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Sterling SXS Series Paper Shredder User Manual

1. eene nnn 27 4 1 Cu cr 27 4 2 Operation Procedures oe po eee 27 453 LSRUDOOWE essed tees lec eot Eo tote fib toS eu eto Pe Tate re Maman ede E ELM 29 CHAPTER 5 MAINTENANCE eere rennen 32 5 1 Preventative Maintenance Schedule sss 32 5 2 Preventative and Corrective Maintenance esses 33 CHAPTER 6 TROUBLESHOOTING mA 54 29 trodde 54 APPENDIX solistene 59 A 1 Returned Material Policy nce rentre uta Pent eost dee bedende nede 59 A 2 Technical SpeoliCatlons drerit Pee ette nec pae cp iudices dti me tapa tied quant grade 60 A 3 Drawings and Diagrams 5 peat ore et te to ot v De o EO eds aM 60 A 4 SSPARE Parts LUR 67 A 5 Technical ASSISIAHCO o eerie eet derer Sce tese ee ae Pes ER BARI dimme 73 Parts Deparimont si i ET Iud de 73 Service DEDE se ber 73 Sales Deparmen sage 73 Contract Department sv muarkjsersigtuijosteiiuvedamladne dekar paipai 73 BJ5 615 iv Chapter 1 Safety 1 1 BJ5 620 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 engineer The Functional Description section o
2. 3 5 r Q 3 a D Oo e me Q o lt ale o U T g mn oO vo a E J om le A D gt o Q 9 O c z 2 Q Number of Rotor knives 15 11 15 11 1 4 1 4 20 100 20 100 Mounted Knife holders Included Included Hopper for manual conveyor feeding Included Included Hydraulic feeding ram Included Included Two speed Turbo Hydraulic Included Included Included Included Included Included Ampere Meter in control cabinet Included Included Motor of Hydraulic device hp kW Screen Sizes Available in mm Number of Bed Blades Rotor Diameter in mm Rotor speed in rpm Ram comb plate Control panel SPS Appendix 60 of 73 A 3 Drawings and Diagrams NOTE Please refer to the corresponding spare parts lists in the following section Cutter mounting BJ5 620 Appendix 61 of 73 Bed knife fixing 62 of 73 Appendix BJ5 620 Rotor Assembly BJ5 620 63 of 73 BJ5 620 Appendix BJ5 620 65 of 73 Ram scraper BJ5 620 Appendix 66 of 73 SXS 1500 2000 Standard Hydraulic Diagram De m la gt AU AR SS 7 id AN 4 m FFE 263 3H H 17125 Y ae O MRED 15MPa gt MRED S361 XE EE D Y gt Pa 9MP3 ja TE EH Lm a A f U L X lt gt VEN F ix P Py N 12m rec 33m
3. A 1 BJ5 620 Returned Material Policy 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 is subject to 15 75 00 minimum restocking charge All returns are to be shipped prepaid The invoice number and ate or purchase order number and ate must supplied No credit will be issued for material that is not within the manufacture 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 All returns are to be shipped prepaid The invoice number and ate or purchase order number and ate must supplied After inspecting the material a replacement or credit will be given at the manufacturer s discretion if the item is found to be defective in materials or workmanship Purchased components are covered under their specified warranty terms Appendix 59 of 73 A 2 Technical Specifications BJ5 620 Standard Description SxS 1500 100 x 79 Opening in mm 2540 x 1620 2540 x 2020 Chamber in mm 1500 x 1490 1500 x 1900 Standard motor in hp kW 2 Mw 5 29 5 750
4. v 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 is fixed at the end position with tightened mounting screws v The cutting chamber is free of foreign matter lt S The machine and hopper doors are closed v All safety devices including those of the installed 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 4 2 Operation Procedures Manual In feed of Material DANGER Rotating Knives Can cause serious cutting and crushing injuries that could result 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 BJ5 620 Operation 27 of 73 Throw the 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 DANGER Do not climb into the in feed hopper while operating the machine Death will result Emptying the Screen 1 p
5. SXS Extreme Duty Shredder SXS 1500 amp 2000 Part Number EXS 0003 S Bulletin Number BJ5 620 Effective 9 30 2008 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 Copyright 2008 All rights reserved Shipping Info BJ5 615 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 Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise customer serv
6. Tighten the cutter mounting bolts using a torque wrench NOTE The required torque for the cutter holder mounting bolts is 83 Nm also see the table under Replacing and checking the cutting knife mountings WARNING Danger of cutting caused by sharp knives at all times even when rotor is at standstill Serious Injury especially to the hands and fingers can occur Wear protective gloves BJ5 620 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 bolt DIN912 M16x50 12 9 and the washer DIN433 17 300HV Screw in the mounting screws and tighten lightly first Make sure the cutter fits planar in the seat Tighten the cutter mounting bolts using a torque wrench NOTE The required torque for all cutter mounting bolts is 355 Nm also see the table under Replacing and checking the cutting cutter mountings Check if the cutting gap is correct and if the cutting knives 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 grinding 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
7. r ec BJ5 620 Appendix 67 of 73 A 4 Spare Parts List SXS 1500 Pos Pc Description Standard 100 Machine complete 1 1 FER SSS 200 Screen complete Hydraulic 202 6 Screen support screws DIN912 M16x25 8 8 ee te a 303 304 305 kB 306 Sealing DIN3760 D200 x 230 x 15 le PE a as 400 401 Motor 75 kW 460V 60Hz right 1 Motor 75 kW 460V 60Hz left 402 2 _ Gear pulley SPC375 5 Gear pulley taper bush TB 3535 48 404 1 2 0 405 V Belt SPC3250 406 408 BJ5 620 Appendix 68 of 73 Rubber bush plate bolts DIN933 M20x65 12 9 ENGS Ke Aili FER ES FEE 600 1 Bed knife complete Bed knife 399x110x30 602 8 Mounting Bolt DIN 912 M16x60 12 9 FET Bed knife adjusting bolt for pushing DIN 912 M16x45 12 9 604 EIET Bed knife adjusting bolt for pulling DIN912 M16x65 12 9 m 703 8 Mounting bolt for bearing DIN912 M16x80 12 9 705 711 Cover plate for scraper Fiscal cae Mounting bolt for cylinder bolt DIN912 M16x45 12 9 kl EEG 800 Hydraulic 803 Piping 0 0 0 0 804 Connectors 1 1 BJ5 620 Appendix 69 of 73 Oil filter SP 10 ees ae FETE 900 _ Electricalparts pp SXS 2000 Pos Pc Description Standard 100
8. Empty the screen WARNING 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 suction device BJ5 620 Maintenance 33 of 73 9 Remove clinging shredded material residue using a suitable wooden scraper 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 designed so a replacement is only necessary in exceptional cases Dismounting and mounting of 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 design so a replacement is necessary only after a crash i e a hammer fall inside Dismounting and mounting of the rotor requires specialist knowledge and a careful working method Contact the Service Department for assistance Dismounting the Rotor Dismount the V belt cover Dismount the V belts Dismount the gearbox Remove the screen Remove the rotor mounting slot cover plates from the housing Screw in hooks on both shaft ends
9. N o I m I OQ o BENE 8 78 n 12 d 2 D 1 713 1 Cover plate for scraper 2 Upper cylinder bolt 715 Lower bolt for cylinder fixing si 406 408 ea 420 421 422 423 a 500 505 aa 600 601 603 FERES 700 702 706 707 1 708 709 710 7i 73 715 Appendix 71 of 73 716 Fixing bolt for cylinder bolt DIN912 M16x45 12 9 Grease nipple GB1152 89 M8x1 Ho gp Tte ee 800 Hydraulic Hydraulic O Cylinder for pusher 125 x 63 x 1000 Hydraulic unit SHC 406 A Piping ooo O 803 Piping 804 Connectors 1 1 Set of sealing for pusher cylinder Oil filter SP 10 FF EN CSS 900 Electrical parts p ee at a SS Hydraulic Unit Spare Parts List Pos Description Standard Pc Supplier 1 Suction filter MF 06 1 CLC 2 Suction filter MF 08 1 CLC 3 Electric motor 20HPX4P straight system 380V 1 Qunce 4 Gear pump PVL12 12 33 1 Xinhong 5 Oil cooler JC YL AH1012 1 6 Check valve CRG 03 1 10 1 CLC 7 Check valve CRG 03 1 10 1 7Ocean 8 Solenoid control relief valve DBW10 22AL 2 DC DN MSL 02P 1 7Ocean 9 Solenoid control relief valve BSG 03 1PN 2 DC24 DN10 MSL 02P 1 7Ocean 10 Pressure valve 2 1 2 25Mpa 1 7Ocean 11 Solenoid valve DG07 E1 521C T DC24 DN 71 12 Throttle and check valve PT 03 2 FTB 13 Throttle and ch
10. NOTE Although it is possible to reach the knives by climbing into the feeding chamber it is recommended to access the knives through the front side door BJ5 620 Maintenance 46 of 73 5 Clean the hexagon head socket of the knife mounting bolts 2 and the cover plates mounting bolts 6 Loosen the cover plate mounting bolts using a high quality Allen key 10 mm Knock the Allen key lightly with a hammer to loosen if necessary 7 Take out the bolts and cover plates 8 Loosen the knife adjusting screws for pulling and take them out 9 Loosen the knife mounting bolts with Allen key 10 mm Use a hammer to lightly knock key if necessary 10 Take out the knife mounting bolt and knife WARNING Danger of cutting caused by sharp knives at all times even when rotor is at standstill Serious Injury especially to the hands and fingers can occur Wear protective gloves Bed knife Knife mounting screws Knife holder Cover plates Knife adjusting screw for pushing Knife adjusting screw for pulling Cover plate mounting screws 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 BJ5 620 Maintenance 47 of 73 Put in the cutter holder mounting bolts DIN912 M10x30 12 9 and put some Loctite on them Make sure that the cutter holder fits properly
11. Remove the bearing housing fixing bolt poo b Qvo Oo cde 1 ANKER 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 BJ5 620 Maintenance 34 of 73 Mounting the Rotor n2 SO 100 Sy SONS cone EG Before starting clean the bearing seat surfaces and check the key Lift the rotor using suitable lifting and stopping equipment and place carefully into the bearing seats Attach the bearing housing Pos to the bearing seats using screws Put the gear onto the rotor axis Put back the rotor mounting slot cover plates Put in the screen Pull on V belts and adjust the V belt tension force Attach the V belt Carry out a test run NOTE If the spare rotor is delivered without bearings the bearings MUST be mounted first Replacing the Main Bearings BJ5 620 The main bearings of the machine are designed so a bearing replacement is necessary only 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 is required for dismounting and mounting the bearings Dismounting the
12. 73 2 4 Safety Features Protective Devices CAUTION 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 Machine and Hopper Doors 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 BJ5 620 Chapter 2 Functional Description 19 of 73 V Belts and Ram Guards V belt and ram guards are bolted to the machine They can be dismounted for installation and maintenance work when all rotating parts have come to a complete standstill and the machine is 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 the current legal safety regulations if the machine is delivered without drive motors upon customer request 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 providers or from the manufacturer Personal Protective Gear Wear close fitting clothing Hair must be pulled back and loose fitting jewelry is prohibited See table below fo
13. Checking the Condition of the Cutters WARNING Danger of cutting caused by sharp knives at all times even when rotor is at standstill Serious Injury especially to the hands and fingers can occur Wear protective gloves The cutting knives become blunt after a certain number of operation hours they should be checked regularly Using blunt knives can affect the efficiency and performance of the machine in the following ways e Decreased shredding capacity e Increased current consumption of the drive motor e nexact cut e Overheating of the shredded material Maintenance 44 of 73 1 Cutter screw 3 Cutter holder 4 Cutter holder Dismounting the Cutters te cae a p oes Switch OFF the shredder at the main switch 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 Cutter mounting mounting screws BJ5 620 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 Loosen the bolt 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 Hold
14. 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 Care 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 BJ5 620 Chapter 1 Safety 10 of 73 Chapter 2 Functional Description 2 1 Models Covered in This Manual The models included in this manual are the Sterling SXS 1500 and 2000 Extreme Duty Shredders The SXS Extreme Duty Shredders are designed for processing plastic waste for reclamation and recycling large extruder purgings large reject parts trip scraps baled or loose film synthetic fiber wood processing scrap medical waste cardboard paper and carpet 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 staples and nails The guarantee does not cover any damage to
15. Main Bearings DO pos Solo ON UI Ex tar qiue 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 Remove the bearing housing fixing bolt Maintenance 35 of 73 10 11 12 13 14 Carefully lift out the complete rotor using suitable lifting and stopping equipment Lay the rotor down in a safe location Suitable for this are timber beams of appropriate size Loosen the mounting screws on the bearings cover Pull the bearing housing off using a pulling off device Pull the bearing off the rotor axis using a pulling off device Mounting the Main Bearings Aa 5 6 T 8 9 10 11 12 NOTE e The roller bodies will be damaged unless the mounting forces engage into inner ring e 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 e 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 BJ5 620 Before mounting clean the bearing surfaces and the shaft surfaces thoro
16. Torque arm bolt Washer disc Rotor cover Rubber bush plate bolts DIN933 M20x65 12 9 418 419 1 420 421 422 423 Washer DIN433 20 Spring washer DIN127 A 20 Nut DIN934 M20 10 Torque arm complete 90kW Rotor knife 60x60x30 Rotor knife fixing Bolt DIN 912 M16x50 12 9 Washer DIN433 17 Rotor knife holder Knife holder fixing bolt DIN912 M10x30 12 9 12 12 12 2 500 1 E knife rotor 0660x1900 96 96 96 96 192 505 192 Stator knife complete 601 Stator knife 399x110x30 10 Fixing Bolt DIN 912 M16x60 12 9 Stator knife adjusting bolt for pushing DIN 912 M16x45 12 9 Stator knife cover plate Stator knife cover plate right Stator knife cover plate left 2 Cover plate fixing bolt DIN912 M12x30 12 9 20 EA Stator knife adjusting bolt for pulling 2 2 2 2 2 2 2 2 2 2 2 2 2 2 12 12 12 2 1 10 0 1 2 2 2 1 2 2 2 2 2 1 4 1 2 A o DIN912 M16x65 12 9 700 Pusher complete Arm for pusher Bearing for arm HCFC214 Fixing bolt for bearing DIN912 M16x80 12 9 Bolt for arm aa ee 702 2 8 En 1 Pusher 706 12 707 12 708 12 709 12 710 12 711 1 Fixing bolt pusher arm DIN933 M24x120 12 9 1 Nut DIN934 M24 10 1 Washer DIN 433 24 300HV 1 Spring washer DIN127 A 24 1 Fixing pin DIN94 2 5x32 Scraper n hen O UJ hurt Co ol
17. component without written notice from the factory Remaining Risks The machine is constructed so that you are able to operate it 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 Consequences Preventative Measures Danger of crushing by heavy parts falling down over Unloading and transporting the machine and or components Serious injury Wear personal protective gear Follow safety instructions in manual Cutting caused by sharp knives even when rotor is stationary Knife replacement knife setting knife sharpening and other maintenance work Serious injury particularly to hands and fingers Wear personal protective gear Follow safety instructions in manual Crushing when opening closing maintenance doors on front side of machine Tripping over cables and other objects Maintenance work All activities Serious injury Serious injury Make sure no persons are in the danger area while closing the door Lay cables in accordance with regulations Keep work station clean and tidy Crushing cutting amputation caused by run down of the rotor Maintenance work Serious injury or death Maintenance doors must a
18. cutters and bed knives see mounting the stator knives NOTE The cutting knives in particular the rotor knives should only be sharpened or replaced in sets There is a danger of balance error if a combination of cutters from different knife sets is used WARNING Danger of cutting caused by sharp knives 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 SXS series shredder do not have to be adjusted All adjustments have to be done with the bed knives To simplify knife setting and shorten standstill periods when replacing knives bed knives have 4 adjusting screws 2 each for pushing and pulling the knife Having several knife sets helps to avoid standstill periods Correct and careful setting of the gap between the cutters and bed knives cutting gap is important for productive capacity of the shredder Factors for the size of the knife gap are the size of the rotor the design of the rotor and the material to be ground Maintenance 50 of 73 1 2 3 4 5 6 7 Bed knife Knife mounting screws Knife holder Cover plates Knife adjusting screw for pushing Knife adjusting screw for pulling Cover plate mounting screws BJ5 620 1 2 3 4 5 Remove old knives see Dismounting the bed knives Insert sharp knife or turn old knife Put in the knife adjusting bolts
19. freely accessible from all sides There must be sufficient room for operating and service personnel Spatial requirements Refer to the Drawings and Diagrams in the Appendix for machine dimensions All hinged parts must be able to be opened completely The site is a vibration free environment The site has sufficient lighting The machine may not be exposed to direct radiation caused by radiators or the sun e Room temperature 41 to 104 F 45 to 40 C Relative atmospheric 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 these at the site of application in accordance with the Assembly Drawing This is the only way to guarantee there are sufficient piping parts tubing and cable connections and that the lin
20. 6 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 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 of the machine The same type of oil must be used when adding hydraulic oil If the same type of oil is 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 is necessary in preventing the valves from gumming Maintenance 52 of 73 Hydraulic liquid recommendation Designation to DIN 51 524 HLP 32 FG Ambient temperature 7 to 70 ber EE Supplier Name of the oil ee ee Aral Vitam HF 32 BP Energol HLP D 32 BP Energol HLP 32 BP Energol SHF 32 Hydrelf 32 HLPD Oel 32 Renolin B 10 Mobil DTE 24 Mobil DTE 17 Druck l HLP 32 C Hydraulik l HLPD 32 TEXACO Rando Oil HD A 32 Rando Oil HD AZ 32 Alcor Oil DD 32 BJ5 620 Maintenance 53 of 73 Chapter 6 Troubleshooting 6 1 BJ5 620 Introduction The utmost in safety precautions should be observed at all times when working on or
21. ALL SAFETY GUARDS AND COVERS are securely and properly fastened prior to resuming machine operation All fasteners must be in place and properly tightened ANY SHORTCUTS MAY RESULT IN INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT NEVER wear 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 is in operation or open for maintenance NEVER stand on the granulator when it is in operation Chapter 1 Safety 7 of 73 M 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 M 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 M ALWAYS DISCONNECT AND LOCKOUT the main electrical power to the granulator before performing any service M 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 M NEVER modify the machine configuration or any individual
22. Machinecomplete EE EBAEANMEFCKHNENUEECEE12 200 Screen complete Hydraulic 201 202 6 Screen support screws DIN912 M16x25 8 8 203 2 Screeadjstngbot 204 1 Screensuppot S O 205 2 Cylinder for screen support opening 63x 35x155 200 4 WasherDINI25 A 13 207 4 LockwasherDIN 127 12 page FEE Eee 300 2 Bearing 1 1 O 301 2 Bearing housing SN236 A AIN N MJIN 302 2 _ Bearing 22236 W33 N 303 304 305 3 Bearing Cover A Bearing Cover B a ee ee l 306 307 308 2 Sleeve gt o y 310 2 Washerdisc Z o y yY ER eg 40 Drive y O 401 Motor 75 kW 460V 60Hz right Motor 75 kW 460V 60Hz left Motor 90 kW 460V 60Hz right Motor 90 kW 460V 60Hz left 402 2 Gear pulley SPC375 5 Gear pulley SPC400 6 403 2 Gear pulley taper bush TB 3535 48 Gear pulley taper bush TB 4040 50 404 OP V Belt SPC3250 BJ5 620 Appendix 70 of 73 N BJ5 620 Motor pulley SPC315 5 Motor pulley SPC335 6 Motor pulley taper bush TB 3535 75 Motor pulley taper bush TB 4040 75 Key Motor shaft Pulley cover support Base frame for motor EE I2 NEG EA 2 Gearbox SEW MC3PLHF07 SD i 23 2 2 2 EE NE ES 2 za 407 408 Torque arm plate Rubber bush plate Rubber bush 116x68x100 Copper bush 68x63x100
23. RNING Danger of cutting caused by sharp knives at all times even when rotor is at standstill Serious Injury especially to the hands and fingers can occur Wear protective gloves Maintenance 49 of 73 BJ5 620 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 fix them with the long hole 1 Dismount the cutters and bed knives see dismounting the cutters 2 Sharpen the cutters and bed knives NOTE A specialist in accordance with the sharpening plan using particular care should uniformly sharpen the cutting knives 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 number of possibilities for sharpening is unnecessarily reduced For the sharpening process use soft grinding wheels Quality 40 H or 46 K Knives which have grinding cracks are not to be reused due to danger of breakage during operation 3 Whet the cutting edges of the cutting knives using a whetstone NOTE The service life of the cutting knives can be increased by taking this measure 4 Set the cutters and bed knives see setting the cutting knives 5 Mount the
24. V belt by shifting the drive motor Put new V belt in Tension the V belt see Checking the Tension Force of the V belt Mount the V belt cover Maintenance 43 of 73 BJ5 620 Working on the Cutting Knives Correctly setting and mounting the cutting knives is important when working with shredders to ensure efficient and economic function Replacing and Checking the Cutting Knife Mountings Certain machine parts are subject to stress during operation as a result of vibrations that can lead to loosening of the screw connections 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 knife fixing bolts is 355 Nm NOTE You can find out the required torque from the following table Tightening capacity decreases for screws when loosened and tightened again several times New screws of the same material quality must replace the cutting knife mounting screws after they have been loosened and tightened several times Torque Bolt type Grade 8 8 Grade 10 9 Grade 12 9 Nm Ibf ft Nm Ibf ft Nm Ibf 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
25. a danger of balance error if a combination of rotor knives from different cutter sets is used Cutters are reversible and have four symmetrical cutting edges This makes it possible to turn the knives and only to sharpen after every fourth cutter change Maintenance 48 of 73 BJ5 620 Mounting the Bed Knives Bgm eh 10 11 12 Clean the knife supporting surface and the holes on the knife holder Insert sharp knife or turn old knife Put in the knife adjusting bolts and adjust them roughly Put in the knife mounting bolts DIN912 M16x60 12 9 and tighten lightly first Adjust the gap between cutter and bed knife to 0 8 1 0 mm Tighten the knife mounting bolts using a torque wrench NOTE The required torque for all knife mounting bolts is 355 Nm also see the table under Replacing and checking the cutting knife mountings Turn the rotor by hand Check whether the cutting gap is correct and make sure the cutting knives do not collide as the rotor turns Put back the cover plates and mount them with the bolts Remove tools and other objects from the cutting chamber Put screen back and mount 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 Cutters are reversible and have four symmetrical cutting edges This makes it possible to turn the knives and only to sharpen after every fourth knife change WA
26. and adjust them roughly Put in the knife mounting bolts and tighten lightly first Adjust the gap between cutters and bed knife to 0 8 1 0 mm using a calibre gauge Tighten the knife mounting bolts using a torque wrench NOTE The required torque for all knife mounting bolts is 355 Nm see the table under Replacing and checking the cutting knife mountings 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 knife gap 0 8 mm 1 mm Fix the knife cover plates Maintenance 5 of 73 BJ5 620 Transporting and Storing the Cutting Knives WARNING e Danger of cutting caused by sharp knives e Serious injury in particular to hands and fingers can result e Wear protective gloves e Only transport and store the packaged cutting knives e Grease the cutting knives well so they do not rust Protect the cutting edges with doubled cardboard and use adhesive tape to safeguard the knives against slipping out of the sides of the sheath e De grease the cutting knives so that they can be gripped safely after unpacking Hydraulic Maintenance 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 Recommended oils include of the type DIN 51524 HLP 32 for areas with temperatures below 32 F 0 C in the winter and HLP 46 for temperatures of around 8
27. aring 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 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 shredded material All shredded 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 See below BJ5 620 Chapter 2 Functional Description 16 of 73 1 Hydraulic cylinder 2 Screen support 3 Screen Discharge of Shredded Material Normally the shredded material will be discharged onto a conveyor belt Options include a discharge with blower or with a screw conveyor Conveyor belt discharge BJ5 620 Chapter 2 Functional Description 17 of 73 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 The ram can be moved by hand on the control panel when run in manual mode Hydraulic cylinder Bearing Ram Arm Ram Hydraulic unit GEGEE GEGE 1 Serrated ram front plate 2 Rotor BJ5 620 Chapter 2 Functional Description 18 of
28. 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 is 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 provide 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 Troubleshooting 54 of 73 Problem Possible Cause Possible Remedy Machine blocks or switches itself off Too much feed material Reduce grinding material in feed Screen blocked V belts slip Clean screen check condition select larger screen perforation if necessa
29. artment Call 262 641 8610 Monday Friday 8am 5pm CST Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations Sterling Inc 2900 S 160 Street New Berlin WI 53151 WWW sterlco com BJ5 620 Appendix 73 of 73
30. belts by using tensioning screws The V belt pulley is attached to the motor shaft with a special tensioning element Drive motor NOTE Please observe the operation manual from the manufacturer Rotor Cutters and Bed Knives Rotor cutters bed knives e The material is shredded between the cutters assembled on the rotor and the bed knives that are mounted in a fixed position in the machine lower section e All rotors are equipped with square cutters These cutters make light work of the heaviest pieces NOTE The knives have four corners so they can be easily turned once a corner has worn out e The 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 BJ5 620 Chapter 2 Functional Description 14 of 73 1 Rotor cutter 2 Screen support hydraulic 3 Bed knife 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 are 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 BJ5 620 Chapter 2 Functional Description 15 of 73 An optional feature is a water cooling system for the rotor used for special applications Be
31. c es Die du he ed ON BJ5 620 Switch off the shredder at the main switch Safeguard main switch using a padlock Open the machine door Safeguard 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 Close the machine Shredder can be started again 1 Hydraulic cylinder 2 Screen support 3 Screen 4 Rotor Operation 28 of 73 Hydraulic Set up Connect hydraulic pipes to the machine make sure the upper hydraulic pipe is connected to the upper pipe at the machine Connect the wires for the motor and magnetic valves Fill the oil tank with hydraulic oil No 46 or No 32 until the maximum is reached and mark the level indicated by the gauge Run motor to see whether the running direction is correct facing the motor blade the motor should run clockwise if the direction is not correct change the position of 2 of the 3 electrical wires Run motor operate the magnetic valve to check the function and wiring connections With the magnetic valve 11 YA1 current switch on set the sequence valve 9 pressure to 30 bar With the magnetic valves 11 YA2 and 24 YA6 current switches on set the spillover valve 8 pressure to 110 bar NOTE Refer to the corresponding drawing on th
32. check knife 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 for foreign matter Check that the Emergency Stop buttons are unlocked Check all safety devices for proper functioning Installation 25 of 73 BJ5 620 s 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 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 material can lead to overload of the machine Check the temperature of the ground material if necessary Monitor the ammeter This displays the present current consumption and gives information on the load of the machine Installation 26 of 73 Chapter 4 Operation 4 1 Start up WARNING No persons should operate the machine until they have read and understand all parts of the operation manual Machine Check Before Switching Machine ON
33. e in position desired 4 Tighten screws see note alternately and evenly until all 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 BJ5 620 Maintenance 7060 to 10085 120100 FOR REMOVAL ONLY 1 Remove all screws 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 amp 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 40 of 73 Tightening Torque of the Screws Refer to the table below element Type ert P TET TEE torque in Nm REED Size BSW ee a a ee SEE 3020 190 a e 320900 J0 er E 35355 de 18 1 Replacing the Screen The condition of the screen
34. e next page refer to Chapter 6 for BJ5 620 Hydraulic troubleshooting Operation 29 of 73 Figure Hydraulic Set up 4 OD S g lt 8 N F1E 763 ih 4 H MA 11125 4 038 R XE ER 2 15NPa RC BREED Y 9MPa E MU tt A is X S we W wa N 12m rec BJ5 620 MAREE gt MPa 33m rec Operation 30 of 73 4 3 Shut down Switch OFF Machine 1 Switch OFF the material in feed device accessories 2 Wait until the remaining material has been shredded and then switch OFF the shredder main switch to 0 3 Switch OFF the material discharge device BJ5 620 Operation 31 of 73 Chapter 5 Maintenance 5 1 Preventative Maintenance Schedule Only trained and specialized personnel should carry out maintenance work Maintenance Plan WARNING e Danger caused by electrical voltage and starting the machine during maintenance work Death can result e ALWAYS turn main switch to 0 safeguard using a 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 e Check protective devices e Check cutting knife mountings e Check condition of cutting knives Perform the following after every 40 operation hours e Check V belt tension force and V belt condition e Ch
35. eck all screws of the machine for a tight fit e Check wearing parts e Check hydraulic oil level and consistence Per form the following after every 2000 operation hours e Change hydraulic oil e Check gearbox oil level Yearly maintenance e 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 BJ5 620 Maintenance 32 of 73 5 2 Preventative and Corrective Maintenance Checking the Protective Devices Check the safety devices for e Stipulated condition e Stipulated location e Safe mounting e Stipulated function WARNING Danger due to non functioning protective devices can cause serious injury or death e Eliminate all defects before operating the machine e If defects occur during operation stop the machine immediately and eliminate the defects e Do NOT change or remove any protective devices Do NOT put any protective devices out of action by modifying them Cleaning the Machine WARNING Danger of cutting caused by sharp cutting knives 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 machine and hopper doors Safeguard the machine and hopper doors Remove the screen ON RD
36. eck valve MTC 04 B O 10 1 7Ocean 14 Pressure switch PS 02 3 10 1 7Ocean 15 Fluid level LS 3 1 CLC 16 Filler breather AB 1163 1 CLC 17 Return suction filter SP 10 1 7Ocean 18 Tank 160 1 7Ocean 19 Solenoid valve DSD G02 6C DC24 31 1 7Ocean 20 Modular pilot check valve MPC 02 W1 10 1 7Ocean BJ5 620 Appendix 72 of 73 A 5 Technical Assistance Parts Department Call toll free 7am 5pm CST 800 423 3183 or call 262 641 8610 Fax 262 641 8653 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 Service Department Call toll free 8am 5pm CST 800 423 3183 or call 262 641 8610 Emergencies after 5pm CST call B47 439 5655 We have a qualified service department ready to help Service contracts are available for most of our products Sales Department Call 262 641 8610 Monday Friday 8am 5pm CST 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 Contract Dep
37. ed of at authorized drop off points Transportation WARNING Suspended load e Falling loads can cause serious injury or death Only use a crane or forklift that can withstand the weight and dimension of the load e Use suitable stopping means and pay attention to gravity center location e Do NOT step under the suspended load e Wear protective helmet in addition to basic protective gear BJ5 615 iii Table of Contents CHAPTER T SAFER Vunnet 5 11 Howto Use This Manual sedanen dets e eoe pp Rad Fe Er ERR ERR dea aue 5 Safety Symbols Used in this Manual sse 5 1 2 General Safety Regulations dnce treu eine hag ved poene dead 6 Ete lel REI I UU UU TR 6 14 Marnirigs nd Precaulloris aa teneret estes duree Dedi pa e eso onn aude 7 CHAPTER 2 FUNCTIONAL DESCRIPTION 11 2 1 Models Covered in This Manual eseseessseeseeee ensem 11 2 2 General DESChPUOM eI 11 2 3 Typical Features and Components sss enne 12 2 4 Satety Features exe S s E nuntius 19 CHAPTER 3 INSTALLATION eeeeee ee 22 3 1 Unerating the Equipment preter ken 22 d 2 Electrical Conrieetloris oc e e e eee o reatu e Ea p pa Mia ER E I Me eu Lut 23 359 Initial Start up does aede tt th perpeti tech der dee aped ede t ea rate ER dax da 25 CHAPTER 4 OPERATION
38. ers Ole Ver VOD te Switch OFF the shredder at the main switch 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 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 Maintenance 45 of 73 6 Clean the hexagon head socket of the cutter mounting screw 2 7 Loosen the bolt using a high quality Allen key 10 mm If necessary knock the Allen key lightly with a hammer to loosen it 8 Take out the cutter mounting screw the washer and the cutter 9 Clean the hexagon head socket of the knife holder fixing bolts 4 10 Loose the bolt using a high quality Allen key 6 mm Knock the Allen key lightly with a hammer to loose it if necessary 11 Take out the cutter holder mounting screws 4 12 Remove the cutter holder with the delivered Extractor NOTE See drawing in Dismounting the rotor knives WARNING Danger of cutting caused by sharp knives 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 Knives 1 Switch OFF the shredder at the main switch 2 Safeguard main switch using a padlock 3 Open the hopper door 4 Safeguard the hopper door
39. evice Current relay switches off Correct setting BJ5 620 Troubleshooting 57 of 73 Hydraulic Troubleshooting Problem Possible Cause Possible Remedy Motor doesn t work Electric source Correct wire connection Motor damage Replace motor Oil pump doesn t work Motor not functioning Correct wire connection Pump damage Replace pump Oil pump noise Filter jam Clean the filter Hydraulic oil is too thick Change hydraulic oil Hydraulic oil has bad quality Change hydraulic oil Pipe is leaking Tighten pipe connectors Pump damage Change pump Motor and pump misalignment Working pressure is abnormal Spillover valve and sequence valve jam Clean spillover and sequence valves Pump damage Replace pump Pressure maintain is abnormal Sealing is broken Change sealing Pipe is leaking Check and solve leak Single direction valve jam Clean the valve Work is abnormal Pressure is abnormal Clean spillover valve and sequence valve Magnetic valve is abnormal If the valve jams clean it if it is broken replace it Electrical problem Check and change the broken electrical parts High oil temperature Sequence valve pressure is too high Correctly set it to 30 bar BJ5 620 Troubleshooting 58 of 73 Appendix
40. fic 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 DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation or practice that if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice that if not avoided may result in minor or moderate injury or in property damage Chapter 1 Safety 5 of 73 1 2 General Safety Regulations This machine uses knives 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 guard
41. g surfaces are well greased e 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 e 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 BJ5 620 Maintenance 37 of 73 Refilling lubricant The grease reaches through the circulating grooves and bores via lubrication nipples into the interior of the bearing The greasing quantity is 13 to 22 lbs 60 to 100 g roller bearing grease F3 per bearing Grease Nipple Replacing Lubricant Renewing the lubricant between intervals is 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 Clean the bearing carefully using petroleum ether 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 Fil
42. g the distance between roller centres at a right angle to the V belt Force required for 1m distance between roller centres and 16mm sag Profile section Efficiency of xin P in Newton mm 4 Compare determined value with the value in the above table If the value lies below the lowest tolerance limit the V belt must be re tensioned If the value lies above the highest tolerance limit the V belt must be relaxed BJ5 620 Maintenance 42 of 73 a Distance between roller centers b Sag F Force direction BJ5 620 Re tensioning and relaxing the V belt Enlarging or decreasing the centre distance A tensions or relaxes the V belt 1 2 3 5 Loosen the tensioning screw Shift the drive motor as required onto the sliding rails Lock the drive motor into new position using tensioning screws so that the motor shaft is parallel to the rotor axis and aligned Check the tension force of the V belt see Checking the Tension Force of the V belt Mount the V belt cover Checking V belt condition replacing V belt CAUTION Danger of pulling into machine caused by running V belts Hair jewelry etc can be pulled into machine without proper precaution resulting in serious injury NEVER dismount the V belt cover and window during operation A porous or ripped V belt must be replaced as follows 1 Qv wu cR SD Remove the V belt cover Loosen the front and rear tensioning screw Relax the
43. ice 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 M Packing list M Operating and Installation packet M Electrical schematic and panel layout drawings M 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 parts and service department immediately at 262 641 6410 Have the order number and item number available Hold the items until you receive shipping instructions Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department il Storage Disposal Transportation Storage Clean the machine see Cleaning the Machine Preserve all polished metal surfaces using a suitable rust preventing agent Store the machine in an dry and 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 i e regional and national Water Conservation Bureau and Environmental Protection Agencies Only deposit the material to be dispos
44. king places match Installation 22 of 73 WARNING SUSPENDED LOAD e Falling loads can cause serious injury or death e Only use acrane or forklift suitable for the weight and the dimensions of the load e Use suitable stopping equipment and pay attention to the gravity center location e DO NOT step under the suspended load e Wear a safety helmet in addition to basic protective gear WARNING OVERTURNING OR FALLING MACHINE e Serious injury or death can result e 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 using 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 3 2 Electrical Connections BJ5 620 CAUTION Electrical connections should only be made by a qualified electrician WARNING DANGEROUS VOLTAGE Touching live parts can lead to serious injury or death 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 tolera
45. l bearing with approved lubricant refer to the List of Lubricants BJ5 620 Maintenance 38 of 73 List of Recommended Lubricants Country of Manufacturer Manufacturer Roller Bearing Grease ARAL ARL Grease HL 3 BP BP ENERGREASE LS 3 CASTROL CASTROL SPHEEROL AP 3 ESSO Beacon 3 FUCHS FUCHS Grease 1200 FUCHS Grease FWA 220 SHELL SHELL Alvania Grease 3 MOBIL OIL MOBILUX 3 WISURA WISURA Liba L 3 Zeller Gmelin ZET GE Grease M 50 FAG FAG L 71 ANTAR ROLEXA Holland Beverol Beverol Multi Purpose Grease Italy Agip AGIP Grease 33 FD Swede NYNAS Nynas FI 3 42 BJ5 620 Maintenance 39 of 73 Mounting and Dismounting TAPER LOCK Tensioning Element The motor 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 locat
46. lways be tightly locked during operation 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 BJ5 620 Chapter 1 Safety 8 of 73 Type of Danger Pulling in caused by running V belts Activity All activities Possible Consequences Serious injury can result from hair jewelry etc being pulled into the machine Preventative Measures e Never dismount V belt protection and window Direct indirect contact with live parts in terminal box Maintenance work start up Serious injury or death e Only trained electricians may carry out all work on the electrical 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 e 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 e Faulty electrical components must be replaced immediately e If faults occur in the electrical energy supply switch machine off immediately e The terminal box must be locked during operation Before opening the terminal box switch too off O Failure of Emergency All activities Serious injury or death e t must be guaranteed that failure Stop function of an Emergency Stop butto
47. 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 the shredding material when Screen holes too fine overheating of the material can occur Screen holes too course shredded material can have larger pieces that are unacceptable Hydraulic Screen Support optional Switch OFF the shredder at the main switch Safeguard main switch using a padlock Open the machine door Safeguard the machine door ye oe ces Pivot the screen support downwards by pushing the button screen open on the control box OY Remove the screen 7 Puta new screen into the screen support BJ5 620 Maintenance 41 of 73 8 Pivot the screen support into the working position and fasten using mounting screws 9 Close the machine door 10 Shredder can be started again Please refer to image from Emptying the Screen 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 of the V belts Checking the tension force of the V belt 1 Remove the V belt cover 2 Measure the distance between the roller centres Determine the belt sag force F for each belt at 16 mm sag if sag b is equal to 1 m distance between roller centres Do this by measurin
48. n is displayed and leads to an immediate stop Fire explosion caused Grinding Serious injury or death e Only grind material which by throwing corresponds to the agreed dangerous objects customer specific specifications in i e spray cans into all points the shredder Damage to hearing All activities Diminished hearing e Reduce noise emissions by taking headaches impaired suitable measures balance deterioration of concentration e Wear ear protection 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 e Check the cutting knife mountings cutting knife regularly according to the mountings caused by instructions in the manual vibration Inhalation of grinding All activities Diseases of the e Mount a suitable air suction device dust BJ5 620 respiratory tract etc Chapter 1 Safety and wear breathing equipment if necessary e When cleaning the machine use suction do not blow out grinding dust 9 of 73 Type of Danger Crushing cutting amputation caused by manipulation of protective devices Activity All activities Possible Consequences Serious injury or death Preventative Measures e Never make the protective devices ineffective e Check the protective devices regularly for proper function according to the manual s specifications
49. nce 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 is determined according to the rated capacity of the units Installation 23 of 73 BJ5 620 WARNING 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 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 The connecting cables between the control panel and the machine mus
50. nity 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 outlined All caution warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor BJ5 620 Chapter 1 Safety 6 of 73 1 4 BJ5 620 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 M M 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 dimen
51. nsulting the service department Material rubs against the housing wall Fit anti winding device Insufficient cooling Fit rotor cooling Unusual vibrations Rotor out of balance Weight knives balance rotor Bearing damage Check bearings and replace if necessary Anti vibration pads defective Check mounting pads and replace if necessary Extreme cutter wear Bearing damage Check bearings and replace if necessary Knife finish Check knife and sharpen or replace if necessary Wrong cutting gap Check cutting gap and set following the instructions in this manual Foreign matter Fit feed device with metal detector Bearings too hot Too much grease in bearing Reduce amount of grease V belts too tight Rubbing on housing sealing ring Bearing damage Reduce tension Check sealing ring and oil or replace Check bearings and replace if necessary No grease in bearing Lubricate bearing Too many fines in shredded material Screen worn Renew screen possibly using manganese steel Unsuitable screen perforation Replace screen after consulting the service department BJ5 620 Troubleshooting 56 of 73 Problem Possible Cause Possible Remedy Cutting gap alters during operation Screen damage Knife mounting screws not tight Re tighten using torque wrench foll
52. owing the instructions in this manual Screw fatigue Fit new screws Washers deformed Insert new washers Knife holder surface deformed Insert new knife holders Supporting surfaces not clean Threads in housing worn Screen wrongly inserted Clean and re dust supporting surfaces Fit new bushes in housing Fit screen correctly Screen support buckled Replace screen support Wrong screen radius Correct it Shredder does not start Limit switches not activated Check position of limit switch and correct Main and control fuses Replace fuse Feed device not connected Switch on in sequence Material jam Empty shredder before switching ON Star delta connection Correct wiring on motor Motor protection switches off Check motor relay for correct setting and increase if necessary Star delta time relay Correct time Shredder blocks when under load Feed starts too early Start feed only after switch over from star to delta Limit switch loose or wrongly set Re position and tighten limit switch Fuse defective e Replace fuse e Fit larger fuse only after consulting the service department Motor fuse switches off red indicator e Reduce feed quantity of the grinding material e Correct setting e Replace fuse Frequent switching off of grinding material in feed d
53. r more details BJ5 620 Chapter 2 Functional Description 20 of 73 BJ5 620 The following protective gear must be worn when performing the outlined tasks Lc Pe fe ae tee helmet boots gloves goggles Unloading machine x x x f Connecting machine x 1 PP X X X Screen replacement Maintenance of V belts Maintenance of cutting knives Knife sharpening Maintenance of bearings Emergency Stop Button The machine may only be operated with the installed Emergency Stop buttons An 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 CAUTION 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 Chapter 2 Functional Description 21 of 73 Chapter 3 Installation 3 1 BJ5 620 Uncrating the Equipment Requirements at Application Site Check the application site to make sure it conforms to the qualifications listed below The site has enclosed space The ground has sufficient load bearing capacity refer to the Technical Specifications in the Appendix for machine weight The unevenness of the ground surface may not exceed 5 mm The machine must be
54. rive 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 feed The grinding material can be fed into the shredder in the following ways Manual in feed of the material directly into the in feed hopper e 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 material via an additional in feed device e g conveyor belt BJ5 620 Chapter 2 Functional Description 12 of 73 In feed Hopper The material in feed flows through an in feed hopper made to ensure the material is 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 Hopper for conveyor belt in feed BJ5 620 Chapter 2 Functional Description 13 of 73 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
55. ry Check V belt tension and condition Re tighten or replace if necessary Knife condition Check knives and re sharpen or replace if necessary Cutting gap Check cutting gap and set following the instructions in this manual Discharge blocked Check if discharge conveyor belt is running Current failure e Check limit switch for defective contact e Check electrical connection e Tighten limit switch if necessary Fuse too small Rotational direction of rotor Fit larger fuse only after consulting the service department Check motor and reverse polarity if necessary Rotor speed Change rotor speed only after consulting the service department Rotor does not grip bulky material Knife condition Check and sharpen if needed following the instructions provided in this manual Protruding bed knife Consult the service department Knives not aggressive enough Fit underlay plates below knife holders BJ5 620 Troubleshooting 55 of 73 Problem Possible Cause Possible Remedy Overheating of the shredded material View first 5 possible causes for Machine blocks or switches itself off View first 5 possible remedies of Machine blocks or switches itself off Screen perforation too small Knives wrongly sharpened Insert a screen with larger perforation Modify knife finish only after co
56. s 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 not 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 bolts are properly tightened at all times During the operation of the machine rotor knife bolts may come loose Although fine threads are used on the rotor knife bolts because vibration does not easily loosen them you should inspect the tightness of the bolts frequently This machine is designed for the granulation of plastic materials Do not feed any other materials into the machine 1 3 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 vici
57. sions SHREDDER LOCATION Adequate area for routine maintenance should be provided in order to open the machine for knife screen or cleanout service Proper service area clearances also should allow people who are working on the machine 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
58. t 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 Installation 24 of 73 3 3 BJ5 620 Checking the Rotational Direction Rotational direction of the motors must 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 is 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 All 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 has occurred 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 you must carry out necessary checks according to the section Machine Check Prior to Initial Start up below 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 S N NN NS S S Use a torque wrench to
59. the machine as a result of metal parts being fed into the machine The material in the hopper is shredded by the cutters on the rotor This shredding process is repeated as often as required 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 is fitted with an automatic shut down i 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 20 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 BJ5 620 Chapter 2 Functional Description 11 of 73 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 d
60. ughly and grease lightly Mount bearing in bearing housing Attach the bearing with the bearing housing to the rotor axis Lift the rotor using suitable lifting and stopping equipment and place carefully into the bearing seats Attach the bearing housing to the bearing seats using screws Push the distance sleeve onto the rotor axis Put the gear onto the rotor axis Put back the rotor cover plates Put in the screen Pull on V belts and adjust the V belt tension force Attach the V belt cover Carry out a test run Lubricating the Main Bearings An important requirement for high operational safety and long service life of the arrangement of bearings is 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 Maintenance 36 of 73 Lubrication Intervals Shift Operation One shift operation Two shift operation Three shift operation Replace Lubricant Every 18 months Every 9 months Every 6 months Check Monthly Monthly Monthly Check lubricant quality You can judge whether the lubricant needs to be replaced by checking for the following features e e Change in consistency Discoloration Degree of soiling Replacing or Refilling Lubricant e Fill the bearings uniformly with grease until all operatin
61. utlines 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 options A spare parts list with part numbers speci

Sterling SXS Series Paper Shredder User Manual

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