrench (see E furnished tools list, Form 2013C) over the end of the roll pins and turn counterclockwise until the rolls swing away from the face of the die. SECURE DIE TO LIFTING DEVICE BEFORE STARTING REMOVAL PROCEDURE. Die can now be removed. First, remove the die bolts (33) and special hardened washers (34). Then use the jack screws (35) to push the die out of its seat and onto the rolls. Be sure to turn the jack screws back into the housing. If necessary, the roll assemblies would be removed at this point. Anew set of roller assemblies would be inserted prior to installing the die. WEAR RING REPLACEMENT: Replace wear ring es follows: Grind out welds to allow WEAR RING removing ring with cold chisel. Grind six spots in new locations to 1/8 deep x 3/4 long. Press in ring and tack weld it in place as shown. Grind welds flush. Use stainless steel rods and avoid large welds in order to minimize the heat effected zones which could cause failure in the housing or stiffener ring. DIE HOUSING OR STIFFENER RING) 21-250 Pellet Mill Dies- Page D-2 April, 1984DIE_REPLACEMENT: 1, Before replacing the die, make absolutely sure the die cavity is clean and all dirt is blown free of the die seating area in the die housing. Check all jack screws to make sure they are all withdrawn far enough to allow proper seating of the die. Install the three threaded guidestuds (evenly spaced) in the one side of the die, leaving the flat milled end sticking out. Pull die into housing with the 5/8" hex nuts on studs. Remove studs and secure die in place with the die bolts that must be torqued to 150 ft.-Ib. Always use hardened washers with the hardened (GR-5) die bolts. NOTE: The die, housing and stiffener ring should be at the same temperature to determine the proper die fit (0.002" loose to 0.004" tight). If this fit is less than recoumended, it could cause die and die bolt breakage. If replacement is needed, please see Page D-2). 2. Next install the die stiffener ring (36), using the guidestuds in a similar manner as before. Make sure it is clean so it fits properly. Bolt in place, being careful to torque these bolts to 150 ft.~Ibs. 3. When the die stiffener ring is seated, adjust the rolls as specified in Section E. 4, Start the four bolts (38) for the die cover (37) and then after checking to make sure all mating surfaces are absolutely clean, slip the cover in place. Torque these 5/8" bolts to 150 ft.-lbs. or 3/4" bolt to 250 ft-lbs. SELECTION AND CARE OF PELLET MILL DIE: The specific die used will have a great deal of influence upon pellet quality, pelleting capacity and power consumption. We strongly recommend contacting Koppers if you have any questions on die selection. This will enable you to take advantage of our engineering facilities and years of experience in selecting and designing pellet mill dies to meet your specific formulations. 21-250 Pellet Mill Dies Page D-3 April, 1984DIE LIFE AND WEAI Proper care of this die will have much to do with the determination of its ultimate service life. It is highly essential that the die wear evenly and uniformly across the inside face. It any foreign material such as vires, nails, bolts, etc., should become imbedded in the face of the die, wear will be uneven. This foreign material tends to form a "dead spot" at this point on the face and prevents the die from wearing evenly, This will eventually create a high spot on a die, thus waking it impossible to properly adjust the rolls to the working face of the die. If possible, knock out tram metal every 24 hours. Use a drive pin or punch and drive from the outside toward the center. To help obtain uniform wear, it is important that the rolls be adjusted out close to and square with the face of the die. It is also advisable if the die wears unevenly to have the inner face ground true. This insures a good roll setting to the die face and keeps production at a maximum. This reworking is a special feature offered by Koppers. We recommend new rolls with a reground die to guarantee the proper die-roll relationship. If a die wears unevenly on the inner face, with a pronounced groove on either the front or back, this is a result of feed stock concentration. This concentration is due to improper adjustment of the feed plow. Please see instructions ("Adjusting Feed Plow") for per adjustment procedure ADJUSTING FEED PLOW: WARNING: MAKE ABSOLUTELY SURE ALL POWER IS OFF! ‘The purpose of the feed plow is to spread the feed uniformly across the die face ahead of each roll. This is very important toward achieving even die wear. The three plows are mounted on one adjustable base which is held in position by the center bolt and the roll clamping disc. To adjust plow, loosen disc and the center bolt and turn plow in either direction by tapping on plow holding bar. To determine direction: Turn plow toward roll to spread feed toward the front (die cover). Adjust in this manner when the rear face of die wears faster. Turn plow avay from roll to spread feed toward the rear (die housing). Adjust in this manner when the front face of die wears faster. 21-250 Pellet Mill Dies Page D-4 April, 1984ROLL HOLDING PLATE MAX. POSITION TOWARD ROLL y CENTER BOLT pisc. ROLL CLAMPING FEED_ PLOW MAX. POSITION AWAY FROM ROLL ‘The proper setting of plow will depend on the bulk density of feed and the rate of pelleting. Use the index numbers (1, 2, 3, 4, 5, located on "roll holding plate") for reference to the proper feed plow setting. Periodically check this and readjust if needed. DETERMINING DIE WEAI ‘There appears to be no sure-fire method of determining whether a die is worn out. Some users consider a die worn out when the diameter of the pellet at exit is about .008" over the diameter of the pellet from anew die. Others would consider this die half worn, etc. Some dies wear too thin and will no longer make a pellet that is hard or firm enough to meet the inspection of quality control personnel. Thin dies can also generate excessive fines. Each individual maintenance or production supervisor is the best judge of die wear since each knows his own requirements best. one of the areas treated too casually in the past has been wear of the die itself. When comparing the life of dies, we need to be sure that the dies under comparison are both worn to the same degree -~ and if 21-250 Pellet Mill Dies Page D-5 April, 1984not to same degree one needs to determine why one could not be worn as much as the other. Corrective action can then be taken and reliable comparisons made. The following sheet titled "DIE TEST DATA" provides you with a method to measure wear on a die to establish how much metal has been worn avay during the life of the die. There is also a location to record life on the die at the time measurements were made, condition of the pellet mill, operating conditions and quality of pellet produced. The result of this approach is to develop a figure for tonnage obtained per cubic inches of die metal worn away. SAMPLE PROCEDURE FOR MEASURING DIES Supplies A. Pocket scale in increments of 1/32" or less. B. Straight Edge - Preferably the same length as width of the die; i.e. 6" for 6" wide Ace die. This allows measuring while die is still on mill. A piece of square bar stock works nicely. Sears sells a 6" contour gauge which I have found to be a tool that is very easy to use when making die measurements. It simply requires that you lay it across the die I.D., press it down, remove it, and then measure. Instructions I. All areas of the die being measured should be clean from any feed and foreign material on die surface. This includes the inside diameter of the shoulders where the straight edge is resting. Il. At least five measurements should be made across the working width of the die by laying the straight edge across the total width of the die and measuring the space between the die face and the straight edge. This is illustrated in the drawing (Point No. 1 - Point No. 5) on "DIE TEST DATA" sheet. 21-250 Pellet Mill Dies Page D-6 April, 1984DIE TEST DATA Customer » Date Location >» Test Run By drawing No. > Serial No. » Pellet Mill ID DIE MEASUREMENT DATA cog erties rit Tonnage or Hours Operation, on Die. Date Die was Installed p Field Measurements for Wear Depth Point n Ye ¥3 va Y5 Wear Depth Y Avg. = YU + Y2 + 3 + Ya + Y5 = in. Maye + 3s Va YB = is Y= Metal Volume of Die Wear = (X) (Y Avg.) [4p(Die ID + Y Avg.) J ¥et d¢ ) ome + v1 Ve ind Comparison Die Wear Calculation. Tonnace = Tons/in® a "5 or Hours = = Hours/ in! i sear Pellet Mill Operation - Check List Main Bearings > Die Fit » Scrapers Roll Assy: Type of Shell Wear Pattern Roll Turns Freely , Centered on Face Motor: Serial No. » Full Load Amps Tie Bar or Plows: Type » Fit > Condition date Formula | Tons | Time | Amps | Cond. | Cond. | Pellet | ‘*tol. | Pellet Temp. | Moist | Temp. DurabilityDIE AND BOLT BREAKAGE: Dies that break with a crack which starts at the outer edge of the die immediately above the bolt hole, are doing so because the die is too loose in the housing or the cover. The die itself is not rigid enough to withstand the pressures generated by the rolls. The lip on the die that fits in the housing and cover is designed to take the pressure transmitted from the roll to the die. These parts are sufficiently sturdy and rigid to adequately absorb the pressure. ‘The function of the bolt is to hold the die against the face of the cover on the housing. It is not intended to resist the outward push from the rolls. If this fit becomes excessively loose, the bolt will be forced to take the load. Since it is structurally not designed to do this, it will break. The end of the bolt is tapped into the die and is securely anchored to it. The head of the bolt is anchored on the housing or the cover. Therefore, if the fit is loose between the die and the supporting menbers, the die and the bolts will flex. The pressure will be concentrated over the bolt. Cracks may occur in the die at this point and the bolt is liable to break next to the thread where it enters the die, Normally the bolt will break first, thus excessive amounts of broken bolts indicate poor die fits. Always use the special hardened washers under the Grade 5 high strength die bolts. We have had dies returned to us that were worn down as much as .015" where the die fits into the housing and into the cover. The reason for this wear is that the die has been used in a worn housing or cover and has been worked extensively against these hardened parts. A new die can be damaged considerably by putting it in a housing or cover that is badly worn. CLOSE AND TIGHT FITS ARE THE ANSWER TO DIE BREAKAGE PROBLEMS When a die breaks around the circumference it is the result of foreign material getting between the roll and the die, or extreme pressure from the feed stock itself. 21-250 Pellet Mill Dies Page D-7 April, 19843-BOLTS ROLL CLAMPING CENTER DISC AJUSTING SCREW JAM_NUT SEGMENT ROLL AJUSTMENT ROLL! INSTALLING ROLLS: WARNING: MAKE ABSOLUTELY SURE THE POWER IS OFF! NOTE: When removing larger rolls, use the roll lifting device which was supplied. Clean and grease the supporting end of the replacement rolls (where the two o-rings are mounted) and install new o-rings in the appropriate grooves. NOTE: Always install new o-rings on replacement rolls because the used o-rings are usually damaged (cut or deformed) thus allowing the grease to by-pass, which results in bearing failure due to lack of lubrication. Thoroughly clean the roll supporting holes in the main shaft head and install replacement rolls. 21-250 Pellet Mill Rolls Page E-1 April, 1984NOTE: In order to be sure that the newly installed o-rings are properly seated (or not leaking), you should lubricate each Toll through the end of main shaft. The o-rings could be damaged (cut) if not slid into place with care. Set rolls toward the center of main shaft by turning the eccentric pin with the geared adjusting wrench (furnished with the mill) in order to provide clearance for the die. After installing the roll holding devices (plate, plow, segments, dise, etc.) adjust the feed plow and rolls as described in a separate article. NOTE: In case only one roll must quickly be replaced, just remove the die cover from the stiffener ring and proceed as described above. IMPORTANT: Be sure the rolls are greased before restart of pelleting! Follow this procedure for all roll assemblies. ADJUSTING ROLL SETTING: This is the most important adjustment on the pellet mill! Correct roll setting will result in: Maximum capacity. Minimum wear on rolls and die. Minimum destructive stresses in mill. Fach roll is mounted on an eccentric pin and mst be adjusted for the proper clearance in the following manner: Indented or Corrugated Roll Settings (Use this procedure if you receive either corrugated or indented roller shells that have the outer face ground smooth, true and round.) A. Loosen three roll clamping bolts and jam nuts on each adjusting screw. Set the rolls by turning segments clockwise by tapping with a hamner or by using adjusting screws. B, Make sure that the inner face of the die and rolls are clean and free of foreign material. It is well to note here that if the roll is vorn to a different contour than the die face and there is no contact with the die, there will be no pelleting in this area. 21-250 Pellet Mill Rolls Page E-2 April, 1984Adjust the rolls clockwise (the same rotation as the die) so that the roll is in close proximity to the die face. Then rotate the mill by hand and tap the roll adjusting wrench until the roll lightly contacts the face of the die. Contact with the die face should be such that the roll does not stop at any time while the die is rotated 360° or more. ©. Make sure that the adjusting screws are set against the segment (holding the proper roll setting) and tighten the three roll clamp bolts. Lock adjusting bolts in position with the jam nuts. NOTE: If you reach the end of the adjustment, (when the adjusting screw length is used up) remove the center disc, reset adjusting screws, lift off the segment from the end of the gear and reinstall it as close as possible to the post, thus achieving a new start. Ruftex Roll Settings (If you pellet mill uses Ruftex rolls, adjust them as follows:) A. Loosen three roll clamping bolts and jam nuts on each adjusting screw. Set the rolls by turning segment clockwise by tapping with a hammer or by using adjusting screws. B. Set the face of the roll up to the inside face of the die so they all but touch. Now, due to variations in the diameter of the roller shell, you must rotate the main shaft by hand, make absolutely sure that the entire periphery of the roll shell, as it rotates, only touches the die very lightly on the high spots of the roll. Extreme care mst be exercised here since serious damage could occur if an improper roll setting is made. In pelleting, the rotation of the rolls is dependent upon friction from the thin layer of feed as it passes between the roll and the die face. This is necessary for good pelleting. If the roll setting should become too open and permit a thick mat of fed to pass through, then slippage could occur and you would not make pellets. If the roll is set too close to the die, you will peen the inner face of the die. This restricts the flow of feed, eventually makes pelleting impossible and may destroy the die. C. Make sure that the adjusting screws are set against the segment (holding the proper roll setting) and tighten the three roll clamp bolts. Lock adjusting bolts in position with the jam nuts. 21-250 Pellet Mill Rolls_ Page E-3 April, 1984NOTE: If you reach the end of the adjustment, (when the adjusting screw length is used up) remove the center disc, reset adjusting screws, lift off the segment from the end of the gear and reinstall it as close as possible to the post, thus achieving a new start. Checking Roll Setting Rolls and die will wear as the pellets are produced. Roll settings should be checked and adjusted periodically as your experience will dictate. If the rolls are not set properly, it will result in the following operational difficulties: Start-Up Problems Erratic Operation (fluctuating ammeter) Frequent Plug-Ups Always maintain proper roll clearance by checking regularly. As the die wears, it is absolutely necessary to maintain proper roll setting because excessive clearance will not allow the feed being pelleted to be nipped properly between the rolls and the die. Eventually, the pellet mill will behave erratically since excessive clearance will cause the rolls to slip and the mill to plug. In many instances this roll slippage will be indicated in a fluctuating reading on the main motor anmeter. The result will be low production per power input and excessive wear on the rolls and die face as well as high pressure inside the die. Also, if the roll is set too close to the die you can peen the inner surface of the die, thus restricting the flow of feed and eventually make pelleting impossible. 21-250 Pellet Mill Rolls Page E-4 April, 1984REBUILDING ROLLS: In order to perform the necessary maintenance safely and economically on the rolls such ast bearing, seal and shell replacement, it is dnperative to use the suitable equipment as follows: a. Hydraulic press (minimum 20 tons capacity) b. Snap-ring pliers (furnished with mill) c. Pressing tubes, one that just fits over the roll pin and the other that just fits inside of the shell d. Dial indicator with stand Disassemble Used Roll Remove the snap-ring and the lock nut from the roll pin. Support the roll assenbly on either side of the shell and press out the roll pin. Remove both outer labyrinth seals and the large snap-rings. Press out the remaining bearing cups, spacer ring and the inner labyrinth seals. Recommended Bearing Fits Bearing Cup: .002~.004 tight in shell Bearing Cone: .000-.002 tight on pin 21-250 Pellet Mill Rolls Page E-5 April, 1984Assemble Roll STEP A 1, Place a snap-ring in shell, either side. PRESSING TUBE 2. Slide inner labyrinth eet seal against snap-ring. Lower bearing cone against inside of labyrinth seal. 4. Press in bearing cup, against labyrinth seal. Lower spacer ring in place. 6. Press in the other bearing cup. STEP B 7. Install snap-ring on roll pin. 8. Slide on outer labyrinth seal against snap-ring. 9. Life up the preassembled roll (as shown in Step A) and press bearing cone against labyrinth seal. 21-250 Pellet Mill Rolls Page E-6 April, 1984STEP C 10. Press on the other bearing cone but leave some clearance to allow final adjustment. OUTER LABYRINTH SEAL- 11, Slide inner labyrinth mmm wor seal in place. seco SHER 12. Install snap-ring in INNER LABYRIN’ shell. SEAL 13, Slide on the outer labyrinth seal against the bearing. 14, Slide on lock washer and install lock nut. 15. The bearing should be set to zero clearance. To do this, tighten the lock nut until a slight drag is felt when turning the roll about the roll pin. -O-RINGS, DO NOT OVERTIGHTEN. WHEN ADJUSTMENT IS MADE TO BEARING SETTING, THE ROLL MUST BE TURNED SEVERAL REVOLUTIONS TO SEAT THE TAPERED ROLLS IN THE RACES. When the roll is turned and the bearings seat, the drag may disappear. This procedure may need to be repeated until the slight drag remains. 16, Secure nut in place with lock washer by bending one of the tongs into the appropriate slot on lock nut. 17, Install new O-rings. 21-250 Pellet Mill Rolls Page E-7 April, 1984MAINTENANCE WARNING: BEFORE PERFORMING MAINTENANCE OR REPAIR WORK, DISCONNECT THE ELECTRICAL SWITCH AND SECURE IT IN THE "OFF" POSITION WITH PADLOCK. EACH PERSON WORKING ON THE MACHINE SHOULD ACCOMPLISH ‘THIS LOCKOUT WITH HIS OWN LOCKOUT DEVICE AND SHOULD RETAIN KEY WHILE WORK IS BEING PERFORMED. LUBRICATION ‘The following instructions describe the proper lubricant and lubrication data for your pellet mill. Please follow these instructions and observe recommended lubricants and lubrication intervals. REMOTE MANUAL~TYPE LUBRICATION SYSTEM: (Ref. Forms 1849F & 1863) ‘The pellet mill (including conditioner and centrifeeder) is designed for remote manual-type greasing, which makes it possible to lubricate all the bearings and parts (except coupling) while the mill is in operation. RECOMMENDED LUBRICANT (GREASE) only a high grade grease should be used, which is designed for anti- friction bearings and has the following characteristics: = Drop Point of 450° F. = Non-toxic = Non-corrosive = Unaffected by exposure to moisture = should meet USDA lubricant specifications for aninal feed consumption CAUTION: ALWAYS CLEAN GREASE FITTINGS AND GREASE GUN HEAD BEFORE SERVICING BEARINGS. KEEP ALL GREASE CANS COVERED TO AVOID CONTAMINATION. ROLLS, PELLETING The three pelleting rolls are greased through the main shaft from the gear. Extended type "long fittings" are provided for ease of identifi- cation. Lubricate all three rolls at least every 2-3 hours. 21-250 Pellet Mill Maintenance Page -F-1 April, 1984NOTE: The amount and the time interval of lubrication will vary with different applications and will have to be determined by experience. When lubricating the rolls for the first time, ft is suggested that it be done with the mill shut down, so the amount of grease required can be determined. IMPORTANT: ENOUGH GREASE SHOULD BE ADDED EACH TIME TO FLUSH OUT THE SPENT GREASE THROUGH THE FRONT BEARING SEAL. MAIN SHAFT BEARINGS qThe main shaft is supported by the "center main bearings" (in cartridge) ‘and the bronze bearing (in shear pin hub). Center Main Bearing is greased through the main shaft from the rear and it should be lubricated daily. The required amount should be determined as described for pelleting rolls. (Purge grease through front seal.) Bronze Bearing is greased through the shear pin hub and it must be lubricated every time when replacing broken shear pins. If the shear pins do not require frequent replacement, then lubricate once every month. COUPLING, MAIN DRIVE (IF " Is USED) Lubrication of coupling should be done with the mill shut down. Remove drive guard and the two plugs from the coupling cover. Screw a grease fitting in one of the holes and grease coupling until the Excess amount if coming out from the other hole. You may keep the grease fitting in the cover but the plug must be installed in the vent hole! Lubricate once every three months. CENTRIFEEDER BEARINGS Only a small amount of grease is required for the flanged type ball bearings (a couple of shots or so). Over-greasing could harm the bearings by blowing the seals out. Lubricate once every week. 21-250 Pellet Mill Maintenance Page F-2 April, 1984GREASE LUBRICATION OF THE 21-250 PELLET Centrifeeder shaft supporting bearings, lube once every week. Sy > 7 Coupling (Grid-type) Lube once every 3 months. See motor manufac- turer's instruction for lubrication. bE rt peal R | oe PELLET MILL WITH CENTRIFEEDER Bronze bearing Lube every time when replacing broken shear pins. “Long Fittings” Center main bearing (In cartridge) Lube daily. rolls - pelleting Lube every 2-3 hours | G VIEW AA OF THE SHEAR PIN HUB FORM 18492Lubricate all points once every week, but DO NOT overgrease, NOTE: Follow the manufacturer's recommendations to lubricate the drive motors and gear reducer (if used). MOTOR, MAIN DRIVE Prior to running any of the drive motors for your pelleting equipment, we recommend that the motor bearings be greased. This guarantees all bearings will have a fully supply of fresh grease and eliminates possibilities of bearing failure because of grease deterioration or loss during shipment or storage. ‘This is particularly important for the main drive motor and the proper method of doing this is to pull the drain plug and flush the bearing and fill completely with new grease. The drain plug must be removed prior to greasing these motor bearings -- or the motor itself may be damaged. Also, proper flow of grease into the bearings can only be obtained if the plugs are removed to eliminate back pressures within the bearing. These plugs are located to direct the flow of grease through the bearing to purge old, deteriorated grease and any dirt or contaminants that may have found their way into the bearings. Greasing techniques will vary on the smaller motor, so we recommend following, the manufacturer's specifications attached to motor. All gear boxes should be checked for proper lubrication levels prior to initial start-up. Grease every six months, or (1000 hours). 21-250 Pellet Mill Maintenance Page F3 April, 1984LUBRICATION OF FEEDER CONDITIONER: Sizes: 18 x 56 and 24 x 64 (Dual or Single Drive) Lubricate all points indicated by arrows once every week, or as your experience will dictate. Dual drive conditioner only: Maintain oil level in reservoir. This oil is used to lubricate the bearings which support the feed screw on the shaft. If oil level is depleted rapidly or consumption rises, the seal on the front of the feeder screw should be inspected for damage along with the bearings. Replace as necessary. CAUTION: DO NOT OVERGREASE! OIL RESERVOIR —> l FORM 1863EAR DRIVE LUBE SYSTEM AND CONTROLS: (Single Speed Pellet Mill) Ref: O41 Lube System Form 2100 (Section G) ‘The single reduction gear drive of the Model 21-250 Pellet Mill ts oil lubricated. To assure long gear and bearing life, a combination of forced and splash type recirculating lube system is provided, which consists of: 1, 041 Sump 4. Pressure Switch 2. Pump 5. Pressure Relief Valve 3. Filter 1. O41 Sump is built in the bottom of the pellet mill gear housing, ‘and contains approximately 20 - 22 gal. of oil. An oil level gauge is provided which indicates . . . at the half-way mark . « « the required amount. This should be checked daily. ‘The thermometer, located on the hinge side of gear housing, under the bottom hinge lug (for protection), indicates the oil tempera— ture. CAUTION: IF THE OTL TEMPERATURE IS LESS THAN 40° F., WE RECOMMEND THE USE OF AN OTL HEATER 70 BRING THE TEMPERATURE TO AT LEAST 50-60° F. BEFORE STARTING THE PELLET MILL. ‘The maximum operating temperature is 150-155° F. 2. Pump (Part No. 3) is belt driven from the input shaft of the pellet mill, which circulates the oil at the rate of 3 GPM. Cheek and tighten V-belt periodically during the first month of operation, until it takes the permanent set, to avoid belt slippage. 3. Filter (Part No. 18) is a micronic type unit, with replaceable TO-micron filter element (Purolator No. 30316-20). Filter change: Two pressure gauges are mounted on the filter (inlet and outlet) to determine the pressure drop (difference between inlet and outlet pressure) increases. When the pressure drop (differential pressure) reaches 20 PSI (at operating temperature), the filter element should be changed. ‘The pressure gauge on top of filter will indicate an operating pressure range of 25-35 PSI, at operating temperature of 130-140" F., when the oil and the filter are clean. 21-250 Pellet Mill Maintenance Page Ps April, 1984‘The maximum operating pressure is 100 PSI which could occur during start-up (when the oil is cold). This pressure should fall as the temperature rises to the operating range. 4. Pressure Switch (Part No. 19) is provided to protect the pellet mill by shutting it down on loss of oil pressure. The switch is permanently set to trip at approximately 10 PSI. The switch must be connected in the pellet mill control circuit as shown in the wiring diagram (Form 2022). This position is in series with the shear pin micro-switch. NOTE: Failure to properly connect this switch interlock can result in severe damage to the pellet mill if oil pressure is lost while mill is operating. Pressure Relief Valve (Part No. 20) protects the lube system from high pressure build-up, during start-up of mill when the oil is cold and the viscosity is high, thus it is set to by-pass the oil at 80 to 100 PSE. As the oil temperature rises, the operating pressure will drop and all the 3 GPM ofl will circulate through the system. NOTE: The valve (Part No. 21) is set at factory to proportion the oil flow to the gear spray and to the bearings. Do not tamper with this valve! If you have any questions concerning this valve please contact Koppers. 21-250 Pellet Mill Maintenance Page F-5 April, 1984RECOMMENDED LUBRICANT (OTL) : To assure long bearing and gear life, a premium quality EP gear oil should be used, which meets the following specifications: High oxidation stability. High demulsibility (water separation). III nigh viscosity index (90 or higher). 1 High alkaline reserve (helps control rusting). TI] wigh metal deactivation (protect from the catalytic effects of copper and bronze). ... Must contain: Foam inhibitor and anti-vear additive. III For normal operating conditions, the oil viscosity should meet AGMA Grade 5-EP specifications. Some of the commercially available oils, which have all the desirable properties, are: Texaco "Meropa 220"... . . + + + + Texaco Co. Chevron "Industrial 011 220X" . . . . + Chevron O11 Co. Gulf "HD 220"... . +++ ++ ++ + Gulf O11 Corp. Mobil "Gear 630"... ... ++ + + + Mobil O11 Co. Citgo "EP Compound 220"... . . . - « Citgo Co. RECOMMENDED OTL CHANGE: Any oil, that meets the above specifications, is suitable for minimum 2,000 hours of service. To assure this service life, the oil must be kept clean! ae Be Change filter element when required. Drain off the accumulated water from the ofl sump (once a month) after the pellet mill has been shut down for over 12 hours. Add clean oil, to bring oil level to normal. Mo matter what operating conditions exist, the of1 should be changed at least once a year! 21-250 Pellet Mill Maintenance Page -F-6 April, 1984UG TED MAINTENANCE TIMETABL Part I - Lubrication As Specified 2 - 3 Hours Daily 100 Hours (weekly) Monthly 3 Months 6 Months As specified by manufacturers of motors of feeder, conditioner and centrifeeder; lubricate per instructions. (Or more often if dictated by application.) Grease roll assemblies; purge grease through seals. (See Page F-1 and Form 18495.) Check of1 level gauge for gearbox level. (See Page F-43 Gear Drive Lube System and Controls.) Check pressure drop across of] filter. Whenever pressure drop exceeds 20 PSI, change oil filter element. (See Page F-4), Drive Lube System and Controls, No. 3 - Filter.) Grease center main bearing; purge grease through front seal. (See Page F-2, Main Shaft Bearings and Form 18495. Lubricate centrifeeder bearings. (See Page F-2, Centrifeeder Bearings and Form 18498.) Lubricate feeder-conditioner bearings. (See Page F-3, Feeder-Conditioner Bearings and Form 1863.) (Or whenever shear pins break.) Grease bronze bushing in shear pin hub. (See Page F-2, The Bronze Bushing and Form 1849E.) Drain off any accumulated water in oil sump. (See Page F-6, Recommended Oil Change.) Grease main drive coupling. (See Page F-2, Main Drive Coupling, Form 1849E and Falk Page 2, reprinted from Falk Service Manual 428-110.) Grease main drive motor. (See Page F-3, Motor - Main Drive.) When cartridge is not used as a quick-change feature, remove cartridge and coat tapered end of die housing with NEVER-SERZ. At the same time coat main shaft in the keyway area at the shear pin hub with "LOCTITE" No. 242. (See Page F-14, Rotating Shear Pin Hub.) 21-250 Pellet Mill Maintenance Page F-7 April, 19842000 Hrs. - Change oil in gearbox. (See Page F-6, Recommended O11 (12 month) Change) and oil filter element (See Page F-4, Filter.) Part II - Adjustment Daily = Check roll-to-die adjustment. (See Page E-2.) IMPORTANT: Before adjusting rolls, check condition of roll bearings for looseness. If excessive looseness in the radial direction is detected between the roll shell and seals, do not attempt to adjust the roll. It must be replaced. The looseness indicates the bearings have failed and the roll must be rebuilt. As Needed - Check feed plow adjustment. (See Page D-4.) = Check drive belt tension on feeder, conditioner and centrifeeder. Monthly = Check V-belt on ofl pump. (See Page F-4, Pump.) 21-250 Pellet Mill Maintenance Page F-8 April, 1984RAPID CHANGE PELLETING CARTRIDG! Your Model 21-250 Pellet Mill utilizes a rapid change pelleting cartridge, which consists of the die housing, die, die cover, rolls, etc. The cartridge makes short production runs economically feasible where frequent die changes are necessary. The cartridge concept minimizes maintenance costs and the time required to change dies. The rapid change feature requires a cart (cartridge carrier), two or nore pedestals (storage and service stands) and an extra pelleting cartridge. WARNING: TO ASSURE MAXIMUM SAFETY DURING THE RAPID CARTRIDGE CHANGE, THE FLOOR IN THE AFFECTED AREA MUST: (1) SUPPORT 3,400 POUNDS OF ROLLING WEIGHT WITHOUT SAGGING (1,000 POUNDS ON EACH FRONT WHEEL AND 700 POUNDS ON EACH CASTER WHEEL; (2) BE SMOOTH SURFACED TO AVOID DESTRUCTIVE SHOCK LOADS ON CART; AND (3) BE LEVELED. NOTE ON PEDESTAL ANCHORING: To prevent possible pulling loose of anchor bolts from the concrete, the pedestal mounting pad must be properly prepared as shown per the pedestal installation drawing (Section 1). NOTE: When you do not have the above equipment (cart, pedestal, etc.) use any adequate lifting device (hoist, fork lift, ete.) to remove the cartridge for the regular pellet mill maintenance. WARNING: WHEN CARTRIDGE IS BEING REMOVED FROM THE MILL WITH THE DIE OR PART OF THE CARTRIDGE ASSEMBLY REMOVED, SECURE PELLET MILL MAIN SHAFT 70 THE DIE HOUSING BEFORE REMOVING SPINNER NUT FROM THE MAIN SHAFT. A MAIN SHAFT RETAINER (SEE FORM 2013C) HAS BEEN FURNISHED FOR THIS PURPOSE AND SHOULD BE USED AS DESCRIBED ON PAGE F-12. IF THIS PROCEDURE IS NOT FOLLOWED, THE MAIN SHAFT WILL BECOME LOOSE WHEN THE SPINNER NUT IS REMOVED AND COULD FALL OUT OF THE PELLET MILL, CAUSING SERTOUS INJURY OR DEATH. Proceed with the rapid change as follows: A. Shut off pellet mill and rotate cartridge until the indicator (on the back of the die housing ) is lined up with the pointer on the gear housing (on the vertical center). This will align the Keyways on the end of the main shaft and on the die housing. 21-250 Pellet Mill Maintenance Page F-9 April, 1984Push cart against the mill until the securing hook on the cart is latched to the mill. Push the movable trolley under and against the cartridge and raise saddle to support the cartridge by turning the handwheel. Secure cartridge to trolley with the safety clamp above handwheel and reverse the ratchet lock on the handle to allow the trolley to roll away from the mill while the cartridge is being pushed out from the mill. Knock off the spinner nut from the end of the main shaft (at the rear). Loosen the four cartridge holding bolts (reach through the shear pin hub) until they come to a stop. After all four bolts are in this position, apply up to 400 ft. Ib. torque to one of these bolts, in order to break the cartridge loose. If it becomes necessary to use more than one bolt to break the fit, then use the rest of the bolts (on the same centerline opposite the previous bolt). When the cartridge is loose, continue to push out cartridge with the same bolts (about 5/8" bolt engage- ment exists in the cartridge at this time). After the cartridge has been freed from the rear, pull it the rest of the way out with the ratchet handle until the trolley comes against the front of the cart. Unlatch cart from mill (using foot pedal) and transport cartridge to the pedestal. Mount cartridge in pedestal as follows: 1, Lateh cart to pedestal. Reverse the ratchet handle and push cartridge into place until it comes in contact with the two bolts at the rear. 3. Pull cartridge in place with the two bolts. 4, Dismount cart from cartridge. Pick up the other cartridge from its pedestal and install it in the mill as follows: NOTE: Before installation of cartridge in mill, the bull gear hub in the pellet mill should be wiped clean of any grease, dirt, ete., which could cause a material build-up. 1, Lateh cart to mill. 2, Reverse the ratchet handle and push cartridge into mill until it touches the four holding bolts at the rear. 3. Pull cartridge in place with the four bolts. 4. Torque each of the four bolts to 400 ft. 1b. CAUTION: Tighten bolts in steps (one by one) to avoid cocking the cartridge in the tapered fit. 21-250 Pellet Mill Maintenance Page F-10 April, 19845. Install the spinner nut and tighten by rapping with hanmer. 6. Dismount cart from cartridge and mill. NOTE: Keep the mounted portion of the tapered fit (cartridge and bore in hub) free of dirt. Be sure it is lightly coated with "NEVER-SEEZ! and wiped clean before each installation. THE "NEVER-SEEZ" COATING SHOULD BE SPREAD TO A VERY THIN LAYER WITH A CLEAN RAG. ANY BUILD-UP OF LUBRICANT SHOULD BE AVOIDED, CHECK THE TAPERED BORE IN THE PELLET MILL TO BE SURE IT IS WIPED CLEAN BEFORE EACH CARTRIDGE INSTALLATION. caury 21-250 Pellet Mill Maintenance Page F-11 April, 1984Cap Screw, GR5, 5/8 x Lae Die Housing MAIN SHAFT RETAIN WARNING: THE MAIN SHAFT RETAINER MUST BE USED WHEN REMOVING A CARTRIDGE WITH THE DIE OR PART OF THE CARTRIDGE ASSEMBLY REMOVED. FAILURE TO USE THE RETAINER MAY RESULT IN SERIOUS INJURY OR DEATH. ‘The main shaft retainer is used to prevent the main shaft from sliding out of the die housing during removal from the pellet mill. The retainer must be installed before the spinner nut is removed from the main shaft assembly. The retainer is bolted to the die housing with the cap screw using any of the die holding bolt holes. The narrow bar must be in front (opposite side of die housing) of the main shaft as shown in front view. The bolt and nut are then tightened through the die holding bolt hole as shown in the blow-up section. With the bolt tightened, the main shaft will be secured in the die housing. In addition to the safety aspect, a lifting hole is provided so that the cartridge assembly can be supported by an overhead lifting device. When removing the cartridge from the pellet mill or a pedestal, another lifting point must be used to prevent the cartridge from dropping during removal. This device is not intended as a pulling device for the cartridge. Before removing the retainer, the spinner nut must secure the pellet mill main shaft in the mill housing. 21-250 Pellet Mill Maintenance Page F-12 April, 1984SHEAR PIN HUB ASSEMBLY: ‘The purpose of the shear pins is to protect the pellet mill from extreme overloads when tramp metal wedges between the die and the roller. When this occurs, the shear pins break allowing the main shaft and shear pin hub to rotate. The limit switch will auto~ matically shut off the pellet mill when this happens. NOTE: Be ‘This limit switch automatically resets so the pellet mill can be restarted. Replacing Shear Pin Remove the outside half of the broken shear pins by sliding out the retaining plates. Rotate the cartridge manually (at the front of the mill) until the V-notches are lined up on the rotating and stationary shear pin hubs. This will align the hardened shear pin bushings and locate the main shaft in the proper position. Slide in the new shear pins and secure them with the retaining plates. NOTE: Before installing the new shear pins, check the hardened shear pin bushings and if they are cracked or broken, replace them with new ones before installing the new shear pins. IMPORTANT: Do not substitute a bolt or a piece of rod for the proper size shear pins. These shear pins are designed to break at a load below that which will damage the pellet mill. Always keep on hand a generous supply of spare shear pins. Bronze Bushing, The rotating shear pin hub is supported by a bronze bushing. Fach time when replacing shear pins, this bronze bushing must be lubricated through the fitting on the top center of the stationary casing. This bronze bushing should be replaced as follows when it becomes worn to the extent that the shear pin bushing cannot be aligned to accept the new pins. 1. Remove the limit switch. 2. Remove the stationary shear pin hub which holds the shear pin and the bronze bushing. 21-250 Pellet Mill Maintenance Page-F-13 April, 19843, The bronze bushing is held in place by three set screws (driven between the bronze and the hub on the face). Remove these set screws and press out the worn bushing. 4. Press new bushing in place and drill and tap 1/4 20NC by 3/8 deep holes in three places. Install the three set screws to retain the bushing in the same way as the previous bushing was installed. 5, Install stationary hub in place and lubricate the bronze bushing. 6. Install the limit switch. 7. Install the new shear pins. Rotating Shear Pin Hub The rotating hub is mounted on the keyed shaft end with a loose fit in order to utilize the Rapid Cartridge Change feature, where the shaft must be free to slide in and out of the hub. When the Rapid Cartridge Change feature is not used, or the cartridge is not removed periodically, the rotating hub is fixed to the shaft with an anaerobic adhesive compound such as Loctite No. 242 (or equal) in order to prevent stress corrosion between shaft and hub. Remove fixed hub as follows: 1. Remove the stationary shear pin casing with the limit switch, all the grease fittings and the spinner nut from the end of the shaft. 2. Install hub-puller as shown and tighten the 3/4 puller bolts with 250 ft. 1b. torque; if the hub did not loosen, then hit center pad on the puller to break it loose. Wear Segments Hub-puller (Dwg. #83654-300) nor 3/4,x15-1/2 19. When hub is removed, scrape of f Gre (3 req'd.) all the residue from the shaft aa and the hub bore. I\___ Rotating Shear Pin Hub 21-250 Pellet Mill Maintenance Page F-1é April, 1984Check wear segments as follows: 1. Examine each wear segment for wear on the face of segment. If wear is greater than 1/32 inch, the wear segment may be reversed and used with good face to wearing surface. If both faces are worn, the wear segment must be replaced. Install fixed hub as follows: 1, ‘Thoroughly clean all mounting surfaces and spray on primer (Loctite "Locquic") on both pieces (shaft and hub bore) in order to reduce the cure time. 2. Apply adhesive (Loctite No. 242) on shaft end and in the hub bore. The keys and keyways also must be coated. 3. Slide hub on shaft and secure it in place with the spinner nut. NOTE: The curing time of the adhesive is a minimum of two hours when primer is used (under adhesive). Do not start mill during this time, and if possible, extend this to six houre to assure complete curing. CENTER BEARING REPLACEMENT: ‘The main shaft is supported by the center bearing in the cartridge. This ie a cylindrical roller bearing with a straight inner-race for simplifying the assembly. ‘The following procedure applies if the cartridge assembly is in the mill or mounted in a cartridge. Replace bearing as follows: 1. Remove die cover and die with the mounted stiffener ring. 2. Support main shaft assembly in the roller area with an overhead hoist or similar method. THE MAIN SHAFT MUST BE SUPPORTED BEFORE THE SPINNER NUT 1S REMOVED. THE KEYED END OF THE SHAFT MUST ALSO BE SUPPORTED BEFORE IT 1S TOTALLY REMOVED FROM THE DIE HOUSING. NOT SUPPORTING THE SHAFT AT BOTH ENDS ALLOWS THE KEYED END TO DROP AS IT EXITS THE DIE HOUSING. WARNIN Remove thrust nut (spinner nut) from the end of the shaft. 21-250 Pellet Mill Maintenance Page F-15 April, 198410. Le ize 13. Slowly pull it out the shaft assembly. WARNING: SUPPORT SHAFT AT KEYED END BEFORE COMPLETE REMOVAL. The cylindrical roller bearing will come apart due to the straight inner-race, Be sure to secure and support shaft at two points (see warning above). NOTE: The keyed shaft end is fixed into the rotating hub with "Loctite", when the Rapid Cartridge Change feature is not used. See instructions on Page F-14 for removal. Remove the sleeve-type retaining nut from the shaft after loosening the two set screws which lock it in place. Remove the bearing inner-race from shaft. (Preferably use "chisel" to break it loose.) Remove bearing cover from die housing and the front lip seal which is mounted in this cover. Knock out the outer race of the roller bearing through the small end of the die housing and remove the rear lip seal which is located directly behind the bearing. Clean out the bore and install a new lip seal (lip toward the front) and press in the new roller bearing. (The press fit is normally between .0005 - .0018".) Install a new outer lip seal into bearing cover (lip toward front) and bolt bearing cover in place. Clean the main shaft and check the wear ring next to the head; if it is grooved by the lip seal, it should be replaced. Press on the bearing inner race (heat to about 200° F. and drop in place on shaft). Install the sleeve-type retaining nut by tightening with a drift pin. Lock the nut in place with the two set screws provided. To assure that the sleeve-type nut is locked into place, it is recommended to spot the shaft to receive the set screws using 3/8” diameter x 1/8" deep holes. If the outer surface of this retaining nut is grooved by the lip seal, it should be replaced with a new one. (The bearing fit on the shaft is normally 0.001 - 0.003" tight.) If the Rapid Cartridge Change feature is used, a light coat of "NEVER-SEEZ" should be applied on the keyed portion of main shaft end as outlined on Page F-15. 21-250 Pellet Mill Maintenance Page F-16 April, 1984When the Rapid Cartridge Change feature is not used, the rotating shear pin hub must be fixed to the keyed shaft end with "LOCKTITE” adhesive as outlined on Page F-14. Pack the roller bearing with grease in the die housing and slide the main shaft into the cartridge, using an overhead hoist or similar device for support. WARNING: THE MAIN SHAFT MUST BE SUPPORTED WHILE INSERTING INTO DIE HOUSING UNTIL THE SPINNER NUT SECURES SHAFT INTO CARTRIDGE. SUPPORT THIS LARGE SHAFT AT ALL TIMES TO PREVENT THE SHAFT FROM DROPPING. CAUTION: THE SHAFT MUST BE CAREFULLY GUIDED INTO PLACE TO AVOID DAMAGING THE LIP SEALS. MAKE SURE THE KEYWAYS ON THE MAIN SHAFT ARE IN THE RIGHT POSITION BEFORE SLIDING THE SHAFT INTO THE SHEAR PIN HUB. 14. Secure the main shaft into the shear pin hub with the spinner nut and proceed with the installation of the die and die cover. GEAR DRIVE ASSEMBLY: A single reduction helical gear drive is used in this pellet mill which consists of the bull gear and the stem pinion gear. The life of the bull gear is twice that of the stem pinion because the bull gear can be turned around (to use the unworn backside of the gear) and reinstalled with a new pinion. Gear Replacement 1. Remove the pelleting cartridge and the shear pin hub assembly as described in this manual. Remove the gear access cover and the inspection cover from both sides of the gear housing. Drain the oil out from the housing and from the ofl filter. 2. Disassemble the drive coupling and slide the main motor out of the way. Digmount coupling and pump drive from the pinion shaft and remove the ofl supply tubes from inside of casing. Remove the front bearing supporting cap (using jack screws). The bearing will come apart. Remove the rear main bearing cap. While removing these bearing caps, support the pinion gear by hand through the inspection opening. Push out pinion gear with the rear bearing assembly through the rear opening. 3. Remove the front seal retainer which is bolted on the face of the main bearing cap. Remove the main bearing supporting caps, first the front, then the rear, (use jack screws to pull them out of 21-250 Pellet Mill Maintenance Page F-17 April, 1984on the housing). The bull gear then will rest on the internal supports. Unbolt the bull gear from the hub and slide out the hub through the front main bearing opening. NOTE: Use a 3” pipe about 4 ft. long (wedged in tapered bore with the wood blocks) to support and remove the hub. Pull out the bull gear through the side opening of the gear housing. Turn it around to use the other side or if both sides of the gear are used, put it in anew bull gear. Roll the gear back to the center of the housing to rest on the internal supports. Examine the main bearings on the hub and in the supporting caps. If they are worn out, replace them with new ones. The inner-races (or cones) are pressed on the hub with .004~.006" tight fit. The outer-races (or cups) are pressed in the supporting caps with .001-.005" tight fit. NOTE: Take care when installing the new bearings to be sure that they are pressed against the shoulders. In order to remove the BRG-inner race (or cone) the wear ring must be removed which is pressed on the hub ahead of the BRG. In most cases this ring has to be replaced with a new one because it is difficult to remove undamaged. Install the hub in the bull gear (slide in from the front). Apply NEVER-SEEZ on the SAE GR-8, 3/4 x 3-1/2 long bolts and install them with the spring washers. Install five spring washers as shown on the sketch below. Torque these bolts to 280 ft./Ibs., or until the spring washers are flattened. (At this torque level the spring washers are flattened to 0.056".) SPRING WASHERS Stack washers on bolt with cone pointing toward bolt head. Install the front main bearing cap and make sure that the oil supply hole is located on the top center. Torque the cap holding bolts (5/8 SAE GR-5) to 130 ft.-Ibs. 21-250 Pellet Mill Maintenance Page F-18 April, 1984If you are reinstalling the used main bearings, then put the old shim stock back on the rear main bearing cap and bolt rear main bearing cap in place using new O-rings. Tighten these SAE GR-5 bolts 130 ft.-Ibs. Adjusting new main bearings. In case a new set of main bearings is being installed, the shim stock must be readjusted in order to obtain the proper bearing set-up. These main bearings are slightly pre-loaded to avoid gear wobble due to loose bearings. ‘An accurate and easy way to set these bearings is the "torque-set" method which is described in the following: ‘A, DETERMINE ZERO CLEARANCE IN BEARINGS. Install the rear main bearing cap (do not tighten) and leave out the shims. Attach a spring-loaded pull-type scale (0-100 Ibs. cap.) to the rim of the bull gear. Pull on the scale in a slow and steady fashion (always keeping the scale perpendicular to the gear) in order to read the tangential force that is required to turn the gear. If this force is between 8 and 10 Ibs. (or less), the main bearings are loose. Tighten the rear main bearing cap (evenly all around) with its holding bolts, while slowly turning the bull gear (in order to straighten the tapered rollers in the main bearings.) Measure the pulling force again. Continue to do this until a slight increase (about ] to 2 Ibs.) is detected. This will indicate a zero clearance situation in the main bearings. B. SHIM TO PRE-LOAD BEARINGS. After setting the bearings to zero clearance, measure the gap between gear housing and the rear bearing cap (in place of the shim). NOTE: In order to assure accurate measurement, you should check at least four places all around and average out the readings. Deduct .003" from the above obtained measurement and set the shim to this thickness. Loosen rear main bearing cap holding bolts and slide main bearing cap avay from case. (Do Not Let Pinion Shaft Slide Out of Bearing Cap.) Place shim on bearing cap. Tighten the bearing 21-250 Pellet Mill. Maintenance Page F-19 April, 198410. Le. cap holding bolts to 130 ft.-Ibs. torque. Turn bull gear a minimum of two revolutions, and check the pulling force. It should be about 6 to 10 Ibs. greater than the zero clearance force. In case you did not obtain the proper pre-load, the shim should be readjusted. For each .003" thick shim change, the corresponding force change is 6 to 8 Ibs. Install front main seal. This is a lip type seal which is mounted in a removable retainer ring (for ease of replacement). Tt is recommended to replace this seal every time when changing gears, or as often as required. Check the wear ring (on the hub) on which the seal rides and if it is grooved by the lip then locate the seal in the retainer such that the lip could ride about 1/16" avay from the groove. This could be accomplished by not pressing the seal all the way back in the retainer. If the wear ring is worn to the extent where the above mentioned seal adjustment is not possible then replace it with a new one. Install reer main seal. This is a labyrinth seal with flinger ring. The only parts that require replacement are the gaskets if damaged, at disassembly or by heat. Place flinger with gasket against the bearing on the bub, then bolt labyrinth seal with gasket to rear main bearing cap. Install pinion gear and bearings. Every time you install a new pinion gear, you should replace the supporting bearings. Remove the two pipe plugs from each bearing cap and knock out the used bearing (outer-races). Press in the new bearings and make sure that the béarings are driven against the shoulders. Press the bearing inner-races (cones) on the new pinion shaft. Install flinger ring on the drive end of the pinion shaft (secure it in place with two 1/4 x 1/2 1g. set screws). The lip on the outer flange must point toward the shaft end. Install the front bearing cover and tighten the bolts (70 ft.-1b. torque). NOTE: Make sure that the O-ring is mounted on the outside shoulder of the cap, and the oil holes are located 45° up and toward the large gear opening. 21-250 Pellet Mill Maintenance Page -F-20 April, 1984NOTE: If in doubt about which of the following procedures to follow, please consult factory before proceeding. Adjustable Pinion Bearing Only (21-200) If your mill is equipped with an adjustable pinion bearing, proceed as follows: Slide pinion gear in place (supporting it by hand) through the side opening and install the rear bearing cap without the shin. Use three bolts, equally spaced, to tighten the bearing setting until the end play of the pinion shaft is .009 - .011" loose. Use dial indicator to measure end play. Measure the gap between cap and housing (in place of shim) at a minimum of three different places to obtain accurate shim thickness. Adjust shim to this thickness and {nstall it in place. After tightening rear bearing cap, check the end play and adjust shim if fe is not .009 - .011" loose (shim is .002" laminated) « Non-Adjustable Pinion Bearing Only (21-250) If your mill is equipped with a non-adjustable pinion bearing, proceed as follows: Slide pinion gear in place (supporting it by hand) through the side opening. Install assembled rear bearing cap. Tighten screws to 65 ft.-Ib, torque. Replace cylindrical roller pearing in front main bearing cap (remove pipe plug, if applicable, to renove old bearings). Install front bearing cap and tighten screws to 65 ft.-lb. torque. ‘The double tapered roller bearings do not require adjustment when properly installed. Both Mills Install the oil supply tubes between the top oil reservoir and the pinion bearing caps (on each side of the bull gear). Make sure that the inside of the gear housings, particularly the bottom of the oil sump is wiped clean and install the cover plates on both sides of the gear box. NOTE: The large gear access cover plate is mounted on gear housing with "Permatex" (liquid seal). Clean off the mounting surfaces and apply fresh "Permatex" seal. Tighten each 1/2” bolt (holding cover) to 60 ft.-1b. torque. 12. Remount the oil pump drive and the main drive coupling. Align coupling within 0.008" and be sure to grease it if it is a steel flex type. 21-250 Pellet Mill Maintenance Page-F-21 April, 1984Install pelleting cartridge (be sure to tighten the holding bolts to 250 ft.-1b.). (See Rapid Cartridge Change, Page F-9.) Install shear pin hub assembly. (See Page F-13.) Fill the gear box with fresh oil. (See 041 Lubrication, Page F-4.) 21-250 Pellet Mill Maintenance Page F-22 April, 1984PARTS LIST ORDERING INSTRUCTIONS: When ordering spare or replacement parts be sure that you include all the necessary information needed to service your order properly. List: 1. Serial number of pellet mill (See Page A). 2. Quantity and description of each item desired. 3. Item number of each piece (a combination of the form number and the part number). RECOMMENDED SPARE PARTS: Always carry the following items in stock for routine maintenance: Qty. Description Item N 24 Shear Pins F-1936-16 1 O41 Filter Element F-2100-57 24 Bolts (Die Mounting) F-1917-33 24 Washers ~ Hardened (for 5/8 die bolts) F-1917-34 6 Washers - Hardened (for 3/4 bolts) F-1917-11 2 Wear Ring Inserts (Die Mount) F-1917-31 3 Scrapers (die housing) P-1917-15 3 Segments - Roll Adjusting F-1917-4 2 O-rings (for roller pin) F-1917-13 ei Cut-Off Knives (Ni-Hard) F-1937-8 1 Pump, O11 Supply F-2100-3 3 Roller Assembly (Complete) F-1919C or NOTE: Order individual items (shell, F-20238 bearing, seal, etc.) separately and identified with the proper part number. NOTE: For Standard Width Rolls ONLY (used with 6-1/4" width die) order F-1919C. For Wide Rolls ONLY (used with 8" wide die), order F-2023B. 21-250 Pellet Mill Parts List Page G-1 April, 1984ROLL ASSEMBLY - STANDARD WIDTH NOTE: Refer to this form for standard width rolls only. (Standard width roll is used with 6-1/4" width die.) (For wide rolls, refer to Form 2023B.) Part No. ary. Description 1 1 Shell - Roller 2 1 Pin - Roller, Eccentric 3 ny Ring - Retaining, External, Truarc #5100-334 4 2 Labyrinth Seal (Outer) 5 2 Ring - Retaining, Internal, Truare #5000-600 6 2 Labyrinth Seal (Inner) 7 2 Bearing, Timken Cone #749, Cup #742 8 1 Spacer Ring 9 at Lockwasher, SKF No. W17 10 1 Nut, Bearing Adjusting, No. B2769-500/1 M1 Zz O-ring, 1/8 dia. x 2-1/4 0.D, x 2 1.D. Form 1919 (Ref. €2698-502) 21-250 Pellet Mill Parts List Page G-2 April, 1984ROLL ASSEMBLY - WIDE ROLLS ONL’ NOTE: Refer to this form for wide rolls only. (Wide roll is used with 8" wide die.) (For standard width rolls, refer to Form 1919C.) Part No. ary. Description 1 1 shell - Roller 2 1 Pin - Roller, Eccentric 4 2 Labyrinth Seal (Outer) 5 2 Ring - Retaining, Internal, Truare #N5000-575 6 2 Labyrinth Seal (Inner) 7 2 Bearing, Timken Cone #8415647, Cup #JH415610 8 1 Spacer Ring 9 1 Lockwasher, SKF No. W15 10 1 Nut, Bearing Adjusting, No. B2769-900/1 u 2 O-ring, 1/8 dia. x 2-1/4 0.D. x 2 1.D. (Ref. €2698-901) 21-250 Pellet Mill Parts List Page C-3 April, 1984DO 9L6L WHuOd TIW 13113d OST-1Z ASSV ONISNOH GNV 3AIud Yv39GEAR DRIVE AND HOUST (See Form 1916¢) 1 1 6 1 1 8 0 HBP Kaen eee ASSEMBLY: Description Housing (Gear Box) Top Cover Bolt, Hex Hd. 5/8 x 1-1/2 Lg. Gear - Bull Hub - Bull Gear Bolt, Hex Head, SAE GR-8, 3/4"-10 x 3-1/2" Lg. Washer, compression spring (cone type) Bearing, Timken Cup #1M451310, Cone #1M451349 Bearing, Timken Cup #8520, Cone #FE8578 Ring-Wear, Hardened SST Flinger Ring O-ring, 3/16 dia. x 15-5/8 1.D. Cap, Front Main Brg. Bolt, Hex Hd. 5/8 x 1-1/2 Lg.» GR-5 Washer, Hardened 21/32 I.D. x 1-3/16 0.D. x 3/16 Thk. Cap, Rear Main Brg. Cover (Seal Retainer) Seal, Garlock #53X3691 (11" shaft) O-ring, 1/8 dia. x 12-1/2 1.D. Screw, Soc. Hd. Cap, 3/8 x 5/8 Lg., SST Pinion Gear Bearing, Tinken Cup #1715311, Cone #4715336 Cap, Brg., (Front End) O-ring, 1/8 dia. x 6-1/4 I.D. Screw, Soc. Hd. Cap, 3/8 x 3/4 Lg. SST Cap, Brg. (Drive End) with Labyrinth Seal Seal, Flinger Ring Tube (Pinion Brg. Lube) Fitting, Connector Parker #4-FBU-S Plate Inspection w/Oil Filler Gasket O41 Filler Breather Bolt, Hex Hd. 3/8 x 1 Le. Washer, Lock, 3/8 Gauge, O11 Level Screw, Rd, Hd. Mach., #10 x 3/8 Lg. Thermometer, 0-250° F., 3" dial Plate, (Gear Access Cover) Bolt, Hex Hd., 1/2 x 1 Lg. GR-5 Washer, Hardened 1/2 Latch Assembly 21-250 Pellet Mill Parts List Page G-4 April, 1984Part No. 43 4h 45 47 48 49 50 51 52 54 Description Bolt, Hex Hd. 3/8 x 1-1/4 Lg. Washer, Lock 3/8 Nut, Huglock 3/8 Shim, .003 Lam., (.093ThK.) x 19-5/8 0.D. x 16-9/16 I.D. Shim, .002 Lam., (.094ThK.) x 8-1/4 0.D. x 6-3/4 I.D. Bracket, Camfollower Camfollower, McGill #CF2S Screw, Soc. Hd. Cap 5/16 x 5/8 Lg. Stl. Bolt, Hex Hd. 1/2 x 1 Lg. w/Lock Washers Serew, Soc., Set, 1/4 x 1/2 Lg. Stl. (for Part~28) Seal - Labyrinth (Rear Main Brg.) Gasket, 1/16 x 13-1/2 0.D. x 11-3/4 I.D. Cork Impreg. Rubber 21-250 Pellet Mill Parts List Page G-5 April, 1984OL16L WuOd ‘T1W 1aT1ad OSZ~1z ONILATIAd - 3DGIULYVDCARTRIDGE PELLETING ASSEMBLY (See Form 1917¢) Part No. Qty. PROP BAA OWUU EEE ERE HUE peer e Renn enee Description Bolt, Hex Hd. 5/8 x 2-1/2" 1g., SAE GR-5 Washer, Lock 5/8, Stl. Center Dise Segment, Roll Adjusting Bolt, Hex Hd. 5/8 x 2-1/2 lg-, SAE GR-5 Washer, Lock 5/8 Feed Plow Plate, Roll Holding Screw, Set, Sq. Hd. 5/8 x 3-1/4 lg, Stl. Nut, Jan 5/8, Stl. Washer, Hardened 25/32 1.D. x 1/4 Thk. Bolt, Hex Hd. 3/4 x 3" 1g., SAE GR-5 O-ring, 1/8 dia. x 2-1/4 0.D. x 2" I.D. Roller Assembly (See Separate Parts List) Seraper for Die Housing Washer, Lock 3/8 SST Bolt, Hex Hd. 3/8 x 1 1g. SST Main Shaft Fitting, Straight Alemite, 1/8 NPT Fitting, Long Str. Alemite, 1/8 NPT Cover, Center Rearing (with labyrinth seal) Bearing Inner Race (See Part 25) Bearing, Cyl. Roller, Torrington (#S-4418-B inner, #139612040 outer) Seal, Garlock #53x3176 (5-1/2" shaft) Nut, Brg. Retaining (Special Sleeve Type) Screw, Set, Soc. 5/16 x 1/2 lg. Screw, Soc. Hd. cap, 3/8 x 1/2 lg, SST Die Housing Insert, Wear Ring (for die housing and stiffener) Die Bolt, Hex Hd. 5/8 x 2-1/2 1g., GR-5 Washer, Hardened 21/32 I.D. x 1-3/16 0.D. x 3/16 Screw, Set, Sq. Hd. 5/8 x 3” Ig. Die stiffener Ring Die Cover, Conical Bolt, Hex Hd. 5/8 x 1-1/4 1g., GR-5 Key, (Special Hardened) Screw, Soc. Hd. 5/16 x 3/4 1g. 21-250 Pellet Mill Parts List Page C-6 April, 1984SHEAR PIN HUB ASSEMBLY 21” PELLET MILLS ean sacSHEAR PIN HUB ASSEMBLY: (See Form 1936B) Part No. Qty. Description 1 4 Bolt, Special ~ Cartridge Holding 2 1 Ring - Back up a 8 Screw, Soc, Hd. Cap, 5/8 x 1 Lg., Stl 4 2 Bushing - Drill, straight (for shear pin) 5 1 Hub - Shear Pin (Rotating) 6 4 Key, Special (Hardened) 7 8 Bolt, Hex. Hd. 5/16 x 1 1g. w/Lock Washers 8 1 Actuator, Limit Switch 9 1 Screw, Soc. Hd. Cap, 3/8 x 1/2 1g. 10 1 Pin-Rol1, 1/8 dia. x 1/2 1g. u 1 Bearing (Bronze Bushing) 12 3 Screw, Set Soc. 1/4 x 3/8 Ig. 13 1 Casing - Stationary Shear Pin 6 6 Bolt, Hex Hd., 5/8 x 2-1/2 1g., SAE GR-5 15 2 Bushing - Drill, Flanged (for shear pin) 16 2. Shear Pin 7 2 Plate, Pin Retainer 18 2 Bolt, Hex Hd., 3/8 x 1 1g., w/washer 19 1 Shim Assembly 20 1 Collar - Thrust 2 4 Screw, Soc. Rd. Cap, 3/8 x 3/4 1g. 2 1 Nut-Thrust (Spinner) 23 2 Screw, Set, Sq. Hd., 5/8 x 2-1/2 24 1 Fitting, Alemite - Straight, 1/8-27 NPT 25, 6 Washer, Hardened 21/32 1.D. x 1-3/16 0.D. x 3/16 Thk. 26 1 Limit Switch, "Co-Proximity" Model No. 62-1008 27 2 Screw, Rd. Hd. #10-24 x 2 1g. w/washers 28 6 Segment, Wear 29 12 Bolt, Hex hd., 3/8 x 2-1/4 1g. steel with lock washer 21-250 Pellet Mill Parts List Page G-7 April, 1984HINGED DIE CASING WITH CUT-OFF KNIVES 21° PELLET MILLSHINGED DIE CASING WITH CU’ (See Form 1937B) Part N Description Casing ~ Hinged Die Base, Centrifeeder Mount Washer, Lock 1/2 Bolt, Hex Hd., 1/2 x 1-1/4 1g. Base, Knife Holding Screw, Soc. Hd. 1/2 x 2 1g. Knife Holder Bar Knife, Cut-Off Washer, Lock 3/8 SST Bolt, Hex Hd. 3/8 x 1 1g., SST Bracket, Knife (Pivoting) Bolt, Shoulder 5/8 x 1-1/4 lg. Screw, Hex Hd, 1/4 x 1-3/4 1g. Collar, Stop Screw, Set, Sq. Hd. 3/8 x 1 1g., SST Nut, Huglock 1/4 Rod, Threaded 5/8 x 11-7/8 1g. Handle Door, Inspection Screw, Rd. Hd. 1/4 x 3/4 SST Tag, Safety Plate Screw, Set, Hollow Soc., 1 x 3 1g. Washer, Plain 1" Nut, Hex 1" Cam Follower, McGill #CFH2S Screw, Set, Hollow Soc. 5/8 x 1-1/2 1g. SST Nut, Hex. 5/8, SST Fitting, Alemite 3/16 Drive Type Cover Plate (in place of knife assembly) Washer, Lock 1/2 Bolt, Hex Hd. 1/2 x 3/4 ssT Bolt, Hex Hd. 1/2 x 1-1/4 SST Plate, Support (Die Casing) Pin, Roll, 1/4 dia. x 1" 1g. 21-250 Pellet Mill Parts List Page 6-8 April, 1984Nos esas W3ISAS NOILW2I48N1 10 YY ~ Cyr | | 7 oul Od fay FOR 6 A A oe) pees 5 ee N a & } \ Ys IN Be ogo) 30s “ana a SS Wh § Ree Ky) a @| i ; WY) /; © >| aN A\ y + oY ce a) (Ge 92 ¥2) © C ‘ ee is I) me GS LAN 42/1 WILY ONMOOD.