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1. X JCITOSCIT O4 12 CLC 8 Spillover valve 7 56 03 2 1 X 7Ocen 9 Sequencevalve 03 1 7Ocemn 14 Pressure relay PS02240 1 __ Scavengeoilfiller 7 7014 40 55 71 Solenoid valve DSD G02 2C DC24 Throttle check valve PT 03 GRN4 605 OAppendix 90 of 93 WHITAKER 800 243 9226 Model 1200 2000 Hydraulic Unit Spare Parts Pos Description Standard Supplier 6 Checkvave CITOSCITO4 2 CC gt 8 __ Spillover valve 6 03 3 10 11 9 __ Sequence valve HG 03 1 10 70kgf 1 ____ LA 250kgf including connector 17 Scavengeoilfiler 12AT I CR 111 Model 1200 2000 Hydraulic Screen Spare Parts Pos Description 1 Standad __ Supplier 4 Wheelpump HGP2AF9R 1 X Xinhong Vane pump 57 6 1 Kaja 2 Check vale 04 2 14 7 10 11 11 1 DSD G02 6C 31 1 7Ocen 12 Pilot operated check MPD 03 W 110 1 ___ 12 1 Pilot operated check valve MPD 02 W 1 10 1 7Ocen 13 Throttle check valve PT 04 _ 2 7Ocean 15 185 1 16 __ Oillubricator AB 112 1 Haa ___ 417 Scavenge oil filter 70134 10 1 X 7Ocean 18 Ocean N GRN4 605 OAppendix 91 of 93 WHITAKER 800 243 9226 A 4 Techn
2. 33 459 ico E 36 CHAPTER 5 MAINTENANGCE 37 5 1 Preventative Maintenance Schedule 37 5 2 Preventative and Corrective Maintenance 38 CHAPTER 6 TROUBLESHOOTING 59 eM lt ol uu m 59 APPEND 63 AST TENNENE 63 A 2 Drawings and 64 Ram 68 Model 850 Hydraulic 70 M d l g0 Aydradlie m 11 Models 1200 2000 Hydraulic nennen nnn nnn 75 Models 1200 2000 Hydraulic 9 77 Pes 78 4 Technical Assistance 92 Parts and Service 92 Sales and Contracting Department 92 BJ5 615 vi WWHEASER 800 243 9226 Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your equipment The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service eng
3. W AWARNING Use caution when operating specific equipment to prevent electrical shock Installation service alterations and or modifications must only be done by qualified personnel and with high regard for safety Not conforming to the requirements could result in bodily harm death or costly damage NOTE Alterations to the wiring diagrams require approval Failure to do this will exclude all guarantee claims The wiring schematics are located in the control panel Connection of Emergency Stop Button The machine may only be operated with installed Emergency Stop buttons An Emergency Stop button must be installed at the control cabinet and at the grinding material in feed if no Emergency Stop buttons have been installed at the factory NOTE The control panel with the switches and Emergency Stop button must be installed near the machine The distance should not exceed 5 m The distance between the floor and the lower edge of the control panel should be at least 1 m 1m The connecting cables between the control panel and the machine must be protected against damage cable tray protective sleeve An additional Emergency Stop button has to be installed on the machine if the control box cannot be installed according to these rules GRN4 605 Chapter 3 Installation 30 of 93 W 3 3 GRN4 605 BROTHERS SINCE 1945 WHITAKER 900 243 9226 Checking the Rotational Direction Rotational direction of the motors m
4. and the gear V belt pulleys are attached to the shaft using a TAPER LOCK tensioning element The disks must be dismounted for certain maintenance processes 1008 to 3030 3535 to 6050 To Install 1 Clean shaft bore and outside of bushing and bore of hub taking bushing from hub if already assembled Remove any oil lacquer or dirt Place bushing in hub and match half holes to make complete holes each complete hole will be threaded on one side only 2 Oil thread and point of set screws or thread and under head of cap screws Place screws loosely in holes that are threaded on hub side shown thus in diagram 3 Make sure bushing is free in hub Slip assembly onto shaft and locate in position desired 4 Tighten screws see note alternately and evenly until are pulled up very tightly Use a piece of pipe on wrench to increase leverage See table for wrench torque on reverse side 5 Hammer against large end of bushing using hammer and block or sleeve to avoid damage Screws can now be turned a little more using the specified wrench torque Repeat this alternate hammering and screw re tightening until the specified wrench torque no longer turns the screws after hammering 6 After drive has ben running under load for a short time stop and check tightness of screws Fill other holes with grease to exclude dirt GRN4 605 Chapter 5 Maintenance 120100 FOR REMOVAL ONLY To Remove 1 Remove all screw
5. bed knife to 0 8 1 0 mm Tighten the cutter mounting screws using a torque wrench NOTE The required torque for all cutter mounting screws is 120 Nm also see the 10 11 12 table under Working on Cutting Cutters Turn the rotor by hand Check whether the cutting gap is correct and make sure the cutting cutters do not collide as the rotor turns Put back the cover plates and mount them with the screws Remove tools and other objects from the cutting chamber Put screen back and mount it Switch ON the shredder for a short time without grinding material and listen for noises If there are unusual noises determine the cause and eliminate it NOTE Cutters are reversible and have four symmetrical cutting edges This makes 1 2 it possible to turn the cutters and only to sharpen after every fourth cutter change Danger of cutting caused by sharp cutters at all times even when rotor is at standstill Serious Injury especially to the hands and fingers can occur Wear protective gloves Sharpening Cutters and Bed Knives Shredder cutters have 4 cutting edges This means they can be turned 3 times The cutters should be replaced after the third use Bed knives can be turned 2 times and can be re sharpened as long as you can mount them with the long hole Dismount the cutting cutters see dismounting the rotor cutters Sharpen the cutters and bed knives NOTE A specialist in accordance with the sharpening plan
6. chamber tt ts recommended to access the cutters through the machine door located at the front of the machine The shaft can be rotated manually by turning the motor v belt pulley Clean the hexagon head socket of the cutter mounting screw 2 Loosen the screw using a high quality Allen key 10 mm Knock the Allen key lightly with a hammer to loosen it if necessary Take out the cutter mounting screw the washer and the cutter Dismounting the Cutter Holders B s 20 qe GRN4 605 Switch OFF the shredder at the main switch Safeguard main switch using a padlock Open the lower machine door Safeguard the machine door Remove screen NOTE Although it is possible to reach the cutting shaft by climbing into the feeding chamber it is recommended to access the cutters through the machine door located at the front of the machine The shaft can be rotated manually by turning the motor v belt pulley Clean the hexagon head socket of the cutter mounting screw 2 Chapter 5 Maintenance 49 of 93 WHITAKER 800 243 9226 7 Loose the screw using a high quality Allen key 10 mm If necessary knock the Allen key lightly with a hammer to loose it 8 Take out the cutter mounting screw the washer and the cutter 9 Clean the hexagon head socket of the cutter holder mounting screws 4 10 Loose the screw using a high quality Allen key 6 mm Knock the Allen key lightly with a hammer to loose it if necessary 11 Take
7. of the machine The same type of oil must be used when adding hydraulic oil If the same type of oil 1s unavailable or if it is unknown then the oil in the tank and the entire hydraulic system has to be removed and carefully and completely flushed The system may only be filled with new oil after this procedure has been done because it 1s necessary in preventing the valves from gumming Checking and Adjusting of the Hydraulic System see figure below 1 Start the machine in automatic running mode and wait for approximately 20 minutes 2 When the ram moves forward the pressure gauge 1 should indicate 0 30 bars depends on the adjustment of the throttle check valves 2 Also adjust the speed of the ram with this valve 3 When the ram moves backwards the pressure gauge 1 should indicate 0 30 bars depends on the adjustment of the throttle check valves 2 4 The pressure gauge 1 should indicate 50 70 bar at the change over point of the hydraulic cylinders other wise the spill over hand wheel 3 should be adjusted 5 The pressure gauge 4 should indicate a maximum of 2 5 MPa other wise the screw of the sequence valve 5 has to be adjusted 6 The ram should run upwards in less than 10 seconds otherwise the throttle check valve 2 has to be adjusted 7 When pressure gauge at the oil filter 6 indicates gt 5 bar the filter should be replaced GRN4 605 Chapter 5 Maintenance 56 of 93 WHITAKER 800 243 922
8. safely Structurally non avoidable dangers are prevented as well as possible by the protective devices Certain risks still remain It is imperative to be aware of these risks in order to avoid accidents To avoid danger please observe all safety advice provided Type of Danger Activity Possible Preventative Measures Consequences Danger of crushing by Unloading and Serious injury Wear personal protective gear heavy parts falling transporting the down over machine and or components Follow safety instructions in manual Cutting caused by Cutter replacement Serious injury Wear personal protective gear sharp cutters even cutter setting cutter particularly to hands when rotor is sharpening and other and fingers Follow safety instructions in stationary maintenance work manual Crushing when Maintenance work Serious injury Make sure no persons are in the opening closing danger area while closing the door maintenance doors on front side of machine Tripping over cables All activities Serious injury Lay cables in accordance with and other objects regulations Keep work station clean and tidy Crushing cutting Maintenance work Serious injury or death Maintenance doors must always amputation caused by be tightly locked during operation run down of the rotor DO NOT make the run down safety devices ineffective by using technical aids or other manipulations NEVER use hands to check if the rotor has stopped GRN4
9. speed only Rotor speed after consulting the service department Check and sharpen if needed following the instructions provided in this manual Protruding bed cutter Consult the service department Fit underlay plates below cutter holders Cutter condition Rotor does not grip bulky material Cutters not aggressive enough Possible Cause Possible Remedy GRN4 605 Chapter 6 Troubleshooting 60 of 93 WHITAKER 800 243 9226 View first 5 possible causes for Machine blocks or View first 5 possible remedies of Machine blocks switches itself off or switches itself off Insert a screen with larger Screen perforation too small perforation Modify cutter finish only Cutters wrongly sharpened after consulting the Overheating of the shredded material service department Material rubs against the Fit anti winding device housing wall Insufficient cooling Fit rotor cooling Rotor out of balance Weight cutters balance rotor Unusual vibrations Bearing damage Check bearings and replace if necessary Anti vibration pads defective Check mounting pads and replace if necessary Bearing damage Check bearings and replace if necessary Cutter finish Check cutter and sharpen or replace if necessary Wrong cutting gap Extreme cutter wear Check cutting gap and set following the instructions in this manual Fit feed device with metal detector Too much gr
10. to be clearly visible to others thereby reducing the potential safety hazards SAFE HOUSEKEEPING The work area must be kept clean and uncluttered during periods of operation or maintenance No hand tools or other metal objects should be left on or around the machine Any tools or other metal objects that mistakenly fall into the hopper feed opening can cause severe damage to internal cutting chamber rotor and screen components SAFETY GLASSES OR A FACE SHIELD MUST ALWAYS BE WORN when servicing or operating the machine Although our machines are designed for the maximum in flyback control caution must be used when operating near the hopper feed opening in order to guard against unexpected material flyback EAR PROTECTION may be required when operating the machine during granulation of very hard or noisy materials The Occupational Safety and Health Act of 1970 has established guidelines for Permissible Noise Exposures OSHA 1910 95 that should be followed NEVER attempt to operate the machine unless it is fully assembled with all guards and interlocks in place and functional OBSERVE all danger warning caution and safety labels on the equipment Upon completion of any machine maintenance be certain ALL SAFETY GUARDS AND COVERS are securely and properly fastened prior to resuming machine operation fasteners must be in place and properly tightened ANY SHORTCUTS MAY RESULT IN INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT NEVER we
11. using particular care should uniformly sharpen the cutting cutters mechanically It is important to make sure that sharpening takes place with small grinding allowance and sufficient coolant supply The sharpening process is finished when the cutting edge is sharply cut Not all indentations must be ground out otherwise the Chapter 5 Maintenance 53 of 93 WHITAKER 800 243 9226 number of possibilities for sharpening is unnecessarily reduced For the sharpening process use soft grinding wheels Quality 40 H or 46 K Cutters which have grinding cracks are not to be reused due to danger of breakage during operation 3 Whetthe cutting edges of the cutting cutters using a whetstone NOTE the service life of the cutting cutters can be increased by taking these measures 4 Set the cutters and bed knives refer to Setting the cutters 5 Mount the cutters and bed knives see Mounting the cutters and bed knives NOTE The cutting cutters in particular the cutters should only be sharpened or replaced in sets There is a danger of balance error if a combination of cutters from different cutter sets is used Danger of cutting caused by sharp cutters at all times even when rotor is at standstill Serious Injury especially to the hands and fingers can occur Wear protective gloves Setting the Cutting Knives Cutters for the CMS series shredder do not have to be adjusted adjustments have to be done with the bed cutte
12. 0 243 9226 Ram scraper GRN4 605 OAppendix 69 of 93 WHITAKER 800 243 9226 Model 850 Hydraulic Diagram SFT m og OO AN GRN4 605 0 Appendix 70 of 93 WHITAKER 800 243 9226 Model 850 Hydraulic Unit E9 51 aller eae mil WII d r ZT 7 of 93 OAppendix GRN4 605 WHITAKER 800 243 9226 Model 850 Hydraulic Screen Diagram B a Sk 09 v d ap i 205 wn q5 SPI GRN4 605 O Appendix 72 of 93 WHITAKER 800 243 9226 Model 850 Hydraulic Unit Screen ve re INA Nx GRN4 605 OAppendix 73 of 93 WHITAKER 800 243 9226 Models 1200 2000 Standard Hydraulic Diagram 502 1 G 5 5 1 CH DY DY 7 lt gt e 18 OF NW GRN4 605 OAppendix 74 of 93 WHITAKER 800 243 9226 Models 1200 2000 Hydraulic Unit GRN4 605 0 Appendix 75 of 93 WHITAKER 800 243 9226 Models 1200 2000 Hydraulic Screen Diagram 11 1 x e 3 YA1 V 20 LOS GRN4 605 0 Appendix 76 of 93 WHITAKER 800 243 9226 Models 1200 2000 Hydraulic Unit i J EN GRN4 6U5 UAppendix 11 ot WAKER 800 243 9226 A 3 Spare Parts List Model 850
13. 26 Bearing with water plug for rotor cooling Screen and screen support The screen and the screen support are welded together and fixed to the housing by screws in the standard execution The screen is slightly larger in radius than the cutting circle of the rotor cutters The screen perforation is selected according to the desired grain size of the grinding material All shredding material parts which are smaller than the screen perforation fall through the screen The screen is replaceable and can be taken out after opening the machine door Standard screen Another optional feature is a screen support that can be lowered by a hydraulic system GRN4 605 Chapter 2 Functional Description 21 of 93 WAKER 800 243 9226 i 1 Hydraulic cylinder 2 Screen support 3 Screen 2 Ei Discharge of Shredding Material Normally the shredded material will be discharged onto a conveyor belt Options include a discharge with blower or with a screw conveyor Discharge with conveyor GRN4 605 Chapter 2 Functional Description 22 of 93 WHITAKER 800 243 9226 Hydraulic Ram The hydraulic ram is fixed on two arms arranged on flange bearings Two heavy duty hydraulic cylinders move the ram back and forth The ram moves automatically after switching ON the hydraulic system and the shredder when the machine is operated in automatic mode NOTE be moved by hand on the control p
14. 3 Screw in the mounting screws and tighten lightly first Make sure the cutter fits planar in the seat Tighten the cutter mounting screws using a torque wrench NOTE The required torque for all cutter mounting screws is 120 Nm also see the table under Working on Cutting Cutters Check if the cutting gap is correct and make sure the cutters do not collide as the rotor turns Remove tools and other objects from the cutting chamber Put back screen and fix it Switch on the shredder for a short time without material and listen for noises If there are unusual noises determine the cause and eliminate it NOTE The cutting knives in particular the cutters should only be sharpened or replaced in sets There is a danger of balance error if a combination of rotor cutters from different cutter sets is used Cutters are reversible and have four symmetrical cutting edges This makes it possible to turn the cutters and only to sharpen after every fourth cutter change Chapter 5 Maintenance 52 of 93 W WHITAKER BROTHERS SINCE 1945 800 243 9226 Mounting the Bed Cutters GRN4 605 me o 47 Clean the cutter supporting surface and the holes on the cutter holder Insert sharp cutter or turn old cutter Put in the cutter adjusting screws and adjust them roughly Put in the cutter mounting screws DIN912 M12x55 12 9 and tighten lightly first Adjust the gap between cutter and
15. 6 433 16 421 6 SpringwasherDIN127 A 16 422 6 _ NutDIN934M1610 1 __ Rotor knife mounting Screw DIN912 M12x40 12 9 505 204 Knife holder mounting screw DIN912 M8x25 12 9 Lg 600 2 j Bedknifecomplete _ Upper bed knife adjusting screw for pushing DIN912 M16x45 12 9 Bed knife adjusting screw for pulling DIN912 M16x60 12 9 Bed knife cover plate right 1 Bed knife cover plate left 3 Bed knife cover plate Cover plate mounting screw DIN912 M12x35 12 9 NENNEN NEN Armmforram S Arm for ram Bearing for arm UCF212 1 703 Mounting screw for bearing DIN912 M16x70 12 9 Mounting screws ram arm DIN912 M16x90 12 9 Spring for scraper GB1356 78 n 14 d 2 D 12 H 50 7 RN OAppendix 2 2 2 o 2 10 20 LN Lower bed knife adjusting screw for pushing Kam DIN912 M16x35 12 9 3 10 0 10 10 0 1 1 3 85 of 93 WHITAKER 800 243 9226 Cover plate for scraper Upper cylinder screw Lower screw for cylinder mounting 716 Mounting screw for cylinder screw DIN912 M16x25 12 9 Grease nipple GB1152 M10x1 e 800 Hydraulic 802 Piping 4 803 Connectors Lo qq 900 Electrical parts GRN4 605 OAppendix 86 of 93 WHITAKER 800 243 9226 Model 2000 Pos Pc Description Standard 100 Machine comple
16. 6 Figure Checking and adjusting the hydraulic system Sale hu 3 2 TE 4 x 4 B Hydraulic liquid recommendation Designation to DIN 51 524 HLP 32 Ambient temperature 7 to 70 Supplier Name of the oil 2 ARAL Aral Vitam GF 32 Aral Vitam HF 32 BP Energol HLP D 32 BP Energol HLP 32 BP Energol SHF 32 ELF Elfolna 32 me ____ HLPD Oel 32 FUCHS Renolin MR 10 Renolin B 10 MOBIL Mobil DTE 24 Mobil DTE 17 Druck l HLP 32 C Hydraulikol HLPD 32 GRN4 605 Chapter 5 Maintenance 57 of 93 WHITAKER 800 243 9226 TEXACO Rando Oil HD A 32 Rando Oil HD AZ 32 Alcor Oil DD 32 GRN4 605 Chapter 5 Maintenance 58 of 93 W WHITAKER 800 243 9226 Chapter 6 Troubleshooting 6 1 GRN4 605 Introduction The utmost In safety precautions should be observed at all times when working on or around the machine and the electrical components All normal troubleshooting must be accomplished with the power off line fuses removed and with the machine tagged as out of service The use of good quality test equipment cannot be over emphasized when troubleshooting 1s indicated Use a good ammeter that can measure at least twice the AC and DC current that can be encountered for the machine Be sure that the voltmeter has at least minimum impedance of 5 000 OHMS per volt on AC and 20 000 OHMS per volt on DC scales Popular combination meters VOM and VTVM can be selected to prov
17. 605 Chapter 1 Safety 13 of 93 WHITAKER 800 243 9226 Type of Danger Activity Possible Preventative Measures Consequences Pulling in caused by All activities Serious injury can result Never dismount V belt protection running V belts from hair jewelry etc and window being pulled into the machine Direct indirect contact Maintenance work Serious injury or death Only trained electricians may carry with live parts in start up out all work on the electrical terminal box equipment If work is necessary on parts that conduct dangerous voltage a second person should be present to break the power supply in case of emergency The yellow marked lines conduct voltage at all times even when the machine is switched off e Only use original safety fuses with stipulated intensity of current Faulty electrical components must be replaced immediately e If faults occur in the electrical energy supply switch machine off immediately e terminal box must be locked during operation Before opening the terminal box switch too off Failure of Emergency All activities Serious injury or death t must be guaranteed that failure Stop function of an Emergency Stop button is displayed and leads to an immediate stop Fire explosion caused Grinding Serious injury or death Only grind material which by throwing corresponds to the agreed dangerous objects customer specific specification
18. Eliminate all defects before operating the machine If defects occur during operation stop the machine immediately and eliminate the defects Do NOT change or remove any protective devices Do NOT put any protective devices out of action by modifying them Cleaning the Machine Danger of cutting caused by sharp cutting cutters even when the rotor is not operating Serious injury especially to the hands and fingers can result Wear protective gloves Proceed as follows 1 Switch OFF the shredder at the main switch Safeguard main switch using a padlock Open the machine and hopper doors Safeguard the machine and hopper doors Remove the screen oy oe Pe Empty the screen AWARNING Inhalation of process dust is hazardous to your health Never blow out the shredded material residue always use suction instead Wear breathing protection if necessary 7 Pre clean the cutting chamber using a hand brush 8 Vacuum the remaining shredded material residue using a suitable device 9 Remove clinging grinding material residue using a suitable wooden scraper GRN4 605 Chapter 5 Maintenance 38 of 93 BROTHERS WAKER 800 243 9226 SINCE 1945 GRN4 605 10 Place the screen back into its working position and fasten with the mounting screws 11 Close the machine and hopper doors 12 Machine can be started again Replacing the Gear Box The gearbox is made so a replacement is only necessary i
19. Emergency Stop Button must be mounted to the control cabinet and another on the grinding material in feed Immediately press one of the Emergency Stop buttons in case of an emergency The Emergency Stop must be activated in all situations where injury or damage could result Re operation 1 Eliminate cause of Emergency Stop 2 Unlock Emergency Stop button 3 Acknowledge fault 4 The machine is now ready for operation GRN4 605 Chapter 2 Functional Description 27 of 93 W WHITAKER BROTHERS SINCE 1945 800 243 9226 Chapter 3 Installation 3 1 GRN4 605 Uncrating the Equipment Requirements at Application Site Check the application site to make sure it conforms to the qualifications listed below The site is an enclosed space The ground has sufficient load bearing capacity Refer to Technical Specifications in the Appendix for machine weight The unevenness of the ground surface may not exceed 5 mm The machine must be freely accessible from all sides There must be sufficient room available for operating and service personnel Spatial requirements Refer to Drawing and Diagrams in the Appendix for machine dimensions All hinged parts must be able to be opened completely Vibration free environment The site has sufficient lighting The machine may not be exposed to direct radiation caused by radiators or the sun Room temperature 41 to 104 F 5 to 40 C Relative atmospheric
20. GRN4 605 Pos Pc Description Standard 100 Machine complete Z AE 200 Screen complete Standard EE EE 200 Screen complete Hydraulic 206 2 Cylinder for screen support opening 50x 25x145 Bearing housing SN320 16Mn 303 Bearing housing cover plate 8 ___ Mounting screw cover plate DIN912 M10x45 8 8 Bearing mounting plate 312 2 WasherDIN 125 A24 4 EMEN NEN 400 Drive 4 mp Motor 37 kW 460V 60Hz Motor 55 KW 460V 60HZ hol Gear pulley SPB280 4 Gear pulley SPC300 4 Gear pulley taper bushing TB 3020 48 Gear pulley taper bushing TB 3535 50 OAppendix 78 of 93 WHITAKER 800 243 9226 GRN4 605 V Belt SPB 2150 V Belt SPC 2430 Motor pulley SPB 224 4 Motor pulley SPC 250 4 Motor pulley taper bushing TB 3020 60 Motor pulley taper bushing TB 3535 65 501 60 34 34 20 mom Rotor knife mounting Screw DIN912 M12x40 12 9 503 60 WasherGB T1230 13 4 504 60 Rotorknifeholder 4 Knife holder mounting screw DIN912 M8x25 12 9 dq 600 2 Bed knife complete 601 6 Bed knife 279x80x30 Mounting Screw DIN912 M12x55 12 9 me I Lower bed knife adjusting screw for pushing DIN912 M16x35 12 9 MN LM Upper bed knife adjusting screw for pushing DIN912 M16x45 12 9 Bed knife adjusting screw for pulling DIN912 M16x50 12 9 Bed knife cover plate Bed knife cover
21. ance 39 of 93 W wes 800 243 9226 9 Carry out a test run NOTE If the spare rotor is delivered without bearings the bearings MUST be mounted first Replacing the Main Bearings GRN4 605 The main bearings of the machine are made so a bearing replacement is only necessary in exceptional cases Dismounting and mounting of the bearings requires specialist knowledge and a careful working method In addition to the following advice please observe the instructions given in the installation manual of the bearing manufacturer or ask the service department for help The bearings mounted in this machine are indicated in the spare parts list A suitable pulling off device 1 a required for dismounting and mounting the bearings Dismounting the Main Bearings Dismount the V belt cover Dismount the V belts Dismount the gearbox Pull the distance sleeve off the rotor axis Remove the screen Remove the rotor cover plates from the machine housing Screw in hooks on both shaft ends Hang on rotor on both shaft ends 2029 de wo A v Remove the bearing housing mounting screw Carefully lift out the complete rotor using suitable lifting and stopping equipment Lay the rotor down in a safe location using timber beams of appropriate size ID Loosen the mounting screws on the bearings cover 92 Pull the bearing housing off with a pulling off device 14 Pull the bearing off t
22. anel when run manual mode gt gt p Hydraulic cylinder Sk S a Flange bearing ra zd 7 3 Ram arm Ram Hydraulic unit DT 1 Serrated ram front plate 2 Rotor GRN4 605 Chapter 2 Functional Description 23 of 93 WHITAKER 800 243 9226 Pulse Push Function In normal process mode the ram pushes forward continuously until the ram arm reaches the proximity switch reverses the function and the ram moves backwards The ram moves forward in steps when the switch 1 is changed to Pulse Push This means that after each step the ram remains in position for a couple of seconds before it moves forward again This function should be used for very heavy applications and when overloading the system 15 a concern 1 Pulse push switch GRN4 605 Chapter 2 Functional Description 24 of 93 WHITAKER 800 243 9226 2 4 Safety Features Protective Devices The Machine may under no circumstances be operated without these protective devices The use of faulty or manipulated protective devices is strongly prohibited Safety Device for Housing Flap Safety device machine door Safety device hopper door The shredder can only be operated if the doors are closed deactivating the safety switch The safety contact is broken when the machine or hopper door is open thus switching off the machine GRN4 605 Chapter 2 Functional Description 25 of 93 vy WHITAKER v s
23. ar any loose fitting clothes neckties or dangling items such as earrings belts or shoestrings Jewelry such as wristwatches bracelets or rings should NEVER be worn Long hair must be tied back or placed in a tight fitting hairnet NEVER lean against or rest hands or feet on the granulator when it 15 in operation or open for maintenance NEVER stand on the granulator when it is in operation Chapter 1 Safety 11 of 93 W GRN4 605 WHITAKER 800 243 9226 SINCE 1945 ROTATION OF MOTORS The correct rotating direction for the machine motor is clearly marked on the machine Always check for proper rotation of motors Incorrect rotation direction can cause severe damage ELECTRICAL GROUNDING All electrical equipment on the granulator must be grounded in accordance to all local codes and Article 250 of the National Electric Code ALWAYS DISCONNECT AND LOCKOUT the main electrical power to the granulator before performing any service SAFETY INTERLOCKS MUST NOT BE BYPASSED The mechanical and electrical safety interlocks ensure the safety of personnel They should never be tampered with or removed for ANY reason They should be checked frequently by a qualified mechanic for proper operation NEVER modify the machine configuration or any individual component without written notice from the factory Chapter 1 Safety 12 of 93 WHITAKER 800 243 9226 Remaining Risks The machine 1s constructed so that you are able to operate it
24. are and Use ANSI B151 11 1982 We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality GRN4 605 Chapter 1 Safety 15 of 93 WHITAKER 800 243 9226 Chapter 2 Functional Description Models Covered in This Manual This manual covers the 850 1200 1500 and 2000 Medium Duty Single Shaft Shredders which include models AMS CMS SLS ESS and MMS The Medium Duty Single Shaft Shredder Series is designed for processing scrap from wood industries miscellaneous trim and panel scraps furniture injection and extrusion mold start up purge heavy wall parts paper and cardboard and film baled and loose 2 2 General Description Mechanical Section After the machine has been switched ON a hydraulically controlled swing style ram pushes a quantity of material onto the slow running profiled rotor The in feed is controlled according to load The material can be placed unsorted in the hopper mounted on top of the machine Pay attention to this material it cannot contain any other metal parts except for staples and nails The guarantee does not cover any damage to the machine as a result of metal parts being fed into the machine The cutters on the rotor shred the material in the hopper This shredding process is repeated as often as req
25. ding 15 attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise customer service regarding your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list You should have M Bill of lading Packing list M Operating and Installation packet M Electrical schematic and panel layout drawings Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact the shipping department immediately For immediate assistance please contact the correct facility located in the technical assistance section of this manual Have the order number and item number available Hold the items until you receive shipping instructions ii WHITAKER 800 243 9226 BJ5 615 Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department Credit Returns Prior to the return of any material authorization must be given by the manufacturer A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given ALL returned material purchased from the manufacturer returned is subject to 15 75 00 minimum restocking c
26. djusting screw for pushing DIN912 M16x45 12 9 Bed knife adjusting screw for pulling DIN912 M16x60 12 9 Bed knife cover plate right Bed knife cover plate left _ 5 Bed knife cover plate 2 gt 2 604 605 607 8 Cover plate mounting screw DIN912 M12x35 12 9 Ram complete 701 702 Bearing for arm UCFC212 703 Mounting screw for bearing DIN912 M16x70 12 9 Mounting screws ram arm DIN912 M 16x90 12 9 712 4 Spring for scraper GB1356 78 n 14 d 2 D 12 H 50 Cover plate for scraper Upper cylinder screw Lower screw for cylinder mounting 716 Mounting screw for cylinder screw DIN912 M16x25 12 9 Grease nipple GB1152 M10x1 2 14 28 14 14 28 1 1 5 2 700 1 2 2 OAppendix 88 of 93 WHITAKER 800 243 9226 PP 800 Hydrauic 802 803 Connectors 7 p 900 jElecricalparts GRN4 605 OAppendix 89 of 93 WHITAKER 800 243 9226 Model 850 Hydraulic Unit Spare Parts Pos Description 5 Supplier __ Wheel pump 5 Vanepump 180149 11 6 Chekvave CITOSCIT 4 2 CRG 03 8 __ Spillovervalve 18608 Ocean 9 Sequence vave 03 1 Jj 7Ocan 1 17 Scavengeoilfiller 170134100R 171 0 Model 850 Hydraulic Screen Spare Parts Pos Description Standard 1 1 Pc Supplier 5 Vanepum 57 404 141 1 gt 6 Chekvave
27. ease in bearing Reduce amount of grease Rubbing on housing sealing Check sealing ring and oil or ring replace Bearing damage Check bearings and replace if necessary No grease in bearing Lubricate bearing Renew screen possibly using manganese steel Foreign matter Bearings too hot Screen worn Replace screen after consulting the service Too many fines in shredded department material Unsuitable screen perforation Possible Cause Possible Remedy Re tighten using torque Cutting gap alters during Cutter mounting screws not wrench following the GRN4 605 Chapter 6 Troubleshooting 61 of 93 WAKER 800 243 9226 operation tight instructions in this manual ERE NOUS SINCE Insert new cutter holders deformed Supporting surfaces not Clean and re dust supporting clean surfaces Threads in housing worn Fit new bushings in housing Screen wrongly inserted Fit screen correctly Screen damage Screen support buckled Replace screen support Limit switches not activated and correct Main and control fuses Replace fuse Feed device not connected Switch on in sequence Material iam Empty shredder before Shredder does not start Jo switching ON Star delta connection Correct wiring on motor Check motor relay for correct setting and increase if necessary Start feed only after switch over from star to delta Limit switch loose or wrongly Re position and tighten li
28. eed The material can be fed into the shredder in the following ways Manual in feed of the material directly into the in feed hopper Manual in feed of the material with the help of an additional in feed device e g hydraulic feeding unit Automatic in feed of the grinding material via an additional in feed device 1 e conveyor belt In feed Hopper GRN4 605 Chapter 2 Functional Description 17 of 93 800 243 9226 The material in feed flows through an in feed hopper to ensure the grinding material 1s delivered safely and correctly NOTE An optional top hinged cover to prevent in feed material fly back during size reduction is available Special hopper with hydraulic cover Additional In feed Device If the machine has an optional in feed device such as a conveyor belt please refer to the additional information about the accessory in the manufacturer s manual that accompanied the accessory A special hopper for an in feed with conveyor arrangement can be supplied as an option to the standard hopper F II lt 7 wh il C TE pu z gt 7c X Hopper for conveyor belt in feed GRN4 605 Chapter 2 Functional Description 18 of 93 WHITAKER 800 243 9226 Drive The drive of the rotor runs using an electric motor via V belts The motor mounted on sliding rails or a motor plate can be adjusted for regulating the tension of the V belts using tensioning screws The V belt pulley is attached to t
29. er gap 0 8 mm I mm Mount the cutter cover plates Transporting and Storing the Cutting Cutters AWARNING Danger of cutting caused by sharp cutting cutters e Serious injury in particular to hands and fingers can result Wear protective gloves Only transport and store the cutting cutters packaged Grease the cutting cutters well so that they do not rust Protect the cutting edges with doubled cardboard and use adhesive tape to safeguard the cutters against slipping out of the sides of the sheath After unpacking you must de grease the cutting cutters so that they can be gripped safely Hydraulic Maintenance GRN4 605 Hydraulic oil has to be filled into the tank before start up of the machine The type of oil that should be used depends on location Recommend oils include type DIN 51524 HLP 32 for areas with temperatures below 32 F 0 C in the winter and HLP 46 for temperatures of around 86 F 30 C in the summer For extremely hot tropical areas i e Thailand Malaysia Nigeria etc it is recommended to use HLP 68 The first oil replacement should be done after 1 000 operating hours and then after every 2 000 operating hours The oil filter must be replaced too Chapter 5 Maintenance 55 of 93 wes 800 243 9226 W NOTE Overheating of the oil and dirt in the oil will cause damage to the hydraulic system if the oil is not replaced in the specified amount of time This can lead to complete standstill
30. fe mounting screws CX 3 Knife holder Cover plates 5 Knife adjusting screw for 2S pushing 6 Cutter adjusting screw for pulling 7 Cover plate mounting gt Screws hee 74 Y 2 4 1 WV Mounting the Cutter Holders 1 Clean the cutter pocket and the cutter holder 2 Insert cutter holder into the pocket NOTE Cutter holder must slide in easily Do not damage the cutter holder surfaces with a hammer GRN4 605 Chapter 5 Maintenance 51 of 93 W SINCE 1945 GRN4 605 WHITAKER BROTHERS 800 243 9226 Put in the cutter holder mounting screws DIN912 M8x25 12 9 and put some Loctite on them Make sure that the cutter holder fits properly Tighten the cutter mounting screws using a torque wrench NOTE The required torque for the cutter holder mounting screws is 59 Nm also see the table under Working on Cutting Cutters Danger of cutting caused by sharp cutters at all times even when rotor is at standstill Serious Injury especially to the hands and fingers can occur Wear protective gloves Mounting the Cutters 10 Clean the cutter supporting surface and the hole on the cutter holder Insert sharp cutter or turn old cutter and push against the cutter holder surface Put in the cutter mounting screw DIN912 M12x40 12 9 and the washer DIN433 1
31. harge ALL returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied No credit will be issued for material that is not within the manufacturer s warranty period and or in new and unused condition suitable for resale Warranty Returns Prior to the return of any material authorization must be given by the manufacturer A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied After inspecting the material a replacement or credit will be given at the manufacturer s discretion If the item 1s found to be defective in materials or workmanship and it was manufactured by our company purchased components are covered under their specific warranty terms IV W Storage Disposal Transportation WHITAKER 800 243 9226 Storage Clean the machine see Cleaning the Machine Preserve all polished metal surfaces using a suitable rust preventing agent Store the machine in a dry enclosed space Cover the machine completely with a plastic sheet Disposal The disposal of machines machine components and process materials is partially subject to legal controls More detailed information is given at the relevant administrative authority 1 e regional and national Water Conservation Bureau and Enviro
32. have been loosened and tightened several times Torque Screw type Grade 8 8 Grade 10 9 Grade 12 9 Nm Ib ft Nm Ib ft Nm Ib ft M8 25 18 4 35 25 8 41 30 2 M10 49 36 1 69 50 9 83 61 2 M12 86 63 4 120 88 5 145 106 M16 210 154 295 217 355 261 M20 410 302 580 428 690 508 M24 710 523 1000 737 1200 885 Checking the Condition of the Cutters AWARNING Danger of cutting caused by sharp cutters at all times even when rotor is at standstill Serious Injury especially to the hands and fingers can occur Wear protective gloves The cutting cutters become blunt after a certain number of operation hours they should be checked regularly Using blunt cutters can affect the efficiency and performance of the machine in the following ways Decreased shredding capacity Increased current consumption of the drive motor nexact cut Overheating of the shredded material Dismounting the Cutters see drawing below 1 Switch OFF the shredder at the main switch GRN4 605 Chapter 5 Maintenance 48 of 93 BROTHERS SINCE 1945 vy WHITAKER v 2 3 4 5 6 7 8 Cutter Cutter mounting screw Cutter holder Cutter holder mounting screws 800 243 9226 Safeguard main switch using a padlock Open the machine door Safeguard the machine door Remove screen NOTE Although it is possible to reach the cutting shaft by climbing into the feeding
33. he motor shaft with a special tensioning element Drive motor NOTE Please observe the operation manual from the manufacturer Rotor Cutters Bed Cutters Rotor cutters bed cutters The material is shredded between the cutters assembled on the rotor and the bed cutters they are mounted in a fixed position in the machine lower section All rotors are equipped with square cutters These cutters make light work of the heaviest pieces NOTE The cutters have four corners so they can be easily turned once a corner has worn out e design of the rotor has a significant influence on the quality of the shredding process and the results The rotor construction the type of cutter mounting and the number of cutters have been matched to the application GRN4 605 Chapter 2 Functional Description 19 of 93 SINCE 1945 WY WHITAKER 800 243 9226 1 Rotor cutter 2 Screen support hydraulic 3 Bed cutter 1 Rotor cutter 2 Screen support The rotor is accessible after opening the machine door and removing the screen The rotor is arranged on roller bearings that situated outside the housing The V belt pulley is attached to the rotor axis with a taper brush The rotor is dynamically counter balanced and has vibration free concentricity An optional feature is a water cooling system for the rotor used for special applications GRN4 605 Chapter 2 Functional Description 20 of 93 WHITAKER 800 243 92
34. he rotor axis using a pulling off device Mounting the Main Bearings 1 Before mounting clean the bearing surfaces and the shaft surfaces thoroughly and grease lightly 2 Mount bearing in bearing housing 3 Attach the bearing with the bearing housing to the rotor axis 4 Lift the rotor using suitable lifting and stopping equipment and place carefully into the bearing seats Chapter 5 Maintenance 40 of 93 WHITAKER 800 243 9226 W 5 Attach the bearing housing to the bearing seats using screws 6 Push the distance sleeve onto the rotor axis 7 Putthe gear onto the rotor axis 8 Put back the rotor cover plates 9 Putin the screen 10 Pull on V belts and adjust the V belt tension force 11 Attach the V belt cover 12 Carry out a test run NOTE The roller bodies will be damaged unless the mounting forces engaged into inner ring The hardened bearing rings are sensitive to impact stress never hit the rings with the hammer Use a brass arbor or a striking bushing piping piece made from a soft material The inner diameter of the striking bushing should be only slightly larger than the diameter of the bearing base The bearing is then pushed onto the shaft using light blows The force of pressure must be evenly distributed on the circumference of the bearing ring Lubricating the Main Bearings An important requirement for high operational safety and long service life of the arrangement of bearings 1
35. humidity according to DIN 40040 15 to 70 indoor NOTE By humidity levels higher than 70 apply anticorrosive agent to the metallic finished machine parts Insulation for the tropics is also necessary The machine may not be operated within range of static discharges or strong magnetic fields as this could lead to faults in the machine control system Unloading and Installing the Machine The machine and components are packed so they arrive safely Use a suitable crane or forklift for unloading the packaged machine and or components 1 Remove the packaging material and all transportation safety devices after unloading the machine 2 Inthe case that the shredder and its accessory components have been delivered as individual items mount them at the site of application in accordance with the Assembly Drawing This 1s the only way to guarantee there are sufficient piping parts tubing and cable connections and that the linking places match Chapter 3 Installation 28 of 93 WHITAKER BROTHERS SINCE 1945 W 800 243 9226 A Falling loads can cause serious injury or death Only use a crane or forklift suitable for the weight and the dimensions of the load Use suitable stopping equipment and pay attention to the gravity center location DO NOT step under the suspended load Wear a safety helmet in addition to basic protective gear WARNING OVERTURNING OR FALLING MACHINE Serious injury or death ca
36. ical Assistance Parts and Service Department The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service For immediate assistance please contact North Central and South America 8am 5pm CST 1 800 483 3919 for drying conveying heating and cooling and automation For size reduction 1 800 229 2919 North America emergencies after 5pm CST 847 439 5855 North America email acsuscanadacustserv Qcorpemail com Mexico Central amp South America Email acslatinamericacustserv corpemail com Europe Middle East amp Africa 48 22 390 9720 Email acseuropecustserv corpemail com India 91 21 35329112 Email acsindiacustserv corpemail com e Asia Australia 86 512 8717 1919 Email acsasiacustserv corpemail com Sales and Contracting Department Our products are sold by a worldwide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Let us install your system The Contract Departmen
37. ide the necessary functions Before making haphazard substitutions and repairs when defective electrical components are malfunctioning we recommend that you check the associated circuitry and assemblies for other defective devices It is common to replace the obviously damaged component without actually locating the real cause of the trouble Such hasty substitutions will only destroy the new component Refer to wiring diagrams and schematics Locating mechanical problems should they occur is relatively straightforward When necessary refer to the parts catalog section Chapter 6 Troubleshooting 59 of 93 WHITAKER W somers 000 243 9220 Too much feed material SHORING n a Clean screen check condition select larger screen perforation if necessary Check V belt tension and V belts slip condition Re tighten or replace if necessary Check cutters and re sharpen or replace if necessary Check cutting gap and set Cutting gap following the instructions in this manual Machine blocks or switches Check if discharge conveyor itself off Discharge blocked belt is running Check limit switch for defective contact Screen blocked Cutter condition Check electrical Current failure connection Tighten limit switch if necessary Fit larger fuse only after Fuse too small consulting the service department Rotational direction of rotor SIGN did revels polarity if necessary Change rotor
38. ined and specialized personnel should carry out maintenance work Maintenance Plan GRN4 605 Danger caused by electrical voltage and starting the machine during maintenance work Death can result ALWAYS turn main switch to 0 safeguard using padlock and attach a warning sign while carrying out maintenance work The tasks for maintenance work are described below Perform the following after every 8 operation hours Check protective devices Check cutting cutter mountings e Check condition of cutting cutters Perform the following after every 40 operation hours Check V belt tension force and V belt condition Check all screws of the machine for a tight fit Check wearing parts Check hydraulic oil level and consistence Per form the following after every 2000 operation hours e Change hydraulic oil Check gearbox oil level Yearly maintenance The purpose of yearly maintenance is primarily to check the general condition of the machine and to arrange for the supply of any necessary replacement parts A service engineer can carry out this request Chapter 5 Maintenance 37 of 93 WHITAKER 800 243 9226 5 2 Preventative and Corrective Maintenance Checking the Protective Devices Check the safety devices for e Stipulated condition e Stipulated location e Safe mounting Stipulated function Danger due to non functioning protective devices can cause serious injury or death
39. ineer The Functional Description section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the equipment We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the equipment These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the equipment safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your equipment provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics parts lists and available optio
40. ith a forklift 1 Screen 2 Screen mounting screws 3 Cutter adjusting screws 4 Forklift Remove the screen Empty the screen Put the screen back using a forklift Fasten the mounting screws 10 Close the machine door 11 Shredder can be started again Chapter 4 Operation 34 of 93 WHITAKER 800 243 9226 GRN4 605 Emptying the Screen hydraulic screen l ee QU X Switch OFF the shredder at the main switch Safeguard main switch using a padlock Open the lower machine door Safeguard the machine door Pivot the screen support downwards by pushing the button screen open on the control box Remove the screen Empty the screen Put the screen back into the screen support Pivot the screen support into the working position and fasten using the mounting screws 10 Close the machine door 11 Shredder can be started again 1 Hydraulic cylinder 2 Screen support 3 Screen 4 Rotor Chapter 4 Operation 35 of 93 SINCE 1945 WHITAKER 800 243 9226 4 3 Shut down Switch OFF Machine 1 Switch OFF the material in feed device accessories 2 Waituntil the remaining grinding material has been shredded and then switch OFF the shredder main switch to 0 3 Switch OFF the material discharge device GRN4 605 Chapter 4 Operation 36 of 93 SINCE 1945 W WHITAKER 800 243 9226 Chapter 5 Maintenance 5 1 Preventative Maintenance Schedule Only tra
41. linder screw DIN912 M16x25 12 9 Grease nipple GB1152 M10x1 Lo p 80 ________ 7 82 803 Connectors gt Lj 900 Electrical parts GRN4 605 OAppendix 83 of 93 WHITAKER 800 243 9226 Model 1500 Pos Pc Description Standard 10 Machine complete j 200 Screen complete Standard 202 6 ___ Screen support screw DIN912 M12x35 8 8 203 16 WasherDIN125 B 13 140HV 204 6 Springwasher DIN127 A 13 205 X Clamp me 8 Clamp mounting screws DIN933 M20 207 _ 2 WasherDIN125 A 20 140HV EMEN 200 Screen complete Hydraulic 201 202 6 Screen support screws DIN912 M12x35 8 8 203 6 ___ Washer DIN125 B 13 140HV 203 16 jSpringwasherDIN127 A 13 205 2 Cylinder for screen support opening _ ar Bearing 301 2 Bearing housing SN324 16Mn 302 2 Bearing GB T288 94 22324 gt 303 2 Bearing Cover Bearing housing cover plate 307 2 Grease nipple GB1152 89 MBx1 308 2 SleeveQ150x16 Sleeve 150x16 DIN912 M10x40 8 8 DIN912 M10x45 8 8 Bearing mounting plate Mounting plate screw DIN912 M24x50 8 8 LJ p 400 Dive 27 404 GRN4 605 OAppendix 84 of 93 BROTHERS SINCE 1945 vy WHITAKER v GRN4 605 800 243 9226 408 416 Torque arm screw a DIN933 M16x50 12 9 420
42. lined All caution warning and danger signs must be observed and obeyed actual or potential danger areas must be reported to your immediate supervisor Chapter 1 Safety 10 of 93 W 1 4 GRN4 605 BROTHERS SINCE 1945 WHITAKER 900 243 9226 Warnings and Precautions Our granulators are designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes To avoid possible personal injury or equipment damage when installing operating or maintaining this granulator use good judgment and follow these safe practices LEARN AND OBEY your company s safety policy regarding granulating equipment MOVING OR LIFTING THE GRANULATOR Although our equipment is built and engineered for great ruggedness in operation care must be taken when moving the machine along the floor or lifting it Damage may occur to sheet metal covers electrical cabinets or small brackets if pressure is applied to them when moving the granulator When lifting the granulator be certain of total machine weight and the capability of the lifting equipment See the Granulator Specification Sheets for machine weights and dimensions SHREDDER LOCATION Adequate area for routine maintenance should be provided in order to open the machine for cutter screen or cleanout service Proper service area clearances also should allow people who are working on the machine
43. mber is free of foreign matter lt The machine and hopper doors are closed safety devices including those of the installed grinding material in feed and discharge devices are checked and operative Switch ON Machine 1 Switch ON the material discharge device 2 Switch ON the shredder main switch to 1 Wait until the rotor has reached its full speed and switched from star to delta 3 Switch ON the hydraulic system 4 Switch ON the material in feed device accessories Operation Procedures Manual In feed of Material Rotating Cutters DANGER Can cause serious cutting and crushing injuries that could result GA GRN4 605 in death Do NOT reach into the in feed hopper or lean in while the rotor is running Pay attention to the run down time Only use approved grinding material Chapter 4 Operation 33 of 93 WHITAKER 800 243 9226 GRN4 605 Throw the grinding material into the in feed hopper The machine should be fed from the front If your machine has an additional in feed device installed please observe the additional information for working with the in feed device Do not climb into the in feed hopper while operating the machine Death will result Emptying the Screen standard screen l 2 3 4 5 6 7 8 9 Switch OFF the shredder at the main switch Safeguard main switch using a padlock Open the machine door Safeguard the machine door Hold the screen w
44. mit set switch Replace fuse Motor protection switches off Feed starts too early Shredder blocks when under load Fuse defective Fit larger fuse only after consulting the service department Reduce feed quantity of the grinding material Motor fuse switches off red indicator Correct setting Replace fuse n MENN Br di Current relay switches off Correct setting material in feed device GRN4 605 Chapter 6 Troubleshooting 62 of 93 W VHETRISER 800 243 9226 Appendix A 1 Technical Specifications Specifications rx46 In 8 In 69 76 in 91 76 in 27 5x28 8 in 31 5x39 8 in 31 5x50 B in 31 5x72 8 in Rotor Dia mm 387 mm 15 3 457 mm 18 Drive Capacity KW 37 50 HP 55 50 HP 75 101 HP 2x55 148 HP _ Rotor Knives 50 85 60 108 110 81 136440402 192 195 144 pieces TIT Screen Size mm 20 100 79 4 GRN4 605 Appendix 63 of 93 800 243 9226 A 2 Drawings and Diagrams NOTE Please refer to the corresponding Spare Parts lists in the following section Cutter Mounting GRN4 605 O Appendix 64 of 93 WHITAKER 800 243 9226 Bed Knife Mounting GRN4 605 OAppendix 65 of 93 WHITAKER 800 243 9226 Rotor Assembly GRN4 605 OAppendix 66 of 93 WHITAKER 800 243 9226 GRN4 605 OAppendix 67 of 93 WHITAKER 800 243 9226 Ram GRN4 605 OAppendix 68 of 93 WHITAKER 80
45. n exceptional cases Dismounting and mounting the gear box requires specialist knowledge and a careful working method Please observe the instructions given in the installation manual of the gear box manufacturer or ask the service department for help Replacing the Rotor The rotor s design is heavy duty so a replacement is only necessary after a crash 1 e a hammer fall inside Dismounting and mounting of the rotor requires specialist knowledge and a careful working method Call the Service Department for assistance Dismounting the Rotor 1 Dismount the V belt cover 2 Dismount the V belts 3 Dismount the gearbox 4 Remove the screen 5 Remove the rotor mounting slot cover plates from the housing 6 Screw in hooks on both shaft ends 7 Remove the bearing housing mounting screw 8 Carefully lift out the complete rotor using suitable lifting and stopping equipment 9 Lay the rotor down in a safe location using appropriately sized timber beams Mounting the Rotor 1 Before starting clean the bearing seat surfaces and check the key 2 the rotor using suitable lifting and stopping equipment and place carefully into the bearing seats 3 Attach the bearing housing Pos to the bearing seats using screws 4 Putthe gear onto the rotor axis 5 Put back the rotor mounting slot cover plates 6 Putin the screen 7 Pull on V belts and adjust the V belt tension force 8 Attach the V belt Chapter 5 Mainten
46. n matter Check that the Emergency Stop buttons are unlocked Check all safety devices for proper functioning Switch ON machine for a short period of time and check rotational direction The rotational direction can be seen at the discharge air fan of the drive motor observe running direction arrow Switch ON hydraulic unit for a short time and check rotational direction Chapter 3 Installation 31 of 93 WHITAKER 800 243 9226 GRN4 605 Allow machine to run for approximately 10 minutes without shredding material Connect material discharge device and in feed device check rotational direction drives Feed grinding material uniformly Too much grinding material can lead to overload of the machine Check the temperature of the shredded material 1f necessary Monitor the ammeter This displays the present current consumption and gives information on the load of the machine Chapter 3 Installation 32 of 93 W WHITAKER 800 243 9226 Chapter 4 Operation 4 1 4 2 Start up No persons should operate the machine until they have read and understand all parts of the operation manual Machine Check Before Switching Machine ON Cutters and bed knives are properly set and the screws are tightened with the specified torque v Screen is inserted into the screen support according to the instructions and the screen support 15 fixed at the end position with tightened mounting screws v cutting cha
47. n result If erecting the granulator over a pit on a frame or on a platform you MUST secure the machine by putting mounting screws through the holes on the mounting pads see Assembly Drawing If assembling the machine on solid ground this safety device is not always necessary Align the machine horizontally with the help of a suitable spirit level 4 Do not use blocks to place underneath the machine use metal strips to prevent buckling of the base frame Make sure that an even distribution of weight is achieved on all the points of support Electrical Connections DANGEROUS VOLTAGE Touching live parts can lead to serious injury or death 3 2 NCAUTION Electrical connections should only be made by a qualified electrician All work relating to the electricity of the machine may only be carried out by trained electricians Observe the currently effective EMC regulations Voltage current frequency and protection are marked on the type plate The voltage tolerance Is 10 The electrical connection is to be carried out in accordance with the wiring diagram in the terminal box for machines not pre wired by the manufacturer NOTE When making electrical connections the regulations of the local electricity authority must be followed The required cable cross section required is determined according to the rated capacity of the units GRN4 605 Chapter 3 Installation 29 of 93 800 243 9226 SINCE 1945
48. nance 45 of 93 WHITAKER 800 243 9226 Checking and adjusting the tension force of the V belt 1 Verify that the alignment of the pulley is correct Utilizing a straightedge of sufficient length to span from one pulley to the other place it along the sides of both pulleys The entire face of each pulley should fully contact the straightedge 2 Measure the belt SPAN with a measuring tape Record this dimension in your note book 3 Using the deflection tester apply a perpendicular force at the midpoint of any one of the belts to deflect the belt 1 64th of an inch 4 Calculate the deflection force FORCE Lb SPAN IN X 1 64 Lb IN 5 Identify the belt type and measure the small sheave diameter Look up the proper model belt deflection force table and find out what the force is supposed to be 6 The motor position should be adjusted until the actual deflection force matches the force listed in the table BELT SPAN GRN4 605 Chapter 5 Maintenance 46 of 93 W ACAUTION 7 no case should the belts be over tensioned as this can significantly reduce belt and or bearing life WHITAKER 800 243 9226 DEFLECTION BELT CROSS SME SEE FORCE SECTION DIAMETER RANGE Lbs SPA 3 9 5 2 5 9 SPA 5 5 7 9 7 7 SPB 6 2 8 9 11 SPC 8 8 14 0 19 8 SPC 14 7 22 0 26 4 XPB 8 8 9 84 7 7 Checking V belt condition replacing V belt ACAUTION Running V belts can pull objects into the machine Hair jewelry etc can be pulled int
49. nance Chapter in this manual When equipped with belts Every month inspect the and sheaves hands could belt s for any type of wear become entangled For further information see the Maintenance Chapter in this manual Hands can become Every month inspect the entangled or cut if they shears blades for any type of enter the danger zone of wear For further information gears or cutting shears see the Maintenance Chapter in this manual The unit can produce Always wear eye and ear continuous noise above 85 protection when the machine dBA and or produce is in operation or performing projectiles under normal maintenance operating conditions A person could be exposed Always be aware of your to a crushing movement if surroundings and do not walk walking around or under underneath a suspended machine that is machine open suspended for moving GRN4 605 Chapter 1 Safety 8 of 93 WHITAKER 800 243 9226 Mandatory Symbol Description Explanation Read Operators Manual This equipment must be operated and maintained by properly trained personnel The information contained within this manual must be read and understood prior to operating this equipment Lock Out This equipment is operated with 3 phase electrical power Therefore when performing any maintenance operations we recommend following the local standards for performing a lock out tag out procedure Wear Safety Gloves This equipment operates with sharp blades and r
50. nmental Protection Agencies Only deposit the material to be disposed of at authorized drop off points Transportation Z WARNING Suspended load Falling loads can cause serious injury or death Only use a crane or forklift that can withstand the weight and dimension of the load Use suitable stopping means and pay attention to gravity center location NOT step under the suspended load Wear protective helmet in addition to basic protective gear BJ5 615 V WHITAKER 800 243 9226 Table of Contents CHAPTER 1 SAEPE TY en 7 t i Em 7 Safety Symbols Used this 0 00600000000000000050 nna nenas 7 1 2 General Safety Regulations 10 ES 00 10 1 4 Warnings and Precautions a r 11 CHAPTER 2 FUNCTIONAL DESCRIPTION 16 2 1 Models Covered in This Manual a a a 16 NENNE 16 2 3 Typical Features and Components 17 MEME i um m 25 CHAPTER 3 INSTALLATION 28 S VENTE Eguipi 8nt uuu u uuu ETT 28 32 EE EN 29 586 reli elici e NE 31 OPERATION u u 33 NL UNN 33 4 2 Operation
51. ns A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation or practice that if AWARNING not avoided could result in death or serious injury ACAUTION CAUTION indicates a potentially hazardous situation or practice that if GRN4 605 not avoided may result in minor or moderate injury or in property damage Chapter 1 Safety 7 of 93 WHITAKER 800 243 9226 Figure 1 Safety Tags and warning features Hazard Alert Symbol Description Explanation High Voltage Hazard The Every six months inspect all electrical enclosure is supplied electrical connections for with 3 phase electrical power secure attachment For Use caution when using or further information see the maintaining this product Maintenance Chapter in this manual Hands could be exposed to Every month inspect the a crushing movement shears blades for any type of wear For further information see the Mainte
52. nterior of the bearing The greasing quantity 1s 13 to 22 Ibs 60 to 100 2 roller bearing grease F3 per bearing Grease Nipple Replacing Lubricant Renewing the lubricant between intervals 1s only necessary when there unusual noises or overheating Mounting and dismounting of the bearings must be carried out in accordance with the instructions in this operation manual see replacing the bearings 1 Open the bearing 2 Remove the bearing housing and the bearing cover 3 Clean the bearing carefully using petroleum ether GRN4 605 Chapter 5 Maintenance 42 of 93 W WHITAKER 800 243 9226 NOTE Petroleum ether petroleum spirit aqueous neutral or alkaline cleaning agents may be used to clean the bearings After washing out the bearing must immediately be preserved using lubricant in order to avoid corrosion 4 Fill bearing with approved lubricant refer to List of Lubricants List of Recommended Lubricants Country of Manufacturer Manufacturer Roller Bearing Grease ARAL ARL Grease HL 3 BP ENERGREASE LS 3 CASTROL CASTROL SPHEEROL AP 3 ESSO Beacon 3 FUCHS FUCHS Grease 1200 FUCHS Grease FWA 220 SHELL Alvania Grease 3 Holland Beverol Beverol Multi Purpose Grease Italy Agip AGIP Grease 33 FD owede NYNAS Nynas FI 3 42 GRN4 605 Chapter 5 Maintenance 43 of 93 WHITAKER BROTHERS SINCE 1945 W 800 243 9226 Mounting and Dismounting TAPER LOCK Tensioning Element The motor
53. o machine without proper precaution resulting in serious injury NEVER dismount the V belt cover and window during operation If a V belt is porous or ripped it must be replaced as follows Remove the V belt cover Loosen the front and rear tensioning screw Relax the V belt by shifting the drive motor Put new V belt in Tension the V belt refer to previous section Ss hs idee ds gt Mount the V belt cover Working on the Cutting Cutters Correctly setting and mounting the cutting cutters 1s important when working with shredders to ensure efficient and economic function GRN4 605 Chapter 5 Maintenance 47 of 93 WHITAKER 800 243 9226 SINCE 1945 W Replacing and Checking the Cutting Cutter Mountings Certain machine parts are subject to stress during operation as a result of vibrations that can lead to loosening of the screw connections Therefore it is absolutely necessary to check the cutter and bed knife mounting screws in accordance with the Maintenance Plan 1 Tighten the mounting screws on the cutters and bed knives using a torque wrench Check required torque for the screw size The required torque for the cutter mounting screws is 120 Nm NOTE You can find out the required torque from the following table Tiehtening capacity decreases for screw when loosened and tightened again several times New screws of the same material quality must replace the cutting cutter mounting screws after they
54. ot extend any part of the body into feed roll openings or discharge area unless the motors are electrically locked out and the rotor and feed rolls are motionless Never extend fingers through holes in screen Be sure that the v belts are properly aligned and that tension is at its maximum Extreme care should be taken to see that all screws are properly tightened at all times During the operation of the machine rotor cutter screws may come loose Although fine threads are used on the rotor cutter screws because vibration does not easily loosen them you should inspect the tightness of the screws frequently This machine is designed for the granulation of plastic materials Do not feed any other materials into the machine Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Becoming familiar with materials inspection speed limitations screens and guard maintenance and total user responsibility will assist you in learning potential areas in need of observation for danger Each individual must take responsibility for observing the prescribed safety rules as out
55. otors We recommend that technicians use safety gloves while performing maintenance to protect hands from being exposed to these sharp surfaces Wear ear and eye protection This unit may produce loud and continuous noise and may produce projectiles Pneumatic or hydraulic equipment Pneumatic or hydraulic equipment must be kept at a safe pressure Do not reach into unit Reaching into a unit 1 prohibited while the unit is in operation and may cause serious injury GRN4 605 Chapter 1 Safety 9 of 93 WAS 800 243 9226 1 2 GRN4 605 General Safety Regulations This machine uses cutters for the performance of its intended use Consequently it can be a dangerous machine to operate and maintain unless these safety regulations are followed These regulations should be read understood and periodically reviewed by all personnel involved in any way with this machine Never operate or remove any machine components that are secured by wrench type fasteners unless the motor is electrically locked out and the rotor is motionless Never operate the machine or jog the rotor unless the cutting chamber covers discharge chute or any guards or covers are in place and secure Do not circumvent the safety interlocks Prior to clearing a jam or performing any maintenance the motor should be turned off and electrically locked out Be sure that the rotor has come to a stop Hands must not be inserted into the machine to clear the jam Do n
56. out the cutter holder mounting screws 12 Remove the cutter holder with the delivered Extractor NOTE See previous drawing Danger of cutting caused by sharp cutters at all times even when rotor is at standstill Serious Injury especially to the hands and fingers can occur Wear protective gloves Dismounting the Bed Cutters Switch OFF the shredder at the main switch Safeguard main switch using a padlock Open the upper hopper door me m A Safeguard the hopper door NOTE Although it is possible to reach the cutters by climbing into the feeding chamber it is recommended to access the cutters through the front side door GRN4 605 Chapter 5 Maintenance 50 of 93 WHITAKER 800 243 9226 5 Clean the hexagon head socket of the cutter mounting screws 2 and the cover plates mounting screws 6 Loosen the cover plate mounting screws using a high quality Allen key 10 mm Knock the Allen key lightly with a hammer to loosen if necessary 7 Take out the screws and cover plates 8 Loosen the cutter adjusting screws for pulling and take them out Loosen the cutter mounting screws with Allen key 10 mm Use a hammer to lightly knock key if necessary 10 Take out the cutter mounting screw and cutter WARNING Danger of cutting caused by sharp cutters at all times even when rotor is at standstill Serious Injury especially to the hands and fingers can occur Wear protective gloves 1 Bed knife 2 Kni
57. plate left Bed knife cover plate right Cover plate mounting screw DIN912 M12x35 12 9 pu 8 Mounting screw bearing DIN912 M16x50 12 9 712 4 Spring for scraper GB1356 78 n 12 d 2 D 12 H 60 Cover plate for scraper Upper cylinder screw Lower screw for cylinder mounting OAppendix 79 of 93 WHITAKER 800 243 9226 716 Mounting screw for cylinder screw DIN912 M16x25 12 9 Grease nipple GB1152 M10x1 pop 800 802 4 803 Connectors gt 0 0 0 0 Set of sealing for cylinders Oil filter 12AT 10 CR __ E 900 jElectricalpats GRN4 605 OAppendix 80 of 93 WAKER 800 243 9226 Model 1200 Pos jDescription Standard Lj 200 Screen complete Standard 201 1 Sereen m TE Screen support screw DIN912 M12x35 203 5 __ Washer DIN125 B 13 140HV 204 5 Spring washer DIN127 A 13 205 2 Clamp y 58 Clamp mounting screws DIN933 M20 207 2 WasherDIN125 A 20 140HV EMEND SEEN 200 1 Screen complete Hydraulic 21 1 Screen 4 M MN Screen support screws DIN912 M12x35 8 8 203 15 J WasherDIN125 B 13 140HV 204 5 Spring washer DIN127 A 13 205 11 Seren support _____________ Screen support 206 Cylinder for screen support opening ee DIN912 M10x40 8 8 DIN912 M10x45 8 8 Bearing mounting plate Mounting plate scre
58. rs To simplify cutter setting and shorten standstill periods when replacing cutters bed cutters have 4 adjusting screws 2 each for pushing and pulling the cutter Having several cutter sets helps to avoid standstill periods Correct and careful setting of the gap between the cutters and bed knives cutting gap 1s important for productive capacity of the shredder Factors for the size of the cutter gap are the size of the rotor the design of the rotor and the material to be ground 1 Bed knife 2 Knife mounting screws 3 Knife holder 4 Cover plates 5 Knife adjusting screw for pushing 6 Knife adjusting screw for pulling 7 Cover plate mounting screws GRN4 605 54 of 93 W WHITAKER BROTHERS SINCE 1945 m xe pe i 9 800 243 9226 Remove old knives see dismounting the bed knives Insert sharp cutter or turn old cutter Put in the cutter adjusting screws and adjust them roughly Put in the cutter mounting screws DIN912 M12x55 12 9 and tighten lightly first Adjust the gap between cutters and bed knife to 0 8 1 0 mm using a calibre gauge Tighten the cutter mounting screws using a torque wrench NOTE The required torque for all cutter mounting screws is 120 Nm see the table under Working on the Cutters Turn the rotor by hand Check whether the cutting gap is correct and make sure the cutters and bed knives do not collide as the rotor turns NOTE Recommended cutt
59. s Oil thread and point of set screws or thread and under head of cap screws 2 Insert screws in holds that are threaded on bushing side shown thus e in diagram In sizes where washers are found under screw heads be sure to use these washers Note that one screw in each hub is left over and is not used in this loosening operation 3 Tighten screws alternately until bushing is loosened in hub If bushing does not loosen immediately tap on hub 44 of 93 WHITAKER 800 243 9226 W Tightening Torque of the Screws Refer to the table below Tensioning Screws Screw details element Type Tightening torque in Nm Number BSW 108 Replacing the Screen The condition of the screen must be checked regularly in order to keep the throughput of the shredder and the quality of the shredded material constant The screen may be damaged dirty or not suitable for shredding material when Screen holes are too fine overheating of the shredded material can occur Screen holes too course shredded material have larger pieces that are unacceptable Standard Screen and Hydraulic Screen Please refer to the section Emptying the Screen in Chapter 4 V Belts V belts are wearing parts that stretch and must be re tensioned Regular checks on the tension force of the V belts and the condition of the V belts are necessary in order to guarantee a long service life GRN4 605 Chapter 5 Mainte
60. s in i e spray cans into all points the shredder Damage to hearing All activities Diminished hearing Reduce noise emissions by taking headaches impaired suitable measures balance deterioration of concentration Instability of machine All activities Serious injury e Install the machine according to caused by vibration the instructions in the manual Loosening of the All activities Serious injury Check the cutting cutter mountings cutting cutter regularly according to the mountings caused by instructions in the manual vibration Wear ear protection Inhalation of grinding All activities Diseases of the e Mount a suitable air suction device dust respiratory tract etc and wear breathing equipment if necessary When cleaning the machine use suction do not blow out grinding dust GRN4 605 Chapter 1 Safety 14 of 93 WHITAKER 800 243 9226 Type of Danger Activity Possible Preventative Measures Consequences Crushing cutting All activities Serious injury or death Never make the protective devices amputation caused by ineffective manipulation of protective devices Check the protective devices regularly for proper function according to the manual s specifications For further information on granulator safety installation and operation see the American National Standard for Plastics Machinery Granulators Pelletizers and Dicers Used for Size Reduction of Plastics Construction C
61. s the correct lubricant supply Every machine is greased and checked in test runs before delivery NOTE Unsuitable lubricant lubricant deficiency excessive lubricant or impurities in the lubricant lead to overheating and extreme wear of the bearings Lubrication Intervals Shift Operation Replace Lubricant Check One shift operation Every 18 months Monthly Two shift operation Every 9 months Monthly Three shift operation Every 6 months Monthly Check lubricant quality You can judge whether the lubricant needs to be replaced by checking for the following features Change in consistency e Discoloration Degree of soiling GRN4 605 Chapter 5 Maintenance 41 0 93 WHITAKER 800 243 9226 Replacing or Refilling Lubricant Fill the bearings uniformly with grease until all operating surfaces are well greased For the rotor bearings a lubricant quantity of one third to a maximum of half of the bearing volume per bearing is required If too much grease is used the lubricant will become unusable due to excessive temperature Only one type of grease may be used mixing different types of grease is prohibited The bearings have been filled at the factory with lithium base saponification roller bearing grease F3 e Refer to the List of Lubricants in this section for recommended bearing grease Refilling lubricant The grease reaches through the circulating grooves and bores via lubrication nipples into the i
62. t offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations For assistance with your sales or system contracting needs please Call North Central and South America 1 262 641 8600 or 1 847 273 7700 Monday Friday 8am 5pm CST Europe Middle East Africa 48 22 390 9720 India 91 21 35329112 e Asia Australia 86 512 8717 1919 Facilities ACS offers facilities around the world to service you no matter where you are located For more information please visit us at www acscorporate com United States ACS Schaumburg Corporate Facility 1100 E Woodfield Road Suite 588 Schaumburg IL 60173 Phone 1 847 273 7700 Fax 1847 273 7804 ACS New Berlin Manufacturing Facility 2900 S 160 Street New Berlin WI 53151 Phone 1 262 641 8600 Fax 1 262 641 8653 Asia Australia ACS Suzhou 109 Xingpu Road SIP Suzhou China 215126 Phone 86 8717 1919 Fax 86 512 8717 1916 Europe Middle East Africa ACS Warsaw Ul Dzia kowa 115 02 234 Warszawa Phone 48 22 390 9720 India ACS India Gat No 191 1 Sandbhor Complex Mhalunge Chakan Tal Khed Dist Pune 410501 India Phone 91 21 35329112 Fax 91 20 40147576 92 of 93 WHITAKER 800 243 9226 GRN4 605 OAppendix 93 of 93
63. te pd 200 Screen complete Hydraulic 202 8 Screen support screws DIN912 M12x35 8 8 203 8 WasherDIN125 B 13 140HV 204 8 Spring washer DIN127 A 43_ 25 11 Sereen suppot Screen support 206 Cylinder for screen support opening ms 3 Bearing housing SN324 16Mn 35 _ _____ DIN912 M10x40 8 8 310 2 Bearing mounting plate Pp Mounting plate screw DIN912 M12x70 12 9 H4 Drive 401 Motor 55 kW 460 60 2 right 1 Motor 55 kW 460V 60HZ left 1 Motor 75 KW 460V 60HZ right T Motor 75 kW 460V 60HZ left EAE T Gear pulley taper bushing TB 3535 50 Gear pulley taper bushing TB 3535 55 V Belt SPC 2430 V Belt SPC 2550 Motor pulley SPC 250 4 Motor pulley SPC 300 4 Motor pulley taper bushing 3535 65 Motor pulley taper bushing 3535 75 40 2 Motorplate 4 2 GRN4 605 OAppendix 87 of 93 BROTHERS SINCE 1945 vy WHITAKER v GRN4 605 800 243 9226 DIN933 M16x50 12 9 2222 27 MEE Rotor knife 34x34x20 502 144 Rotor knife mounting Screw me ee DIN912 M12x40 12 9 144 Washer GB T1230 13 504 144 Rotor knife holder 505 288 Knife holder mounting screw DIN912 M8x25 12 9 2 Bed knife complete 601 14 Bed knife 279x80x30 Cr12Mo1V1 602 128 __ Mounting Screw DIN912 M12x55 12 9 603 Lower bed knife adjusting screw for pushing DIN912 M16x35 12 9 Upper bed knife a
64. uired until the whole diameter of the screen below the rotor has been reached The shredder can also be switched off with material still in the hopper Control The machine 15 fitted with an automatic shutdown 1 e when set to automatic the machine switches off after a pre set period in the time relay The ram feeds the shredding unit rotor with as much material as it is able to process Upon reaching 70 to 90 of rated current the feeding of the ram will be stopped and automatically started again after the power consumption has fallen by 2096 in comparison with rated current If the high current is applied longer than 0 7 1 5 seconds the main drive motor switches off and runs back after about 3 seconds standstill time The ram plate also runs back while the rotor runs back The drive motor then stops for another 3 seconds before starting again Duration of pauses and return and current settings can be adjusted NOTE Any alterations should only be carried out after consulting the manufacturer Chapter 2 Functional Description 16 of 93 WHITAKER 800 243 9226 Machine Standard Execution 1 Base Frame 2 Machine door 3 Hopper door 4 Gear Box 5 Drive motor 6 V belt guards 7 Ram hydraulic guards 8 Discharge area The machine housing drive motor gear box hydraulic system and terminal box are mounted on the base frame for electrical connections 2 3 Typical Features and Components Material In f
65. ust be checked before initial start up The following steps must be completed 1 Switch the machine ON and then immediately OFF again 2 Observe whether the discharge air fan in the drive motor 15 rotating in the direction of the direction arrow NOTE If running in the wrong direction reconnect the motor connection immediately Damage to the machine will result from operation in the wrong direction Initial Start up General Advice work related to start up may only be carried out by trained and specialized personnel Check the machine for possible transportation damage or other damage If any damage exists confirm it with the freight company and report it to the manufacturer After setting up for service and before starting up for the first time necessary checks must be completed Check the oil level of the gear box before operating the machine Fill oil into the hydraulic tank Please observe the operation manual from the manufacturer Machine Check Prior to Start up v v lt NON lt 5 5 5 5 Use a torque wrench to check the cutter mounting screws when lower housing flap is open Search the grinding chamber for foreign matter Open the lower housing flap and make sure the screen has been inserted in accordance with the regulations Close upper housing flap and fasten screws tightly Check oil level of the gear box Fill oil into the hydraulic unit Examine in feed device accessories for foreig
66. w DIN912 M24x50 8 8 32 1 Washer DIN125 A 24 400 Drive O m T Motor 55 kW 460V 60Hz Motor 75KW 460V 60Hz m PF Gear pulley SPC300 4 Gear pulley SPC375 4 Gear pulley taper bushing TB 3535 50 GRN4 605 OAppendix 81 of 93 WHITAKER 800 243 9226 Gear pulley taper bushing TB 3535 55 Key C28x250 V Belt SPC 2430 V Belt SPC 2550 Motor pulley SPC 250 4 Motor pulley SPC 300 4 Motor pulley taper bushing TB 3535 65 Motor pulley taper bushing TB 3535 75 Key Motor shaft Torque arm screw Log 81 Rotor knife mounting Screw 01912 M12x40 12 9 81 81 Knife holder mounting screw DIN912 M8x25 12 9 Bed knife complete Bed knife 279x80x30 Mounting Screw DIN912 M12x55 12 9 Lower bed knife adjusting screw for pushing DIN912 M16x35 12 9 Upper bed knife adjusting screw for pushing DIN912 M16x45 12 9 Bed knife adjusting screw for pulling DIN912 M16x60 12 9 Bed knife cover plate Bed knife cover plate left Bed knife cover plate right Cover plate mounting screw DIN912 M12x35 12 9 Ram complete Arm for ram Bearing for arm UCFC212 703 Mounting screw for bearing DIN912 M16x70 12 9 M16x90 12 9 712 4 Spring for scraper YI GB1356 78 n 14 d 2 D 12 H 50 GRN4 605 OAppendix 82 of 93 WHITAKER 800 243 9226 Cover plate for scraper Upper cylinder screw Lower screw for cylinder mounting 716 Mounting screw for cy
67. wenes 000 243 9226 V Belts and Ram Guards V belt and ram guards are screwed to the machine They can be dismounted for installation and maintenance work only when all rotating parts have come to a complete standstill and the machine 15 electronically locked out 1 Ram guarding 2 V belt guarding NOTE The operator must fit and mount the protective devices delivered with the machine according to current legal safety regulations if a machine is delivered without drive motors per request of the customer Safety Markings Safety markings are attached to the machine Should one of these markings becomes detached or is no longer recognizable it must be replaced New safety markings can be ordered through safety signage provides or from the manufacturer Personal Protective Gear Wear close fitting clothing Hair must be pulled back and loose jewellery is prohibited GRN4 605 Chapter 2 Functional Description 26 of 93 SINCE 1945 WHITAKER 800 243 9226 AXCAUTION The following protective gear must be worn when carrying out the following tasks Safety Safety Safety Safety emat Sow goggles Unloading machine x x x 3 Connecting machine x 1 Screen replacement Maintenance of V belts Maintenance of cutting cutters Cutter sharpening X Emergency Stop Button The machine may only be operated with the installed Emergency Stop buttons An
68. www WhitakerBrothers com 850 1200 1500 2000 Medium Duty Single Shaft Shredder Models Covered AMS CMS SMS ESS MMS Part Number MAN EPS 0001 Bulletin Number GRN4 605 Effective August 1 2012 an ACS company WHITAKER 800 243 9226 Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No O Copyright 2013 All rights reserved BJ5 615 ii WHITAKER 800 243 9226 Shipping Info Unpacking and Inspection You should inspect your equipment for possible shipping damage Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In the Event of Shipping Damage According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a claim with the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of La

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