Sterling SXS Series 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 Number s H ere For Future Referen ce: ___________________ ______ ___________________ ______ ___________________ ______ ___________________ ______ ___________________ ______ ___________________ ______ We are comm[...]

BJ5-615 ii Shipping Info Unpacking and Inspection You should inspect your equipm ent for possible shipping damage. Thoroughly check the equipment for any dam age th at might have occurred in transit, such as broken or loose wiring and components, l oose hardware and mounting screws, etc. In the Event of Shipping Damage According to the contract ter[...]

BJ5-615 iii Storage, Disposal, Transportation Storage Clean the machine (see Cleaning the Machine). Preserve all polished metal surfaces using a suitable rust preventing agent. Store the mach ine in an dry and enclosed space. Cover the machine completely with a plastic sheet. Disposal The disposal of machines, machine components, and process materi[...]

BJ5-615 iv Table of Contents CHAPTER 1: SAFETY ................................................................ 5 1-1 How to Use This Manual ............................................................................................. 5 Safety Symbols Used in this Manual ..................................................................... 5 1-2 Ge[...]

BJ5-620 Chapter 1: Safety 5 of 73 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 a pplying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective main tenance. No other[...]

BJ5-620 Chapter 1: Safety 6 of 73 1-2 General Safety Regulations This machine uses knives for th e 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 [...]

BJ5-620 Chapter 1: Safety 7 of 73 1-4 Warnings and Precautions Our granulators are designed to provide safe and reliable operation when installed and operated within design specifications, fo llowing national and local safety codes. To avoid possible personal injury or equi pm ent damage when installing, operating, or maintaining this granulator, u[...]

BJ5-620 Chapter 1: Safety 8 of 73 ; ROTATION OF MOTO RS: 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 loc[...]

BJ5-620 Chapter 1: Safety 9 of 73 Type of Danger Activity Possible Consequences Preventative Measures Pulling in caused by running V-belts All activities Serious injury can result from hair, jewelry, etc. being pulled int o the machine. • Never dismount V-belt protection and window. Direct/indirect contact with live parts in terminal box. Mainten[...]

BJ5-620 Chapter 1: Safety 10 of 73 Type of Danger Activity Possible Consequences Preventative Measures Crushing, cutting, amputation caused by manipulation of protective devices All activities Serious injury or death • Never make the protective devices ineffective. • Check the protective devices regularly for proper function according to the ma[...]

BJ5-620 Chapter 2: Functional Description 11 of 73 Chapter 2: Functional Description 2-1 Models Covered in This Manual The models included in this m anual 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 r[...]

BJ5-620 Chapter 2: Functional Description 12 of 73 Machine (Standard Execution) The machine housing, drive motor, gear box, hydraulic system and terminal box are mounted on the base frame for electrical connections. 2-3 Typical Featur es and Components Material In-feed The grinding material can be fed into the shredder in the following ways: • Ma[...]

BJ5-620 Chapter 2: Functional Description 13 of 73 In-feed Hopper The material in-feed flows through an in-f eed hopper made to ensure the material is delivered safely and correctly. NOTE: An optional top-hinged cover to preve nt in-feed material fly-back during size reduction is available. Additional In-feed Device If the machine has an optional i[...]

BJ5-620 Chapter 2: Functional Description 14 of 73 Drive The drive of the rotor runs using an electric motor via V-belts. The motor (m ounted 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 a ttached to the motor shaft with a special tensioning element. NO[...]

BJ5-620 Chapter 2: Functional Description 15 of 73 The rotor is accessible after opening th e 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 dynam ically counter balanced and has vibration-free conc[...]

BJ5-620 Chapter 2: Functional Description 16 of 73 An optional feature is a water cooling system for the rotor used for special applications. Screen and screen support The screen and the screen support are welded t ogether and fixed to the housing by screws in standard execution. The screen is slightly larger in radius than the cutting circle of th[...]

BJ5-620 Chapter 2: Functional Description 17 of 73 Discharge of Shredded Material Normally the shredded material will be di scharged onto a conveyor belt. (Options include a discharge with blower or with a screw conveyor.) (1) Hydraulic cylinder (2) Screen support (3) Screen 3 2 1 Conveyor belt discharge[...]

BJ5-620 Chapter 2: Functional Description 18 of 73 Hydraulic Ram The hydraulic ram is fixed on two arms a rranged on flange bearings. Two heavy duty hydraulic cylinders move the ram back and forth. The ram m oves automatically after switching on the hydraulic system and the shredder when the machine is operated in automatic mode. NOTE: The ram can [...]

BJ5-620 Chapter 2: Functional Description 19 of 73 2-4 Safety Features Protective Devices CAUTION! The Machine may under no circumstances be operated without these protective devices. The use of faulty or manipulated protective devices is strongly prohibited. Safety Device for Machine and Hopper Doors The shredder can only be operated if the doors [...]

BJ5-620 Chapter 2: Functional Description 20 of 73 V-Belts and Ram Guards V-belt and ram guards are bolted to the m achine. 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. NOTE: The operator must fit and mount the protective devices[...]

BJ5-620 Chapter 2: Functional Description 21 of 73 The following protective gear must be worn when performing the outlined tasks: Emergency Stop Button The machine may only be operated with the installed Emergency Stop buttons. An Emergency Stop Button must be mounte d to t he control cabinet and another on the grinding ma terial in-feed. Immediate[...]

BJ5-620 Installation 22 of 73 Chapter 3: Inst allation 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 [...]

BJ5-620 Installation 23 of 73 WARNING! SUSPENDED LOAD! • Falling loads can cause serious injury or death. • Only use a crane or forklift su itable 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[...]

BJ5-620 Installation 24 of 73 WARNING! Use caution when operating sp ecific equipment to prevent electrical shock. Installation, service, alterations, an d/or modifications mu st only be done by qualified personnel and with high regar d for safety. Not conforming to the requirements could result in bodily harm, death, or costly damage. NOTE: Altera[...]

BJ5-620 Installation 25 of 73 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. N[...]

BJ5-620 Installation 26 of 73 9 Switch ON machine for a short period of tim e and check rotational direction. The rotational direction can be seen at the disch arge 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 approxima tely 10 mi[...]

BJ5-620 Operation 27 of 73 Chapter 4: Operation 4-1 Start-up WARNING! No persons should operate the ma chine 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 th[...]

BJ5-620 Operation 28 of 73 • Throw the material into the in-feed hopper. • The machine should be fed from the front. • If your machine has an additional in-feed device installed, please observe the additional information for working with the in-feed device. DANGER! Do not climb into the in-feed hopper while operating the machine. Death will r[...]

BJ5-620 Operation 29 of 73 Hydraulic Set-up 1. Connect hydraulic pipes to the machine— make sure the upper h ydraulic 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 [...]

BJ5-620 Operation 30 of 73 Figure: Hydraulic Set-up SQ1 SQ2 工进 SQ3 SQ4 ( 初始设定压力 9M Pa ) ( 初始设定压力 9M Pa ) ( 初始设定压力 15M Pa ) 缸 径 ?125 杆径? 63 33m l/ r e c 12m l/ r e c[...]

BJ5-620 Operation 31 of 73 4-3 Shut-down Switch OFF Machine 1. Switch OFF the material in-feed device (accessories). 2. Wait until the remaining material has be en shredded, and then switch OFF the shredder (main switch to 0). 3. Switch OFF the material discharge device.[...]

BJ5-620 Maintenance 32 of 73 Chapter 5: Maintenance 5-1 Preventative Maintenance Schedule Only trained and specialized personne l 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, sa feguard using[...]

BJ5-620 Maintenance 33 of 73 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 serio u s injury or death! • Eliminate all defects bef[...]

BJ5-620 Maintenance 34 of 73 9. Remove clinging shredded material resi due 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 replaceme nt is only necess[...]

BJ5-620 Maintenance 35 of 73 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 t[...]

BJ5-620 Maintenance 36 of 73 10. Carefully lift out the complete roto r using suitable lifting and sto pping equipment. 11. Lay the rotor down in a safe location. Su itable 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 pu lling-off device. 14. Pull the b[...]

BJ5-620 Maintenance 37 of 73 Lubrication Intervals Shift Operation Replace Lubricant Check One shift operation Every 18 months Monthly Two shift operation Every 9 months Monthly Three shift operation Every 6 months Monthly Check lubricant quality You can judge whether the lubricant needs to be replaced by checking for the following features: • Ch[...]

BJ5-620 Maintenance 38 of 73 Refilling lubricant The grease reaches through the circulating groov es 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 neces[...]

BJ5-620 Maintenance 39 of 73 List of Recommended Lubricants Country of Manufacturer/Manufacturer Roller Bearing Grease ARAL ARL Grease HL 3 BP BP ENERGREASE LS 3 CASTROL CASTROL SPHEEROL AP 3 ESSO Beacon 3 FUCHS FUCHS Grease 1200 FUCHS Grease FWA 220 SHELL SHELL Alvania Grease 3 MOBIL-OIL MOBILUX 3 WISURA WISURA Liba L 3 Zeller $ Gmelin ZET GE Grea[...]

BJ5-620 Maintenance 40 of 73 Mounting and Dismounting TAPER-LOCK Tensioning Element The motor and the gear V-belt pulleys are attached to the shaft using a TAPER-LOCK tensioning element. The disks must be dismounted for certain maintenance processes.[...]

BJ5-620 Maintenance 41 of 73 Tightening Torque of the Screws Refer to the table below. Tensioning Screws- Screw details element (Type) Tightening torque in Nm Number Size (BSW) 1008 5,6 2 1 / 4 " 1108 5,6 2 1 / 4 " 1310 20 2 3 / 8 " 1315 20 2 3 / 8 " 1210 20 2 3 / 8 " 1215 20 2 3 / 8 " 1610 20 2 3 / 8 " 1615 20 2 [...]

BJ5-620 Maintenance 42 of 73 8. Pivot the screen support into the working position and fasten using mounting screws. 9. Close the machine door. 10. Shredder can be started again. (Please refer to image from “Emptying the Screen”.) V-Belts V-belts are wearing parts that stretch and must be re-tensioned. Regular checks on the tension force of the[...]

BJ5-620 Maintenance 43 of 73 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 t[...]

BJ5-620 Maintenance 44 of 73 Working on the Cutting Knives Correctly setting and mounting the cutting knives is important when working with shredders to ensure effici ent and economic function. Replacing and Checking the Cutting Knife Mountings Certain machine parts are subject to stress dur ing operation as a result of vibrations that can lead to [...]

BJ5-620 Maintenance 45 of 73 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 recommende d to access the cutte[...]

BJ5-620 Maintenance 46 of 73 6. Clean the hexagon head socket of the cutter mounting screw (2). 7. Loosen the bolt using a high quality Al len 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[...]

BJ5-620 Maintenance 47 of 73 5. Clean the hexagon head socket of the knife mounting bolts (2) and t he cover plates mounting bolts. 6. Loosen the cover plate mounting bolts using a high q uality 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 [...]

BJ5-620 Maintenance 48 of 73 3. Put in the cutter holder mounting bolts (DIN912 – M 10x30 – 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 “Replac[...]

BJ5-620 Maintenance 49 of 73 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 – M1 6x60 – 12.9) and tighten lig htly first 5. Adjust the gap between cutter[...]

BJ5-620 Maintenance 50 of 73 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 tim es and can be re-sharpened as long as you can fix them with the long hole. 1. Dismount the cutters and bed knives (see “dism[...]

BJ5-620 Maintenance 51 of 73 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 ti ghten lightly first 5. Adjust the gap between cutters and bed knife to 0.8-1.0 mm using a calibre gauge. 6. Tighten t[...]

BJ5-620 Maintenance 52 of 73 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 th e packaged cutting knives. • Grease the cutting knives well so th ey do not rust. Protect th[...]

BJ5-620 Maintenance 53 of 73 Hydraulic liquid recommendation Designation to DIN 51 524 HLP 32 Ambient temperature: -7 to +70°C Supplier Name of the oil ARAL Aral Vitam GF 32 Aral Vitam HF 32 BP BP Energol HLP-D 32 BP Energol HLP 32 BP Energol SHF 32 ELF Elfolna 32 Hydrelf 32 ESSO Nuto H 32 HLPD-Oel 32 FINA Fina Hydran 32 FUCHS Renolin MR 10 Renoli[...]

BJ5-620 Troubleshooting 54 of 73 Chapter 6: T roubleshooting 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 m ust be accomplished with the power off, line fuses removed, and with the machine tagged as out of service. Th[...]

BJ5-620 Troubleshooting 55 of 73 Problem Possible Cause Possible Remedy Too much feed material. Reduce grinding material in- feed. Screen blocked. Clean screen, check condition, select larg er screen perforation if necessary. V-belts slip. Check V-belt tension and condition. Re-tighten or replace if necessary. Knife condition. Che c k knives and re[...]

BJ5-620 Troubleshooting 56 of 73 Problem Possible Cause Possible Remedy View first 5 po ssible causes for “Machine blocks or switches itself off” View first 5 possible remedies of “Machine bloc ks or switches itself off” Screen perforation too small. Insert a screen with larger perforation. Knives wrongly sharpened. Modify knife finish only[...]

BJ5-620 Troubleshooting 57 of 73 Problem Possible Cause Possible Remedy Knife mounting screws not tight. Re-tighten using torque wrench following the instructions in this manual. Screw fatigue. Fit new screws. Washers def ormed. Insert new washers. Knife holder surface deformed. Insert new knife holders. Supporting surfaces not clean. Clean and re-[...]

BJ5-620 Troubleshooting 58 of 73 Hydraulic Troubleshooting Problem Possible Cause Possible Remedy Electric source. Corr ect wi re connectio n. Motor doesn’t work. Motor damage. Replace motor. Motor not functioning. Co rrect wi re connectio n. Oil pump doesn’t work. Pump damage. Replace pump. Filter jam. Clean the filter. Hydraulic oil is too th[...]

BJ5-620 Appendix 59 of 73 Appendix A-1 Returned Material Policy Credit Returns Prior to the return of any material, authoriz ation 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 manufact urer is subject to 15[...]

BJ5-620 Appendix 60 of 73 A-2 Technical Specifications[...]

BJ5-620 Appendix 61 of 73 A-3 Drawings and Diagrams NOTE: Please refer to the corresponding spare parts lists in the following section. Cutter mounting[...]

BJ5-620 Appendix 62 of 73 Bed knife fixing[...]

BJ5-620 Appendix 63 of 73 Rotor Assembly[...]

BJ5-620 Appendix 64 of 73 Drive[...]

BJ5-620 Appendix 65 of 73 Ram[...]

BJ5-620 Appendix 66 of 73 Ram scraper[...]

BJ5-620 Appendix 67 of 73 SXS 1500/2000 Standard Hydraulic Diagram SQ1 SQ2 工进 SQ3 SQ4 ( 初始设定压力 9M Pa ) ( 初始设定压力 9M Pa ) ( 初始设定压力 15M Pa ) 缸径? 1 2 5 杆 径 ?63 33m l/ r e c 12m l/ r e c[...]

BJ5-620 Appendix 68 of 73 A-4 Spare Parts List SXS 1500 Pos. Pc Description/Standard 100 Machine complete 101 1 Standard hopper 102 2 PP-scraper side 103 1 PP-scraper top 104 1 Upper door 105 1 Lower door 106 2 Safety grid side 107 1 Safety grid back 108 1 Safety grid back 109 1 Ram residual chute 200 Screen complete (Hydraulic) 201 1 Screen 202 6 [...]

BJ5-620 Appendix 69 of 73 413 2 Rubber bush plate 414 2 Rubber bush Ø116x68x100 415 2 Copper bush ø68x63x1 00 416 2 Torque arm bolt 417 2 Washer disc 418 2 Rotor cover 419 12 Rubber bush plate bolts DIN933 – M20x65 – 12.9 420 12 Washer DIN433 – 20 421 12 Spring washer DIN127 – A – 20 422 12 Nut DIN934 – M20 – 10 423 2 Torque arm com[...]

BJ5-620 Appendix 70 of 73 806 1 Oil filter SP-10 900 Electrical parts 901 2 Safety switch CAZ15zvrk 902 1 Small control box 903 1 Control panel 904 2 Proximity switch II0297 905 2 Cable for Proximity switch E10200 SXS 2000 Pos. Pc Description/Standard 100 Machine complete 101 1 Standard hopper 102 2 PP-scraper side 103 1 PP-scraper top 104 1 Upper [...]

BJ5-620 Appendix 71 of 73 V-Belt SPC3250 Motor pulley SPC315-5 406 2 Motor pulley SPC335-6 Motor pulley taper bush T B 3535-75 407 2 Motor pulley taper bush T B 4040-75 408 2 Key Motor shaft 409 2 Pulle y cover + supp ort 410 2 Base frame for motor 411 2 Gear box SEW MC3PLHF 07-SD i=23 412 2 T orque arm pla te 413 2 Rubber bus h plate 414 2 Rubber [...]

BJ5-620 Appendix 72 of 73 716 8 Fixing b olt for cylinder bolt DIN912 – M16x45 – 12.9 717 4 Grease nipple GB1152-89-M8x1 800 Hydraulic 801 2 Cylinder for pu sher ø125 × ø63 × 1000 802 1 Hydraulic unit SHC-40 6 A 803 Piping 804 Connectors 805 1 Set of sealing for push er c ylinder 806 1 Oil filter SP-10 900 Electrical parts 901 2 Safety s wi[...]

BJ5-620 Appendix 73 of 73 A-5 Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423- 3183 or call [ 262 ] 641-861 0, Fax [262] 641-8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineerin g design specificatio ns, which will maximize your equipment’s performan[...]