Sterling Saw D48160s User Manual

1 BBPP22440000 SSEERRIIEESS GGRRAANNUULLAATTOORRSS SStteerrlliinngg,, IInncc OOPPEERRAATTIIOONN AANNDD MMAAIINNTTEENNAANNCCEE MMAANNUUAA

10 TTAABBLLEE OOFF CCOONNTTEENNTTSS TOPIC SECTION/PAGE SECTION – 8 PARTS LISTS AND DRAWINGS Recommended spare parts……………………………………

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

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

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

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

104 PARTS LISTS AND DRAWINGS SECTION 8-4 Part Identification Drawing No.348070 (Sheet 1 of 1)

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

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

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

108

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

11 THANK YOU FOR PURCHASING AN STERLING BP2400 SERIES GRANULATOR. READ THIS MANUAL to learn how to operate and service your granulator safely. It

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

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

112

113

12 IINNTTRROODDUUCCTTIIOONN WHAT IS A GRANULATOR? A GRANULATOR is a machine that is designed to size-reduce plastic materials to chips or

13 SAFETY SECTION 1-1 Safety Symbols and Plates LEARN MACHINE SAFETY Read this manual. Learn how

14SAFETY SECTION 1-2 Safety Symbols and Plates FOLLOW THE SAFETY INSTRUCTIONS: Read all safety messages in this manual and on your machine safety

15SAFETY SECTION 1-3 Safety Symbols and Plates ROTATING MACHINERY SAFETY PLATE (One located on the machine guard on the left side of the machine,

16SAFETY SECTION 1-4 Safety Symbols and Plates JACKSCREW REVERSING OPERATION (Located on the jackscrew operating console) This information p

17SAFETY SECTION 1-5 Safety Symbols and Plates SAFETY INSTRUCTION PLATE (Located on the front of the drive guard) The safety instruction pla

18SAFETY SECTION 1-6 Safety Symbols and Plates ROTATING KNIVES SAFETY PLATE (One located on the front of the cutting chamber and one on the

19SAFETY SECTION 1-7 Safety Clothing & Practices (Located above the infeed opening at the front of the machine) Always wear

2Sterling, Inc. 2900 South 160th Street New Berlin, WI 53151 Tel: 1-262-641-8600 Fax: 1-262-641-8653 Parts and Service 1-800-229-2919 MACHI

20SAFETY SECTION 1-8 Safety Clothing & Practices WEAR PROTECTIVE CLOTHING Never wear neckties, dangling jewelry, loose-fitting clothi

21 SAFETY SECTION 1-9 Safety Clothing & Practices TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag-out of

22SAFETY 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 S

23SAFETY 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 p

24MACHINE AND CONTROLS SECTION 2-1 BP 2400 Series Granulator -Left Front Quarter View 1. Hold-down clamps - cutting chamber 2. Screen crad

25 MACHINE AND CONTROLS SECTION 2-2 BP 2400 Series Granulator Right Front Quarter View 1. Drive guard 2. Drive guard cover 3. Inlet ven

26MACHINE AND CONTROLS SECTION 2-3 BP 2400 Series Granulator Left Rear Quarter View I. Hydraulic cylinder/ jackscrew console 2. Hydraulic

27INSTALLATION SECTION 3-1 OVERVIEW This section deals with the procedures required to place your BP 2400 Series Granulator into service after you

28INSTALLATION SECTION 3-2 MOVE THE GRANULATOR TO ITS WORK SITE If lifting the machine is necessary, use appropriately rated lifting equipment.

29INSTALLATION SECTION 3-3 The hydraulic cylinders or jackscrews, which open the machine should not operate until the rotor is completely stop

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30INSTALLATION SECTION 3-4 ELECTRICAL WIRING To wire the granulator, run power (of the proper voltage) from the plant source through a lockable, f

31INSTALLATION SECTION 3-5 CHECK FOR MECHANICAL INTERFERENCES TURN POWER OFF and LOCK IT OUT per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Ta

32INSTALLATION SECTION 3-6 With all power to the electrical control panel disconnected and locked out, reverse any two of the three power line c

33INSTALLATION SECTION 3-6 With all power to the electrical control panel disconnected and locked out, reverse any two of the three power line c

34INSTALLATION SECTION 3-7 ALTERNATE TEST FOR THE INTERLOCK SWITCHES (Continued from previous page). After the test or repair, engage the screen c

35INSTALLATION SECTION 3-8 LUBRICATION The machine is pre-lubricated except for the motor. For motor lubrication, check the tag supplied by the

36SETTINGS AND ADJUSTMENTS SECTION 4-1 Adjusting or Replacing Bed Knives BASIC FACTS ABOUT THE KNIVES All of the rotor knives are ground in sets

37 SETTINGS AND ADJUSTMENTS SECTION 4-2 Adjusting or Replacing Bed Knives (Continued from previous page) The hydraulic cylinders or jackscrews,

38SETTINGS AND ADJUSTMENTS SECTION 4-3 Adjusting or Replacing Bed Knives The rotor knives and bed knives are very sharp wear heavy glov

39SETTINGS AND ADJUSTMENTS SECTION 4-4 Adjusting or Replacing Bed Knives LOOSEN THE MOUNTING SCREWS Select either the upstroke knife or the down

4 TOPIC SECTION/PAGE SECTION 2 – MACHINE PARTS AND CONTROLS…………………………………….…2-1 BP-Series granulators left f

40SETTINGS AND ADJUSTMENTS SECTION 4-5 Adjusting or Replacing Bed Knives CLEAN THE KNIFE MOUNTING SURFACES Clean the knife mounting surfaces wi

41SETTINGS AND ADJUSTMENTS SECTION 4-6 Adjusting or Replacing Bed Knives REPLACE THE DOWNSTROKE BED KNIFE Install the down-stroke bed knife (loc

42SETTINGS AND ADJUSTMENTS SECTION 4-7 Adjusting or Replacing Bed Knives MEASURE THE KNIFE GAP If you are changing the rotor knives, do that n

43 SETTINGS AND ADJUSTMENTS SECTION 4-8 Adjusting or Replacing Bed Knives TIGHTEN THE SCREWS TO FINAL TORQUE When the knife gap is adjusted

44SETTINGS AND ADJUSTMENTS SECTION 4-9 Adjusting or Replacing Bed Knives FASTEN THE CUTTING CHAMBER Raise the hold-down clamps to their

45 SETTINGS AND ADJUSTMENTS SECTION 4-10 Adjusting or Replacing Rotor Knives BASIC FACTS ABOUT THE KNIVES All of the rotor knives are ground in

46SETTINGS AND ADJUSTMENTS SECTION 4-11 Adjusting or Replacing Rotor Knives RELEASE THE CUTTING CHAMBER FASTENERS Turn the hold-down cla

47SETTINGS AND ADJUSTMENTS SECTION 4-12 Adjusting or Replacing Rotor Knives The rotor knives and bed knives are very sharp wear heavy gloves to

48SETTINGS AND ADJUSTMENTS SECTION 4-13 Adjusting or Replacing Rotor Knives CLEAN PARTS FOR REASSEMBLY Clean the rotor knife seats with a stone

49 SETTINGS AND ADJUSTMENTS SECTION 4-14 Adjusting or Replacing Rotor Knives TIGHTEN THE ROTOR KNIVES TO FINAL TORQUE Use a 30 mm socket wrenc

5 TOPIC SECTION/PAGE SECTION 4 – SETTINGS AND ADJUSTMENTS (Continued from previous page) Adjusting or replacing the bed knives (Continue

50SETTINGS AND ADJUSTMENTS SECTION 4-15 Adjusting or Replacing Rotor Knives SET THE DOWNSTROKE KNIFE SHIELD Position the knife shield so that i

51SETTINGS AND ADJUSTMENTS SECTION 4-16 Adjusting or Replacing Rotor Knives FASTEN THE CUTTING CHAMBER Raise the hold-down clamps to their upri

52SETTINGS AND ADJUSTMENTS SECTION 4-17 Drive Belt Replacement Or Adjustment OVERVIEW Belt tension is important to the proper operation of the

53SETTINGS AND ADJUSTMENTS SECTION 4-18 Drive Belt Replacement Or Adjustment INSPECT THE DRIVE BELTS Check the belts for cracks in the V-se

54SETTINGS AND ADJUSTMENTS SECTION 4-19 Drive Belt Replacement Or Adjustment CHECK THE PULLEY ALIGNMENT Tug outward on the pulleys to verify th

55 SETTINGS AND ADJUSTMENTS SECTION 4-20 Drive Belt Replacement Or Adjustment COMPARE MEASURED FORCE TO RECOMMENDED FORCE Compare the deflectio

56SETTINGS AND ADJUSTMENTS SECTION 4-21 Drive Belt Replacement Or Adjustment REPLACE THE DRIVE GUARD COVER Replace the guard cover. Use

57SETTINGS AND ADJUSTMENTS SECTION 4-22 Setting and Adjusting the Chamber Jackscrew OVERVIEW Proper adjustment of the two machine-mounted jackscr

58SETTINGS AND ADJUSTMENTS SECTION 4-23 Setting and Adjusting the Chamber Jackscrew RELEASE THE CUTTING CHAMBER FASTENERS Turn the hold-down c

59SETTINGS AND ADJUSTMENTS SECTION 4-24 Setting and Adjusting the Chamber Jackscrew The jackscrews, which open the machine, should not operate

6 TOPIC SECTION/PAGE SECTION 4 – SETTINGS AND ADJUSTMENTS (continued from previous page) Adjusting or replacing the bed knives (Continu

60SETTINGS AND ADJUSTMENTS SECTION 4-25 Setting and Adjusting the Chamber Jackscrew Make sure that no one is near the jackscrew or hopper.

61SETTINGS AND ADJUSTMENTS SECTION 4-26 Setting and Adjusting the Chamber Jackscrew SET THE JACKSCREW CLOSED-POSITION LIMIT SWITCH (Continued from

62SETTINGS AND ADJUSTMENTS SECTION 4-27 Setting and Adjusting the Chamber Jackscrew SET & TEST THE MOUNTING BRACKET LIMIT SWITCH (Continue

63SETTINGS AND ADJUSTMENTS SECTION 4-28 Setting and Adjusting the Chamber Jackscrew CLOSE THE CUTTING CHAMBER SAFETY INTERLOCK Engage the sa

64SETTINGS AND ADJUSTMENTS SECTION 4-29 Setting and Adjusting the Cradle Jackscrew OVERVIEW Proper adjustment of the two machine-mounted jackscrew

65SETTINGS AND ADJUSTMENTS SECTION 4-30 Setting and Adjusting the Cradle Jackscrew When you REVERSE the jackscrew operating direction, always

66SETTINGS AND ADJUSTMENTS SECTION 4-31 Setting and Adjusting the Cradle Jackscrew (continued from previous page) Actuate the screen cra

67SETTINGS AND ADJUSTMENTS SECTION 4-32 Setting and Adjusting the Cradle Jackscrew CHECK THE CRADLE CLOSED-POSITION SWITCH When the screen cradle

68SETTINGS AND ADJUSTMENTS SECTION 4-33 Setting and Adjusting the Cradle Jackscrew ADJUST THE CRADLE CLOSED-POSITION LIMIT SWITCH Jog the cr

69SETTINGS AND ADJUSTMENTS SECTION 4-34 Zero Speed Sensor ZERO SPEED SENSOR The zero speed sensor detects the motion of the rotor assembly. The

7 TOPIC SECTION/PAGE SECTION 4 – SETTINGS AND ADJUSTMENTS (Continued from previous page) Setting and adjusting the chamber jackscrew (Con

70SETTINGS AND ADJUSTMENTS SECTION 4-35 Adjustable rotor knives ROTOR KNIFE PREPARATION Prepare the rotor knives for setting by installin

71SETTINGS AND ADJUSTMENTS SECTION 4-35 Adjustable rotor knives KNIFE LENGTH SETTING-INSPECTION Check with a .0015 feeler gauge to ensu

72SETTINGS AND ADJUSTMENTS SECTION 4-36 Settings and Adjustments Hydraulic opening HYDRAULIC OPENING POSITION SWITCHES Both the Upper Chamber/Ho

73OPERATION SECTION 5-1 Initial Startup Before operating the granulator, make sure that all of the electrical, mechanical, and lubrication re

74OPERATION SECTION 5-2 to 5-3 Initial Startup CHECK THE MOTOR ROTATION DIRECTION Unlock the power. Push the start-stop pushbutton in quick

75OPERATION SECTION 5-4 Normal Operation Never reach beyond the hopper curtain while the machine is running. To clear a jam, refer to the p

76OPERATION 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 Ener

77MAINTENANCE SECTION 5-6 Periodic Maintenance CLEAR THE JAM A leather mallet and block of wood of sufficient length to keep hands away from

78MAINTENANCE SECTION 6-1 Periodic Maintenance TABLE 1: PERIODIC MAINTENANCE SCHEDULE CHECK DAILY WEEKLY MONTHLYCheck tightness of upper chamber

79MAINTENANCE SECTION 6-2 Periodic Maintenance LUBRICATION Motor lubrication: check the tag from the motor manufacturer. Main rotor bear

8 TOPIC SECTION/PAGE SECTION 5 - (Continued from previous page) Normal operation……………………………………………………………………………………..5-4 Feed the machine S

80MAINTENANCE SECTION 6-3 Periodic Maintenance INFEED FLAP CONDITION Daily, check the overall condition of the (3) infeed flaps, pictured

81MAINTENANCE 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

82MAINTENANCE SECTION 6-5 Screen Replacement SEE SECTION 6-12 PAGE 90 FOR SCREEN CRADLE LOWERING INSTRUCTIONS Avoid contact with the r

83MAINTENANCE SECTION 6-6 Screen Replacement REMOVE THE SCREEN The screen is divided into segments. Remove one segment at-a-time. Grasp it on

84MAINTENANCE SECTION 6-7 Screen Replacement REPLACE THE SCREEN (Continued from previous page) Guide the screen carefully as you "roll&quo

85MAINTENANCE SECTION 6-8 Screen Replacement CLOSE THE SCREEN CRADLE INTERLOCK Engage the interlock screw by turning it clockwise with a box

86MAINTENANCE 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

87MAINTENANCE SECTION 6-10 Cutting Chamber Access When you REVERSE the jackscrew operating direction, always ALLOW THE JACKSCREW MOTOR TO CO

88 CLOSE THE CUTTING CHAMBER WITH JACKSCREWS MAINTENANCE SECTION 6-11 Cutting Chamber Access

89RESTART THE GRANULATOR If necessary to replace the fuses, call an electrician to do it. UNLOCK AND TURN ON the main power. Remove the OUT

9 TOPIC SECTION/PAGE SECTION - 6 – MAINTENANCE (continued) Screen replacement (Continued from previous page) Close screen cradle interl

90 MAINTENANCE SECTION 6-12 Cutting Chamber Access When you REVERSE the jackscrew operating direction, always ALLOW THE JACKSCREW MOTOR TO CO

91 RAISING THE SCREEN CRADLE WITH HYDRAULICS From the open/close control panel, raise the cradle approximately two-thirds of its full travel by tu

92 MAINTENANCE SECTION 6-14 Knife Sharpening ROTOR KNIFE SHARPENING The rotor knives must be sharpened to within 0.003" (0.076 mm) of e

93 MAINTENANCE SECTION 6-15 Knife Sharpening BED KNIFE SHARPENING Each bed knife is provided with two cutting edges. When the exposed edges become

94 TROUBLESHOOTING SECTION 7-1 Overview OVERVIEW This section is intended to serve as a guide in checking possible problems that may occur with th

95TROUBLESHOOTING SECTION 7-2 Processing Faults PROBLEM Processing Faults PROBABLE CAUSE REMEDY 1. Pneumatic discharge blower not running 1. Start

96TROUBLESHOOTING SECTION 7-3 Mechanical Faults PROBLEM Mechanical Faults PROBABLE CAUSE REMEDY 1. Excessive wear on the V-Belt drive 1. Check bel

97TROUBLESHOOTING SECTION 7-4 Electrical Faults PROBLEM Electrical Faults PROBABLE CAUSE REMEDY 1. Power supply failure. 1. Check fuses. 2. Star

98PARTS LIST AND DRAWINGS SECTION 8-1 Recommended Spare Parts BP2400 SERIES PARTS LIST AND DRAWINGS SECTION 8-2 Parts Identification D

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