Sterling D48160s manual

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A good user manual

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- informations concerning technical data of Sterling D48160s
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Table of contents for the manual

  • Page 1

    1 B B P P 2 2 4 4 0 0 0 0 S S E E R R I I E E S S G G R R A A N N U U L L A A T T O O R R S S S S t t e e r r l l i i n n g g , , I I n n c c O O P P E E R R A A T T I I O O N N A A N N D D M M A A I I N N T T E E N N A A N N C C E E M M A A N N U U A A L L P P A A R R T T N N O O . . D D 4 4 8 8 1 1 6 6 0 0 s s B B u u l l l l e e t t i i n n N N [...]

  • Page 2

    2 Sterling, Inc . 2900 South 160 th Street New Berlin, WI 53151 Tel: 1-262-641-8600 Fax: 1-262-641-8653 Parts and Service 1-800-229-2919 MACHINE DATA MODEL ________________ _______________ ________________ ____________ SERIAL NUMBER ______ ___________________________ ____________________ CUMBERLAND CUSTOMER ORDER NUMBER __________________ _________[...]

  • Page 3

    3 T T O O P P I I C C : : S S E E C C T T I I O O N N / / P P A A G G E E F F a a c c t t o o r r y y a a d d d d r r e e s s s s . . ……………………………………………… ……………….……… 2 I I N N T T R R O O D D U U C C T T I I O O N N W W h h a a t t i i s s a a g g r r a a n n u u l l a a t t o o r r ? ? … … . [...]

  • Page 4

    4 TOPIC SECTION/PAGE SECTION 2 – MACHINE PARTS AND C ONTROLS …………………………………….…2-1 BP-Series gra nulators le ft front qua rter view BP-Series granulators, right front quarter vie w..………………………………………… ………….….2-2 BP-Series granulators, m achine open front view BP-Series granulator[...]

  • Page 5

    5 T O P I C S E C T I O N / P A G E SECTION 4 – SETTINGS AND ADJUSTMENTS ( Continue d from previ ous page) Adjusting or replacing the bed knives (Continue d from previous page) Loosen the mounting screws ………………………………………… …………………………………..4-4 Remove the first knife clamp or shield Remove the [...]

  • Page 6

    6 T O P I C S E C T I O N / P A G E SECTION 4 – SETTINGS AND ADJUSTMENTS (continue d from previous page) Adjusting or replacing the bed knives (Continue d from previous page) Set the down stroke knife s hield……………………………………… …………………………...4-15 Check the knife gap Tighten the scr ews to final t orque[...]

  • Page 7

    7 T O P I C S E C T I O N / P A G E SECTION 4 – SETTING S AND ADJUSTMENTS (Cont inued from previous pa ge) Setting and adjusting the chamber jackscrew (Continued f rom the previ ous page ) The chamber st ops before it closes but th e motor continues to run……… ……………………..…..4-26 Set and test the mounting brack et limit switc[...]

  • Page 8

    8 T O P I C S E C T I O N / P A G E SECTION 5 - (Continue d from previ ous page) Normal operation ……………………… ……………………………………………… ……………..5-4 Feed the machine Shut down the machine Discharge clea nout safety Cleaning the discharge transiti on Safely clearing the jam …………………?[...]

  • Page 9

    9 T O P I C S E C T I O N / P A G E SECTION - 6 – MAINTENANCE (continued) Screen replacement (Continued from pre vious page) Close screen cradle interlock………… …………………………………… ……………………………6-8 Restart gran ulator Cutting chamber access …………………………………………………?[...]

  • Page 10

    10 T T A A B B L L E E O O F F C C O O N N T T E E N N T T S S T O P I C S E C T I O N / P A G E SECTION – 8 PARTS LISTS AND DRAWINGS Recommended spare parts… ………………………………………… …………………………………… 8-1 Parts identification Sterling drawing no . A-48050 ………………… ………………[...]

  • Page 11

    11 THANK YOU FOR PURCHASING AN STERLING BP2400 SERIES GRANULATOR. READ THIS MAN UAL to learn how to operate and service your granulator safely. It covers t he family of granulators called the BP2400. This series of Sterling Granulators is designed for the big jobs in reclamation of larg e blow-m olded and thin walled, in jection molded plastic part[...]

  • Page 12

    12 I I N N T T R R O O D D U U C C T T I I O O N N WHAT IS A GRANU LATOR? A GRANULATOR is a machine that is designed to size-reduce plastic materials to chips or granulate. The machine can be fed either by ha nd through a hopper opening in the front or automatically from a special hopper opening, which can be specially designed. THE GRANULATING OF [...]

  • Page 13

    13 SAFETY SECTION 1-1 Safety Symbols and Plates LEARN MACHINE SAFETY Read this manual. Learn how to operate and how to use th e control. DO NOT ALLOW ANYONE TO OP ERATE THIS MAC HINE WITHOUT PROPER INSTRUCTIONS. THIS SAFETY alert sym bol MEANS ATTENT ION…BE ALERT! YOUR SAFET Y IS INVLOVED! This symbol appears frequently in this manual and on your[...]

  • Page 14

    14 SAFETY SECTION 1-2 Safety Symbol s and Plates FOLLOW THE SAFETY INSTRUCTIONS : Read all safety messages in this manual and on your machine safety plates. Follow the recommended precautions and safe operating practices. Keep safety plates in good condition. Replace missing or damaged plates. ROTATING KNIVES SAFETY PLATE (Located below the infeed [...]

  • Page 15

    15 SAFETY SECTION 1-3 Safety Symbol s and Plates ROTATING MACHINERY SAFETY PLATE (One located on the machine guard on the left side of the machine, one on the screen cradle on the front panel, to the right of the machine center.) Avoid personal injury by making sure that the rotor is stopped and the power is disconnected and locked out before remov[...]

  • Page 16

    16 SAFETY SECTION 1-4 Safety Symbol s and Plates JACKSCREW REVERSING OPERATION (Located on the jackscrew operating console) This information plate reminds you of th e impor tant procedure for reversing the direction of jackscrew operation. Be sure to pause as advised . This allows the jackscrew drive the necessary time to coast to a stop before rev[...]

  • Page 17

    17 SAFETY SECTION 1-5 Safety Symbol s and Plates SAFETY INSTRUCTION PLATE (Located on the front of the drive guard) The safety instruction plate summarizes the most important safety rules that you need to operate this machine safely. Read it care- fully and observe it always to promote safe machine operation. HAZARDOUS VOLTAGE SAFETY PLATE (Located[...]

  • Page 18

    18 SAFETY SECTION 1-6 Safety Symbol s and Plates ROTATING KNIVES SAFETY PLATE (One located on the front of the cutting cham ber and one on the front of the cradle) The rotating knives are razor-sharp to the touch. Always verify that the rotor is not moving. Avoid personal injury by making sure that the rotor is stopped and the power is disconnected[...]

  • Page 19

    19 SAFETY SECTION 1-7 Safety Cl othing & Practices (Located above the infeed opening at the front of the machine) Always wear proper eye protection when operating and/or servicing this equipment. Wear safety glasses with side shields or full-face safety shields. (Located above the infeed opening at the front of the machine) It is recommended th[...]

  • Page 20

    20 SAFETY SECTION 1-8 Safety Clothi ng & Practices WEAR PROTECTIVE CLOTHING Never wear neckties, dangling jewelry, loose-fitting clothing, watches, bracelets, or rings. Tie back long hair or restrain it with a hair net to ensure your safety. KEEP YOUR WORK AREA SAFE Keep your work area clean and uncluttered. Store yo ur maintenance tools away f[...]

  • Page 21

    21 SAFETY SECTION 1-9 Safety Clothi ng & Practices TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag-out of Energy Sources). If it is not possible to lock out the power, have an electrician remove the fuses. Make sure the rotor has come to a complete stop. The hydraulic cylinders or jackscrews, which open the mac[...]

  • Page 22

    22 SAFETY SECTION 1-10 Safely Cleaning A Jam TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag-out of Energy Sources). If it is not possible to lock out the power, have an electrician remove the fuses. Make sure the rotor has come to a complete stop. The hydraulic cylinders or jackscrews, which open the machine, shou[...]

  • Page 23

    23 SAFETY SECTION 1-11 Safely Cleaning A Jam CLEAR THE JAM A leather mallet and block of wood of sufficient length to keep hands away from the path of the knives can be used if required. Use the block of wood to exert force on the rotor, usu ally in the direction opposite normal rotation. Make sure you have secure footing on a clean floor and keep [...]

  • Page 24

    24 MACHINE AND CONTROLS SECTION 2-1 BP 2400 Series Granulator -Left Fr ont Quarter View 1. Hold-down clamps - cutting cham ber 2. Screen cradle retainers 3. Interlock actuator screw - cutting chamber 4. Safety plates 5. Feed hopper 6. Rotor bearing housing 7. Discharge duct (pipe not shown-optiona l mount to either side) 8. Start/stop pushbuttons a[...]

  • Page 25

    25 MACHINE AND CONTROLS SECTION 2-2 BP 2400 Series Granulator Right Front Quarter View 1. Drive guard 2. Drive guard cover 3. Inlet vent -discharge blower 4. Safety plates 5. Interlock actuator screw screen cradle 6. Infeed flap BP 2400 Series Granulator Machine Open Front View 1. Screen 2. Rotor Knife 3. Bed knife (down stroke) 4. Rotor locating p[...]

  • Page 26

    26 MACHINE AND CONTROLS SECTION 2-3 BP 2400 Series Granulator Left Rear Quarter View I. Hydraulic cylinder/ jackscrew console 2. Hydraulic cylinder or jackscrew- cutting chamber 3. Cleanout- discharge transition 4. Discharge outlet (pipe not shown-optional mount to either side) 5. Rotor bearing housing 6. Rotor zero speed sensor 7. Upper chamber pi[...]

  • Page 27

    27 INSTALLATION SECTION 3-1 OVERVIEW This section deals with the procedures required to place your BP 2400 Series Granulator into service after you receive it at your plant. The follo wing basic steps need to be accomplished. Uncrating the machine Accounting for all necessary parts Inspecting for damage and reporti ng any damage to the carrier Clea[...]

  • Page 28

    28 INSTALLATION SECTION 3-2 MOVE THE GRANULATOR TO ITS WORK SITE If lifting the machine is necessary, use appropriately rated lifting equipment. Always lift the unit from beneath the base plate. The machine weights for the BP-Series Granulators are as follows : BP 2428-10000 pou nds BP 2439-13000 pounds BP 2456-16000 pounds ALLOW ADEQUATE WORK SPAC[...]

  • Page 29

    29 INSTALLATION SECTION 3-3 The hydraulic cylinders or jackscrews, which open the machine should not operate until the rotor is completely stopped. If you discover that the hydraulic cylinders or jackscrews DO operate while the rotor is still turning, im mediately shut down the machine and call for maintenance to adjust it. Wear gloves to protect a[...]

  • Page 30

    30 INSTALLATION SECTION 3-4 ELECTRICAL WIRING To wire the granulator, run power (of the proper voltage) from the plant source through a lockable, fusible disconnect to the machin e electrical control panel. To wire the jackscrew motor s, run power (of proper voltag e) from the plant sour ce through a fusible disconnect to the machine-mounted jack s[...]

  • Page 31

    31 INSTALLATION SECTION 3-5 CHECK FOR MECHANICAL I NTERFERENCES TURN POWER OFF and LOCK IT OUT per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag-out of Energy Sources). Open the cutting chamber. Refer to the pr ocedures entitled Screen Replacement and Cutting Chamber Access in Section 6. Turn the rotor slowly with gloved hands, at least one full r[...]

  • Page 32

    32 INSTALLATION SECTION 3-6 With all power to the electrical control panel disc onnected and locked out, reverse any two of the three power line conductors to the machine. If there is more than one motor on t he machine, and one is turning in the wrong direction, and one i sn't: reverse any two of the three line conductors at the overload rela[...]

  • Page 33

    33 INSTALLATION SECTION 3-6 With all power to the electrical control panel disc onnected and locked out, reverse any two of the three power line conductors to the machine. If there is more than one motor on t he machine, and one is turning in the wrong direction, and one i sn't: reverse any two of the three line conductors at the overload rela[...]

  • Page 34

    34 INSTALLATION SECTION 3-7 ALTERNATE TEST FOR THE INTERL OCK SWITCHES (Continued from previous page). After the test or repair, engage the screen cradle interlock actuator screw. If necessary, unlock and turn on the power. Push the start button to start the granulator. Retract the cutting chamber interlock actuator screw by turning it counterclock[...]

  • Page 35

    35 INSTALLATION SECTION 3-8 LUBRICATION The machine is pre-lubricated excep t for the motor. For motor lubrication, check the tag supplied by the motor manufacturer. After the BP2400 Series Granulator has been in servi ce for some time, the jackscrews and the main bearings should be lubricated periodically. Refer to Section 6, Maintenance, for furt[...]

  • Page 36

    36 SETTINGS AND ADJUSTMENTS SECTION 4-1 Adjusting or Replacing Bed Knives BASIC FACTS ABOUT THE KNIVES All of the rotor knives are ground in sets to e qual dimensions. M ount and servi ce them as sets. The rotor kniv es must be mount ed tightly agai nst the backs of the knife seats, in order to m ake it possible to achieve consistent knife clearanc[...]

  • Page 37

    37 SETTINGS AND ADJUSTMENTS SECTION 4-2 Adjusting or Replacing Bed Knives (Continued from previous page) The hydraulic cylinders or jackscrews, which open the machine, should not operate until the rotor is completely stopped. If you discover that the hydraulic cylinders or jackscrews DO operate while the rotor is still turning, immediately shut dow[...]

  • Page 38

    38 SETTINGS AND ADJUSTMENTS SECTION 4-3 Adjusting or Replacing Bed Knives The rotor knives and bed knives are very sh arp wear heavy gloves to avoid injury. Use the rotor-locating pin to lock the rotor in th e position that is least likely to cause injur y as you work. The pin keeps the rotor from turning. If the rotor knives and the bed knives are[...]

  • Page 39

    39 SETTINGS AND ADJUSTMENTS SECTION 4-4 Adjusting or Replacing Bed Knives LOOSEN THE MOUNTING SCREWS Select either the upstroke knife or the down-stroke knife for first removal. Loosen the bed knife screws with a 30 mm socket mounted on a breaker bar. These screws are tightened to a torque of 472 ft Ibs (640 Nm ) so make sure you have the proper br[...]

  • Page 40

    40 SETTINGS AND ADJUSTMENTS SECTION 4-5 Adjusting or Replacing Bed Knives CLEAN THE KNIFE MOUNTING SURFACES Clean the knife mounting surfaces with a stone or other non-marring tool and wipe them with a clean cloth. Make sure they are free of all material, dust, and dirt. DO NOT REPLACE THE MOUNTING SCREWS WITH ANY TYPE OF SCREW OTHER THAN THAT SPEC[...]

  • Page 41

    41 SETTINGS AND ADJUSTMENTS SECTION 4-6 Adjusting or Replacing Bed Knives REPLACE THE DOWNST R OKE BED KNIFE Install the down-stroke bed knife (located on the near side of the rotor) making sure to install it with the knife- edge on the upper side. Engage the captive screws in th e slots on the near side of the knife bed and lower the knife onto th[...]

  • Page 42

    42 SETTINGS AND ADJUSTMENTS SECTION 4-7 Adjusting or Replacing Bed Knives MEASURE THE KNIFE GAP If you are changing the rotor knives, do that now, otherwise, continue with this procedure. Use brass shim stock to set the knife gap to the cutting clearance of 0.006 in. to 0.008 i n. (0.15 mm to 0.20 mm). Remove the rotor-locating pin. Rotate the roto[...]

  • Page 43

    43 SETTINGS AND ADJUSTMENTS SECTION 4-8 Adjusting or Replacing Bed Knives TIGHTEN THE SCREWS TO FINAL TORQUE When the knife gap is adjusted to the proper dimension, tighten the mounting screws to a torque o f 472 ft lbs (640 Nm). For safety, make sure that you have solid footing when you apply this final torque. Recheck the gap after tightening the[...]

  • Page 44

    44 SETTINGS AND ADJUSTMENTS SECTION 4-9 Adjusting or Replacing Bed Knives FASTEN THE CUTTING CHAMBER Raise the hold-down clamps to their upright positions Turn the knobs clockwise until they are tight against the chamber housing. CLOSE THE CUTTING CHAMBER SAFETY INTERLOCK Engage the safety interlock by turning the actuator screw clockwise with a bo[...]

  • Page 45

    45 SETTINGS AND ADJUSTMENTS SECTION 4-10 Adjusting or Replacing Rotor Knives BASIC FACTS ABOUT THE KNIVES All of th e rotor knives are ground in sets to e qual dimension s. Mount and s ervice them as sets . . The rotor kniv es must be mount ed tightly against the backs of kni fe seats in order to make it possi ble to achieve consistent knife cleara[...]

  • Page 46

    46 SETTINGS AND ADJUSTMENTS SECTION 4-11 Adjusting or Replacing Rotor Knives RELEASE TH E CUTT ING CHAMBER FASTENERS Turn the hold-down clamps counterclockwise to loosen them. Swing the hold-down clamps toward you until the y are disengaged from the cutting chamber housing. SEE SECTION 6-10 PAGE 87 FOR CUTTING CHAMBER OPENING INSTRUCTIONS .[...]

  • Page 47

    47 SETTINGS AND ADJUSTMENTS SECTION 4-12 Adjusting or Replacing Rotor Knives The rotor knives and bed knives are very sh arp wear heavy gloves to avoid injury. Use the rotor-locating pin to lock the rotor in the position that is least likely to cause injur y as you work. The pin keeps the rotor from turning. If the rotor knives and the bed knives a[...]

  • Page 48

    48 SETTINGS AND ADJUSTMENTS SECTION 4-13 Adjusting or Replacing Rotor Knives CLEAN PARTS FOR REASSEM BLY Clean the rotor knife seats with a stone or other non-mar- ring tool. Make sure that the backs of the knife seats are clean so that the rotor knife can be placed squarely against them. Wipe the screws with lightly oiled cloth, do not leave an oi[...]

  • Page 49

    49 SETTINGS AND ADJUSTMENTS SECTION 4-14 Adjusting or Replacing Rotor Knives TIGHTEN THE ROTOR KNIVES TO FINAL TORQUE Use a 30 mm socket wrench to tighten the mounting screws on each knife in small steps keeping them about even as you increase the torque on them. Use a torque wrench to apply the final torque of 472 ft lbs (640 Nm) to the mounting s[...]

  • Page 50

    50 SETTINGS AND ADJUSTMENTS SECTION 4-15 Adjusting or Replacing Rotor Knives SET THE DOWNSTROKE KNIFE SHIELD Position the knife shield so that it sets back from the bed knife edge about 1/32 in. for film and 1/16 in. for thicker materials. Use a plastic or leather mallet, if necessary , to tap the shield or knife- The upstroke knife clamp does not [...]

  • Page 51

    51 SETTINGS AND ADJUSTMENTS SECTION 4-16 Adjusting or Replacing Rotor Knives FASTEN THE CUTTING CHAMBE R Raise the hold-down clamps to their upright positions. Turn the knobs clockwise until they are tight against the chamber housing. RESTART TH E GRANULATOR If necessary to replace the fuses, ca ll an electrician to do it. UNLOCK AND TURN ON the ma[...]

  • Page 52

    52 SETTINGS AND ADJUSTMENTS SECTION 4-17 Drive Belt Replacement Or Adjustment OVERVIEW Belt tension is important to the proper operation of the drive system of your granulator. Improper belt tension can lead to excessive belt wear and/or undue bearing wear on the rotor and motor bearings. This procedure shows you how to access the driv e belts and [...]

  • Page 53

    53 SETTINGS AND ADJUSTMENTS SECTION 4-18 Drive Belt Replacement Or Adjustment INSPECT THE DRIVE BELTS Check the belts for cracks in the V-sections that ride in the pulley grooves as well as on the outside surface of the belts. Also look for signs of excessive wear. If replacement is necessary , conti nue with the steps that follow. If it is not nec[...]

  • Page 54

    54 SETTINGS AND ADJUSTMENTS SECTION 4-19 Drive Belt Replacement Or Adjustment CHECK THE PULLEY ALIGNMENT Tug outward on the pulleys to verify that they are tight on their shafts. Check the pulley alignment by holding a straight edge against the edge of the large pulley and verifying that it is aligned with the edge of the small pulley. If the edges[...]

  • Page 55

    55 SETTINGS AND ADJUSTMENTS SECTION 4-20 Drive Belt Replacement Or Adjustment COMPARE MEASURED FORCE TO RECOMMENDED FORCE Compare the deflection force measured, to the value shown in the table. For new belts the value for run-in should be used. For belts, which have been running two days or more, use the values for normal running. ADJUST THE BELT T[...]

  • Page 56

    56 SETTINGS AND ADJUSTMENTS SECTION 4-21 Drive Belt Replacement Or Adjustment REPLACE THE DRIVE GUARD COVER Replace the guard cover. Use a socket wrench to replace the fasteners. RESTART THE GRANULATOR If necessary to replace the fuses, call an electrici an to do it. UNLOCK AND TURN ON the main power. Remove the OUT OF SERVICE tag. Start the granul[...]

  • Page 57

    57 SETTINGS AND ADJUSTMENTS SECTION 4-22 Setting and Adjusting the Chamber Jackscrew OVERVIEW Proper adjustment of the two machine-mounted jack screws is important to performance and safety. Improper settings can result in premature failure of the jackscrews. To avoid severe damage to the jackscrews, BE PREPARED TO SHUT THEM DOWN IMMEDIATELY WHEN T[...]

  • Page 58

    58 SETTINGS AND ADJUSTMENTS SECTION 4-23 Setting and Adjusting the Chamber Jackscrew RELEASE THE CU T TING CHAMBER FASTENERS Turn the hold-down clamps counterclockwise to loosen them. Swing the hold-down clamps toward you until they are disengaged from the cutting chamber housing When you REVERSE the jackscrew operating direction, always ALLOW THE [...]

  • Page 59

    59 SETTINGS AND ADJUSTMENTS SECTION 4-24 Setting and Adjusting the Chamber Jackscrew The jackscrews, which open the machine, should not operate until the rotor is completely stopped. If you discover that the jack- screws DO operate while the rotor is still turning, immediately shut down the machine and call for maintenance to adjust it. Make sure n[...]

  • Page 60

    60 SETTINGS AND ADJUSTMENTS SECTION 4-25 Setting and Adjusting the Chamber Jackscrew Make sure that no one is near the jackscrew or hopper. Clear the mating surfaces of the cutting chamber of any debris that might prevent tight closure. At the jackscrew console, turn the CC/Hopper (Cutting Chamber/Hopper) switch to the LOWER position. Hold the swit[...]

  • Page 61

    61 SETTINGS AND ADJUSTMENTS SECTION 4-26 Setting and Adjusting the Chamber Jackscrew SET THE JACKSCREW CLOSED-POSITION LIMIT SWITCH (Continued from previous page) Rotate the CLOSED POSITION NUT (4) until the switch (5) trips. Then turn it an additional half turn toward the switch. Replace the keeper (1). Test the closed position and be prepared to [...]

  • Page 62

    62 SETTINGS AND ADJUSTMENTS SECTION 4-27 Setting and Adjusting the Chamber Jackscrew SET & TEST THE MOUNTING BRACKET LIMIT SWITCH (Continued from previous page) Place a 4 in. x4 in.x12 in. (100 mm x l00 mm x 300 mm) wood block on its 4 in. (l00 mm) side between the mating surfaces of the cutting chamber, as shown. Carefully close the chamber un[...]

  • Page 63

    63 SETTINGS AND ADJUSTMENTS SECTION 4-28 Setting and Adjusting the Chamber Jackscrew CLOSE THE CUTTING CHAMBER SAFETY INTERLOCK Engage the safety interlock by turning the actuator screw clockwise with a box wrench or a ratchet wrench. Make sure the screw is fully seated against the top surface of its housing. When engaged, the interlock closes the [...]

  • Page 64

    64 SETTINGS AND ADJUSTMENTS SECTION 4-29 Setting and Adjusting the Cradle Jackscrew OVERVIEW Proper adjustment of the two machine-mounted jackscrews is important to performance and safety. Improper settings can result in premature failure of the jackscrews. To avoid severe damage to the screen cradle jackscrew, BE PREPARED TO SHUT IT DO WN IMMEDIAT[...]

  • Page 65

    65 SETTINGS AND ADJUSTMENTS SECTION 4-30 Setting and Adjusting the Cradle Jackscrew When you REVERSE the jackscrew operating direction, always ALLOW THE JACKSCREW MOTOR TO COME TO A COMPLETE STOP. Re lease the control switch and allow a minimum of 5 seconds before switching to the opposite operating positi on. If you don't allow this pause, th[...]

  • Page 66

    66 SETTINGS AND ADJUSTMENTS SECTION 4-31 Setting and Adjusting the Cradle Jackscrew (continued from previous page) Actuate the screen cradle jackscrew s by turning the selector switch to LOWER at the jackscrew console. Hold the switch in position until th e cradle approaches the open stop location described previously. TO AVIOD SERIOUS DAMAGE TO TH[...]

  • Page 67

    67 SETTINGS AND ADJUSTMENTS SECTION 4-32 Setting and Adjusting the Cradle Jackscrew CHECK THE CRADLE CLOSED-POSITION SWITCH When the screen cradle is fully closed, the cradle front flange should be parallel with the down stroke knife block and the cradle wedges should engage the cradle freely. If this does not occur, or if the jackscrew motor conti[...]

  • Page 68

    68 SETTINGS AND ADJUSTMENTS SECTION 4-33 Setting and Adjusting the Cradle Jackscrew ADJUST THE CRADLE CLOSED-POSITION LIMIT SWITCH Jog the cradle to close until it arrives at the stop position. Open the cradle jackscrew switch housing cover (1) and remove the keeper (2). Turn the CLOSED-POSITION NUT on the bottom (3) toward the switch until the swi[...]

  • Page 69

    69 SETTINGS AND ADJUSTMENTS SECTION 4-34 Zero Speed Sensor ZERO SPEED SENSO R The zero speed sensor detects the motion of the rotor assembly. The sensor is interlocked to the control circuits of the two machine jackscrews. If th e rotor is turning, then the jackscrews should not operate. If you notice that the jackscrews are operational while the r[...]

  • Page 70

    70 SETTINGS AND ADJUSTMENTS SECTION 4-35 Adjustable rotor knives ROTOR KNIFE PREPAR ATION Prepare the rotor knives for setting by installi ng the adjusting screws PHOTO and lock nuts int o the rear of the knife. Knife with screws Be sure that the screws are fully eng aged into the knif e. This will assure easy installati on into the kni fe setting [...]

  • Page 71

    71 SETTINGS AND ADJUSTMENTS SECTION 4-35 Adjustable rotor knives KNIFE LENGTH SETTING-INSPECTIO N Check with a .0015 fe eler gauge to ensure that cutting ed ge of the knife PHOTO is snug ag ainst the front setting b lock. This should b e consistent along Knife in fixture the entire block length . If the fit is proper then the knife is at it’s pro[...]

  • Page 72

    72 SETTINGS AND ADJUSTMENTS SECTION 4-36 Settings and Adjustments Hydraulic opening HYDRAULIC OPENING POSITION SWITCHES Both the Upper Cham ber/Hopper and the S creen Cradle have swi tches to assure proper closi ng positions. These switch locations are set a t the factory and shou ld not require adjustm ent. When operating properly, the hydraulic p[...]

  • Page 73

    73 OPERATION SECTION 5-1 Initial Startup Before operating the granulator, make sure that a ll of the electrical, mechanical, and lubrication requirements have been completed in accordance wi th the installation instructions in Section 3. Proper adjustments and set- tings are made prior to shipment, however the machine may require readjustment. For [...]

  • Page 74

    74 OPERATION SECTION 5-2 to 5-3 Initial Startup CHECK THE MOTOR ROTATION DIRECTION Unlock the power. Push the start-stop pushbutton in quick succession to start the machine, then, let it coast without power. While the machine is coasting to a st op, check the V-belt direction by looking through the slots in the driv e guard. The top of the V-belt s[...]

  • Page 75

    75 OPERATION SECTION 5-4 Normal Operation Never reach beyond the hopper curtain while the machine is running. To clear a jam, refer to the procedure for clearing a jammed cutting chamber, which follows in this section. Avoid excessive feed rates. Feed the machine by placing the plastic pieces into the hopper at a rate approximating the rated capaci[...]

  • Page 76

    76 OPERATION SECTION 5-5 Safely Clearing a Jam TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag out of Energy Sources). If it is not possible to lock out the power, have an electrician remove the fuses. Make sure the rotor has come to a complete stop. The hydraulic cylinders or jackscrews, which open the machine, sh[...]

  • Page 77

    77 MAINTENANCE SECTION 5-6 Periodic Maintenance CLEAR THE JAM A leather mallet and block of wood of sufficient length to keep hands away from the path of the knives can be used if required. Use the block of wood to exert force on the rotor, usu ally in the direction opposite normal rotation. Make sure you have secure footing on a clean floor and ke[...]

  • Page 78

    78 MAINTENANCE SECTION 6-1 Periodic Maintenance TABLE 1: PERIODIC MAINT ENANCE SCHEDULE CHECK DAILY WEEKLY MONTHLY Check tightness of upper chamber hold d own handles. Refer to Section 6, Cutting Chamber X Check tightness of screen chamber wedges. Refer to Section 6, Screen Replacement X Check infeed flap position/condition. Refer to Section 6 Peri[...]

  • Page 79

    79 MAINTENANCE SECTION 6-2 Periodic Maintenance LUBRICATION Motor lubrication: check the tag from the motor manufacturer. Main rotor bearings are lubricated at the factory but need re-lubrication periodically. Grease fittings are pro- vided for re-lubrication and are located on the ri ght and left-ha nd bearing housings. Lubricate every month or 75[...]

  • Page 80

    80 MAINTENANCE SECTION 6-3 Periodic Maintenance INFEED FLAP CONDITION Daily, check the overall condition of the (3) infeed flaps, pictured in Section 2, Right Quarter View. Check for wear, or tears in the flap, or if pieces are missing. Replace them if you see damage. Check the rods that support the flaps: they should be in good condition and in pr[...]

  • Page 81

    81 MAINTENANCE SECTION 6-4 Screen Replacement TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag out of Energy Sources). If it is not possible to lock out the powe r, have an electrician remove the fuses Make sure the rotor has come to a complete stop The hydraulic cylinders or jackscrews, which open the machine, shou[...]

  • Page 82

    82 MAINTENANCE SECTION 6-5 Screen Replacement SEE SECTION 6-12 PAGE 90 FOR SCREEN CRADLE LOWERING INSTRUCTIONS Avoid contact with the rotor knives, which are just above the screen. The cutting edges are very sharp. Wear gloves to avoid injury when working in this area.[...]

  • Page 83

    83 MAINTENANCE SECTION 6-6 Screen Replacement REMOVE THE SCREEN The screen is divided into segments. Remove one segment at-a-time. Grasp it on its near edge and raise the edge by allowing the screen to slide in the cradle. Pull it toward you slowly allowing it to slide over the edge of the screen cradle then, let it down onto the machine support ba[...]

  • Page 84

    84 MAINTENANCE SECTION 6-7 Screen Replacement REPLACE THE SCREEN (Continued from previous page) Guide the screen carefully as yo u "roll" it into the cradle, then slide it down around the cradle until you can hang the front lip of the screen over the front edge of the cradle. Be careful not to hit the rotor knives with the far end of the [...]

  • Page 85

    85 MAINTENANCE SECTION 6-8 Screen Replacement CLOSE THE SCREEN CRADLE INTERLOCK Engage the interlock screw by turning it clockwise with a box wrench or a ratchet wrench. Make sure the interlock actuator screw is fully seated against the top surface of its housing. When engaged, the interlock switch closes the electrical control circuit to the machi[...]

  • Page 86

    86 MAINTENANCE SECTION 6-9 Cutting Chamber Access TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag out of Energy Sources). If it is not possible to lock out the power, have an electrician remove the fuses. Make sure the rotor has come to a complete stop. The hydraulic cylinders/jackscrews, which open the machine, sh[...]

  • Page 87

    87 MAINTENANCE SECTION 6-10 Cutting Chamber Access When you REVERSE the jackscrew operating direction, always ALLOW THE JACKSCREW MOTOR TO COME TO A COMPLETE STOP. Release th e control switch and allow a minimum of 5 seconds before switching to the op posite operating position. If you don' t allow this pause, the JACKSCREW AND OTHER COMP ONENT[...]

  • Page 88

    88 CLOSE THE CUTTING CHAM BER WITH JACKSCREWS MAINTENANCE SECTION 6-11 Cutting Chamber Access CLOSE THE CUTTING CHAMBER WITH H YDRAULICS After completing any m aintenance or a djustments inside the cutting ch amber, use the followin g procedure to close the cutting chamber and resum e use of the granulator. Make sure that no one is near the hydraul[...]

  • Page 89

    89 RESTART THE GRANULATOR If necessary to replace the fuses, call an electrici an to do it. UNLOCK AND TURN ON the main power. Remove the OUT OF SERVICE tag. Start the granulator by depressing the start pushbutton on the electrical cabinet. MAINTENANCE SECTION 6-11 Cutting Chamber Access FASTEN THE CUTTING CHAMBER Raise the hold-down clamps to thei[...]

  • Page 90

    90 MAINTENANCE SECTION 6-12 Cutting Chamber Access When you REVERSE the jackscrew operating direction, always ALLOW THE JACKSCREW MOTOR TO COME TO A COMPLETE STOP. Release the c ontrol switch and allow a minimum of 5 seconds before switching to the opposite operating position. If you don't allow this pause, the JACKSCREW AND OTHER COMPONENTS M[...]

  • Page 91

    91 RAISING THE SCREEN CR ADLE WITH HYDRAULICS From the open/close co ntrol panel, ra ise the cradle approximat ely two-thirds of its fu ll travel by tur ning the Screen Cradle selector switc h to the “RAISE” position. Check the scr eens to make sure that they are seated pr operly in the cradle. Continue raising the cradle by turning the switc h[...]

  • Page 92

    92 MAINTENANCE SECTION 6-14 Knife Sharpening ROTOR KNIFE SHARPENING The rotor knives must be sharpened to within 0.003" (0.076 mm) of each other. Greater dimensional variations prevent the proper setting of the knife gap and may create other serious complications. Grinding the cutting edge until it is free of nicks can be wasteful. It is not h[...]

  • Page 93

    93 MAINTENANCE SECTION 6-15 Knife Sharpening BED KNIFE SHARPENING Each bed knife is provided with two cutting edges. When the exposed edges become blunt, the knives can be turned over and repositioned to present the new cutting edges. It is not necessary to grind bed knives to the closely matched tolerance of the rotor knives and as with the rotor [...]

  • Page 94

    94 TROUBLESHOOTING SECTION 7-1 Overview OVERVIEW This section is intended to serve as a guide in ch ecking possible problems that may occur with the operation of your granulator. SAFETY The most important ingredient in any machinery operation is a constant a dherence to sound safety practices. The best way to assure safety in any ac tivity that inv[...]

  • Page 95

    95 TROUBLESHOOTING SECTION 7-2 Processing Faults PROBLEM Processing Faults PROBABLE CAUSE REMEDY 1. Pneumatic discharge blower not running 1. Start the blower 2. Damper on discharge blower not open enough 2. Adjust the damper (on opposite side of machine from blower) A. Material building up below screen 3. Damper line is blocked 3. Open line and re[...]

  • Page 96

    96 TROUBLESHOOTING SECTION 7-3 Mechanical Faults PROBLEM Mechanical Faults PROBABLE CAUSE REMEDY 1. Excessive wear on the V- Belt drive 1. Check belt tension and adjust as necessary 2. Inadequate lubrication 2. Check lubrication frequency and the recommended lubricants in motor and rotor bearings A. Bearing overheating 3. Dirt/Contamination in bear[...]

  • Page 97

    97 TROUBLESHOOTING SECTION 7-4 Electrical Faults PROBLEM Electrical Faults PROBABLE CAUSE REMEDY 1. Power suppl y failure. 1. Check fuses. 2. Starter is inoperative. 2. Check supply mains. Also, check starter contacts for burning, replace if necessary. 3. Starter overloads cut out. 3. Check current re quirements on motor nameplate and adjust. A. Mo[...]

  • Page 98

    98 PARTS LIST AND DRAWINGS SECTION 8-1 Recommended Spare Parts BP2400 SERIES PARTS LIST AND DRAWINGS SECTION 8-2 Parts Identification Drawing No. A-48050 (Sheet 1 of 4) PARTS LIST AND DRAWINGS SECTION 8-2 Parts Identification Drawing No. A-48050 (Sheet 2 of 4) PARTS LIST AND DRAWINGS SECTION 8-2 Parts Identification Drawing No. A-48050 (Sheet 2 of [...]

  • Page 99

    99 PARTS LIST AND DRAWINGS SECTION 8-2 Parts Identification Drawing No. A-48050 (Sheet 1 of 4)[...]

  • Page 100

    100 PARTS LIST AND DRAWINGS SECTION 8-2 Parts Identification Drawing No. A-48050 (Sheet 2 of 4)[...]

  • Page 101

    101 PARTS LIST AND DRAWINGS SECTION 8-2 Parts Identification Drawing No. A-48050 (Sheet 3 of 4)[...]

  • Page 102

    102 PARTS LIST AND DRAWINGS SECTION 8-2 Parts Identification Drawing No. A-48050 (Sheet 4 of 4)[...]

  • Page 103

    103 PARTS LIST AND DRAWINGS SECTION 8-3 Parts Identification Drawing No. A-48150 (Sheet 1 of 1)[...]

  • Page 104

    104 PARTS LISTS AND DRAWINGS SECTION 8-4 Part Identificatio n Drawing No.3 48070 (Sheet 1 of 1)[...]

  • Page 105

    105 PARTS LISTS AND DRAWINGS SECTION 8-5 Parts Identification Drawing No. 348185 (Sheet 1 of 1)[...]

  • Page 106

    106 PARTS LISTS AND DRAWINGS SECTION 8-6 Parts Identification Drawing No. 1554-460 (Sheet 1 of 1)[...]

  • Page 107

    107 PARTS LIST AND DRAWINGS SECTION 8-7 Wiring Diagram Drawing No. A-399598 (Sheet 1 of 2)[...]

  • Page 108

    108[...]

  • Page 109

    109 PARTS LIST AND DRAWINGS SECTION 8-8 Drawing No. 348078-1 (Sheet 1 of 1)[...]

  • Page 110

    110 PARTS LIST AND DRAWINGS SECTION 8-9 Wiring Diagram for Hydraulics Drawing No. D-499061 (Sheet 1 of 1)[...]

  • Page 111

    111 PARTS LIST AND DRAWINGS SECTION 8-10 Wiring Drawing No. D-499044 (Sheet 1 of 1)[...]

  • Page 112

    112[...]

  • Page 113

    113[...]