JK Machineries Double Stage Double Head Multi Mill User manual

Original Instructions
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1.)Specification
Product Name: Double Stage Double Head Multi Mill
Product Code: DDS-40
Required Motor Capacity: 10 to 15 HP
Required Motor RPM: 1440
Purpose: Size reduction of the cereals, grains, spices, etc.
2.)Typical application of double stage pulveriser
JK Machineries double stage Double head multi mill pulveriser can be
used for a wide range of application e.g. Grinding spices, food stuffs,
chemicals, pigments, pharmaceuticals, herbals, coffee seeds, tea leaves, fillers,
sugar, etc.,

Original Instructions
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3.)Operating principle of multi mill pulveriser
JK Machineries Double stage double head multi mills (Multi Chamber)
are the latest version of the JK Machineries Pulveriser. It provided with a Pre -
crushing chamber where the material undergoes a coarse grinding and passes
on to the fine powdering chamber. Therefore, we can feed the hard materials
like turmeric directly for fine grinding in single feeding. This also gives more
evenness for the spices powder. The feeding of this machine is through the
canter of the back end. The crushing chamber and bearing blocks are made of
high quality cast iron Bearings lubricated in oil.
Double stage double head multi mill, has two stages of pulverising. In
this Pulveriser, the raw material enters the first chamber and gets crushed to
75% of its fineness, later it enters the second chamber where the material is
crushed more to obtain fine powder. The arrangement of the machine is in
such a way that both machines can be operated independently or at a time by
using a single electric motor. Eccentric cam system helps to minimise the
human effort
The flow of material from feeding hopper is regulated means of a
vertical adjustable. The T beater and back beater are mounted on shaft,
running in ball bearing housing at a speed of 4500-5000 RPM first chamber
having beater with four legs functions in anti-clockwise or clockwise direction.
The beater pass just beneath the "V" shaped teeth liner fitted inside the
crushing chamber, leaving approximately a gap of 3 mm between the liner
teeth and the tips of the rotating beater. This cuts the material caught
between the liner teeth like a sword with a scissors action at a high speed.
After getting recoverable mesh crushed material is enter in to final stage of
crushing chamber, is inlaid with a delivery trough attached at the bottom, with
a delivery trough attached at the discharged end.

Original Instructions
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4.) Servicing guidelines
4. a) General safety
All mechanical equipment can be hazardous if operated without due
care or correct maintenance. Most accidents involving machine operation and
maintenance are caused by failure to observe basic safety rules or precautions.
An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs.
Because it is impossible to anticipate every possible circumstance that
might involve a potential hazard, the warnings in this guide and on the
machine are not all inclusive. If a procedure, tool, working method or
operating technique not specifically recommended by manufacturer is used,
you must satisfy yourself that it is safe for you and others. You should also
ensure that the product will not be damaged or made unsafe by the method of
operation or maintenance procedures you choose.
Safety is not just a matter of responding to the warnings. All the time
you are working with your attachment you must pay attention to what
hazards there might be and how to avoid them. Do not work with the product
until you are sure that you control it. Do not start any job until you are sure
that you and those around you will be safe.
Warning! Read the following warning messages carefully. They tell you of
different hazards and how to avoid them. If proper precautions are not taken
you or others could be seriously injured.
4.a.i) Manual
Study this manual before installing, operating or maintaining the product.
If there is anything you don't understand, ask your employer or your local
dealer to explain it. Keep this manual clean and in good condition.

Original Instructions
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4.a.ii) Care and Alertness
All the time you are working with the product, take care and stay alert.
Always be alert for hazards. The possibility of a serious or even fatal accident
is increased when you are intoxicated.
4.a.iii) Clothing
You can be injured if you do not wear proper clothing. Loose clothing
can get caught in the machinery. Wear protective clothing to suit the job.
Examples are: a safety helmet, safety shoes, safety glasses, well-fitting
overalls, ear-protectors and industrial gloves. Keep cuffs fastened. Do not
wear a necktie or scarf. Keep long hair restrained.
4.a.iv)Practice
You and others can be killed or injured if you do unfamiliar operations
without practicing them first. Practice away from the job site, in a clear area
Keep other people away. Do not perform new operations until you are sure
you can do them safely.
IGNORING
INSTRUCTIONS
HAZARD
Faulty handling practice could
cause death or severe injury.
Read and follow the instructions
in the operator’s manual.
WARNING

Original Instructions
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4.a.v) Spare parts
Use only genuine spare parts. Use only genuine cutting blades with
crushers. The use of other spare part or cutting blade brands may damage the
product.
4.a.vi)Equipment condition
Defective equipment can injure you or others. Do not operate equipment
which is defective or has missing parts.
Make sure the maintenance procedures in this manual are completed
before using the product.
4.a.vii) Repair and maintenance
Do not try to do repairs or any other maintenance work you do not
understand.
4.a.viii) Modification and welding
Non-approved modifications can cause injury and damage. Contact your local
dealer for advice before modifying the product. Before welding on the product
while it is installed on the carrier, consult your carrier dealer for precautions in
welding.
DUST HAZARD
Breathing dust will cause death
or severe injury.
Always wear approved
respirator.
DANGER

Original Instructions
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4.a.ix)Foundation requirements:
The floor or foundations where the Pulveriser is to be located must be
level. The floor must be at least 6" reinforced concrete on firm soil base. If
concrete piers are used, they must be at least one foot square and not more
than 6" high.
4.a.x)Clearance requirement:
There should be a minimum of 2 feet of clearance on all four sides of the
mill once it is installed. Consideration must be given to the placement of the
mill so that the receiving containers can be changed without difficulty. There
must be enough headroom to properly support the filter bag and to permit
installation of appropriate rigging to assist in routine maintenance.
5.) Unloading equipment’s:
5. a) Crates and equipment inspection:
Inspect all the crates visually before opening them to identify any
damage during transportation.
Inspect the appearance of all painted items.
Check for hardware that may have loosened during transport. Tighten any
loose hardware.
5. b) Unloading:
Use a 0.5 Ton (1,000 lb.) capacity hoist for unloading and assembling the
Pulveriser.
When handling the Pulveriser Assembly, use nylon straps around the end of
housing arms.
NOTES: DO NOT PUT SLINGS OR STRAPS AROUNDTHE ROTOR OR SCREEN
AREA, SINCE THIS COULD RESULT IN DAMAGE TO THE SCREEN.DO NOT USE
THE SWING BOLTS TO LIFT THE PULVERIZER.DO NOT REST ROTOR ASSEMBLY
ON FLOOR. ASSEMBLY MUST BESUPPORTED BY THE HOUSING.DO NOT
BOUNCE OR HIT ASSEMBLY DURING LIFTING.

Original Instructions
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6.) Operations
6. a) Assembly instruction:
The Pulveriser has been assembled at our factory and only the TRAY
must be put together.
•Check Foundation level.
•Bolt four legs to Structural Mill Base Frame, Snug nuts.
•Lift Frame with legs and locate over Foundation, using nylon straps
around Frame. Make sure load is well balanced.
•Secure Legs to Floor or Foundation using 1/2" lag bolts.
•Level and square Pulveriser Frame.
•Tighten bolts of Legs to Frame.
•Rotate beater by hand to make sure it rotates freely. If Rotor is not free
to rotate, refer to Section VI "Maintenance
Use required filter size for your purpose Etc. (For chilly filter No:2
•Adjust V-Belt tension by moving Motor on Slide Rails. Proper V-Belt
tension is a belt deflection of 3/16" when subjected to a 5 lb. load at the
centre between the sheaves.
•Tighten Motor bolts.
•Install V-Belt Safety Guard.
•Install Hopper over the machine Make sure both contacting surfaces
are clean. Use M-seal if necessary to get a good seal.
•Check all lubrication points for proper lubrication.
•Make sure that the machine is clear of all foreign objects and that all the
bolts are properly tightened.
•Jog Pulveriser to check direction of Change Rotation if it is not correct.
•Install Air Relief Bag.

Original Instructions
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•Install Receiving Container.
•Connect power to Control Box.(
•Run pulveriser empty for 1/2 hour to check bearing temperature and
listen for any unusual noise or vibration.
•After the run-in period, re-check all bolts and fasteners for tightness.
6. b) Initial lubrication:
The equipment is fully lubricated prior to testing at the factory, however, after
installation; all the lubrication points should be checked
6. c) Precautions before start-up:
Before starting up after the Run-In period, make sure that:
•All bolts are properly tightened
•The Screen is properly installed in the mill.
•Lubrication levels have been checked.
•No tools have been left around the machine and drives.
•The Safety Guards are in place.
•Vent port is connected to Air Relief Bag.
• Operators are using all the safety equipment required and are following
all plant safety rules and regulations.
•Operators have been properly trained in the operation of the Mill.
6. d) START-UP:
The actual Start-up (and Operation) of the pulveriser is very simple and
requires normal attention by the operator.
To start a grinding cycle:
•Start the pulveriser Motor by pushing START Push-button for Main
Motor. (For oil starter please refer its manual)

Original Instructions
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•Feed raw material into the Hopper.
•Stop system as required to change Receiving Container and/or Air Relief
Bag. Follow Shut-Down Procedure.
•NOTE: Once the rotor has stopped, any material that remains in the
grinding chamber must be removed before the mill is restarted. Since
the fan action of the rotor may also pull certain types of material past
the feed screw, the hopper and feed trough should also be free of
material before starting a grinding cycle.
6. e) SHUT-DOWN:
At the end of the grinding cycle or at any time during the operation, the
pulveriser can be stopped using the following procedure:
•Stop feeding the pulveriser by pushing the STOP push-button of the Feed
Screw Motor.
•Continue to run the pulveriser until it is empty.
•When Main Motor Ammeter reads "idle load", stop pulveriser by
pushing the STOP push-button of the Main Motor.
•Make sure that the pulveriser comes to a complete stop before
attempting to do anything.
•After changing Container or Air Relief Bag, the pulveriser can be started
again, by following the above start-up procedure (Par. 5-2).
7.) Emergency shutdown:
In case of emergency push the STOP push-button at the Control Panel.
Caution:
Before opening the Mill, make sure that the Main Power Switch is
disconnected, properly tagged out and locked out.When the emergency
condition is over, open the Mill and clean the material in the Rotor area, to
make sure the Rotor is free to rotate.
7. a) Power failure:
If there is a power failure while the pulveriser is operating, the Main Motor will
stop, and they will not re-start by themselves when the power is restored.

Original Instructions
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Before attempting to re-start the Main Motor, the grinding chamber must be
emptied.
Caution:
Before opening the Mill, make sure that the Main Power Switch is
disconnected, properly tagged out and locked out.
When the grinding chamber is empty, re-start the pulveriser by following
the Start-up procedure (Par. 5-2).
8.) Maintenance
8. a) Preventive maintenance:
Maintenance of the pulveriser is very simple and only requires a small amount
of planned maintenance time.
8.a.i) Lubrication:
Every week refill the housing chamber with grease or oil
•Pulveriser Drive Motor:
Follow recommendations of Motor Manufacturer.
8.a.ii) Pulveriser housing:
The housing is supplied with Oil /Grease CUPS that have spring hinged covers.
The oil/grease level in the oil/grease cup should be 1/8" from the top, when
the machine is not running. When the pulveriser is running, the oil/grease level
in the cup will lower as some of the oil/grease is drawn into the bearing.
Oil/Grease should never be added while the unit is running the proper oil level
in the cup can only be determined when the machine is stopped. The oil in the
pillow blocks should be changed once a month. Drain the oil through the drain
plug located at the base of the pillow block and refill through the fill plug
located at the top.
Note that the oil level in the cup is the same as the oil level in the pillow block.
Do not replace the oil cups with any type other than the type that is supplied
with the mill The reference for proper oil level will be lost if different oil cups
are used. Also, note the location of the oil cups in relation to mill rotation.
Recommended oil: SAE-20 grade, non-foaming, non-detergent oil (See chart
for industrial grade oils of equivalent viscosity).

Original Instructions
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8. b) Daily preventive maintenance:
Check Rotor housing for any unusual temperature change. After the mill has
run for one hour under load, carefully touch the housing. If you cannot hold
your hand to the pillow block, the bearing is too hot (over 140°F) and requires
attention.
While the unit is running under load, listen for any unusual noise. (DO NOT
remove your ear plugs). If you hear any unusual noise or vibration, notify your
supervisor immediately.
9.) Changing machine parts
9. a) Changing screens:
Stop feeding the pulveriser but keep the Mill running until the grinding
chamber is empty.
Stop main motor.
Disconnect main power switch, lock it out, and tag it out. Remove housing
cover by loosening the cover clamp assembly.
Remove hold down plate and end dust seal nearest feed screw. Remove end
dust seal opposite to feed screw. Pull up on the screen at the end opposite the
Feed Screw while pushing down on the Screen at the Feed Screw end to slide
the Screen out of its retaining groove.
Before installing a new Screen, clean the guide groove.
- Slide new Screen in the retaining grooves. If the grooves are
Clean, the screen will slide very easily, with no effort.
•Rotate Rotor by hand to make sure it rotates freely.
•Connect Power and start the unit.
9. b) Changing beater and hammers:
NOTE: Worn beater can significantly reduce output capacity. A spare set of
beater should be kept on hand in the event an unscheduled replacement is
required

Original Instructions
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• Stop feeding the pulveriser but keep the Mill running until the grinding
chamber is empty.
•Stop Main Motor.
•Disconnect Main Power Switch, lock it out, and tag it out.
•Remove belt guard.
•Loosen motor mounting bolts and move motor to loosen and remove
drive belts.
•Remove Rotor assembly using nylon slings at both ends of the shaft. DO
NOT sling through hammer stirrups. Rest the Rotor Assembly on Pillow
Blocks.
•If beater are to be replaced, make sure that balanced hammers are
installed in the proper position.
• To remove and beater, first remove the bolt and washer at the side After
the bolt is removed, the beater can be taken off the shaft by using a
puller.
• Once all the hammers have been replaced, reinstall bolt the locking bolt
and washer.
NOTE: Always use complete beater that are properly balanced.
Before reinstalling the Rotor in the mill, check that all components in the
grinding chamber are serviceable (Screen, End Dust Seals, etc.).
Check for free rotation of the beater by hand ensuring that there is no
interference with the beater.
• Check the oil /grease level in the housing. Fill if necessary.
- Install belts and belt guard.
Jog the main motor to check again for interference of the Rotor Assembly.
9. c)
Changing bearing:
• Stop feeding the Pulveriser but keep the Mill running until \ the
grinding chamber is empty.
• Stop Main Motor.
•Disconnect Main Power Switch, lock it out, and tag it out..

Original Instructions
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•Loosen motor mounting bolts and move motor to loosen and
remove drive belts. Remove hosing bolts.
•Remove Rotor assembly (T-beater, Back Beater)
•Remove All the bolts which is attached to the housing.
•Remove the machine pulley using a puller
•loosen the Allen key on collar and remove it Properly supporting
the front face of housing, press the Shaft out of the Bearing.
Contact the Service Department for assistance.
NOTE: Prior to installing new bearings, inspect the
shaft journals and bearing bores.
• Once the shaft journal has been determined to provide a
proper fit, the new bearing may be installed using a press and
sleeve or a sleeve and a hammer. In either case, the sleeve
must fit against the outside wall of the inner race. A film of light
oil will aid in the installation. This applies only to bearings with
an O.D. of four inches or less. The shoulder on the shaft
should make contact with the inner race of the bearing. Install
collar.
• Repeat above steps for opposite side. It is recommended that
both bearings be changed during the same disassembly operation.
- Before installing the Rotor Assembly, clean all machined
surfaces. These surfaces should also be free of nicks orpeens.
9. d)
Changing V-belt:
• Stop feeding the pulveriser but keep the Mill running until the
grinding chamber is empty.
•Stop Main Motor.
•Disconnect Main Power Switch, lock it out, and tag it out.
•Remove V-Belt Guard.
•Loosen Belts by sliding Main Motor on rails.
•Remove Belts and install a new matched set.
•Adjust Belt tension
•Install Guard.

Original Instructions
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TROUBLESHOOTING CHART
Equipment Symptoms Possible Cause
Section
MILL Mill stops - Starter heaters a.- Feeding too fast Slow Feeder
Overload b.-Rotating backwards
c.-Foreign object jamming
rotor
d.- Screen is blinding
Material stays on screen
Screen is blinding a.- Material is too sticky
b.- Material is melting
Material is blowing out of the a.- Air inlet and/or exhaust
Mill are closed
b.- Cover not tight
c.-Incorrect rotation
d.-Screen has blinded
Condition
e.- Discharge bag or chute is
full or plugged
Remedy
Reverse rotation
Remove object
See following symptom
Reduce stickiness of feed
material
Cool material and/or air
Open intake and/or exhaust
Clear obstruction and secure
cover
Reverse rotation
See above symptom
Turn off machine and empty
bag or unplug chute/hopper

Original Instructions
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TROUBLESHOOTING CHART
Equipment Symptoms Possible Cause
Section
MILL Premature bearing failure a- Improper lubrication
b- Insufficient lubrication
c- Wrong bearing
d- Rotor imbalance
e- Improper hammer
Installation
f.- Head and/or inconsistent
feeding material
_9-Excessive V-Belt tension
Change in product particle size.- Feed material has changed
(in composition or size)
b.- Worn or damaged screen
Variation in Mill Motor load a.- V-belts slipping
b.- Feed rate varying
c.- Inconsistent feed material
Remedy
Provide specified oil
Keep oil to specified level
Procure correct bearing
Balance rotor
Install hammers per
instructions
Adjust feed mechanism to
deliver material at a slower
rate
Adjust to proper tension
Adjust feeder
Replace screen
Adjust belt tension
1. Check feed supply
2. Check feeder operation
Adjust preparation of feed
material

Original Instructions
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TROUBLESHOOTING CHART
Equipment Symptoms Possible Cause
Section
MILL Reduced capacity a.- Worn hammers
b.- Worn liner
c.- Reduced rotor speed
_
d.- Feeding rate too slow
NOTE: FOR ANY PROBLEMS NOT IDENTIFIED HERE, PLEASE CONTACT JK
SERVICE DEPARTMENT
Remedy
Replace with new set
Replace with new liner
Check drive for worn or loose
V-belts. Replace belts with
matched set.
For direct drive, check
coupling installation
Increase Feed Screw speed to
max. 95% of motor full load

Original Instructions
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