Sterling Paper Shredder SXS Series User Manual
SXS Extreme Duty Shredder  
SXS 1500 & 2000  
Part Number: EXS-0003-S  
Bulletin Number: BJ5-620  
Effective: 9.30.2008  
Write Down Your Serial Numbers Here For Future Reference:  
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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.  
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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 disposed of at authorized drop-off points.  
Transportation  
WARNING! Suspended load!  
•
Falling loads can cause serious injury or death. Only use a crane or  
forklift that can withstand the weight and dimension of the load!  
•
Use suitable stopping means and pay attention to gravity center  
location!  
•
•
Do NOT step under the suspended load!  
Wear protective helmet in addition to basic protective gear!  
BJ5-615  
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Table of Contents  
CHAPTER 1: SAFETY................................................................5  
1-1  
How to Use This Manual .............................................................................................5  
Safety Symbols Used in this Manual.....................................................................5  
General Safety Regulations ........................................................................................6  
Responsibility ..............................................................................................................6  
Warnings and Precautions ..........................................................................................7  
1-2  
1-3  
1-4  
CHAPTER 2: FUNCTIONAL DESCRIPTION...........................11  
2-1  
2-2  
2-3  
2-4  
Models Covered in This Manual................................................................................11  
General Description...................................................................................................11  
Typical Features and Components ...........................................................................12  
Safety Features.........................................................................................................19  
CHAPTER 3: INSTALLATION..................................................22  
3-1  
3-2  
3-3  
Uncrating the Equipment...........................................................................................22  
Electrical Connections...............................................................................................23  
Initial Start-up ............................................................................................................25  
CHAPTER 4: OPERATION.......................................................27  
4-1  
4-2  
4-3  
Start-up......................................................................................................................27  
Operation Procedures ...............................................................................................27  
Shut-down .................................................................................................................29  
CHAPTER 5: MAINTENANCE .................................................32  
5-1  
5-2  
Preventative Maintenance Schedule.........................................................................32  
Preventative and Corrective Maintenance ................................................................33  
CHAPTER 6: TROUBLESHOOTING .......................................54  
6-1  
Introduction................................................................................................................54  
APPENDIX  
............................................................................59  
A-1 Returned Material Policy ...........................................................................................59  
A-2 Technical Specifications............................................................................................60  
A-3 Drawings and Diagrams............................................................................................60  
A-4 Spare Parts List.........................................................................................................67  
A-5 Technical Assistance.................................................................................................73  
Parts Department ................................................................................................73  
Service Department.............................................................................................73  
Sales Department................................................................................................73  
Contract Department...........................................................................................73  
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Chapter 1: Safety  
1-1 How to Use This Manual  
Use this manual as a guide and reference for installing, operating, and maintaining your  
equipment. The purpose is to assist you in applying efficient, proven techniques that enhance  
equipment productivity.  
This manual covers only light corrective maintenance. No other maintenance should be  
undertaken without first contacting a service engineer.  
The Functional Description section outlines models covered, standard features, and safety  
features. Additional sections within the manual provide instructions for installation, pre-  
operational procedures, operation, preventive maintenance, and corrective maintenance.  
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup  
of the equipment. We can also provide the assistance of a factory-trained technician to help  
train your operator(s) for a nominal charge. This section includes instructions, checks, and  
adjustments that should be followed before commencing with operation of the equipment.  
These instructions are intended to supplement standard shop procedures performed at shift,  
daily, and weekly intervals.  
The Operation chapter includes a description of electrical and mechanical controls, in  
addition to information for operating the equipment safely and efficiently.  
The Maintenance chapter is intended to serve as a source of detailed assembly and  
disassembly instructions for those areas of the equipment requiring service. Preventive  
maintenance sections are included to ensure that your equipment provides excellent, long  
service.  
The Troubleshooting chapter serves as a guide for identification of most common problems.  
Potential problems are listed, along with possible causes and related solutions.  
The Appendix contains technical specifications, drawings, schematics, parts lists, and  
available options. A spare parts list with part numbers specific to your machine is provided  
with your shipping paperwork package. Refer to this section for a listing of spare parts for  
purchase. Have your serial number and model number ready when ordering.  
Safety Symbols Used in this Manual  
The following safety alert symbols are used to alert you to potential personal injury hazards.  
Obey all safety messages that follow these symbols to avoid possible injury or death.  
DANGER! 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.  
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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 guards or covers are in place and secure. Do not circumvent the safety  
interlocks.  
Prior to clearing a jam or performing any maintenance, the motor should be turned off and  
electrically locked out. Be sure that the rotor has come to a stop. Hands must not be inserted  
into the machine to clear the jam.  
Do 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  
vicinity.  
Becoming familiar with materials, inspection, speed limitations, screens, and guard  
maintenance and total user responsibility will assist you in learning potential areas in need of  
observation for danger.  
Each individual must take responsibility for observing the prescribed safety rules as 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.  
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1-4 Warnings and Precautions  
Our granulators are designed to provide safe and reliable operation when installed and  
operated within design specifications, following national and local safety codes.  
To avoid possible personal injury or equipment damage when installing, operating, or  
maintaining this granulator, use good judgment and follow these safe practices:  
; LEARN AND OBEY your company’s safety policy regarding granulating  
equipment.  
; MOVING OR LIFTING THE GRANULATOR: Although our equipment is built  
and engineered for great ruggedness in operation, care must be taken when moving  
the machine along the floor or lifting it. Damage may occur to sheet metal covers,  
electrical cabinets, or small brackets if pressure is applied to them when moving the  
granulator. When lifting the granulator, be certain of total machine weight and the  
capability of the lifting equipment. (See the Granulator Specification Sheets for  
machine weights and dimensions.)  
; SHREDDER LOCATION: Adequate area for routine maintenance should be  
provided in order to open the machine for 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 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.  
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; ROTATION OF MOTORS: The correct rotating direction for the machine motor is  
clearly marked on the machine. Always check for proper rotation of motors. Incorrect  
rotation direction can cause severe damage.  
; ELECTRICAL GROUNDING: All electrical equipment on the granulator must be  
grounded in accordance to all local codes and Article 250 of the National Electric  
Code.  
; ALWAYS DISCONNECT AND LOCKOUT the main electrical power to the  
granulator before performing any service.  
; SAFETY INTERLOCKS MUST NOT BE BYPASSED. The mechanical and  
electrical safety interlocks ensure the safety of personnel. They should never be  
tampered with or removed for ANY reason. They should be checked frequently by a  
qualified mechanic for proper operation.  
; NEVER modify the machine configuration or any individual component without  
written notice from the factory.  
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  
Preventative Measures  
Consequences  
Danger of crushing by Unloading and  
Serious injury  
•
•
Wear personal protective gear  
heavy parts falling  
down/over  
transporting the  
machine and/or  
components  
Follow safety instructions in  
manual  
Cutting caused by  
sharp knives—even  
when rotor is  
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  
stationary  
Crushing when  
opening/closing  
Maintenance work  
Serious injury  
•
Make sure no persons are in the  
danger area while closing the door  
maintenance doors on  
front side of machine  
Tripping over cables  
and other objects  
All activities  
Serious injury  
•
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 always  
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.  
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Type of Danger  
Activity  
Possible  
Preventative Measures  
Consequences  
Pulling in caused by  
running V-belts  
All activities  
Serious injury can result  
from hair, jewelry, etc.  
being pulled into the  
machine.  
•
Never dismount V-belt protection  
and window.  
Direct/indirect contact  
with live parts in  
terminal box.  
Maintenance work,  
start up  
Serious injury or death  
•
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.  
•
The yellow-marked lines conduct  
voltage at all times—even when  
the machine is switched off.  
•
•
•
Only use original safety fuses with  
stipulated intensity of current.  
Faulty electrical components must  
be replaced immediately.  
If faults occur in the electrical  
energy supply, switch machine off  
immediately.  
•
•
•
The terminal box must be locked  
during operation. Before opening  
the terminal box switch too off  
(“O”).  
Failure of Emergency  
Stop function  
All activities  
Grinding  
Serious injury or death  
Serious injury or death  
It must be guaranteed that failure  
of an Emergency Stop button is  
displayed and leads to an  
immediate stop.  
Fire/explosion caused  
by throwing  
dangerous objects  
(i.e. spray cans) into  
the shredder  
Only grind material which  
corresponds to the agreed  
customer-specific specifications in  
all points.  
Damage to hearing  
All activities  
Diminished hearing,  
headaches, impaired  
balance, deterioration of  
concentration  
•
Reduce noise emissions by taking  
suitable measures.  
•
•
Wear ear protection.  
Instability of machine  
caused by vibration  
All activities  
All activities  
Serious injury  
Install the machine according to  
the instructions in the manual.  
Loosening of the  
cutting knife  
Serious injury  
•
Check the cutting knife mountings  
regularly according to the  
mountings caused by  
vibration  
instructions in the manual.  
Inhalation of grinding  
dust  
All activities  
Diseases of the  
respiratory tract, etc.  
•
•
Mount a suitable air suction device  
and wear breathing equipment if  
necessary.  
When cleaning the machine, use  
suction; do not blow out grinding  
dust.  
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Type of Danger  
Activity  
Possible  
Preventative Measures  
Consequences  
Crushing, cutting,  
amputation caused by  
manipulation of  
All activities  
Serious injury or death  
•
•
Never make the protective devices  
ineffective.  
Check the protective devices  
regularly for proper function  
according to the manual’s  
specifications.  
protective devices  
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.  
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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 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.  
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Machine (Standard Execution)  
(1) Base Frame  
(2) Machine door  
(3) Hopper door  
(4) Gear Box  
3
(5) Drive motor  
(6) V-belt guards  
(7) Ram hydraulic guards  
(8) Discharge area  
7
4
2
6
5
8
1
The machine housing, drive motor, gear box, hydraulic system and terminal box are  
mounted on the base frame for electrical connections.  
2-3 Typical Features and Components  
Material In-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.  
• 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).  
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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  
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Drive  
The drive of the rotor runs using an electric motor via V-belts. The motor (mounted on  
sliding rails or a motor plate) can be adjusted for regulating the tension of the V-belts 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  
•
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.  
•
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.  
•
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.  
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1
3
(1) Rotor cutter  
(2) Screen support  
(hydraulic)  
(3) Bed knife  
2
(1) Rotor cutter  
(2) Screen support  
1
2
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.  
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An optional feature is a water cooling system for the rotor used for special applications.  
Bearing with water plug  
for rotor cooling  
Screen and screen support  
The screen and the screen support are welded together and fixed to the housing by screws  
in 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.)  
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(1) Hydraulic cylinder  
(2) Screen support  
(3) Screen  
3
1
2
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  
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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.  
3
(1) Hydraulic cylinder  
(2) Bearing  
(3) Ram Arm  
(4) Ram  
(5) Hydraulic unit  
2
4
1
5
(1) Serrated ram front  
plate  
(2) Rotor  
1
2
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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.  
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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
2
(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 for more details.)  
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The following protective gear must be worn when performing the outlined tasks:  
Safety Safety Safety  
Safety  
Ear  
helmet boots  
gloves  
goggles  
muffs  
Unloading machine.  
Connecting machine.  
Operation.  
x
x
x
x
x
x
x
x
x
x
Cleaning.  
x
x
x
x
x
Maintenance of bearings.  
Screen replacement.  
Maintenance of V-belts.  
x
Maintenance of cutting  
knives.  
Knife sharpening.  
x
x
x
x
x
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.  
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Chapter 3: Installation  
3-1 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 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.  
• Room temperature: +41 to 104 °F (+5° 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. In the 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 linking places match.  
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WARNING! SUSPENDED LOAD!  
• Falling loads can cause serious injury or death.  
• Only use a crane or forklift suitable for the weight and the  
dimensions of the load.  
• Use suitable stopping equipment and pay attention to the gravity  
center location.  
• DO NOT step under the suspended load.  
• Wear a safety helmet in addition to basic protective gear.  
WARNING! OVERTURNING OR FALLING MACHINE!  
• Serious injury or death can result.  
• If erecting the granulator over a pit, on a frame, or on a platform,  
you MUST secure the machine by putting mounting screws through  
the holes on the mounting pads (see Assembly Drawing). If  
assembling the machine on solid ground, this safety device is not  
always necessary.  
3. 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  
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  
tolerance is +/- 10%.  
The electrical connection is to be carried out in accordance with the wiring diagram in the  
terminal box for machines not pre-wired by the manufacturer.  
NOTE: When making electrical connections, the regulations of the local electricity  
authority must be followed. The required cable cross section is determined  
according to the rated capacity of the units.  
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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 must be protected  
against damage (cable tray, protective sleeve).  
An additional Emergency Stop button has to be installed on the machine If the control  
box cannot be installed according to these rules.  
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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.  
3-3 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  
9 Use a torque wrench to check knife mounting screws when lower housing flap is  
open.  
9 Search the grinding chamber for foreign matter.  
9 Open the lower housing flap and make sure the screen has been inserted in  
accordance with the regulations.  
9 Close upper housing flap and fasten screws tightly.  
9 Check oil level of the gear box.  
9 Fill oil into the hydraulic unit.  
9 Examine in-feed device for foreign matter.  
9 Check that the Emergency Stop buttons are unlocked.  
9 Check all safety devices for proper functioning.  
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9 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).  
9 Switch ON hydraulic unit for a short time and check rotational direction.  
9 Allow machine to run for approximately 10 minutes without shredding material.  
9 Connect material discharge device and in-feed device; check rotational direction  
drives.  
9 Feed grinding material uniformly. Too much material can lead to overload of the  
machine.  
9 Check the temperature of the ground material if necessary.  
9 Monitor the ammeter. This displays the present current consumption and gives  
information on the load of the machine.  
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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  
9 Cutters and bed knives are properly set and the screws are tightened with the  
specified torque.  
9 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.  
9 The cutting chamber is free of foreign matter.  
9 The machine and hopper doors are closed.  
9 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.  
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•
•
•
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. Switch off the shredder at the main switch.  
2. Safeguard main switch using a padlock.  
3. Open the machine door.  
4. Safeguard machine door.  
5. Pivot the screen support downwards by pushing the button screen open on the control  
box.  
6. Remove the screen.  
7. Empty the screen.  
8. Put the screen back into the screen support.  
9. Pivot the screen support into the working position and fasten using the mounting  
screws.  
10. Close the machine.  
11. Shredder can be started again.  
(1) Hydraulic cylinder  
(2) Screen support  
(3) Screen  
(4) Rotor  
4
3
2
1
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Hydraulic Set-up  
1. Connect hydraulic pipes to the machine—make sure the upper hydraulic pipe is  
connected to the upper pipe at the machine.  
2. Connect the wires for the motor and magnetic valves.  
3. 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.  
4. 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.  
5. Run motor; operate the magnetic valve to check the function and wiring connections.  
6. With the magnetic valve (11-YA1) current switch on, set the sequence valve (9)  
pressure to 30 bar.  
7. 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 the next page; refer to Chapter 6 for  
Hydraulic troubleshooting.  
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Figure: Hydraulic Set-up  
杆径?63  
缸径?125  
( 初始设定压力  
15MPa)  
( 初始设定压力  
9MPa)  
( 初始设定压力  
9MPa)  
33ml / r ec  
12ml / rec  
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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.  
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Chapter 5: Maintenance  
5-1 Preventative Maintenance Schedule  
Only trained and specialized personnel should carry out maintenance work.  
Maintenance Plan  
WARNING!  
• Danger caused by electrical voltage and  
starting the machine during maintenance  
work. Death can result!  
• 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:  
•
•
•
Check protective devices.  
Check cutting knife mountings.  
Check condition of cutting knives.  
Perform the following after every 40 operation hours:  
•
•
•
•
Check V-belt tension force and V-belt condition.  
Check all screws of the machine for a tight fit.  
Check wearing parts.  
Check hydraulic oil level and consistence.  
Per form the following after every 2000 operation hours:  
•
•
Change hydraulic oil  
Check gearbox oil level  
Yearly maintenance:  
•
The purpose of yearly maintenance is primarily to check the general condition of  
the machine and to arrange for the supply of any necessary replacement parts. A  
service engineer can carry out this request.  
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5-2 Preventative and Corrective Maintenance  
Checking the Protective Devices  
Check the safety devices for:  
•
•
•
•
Stipulated condition  
Stipulated location  
Safe mounting  
Stipulated function  
WARNING! Danger due to non-functioning protective devices can cause serious injury  
or death!  
•
•
Eliminate all defects before operating the machine!  
If defects occur during operation, stop the machine  
immediately and eliminate the defects!  
•
Do NOT change or remove any protective devices. Do NOT put any  
protective devices out of action by modifying them.  
Cleaning the Machine  
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.  
2. Safeguard main switch using a padlock.  
3. Open machine and hopper doors.  
4. Safeguard the machine and hopper doors.  
5. Remove the screen.  
6. 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.  
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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  
1. Dismount the V-belt cover.  
2. Dismount the V-belts.  
3. Dismount the gearbox.  
4. Remove the screen.  
5. Remove the rotor mounting slot cover plates from the housing.  
6. Screw in hooks on both shaft ends.  
7. Remove the bearing housing fixing bolt.  
8. Carefully lift out the complete rotor using suitable lifting and stopping  
equipment.  
9. Lay the rotor down in a safe location using appropriately sized timber beams.  
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Mounting the Rotor  
1. Before starting, clean the bearing seat surfaces and check the key.  
2. Lift the rotor using suitable lifting and stopping equipment and place carefully  
into the bearing seats.  
3. Attach the bearing housing (Pos.) to the bearing seats using screws.  
4. Put the gear onto the rotor axis.  
5. Put back the rotor mounting slot cover plates.  
6. Put in the screen.  
7. Pull on V-belts and adjust the V-belt tension force.  
8. Attach the V-belt.  
9. Carry out a test run.  
NOTE: If the spare rotor is delivered without bearings, the bearings MUST be  
mounted first.  
Replacing the Main Bearings  
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 Main Bearings  
1. Dismount the V-belt cover.  
2. Dismount the V-belts.  
3. Dismount the gearbox.  
4. Pull the distance sleeve off the rotor axis.  
5. Remove the screen  
6. Remove the rotor cover plates from the machine housing.  
7. Screw in hooks on both shaft ends.  
8. Hang on rotor on both shaft ends.  
9. Remove the bearing housing fixing bolt.  
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10. Carefully lift out the complete rotor using suitable lifting and stopping  
equipment.  
11. Lay the rotor down in a safe location. Suitable for this are timber beams of  
appropriate size.  
12. Loosen the mounting screws on the bearings cover.  
13. Pull the bearing housing off using a pulling-off device.  
14. Pull the bearing off the rotor axis using a pulling-off device.  
Mounting the Main Bearings  
1. Before mounting, clean the bearing surfaces and the shaft surfaces thoroughly  
and grease lightly.  
2. Mount bearing in bearing housing.  
3. Attach the bearing with the bearing housing to the rotor axis.  
4. Lift the rotor using suitable lifting and stopping equipment and place carefully  
into the bearing seats  
5. Attach the bearing housing to the bearing seats using screws.  
6. Push the distance sleeve onto the rotor axis.  
7. Put the gear onto the rotor axis  
8. Put back the rotor cover plates  
9. Put in the screen  
10. Pull on V-belts and adjust the V-belt tension force.  
11. Attach the V-belt cover.  
12. Carry out a test run.  
NOTE:  
•
•
The roller bodies will be damaged unless the mounting forces engage into inner ring.  
The hardened bearing rings are sensitive to impact stress; never hit the rings with  
the hammer. Use a brass arbor or a striking bushing (piping piece) made from a  
soft material. The inner diameter of the striking bushing should be only slightly  
larger than the diameter of the bearing base.  
•
The bearing is then pushed onto the shaft using light blows. The force of pressure  
must be evenly distributed on the circumference of the bearing ring.  
Lubricating the Main Bearings  
An important requirement for high operational safety and long service life of the arrangement  
of bearings 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.  
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Lubrication Intervals  
Shift Operation  
Replace Lubricant  
Every 18 months  
Every 9 months  
Every 6 months  
Check  
Monthly  
Monthly  
Monthly  
One shift operation  
Two shift operation  
Three shift operation  
Check lubricant quality  
You can judge whether the lubricant needs to be replaced by checking for the following  
features:  
•
•
•
Change in consistency  
Discoloration  
Degree of soiling  
Replacing or Refilling Lubricant  
•
•
Fill the bearings uniformly with grease until all operating surfaces are well greased.  
For the rotor bearings, a lubricant quantity of one third to a maximum of half of the  
bearing volume per bearing is required. If too much grease is used, the lubricant will  
become unusable due to excessive temperature.  
•
•
Only one type of grease may be used, mixing different types of grease is prohibited.  
The bearings have been filled at the factory with lithium base saponification roller  
bearing grease F3.  
Refer to the “List of Lubricants” in this section for recommended bearing grease.  
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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.  
3. 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. Fill bearing with approved lubricant (refer to the “List of Lubricants”).  
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List of Recommended Lubricants  
Country of Manufacturer/Manufacturer  
Roller Bearing Grease  
ARL Grease HL 3  
BP ENERGREASE LS 3  
CASTROL SPHEEROL AP 3  
Beacon 3  
ARAL  
BP  
CASTROL  
ESSO  
FUCHS  
FUCHS Grease 1200  
FUCHS Grease FWA 220  
SHELL Alvania Grease 3  
MOBILUX 3  
SHELL  
MOBIL-OIL  
WISURA  
WISURA Liba L 3  
Zeller $ Gmelin  
FAG  
ZET GE Grease M 50  
FAG L 71  
ANTAR  
ROLEXA  
Holland, Beverol  
Italy, Agip  
Swede, NYNAS  
Beverol Multi Purpose Grease  
AGIP Grease 33 FD  
Nynas FI 3-42  
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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.  
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Tightening Torque of the Screws  
Refer to the table below.  
Tensioning  
Screws-  
Screw details  
element (Type) Tightening torque in Nm  
Number  
Size (BSW)  
1008  
1108  
1310  
1315  
1210  
1215  
1610  
1615  
2012  
2017  
2517  
2525  
3020  
3030  
3535  
4040  
4545  
5050  
5,6  
5,6  
20  
20  
20  
20  
20  
20  
31  
31  
48  
48  
90  
90  
60  
102  
155  
185  
2
2
2
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
1/4"  
1/4"  
3/8"  
3/8"  
3/8"  
3/8"  
3/8"  
3/8"  
7/16"  
7/16"  
1/16"  
1/16"  
5/8"  
5/8"  
1/2"  
5/8"  
3/4"  
7/8"  
Replacing the Screen  
The condition of the screen must be checked regularly in order to keep the throughput of  
the shredder and the quality of the shredded material constant.  
The screen may be damaged, dirty, or not suitable for 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)  
1. Switch OFF the shredder at the main switch.  
2. Safeguard main switch using a padlock.  
3. Open the machine door.  
4. Safeguard the machine door.  
5. Pivot the screen support downwards by pushing the button screen open on  
the control box.  
6. Remove the screen.  
7. Put a new screen into the screen support.  
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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.  
3. 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 measuring 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 x in P in Newton  
mm  
P in lbs  
SPA  
SPA  
SPB  
SPB  
SPC  
SPC  
XPB  
100 - 132  
140 - 200  
160 - 224  
236 - 315  
224 - 355  
375 - 560  
224 - 250  
20 - 27  
27 - 35  
35 - 50  
50 -65  
60 - 90  
90 - 120  
25 - 35  
4,4 - 5,9  
5,9 - 7,7  
7,7 - 11  
11 - 14,3  
13,2 - 19,8  
19,8 - 26,4  
5,5 - 7,7  
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.  
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a: Distance between  
roller centers.  
b: Sag  
F: Force (direction)  
Re-tensioning and relaxing the V-belt  
Enlarging or decreasing the centre distance “A” tensions or relaxes the V-belt.  
1. Loosen the tensioning screw.  
2. Shift the drive motor as required onto the sliding rails.  
3. Lock the drive motor into new position using tensioning screws so that the  
motor shaft is parallel to the rotor axis and aligned.  
4. Check the tension force of the V-belt (see “Checking the Tension Force of  
the V-belt”).  
5. 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. Remove the V-belt cover.  
2. Loosen the front and rear tensioning screw.  
3. Relax the V-belt by shifting the drive motor.  
4. Put new V-belt in.  
5. Tension the V-belt (see “Checking the Tension Force of the V-belt”).  
6. Mount the V-belt cover.  
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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  
lbf ft  
Nm  
lbf ft  
Nm  
lbf ft  
M8  
25  
49  
86  
210  
410  
710  
18.4  
36.1  
63.4  
154  
302  
523  
35  
69  
120  
295  
580  
1000  
25.8  
50.9  
88.5  
217  
428  
737  
41  
83  
145  
355  
690  
1200  
30.2  
61.2  
106  
261  
508  
885  
M10  
M12  
M16  
M20  
M24  
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:  
•
•
•
•
Decreased shredding capacity.  
Increased current consumption of the drive motor.  
Inexact cut.  
Overheating of the shredded material.  
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Dismounting the Cutters  
1. Switch OFF the shredder at the main switch.  
2. Safeguard main switch using a padlock.  
3. Open the machine door.  
4. Safeguard the machine door.  
5. 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.  
6. Clean the hexagon head socket of the cutter mounting screw (2).  
7. Loosen the bolt using a high quality Allen key (10 mm). Knock the Allen key  
lightly with a hammer to loosen it if necessary.  
8. Take out the cutter mounting screw, the washer, and the cutter.  
1
(1) Cutter  
(2) Cutter mounting  
screw  
4
(3) Cutter holder  
(4) Cutter holder  
mounting screws  
3
2
Dismounting the Cutter Holders  
1. Switch OFF the shredder at the main switch  
2. Safeguard main switch using a padlock.  
3. Open the machine door.  
4. Safeguard the machine door.  
5. 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.  
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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.  
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.  
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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!  
6
(1) Bed knife  
(2) Knife mounting screws  
(3) Knife holder  
5
(4) Cover plates  
(5) Knife adjusting screw  
for pushing  
(6) Knife adjusting screw  
for pulling  
2
3
4
(7) Cover plate mounting  
screws  
1
7
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.  
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3. Put in the cutter holder mounting bolts (DIN912 – M10x30 – 12.9) and put some  
Loctite on them.  
4. Make sure that the cutter holder fits properly.  
5. 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!  
Mounting the Cutters  
1. Clean the cutter supporting surface and the hole on the cutter holder.  
2. Insert sharp cutter or turn old cutter and push against the cutter holder surface.  
3. Put in the cutter mounting bolt (DIN912 – M16x50 – 12.9) and the washer  
(DIN433 – 17 – 300HV).  
4. Screw in the mounting screws and tighten lightly first.  
5. Make sure the cutter fits planar in the seat.  
6. 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”).  
7. Check if the cutting gap is correct and if the cutting knives do not collide as  
the rotor turns.  
8. Remove tools and other objects from the cutting chamber.  
9. Put back screen and fix it.  
10. 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 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.  
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Maintenance  
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Mounting the Bed Knives  
1. Clean the knife supporting surface and the holes on the knife holder  
2. Insert sharp knife or turn old knife.  
3. Put in the knife adjusting bolts and adjust them roughly  
4. Put in the knife mounting bolts (DIN912 – M16x60 – 12.9) and tighten lightly  
first  
5. Adjust the gap between cutter and bed knife to 0.8-1.0 mm  
6. 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”).  
7. Turn the rotor by hand  
8. Check whether the cutting gap is correct and make sure the cutting knives  
do not collide as the rotor turns.  
9. Put back the cover plates and mount them with the bolts.  
10. Remove tools and other objects from the cutting chamber.  
11. Put screen back and mount it.  
12. 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.  
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!  
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Maintenance  
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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 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.  
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Maintenance  
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(1) Bed knife  
(2) Knife mounting  
screws  
6
(3) Knife holder  
(4) Cover plates  
(5) Knife adjusting  
screw for pushing  
(6) Knife adjusting  
screw for pulling  
(7) Cover plate  
mounting screws  
5
2
3
4
1
7
1. Remove old knives (see “Dismounting the bed knives”).  
2. Insert sharp knife or turn old knife.  
3. Put in the knife adjusting bolts and adjust them roughly  
4. Put in the knife mounting bolts and tighten lightly first  
5. Adjust the gap between cutters and bed knife to 0.8-1.0 mm using a  
calibre gauge.  
6. 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”).  
7. Turn the rotor by hand.  
8. 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  
9. Fix the knife cover plates.  
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Maintenance  
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Transporting and Storing the Cutting Knives  
WARNING!  
• Danger of cutting caused by sharp knives.  
• Serious injury, in particular to hands and fingers, can result.  
• Wear protective gloves.  
• Only transport and store the packaged cutting knives.  
• 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.  
• 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 86°F (30°C) in the summer. For extremely hot tropical areas (i.e.  
Thailand, Malaysia, Nigeria etc.) it is recommended to use HLP 68. The first oil  
replacement should be done after 1,000 operating hours and then after every 2,000  
operating hours. The oil filter must be replaced too.  
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.  
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Maintenance  
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Hydraulic liquid recommendation  
Designation to DIN 51 524  
HLP 32  
Ambient temperature:  
-7 to +70°C  
Name of the oil  
Supplier  
ARAL  
BP  
Aral Vitam GF 32  
Aral Vitam HF 32  
BP Energol HLP-D 32  
BP Energol HLP 32  
BP Energol SHF 32  
Elfolna 32  
ELF  
Hydrelf 32  
ESSO  
Nuto H 32  
HLPD-Oel 32  
FINA  
FUCHS  
Fina Hydran 32  
Renolin MR 10  
Renolin B 10  
MOBIL  
Mobil DTE 24  
Mobil DTE 17  
Drucköl HLP 32 - C  
Hydrauliköl HLPD 32  
Rando Oil HD A - 32  
Rando Oil HD AZ - 32  
Alcor Oil DD 32  
TEXACO  
BJ5-620  
Maintenance  
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Chapter 6: Troubleshooting  
6-1 Introduction  
The utmost in safety precautions should be observed at all times when working on or around  
the machine and the electrical components. All normal troubleshooting must be accomplished  
with the power off, line fuses removed, and with the machine tagged as out of service.  
The use of good quality test equipment cannot be over-emphasized when troubleshooting 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.  
BJ5-620  
Troubleshooting  
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Problem  
Possible Cause  
Possible Remedy  
Reduce grinding material in-  
feed.  
Too much feed material.  
Clean screen, check  
condition, select larger  
screen perforation if  
necessary.  
Screen blocked.  
Check V-belt tension and  
condition. Re-tighten or  
replace if necessary.  
V-belts slip.  
Check knives and re-  
sharpen or replace if  
necessary.  
Knife condition.  
Check cutting gap and set  
following the instructions in  
this manual.  
Cutting gap.  
Machine blocks or switches  
itself off  
Check if discharge conveyor  
belt is running.  
Discharge blocked.  
•
•
•
Check limit switch for  
defective contact.  
Check electrical  
connection.  
Current failure.  
Tighten limit switch if  
necessary.  
Fit larger fuse only after  
consulting the service  
department.  
Fuse too small.  
Check motor and reverse  
polarity if necessary.  
Rotational direction of rotor.  
Rotor speed.  
Change rotor speed only  
after consulting the  
service department.  
Check and sharpen if  
needed following the  
instructions provided in this  
manual.  
Knife condition.  
Consult the service  
department.  
Protruding bed knife.  
Rotor does not grip bulky  
material.  
Fit underlay plates below  
knife holders.  
Knives not aggressive  
enough.  
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Troubleshooting  
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Problem  
Possible Cause  
Possible Remedy  
View first 5 possible causes  
for “Machine blocks or  
switches itself off”  
View first 5 possible  
remedies of “Machine blocks  
or switches itself off”  
Insert a screen with larger  
perforation.  
Screen perforation too small.  
Knives wrongly sharpened.  
Overheating of the shredded  
material.  
Modify knife finish only after  
consulting the service  
department.  
Material rubs against the  
housing wall.  
Fit anti-winding device.  
Insufficient cooling.  
Rotor out of balance.  
Fit rotor cooling.  
Weight knives, balance rotor.  
Check bearings and replace  
if necessary.  
Bearing damage.  
Anti-vibration pads defective.  
Bearing damage.  
Knife finish.  
Unusual vibrations.  
Check mounting pads and  
replace if necessary.  
Check bearings and replace  
if necessary.  
Check knife and sharpen or  
replace if necessary.  
Extreme cutter wear.  
Check cutting gap and set  
following the instructions in  
this manual.  
Wrong cutting gap.  
Foreign matter.  
Fit feed device with metal  
detector.  
Too much grease in bearing. Reduce amount of grease.  
V-belts too tight.  
Reduce tension.  
Rubbing on housing sealing  
ring.  
Check sealing ring and oil or  
replace.  
Bearings too hot.  
Check bearings and replace  
if necessary.  
Bearing damage.  
No grease in bearing.  
Screen worn.  
Lubricate bearing.  
Renew screen (possibly  
using manganese steel).  
Replace screen after  
consulting the service  
department.  
Too many fines in shredded  
material.  
Unsuitable screen  
perforation.  
BJ5-620  
Troubleshooting  
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Problem  
Possible Cause  
Possible Remedy  
Re-tighten using torque  
wrench following the  
instructions in this manual.  
Knife mounting screws not  
tight.  
Screw fatigue.  
Fit new screws.  
Washers deformed.  
Insert new washers.  
Cutting gap alters during  
operation.  
Knife holder surface  
deformed.  
Insert new knife holders.  
Supporting surfaces not  
clean.  
Clean and re-dust supporting  
surfaces.  
Threads in housing worn.  
Screen wrongly inserted.  
Screen support buckled.  
Wrong screen radius.  
Fit new bushes in housing.  
Fit screen correctly.  
Replace screen support.  
Correct it.  
Screen damage.  
Check position of limit switch  
and correct.  
Limit switches not activated.  
Main and control fuses.  
Replace fuse.  
Feed device not connected.  
Switch on in sequence.  
Empty shredder before  
switching ON.  
Material jam.  
Shredder does not start.  
Star delta connection.  
Correct wiring on motor.  
Check motor relay for correct  
setting and increase if  
necessary.  
Motor protection switches  
off.  
Star delta time relay.  
Feed starts too early.  
Correct time.  
Start feed only after switch  
over from star to delta.  
Limit switch loose or wrongly Re-position and tighten limit  
set.  
switch.  
•
•
Replace fuse.  
Shredder blocks when under  
load.  
Fit larger fuse only after  
consulting the service  
department.  
Fuse defective.  
•
Reduce feed quantity of  
the grinding material.  
Motor fuse switches off – red  
indicator.  
•
•
Correct setting.  
Replace fuse.  
Frequent switching off of  
grinding material in-feed  
device.  
Current relay switches off  
Correct setting.  
BJ5-620  
Troubleshooting  
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Hydraulic Troubleshooting  
Problem  
Possible Cause  
Possible Remedy  
Correct wire connection.  
Replace motor.  
Electric source.  
Motor damage.  
Motor doesn’t work.  
Motor not functioning.  
Pump damage.  
Correct wire connection.  
Replace pump.  
Oil pump doesn’t work.  
Filter jam.  
Clean the filter.  
Hydraulic oil is too thick.  
Change hydraulic oil.  
Hydraulic oil has bad quality. Change hydraulic oil.  
Oil pump noise  
Pipe is leaking.  
Pump damage.  
Tighten pipe connectors.  
Change pump.  
Motor and pump  
misalignment.  
Spillover valve and  
sequence valve jam.  
Clean spillover and  
sequence valves.  
Working pressure is  
abnormal.  
Pump damage.  
Replace pump.  
Sealing is broken.  
Pipe is leaking.  
Change sealing.  
Check and solve leak.  
Clean the valve.  
Pressure maintain is  
abnormal.  
Single direction valve jam.  
Clean spillover valve and  
sequence valve.  
Pressure is abnormal.  
Magnetic valve is abnormal.  
Electrical problem.  
If the valve jams, clean it; if it  
is broken, replace it.  
Work is abnormal.  
Check and change the  
broken electrical parts.  
Sequence valve pressure is  
too high.  
High oil temperature.  
Correctly set it to 30 bar.  
BJ5-620  
Troubleshooting  
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Appendix  
A-1 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.  
BJ5-620  
Appendix  
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A-2 Technical Specifications  
BJ5-620  
Appendix  
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A-3 Drawings and Diagrams  
NOTE: Please refer to the corresponding spare parts lists in the following section.  
Cutter mounting  
BJ5-620  
Appendix  
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Bed knife fixing  
BJ5-620  
Appendix  
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Rotor Assembly  
BJ5-620  
Appendix  
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Drive  
BJ5-620  
Appendix  
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Ram  
BJ5-620  
Appendix  
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Ram scraper  
BJ5-620  
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SXS 1500/2000 Standard Hydraulic Diagram  
杆径?63  
缸径?125  
( 初始设定压力  
15MPa)  
(初始设定压力  
9MPa)  
(初始设定压力  
9MPa)  
33ml / r ec  
12ml / r ec  
BJ5-620  
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A-4 Spare Parts List  
SXS 1500  
Pos.  
100  
101  
102  
103  
104  
105  
106  
107  
108  
109  
Pc  
Description/Standard  
Machine complete  
Standard hopper  
PP-scraper side  
PP-scraper top  
Upper door  
1
2
1
1
1
2
1
1
1
Lower door  
Safety grid side  
Safety grid back  
Safety grid back  
Ram residual chute  
200  
201  
202  
203  
204  
205  
Screen complete (Hydraulic)  
Screen  
Screen support screws DIN912 – M16x25 – 8.8  
Screen adjusting bolt  
Screen support  
Cylinder for screen support opening Ø63xØ35x155  
Washer DIN125 -A- 13  
1
6
2
1
2
4
4
206  
207  
Lock washer DIN 127 - 12  
300  
2
2
2
3
1
0
4
2
2
Bearing  
301  
302  
303  
304  
305  
306  
307  
308  
309  
310  
311  
Bearing housing SN236  
Bearing 22236/W33  
Bearing Cover A  
Bearing Cover B  
Sealing DIN3760 D200 x 230 x 15  
Grease nipple GB1152-89/M8x1  
Sleeve  
Mounting bolt DIN912 – M10x40 – 8.8  
Washer disc  
32  
2
2
Mounting bolt DIN912 – M16x50 – 12.9  
400  
401  
Drive  
1
1
2
2
Motor 75 kW 460V/60Hz (right)  
Motor 75 kW 460V/60Hz (left)  
Gear pulley SPC375-5  
402  
403  
Gear pulley taper bush TB 3535-48  
404  
405  
406  
407  
408  
409  
410  
411  
412  
0
10  
2
2
2
2
2
2
2
Key  
V-Belt SPC3250  
Motor pulley SPC315-5 (60Hz)  
Motor pulley taper bush TB 3535-75  
Key Motor shaft  
Pulley cover + support  
Base frame for motor  
Gear box SEW MC3PLHF06-SD i=23  
Torque arm plate  
BJ5-620  
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413  
414  
415  
416  
417  
418  
419  
2
2
2
2
2
Rubber bush plate  
Rubber bush Ø116x68x100  
Copper bush ø68x63x100  
Torque arm bolt  
Washer disc  
Rotor cover  
Rubber bush plate bolts  
DIN933 – M20x65 – 12.9  
Washer DIN433 – 20  
Spring washer DIN127 – A – 20  
Nut DIN934 – M20 – 10  
Torque arm complete 75kW  
2
12  
420  
421  
422  
423  
12  
12  
12  
2
500  
501  
502  
503  
504  
505  
1
E-knife rotor ø660x1500  
Rotor knife 60x60x30  
Rotor knife Mounting Bolt DIN 912 - M16x50 - 12.9  
Washer DIN433 - 17  
76  
76  
76  
76  
Rotor knife holder  
152 Knife holder Mounting bolt DIN912 - M10x30 12.9  
600  
601  
602  
603  
1
4
8
8
Bed knife complete  
Bed knife 399x110x30  
Mounting Bolt DIN 912 - M16x60 12.9  
Bed knife adjusting bolt for pushing DIN 912 - M16x45  
- 12.9  
604  
2
1
Bed knife cover plate  
Bed knife cover plate right  
1
Bed knife cover plate left  
605  
606  
16  
8
Cover plate Mounting bolt DIN912 - M12x30 - 12.9  
Bed knife adjusting bolt for pulling DIN912 - M16x65 -  
12.9  
700  
701  
702  
703  
704  
705  
706  
707  
708  
709  
710  
711  
712  
713  
714  
715  
716  
1
2
2
8
2
Ram complete  
Arm for Ram  
Bearing for arm HCFC214  
Mounting bolt for bearing DIN912 - M16x80 - 12.9  
Bolt for arm  
1
Ram  
12  
12  
12  
12  
12  
1
4
1
2
2
Mounting bolt Ram arm DIN933 - M24x120-12.9  
Nut DIN934 - M24 - 10  
Washer DIN 433 – 24 – 300HV  
Spring washer DIN127 – A – 24  
Mounting pin DIN94-2.5x32  
Scraper  
Spring for scraper GB1358-78 n=12/d=2/D=12/H=60  
Cover plate for scraper  
Upper cylinder bolt  
Lower bolt for cylinder Mounting  
Mounting bolt for cylinder bolt  
DIN912 – M16x45 – 12.9  
Grease nipple GB1152-89-M8x1  
8
717  
4
800  
801  
802  
803  
804  
805  
Hydraulic  
2
1
Cylinder for Ram ø125 × ø63 × 1000  
Hydraulic unit SHC-406 A  
Piping  
Connectors  
Set of sealing for Ram cylinder  
1
BJ5-620  
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806  
1
Oil filter SP-10  
900  
901  
902  
903  
904  
905  
Electrical parts  
Safety switch CAZ15zvrk  
Small control box  
Control panel  
Proximity switch II0297  
Cable for Proximity switch E10200  
2
1
1
2
2
SXS 2000  
Pos.  
100  
101  
102  
103  
104  
105  
106  
107  
108  
109  
Pc  
Description/Standard  
Machine complete  
Standard hopper  
PP-scraper side  
PP-scraper top  
Upper door  
1
2
1
1
1
2
1
1
1
Lower door  
Safety grid side  
Safety grid back  
Safety grid back  
Ram residual chute  
200  
201  
202  
203  
204  
205  
Screen complete (Hydraulic)  
Screen  
Screen support screws DIN912 – M16x25 – 8.8  
Screen adjusting bolt  
Screen support  
Cylinder for screen support opening Ø63xØ35x155  
Washer DIN125 -A- 13  
1
6
2
1
2
4
4
206  
207  
Lock washer DIN 127 - 12  
300  
2
2
2
3
1
0
4
2
2
Bearing  
301  
302  
303  
304  
305  
306  
307  
308  
309  
310  
311  
Bearing housing SN236  
Bearing 22236/W33  
Bearing Cover A  
Bearing Cover B  
Sealing DIN3760 D200 x 230 x 15  
Grease nipple GB1152-89/M8x1  
Sleeve  
Fixing bolt DIN912 – M10x40 – 8.8  
Washer disc  
32  
2
2
Fixing bolt DIN912 – M16x50 – 12.9  
400  
401  
Drive  
1
1
1
1
2
Motor 75 kW 460V/60Hz (right)  
Motor 75 kW 460V/60Hz (left)  
Motor 90 kW 460V/60Hz (right)  
Motor 90 kW 460V/60Hz (left)  
Gear pulley SPC375-5  
402  
403  
Gear pulley SPC400-6  
Gear pulley taper bush TB 3535-48  
2
Gear pulley taper bush TB 4040-50  
404  
405  
0
10  
V-Belt SPC3250  
BJ5-620  
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V-Belt SPC3250  
406  
407  
2
2
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  
Gear box SEW MC3PLHF07-SD i=23  
Torque arm plate  
408  
409  
410  
411  
412  
413  
414  
415  
416  
417  
418  
419  
2
2
2
2
2
2
2
2
2
Rubber bush plate  
Rubber bush Ø116x68x100  
Copper bush ø68x63x100  
Torque arm bolt  
Washer disc  
Rotor cover  
Rubber bush plate bolts  
DIN933 – M20x65 – 12.9  
Washer DIN433 – 20  
Spring washer DIN127 – A – 20  
Nut DIN934 – M20 – 10  
Torque arm complete 90kW  
2
2
12  
420  
421  
422  
423  
12  
12  
12  
2
500  
501  
502  
503  
504  
505  
1
E-knife rotor ø660x1900  
Rotor knife 60x60x30  
Rotor knife fixing Bolt DIN 912 - M16x50 - 12.9  
Washer DIN433 - 17  
96  
96  
96  
96  
Rotor knife holder  
192 Knife holder fixing bolt DIN912 - M10x30 - 12.9  
600  
601  
602  
603  
1
5
10  
Stator knife complete  
Stator knife 399x110x30  
Fixing Bolt DIN 912 - M16x60 12.9  
108 Stator knife adjusting bolt for pushing  
DIN 912 - M16x45 - 12.9  
604  
3
1
1
Stator knife cover plate  
Stator knife cover plate right  
Stator knife cover plate left  
605  
606  
20  
10  
Cover plate fixing bolt DIN912 - M12x30 - 12.9  
Stator knife adjusting bolt for pulling  
DIN912 - M16x65 - 12.9  
700  
701  
702  
703  
704  
705  
706  
707  
708  
709  
710  
711  
712  
713  
714  
715  
1
2
2
8
2
Pusher complete  
Arm for pusher  
Bearing for arm HCFC214  
Fixing bolt for bearing DIN912 - M16x80 - 12.9  
Bolt for arm  
1
Pusher  
12  
12  
12  
12  
12  
1
4
1
2
2
Fixing bolt pusher arm DIN933 - M24x120-12.9  
Nut DIN934 - M24 - 10  
Washer DIN 433 – 24 – 300HV  
Spring washer DIN127 – A – 24  
Fixing pin DIN94-2.5x32  
Scraper  
Spring for scraper GB1358-78 n=12/d=2/D=12/H=60  
Cover plate for scraper  
Upper cylinder bolt  
Lower bolt for cylinder fixing  
BJ5-620  
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716  
717  
8
4
Fixing bolt for cylinder bolt  
DIN912 – M16x45 – 12.9  
Grease nipple GB1152-89-M8x1  
800  
801  
802  
803  
804  
805  
806  
Hydraulic  
2
1
Cylinder for pusher ø125 × ø63 × 1000  
Hydraulic unit SHC-406 A  
Piping  
Connectors  
Set of sealing for pusher cylinder  
Oil filter SP-10  
1
1
900  
901  
902  
903  
904  
905  
Electrical parts  
Safety switch CAZ15zvrk  
Small control box  
Control panel  
Proximity switch II0297  
Cable for Proximity switch E10200  
2
1
1
2
2
Hydraulic Unit Spare Parts List  
Pos  
1
Description  
Suction filter  
Standard  
MF-06  
Pc  
1
Supplier  
CLC  
2
Suction filter  
MF-08  
1
CLC  
3
4
Electric motor  
Gear pump  
20HPX4P(straight system)380V  
PVL12-12-33  
1
1
Qunce  
Xinhong  
5
6
Oil cooler  
Check valve  
JC-YL-AH1012  
CRG-03-1-10  
1
1
CLC  
7
8
9
Check valve  
CRG-03-1-10  
1
1
1
1
7Ocean  
7Ocean  
7Ocean  
7Ocean  
Solenoid control relief valve  
Solenoid control relief valve  
Pressure valve  
Solenoid valve  
Throttle and check valve  
Throttle and check valve  
Pressure switch  
Fluid level  
Filler breather  
Return suction filter  
Tank  
Solenoid valve  
Modular pilot check valve  
DBW10-22AL-2-DC-DN+MSL-02P  
BSG-03-1PN-2-DC24-DN10+ MSL-02P  
2-1/2“ – 25Mpa  
DG07-E1-521C-T-DC24-DN-71  
PT-03  
MTC-04-B-O-10  
PS-02-3-10  
LS-3“  
AB-1163  
SP-10  
160l  
DSD-G02-6C-DC24-31  
MPC-02-W1-10  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
2
1
1
1
1
1
1
1
1
FTB  
7Ocean  
7Ocean  
CLC  
CLC  
7Ocean  
7Ocean  
7Ocean  
7Ocean  
BJ5-620  
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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 847 439-5655  
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 Department  
[
]
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. 160th Street  
New Berlin, WI 53151  
www.sterlco.com  
BJ5-620  
Appendix  
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