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Sterling SXS Series User Manual

Sxs extreme duty shredder
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SXS Extreme Duty Shredder
Write Down Your Serial Numbers Here For Future Reference:
_________________________
_________________________
_________________________
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.
SXS 1500 & 2000
Part Number: EXS-0003-S
Bulletin Number: BJ5-620
Effective: 9.30.2008
_________________________
_________________________
_________________________

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  • Page 1 SXS Extreme Duty Shredder Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ 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.
  • Page 2 Shipping Info Unpacking and Inspection You should inspect your equipment for possible shipping damage. Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event of Shipping Damage According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and place of shipment.
  • Page 3 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.

  • Page 4: Table Of Contents

    Table of Contents CHAPTER 1: SAFETY... 5 How to Use This Manual ... 5 Safety Symbols Used in this Manual ...5 General Safety Regulations ... 6 Responsibility ... 6 Warnings and Precautions ... 7 CHAPTER 2: FUNCTIONAL DESCRIPTION ... 11 Models Covered in This Manual...

  • Page 5: Chapter 1: Safety

    Chapter 1: Safety 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.

  • Page 6: General Safety Regulations

    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.

  • Page 7: Warnings And Precautions

    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.

  • Page 8: Remaining Risks

    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.
  • Page 9 Type of Danger Activity Pulling in caused by All activities running V-belts Direct/indirect contact Maintenance work, with live parts in start up terminal box. Failure of Emergency All activities Stop function Fire/explosion caused Grinding by throwing dangerous objects (i.e. spray cans) into the shredder Damage to hearing All activities...
  • Page 10 Type of Danger Activity Crushing, cutting, All activities amputation caused by manipulation of protective devices For further information on granulator safety, installation, and operation, see the American National Standard for Plastics Machinery Size Reduction of Plastics We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration.

  • Page 11: Chapter 2: Functional Description

    Chapter 2: Functional Description 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.

  • Page 12: Typical Features And Components

    Machine (Standard Execution) (1) Base Frame (2) Machine door (3) Hopper door (4) Gear Box (5) Drive motor (6) V-belt guards (7) Ram hydraulic guards (8) Discharge area The machine housing, drive motor, gear box, hydraulic system and terminal box are mounted on the base frame for electrical connections.
  • Page 13 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...
  • Page 14 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.
  • Page 15 (1) Rotor cutter (2) Screen support (hydraulic) (3) Bed knife (1) Rotor cutter (2) Screen support 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.
  • Page 16 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.
  • Page 17 (1) Hydraulic cylinder (2) Screen support (3) Screen 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 BJ5-620 Chapter 2: Functional Description 17 of 73...
  • Page 18 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.

  • Page 19: Safety Features

    Safety Features Protective Devices CAUTION! Safety Device for Machine and Hopper Doors Safety device: machine 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.
  • Page 20 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) Ram guarding (2) V-belt guarding NOTE: The operator must fit and mount the protective devices delivered with Safety Markings...

  • Page 21: Emergency Stop Button

    The following protective gear must be worn when performing the outlined tasks: Unloading machine. Connecting machine. Operation. Cleaning. Maintenance of bearings. Screen replacement. Maintenance of V-belts. Maintenance of cutting knives. Knife sharpening. 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.

  • Page 22: Chapter 3: Installation

    Chapter 3: Installation 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”...

  • Page 23: Electrical Connections

    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.
  • Page 24 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.

  • Page 25: Checking The Rotational Direction

    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.
  • Page 26 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). Switch ON hydraulic unit for a short time and check rotational direction. Allow machine to run for approximately 10 minutes without shredding material.

  • Page 27: Chapter 4: Operation

    Chapter 4: Operation 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 Cutters and bed knives are properly set and the screws are tightened with the specified torque.
  • Page 28 • 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.
  • Page 29 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.
  • Page 30 Figure: Hydraulic Set-up 杆径?63 缸径?125 ( 初始设定压力 15M Pa ) ( 初始设定压力 9M Pa ) ( 初始设定压力 9M Pa ) 33m l / r ec 12m l / r ec BJ5-620 Operation 30 of 73...

  • Page 31: Shut-Down

    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. BJ5-620 Operation 31 of 73...

  • Page 32: Chapter 5: Maintenance

    Chapter 5: Maintenance 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.

  • Page 33: Preventative And Corrective Maintenance

    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! 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.

  • Page 34: Replacing The Gear Box

    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.
  • Page 35 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.
  • Page 36 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.

  • Page 37: Lubrication Intervals

    Lubrication Intervals Shift Operation 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: • • • Replacing or Refilling Lubricant • Fill the bearings uniformly with grease until all operating surfaces are well greased.
  • Page 38 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.
  • Page 39 List of Recommended Lubricants Country of Manufacturer/Manufacturer ARAL CASTROL ESSO FUCHS SHELL MOBIL-OIL WISURA Zeller $ Gmelin ANTAR Holland, Beverol Italy, Agip Swede, NYNAS BJ5-620 Roller Bearing Grease ARL Grease HL 3 BP ENERGREASE LS 3 CASTROL SPHEEROL AP 3 Beacon 3 FUCHS Grease 1200 FUCHS Grease FWA 220...
  • Page 40 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 40 of 73...
  • Page 41 Tightening Torque of the Screws Refer to the table below. Tensioning Screws- element (Type) Tightening torque in Nm 1008 1108 1310 1315 1210 1215 1610 1615 2012 2017 2517 2525 3020 3030 3535 4040 4545 5050 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.
  • Page 42 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.
  • Page 43 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.
  • Page 44 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.
  • Page 45 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 6.
  • Page 46 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.
  • Page 47 5. Clean the hexagon head socket of the knife mounting bolts (2) and the cover 6. Loosen the cover plate mounting bolts using a high quality Allen key (10 mm). 7. Take out the bolts and cover plates. 8. Loosen the knife adjusting screws for pulling and take them out. 9.
  • Page 48 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. WARNING! Danger of cutting caused by sharp knives at all times—even when rotor is at standstill.
  • Page 49 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.
  • Page 50 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.
  • Page 51 (1) Bed knife (2) Knife mounting screws (3) Knife holder (4) Cover plates (5) Knife adjusting screw for pushing (6) Knife adjusting screw for pulling (7) Cover plate mounting screws BJ5-620 1. Remove old knives (see “Dismounting the bed knives”). 2.
  • Page 52 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.
  • Page 53 Hydraulic liquid recommendation Designation to DIN 51 524 Ambient temperature: Supplier ARAL ESSO FINA FUCHS MOBIL TEXACO BJ5-620 HLP 32 -7 to +70°C Name of the oil Aral Vitam GF 32 Aral Vitam HF 32 BP Energol HLP-D 32 BP Energol HLP 32 BP Energol SHF 32 Elfolna 32 Hydrelf 32...

  • Page 54: Chapter 6: Troubleshooting

    Chapter 6: Troubleshooting 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.
  • Page 55 Problem Machine blocks or switches itself off Rotor does not grip bulky material. BJ5-620 Possible Cause Too much feed material. Screen blocked. V-belts slip. Knife condition. Cutting gap. Discharge blocked. Current failure. Fuse too small. Rotational direction of rotor. Rotor speed. Knife condition.
  • Page 56 Problem Overheating of the shredded material. Unusual vibrations. Extreme cutter wear. Bearings too hot. Too many fines in shredded material. BJ5-620 Possible Cause View first 5 possible causes for “Machine blocks or switches itself off” Screen perforation too small. Knives wrongly sharpened. Material rubs against the housing wall.
  • Page 57 Problem Cutting gap alters during operation. Screen damage. Shredder does not start. Shredder blocks when under load. Frequent switching off of grinding material in-feed device. BJ5-620 Possible Cause Knife mounting screws not tight. Screw fatigue. Washers deformed. Knife holder surface deformed.

  • Page 58: Hydraulic Troubleshooting

    Hydraulic Troubleshooting Problem Motor doesn’t work. Oil pump doesn’t work. Oil pump noise Working pressure is abnormal. Pressure maintain is abnormal. Work is abnormal. High oil temperature. BJ5-620 Possible Cause Electric source. Motor damage. Motor not functioning. Pump damage. Filter jam. Hydraulic oil is too thick.

  • Page 59: A-1 Returned Material Policy

    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.

  • Page 60: Technical Specifications

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

  • Page 61: Drawings And Diagrams

    A-3 Drawings and Diagrams NOTE: Please refer to the corresponding spare parts lists in the following section. Cutter mounting BJ5-620 Appendix 61 of 73...
  • Page 62 Bed knife fixing BJ5-620 Appendix 62 of 73...
  • Page 63 Rotor Assembly BJ5-620 Appendix 63 of 73...
  • Page 64 Drive BJ5-620 Appendix 64 of 73...
  • Page 65 BJ5-620 Appendix 65 of 73...
  • Page 66 Ram scraper BJ5-620 Appendix 66 of 73...
  • Page 67 SXS 1500/2000 Standard Hydraulic Diagram 杆径?63 缸径?125 ( 初始设定压力 15M Pa ) ( 初始设定压力 9M Pa ) ( 初始设定压力 9M Pa ) 33m l / r ec 12m l / r ec BJ5-620 Appendix 67 of 73...

  • Page 68: Spare Parts List

    A-4 Spare Parts List SXS 1500 Pos. BJ5-620 Description/Standard Machine complete Standard hopper PP-scraper side PP-scraper top Upper door Lower door Safety grid side Safety grid back Safety grid back Ram residual chute Screen complete (Hydraulic) Screen Screen support screws DIN912 – M16x25 – 8.8 Screen adjusting bolt Screen support Cylinder for screen support opening Ø63xØ35x155...
  • Page 69 BJ5-620 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 E-knife rotor ø660x1500 Rotor knife 60x60x30...
  • Page 70 SXS 2000 Pos. BJ5-620 Oil filter SP-10 Electrical parts Safety switch CAZ15zvrk Small control box Control panel Proximity switch II0297 Cable for Proximity switch E10200 Description/Standard Machine complete Standard hopper PP-scraper side PP-scraper top Upper door Lower door Safety grid side Safety grid back Safety grid back Ram residual chute...
  • Page 71 BJ5-620 V-Belt SPC3250 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 Rubber bush plate Rubber bush Ø116x68x100 Copper bush ø68x63x100...
  • Page 72 Hydraulic Unit Spare Parts List Description Suction filter Suction filter Electric motor Gear pump Oil cooler Check valve Check valve 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...

  • Page 73: Technical Assistance

    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. 160 Street New Berlin, WI 53151 www.sterlco.com...

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Sxs 1500Sxs 2000

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