Pepper Maintenance Canada
Maintenance Guidelines
The following suggestions are intended to raise the standard of installation and operation of your operation with the knowledge that there are, at times, exceptions that are acceptable.
Bearings
If kept clean, most bearings need lubrication twice a year. Most bearings fail from too much lubrication rather than not enough.
Cleaning
1. Wipe clean monthly
2. Keep trash and dirt from backside
3. When cleaning, use a rag, towel, or flat piece of wood....never use a screwdriver as it can damage the seal
Run equipment after cleaning; if grease appears moist on the seal, no additional grease should be needed
Lubricating
1. Carry a grease gun only two times a year - most bearings are over-lubricated
2. Grease when equipment is off to prevent over-greasing
3. Never drive a bearing onto the shaft; use a warming plate if necessary
4. Shrink shaft with cold (upside down canned air works)
Aligning
1. Check bearing alignment
2. 2% misalignment is the maximum for bearings, and even that is too much
3. Seals take less than 1/2% misalignment.
Motors
Motors are the power source for everything our equipment will do. Their care and lubrication is of the utmost importance.
Lubricating
1. Ensure that new grease will exit overflow by using a wire to push through to race; be aware this procedure is not 100% effective; if grease does not begin to purge from the passageway, see the rule of thumb below and proceed carefully.
2. Remove grease plug and inject grease slowly. Rule of thumb: 1 pump to 10 hp and quit if necessary; Pepper Maintenance prefers 1 pump to 20 hp
3. With or without plug removed, the motor should not be too full of grease when done once a year
Grease does evaporate
Alignment
1. Alignment is critical for both couplings and sheaves
2. Set tensions with a gauge
3. Understand soft-foot and tightening pattern---by reading the installation guidelines and consulting with the manufacturer; motors are like tires on rims - follow recommended installation.
4. Read the manual provided - go online if necessary.
Reducers - Shaft Mount, Helical, In-Line
Reducers are the harnessers of the energy provided by the motors in our machinery. Precision installation with laser alignment tools is essential. Belt tensions that are too tight ruin bearings and seals.
1. Follow company policy for the type of fluid
2. Do not overfill
3. Use a tension gauge to set belt tensions; gauges run $20 from your belt supplier (or ask for a free one from your belt supplier)
4. Always use alignment tools--dials or lasers are cheaper in the long run; insist on a laser alignment and precision installation from the millwrights
5. Read the Instruction book
Electrical Comtrols
Electrical energy supplies the life-blood power that drives the motor that drives the reducer that drives our facilities. Maintenance and proper care are essential here, too.
Cleaning
1. Cycle disconnects and breakers six times twice a year when de-energized, which cleans internal contacts
2. Keep power rooms clean and as dust-free as possible
3. Never slam a panel door or bucket door
4. Air-conditioned electrical rooms pay big bucks in the long run - by lowering the ambient air temperature and increasing efficiency of electrical flow; temperature changes are controlled and connections are given much longer life; if not air conditioned, pressurize for dust control
5. Filter the air coming into the electrical room
6. Always clean terminals and conductors - tightening fixes less than 30% and over-torque actually makes things worse because it distorts flat surfaces
Moisture
1. Use heaters in panels to remove moisture - PLC (Programmable Logic Controller's) included.
2. Conduits are not usually watertight
3. Notch elbow cover gaskets to allow moisture to escape
4. Install drip caps over doors
5. Put small weep holes in panels that hold moisture in bottom
6. Seal moisture sources where possible
7. Do not use renewable link fuses; they are often the source of high levels of resistance-increasing energy consumption and shortening equipment life
8. Use the same fuse sizes for all three phases - same thermal size is best
General Guidelines
1. Follow all safety rules
2. Insist the utility company respond to what is needed
3. Read the manual
4. Send the crew around every month or so, but keep the grease gun at home
5. Have them clean and inspect, take notes etc.
6. Follow the manufacturer’s specifications and engineering data.
If equipment is supposed to have a 25-year life expectancy, it should give you 25 years, or you should ask why not. If you have questions, give us a call and we will figure out together the best possible plan and implementation of predictive maintenance practices and technologies for your business.
Source: https://www.peppermaintenance.com/resources/maintenance-guidelines