2000 SERIES BP2042&BP2062 GRANULATORS OPERATION AND MAINTENANCE MANUAL COPYRIGHT 2006 ALL RIGHTS RESERVED REVISION 9/04 BJF PART NO.
Sterling 2900 S.
TABLE OF CONTENTS TOPIC/SECTION PAGE INTRODUCTION……………………………………………………….xi Factory address… What is a granulator?……………………………………………………..xii A granulator is… The granulating of plastic… The size of the granulate… The disposal of plastic granulate… SECTION 1 – SAFETY Safety symbols and plates……………………...…………….………....1-1 Learn machine safety Safety alert symbol Understanding the signal words Follow the safety instructions…………………………………………..
Restart the granulator TABLE OF CONTENTS TOPIC/SECTION PAGE SECTION 2- MACHINE PARTS AND CONTROLS ……………………………………..2-1 2000 Series granulator left front quarter view 2000 Series granulator, right front quarter view ……………………….……………...2-2 2000 Series granulator, machine open front view 2000 Series granulator, left rear quarter view…………………………………….…...
TABLE OF CONTENTS TOPIC/SECTION PAGE SECTION 4 -SETTINGS AND ADJUSTMENTS (Continued from previous page) Adjusting or replacing the bed knives (Continued from previous page) Loosen the mounting screws……………………………………………….
TABLE OF CONTENTS TOPIC /SECTION PAGE SECTION 4 SETTINGS AND ADJUSTMENTS (Continued from previous page) Adjusting or replacing bed knives (Continued from previous page) Measure the knife gap ………………………………………………...………4-14 Set the down stroke knife shield……………………………………………….4-15 Check the knife gap Tighten screws for final torque Close the cutting chamber……………………………………………………..
TABLE OF CONTENTS TOPIC /SECTION PAGE SECTION 5 -OPERATION Initial startup……………………………………………………………………………..5.1 Safety Check Work safely Check for mechanical interferences Check the motor rotation direction……………………………………………...5-2 Run the motor Discharge air adjustment SECTION 5 -OPERATION Normal operation………………………………………………………………………...5-4 Feed the machine Shut down the machine Discharge cleanout safety SECTION 6 -MAINTENANCE Periodic maintenance………………………………………………………...
TABLE OF CONTENTS TOPIC/SECTION PAGE SECTION 6 -MAINTENANCE Screen replacement (Continued from previous page) Close the screen cradle interlock. ………………………………………………….6-6 Restart the granulator Cutting chamber access …………...…………………………………………..
INTRODUCTION THANK YOU for purchasing an STERLING 2000-SERIES GRANULATOR. READ THIS MANUAL to learn how to operate and service your granulator safely. It covers the family of granulators called the 2000 Series. This series of STERLING Granulators is designed for the big jobs in reclamation of thin-walled, injection-molded plastic parts, thermoforming sheet, as well as film. *NOTE: This manual covers light maintenance only.
INTRODUCTION WHAT IS A GRANULATOR? A GRANULATOR is a machine that is designed to size-reduce plastic materials to chips, or granulate. The machine can be fed either by hand through the hopper opening in the front or automatically from a special hopper opening, which can be specially designed. THE GRANULATING OF PLASTIC is achieved by the cutting action of sharp rotating knives in close adjustment to one or more stationary knives called bed knives. The rotary knife assembly is called a rotor.
SAFETY SECTION 1-1 Safety Symbols & Plates LEARN MACHINE SAFETY Read this manual. Learn how to operate the machine and how to use the controls properly. DO NOT ALLOW ANYONE TO OPERATE THIS MACHINE WITHOUT PROPER INSTRUCTIONS. THIS SAFETY alert symbol MEANS ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED! This symbol appears frequently in this manual and on your machine. It is used to alert you to the possibility of personal injury or death.
SAFETY SECTION 1-2 Safety Symbols & Plates FOLLOW SAFETY INSTRUCTIONS: Read all the safety messages in this manual and on your machine safety plates. Follow the recommended precautions and safe operating practices. Keep safety plates in good condition. Replace missing or damaged plates.
SAFETY SECTION 1-3 Safety Symbols & Plates ROTATING MACHINERY SAFETY PLATE (One located on the machine guard on the left side of the machine, one on the screen cradle on the front panel, to the right of the machine center.) Avoid personal injury by making sure that the rotor is stopped and the power is disconnected and locked out before removing a machine guard. A motion sensor monitors the rotor and disables the jackscrew motors if there is rotor movement.
SAFETY SECTION 1-4 Safety Symbols & Plates SAFETY INSTRUCTION PLATE (Located on the front of the drive guard) The safety instruction plate summarizes the most important safety rules that you need to operate this machine safely. Read it carefully and observe it always to promote safe machine operation. HAZARDOUS VOLTAGE SAFETY PLATE (Located on the door of the jackscrew console) Always call for the services of a licensed electrician when you think that there is an electrical problem.
SAFETY SECTION 1-5 Safety Symbols & Plates ROTATING KNIVES SAFETY PLATE (One located on the front of the cutting chamber and one on the front of the cradle) The rotating knives are razor-sharp to the touch. Always verify that the rotor is not moving. Avoid personal injury by making sure that the rotor is stopped and the power is connected and locked out before opening the machine. A motion sensor monitors the rotor and disables the jackscrew motors if there is movement.
SAFETY SECTION 1-6 Safety Clothing and Practices (Located above the infeed opening at the front of the machine) It is recommended that hearing protection be used at all times when operating this equipment. It is mandatory that hearing protection be worn when noise exposure exceeds OSHA Standards Section 1910.95. (Located above the infeed opening at the front of the machine) Always wear proper eye protection when operating and/or servicing this equipment.
SAFETY SECTION 1-7 Safety Clothing & Practices WEAR PROTECTIVE CLOTHING Never wear neckties, dangling jewelry, loose-fitting clothing, watches, bracelets, or rings. Tie back long hair or restrain it with a hair net to ensure your safety. KEEP YOUR WORK AREA SAFE Keep your work area clean and uncluttered. Store your maintenance tools away from the granulator to prevent them from falling into the machine and causing severe internal damage to the cutting chamber.
SAFETY SECTION 1 Safety Clothing & Practices TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag-out of Energy Sources). If it is not possible to lock out the power, have an electrician remove the fuses. Make sure the rotor has come to a complete stop. Wear gloves to protect against injury from the rotor or bed knives.
SAFETY SECTION 1-10 Safely Cleaning A Jam TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag-out of Energy Sources). If it is not possible to lock out the power, have an electrician remove the fuses. Make sure the rotor has come to a complete stop. Wear gloves to protect against injury from the rotor or bed knives. OPEN THE CUTTING CHAMBER Open the screen cradle per instructions in Section 6 entitled Screen Replacement.
SAFETY SECTION 1-11 Safely Cleaning A Jam CLEAR THE JAM A leather mallet and block of wood of sufficient length to keep hands away from the path of the knives can be used if required. Use the block of wood to exert force on the rotor, usually in the direction opposite normal rotation. Make sure you have secure footing on a clean floor and keep your body well braced while prying on the rotor. Guard against loss of balance should the jammed condition suddenly come free.
MACHINE PARTS AND CONTROLS SECTION 2-1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
MACHINE PARTS AND CONTROLS SECTION 2-2 22000000 –– SSeerriieess G Grraannuullaattoorr M Maacchhiinnee O Oppeenn FFrroonntt V Viieew w 1. Screen 2. Rotor Knife 3. Bed Knife (Down-stroke) 4. Rotor locking mechanism 5. Drive guard 6.
MACHINE PARTS AND CONTROLS SECTION 2-3 22000000 –– sseerriieess G Grraannuullaattoorr LLeefftt R e a r Q u Rear Quaarrtteerr V Viieew w 1. Hopper jack screen (50” & 62” wide machines will be equipped with an hydraulic system for opening the hopper) 2. Screen cradle gas spring 3. Screen cradle 4. Discharge chute 5.
INSTALLATION SECTION 3-1 OVERVIEW This section deals with the procedures required to place your 2000 Series Granulator into service after you receive it at your plant. The following basic steps need to be accomplished.
INSTALLATION SECTION 3-2 MOVE THE GRANULATOR TO ITS WORK SITE If lifting the machine is necessary, use appropriately rated lifting equipment. Always lift the unit from beneath the base plate. The machine WEIGHTS FOR THE 2OOO SERIES are as follows: 2042…….11,000 lbs. 2050…….12,750 lbs 2062…….14,500 lbs LEVEL THE GRANULATOR Once the granulator is at its final installation site, ensure that the machine is on a level surface and resting firmly on its base-plate. If necessary, use shims to level it.
INSTALLATION SECTION 3-3 REMOVE THE PROTECTIVE COATING The machine is shipped with a protective wax coating, which must be removed prior to start-up. The coating can be removed with an acceptable solvent, such as mineral spirits. Clean the following areas: Inside the feed hopper Inside the cutting chamber (knives, rotor, etc.) Inside the discharge area.
INSTALLATION SECTION 3-4 ELECTRICAL WIRING To wire the granulator, run power (of proper voltage) from the plant source through a lockable, fusible disconnect to the machine electrical control panel. 50” & 62” machines are equipped with a hydraulic system for opening the hopper. To wire the hydraulic controls, run power (of proper voltage) from the plant source through a lockable, fusible disconnect to the machine-mounted control panel.
INSTALLATION SECTION 3-5 CHECK FOR MECHANICAL INTERFERENCES TURN POWER OFF and LOCK IT OUT per OSHA 1910.147 OR ANSI Z244.1-1982 (Lock-out/Tag-out of Energy Sources). Open the cutting chamber. Refer to the procedures entitled Screen Replacement and Cutting Chamber Access in Section 6. Turn the rotor slowly with gloved hands, at least one full revolution, to verify that there are no interferences between the rotor knives and bed knives and/or with the screen.
INSTALLATION SECTION 3-6 IF NECESSARY, REVERSE THE MOTOR ROTATION WARNING! With all power to the electrical control panel disconnected and locked out, reverse any two of the three power line conductors to the machine. If there is more than one motor on the machine, and one is turning in the wrong direction, and one isn't: reverse any two of the three line conductors at the overload relay of the motor that you wish to reverse.
INSTALLATION SECTION 3-6 ALTERNATE TEST FOR THE INTEROCK SWITCHES (Continued from previous page) After the test or repair, engage the screen cradle interlock actuator screw. If necessary, unlock and turn on the power. Push the start button to start the granulator. Retract the cutting chamber interlock actuator screw by turning it counterclockwise. The granulator should stop after several turns. If the machine continues to run, TURN OFF AND LOCK THE POWER per OSHA 1910.147 or ANSI Z244.
SETTINGS AND ADJUSTMENTS SECTION 4-1 Adjusting or Replacing Bed Knives BASIC FACTS ABOUT THE KNIVES All of the rotor knives are ground in sets to equal dimensions. Mount and service them as sets. The rotor knives must be mounted tightly against the backs of the knife seats in order to make it possible to achieve consistent knife clearances. Accurate cutting clearance is obtained by setting the bed knives to a 0.006 in. to 0.008 in. (0.15mm to O.20m) gap from the rotor knives.
SETTINGS AND ADJUSTMENTS SECTION 4-2 Adjusting or Replacing Bed Knives OPEN THE CUTTING CHAMBER INTERLOCK Disengage the interlock actuator screw with a box wrench or a ratchet wrench. Make sure the end of the interlock actuator screw is visible and clear of any contact. When disengaged, the interlock opens the electrical control circuit to the motor and prevents the machine from running. RELEASE THE CUTTING CHAMBER FASTENERS Turn the hold-down clamps counterclockwise to loosen them.
SETTINGS AND ADJUSTMENTS SECTION 4-3 Adjusting or Replacing Bed Knives OPEN THE CUTTING CHAMBER The Jackscrew, which opens the machine, should never be operated until the rotor is completely stopped. Make sure that no one is near the Jackscrew or the hopper during operation. Turn the Jackscrew crank handle until the hopper opens sufficiently to allow access to the cutting chamber and the weight of the hopper is over the pivot center.
SETTINGS AND ADJUSTMENTS SECTION 4-4 Adjusting or Replacing Bed Knives LOOSEN THE MOUNTING SCREWS Select either the upstroke knife or the downstroke knife for first removal. Loosen the bed knife screws with a 30 mm socket mounted on a breaker bar. These screws are tightened to a torque of 472 ft lbs (640 Nm) so make sure you have the proper breaker bar (a four foot long (1.2 m) bar with a 3/4 inch (19 mm) drive is suggested). Make sure you have solid footing while you apply the breaking force.
SETTINGS AND ADJUSTMENTS SECTION 4-5 Adjusting or Replacing Bed Knives CLEAN THE KNIFE MOUNTING SURFACES Clean the knife mounting surfaces with a stone or other non-marring tool and wipe them with a clean cloth. Make sure they are free of all material, dust, and dirt. MOUNTING SCREWS DANGER! DO NOT REPLACE THE MOUNTING SCREWS WITH ANY TYPE OF SCREW OTHER THAN THAT SPECIFIED BY STERLING. Substitution of improper screws could lead to premature failure, equipment damage, and serious injury to personnel.
SETTINGS AND ADJUSTMENTS SECTION 4-6 Adjusting or Replacing Bed Knives REPLACE THE DOWNSTROKE BED KNIFE Install the down-stroke bed knife (located on the near side of the rotor) making sure to install it with the knife-edge on the upper side. Back off the bed knife push screws at the rear of the knife. Repeat these steps for the second half of the downstroke knife. REPLACE THE DOWNSTROKE KNIFE SHEILDS Place the shields over the bed knife.
SETTINGS AND ADJUSTMENTS SECTION 4-7 Adjusting or Replacing Bed Knives MEASURE THE KNIFE GAP If you are changing the rotor knives, do so now, otherwise continue with this procedure. Use brass shim stock to set the knife gap to the cutting clearance of 0.006 in. to 0.008 in. (0.15 mm to 0.20 mm). Remove the rotor-locating pin. (See page 4.3) Rotate the rotor backward, by hand, and measure the gap between it and the bed knife at the point of shear.
SETTINGS AND ADJUSTMENTS SECTION 4-8 Adjusting or Replacing Bed Knives TIGHTEN THE SCREWS TO FINAL TORQUE When the knife gap is adjusted to the proper dimension, tighten the mounting screws to a torque of 472 ft lbs (640 Nm). For safety, make sure that you have solid footing when you apply this final torque. Recheck the gap after tightening the screws to the final torque. Make sure that both halves of the bed knife are adjusted.
SETTINGS AND ADJUSTMENTS SECTION 4-9 Adjusting or Replacing Bed Knives FASTEN THE CUTTING CHAMBER Raise the hold-down clamps to their upright positions Turn the knobs clockwise until they are tight against the chamber housing. CLOSE THE CUTTING CHAMBER SAFETY INTERLOCK Engage the safety interlock by turning the actuator screw clockwise with a box wrench or a ratchet wrench Make sure the screw is fully seated against the surface of its housing.
SETTINGS AND ADJUSTMENTS SECTION 4-10 Adjusting or Replacing Rotor Knives BASIC FACTS ABOUT THE KNIVES All of the rotor knives are ground in sets to equal dimensions. Mount and service them as sets. The rotor knives must be mounted tightly against the backs of the knife seats in order to make it possible to achieve consistent knife clearance. Accurate cutting clearance is obtained by setting the bed knives to a 0.006 in. to 0.008 in. (0.15mm to 0.20mm) gap from the rotor knives.
SETTINGS AND ADJUSTMENTS SECTION 4-11 Adjusting or Replacing Rotor Knives RELEASE THE CUTTING CHAMBER FASTENERS Turn the hold-down clamps counterclockwise to loosen them. Swing the hold-down clamps toward you until they are disengaged from the cutting chamber housing. OPEN THE CUTTING CHAMBER The jackscrew, which opens the machine, should never be operated until the rotor is completely stopped. Make sure no one is near the jackscrew or the hopper during operation.
SETTINGS AND ADJUSTMENTS SECTION 4-12 Adjusting or Replacing Rotor Knives CARE IN HANLDING KNIVES WARNING! The rotor knives and bed knives are very sharp; therefore, it is imperative that you wear a pair of heavy gloves to avoid injury. Use the rotor locking mechanism to lock the rotor in the least likely position to cause you injury while you work. The locking mechanism keeps the rotor from turning. A block of wood wedged around the rotor can also be used to lock to rotor in place.
SETTINGS AND ADJUSTMENTS SECTION 4-13 Adjusting or Replacing Rotor Knives CLEAN PARTS FOR REASSEMBLY Clean the rotor knife seats with a stone or other nonmarring tool. Make sure that the backs of the knife seats are clean so that the rotor knife can be placed squarely against them. Wipe the screws with lightly oiled cloth, do not leave an oil film since lubrication can adversely affect the stress on a screw installed to a fixed torque value.
SETTINGS AND ADJUSTMENTS SECTION 4-14 Adjusting or Replacing Rotor Knives TIGHTEN THE ROTOR KNIVES TO FINAL TORQUE Use a 30rnm socket wrench to tighten the mounting screws on each knife in small steps keeping them about even as you increase the torque on them. Use a torque wrench to apply the final torque of 472 ft lbs (640 Nm) to the mounting screws. Make sure your footing is secure before you apply the final torque. Check with a 0.0015" (0.
SETTINGS AND ADJUSTMENTS SECTION 4-15 Adjusting or Replacing Rotor Knives SET THE DOWNSTROKE KNIFE SHIELD Position the knife-shield so that it sets back from the bed knifeedge about 1/32 in. for film and 1/16 in. for thicker materials. Use a plastic or leather mallet, if necessary, to tap the shield or knife. The upstroke knife clamp does not need this adjustment. Carefully adjust the bed knife clearance to its final setting and snug down the mounting screws with a 30 mm socket wrench.
SETTINGS AND ADJUSTMENTS SECTION 4-16 Adjusting or Replacing Rotor Knives CLOSE THE CUTTING CHAMBER Make sure that no one is near the hopper. Clear the mating surfaces of the cutting chamber of and debris that might prevent closure. REMOVE THE ROTOR LOCKING PIN and back out the plunger, turn the handle until the hopper stops. Do not continue to turn the crank after the hopper has stopped. On 50” and 62” machines, activate the hydraulic system to close the hopper.
SETTINGS AND ADJUSTMENTS SECTION 4-17 Drive Belt Replacement Or Adjustment OVERVIEW Belt tension is important to the proper operation of the drive system of your granulator. Improper belt tension can lead to excessive belt wear and/or undue bearing wear on the rotor and motor bearings. This procedure shows you how to access the drive belts and how to adjust the tension to recommended levels. It also shows you how to replace the belts. WORK SAFELY TURN OFF AND LOCKOUT the power per OSHA 1910.
SETTINGS AND ADJUSTMENTS SECTION 4-18 Drive Belt Replacement Or Adjustment INSPECT THE DRIVE BELTS Check the belts for cracks in the V-sections that ride in the pulley grooves as well as on the outside surface of the belts. Also look for signs of excessive wear. If replacement is necessary, continue with the steps that follow. If it is not necessary to replace the belts, skip ahead to the step entitled Measure the Belt Span. REMOVE THE BELTS Loosen the motor mount locking screws.
SETTINGS AND ADJUSTMENTS SECTION 4-19 Drive Belt Replacement Or Adjustment CHECK THE PULLEY ALIGNMENT Tug outward on the pulleys to verify that they are tight on their shafts. Check the pulley alignment by holding a straight edge against the edge of the large pulley and verifying that it is aligned with the edge of the small pulley.
SETTINGS AND ADJUSTMENTS SECTION 4-20 Drive Belt Replacement Or Adjustment COMPARE MEASURED FORCE TO RECOMMENDED FORCE Compare the deflection force measured, to the value shown in the table. For new belts the value for run-in should be used. For belts, which have been running two days or more, use the values for normal running. ADJUST THE BELT TENSION Adjust the sliding motor base to increase the belt tension by turning the adjusting screws clockwise.
SETTINGS AND ADJUSTMENTS SECTION 4-21 Drive Belt Replacement Or Adjustment REPLACE THE DRIVE GUARD COVER Replace the guard cover. Use a socket wrench to replace the fasteners. RESTART THE GRANULATOR If necessary to replace the fuses, call an electrician to do it. UNLOCK AND TURN ON the main power. Remove the OUT OF SERVICE tag. Start the granulator by depressing the start pushbutton on the electrical cabinet.
SETTINGS AND ADJUSTMENTS SECTION 4-22 Setting The Chamber Jackscrew WORK SAFELY TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.11982 (Lockout/Tag-out of Energy Sources). If it is not possible to lock out the power, have an electrician remove the fuses. Make sure the rotor has come to a complete stop. Wear gloves to protect against injury from the rotor or bed knives. OPEN THE CUTTING CHAMBER INTERLOCK Disengage the interlock actuator screw with a box wrench or a ratchet wrench.
OPERATION SECTION 5-1 Initial Startup SAFETY CHECK Before operating the granulator, make sure that all of the electrical, mechanical, and lubrication requirements have been completed in accordance with the installation instructions in Section 3. Proper adjustments and settings are made prior to shipment, however the machine may require readjustment. For knife gap settings refer to Section 4, Settings and Adjustments.
OPERATION SECTION 5-2 Initial Startup CHECK THE MOTOR ROTATION DIRECTION Unlock the power. Push the start-stop pushbutton in quick succession to start the machine then let it coast without power. While the machine is coasting to a stop, check the V-belt direction by looking through the slots in the drive guard. The top of the V-belt should move toward the front of the machine as indicated by the arrow plate on top of the guard cover.
OPERATION SECTION 5-3 Initial Startup DISCHARGE AIR ADJUSTMENT The discharge damper is located on the discharge transition. The damper controls the amount of air that flows through the discharge transition and the discharge blower. Adjust it to obtain the required discharge conveying velocity, while maintaining maximum airflow through the cutting chamber.
OPERATION SECTION 5-4 Normal Operation Never reach beyond the hopper curtain while the machine is running. To clear a jam, refer to the procedure for clearing a jammed cutting chamber in Section 1. Avoid excessive feed rates. Feed the machine by placing the plastic pieces into the hopper at a rate approximating the rated capacity of the granulator. Feed rates in excess of rated capacity will cause the machine to stall.
MAINTENANCE SECTION 6 Periodic Maintenance TABLE 1: Periodic Maintenance Schedule CHECK DAILY WEEKLY MONTHLY Check tightness of the upper chamber hold down handles. Refer to Section 6, Cutting Chamber Access X Check tightness of the screen chamber wedges. Refer to Section 6, Screen Replacement X Check infeed flap position/condition. Refer to Section 6, Periodic Maintenance X Check the interlock actuator switch screws. Position/condition.
MAINTENANCE SECTION 6-2 Periodic Maintenance LUBRICATION Motor lubrication: check the tag from the motor manufacturer. Main rotor bearings are lubricated at the factory but need re-lubrication periodically. Grease fittings are provided for re-lubrication and are located on the right and left-hand bearing housings. Lubricate every month or 750 hours, while the machine is running, with approximately 84 grams (3 oz.) of grease. Use a lithium-based grease conforming to NLGI grade #1.
MAINTENANCE SECTION 6-3 Periodic Maintenance INFEED FLAP CONDITION Daily, check the overall condition of the (3) infeed flaps, at the hopper inlet. Check for wear, or tears in the flap, or if pieces are missing. Replace them if you see damage. Check the rods that support the flaps: they should be in good condition and in proper location. Any flap and/or its mounting hardware that is deteriorated should be replaced to assure proper machine performance and operation.
MAINTENANCE SECTION 6-4 Screen Replacement WORK SAFELY TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag-out of Energy Sources). If it is not possible to lock out the power, have an electrician remove the fuses. Make sure the rotor has come to a complete stop. Wear safety gloves to protect against injury from the rotor and bed knives.
MAINTENANCE SECTION 6-4 Screen Replacement LOWER THE SCREEN CRADLE WARNING! The screen cradle sections are held in place with wedge type retainers at the front of the machine. Gas springs are also used to assist in pivoting the cradle assembly. RETRACT THE SCREEN CRADLE RETAINERS Turn the screen cradle retainer knobs clockwise until they stop. (This retracts the support wedges from beneath the screen cradle).
MAINTENANCE SECTION 6-5 Screen Replacement REMOVE THE SCREEN The screen is divided into segments. Remove one segment at-a-time. Grasp the screen on its near edge and raise the edge by allowing the screen to slide in the cradle. Pull it toward you slowly allowing it to slide over the edge of the screen cradle and then let it down as you continue to pull it toward you. Be careful not to hit the rotor knives with the trailing end of the screen.
MAINTENANCE SECTION 6-5 Screen Replacement REPLACE THE SCREEN (Continued from previous page) Guide the screen carefully as you "roll" it into the cradle, then slide it down around the cradle until you can hang the front lip of the screen over the front edge of the cradle. Be careful not to hit the rotor knives with the far end of the screen. Repeat the foregoing steps for each segment of the screen. RAISE THE SCREEN CRADLE WARNING! Make sure the screens fit properly to the cradle.
MAINTENANCE SECTION 6-5 Cutting Chamber Access CLOSE THE SCREEN CRADLE INTERLOCK Engage the interlock screw by turning it clockwise with a box wrench or a ratchet wrench. Make sure the interlock actuator screw is fully seated against the top surface of its housing. When engaged, the interlock switch closes the electrical control circuit to the machine and allows it to operate. RESTART THE GRANULATOR If necessary to replace the fuses, call an electrician to do it. UNLOCK AND TURN ON the main power.
MAINTENANCE SECTION 6-7 Cutting Chamber Access WORK SAFELY WARNING! TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag-out of Energy Sources). If it is not possible to lock out the power, have an electrician remove the fuses. Make sure the rotor has come to a complete stop. Wear safety gloves to protect against injury from the rotor and bed knives. OPEN THE CUTTING CHAMBER INTERLOCK Disengage the interlock actuator screw with a box wrench or a ratchet wrench.
MAINTENANCE SECTION 6-7 Cutting Chamber Access OPEN THE CUTTING CHAMBER WARNING! The jackscrew, which opens the machine, should never be operated until the rotor is completely stopped. Make sure no one is near the jackscrew or hopper during operation. Turn the jackscrew crank handle until the hopper opens sufficiently to allow access to the cutting chamber and the weight of the hopper is over the pivot center. *NOTE: 50” & 62” machines are equipped with a hydraulic system to open the hopper.
MAINTENANCE SECTION 6-8 Cutting Chamber Access FASTEN THE CUTTING CHAMBER Raise the hold-down clamps to their upright positions. Turn the knobs clockwise until they are tight against the chamber housing. CLOSE THE CUTTING CHAMBER SAFETY INTERLOCK Engage the safety interlock by turning the actuator screw clockwise with a box wrench or a ratchet wrench. Make sure the screw is fully seated against the surface of its housing.
MAINTENANCE SECTION 6-9 Knife Sharpening BED KNIFE SHARPENING Each bed knife is provided with two cutting edges. When the exposed edges become blunt, the knives can be turned over and repositioned to present the new cutting edges. It is not necessary to grind bed knives to the closely matched tolerance of the rotor knives and as with the rotor knives, small nicks in the cutting edges will not seriously affect knife cutting efficiency.
MAINTENANCE SECTION 6-10 Knife Sharpening ROTOR KNIFE SHARPENING (Steep Angle Configuration) The rotor knives must be sharpened to within 0.003" (0.076 mm) of each other. Greater dimensional variations prevent the proper setting of the knife gap and may create other serious complications. Grinding the cutting edge until it is free of nicks can be wasteful. It is not harmful to allow small nicks to remain in the cutting edge.
TROUBLESHOOTING SECTION 7-1 OVERVIEW This section is intended to serve as a guide in checking possible problems that may occur with the operation of your granulator. SAFETY The most important ingredient in any machinery operation is a constant adherence to sound safety practices. The best way to assure safety in any activity that involves troubleshooting or repairing the granulator is to retain complete control of the machine. TURN OFF AND LOCK OUT THE POWER per OSHA 1910.147 OR ANSI Z244.
PROBLEM PROBABLE CAUSE REMEDY -Processing FaultsA.) Material building up below screen. B.) Stalling 1.) Pneumatic discharge blower is not running. 1.) Start the blower. 2.) Damper on discharge blower not open enough. 2.) Adjust the damper on opposite side of the machine from blower. 3.) Discharge line is blocked. 3.) Open line and remove blockage. 1.) Overfeeding. 1.) Reduce feed rate. 2.) Partial or complete screen blockage. 2.) Remove screen, clear and inspect for any damage. 3.
TROUBLESHOOTING SECTION 7-3 PROBLEM -Mechanical FaultsA.) Bearing overheating. PROBABLE CAUSE 1.) Excessive tension on the VBelt drive. 1.) Check belt tension and adjust as necessary. 2.) Inadequate lubrication. 2.) Check lubrication frequency and the recommended lubricants in motor and rotor bearings. 3.) Eliminate source of contamination. 3.) Dirt/Contamination in bearing. B.) Visible cracks in knives. C.) Knives moving on seats. D.) Knives breaking. E.) Excessive knife wear. REMEDY 1.
TROUBLESHOOTING SECTION 7-4 PROBLEM PROBABLE CAUSE REMEDY -Electrical FaultsA.) Motor fails to start. B.) Motor starts, but will not take loads. C.) Motor starts when disconnected from load, but not when connected. REVISION 9/04 BJF 1.) Power supply failure. 1.) Check fuses. 2.) Starter is inoperative. 2.) Check supply mains. Also check the starter contacts for burning, replace in necessary. 3.) Starter overloads cut out. 3.) Check the current requirements on the motor nameplate. 4.
PARTS LIST AND DRAWINGS SECTION 8-1 Recommended Spare Parts 2000 SERIES GARNULATOR TABLE 1: Recommended Spare Parts Model 2042 2050 2062 Item Qty. Qty. Qty. 6/10 6/10 6/10 HCHC 4 4 4 HCHC 24/48 - 36/60 *Property class 10.9M20 x 50 MM Bed Knife Washer 20 - 28 *Property class 10.
*NOTES: Din No. 961-10 When ordering spare parts, please have the model and serial number on hand. Please call one of the following locations: STERLING -So. Attleboro, MA - - 508-399-3000 West Coast Service Center-Ontario, CA - - 909-390-8140/8141 Central Service Center-Kansas City, KA - - 913-780-0215 PARTS LIST AND DRAWINGS SECTION 8-2 Parts Identification Drawing No. CI044035 MODEL 2042 2050 2062 ITEM # Qty. Qty. Qty.
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 REVISION 9/04 BJF 1 16 16 16 1 2 4 4 4 4 16 2 2 1 1 2 1 16 2 2 1 1 2 18 18 18 1 3 6 6 6 6 16 2 2 1 1 Discharge interlock assembly Plain washer M12 Lock washer M12 Hex HD screw M12 Jackscrew assembly/Hydraulic assembly Gas spring bracket Gas spring Plain washer M8 Hex nut M8 Chamber MTG block Hex HD screw M20 Spherical rotor bearing Retaining ring Chamber interlock assembly Rotor assembly 76
Assembly Cutting Chamber Front View Drawing No.
Assembly Cutting Chamber Side View Drawing No.
Assembly Cutting Chamber Drawing No.
VCS Steep Angle 3 Knife Rotor Drawing No.
Rotor Positioning/Locking Assembly Drawing No.
GA Non Sound Enclosed STERLING Drawing No.
GA Non Sound Enclosed Hyd Opening STERLING Drawing No.
GA Non Sound Enclosed Conveyor Feed STERLING Drawing No.
REVISION 9/04 BJF 85
Motor horsepower Voltage Time delay fuses 50 50 50 50 50 60 60 60 60 60 75 75 75 75 75 100 100 100 100 100 125 125 125 125 125 150 150 150 150 150 200 200 200 200 200 250 250 250 250 250 300 300 300 300 300 200 208 230 460 575 200 208 230 460 575 200 208 230 460 575 200 208 230 460 575 200 208 230 460 575 200 208 230 460 575 200 208 230 460 575 200 208 230 460 575 200 208 230 460 575 300A 250A 250A 125A 100A 350A 300A 300A 150A 125A 400A 400A 350A 175A 150A 500A 500A 500A 225A 200A 600A 600A 500A 300A
Regrind Chart 10 Series – Steep Angle STERLING Drawing No.
Sterling Division METRIC KNIFE BOLT/SCREW TIGHTENING TORQUE SPECIFICATIONS FOR GRADE 10.9 FINE THREADS, UNLUBRICATED CONDITIONS SCREW SIZE M8 M10 M12 M14 M16 M18 M20 M24 REVISION 9/04 BJF LBS./FT. 28 54 100 155 232 340 472 810 NM.
Sterling 2900 S.
