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DUAL-SHEAR M120E Operation And Service Manual

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OPERATION AND
SERVICE MANUAL
Model:
Serial Number:
Order Number:
Job Number:
Customer:
South Wake Scrap Tire Facility
This manual contains information that is the
property of SSI Shredding Systems, Inc. By
accepting this information, the borrower
agrees that it will not be used for any other
purpose than that for which it is loaned.
SSI Shredding Systems, Inc.
9760 SW Freeman Drive
Wilsonville, Oregon 97070, USA
+1 (503) 682-3633 phone
+1 (503) 682-1704 fax
www.ssiworld.com
M120E(63)
S3243
422.1175
22.1098
Introduction
Installation
Operation
Preventive Maintenance
Service
Troubleshooting
---
---
---
Warranty
Specifications, Parts Lists,
and Drawings
Vendor Literature

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Summary of Contents for DUAL-SHEAR M120E

  • Page 1 Introduction Installation Operation Preventive Maintenance OPERATION AND SERVICE MANUAL Service Model: M120E(63) Troubleshooting Serial Number: S3243 Order Number: 422.1175 Job Number: 22.1098 Customer: South Wake Scrap Tire Facility This manual contains information that is the property of SSI Shredding Systems, Inc. By...

  • Page 2: Table Of Contents

    SECTION PAGE INTRODUCTION TABLE OF CONTENTS PURPOSE OF THIS MANUAL CUSTOMER ASSISTANCE SAFETY PRECAUTIONS 1.3.1 MACHINE LOCK OUT 1.3.2 DEFINITIONS AND ABBREVIATIONS INTENDED USE AND LIMITATIONS SSI Service Manual - 991285 Rev 1...

  • Page 3: Purpose Of This Manual

    SECTION PAGE PURPOSE OF THIS MANUAL PURPOSE OF THIS MANUAL This manual contains guidelines for the set-up, safety, operation, maintenance, and service of equipment provided by SSI. A copy of this manual should be kept clean and near the machine at all times. Please read and understand the applicable sections and their safety precautions prior to performing any procedures.

  • Page 4: Customer Assistance

    SECTION PAGE CUSTOMER ASSISTANCE SSI provides customer assistance with the operation, maintenance and service of this machine. HOURS: Office: Monday-Friday, 7:00 am to 5:00 pm PST 24-hour phone support available. PHONE: Voice: 503-682-3633 Fax: 503-682-1704 EMAIL: info@ssiworld.com parts-service@ssiworld.com ADDRESS: Shipping and correspondence should be sent to the following address: SSI Shredding Systems, Inc.

  • Page 5: Safety Precautions

    SECTION PAGE SAFETY PRECAUTIONS 1.3.1 SAFETY PRECAUTIONS Machine operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the machine. These safety precautions are provided for your safety. Review them carefully before operating the machine and before performing general maintenance or repairs.
  • Page 6 SECTION PAGE SAFETY PRECAUTIONS 1.3.1 GENERAL SAFETY PRECAUTIONS • Establish a training program for all operators to ensure safe operation. • Do not operate the machine unless thoroughly trained or under the supervision of an instructor. • Always wear safety equipment such as goggles, hearing protection, head protection and safety shoes while operating or working around the machine.

  • Page 7: Machine Lock Out

    SECTION PAGE MACHINE LOCK OUT 1.3.2 MACHINE LOCK OUT Failure to lock out can result in severe personal injury or death. To ensure safety when servicing or inspecting the equipment, all sources of energy must be switched off, locked out and tagged at the source before beginning work. The following four general steps should be followed.
  • Page 8 SECTION PAGE MACHINE LOCK OUT 1.3.2 POSSIBLE SOURCES OF ENERGY All possible sources of energy must be identified and locked out prior to working on the equipment. The following is a list of common sources of energy. It is possible that other sources of energy exist that are not identified here.

  • Page 9: Definitions And Abbreviations

    SECTION PAGE DEFINITIONS AND ABBREVIATIONS CLEANING FINGER A flat metal plate with a bar welded on one side and a semicircular notch cut out of the other. The semicircular notch fits closely around the spacer to prevent material from building up between cutters. CUTTER A thick metal disk usually containing one or more hooks on the outer edge and a hole in the center.
  • Page 10 SECTION PAGE DEFINITIONS AND ABBREVIATIONS CUTTING CHAMBER A rectangular area formed by the shredder gearbox, side walls, and end plate which contains the cutters, spacers and cleaning fingers. CUTTER TO CUTTER CLEARANCE The effective shear gap between overlapping cutters in the cutting chamber. SSI Service Manual –...
  • Page 11 SECTION PAGE DEFINITIONS AND ABBREVIATIONS CONTROLLED TORQUE COUPLING (SSP-SEVERE SHOCK PROTECTION) (Used on some models) A device installed between the electric motor and gear reducer that protects drive components by slipping instantaneously when excessive shredder loads are encountered. GEARBOX A rectangular box, part of the shredder frame, which contains the main cutter shaft bearings and on some models large spur gears.
  • Page 12 SECTION PAGE DEFINITIONS AND ABBREVIATIONS HYDRAULIC POWER UNIT (HPU) (Used on some models) A unit consisting of motors, pumps, and the hydraulic fluid reservoir to power the shredder or equipment. JAM REVERSAL A reversing of the cutter shafts due to shredder overload or non-shreddable objects in the cutting chamber.
  • Page 13 SECTION PAGE DEFINITIONS AND ABBREVIATIONS SHREDDER HEAD An assembly typically consisting of the shredder frame, endplate, shredder gearbox, planetary gear reducer, cutting chamber, and all operating component parts contained therein. SPACER A small, non-hooked disk used to hold cutters a precise distance apart. The center hole may be keyed or hexed and allows the spacer to be mounted on a shaft.
  • Page 14 SECTION PAGE INTENDED USE AND LIMITS OF SHREDDER INTENDED USE AND LIMITS OF SHREDDER • The Shredder is used for the size reduction of material for further processing or disposal. SSI must approve all material prior to shredding. • The shredder is to be operated and maintained only by trained, qualified personnel •...
  • Page 15 SECTION PAGE INSTALLATION TABLE OF CONTENTS SET-UP CONSIDERATIONS INSTALLATION HYDRAULIC CONNECTIONS (IF SUPPLIED) INITIAL START-UP SSI Service Manual – 991186 Rev A...
  • Page 16 SECTION PAGE SET UP CONSIDERATIONS It is important to consider things like material flow and equipment placement when setting up the shredder. The following setup considerations will help ensure: • Safety • Efficiency Ease of service • Optimum performance • A hopper is required to direct material into the cutting chamber.
  • Page 17 SECTION PAGE SET UP CONSIDERATIONS DISCHARGE CONVEYOR The Discharge Conveyor moves shredded material from the Discharge Chute to downstream equipment. The type of conveyor recommended (rubber belt, steel pan, augers, etc.) depends on: Material type • Material size • Downstream requirements •...
  • Page 18 SECTION PAGE SET UP CONSIDERATIONS Hydraulic oil must be filtered thru specific filter(s) when filling the reservoir. See Hydraulic Connections and Lubrication Specification Section in the manual for details CLEARANCE AROUND THE SHREDDER AND HYDRAULIC POWER UNIT (HPU) For safety, ease of service and maintenance, clearance is needed for removal of the endplate, cutters, and spacers.
  • Page 19 SECTION PAGE INSTALLATION Use appropriate fall protection when working on machine platforms. The shredder contains components, which are too heavy for one person to lift. When servicing, use approved lifting devices or equipment and get assistance from other workers when needed. Do not put fingers in bolt holes or between other heavy parts.
  • Page 20 SECTION PAGE INSTALLATION FOUNDATION / STRUCTURAL REQUIREMENTS The foundation must support the weight of the shredder, support structure, peripheral equipment, and material being shredded. SSI cannot evaluate foundation stability and design. If the shredder head is going to be mounted on a support structure, consider the following: •...
  • Page 21 SECTION PAGE INSTALLATION Properly sized and installed wiring is required to prevent fires and equipment damage. POWER REQUIRMENTS On shredders with electrical controls provided by SSI, there will be one or more breakers provided in the motor starter panel. Feeders with Amperage capacity equal to or in excess of the breaker size should be used to supply power to the shredder.
  • Page 22 SECTION PAGE INSTALLATION Control power wiring should be run in separate conduits from motor leads and other higher voltage • wiring. • For all installations inside the USA, all wiring must meet National Electric Code standards. State and local regulations may also apply. For installations in other countries, the local electrical code must be adhered to.
  • Page 23 SECTION PAGE INSTALLATION Braking resistors (Optional – generally not supplied). If the unit is supplied with braking resistors, the • braking resistors need to be mounted in a clean area also, with lots of available air circulation to prevent heat buildup in the resistors and the possibility of fire. In addition to the considerations above, contact SSI for the following information and review it thoroughly prior to receiving and installing the SmartDrive equipment.
  • Page 24 SECTION PAGE INITIAL START-UP Prevent electric shock injuries and damage. External wiring, connections, and interlock devices must be installed in accordance with the latest national electric codes, local codes, and local electric utility requirements. Only competent, authorized electricians should attempt to install, modify, and maintain electrical systems.
  • Page 25 SECTION PAGE INITIAL START-UP 11. Make sure there are no people, tools, or objects that do not belong in or near the shredder. 12. Turn on the main circuit breaker at the motor starter panel. 13. At the control panel, switch the key switch to the ON position. Press the MCR ON / RESET. Confirm that MCR light glows.
  • Page 26 SECTION PAGE INITIAL START-UP HOPPER RAM START-UP (IF UNIT IS SUPPLIED WITH RAM HOPPER) High pressure leaks of hydraulic fluid can penetrate skin, resulting in severe personal injury or death. 1. Make sure that the electric connections are finished. 2. Flush the hydraulic lines leading to the hopper ram ( see “Hydraulic Connections” section for details) 3.
  • Page 27 SECTION PAGE OPERATION TABLE OF CONTENTS CONTROL PANEL OPERATING THE SHREDDER SSI Service Manual – 991187 Rev A...
  • Page 28 SECTION PAGE CONTROL PANEL Check that personnel are clear of all equipment before operating the system. Do not operate this machine unless thoroughly trained or under the supervision of an instructor. OPERATOR CONTROL PANEL (OCP) OVERVIEW Control Power Key Switch and E-Stop Key Switch Options shown below: EMERGENCY STOP Button (IF PROVIDED) Immediately disconnects power to all outputs.
  • Page 29 SECTION PAGE CONTROL PANEL SYSTEM START/RUN Button/Lamp Starts the system. Press and hold the button for 5 seconds to start the startup sequence. After a 5 second warning horn while the button is being pressed, the button can be released, and the system will begin the start sequence.
  • Page 30 ICONS An icon is a button that will launch a pop-up window over the System Screen. Icons can contain many different symbols for what the pop-up window will contain. Typical icons are shown below: UNISHEAR DUAL-SHEAR TRI-SHEAR QUAD-SHEAR POP-UP SCREENS Touching an icon will launch a pop-up screen that will appear in front of the System Screen (Except on the ICON HELP screen.
  • Page 31 SECTION PAGE CONTROL PANEL BUTTONS A button is used to change a condition by pressing it. Buttons are dark grey rectangles with a raised appearance as shown below on the left. Some buttons can or must be held down to change a condition. Text near the button will instruct the operator to do so.
  • Page 32 SECTION PAGE CONTROL PANEL SYSTEM SCREEN Following power up, the operator will see the power up screen. Turning on control power and touching the screen will then display the System Screen. The SYSTEM SCREEN is always visible in the background and is the starting point for all navigation. FUNCTIONAL AREAS Note: Pictured are examples of possible indicators, icons, buttons, and displays based on system options.
  • Page 33 SECTION PAGE CONTROL PANEL AREA A: ICON BAR Contains icons which open pop-up screens for various functions. Press the “?” icon to get a list of the icons and their descriptions. SSI Service Manual – 992259 Rev1...
  • Page 34 SECTION PAGE CONTROL PANEL SSI CONTACT POP-UP This screen shows the address and contact information for SSI. Before contacting SSI, note the model and serial number of the shredder (The model and serial number shown on this screen is an example. Each system will differ).
  • Page 35 SECTION PAGE CONTROL PANEL LOG IN POP-UP To log in press the “LOG IN’ button. This will bring up the password entry dialog box: Enter the password to log in (Password is “1234”) and hit the Enter (down and left arrow) key. The indicator turns on when the password is accepted.
  • Page 36 SECTION PAGE CONTROL PANEL OPERATING MODES POP-UP The Operating Modes pop-up has indicators and switches that allow the operator to change the modes of running the system. • Modes are available when there are multiple ways to operate the system, each using different combinations of equipment.
  • Page 37 SECTION PAGE CONTROL PANEL CONFIGURATION POP-UP The Configuration screen is used to set things that are infrequently modified. Note: The operator must be logged in to make changes. DISABLE / ENABLE MOTION Buttons The Discharge Conveyor may be equipped with a motion switch that detects that the conveyor is operating correctly and can receive material.
  • Page 38 SECTION PAGE CONTROL PANEL AUTO-SMARTFEED Definition Auto-SmartFeed utilizes SmartFeed to process material that might otherwise lead to repeated jams, resulting in a Jam Shutdown fault. See Operating Modes screen for the on / off switch. On shredders equipped with Auto-SmartFeed, this function will automatically engage SmartFeed mode after the preset number (AUTO-SMARTFEED COUNT) of clutch slips or torque reversals are met.
  • Page 39 SECTION PAGE CONTROL PANEL CLOCK Icon - SET SYSTEM TIME (IF PROVIDED) The PLC time is set using this screen. Touch the upper box to bring up a data entry dialog that allows the correct time to be entered. Touch the PRESS TO SET DATA AND TIME button to set the clock. Note that the time is not fully entered until the power to the entire machine is turned off and then on again.
  • Page 40 SECTION PAGE CONTROL PANEL FAULT HISTORY POP-UP This screen displays a listing of the alarm conditions experienced by the system. The fault record can be scrolled up simply by moving a finger up and down on the list of faults. Note that the time stamp is based on the setting of time/date in the control system.
  • Page 41 SECTION PAGE CONTROL PANEL SHREDDER FAULT MESSAGE CORRECTIVE ACTION REQUIRED (11) MOTOR #1 JAM SHUTDOWN Shredder has undergone more than the allowed number of jam reversals without having run in a forward direction for a (12) MOTOR #2 JAM SHUTDOWN preset time.
  • Page 42 SECTION PAGE CONTROL PANEL SHREDDER FAULT MESSAGE CORRECTIVE ACTION REQUIRED (32) PLANETARY COOLER FAULT - The auxiliary motor starter contact for the gearbox cooler OVERLOAD/COIL motor has failed to provide a confirmation signal after the starter was commanded to operate. Check operation of the starter and motor overload.
  • Page 43 SECTION PAGE CONTROL PANEL SHREDDER FAULT MESSAGE CORRECTIVE ACTION REQUIRED (120) E-STOP AT CONTROL PANEL The emergency stop button is depressed. Pull the button and reset the system. (121) E-STOP AT MOTOR PANEL (122) E-STOP AT REMOTE PANEL (125) REMOTE E-STOP ACTIVE (127) E-STOP AT ACCEPTS CONVEYOR (128) E-STOP AT RETURNS...
  • Page 44 SECTION PAGE CONTROL PANEL SHREDDER INFORMATION POP-UP The PLC records the number of hours that have been run in automatic mode, as well as several other key operational items. This data is very useful for determining how the shredder is running. RUNNING HOURS Display Field This is the “hour meter”...
  • Page 45 SECTION PAGE CONTROL PANEL CLUTCH SLIP Display Field Displays a running count of the number of shaft reversals, due to clutch slip, since the system was put into service. CLUTCH SLIP COUNTER Display Field Displays a running count of the number of shaft reversals, due to clutch slip, since the last time the counter was reset.
  • Page 46 SECTION PAGE CONTROL PANEL PLC INPUT / OUTPUT MONITOR POP-UP This pop-up used to display the actual status of PLC “real world” inputs and outputs. This screen changes depending on the PLC hardware provided. The indicators will come ON when the noted input or output is active.
  • Page 47 SECTION PAGE CONTROL PANEL MAINTENANCE SCHEDULE POP-UP Note: The operator must be logged in and in Maintenance Mode to make changes on this screen. The Maintenance Schedule function alerts the operator when specific hourly maintenance intervals are reached. The interval hours are based on the time the system is running in automatic. The standard intervals are 40 hours (approximately weekly), 50 hours (one-time initial gear reducer oil change), 250 hours (approximately 2 months), 1000 hours (approximately 6 months), and 2000 hours (approximately 1 year).
  • Page 48 SECTION PAGE CONTROL PANEL Note: The one-time 50-hour maintenance interval cannot be changed. “hour maintenance due in the following hours:” Display Field This shows how many hours are remaining until the maintenance interval is reached and maintenance must be performed. RESET TIMER Button This reset button resets the specified maintenance interval timer back to the original time.
  • Page 49 SECTION PAGE CONTROL PANEL SSI Service Manual – 992259 Rev1...
  • Page 50 SECTION PAGE CONTROL PANEL BANNER SC10 SAFETY CONTROLLER STATUS (IF PROVIDED) The Shredder is equipped with a “Banner Safety Monitoring Relay. The status lights on this pop-up are designed to aid SSI Customer technicians in analyzing Safety Relay problems SAFETY OK Display If this indicator is on, the safety controller is on and in a reset state.
  • Page 51 SECTION PAGE CONTROL PANEL COMMS FAULT This indicates when there is a communications fault. LOCKOUT FAULT A lockout condition is a response where the Safety Controller turns off all affected Safety Outputs when a safety-critical fault is detected. Recovery from this condition requires all faults to be remedied and a system reset to be performed.
  • Page 52 SECTION PAGE CONTROL PANEL AREA B: SYSTEM LAYOUT This shows the layout of the system. Each piece of equipment has the following display elements: The equipment designator (i.e. “C1”, “C2”) • A Shredder icon or a “ZOOM IN” icon that launches a pop-up with more information and •...
  • Page 53 SECTION PAGE CONTROL PANEL E-Stop Pull Cords are shown as red lines along the side of a conveyor that appear when the cord • is pulled and look like this: NOT PULLED: PULLED: LOAD GAUGE displays may also be shown in the system layout near a shredder. The shredder load gauge displays the torque feedback from the motor(s).
  • Page 54 SECTION PAGE CONTROL PANEL SHREDDER DETAIL POP-UP REMOTE / LOCAL LOCAL A Shredder Detail pop-up contains icons, indicators, display fields, and buttons SHREDDER SHAFT SPEED TREND This graph displays the shaft speeds on a 0-130% scale. It is a 100 second running graph. MOTOR SHAFT ROTATION Symbols Motor shaft rotation is designated by the color and arrow directions within the cutter symbol.
  • Page 55 SECTION PAGE CONTROL PANEL MOTOR#1 % SPEED / MOTOR#2 % SPEED Display Field (IF PROVIDED) This display shows the RPM speed of the motor shaft. JAM COUNT #1 / JAM COUNT #2 Display Field Displays the number of consecutive jam reversals that have occurred on a shaft, before being reset by the JAM RESET TIMER.
  • Page 56 SECTION PAGE CONTROL PANEL AUTOCHOP POP-UP (IF PROVIDED) AUTOCHOP MODE ON/OFF Switch Determines if the Autochop function is on or off. The state of the indicator is based on the state of the switch. REGULAR AUTOCHOP Indicator When the Autochop function is enabled and the Regular Autochop Mode is selected, the shredder shafts will reverse periodically based on the timers shown on this screen.
  • Page 57 SECTION PAGE CONTROL PANEL SMARTFEED POP-UP (IF PROVIDED) SMARTFEED ON/OFF Switch Press to enable and disable the SMARTFEED function. There is a duplicate switch on the OPERATING MODES POP-UP Screen. CONTINUOUS SMARTFEED MODE ACTIVE Indicator This indicator turns on when SMARTFEED is active. METERED TORQUE (%), MIN / MAX Data Entry/Display Field Used to set minimum and maximum torque values of the main shaft.
  • Page 58 SECTION PAGE CONTROL PANEL SMARTFEED MODE TABLE SMARTFEED MODE METERED TORQUE (%) MAX METER SPEED (%) 1 – EASY MATERIAL 2 – MODERATE MATERIAL 3 – DIFFICULT MATERIAL USER 20-100 40-120 0-20 0-20 *The differential between the METERED TORQUE (%) MIN and MAX values must always be atleast SSI Service Manual –...
  • Page 59 SECTION PAGE CONTROL PANEL SMARTFEED THEORY OF OPERATION SMARTFEED is a mode of operation to optimize throughput of difficult to process materials. One shaft is set as the main shaft and rotates at a set speed, while the second shaft acts as a metering shaft and slowly feeds material into or draws material away from the main shaft, depending on the load detected on the main shaft.
  • Page 60 SECTION PAGE CONTROL PANEL VFD SETTINGS POP-UP (IF PROVIDED) Used to set the FORWARD, REVERSE, and JOG preset speeds for the SmartDrive VFD units. This screen is also used to monitor the commanded speed being sent to the VFD, and the actual running speed and torque.
  • Page 61 SECTION PAGE CONTROL PANEL MAINTENANCE MODE JOG SCREEN POP-UP Note: Buttons and displays may appear grey and unable to be operated unless the operator is logged in and in Maintenance Mode. MOTOR#1 RPM / MOTOR#2 RPM Display Fields This display shows the RPM speed of the motor shaft. JOG FWD / JOG REV Button Used during maintenance to jog shafts individually while the button is pushed.
  • Page 62 SECTION PAGE CONTROL PANEL RAM OPERATION POP-UP (IF PROVIDED) RAM AUTO MODE ON/OFF Switch Press and slide, or double tap, this switch to turn on/off the RAM AUTO MODE. Turning on this mode will cause the ram to stroke up and down when the system is running in auto. The ram will stop and retract when the OK TO LOAD signal is lost, due to increased load.
  • Page 63 SECTION PAGE CONTROL PANEL AUTOLUBE POP-UP (IF PROVIDED) This screen shows information about the lubrication pump and allows troubleshooting the lubrication system. The Autolube system consists of a grease pump, a distribution block and a proximity sensor located on the distribution block. The proximity sensor sends a pulse to the PLC every time all the connected bearings have been lubricated once.
  • Page 64 SECTION PAGE CONTROL PANEL AUTOLUBE CYCLES Display Field This accumulation shows the number of times the proximity switch turns on and off to equal one full lubrication cycle. This value is set at SSI and cannot be changed. LUBE SYSTEM COUNT SINCE POWER ON Display Field This displays the accumulation of the proximity switch counts since the power to the system was turned on.
  • Page 65 SECTION PAGE CONTROL PANEL PLANETARY REDUCER TEMPERATURE POP-UP (IF PROVIDED) This screen shows planetary cooler features that may not be provided. If the planetary cooler indicators and buttons do not appear on the screen of the installed system, this means the feature is not available. PLANETARY TEMPERATURE WARM Indicator Turns yellow to indicate that the planetary oil has exceeded the normal operating temperature.
  • Page 66 SECTION PAGE CONTROL PANEL HOPPER LEVEL POP-UP (IF PROVIDED) This feature is not provided on all systems. HOPPER FULL Indicator This indicator turns on when there is too much material in the hopper, and the upper Photo-eye is blocked. HOPPER EMPTY Indicator This indicator turns on when there is too little material in the hopper, and the lower Photo-eye is un- blocked.
  • Page 67 SECTION PAGE CONTROL PANEL CONVEYOR C1 POP-UP (GENERAL CONVEYORS) (IF PROVIDED) This feature is not provided on all systems. For each conveyor, there is a zoom in icon that will open a pop-up showing status indications, settings, and maintenance functions. Not all the functions shown above will be present for all conveyors. RUNNING Indicator This indicator is on when the conveyor is running.
  • Page 68 SECTION PAGE CONTROL PANEL If the conveyor has been latched in via the jog button, pressing this button will cause it to stop. Note that the stop button on the control panel will also stop all conveyors that are being jogged at once. START DELAY (Seconds) Data Entry Field (if provided) This value determines the length of time before the indicated component starts in a sequence.
  • Page 69 SECTION PAGE CONTROL PANEL AREA C: OPERATING MODE Area C contains the status bar (shown as a blue box above) which displays the current operating status of the system. Possible messages are listed below: OPERATING MODE MESSAGE DESCRIPTION SYSTEM OFF This message indicates that the system is currently stopped.
  • Page 70 SECTION PAGE CONTROL PANEL OPERATING MODE MESSAGE DESCRIPTION SHREDDER IN AUTOCHOP This message indicates that the system is running in (IF PROVIDED) AUTOCHOP mode. The operator has switched on the AUTOCHOP Mode from the OPERATING MODES Pop-up screen. SYSTEM IN MAINTENANCE MODE This message indicates that the system has been switched to MAINTENANCE Mode.
  • Page 71 SECTION PAGE CONTROL PANEL AREA D: SYSTEM STATUS Area D shows the status conditions of the system. Below is a description of each condition: STATUS MESSAGE DESCRIPTION The Safety Monitoring Relay is not reset due to an e-stop SAFETY SYSTEM NOT RESET device or gaurd switch being activated.
  • Page 72 SECTION PAGE CONTROL PANEL STATUS MESSAGE DESCRIPTION SYSTEM IN AUTOMATIC The system has been started and is running in Auto. Shredder may be physically stopped due to loss of downstream enable signal and still be in AUTO mode. If this happens it can restart without warning.
  • Page 73 SECTION PAGE CONTROL PANEL STATUS MESSAGE DESCRIPTION PLANETARY REDUCER TEMP On systems equipped with planetary temperature sensors, this WARNING warning appears if the oil temperature inside the reducer is (IF PROVIDED) approaching the PLANETARY OVERTEMP FAULT threshold. This appears only on units with a planetary reducer temperature sensor without a planetary reducer cooler.
  • Page 74 SECTION PAGE CONTROL PANEL AREA E: SYSTEM STATUS INDICATORS Area E shows indicators for conditions that can potentially prevent system startup/operation and also displays the general condition of the system. Below is a description of each indicator: MAINTENANCE LOGGED IN Indicator This indicator turns on when the operator is logged in and has access to several functions.
  • Page 75 SECTION PAGE CONTROL PANEL OK TO RUN Indicator This indicator turns on when the system receives an OK TO RUN signal from the downstream equipment. The system cannot not run without this signal. On systems without downstream equipment supplying this signal, the input is jumped to give this signal.
  • Page 76 SECTION PAGE OPERATING THE SHREDDER Do not operate the machine unless thoroughly trained or under the supervision of an instructor. Always wear safety equipment such as goggles, ear, head protection and safety shoes at all times. Always have all shields and guards in place before operating the machine. OPERATING PRINCIPLES A rotary shear shredder has a row of cutters mounted on two shafts (four shafts for quad units) , inside a heavy steel frame.
  • Page 77 SECTION PAGE OPERATING THE SHREDDER 6. Press the SYSTEM FAULT / RESET button. This turns on the Safety Circuit. If the Safety Circuit fails to energize, make sure all the emergency stop buttons are pulled out. The SAFETY CIRCUIT OK indicator on the HMI System Screen will remain OFF until the Safety Circuit is energized.
  • Page 78 SECTION PAGE OPERATING THE SHREDDER JAM SHUTDOWNS • The PLC monitors both the motor torque from the VFD and pulses from the friction clutch proximity switch. If the motor torque is above a predetermined threshold for a set amount of time, or if the pulses from the proximity switch come too slowly (indicating a slipping clutch), then the shredder stops and reverses.
  • Page 79 SECTION PAGE PREVENTIVE MAINTENANCE TABLE OF CONTENTS MACHINE LOCKING OUT MAINTENANCE SCHEDULE GEARBOX INSPECTION EVALUATING CUTTER WEAR PUMP DRIVE COUPLING (IF SUPPLIED) SSI Service Manual – 991188 Rev 1...

  • Page 80: Machine Locking Out

    SECTION PAGE MACHINE LOCK OUT MACHINE LOCK OUT Failure to lock out can result in severe personal injury or death. To ensure safety when servicing or inspecting the equipment, all sources of energy must be switched off, locked out and tagged at the source before beginning work. The following four general steps should be followed.

  • Page 81: Maintenance Schedule

    SECTION PAGE MAINTENANCE SCHEDULE Always lock out and tag out all power to panels and electric components before servicing. Failure to complete the procedures listed on the maintenance schedule may result in damage to the equipment. Preventive maintenance responsibilities should be shared between the operator and a qualified service technician.
  • Page 82 SECTION PAGE MAINTENANCE SCHEDULE Shields and Guards Visually check for damaged or missing shields and guards. Do not operate machine without all shields and warnings in place. Fasteners Visually check for loose or missing fasteners. Cutting Chamber Check inside hopper and remove non-shreddable objects from the cutting chamber.
  • Page 83 SECTION PAGE MAINTENANCE SCHEDULE EVERY 2 MONTHS OR 250 HOURS CHECK PROCEDURE Wiring Visually inspect wiring for cut or frayed insulation. Check connections for tightness. Remove any corrosion. Fasteners Inspect all hardware and re-torque to specifications. Gear Reducer Drain and refill gear reducer with recommended type oil. Check gear condition if magnetic drain plug contains excessive amount of metal particles.
  • Page 84 SECTION PAGE MAINTENANCE SCHEDULE Ram Timing (If equipped) Refer to Ram Adjustment Section of the manual. EVERY 6 MONTHS OR 1000 HOURS CHECK PROCEDURE Shredder Gearbox Inspect gears and bearings for damage or excessive wear. bearings are loose, tighten according to procedure outlined under Gearbox Inspection in the Service section.

  • Page 85: Gearbox Inspection

    SECTION PAGE GEARBOX INSPECTION Always lock out and tag out all power to panels and electric components before servicing. Gearbox bearing nuts may become loose because of high torque stresses. Regular inspection and maintenance of the gearbox is important. 1. Lock out the shredder 2.
  • Page 86 SECTION PAGE GEARBOX INSPECTION 7. Reseal the gearbox lid with self-adhesive weather stripping (available at hardware stores) and replace it on the shredder. SSI Service Manual - 991174...

  • Page 87: Evaluating Cutter Wear

    SECTION PAGE EVALUATING CUTTER WEAR EVALUATING CUTTER WEAR The torque available from the shredder drive and torque required to shred control the amount of material a machine can process per hour. Most importantly, the shredder should always have enough power to process all the material that the cutters pull in.
  • Page 88 SECTION PAGE EVALUATING CUTTER WEAR Circumference wear Measure and record the radius of the outer edge of the cutter. Generally, cutters should be replaced when the radius of the cutter edge reaches 3/16 in (5mm). This is about the same curvature as a 3/8 in (10mm) bolt.
  • Page 89 SECTION PAGE SERVICE TABLE OF CONTENTS MACHINE LOCK OUT CHANGING CUTTERS SET-UP SPACERS CONTROLLED TORQUE COUPLING RAM ADJUSTMENT (IF SUPPLIED) CURRENT RELAY ADJUSTMENT SPEED SWITCH ADJUSTMENT SSI Service Manual – 991202 Rev A...
  • Page 90 SECTION PAGE MACHINE LOCK OUT MACHINE LOCK OUT Failure to lock out can result in severe personal injury or death. To ensure safety when servicing or inspecting the equipment, all sources of energy must be switched off, locked out and tagged at the source before beginning work. The following four general steps should be followed.
  • Page 91 SECTION PAGE CHANGING CUTTERS Always lock out and tag out all power to panels and electric components before servicing. The shredder contains components which are too heavy for one person to lift. When servicing, use approved lifting devices and get assistance from other workers when needed.
  • Page 92 SECTION PAGE CHANGING CUTTERS Spanner Wrench to fit the gearbox shaft nuts • Torque Wrench with Deep Well Hex Sockets • 8-point sockets to fit hub bolts • Compressed Air with Hand Nozzle • Silicon Sealer • Grease • Rags •...
  • Page 93 SECTION PAGE CHANGING CUTTERS The endplate, seals, seal retainers, and endplate splash plate make up the endplate assembly. The bearings might stay with the endplate assembly or stay on the shafts. Either way is OK. 8. Lower lifting bolts, if they were used. 9.
  • Page 94 SECTION PAGE CHANGING CUTTERS 20. Wash the bearings in solvent. Check them for signs of damage, such as cracks or heavy wear. If a part is damaged, replace it. 21. If the cutters are going to be rebuilt by SSI, the spacers must also be returned and remachined. Place the cutters and spacers in a container for shipping.
  • Page 95 SECTION PAGE CHANGING CUTTERS 6. If the shafts are round shafts with key slots, replace shaft keys. 7. Install the splash plate and any cleaning finger brackets that were removed. Use anti-seize on all of the bolts. 8. Wipe down the shafts. 9.
  • Page 96 SECTION PAGE CHANGING CUTTERS The proper clearance is listed in the Unit Specifications section. The cutter clearance is extremely important and must be correct at the beginning of the stack. If the clearance is not within ±0.005 (.13mm) in of the specified clearance, check for burrs or debris between the spacers and cutters.
  • Page 97 SECTION PAGE CHANGING CUTTERS 32. Use a small rod in the uninstalled bolt holes to align the dowel pin holes. Coat the dowel pins and dowel pin holes with anti-seize. Then use a large hammer to drive the dowel pins through the holes in the endplate and into the shredder frame.
  • Page 98 SECTION PAGE CHANGING CUTTERS The lock ring segments can be installed in two different positions. In one position the preload hub is closer to the bearing spacer than in the other. Choose the position which places the preload hub as close as possible to the bearing spacer, while still allowing the lock rings segments to fit freely into the shaft groove, without forcing them past the preload hub space.
  • Page 99 SECTION PAGE SET-UP SPACERS Always lock out and tag out all power to panels and electric components before servicing. The shredder contains components that are too heavy for one person to lift. When servicing, use approved lifting devices and get assistance from other workers when needed.
  • Page 100 SECTION PAGE SET-UP SPACERS Looking down on the shredder Shredder Gearbox Right Shaft Shaft shoulder Set-up spacer Splash plate Start Clearance Cutter Shear Gap Spacer Cutter Left shaft SETTING THE START CLEARANCE 1. Pre-assemble the first set-up spacer assembly using .082” (2mm) of shims. Tighten the bolts to the torque settings listed on the assembly drawing found in this manual.
  • Page 101 SECTION PAGE SET-UP SPACERS 2. Check the contact areas of the set-up spacers to the shaft shoulder. Use a stone or flat file to remove and burrs to make sure the set-up spacers have solid contact with the shaft shoulder 3.
  • Page 102 SECTION PAGE SET-UP SPACERS See the reassembly subsection of the Changing Cutters section of this manual to restack the cutters. SSI Service Manual – 992100 Rev 1...
  • Page 103 SECTION PAGE CONTROLLED TORQUE COUPLING The Controlled Torque Coupling is installed on electric motor driven shredders to prevent overstressing the planetary gearbox and drive gears in the shredder when the shredder hits something unshreddable and stops instantly. In that situation, the electric motor acts as a fly wheel that can cause a torque spike many times as high as the normal full torque of the motor.
  • Page 104 SECTION PAGE SPEED SWITCH ADJUSTMENT The speed switch is an inductive proximity sensor that detects the speed of the shaft between the friction coupling and the planetary gearbox. The purpose is to detect when the shredder shaft has stopped turning due to an un-shearable object in the cutting chamber. The speed monitoring system will promptly turn off the motor to prevent excessive heat build up at the coupling.
  • Page 105 SECTION PAGE SPEED SWITCH ADJUSTMENT Flag (one of two) Speed Sensor Speed Sensor Mount Bracket 5. If the speed sensor is mounted with the plastic bracket, loosen the allen screw. If the speed sensor is held with two lock nuts, loosen the lock nuts to adjust the sensor. Do not loosen the sensor more than necessary.
  • Page 106 SECTION PAGE SPEED SWITCH ADJUSTMENT Speed Sensor Input 14. If the speed sensor in question is for motor #1, speed sensor input, It should be “on” (lighted). If not, the speed sensor or the wiring to the sensor is bad and the signal is not getting back to the PLC. If the speed sensor is for motor # 2, check Base Unit input #4.
  • Page 107 SECTION PAGE SPEED SWITCH ADJUSTMENT 16. On the touch screen hit the “SCREEN SELECT” and “ROTOR STATUS” to show the information about the rotor. The Motor RPM indicator should read within 200 RPM of the normal speed of the motor. For 60hz installations that would be 1800 RPM, for 50 Hz installations it would be 1500 RPM. 17.
  • Page 108 SECTION PAGE TEMPERATURE SWITCH TEMPERATURE SWITCH ADJUSTMENT NOTE: Temperature switches connected to a remote IO device, using IO-Link for data communication, do not need to be programmed per the instructions below. The program for devices using IO-Link configuration resides within the PLC. If the equipped temperature switch uses digital signals, and does not use IO-Link, please use the following steps below to program the device.
  • Page 109 SECTION PAGE TEMPERATURE SWITCH 3. Change the units to degrees Fahrenheit to complete the following procedure. If Celsius is the preferred units, change back to Celsius after configuring the unit. To adjust the units to °F: Press the ENTER to get to the Menu Press the DOWN ARROW / UP ARROW button until the display reads ‘EF’.
  • Page 110 SECTION PAGE TEMPERATURE SWITCH 6. Note: Programmed correctly the indicator lights will operate as follows: Switch #1 Below 180° Over 180° F Below 179° F Switch #2 Below 200° F Above 200° F Below 199° F 7. For additional information, refer to the vendor literature section of the service manual. SSI Service Manual –...
  • Page 111 SECTION PAGE TROUBLESHOOTING TABLE OF CONTENTS TROUBLESHOOTING CHART SSI Service Manual – 991195 Rev A...
  • Page 112 SECTION PAGE TROUBLESHOOTING CHART TROUBLESHOOTING CHART The following chart gives some guidelines for trouble shooting the shredder and the electrical system. Note that the touch screen indicates all the faults that shut the shredder down (see the Control Panel section). In most cases this is the best starting point for trouble shooting. Always lock out and tag out all power to the shredder to prevent unexpected motion before servicing.
  • Page 113 SECTION PAGE TROUBLESHOOTING CHART Check the PLC fault LED to make sure it is not lit. OK TO RUN input The customer-supplied OK TO RUN enable input to the PLC is not present. Check status of downstream equipment . Shredder Jammed Inspect the cutting chamber for non-shreddable material jammed in the cutters.
  • Page 114 SECTION PAGE TROUBLESHOOTING CHART necessary. Motor Current Relay Check motor current relay manually with a continuity tester. Replace if defective. UNIT OVERLOADS AND/OR REVERSES CONSTANTLY CAUSE CORRECTION Shredder Is Being Fed Too Fast Reduce feeding rate. Non-Shreddable Material In Shredder Shut off machine and remove non-shreddable material from cutting chamber.
  • Page 115 SECTION PAGE TROUBLESHOOTING CHART These sections only apply to units supplied with a ram hopper. RAM HOPPER HPU FAILS TO START CAUSE CORRECTION Emergency Stop Button Check all emergency stop buttons to make sure they are pulled out. Safety Relay Circuit / Master Control Relay The safety relay has 3 green LED's.
  • Page 116 SECTION PAGE TROUBLESHOOTING CHART HOPPER RAM DOES NOT CYCLE AUTOMATICALLY CAUSE CORRECTION Pressure Relief Valve Check main pressure relief valve for proper setting. (See Service Section.) Pressure Switch Check wiring for breaks and loose connections between PLC and pressure switches. Check settings on pressure switches.
  • Page 117 SECTION PAGE WARRANTY TABLE OF CONTENTS 10.0 SSI LIMITED WARRANTY 10.1 SSI Service Manual – 991191 Rev A...
  • Page 118 SECTION PAGE SSI LIMITED WARRANTY 10.1 SSI SHREDDING SYSTEMS, INC. LIMITED WARRANTY WHO IS COVERED This Warranty applies only to the entity who first bought the Equipment from SSI Shredding Systems, Inc. (SSI) or its authorized agents. WHAT IS COVERED This Warranty covers only Equipment both manufactured and supplied by SSI or its authorized agents.
  • Page 119 SECTION PAGE SSI LIMITED WARRANTY 10.1 EXCEPT AS PROVIDED HEREIN, SSI MAKES NO OTHER EXPRESS WARRANTIES. SSI DISCLAIMS ANY AND ALL IMPLIED WARRANTIES INCLUDING IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. SSI'S LIABILITY UNDER THIS AGREEMENT IS LIMITED TO A REFUND OF THE PURCHASE PRICE FOR THE EQUIPMENT, IN ACCORDANCE WITH THE FOREGOING PROVISIONS.
  • Page 120 SECTION PAGE SECTION 11 11.0 SPECIFICATIONS, PARTS LISTS, AND DRAWINGS LUBRICATION SPECIFICATIONS 11.1 SERVICE SPECIFICATIONS STACK SHEET PARTS LISTS DRAWINGS SYSTEM LAYOUT 132437-D R1 (2) ASSEMBLY SHREDDER 46-0296-D R1 (3) DRIVE ASSEMBLY 08-4262-D R1 (1) HOPPER EXTENSION 03-0920-D R1 (1) MANUAL GREASE STATION 07-8870-D R1 (1) ASSEMBLY WATER SPRAY KIT...
  • Page 121 SECTION PAGE LUBRICANT SPECIFICATIONS 11.1 Component Ambient Recommended Temp. Range Lubricant 35°F - 100°F Hydraulic Oil: ISO 46 Viscosity Index – Ram Hydraulic Power Unit (if 90 min. (AW-46-20) equipped) ** Screen Eject Assist 35°F - 100°F Hydraulic Oil: ISO 46 Viscosity Index – Hydraulic Power Unit 90 min.
  • Page 122 DUAL-SHEAR SHREDDER UNIT SPECIFICATIONS Model M120E(63) Customer Name South Wake Scrap Tire Facility 250 HP (186 kW) Customer Order 422.1175 Serial No. S3243 Job No 22.1098 Electrical Shredder Dimensions Voltage/Phase/Freq. Cutting Chamber Width 460/3/60 46 in (1168 mm) Control Voltage...
  • Page 123 SSI SHREDDING SYSTEMS STACK SHEET STACK#: 3243 Serial #: S3243 Orig'l Order#: 422.1175 Model: M120E(63) Customer: South Wake Scrap Tire Facility Job # : 22.1098 Order #: 422.1175 STACK ORDER Cutters &Spacers TYPE: Round 460244T-07 Spacer 460107-09 LEFT RIGHT 2-HK...
  • Page 124 Order No. 422.1175 Released: 3/6/23 - CEK Serial No: S3243 Model: M120E(63) Recomm. Dwg Ref Qty U/M Description Material Text Part No. SHREDDING SYSTEM w/ M120E(63) S3243-M120E(63)/SYSTEM 0 EA SYSTEM LAYOUT 132437/REV 1 1 EA 460288 SHREDDER w/MODIFIED COMPONENTS S3243-SHREDDER HEAD M120(63)
  • Page 125 2 EA RETAINER - SET-UP SPACER, ADJUSTABLE** 460189 12 EA SCREW-SHCS(M10-1.5x30MM:CL 12.9)3Z-ROHS 003144 2 EA SPRING PIN - M10 x 30MM 081828 1 EA C.F. & SPACER BAR - M120(63)/H(2")/T1 S3243-CLEANING FINGER GRP 2 EA SPACER BAR - 1" x 1" x 17.88" ** 460026-04 31 EA SPACER BAR - 1"...
  • Page 126 Model M120E(63) DRIVE GROUP PARTS LIST Customer: SOUTHWAKE SCRAP TIRE FACL. Order No. 422.1175 Released: 3/6/23 - CEK Serial No: S3243 Model: M120E(63) Recomm. Dwg Ref Qty U/M Description Material Text Part No. 1 EA DRIVE CP-E/250HP/1100/60/T/RR15000/89** 460330 0 EA...
  • Page 127 Model M120E(63) ELECTRICAL PARTS LIST Customer: SOUTHWAKE SCRAP TIRE FACL. Order No. 422.1175 Released: 3/6/23 - CEK Serial No: S3243 Model: M120E(63) Recomm. Dwg Ref Qty U/M Description Material Text Part No. 1 EA SCHEMATIC 030956/REV 2 1 EA PLC/HMI PROGRAM...
  • Page 128 6 EA FUSE - 60A - CLASS J QTY. 3 TO SHIP LOOSE 002142 3 EA DISTRIBUTION BLOCK - FINGER SAFE, 310A 075954 4 EA DISTRIBUTION BLOCK - ASSY. PIN 075943 2 EA CONTACTOR - XT IEC, FVNR, 400A 076463 1 EA OVERLOAD RELAY - XT IEC, 120...600A 080258...
  • Page 129 1 EA ENCLOSURE - 10 X 8 X 4 001897 1 EA ENCLOSURE - BACK PANEL - 10 X 8 001704 1 EA ALARM HORN ASSY 24VDC w/ DIODE 083329 1 EA BUSHED NIPPLE - 1/2"/INSULATED 070512 1 EA LOCKNUT - CONDUIT 1/2 073002 1 EA I/O LINK MASTER W/PROFINET 16I/8O, IP69...
  • Page 130 WASHER - FLAT - PLA325 - 1/2"/M12-YZ 002694 29 EA LOCKWASHER(M12:MED) GRD 10.9-3Z-ROHS 002005 29 EA NUT - HEX(M12x1.75:MED)YZ 002008 1 EA STAND - w/ D. FLANGE/B.B.PADS/M120E(63) 460342-01-72" 2 EA MOUNT PAD - BREAKER BAR** 451730 1 EA FLANGE - DISCHARGE, M120(63) THREADED 460343 1 EA...
  • Page 131 1 EA WATER SPRAY KIT - HOPPER,3-PORT-LG,SOFT* 074464-01 0 EA ASSEMBLY DRAWING 077845/REV 2 3 EA NOZZLE - 1/4" WATER SPRAY, BRASS, FLAT 074916 4 EA BULKHEAD - BRASS FPT-FPT SHORT (04) 071882 1 EA BULKHEAD - BRASS FPT-FPT (08) 004664 8 EA FITTING-ST-3/8"DOT PUSH TO LOCK/1/4"...
  • Page 132 " 6 " 0 " 0 " 0 " 0 " 0 " 0 " 8 " 2 " 8 - ' 1 " 8 " 8 " ( " E E " " " 8 " ( " S S "...
  • Page 133 " 3 " 8 " 2 " 6 " 4 " 2 " 8 " 5 " 2 " 2 " 2 " 4 " 6 " 6 " 2 " 0 " 2 " 8 " 4 " 8 "...
  • Page 134 L " " " " T " 2 ) " ) " ) " ) " s l i l l i...
  • Page 135 s l i l l i...
  • Page 136 s l i l l i...
  • Page 137 ' Y ' ' V ' ' X ' " 4 " 2 " 4 " 2 " 6 " 4 " 0 " 6 ' V ' s l i l l i ± ± ±...
  • Page 138 & s l i l l i ± ± ± ±...
  • Page 139 s l i l l i...
  • Page 140 s l i l l i...
  • Page 141 IT WILL NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS LOANED. 1.1-22 SHREDDER ELECTRICAL SYSTEM SHEET INDEX PAGE 1.1-23 ITEM #: DATE: DRAWN BY: SCALE: PLOT SCALE: 10/27/22 C. SIMPSON None 030957 PLC Pgm: DRAWING NUMBER: SHEET: REVISION: 1.1-24 03-0956-B S3243-M120E Model:...
  • Page 142 IT WILL NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS LOANED. 2.1-22 SHREDDER ELECTRICAL SYSTEM BLOCK DIAGRAM & PANEL LAYOUT 2.1-23 ITEM #: DATE: DRAWN BY: SCALE: PLOT SCALE: 10/27/22 C. SIMPSON None 030957 PLC Pgm: DRAWING NUMBER: SHEET: REVISION: 2.1-24 03-0956-B S3243-M120E Model:...
  • Page 143 IT WILL NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS LOANED. 2.2-22 SHREDDER ELECTRICAL SYSTEM BLOCK DIAGRAM & PANEL LAYOUT 2.2-23 ITEM #: DATE: DRAWN BY: SCALE: PLOT SCALE: 10/27/22 None C. SIMPSON 030957 PLC Pgm: DRAWING NUMBER: SHEET: REVISION: 2.2-24 S3243-M120E 03-0956-B Model:...
  • Page 144 (24.00"H x 20.0"W x 8.00"D) CONTROL PANEL LAYOUT (609mm x 508mm x 203mm) 2.3-23 ITEM #: DATE: DRAWN BY: SCALE: PLOT SCALE: NOT TO SCALE 10/27/22 C. SIMPSON None 030957 PLC Pgm: DRAWING NUMBER: SHEET: REVISION: 2.3-24 03-0956-B S3243-M120E Model:...
  • Page 145 DRAWN BY: SCALE: PLOT SCALE: NOTE: 10/27/22 C. SIMPSON None IF MOTOR ROTATION IS INCORRECT SWAP ANY TWO CONDUCTORS 030957 PLC Pgm: DRAWING NUMBER: SHEET: REVISION: ON THE LOAD SIDE (U2, V2, W2) OF AC DRIVE. 3.1-24 03-0956-B S3243-M120E Model:...
  • Page 146 IT WILL NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS LOANED. 4.1-22 SHREDDER ELECTRICAL SYSTEM DC POWER DISTRIBUTION CIRCUIT SCHEMATIC 4.1-23 ITEM #: DATE: DRAWN BY: SCALE: PLOT SCALE: CONSTANT SOURCE 10/27/22 C. SIMPSON None 24V DC POWER 030957 PLC Pgm: DRAWING NUMBER: SHEET: REVISION: DISTRIBUTION 4.1-24 03-0956-B S3243-M120E Model:...
  • Page 147 IT WILL NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS LOANED. 5.1-22 SHREDDER ELECTRICAL SYSTEM SSI SERVICE PORTAL OPTION 5.1-23 ITEM #: DATE: DRAWN BY: SCALE: PLOT SCALE: 10/27/22 C. SIMPSON None 030957 PLC Pgm: DRAWING NUMBER: SHEET: REVISION: 5.1-24 03-0567-B S3243-M120E Model:...
  • Page 148 SHREDDER ELECTRICAL SYSTEM 2W .05% 081078-1 7.1-47 BLOCK DIAGRAM & PANEL LAYOUT 7.1-23 ITEM #: DATE: DRAWN BY: SCALE: PLOT SCALE: 7.1-48 10/27/22 None C. SIMPSON MSP1 PLC Pgm: 030957 MSP1 DRAWING NUMBER: SHEET: REVISION: 7.1-24 03-0956-B S3243-M120E 7.1-49 Model:...
  • Page 149 IT WILL NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS LOANED. DQ b.7 7.2-22 7.2-47 SHREDDER ELECTRICAL SYSTEM BLOCK DIAGRAM & PANEL LAYOUT 7.2-23 7.2-48 ITEM #: DATE: DRAWN BY: SCALE: PLOT SCALE: 10/27/22 None C. SIMPSON PLC Pgm: 030957 DRAWING NUMBER: SHEET: REVISION: 7.2-24 7.2-49 03-0956-B S3243-M120E Model:...
  • Page 150 IT WILL NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS LOANED. 8.1-22 SHREDDER ELECTRICAL SYSTEM JB1 REMOTE INPUT/OUTPUT SCHEMATIC 8.1-23 ITEM #: DATE: DRAWN BY: SCALE: PLOT SCALE: 10/27/22 C. SIMPSON None 030957 PLC Pgm: DRAWING NUMBER: SHEET: REVISION: 8.1-24 03-0956-B S3243-M120E Model:...
  • Page 151 SECTION PAGE SECTION 12 12.0 VENDOR LITERATURE FALK/REXNORDS** STEELFLEX COUPLINGS INSTALLATION & MAINTENANCE IFM** TN7511 OPERATING INSTRUCTIONS REGGIANA TECHNICAL MANUAL REM** INFEED CONVEYOR REM** DISCHARGE CONVEYOR SPIETH BEARING NUT INSTALLATION WEG** ** INCLUDED VENDOR LITERATURE. VENDOR LITERATURE LISTED HERE, BUT NOT INCLUDED, MAY BE OBTAINED BY CONTACTING SSI SHREDDING SYSTEM, INC.
  • Page 152 Falk™ Steelflex® Couplings • Installation and Maintenance Types T41, T41-2, T44, & T44-2 (Page 1 of 12) How To Use This Manual How the Controlled Torque Coupling or Clutch Operates This manual provides detailed instructions on maintenance, lubrication, installation, and parts identification for Sizes In the drawings below, the pressure from the springs (14 and 1020–1200 &...
  • Page 153 Installation and Maintenance • Falk™ Steelflex® Couplings (Page 2 of 12) Types T41, T41-2, T44, & T44-2 USDA Approval 35 lb PAIL — Ideal for larger size couplings or many smaller sizes. 120 lb KEG & 400 lb DRUM — For plants with central storage LTG has the United States Department of Agriculture Food Safety areas.
  • Page 154 Falk™ Steelflex® Couplings • Installation and Maintenance Types T41, T41-2, T44, & T44-2 (Page 3 of 12) Lubrication Fittings 1— Mount Seals (Type T41 Only) Size 1020T thru 1140T cover halves have 1/8 NPT lube holes and 1150T thru 1200T have 3/8 NPT lubrication holes. Use a standard grease gun and Iube fitting as instructed on Page 6.
  • Page 155 Installation and Maintenance • Falk™ Steelflex® Couplings (Page 4 of 12) Types T41, T41-2, T44, & T44-2 3 — Mount T41 Hub 5 — Mount Drive Plate Mount drive plate so that the drive pins are engaged. Temporarily hold the assembly in place with two or three inner springs and adjusting nuts.
  • Page 156 Falk™ Steelflex® Couplings • Installation and Maintenance Types T41, T41-2, T44, & T44-2 (Page 5 of 12) 7 — Offset Alignment (Type T41 Only) 9 — Pack With Grease & Assemble Covers Type T41 Only) Align so that a straight edge rests squarely (or within the limits specified in Table 3) on both hubs as shown above and also at 90°...
  • Page 157 Installation and Maintenance • Falk™ Steelflex® Couplings (Page 6 of 12) Types T41, T41-2, T44, & T44-2 11 — Assemble Balance of Controlled 13 — Distance X (Operating) Torque Parts Determine the Operating Distance X for the required slip torque from the Spring Adjustment Chart for your coupling size.
  • Page 158 Falk™ Steelflex® Couplings • Installation and Maintenance Types T41, T41-2, T44, & T44-2 (Page 7 of 12) Begin at the open end of the grid section and insert the rod or screwdriver into the loop ends. Use the teeth adjacent to each loop as a fulcrum and pry the grid out radially in even, gradual stages, proceeding alternately from side to side.
  • Page 159 Installation and Maintenance • Falk™ Steelflex® Couplings (Page 8 of 12) Types T41, T41-2, T44, & T44-2 FRICTION SEGMENT REPLACEMENT CAUTION: Always replace ALL friction segments. Remove the spring guide ring and drive plate and hang them on the T hub shaft. Insert pry bars as shown to separate the T41 or T44 sleeve from the T41 hub enough to insert new friction segments.
  • Page 160 Falk™ Steelflex® Couplings • Installation and Maintenance Types T41, T41-2, T44, & T44-2 (Page 9 of 12) Type T Coupling Installation & Alignment Data Values may be combined for an installation or operating condition. Maximum life and minimum maintenance for the coupling EXAMPLE: 1060T max.
  • Page 161 Installation and Maintenance • Falk™ Steelflex® Couplings (Page 10 of 12) Types T41, T41-2, T44, & T44-2 TABLE 4 — Coupling Cover Fastener Identification INCH SERIES FASTENERS SIZE METRIC FASTENERS Old Style New Style 1020-1070T10 SAE Grade 8 † SAE Grade 8 Property Class 10.9 1080-1090T10 SAE Grade 8...
  • Page 162 Falk™ Steelflex® Couplings • Installation and Maintenance Types T41, T41-2, T44, & T44-2 (Page 11 of 12) Part Descriptions — Type T41 Controlled Torque Coupling 1. Seal (T10) 8. T41 Hub (Specify Bore & Keyway) 16. Fastener and Adjusting Nut 2.
  • Page 163 Installation and Maintenance • Falk™ Steelflex® Couplings (Page 12 of 12) Types T41, T41-2, T44, & T44-2 Part Descriptions — Type T44 Controlled Torque Clutch 8. T41 Hub (Specify Bore & Keyway) 14. Spring, Outer (not required for T44-2) 19. Drive Plate 9A.
  • Page 164 Operating instructions Electronic temperature sensor TN7511...
  • Page 165 Contents 1 Safety instructions �����������������������������������������������������������������������������������������������3 2 Functions and features ����������������������������������������������������������������������������������������3 3 Function ���������������������������������������������������������������������������������������������������������������3 3�1 Switching function ������������������������������������������������������������������������������������������4 3�2 Display colour change �����������������������������������������������������������������������������������5 3�2�1 Parameter r1ou, r2ou, G1ou, G2ou ������������������������������������������������������5 3�2�2 Parameter r-cF, G-cF ����������������������������������������������������������������������������6 3�2�3 Parameter r-12, G-12 ���������������������������������������������������������������������������6 3�3 IO-Link �����������������������������������������������������������������������������������������������������������7 3�3�1 General information ������������������������������������������������������������������������������7 3�3�2 Device-specific information �������������������������������������������������������������������7 3�3�3 Parameter setting tools �������������������������������������������������������������������������7...

  • Page 166: Safety Instructions

    11 Factory setting �������������������������������������������������������������������������������������������������17 1 Safety instructions • Please read this document prior to set-up of the unit� Ensure that the product is suitable for your application without any restrictions� • If the operating instructions or the technical data are not adhered to, personal injury and/or damage to property can occur�...

  • Page 167: 3�1 Switching Function

    3.1 Switching function OUTx changes its switching status if it is above or below the set switching limits� Hysteresis or window function can be selected� Hysteresis function Window function T = Temperature T = Temperature = set point (SP1 / SP2) = upper limit value (FH1 / FH2) = reset point (rP1 / rP2) = lower limit value (FL1 / FL2)

  • Page 168: 3�2 Display Colour Change

    3.2 Display colour change The colour of the characters in the display can be set via the parameter [colr]� With the parameters rED (red) and GrEn (green), the display is permanently set to one colour� Via further parameters, the colour of the characters changes according to the measured value: OUT1 OUT2...
  • Page 169 3.2.2 Parameter r-cF, G-cF Colour change if the measured value is within definable limits� 3.2.3 Parameter r-12, G-12 Both outputs hysteresis function: Colour change if the measured value is between SP1 and SP2� Both outputs window function: Colour change if the measured value is between the window ranges�...

  • Page 170: 3�3�1 General Information

    Outputs with hysteresis and window function: Colour change if the measured value is outside the switching limits� 3.3 IO-Link 3.3.1 General information This unit has an IO-Link communication interface which requires an IO-Link-capa- ble module (IO-Link master) for operation� The IO-Link interface enables direct access to the process and diagnostic data and provides the possibility to set the parameters of the unit during operation�...
  • Page 171 Mounting dimensions with Mounting dimensions with Mounting dimensions with M12 adapter G¼ adapter G½ adapter Before installing and removing the unit: Ensure that no medium can leak at the process connection� ► Grease the threads of the process connection (1), adapter (2) and nut (3)� The sensor tip (A) must not be in contact with grease�...

  • Page 172: Electrical Connection

    5 Electrical connection The unit must be connected by a qualified electrician� The national and international regulations for the installation of electrical equipment must be adhered to� Voltage supply to EN 50178, SELV, PELV� ► Disconnect power� ► Connect the unit as follows: BK: black BN: brown OUT2...

  • Page 173: Operating And Display Elements

    6 Operating and display elements 1, 2, 3: Indicator LEDs • LED 1 = switching status OUT1 (lights if output 1 is switched) • LED 2 = temperature in the indicated unit of measurement • LED 3 = switching status OUT2 (lights if output 2 is switched) 4: Alphanumeric display, 4 digits •...

  • Page 174: Menu

    7 Menu 7.1 Process value display (RUN) and menu structure - - - - °C °F Hno Hnc Fno Fnc Hno Hnc Fno Fnc 0,0...50 s 0,0...50 s 0,0...50 s 0,0...50 s FOU1 OFF On FOU2 OFF On °C °F PnP nPn 0,0 °C 0,0 °C...

  • Page 175: 7�2 Explanation Of The Menu

    7.2 Explanation of the menu Set point (upper limit value) with hysteresis function Reset point (lower limit value) with hysteresis function Set point (upper limit value) with window function Set point (lower limit value) with window function Extended functions� Opening of the lower menu level� Restoring the factory settings Output function OUTx: Hno = Hysteresis function normally open...

  • Page 176: Parameter Setting

    coLr Colour configuration of the display (→ 3.2): rEd = Display always red� GrEn = Display always green� rxou = Display red in case of switched output OUTx� Gxou = Display green in case of switched output OUTx� r-12 = Display red if measured value is between the limit values of OUT1 and OUT2�...

  • Page 177: 8�1 Parameter Setting In General

    8.1 Parameter setting in general 1� Change from the RUN mode to the main menu [●] 2� Select the requested parameter [▲] or [▼] 3� Change to the setting mode [●] 4� Modification of the parameter value [▲] or [▼] > 1 s 5�...

  • Page 178: 8�1�3 Locking / Unlocking

    8.1.3 Locking / Unlocking The unit can be locked electronically to prevent unintentional settings� On delivery: not locked� Locking ► Make sure that the unit is in the normal operating mode� ► Press [▲] and [▼] simultaneously for 10 s until [Loc] is displayed. During operation: [Loc] is briefly displayed if you try to change parameter values�...

  • Page 179: 8�1�8 Read The Min/Max Values

    8.1.8 Read the min/max values ► Select [Hi] or [Lo] and read the value� [Hi] [Lo] [Hi] = max� value, [Lo] = min� value� Delete memory: ► Select [Hi�T] or [Lo�T]� ► Briefly press [●]. ► Keep [▲] or [▼] pressed. >...

  • Page 180: Technical Data

    [S�Loc] Setting pushbuttons locked, parameter change rejected� Unlock using parameter setting software� 10 Technical data Technical data and scale drawing at www�ifm�com� 11 Factory setting Factory setting User setting 60 °C 50 °C 120 °C 100 °C FOU1 FOU2 °C coLr Further information at www�ifm�com...
  • Page 181 TRC - Transfer Conveyor Operation Manual A Leader in Recycling Equipment Since 1978 PO Box 310 Toll Free (800) 745-4736 Priest River, Idaho 83856 Phone (208) 448-4736 remfg.com (208) 448-1736 sales@remfg.com Revision: 4 10/13/2020...
  • Page 182 Transfer Conveyor OPERATORS MANUAL NAME: South Wake Scrap Tire Facility 6160 Old Smithfield Rd CITY & STATE: Apex, NC ADDRESS: January 24, 2023 MODEL #: TRC 33x90 DATE: Volts 460 3 Phase SERIAL #: 7541-22 ELECTRICAL:...
  • Page 183 TABLE OF CONTENTS FOREIGN LANGUAGE NOTICE ......................I INTRODUCTION ............................1 SAFETY RULES ............................1 LOCKOUT/TAG OUT PROCEDURE ..................... 2 CONVEYOR AND HOPPER CAPACITY WARNING ................3 OTHER WARNINGS ..........................4 SYSTEM DESCRIPTION ........................... 5 BEFORE YOU START ..........................5 OPERATION ..............................

  • Page 184: Foreign Language Notice

    FOREIGN LANGUAGE NOTICE Should the facility using this equipment choose to employ personnel who cannot speak and/or read the English language, it is the responsibility of the facility operator to provide training, equipment warning signs, and operation and maintenance manuals in the appropriate language for the personnel.

  • Page 185: Introduction

    INTRODUCTION This operations manual provides operation, safety, service, and maintenance procedures for the proper use of this equipment. Thoroughly read and understand it before operating or servicing this equipment. Your service manual is a very important resource; use it. ALWAYS FOLLOW COMMON SENSE SAFETY PRACTICES. Any machine with potential hazards should be operated according to its operation manual, within its capacity, and in a careful and deliberate manner.

  • Page 186: Lockout/Tag Out Procedure

    WORKING HABITS: Keep hands and feet away from any and all moving parts. Never walk on or under a conveyor unless lockout/tag out is in effect. Do not overload the machine. (Equipment may jam or people may be injured.) REMOTE OPERATION: Plants with equipment run from remote stations must have strict safety procedures for operators and service technicians and emergency shut off switches or pulls in accordance with Federal, State, and Local Safety Standards.

  • Page 187: Conveyor And Hopper Capacity Warning

    CONVEYOR AND HOPPER CAPACITY WARNING Many times we are asked to build conveyors for multiple materials use. The hopper we place on the equipment represents what would be the maximum recommended capacity for the lightest material going on across the conveyor belt. For example: a customer has requested a conveyor to move plastic bottles and cardboard.

  • Page 188: Other Warnings

    OTHER WARNINGS This conveyor may have been equipped with casters to facilitate movement of this equipment. DO NOT ATTEMPT to move the conveyor/hopper with material on/in the conveyor/hopper. Serious damage, injury to personnel/property may occur, and the casters/legs may fold/collapse/ break.

  • Page 189: System Description

    SYSTEM DESCRIPTION (TRANSFER CONVEYOR) ® The REM Transfer Conveyor consists of one basic component: 1. Conveyor System ® Transfer Conveyors are used for a variety of functions including, but not limited to, the transfer of materials up inclines and into other user supplied balers, bunkers, containers, conveyors, perforators, shredders, and/or other devices for additional processing or transport.

  • Page 190: Operation

    FOR CONVEYOR BELT START-UP THE PROCEDURE IS AS FOLLOWS: 1) Take-up excess slack in the belt by moving the tail (take-up) shaft and pulley to the rear, opposite to the direction of travel. 2) Check belt, conveyor and surrounding area for debris, tools, loose parts, etc. which might obstruct conveyor operation or create a safety hazard.

  • Page 191: Tracking Adjustment

    TRACKING ADJUSTMENT Attach a strip of duct tape securely across the conveyor belt. You will use the strip as a visual indication of the belt rotation. Turn the conveyor power on and remove the tags. Tracking adjustments must be performed while the belt is operating.

  • Page 192: Service Information

    SERVICE INFORMATION MODIFICATIONS: Do not install raker bars or hanging gates or any other obstruction on any conveyor section. This practice may jam the conveyor and results in torn chain, reducer damage and burned out motors. Your warranty is immediately null and void should you do this. MATERIAL WRAPPED ON SHAFTS: Watch for any material wrapped on the head or tail shafts and pulleys (as well as crusher drum shafts) - remove it immediately!

  • Page 193: Maintenance Schedule

    RETURNED GOODS: Please obtain factory authorization prior to returning any parts or materials for warranty exchange or repair. No credit will be issued for materials returned without factory authorization, accompanying instructions and description of the nature of the return. Returns not covered by warranty are subject to restocking and repair charges.

  • Page 194: Troubleshooting Electrical

    TROUBLESHOOTING ELECTRICAL PROBLEM PROBABLE CAUSE REMEDY COMPLETELY LINE DISCONNECT SWITCH IS PLACE LINE DISCONNECT INOPERATIVE IN OFF POSITION SWITCH IN THE ON POSITION CONVEYOR WON’T LINE FUSES OPEN CHECK AND REPLACE OPEN START LINE FUSES IMPROPER ELECTRICAL INPUT CONSULT A QUALIFIED CONNECTION ELECTRICIAN MOTOR STARTER...
  • Page 197 WARRANTY ® Recycling Equipment Manufacturing, Inc., (“REM ”) warrants the (“unit”) to be free from defects in material and workmanship under normal use and service for a period of one (1) year from the date of delivery. ® Because REM has no control over types of material being conveyed (i.e.
  • Page 199 TRC-30 X 90 TRANSFER CONVEYOR 460 VOLT, THREE PHASE South Wake Scrap Tire Facility, Serial # 7541-22 Apex, NC PART # MECHANICAL MOTOR 7.5 HP, 1800, C-FACE, 210TC FLA 9.8 RA 4.5 GEAR REDUCER 56.25 RATIO 31RPM M3 MOUNT REDUCER SPROCKET S32X2-3/8"...
  • Page 200 TOSHIBA MOTOR Maintenance & Lubrication...
  • Page 202 TOSHIBA INTERNATIONAL CORPORATION INDEX MDS-O-0001 Industrial Division / Houston Motor Plant SHEET NO. 1 of 3 ISSUED 01/24/96 Motor Operation Procedure SUPERSEDES REVISION WRITTEN BY I. MARQUEZ REFERENCE USE ONLY WHEN ISSUED BY MOTOR MKTG. APPROVED BY J. Bugbee Motor Lubrication Dist: Mktg.
  • Page 203 TOSHIBA INTERNATIONAL CORPORATION INDEX MDS-O-0001 Industrial Division / Houston Motor Plant SHEET NO. 2 of 3 ISSUED 01/24/96 Motor Operation Procedure SUPERSEDES STANDARD SERVICE (-cont.) Remove relief plug or plate and using a low pressure hand held grease gun, pump the required amount of grease.
  • Page 204 Industrial Division / Houston Motor Plant SHEET NO. 3 of 3 ISSUED 01/24/96 Motor Operation Procedure SUPERSEDES TYPE OF SERVICE Fig. 3 SYNC. RPM FRAME SIZE STANDARD SEVERE VERY SEVERE RANGE DUTY DUTY DUTY 3600 143T-256T 8 Mos. 4 Mos. 1 Mo.
  • Page 205 ® UNICASE 90.1 & 92 Series BIM 1040 Helical Bevel Gearboxes Installation and Maintenance Instructions Retain These Safety Instructions For Future Use INSPECTION OF UNIT Thoroughly inspect the equipment for any shipping and handling damage before accepting shipment from the freight company. If any of the goods called for in the bill of lading or express receipt are damaged or the quantity is short, do not accept until the freight or express agent makes an appropriate notation on your freight bill or express receipt.
  • Page 206 INSTALLATION OF UNIT To ensure Iong service and dependabIe performance, an encIosed gear drive must be rigidIy supported and the shafts accurateIy aIigned. The foIIowing describes the minimum precautions required to accompIish this end. > ∅ 50 ≤ ∅ 80 = +0.000/-0.019 FOUNDATION >...
  • Page 207 AXIAL RETENTION Output and Input shaft Diameter toIerance Each drive shaft must be retained in place relative to the gear Metric (mm) ≤ ∅ 18 = +0.012/+0.001 reducer. Or each gear reducer must be retained in place relative > ∅ 18 ≤ ∅ 30 = +0.015/+0.002 to the drive shaft.
  • Page 208 COUPLING ALIGNMENT CHANGES IN PERFORMANCE SPECIFICATIONS Shaft coupIings shouId be instaIIed according to the coupIing Owner has the responsibiIity to consult with NORD GEAR if such manufacturer’s recommendations for gap, anguIar and paraIIeI items such as applied Ioads, operating speeds or other operating aIignment.
  • Page 209 FILL LEVEL & DRAIN PLUGS LUBRICANT The drain plugs are metric socket head cap screws. They will be AII NORD reducers are shipped from the factory properIy fiIIed located at the lowest part of the gearbox for ease of draining. The with Iubricant and all plugs are installed according to the mounting fill level plug is a hex head cap screw.
  • Page 210 MOUNTING POSITIONS These charts detail the mounting positions for horizontal and vertical mounting. The Autovent, oil fill plug and drain plug are indicated on each mounting position picture. The factory set mounting position and plug locations match that shown on the gearbox nametag. For mounting orientations other than shown consult NORD Gear.
  • Page 211 BIM 1040/2005/03 Page 7 of 16 www.nord.com...
  • Page 212 MAINTENANCE Mineral lubricant should be changed every 10,000 service hours or after two years. For synthetic oils, the lube should be changed every 20,000 service hours or after four years. In case of extreme operating (e.g. high humidity, aggressive environment or large temperature variations), shorter intervals between changes are recommended.
  • Page 213 LUBRICANT CAPACITY Each reducer has the oil level and oil quantity adjusted according to the mounting position shown in the tables. When replacing the oil, consult the tables below to determine the proper amount of oil to be installed according to the reducer size and mounting position. Note that this is approximate and the final level will be adjusted when the reducer is installed.
  • Page 214 LUBRICATION CAPACITY – 92 SERIES HELICAL BEVEL GEARBOXES Model Size Mounting SK92072 SK92172 SK92372 SK92672 SK92772 Position [Quarts] [Liters] [Quarts] [Liters] [Quarts] [Liters] [Quarts] [Liters] [Quarts] [Liters] 0.42 0.40 0.63 0.60 0.95 0.90 1.90 1.80 2.43 2.30 0.85 0.80 1.06 1.00 1.69 1.60...
  • Page 215 PARTS LIST SK 9012 - SK9092 Output gear Foot mounted Output pinion shaft Bevel gearset Input gear Input pinion Output shaft Shaft seal Shaft seal Circlip S him Taper roller bearing Gasket Gear case cover Spacer Vent screw Seal S ocket head screw Circlip Taper roller bearing Sealing plug...
  • Page 216 PARTS LIST Output gear SK 9012 - SK9092 VF Output pinion shaft Flange mounted Bevel gearset Input gear Input pinion Output shaft Shaft seal Shaft seal Circlip S him Taper roller bearing Gasket Gear case cover Spacer Vent screw S eal S ocket head screw Circlip Taper roller bearing...
  • Page 217 PARTS LIST SK 9012 - SK 9092 AZ 701 Output gear S haft mounted 702 Output pinion shaft 703 Bevel gearset 705 Driving gear 706 Driving pinion 707 Hollow shaft 709 Shaft seal 710 Shaft seal 711 Circlip 712 Shim 713 Taper roller bearing 714 Gasket 715 Gear case cover...
  • Page 218 PARTS LIST S K 9013 - SK 9053 Input gear Foot mounted Input pinion Flange mounted VF Bolt Shaft mounted AZ Gasket Supporting disc Third reduction gearcase Ball bearing Ball bearing Circlip Circlip Intermediate shaft, plain Intermediate shaft, gearcut Circlip Circlip S him Circlip...
  • Page 219 PARTS LIST SK92072 703 Bevel gearset 705 Input gear 706 Input pinion 707 Output shaft 708 Key 710 Shaft seal 711 Circlip 712 Shim 713 Taper roller bearing 714 Gasket 715 Gear case cover 716 Spacer 719 Socket head screw 720 Key 721 Circlip 722 Taper roller bearing...
  • Page 220 PARTS LIST SK 92172 - SK 92772 703 Bevel gearset 705 Input gear 706 Input pinion 707 Output shaft 708 Key 709 Shaft seal 710 Shaft seal 711 Circlip 712 Shim 713 Taper roller bearing 714 Gasket 715 Gear case cover 716 Spacer 719 Socket head screw wie Seite...
  • Page 221 MAINTENANCE Mineral lubricant should be changed every 10,000 service hours or after two years. For synthetic oils, the lube should be changed every 20,000 service hours or after four years. In case of extreme operating (e.g. high humidity, aggressive environment or large temperature variations), shorter intervals between changes are recommended.
  • Page 222 LUBRICANT CAPACITY Each reducer has the oil level and oil quantity adjusted according to the mounting position shown in the tables. When replacing the oil, consult the tables below to determine the proper amount of oil to be installed according to the reducer size and mounting position. Note that this is approximate and the final level will be adjusted when the reducer is installed.
  • Page 223 2000 Series Installation Guide Spherical Roller Bearings Collar Mounted Units JA,JE, JYR, JYRP, JN, JT Step 1. Step 2. Step 3. Make sure housing and support surface are clean and flat. Adjust elevations and shim if required. Position shaft into block and align Check shaft diameter.
  • Page 224 Installation Operation Lubrication and parts list For: Pillow Blocks Spherical Units Take-Ups Jones Bearing Company P.O. Box 274 Pelham, AL. 35124 General Jones Pillow Blocks, tapper bearing equipped , are manufactured in two types designated as EXPANSION and NO-EXPANSION. Each pillow block carries a colored name plate indication the type and also the size of shaft the pillow block will accommodate.
  • Page 225 GREASE FITTING & BUSHING General Information (Cont’d). PART NO. 16 The tapered bearing is in a self contained unit designated as a housing with a bearing adjusting cover. The bearing has been adjusted at the factory for proper running clearance and the adjusting cover has been locked in place.
  • Page 226 General Information (Cont’d). GREASE FITTING & BUSHING PART NO. 16 ( BLUE NAME PLATE) pillow blocks again should be Adjusting Cover checked through the grease fitting covers to make sure that grease fittings and bushings are centered in the opening to Seal Ring permit the spherical units free endwise movement without Part No.
  • Page 227 LUBRICATION INSTRUCTIONS MAXIMUM R.P. M .RECOMMENDED GENERAL STANDARD SHAFT SIZE IN INCHES The internal parts of all Jones Roller Bearing equipped items are covered with a coating of grease before they leave the factory. Bearings should in all cases be filled with grease MAXIMUM SHAFT SPEED--R.P .M.
  • Page 228 Parts 1000 Series List ..Extra Heavy Duty FOR PILLOW BLOCK SIZES UP TO AND INCLUDING 3-7/16 FOR PILLOW BLOCK SIZES UP TO AND INCLUDING 3-7/16 Jones Self- Aligning Pillow Blocks Tapered Roller Bearing Equipped Parts List Parts List Quantity Quantity Number Description...
  • Page 229 Parts 1000 Series List ..Extra Heavy Duty FOR PILLOW BLOCK SIZES 3-15/16“ TO 10” INCLUSIVE FOR PILLOW BLOCK SIZES 3-15/16“ TO 10” INCLUSIVE Jones Self- Aligning Pillow Blocks Tapered Roller Bearing Equipped 3-18 Parts List Quantity Quantity Number Description Number Description Each...
  • Page 230 Lubrication Guide Spherical Roller Bearings Collar Mounted Units JA,JE, JYR, JYRP, JN, JT Method All Jones Mounted Units are shipped pre lubricated with enough grease for initial operation. Units are also supplied with a grease fitting for relubrication. It is recommended that bearings be lubricated while running.
  • Page 231 SYSTEM INSTALLATION REVISIONS DESCRIPTION DATE SHEET 1. COVER SHEET 2. 7541 TRC SETUP 00-7541 FINAL ASSY TRC-36x90 SHEET 4. 7542 TBC SETUP 00-7542 TBC 22x48 SHEET 5. 7542 SYSTEM SETUP SHEET 6. OVERALL DIMENSIONS P.O. BOX 310 PRIEST RIVER, IDAHO 83856 FAX (208) 448-1786 (208) 448-4736 TITLE:...
  • Page 232 7541 TRC SETUP STEP 1. UNLOAD TRC AND INSPECT FOR DAMAGE STEP 2. INSTALL TAIL LEGS STEP 3. RAISE HEAD AND INSTALL MID AND MAIN LEGS STEP 4. INSTALL 7541-042 HEAD DEFLECTORS 15'-6 " 35° 7541-072 HEAD DEFLECTOR 7541-061 SUPPORT 7541-141 SUPPORT 7541 MID LEGS...
  • Page 233 7542 TBC SETUP STEP 1. UNLOAD AND INSPECT FOR DAMAGE STEP 2. ADJUST LEGS TO HEIGHT SHOWN STEP 3. ATTACH HOOD FLAPS TO HOOD STEP 4. ATTACH HOOD BACK STOP FLAPS TO HOOD BACK STOP STEP 5. ATTACH HOOD STEP 6. ATTACH SIDEWALL EXTENSIONS STEP 7.
  • Page 234 7542 SYSTEM SETUP STEP 1. POSITION 7542 TBC OVER PIT AS SHOWN STEP 2. POSITION SHREDDER OVER 7542 TBC AS SHOWN 00-7541 FINAL ASSY TRC-36x90 STEP 3. POSITION 7541 TRC WITHIN SHREDDER HOOD STEP 4. LEVEL, FIELD WELD AND ANCHOR FEET AS SHOWN 18'- "...
  • Page 235 TBC - Troughing Belt Conveyor Operation Manual A Leader in Recycling Equipment Since 1978 PO Box 310 Toll Free (800) 745-4736 Priest River, Idaho 83856 Phone (208) 448-4736 remfg.com (208) 448-1736 sales@remfg.com...
  • Page 236 TROUGHING BELT CONVEYOR OPERATORS MANUAL South Wake Scrap Tire Facility NAME: ADDRESS: 6160 Old Smith CITY & STATE: Apex, NC January 17, 2023 MODEL #: TBC 22x48 DATE: 460 Volt 3 Phas SERIAL #: 7542-22 ELECTRICAL:...
  • Page 237 TABLE OF CONTENTS FOREIGN LANGUAGE NOTICE ....................i INTRODUCTION .......................... 1 SAFETY RULES ........................1 & 2 LOCKOUT/TAG OUT ........................2 CONVEYOR AND HOPPER CAPACITY WARNING ..............3 BEARING AND MOTOR LUBRICATON ..................3 SYSTEM DESCRIPTION......................4 BEFORE YOU START ......................... 4 TROUGHING CONVEYOR SETUP PROCEDURE ..............

  • Page 238: Foreign Language Notice

    FOREIGN LANGUAGE NOTICE Should the facility using this equipment choose to employ personnel who cannot speak and/or read the English language, it is the responsibility of the facility operator to provide training, equipment warning signs, and operation and maintenance manuals in the appropriate language for the personnel.

  • Page 239: Introduction

    INTRODUCTION This operations manual provides operation, safety, service, and maintenance procedures for the proper use of this equipment. Thoroughly read and understand it before operating or servicing this equipment. Your service manual is a very important resource; use it. ALWAYS FOLLOW COMMON SENSE SAFETY PRACTICES. Any machine with potential hazards should be operated according to its operation manual, within its capacity, and in a careful and deliberate manner.

  • Page 240: Lockout/Tag Out

    WORKING HABITS: Keep hands and feet away from any and all moving parts. Never walk on or under a conveyor unless lockout/tag out is in effect. Do not overload the machine. (Equipment may jam or people may be injured.) REMOTE OPERATION: Plants with equipment run from remote stations must have strict safety procedures for operators and service technicians and emergency shut off switches or pulls in accordance with Federal, State, and Local Safety Standards.

  • Page 241: Conveyor And Hopper Capacity Warning

    CONVEYOR AND HOPPER CAPACITY WARNING Many times we are asked to build conveyors for multiple materials use. The hopper we place on the equipment represents what would be the maximum recommended capacity for the lightest material going on across the conveyor belt. For example: a customer has requested a conveyor to move plastic bottles and cardboard.

  • Page 242: System Description

    SYSTEM DESCRIPTION (TROUGHING CONVEYOR) The REM® Troughing Conveyor consists of one basic component: 1. Conveyor System REM® Troughing Conveyors are used for a variety of functions including but not limited to the transfer of materials up inclines and into other user supplied balers, bunkers, containers, conveyors, perforators, shredders, and/or other devices for additional processing or transport.

  • Page 243: Troughing Conveyor Setup Procedure

    TROUGHING CONVEYOR SETUP PROCEDURE A conveyor which is properly designed, erected, and maintained will consistently run true as far as the belt alignment is concerned. The following guide is to be used as an aid in setting up and troubleshooting belt misalignment issues that could lead to premature failure of belting, idlers and pulleys.

  • Page 244: Operation

    OPERATION Depends on control package. TBC BELT TRACKING GUIDE BASIC RULES The basic and primary rule of tracking a conveyor belt is simply “THE BELT MOVES TOWARD THAT END OF THE ROLL IT CONTACTS FIRST.” The conveyor structure must be “TRUE” (relative to center-line) and LEVEL (side to side). All pulleys, snub rollers, carrying idlers, and return idlers must be SQUARE with the frame (perpendicular to belt center-line) and parallel to each other.

  • Page 245: Troubleshooting Tracking

    TROUBLESHOOTING “TRACKING” PROBLEM CAUSE CORRECTION ALL PORTIONS OF CONVEYOR BELT ONE OR MORE IDLERS IMMEDIATELY ADVANCE, IN THE DIRECTION OF BELT RUNNING TO ONE SIDE AT A GIVEN PRECEDING TROUBLE POINT NOT AT TRAVEL, THE END OF THE IDLER TO POINT ON STRUCTURE.

  • Page 246: Conveyor Drive Belt

    CONVEYOR DRIVE BELT To adjust the belt tension, lockout/tag out machine. Remove the belt guard from the drive unit. Move the motor adjustment bolts until the proper tension is achieved. Adjust all four bolts equally. Push against belt with your thumb. The belt should depress about 3/4 inch without straining your thumb.

  • Page 247: Service Information

    SERVICE INFORMATION MODIFICATIONS: Do not install raker bars or hanging gates or any other obstruction on any conveyor section. This practice may jam the conveyor and result in torn chain, reducer damage and burned out motors. Your warranty is immediately null and void should you do this. MATERIAL WRAPPED ON SHAFTS: Watch for any material wrapped on the head or tail shafts and pulleys (as well as crusher drum shafts) - remove it immediately!

  • Page 248: Maintenance Schedule

    MAINTENANCE SCHEDULE For maximum life and performance, the machine should be maintained regularly. (Caution: All maintenance should be done with the power disconnected!!) 1. Grease all bearings. (Refer to instruction page for bearings and motors.) 2. Check conveyor belt tension and tracking daily (see page 6). Conveyor belt should be cleaned of all foreign material on a need-to basis.
  • Page 251 WARRANTY Recycling Equipment Manufacturing, Inc., (“REM”) warrants the (“unit”) to be free from defects in material and workmanship under normal use and service for a period of one (1) year from the date of delivery. Because REM has no control over types of material being conveyed (i.e. Oils, solvents, chemicals, corrosives, and/ or abrasive materials), it is impossible to predict the life of components such as belts, chains, and wear glides.
  • Page 252 TBC-22x48 460 VOLT, THREE PHASE South Wake Scrap Tire Facility, Serial #7542-22 Apex, NC MECHANICAL CONVEYOR MOTOR 3HP , 1750 RPM INVERTER RA 1.9 FLA 4.0 GEAR REDUCER 30:1, LEFT OUTPUT HEAD PULLEY 12" X 51" TAIL PULLEY 10" X 51" BELT 48"...
  • Page 253 TOSHIBA MOTOR Maintenance & Lubrication...
  • Page 255 TOSHIBA INTERNATIONAL CORPORATION INDEX MDS-O-0001 Industrial Division / Houston Motor Plant SHEET NO. 1 of 3 ISSUED 01/24/96 Motor Operation Procedure SUPERSEDES REVISION WRITTEN BY I. MARQUEZ REFERENCE USE ONLY WHEN ISSUED BY MOTOR MKTG. APPROVED BY J. Bugbee Motor Lubrication Dist: Mktg.
  • Page 256 TOSHIBA INTERNATIONAL CORPORATION INDEX MDS-O-0001 Industrial Division / Houston Motor Plant SHEET NO. 2 of 3 ISSUED 01/24/96 Motor Operation Procedure SUPERSEDES STANDARD SERVICE (-cont.) Remove relief plug or plate and using a low pressure hand held grease gun, pump the required amount of grease.
  • Page 257 Industrial Division / Houston Motor Plant SHEET NO. 3 of 3 ISSUED 01/24/96 Motor Operation Procedure SUPERSEDES TYPE OF SERVICE Fig. 3 SYNC. RPM FRAME SIZE STANDARD SEVERE VERY SEVERE RANGE DUTY DUTY DUTY 3600 143T-256T 8 Mos. 4 Mos. 1 Mo.
  • Page 258 FLEX-A-LINE SPEED REDUCERS Installation, Lubrication Maintenance Instructions CONGRATULATIONS! Your decision to purchase an American Crafted Speed Reducer from Grove Gear will provide you with many years of trouble free service if the following installation and maintenance instructions are adhered to.
  • Page 259 Instruction Manual Selection Information Read ALL instructions prior to operating reducer. Injury to personnel or reducer failure may be caused by improper installation, maintenance or operation. Written authorization from Grove Gear is required to operate or use reducers in man lift or people moving devices. Check to make certain application does not exceed the allowable load capacities published in the current catalog.
  • Page 260 Instruction Manual General Operation Run the motor which drives the reducer and check the direction of reducer output rotation. Consult motor nameplate for instructions to reverse the direction of rotation. Attaching the load: On direct coupled installations, check shaft and coupling alignment between speed reducer and loading mechanism.
  • Page 261 Instruction Manual Oil should be changed more often if reducer is used in a severe environment. (i.e. dusty, humid) CAUTION In the Food and Drug Industry (including animal food), consult the lubrication supplier for CAUTION recommendation of lubricants which are acceptable to the Food and Drug Administration and/or other authoritative bodies having jurisdiction.
  • Page 262 Instruction Manual Oil Capacities (pints) - Standard Units Mounting UNIT SIZE Position 2600 2700* 2800* 21000* Worm Over 1 1/2 1 3/4 3 3/4 8 1/4 12 1/2 19 1/2 Worm Under 1 1/2 1 3/4 3 3/4 5 1/2 13 1/2 20 1/2 32 3/4 51 1/4 Vertical Output 1 1/2 1 3/4...
  • Page 263 Instruction Manual Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for proper operation. CAUTION Seals: The Grove Gear line of speed reducers utilize premium quality seals which are the state-of-the-art in sealing technology. Seals are, however, a wear item and eventually need to be replaced.
  • Page 264 Installation Operation Lubrication and parts list For: Pillow Blocks Spherical Units Take-Ups Jones Bearing Company P.O. Box 274 Pelham, AL. 35124 General Jones Pillow Blocks, tapper bearing equipped , are manufactured in two types designated as EXPANSION and NO-EXPANSION. Each pillow block carries a colored name plate indication the type and also the size of shaft the pillow block will accommodate.
  • Page 265 GREASE FITTING & BUSHING General Information (Cont’d). PART NO. 16 The tapered bearing is in a self contained unit designated as a housing with a bearing adjusting cover. The bearing has been adjusted at the factory for proper running clearance and the adjusting cover has been locked in place.
  • Page 266 General Information (Cont’d). GREASE FITTING & BUSHING PART NO. 16 ( BLUE NAME PLATE) pillow blocks again should be Adjusting Cover checked through the grease fitting covers to make sure that grease fittings and bushings are centered in the opening to Seal Ring permit the spherical units free endwise movement without Part No.
  • Page 267 LUBRICATION INSTRUCTIONS MAXIMUM R.P. M .RECOMMENDED GENERAL STANDARD SHAFT SIZE IN INCHES The internal parts of all Jones Roller Bearing equipped items are covered with a coating of grease before they leave the factory. Bearings should in all cases be filled with grease MAXIMUM SHAFT SPEED--R.P .M.

  • Page 268: Parts List

    Parts 1000 Series List ..Extra Heavy Duty FOR PILLOW BLOCK SIZES UP TO AND INCLUDING 3-7/16 FOR PILLOW BLOCK SIZES UP TO AND INCLUDING 3-7/16 Jones Self- Aligning Pillow Blocks Tapered Roller Bearing Equipped Parts List Parts List Quantity Quantity Number Description...
  • Page 269 Parts 1000 Series List ..Extra Heavy Duty FOR PILLOW BLOCK SIZES 3-15/16“ TO 10” INCLUSIVE FOR PILLOW BLOCK SIZES 3-15/16“ TO 10” INCLUSIVE Jones Self- Aligning Pillow Blocks Tapered Roller Bearing Equipped 3-18 Parts List Quantity Quantity Number Description Number Description Each...
  • Page 270 2000 Series Installation Guide Spherical Roller Bearings Collar Mounted Units JA,JE, JYR, JYRP, JN, JT Step 1. Step 2. Step 3. Make sure housing and support surface are clean and flat. Adjust elevations and shim if required. Position shaft into block and align Check shaft diameter.
  • Page 271 Lubrication Guide Spherical Roller Bearings Collar Mounted Units JA,JE, JYR, JYRP, JN, JT Method All Jones Mounted Units are shipped pre lubricated with enough grease for initial operation. Units are also supplied with a grease fitting for relubrication. It is recommended that bearings be lubricated while running.
  • Page 272 SYSTEM INSTALLATION REVISIONS DESCRIPTION DATE SHEET 1. COVER SHEET 2. 7541 TRC SETUP 00-7541 FINAL ASSY TRC-36x90 SHEET 4. 7542 TBC SETUP 00-7542 TBC 22x48 SHEET 5. 7542 SYSTEM SETUP SHEET 6. OVERALL DIMENSIONS P.O. BOX 310 PRIEST RIVER, IDAHO 83856 FAX (208) 448-1786 (208) 448-4736 TITLE:...
  • Page 273 7541 TRC SETUP STEP 1. UNLOAD TRC AND INSPECT FOR DAMAGE STEP 2. INSTALL TAIL LEGS STEP 3. RAISE HEAD AND INSTALL MID AND MAIN LEGS STEP 4. INSTALL 7541-042 HEAD DEFLECTORS 15'-6 " 35° 7541-072 HEAD DEFLECTOR 7541-061 SUPPORT 7541-141 SUPPORT 7541 MID LEGS...
  • Page 274 7542 TBC SETUP STEP 1. UNLOAD AND INSPECT FOR DAMAGE STEP 2. ADJUST LEGS TO HEIGHT SHOWN STEP 3. ATTACH HOOD FLAPS TO HOOD STEP 4. ATTACH HOOD BACK STOP FLAPS TO HOOD BACK STOP STEP 5. ATTACH HOOD STEP 6. ATTACH SIDEWALL EXTENSIONS STEP 7.
  • Page 275 7542 SYSTEM SETUP STEP 1. POSITION 7542 TBC OVER PIT AS SHOWN STEP 2. POSITION SHREDDER OVER 7542 TBC AS SHOWN 00-7541 FINAL ASSY TRC-36x90 STEP 3. POSITION 7541 TRC WITHIN SHREDDER HOOD STEP 4. LEVEL, FIELD WELD AND ANCHOR FEET AS SHOWN 18'- "...
  • Page 276 INSTALLATION AND MAINTENANCE MANUAL FOR LOW AND HIGH VOLTAGE THREE PHASE INDUCTION MOTORS AGA Line H Line F Line MASTER Line IMPORTANT ---- ---- READ CAREFULLY THE INSTRUCTIONS INCLUDED IN THIS MANUAL IN ORDER TO ENSURE A SAFE AND CONTINUOUS OPERATION TO THE EQUIPMENT.
  • Page 277 4. MAINTENANCE 3.5. MOTOR USED ON HAZARDOUS AREA – EXPLOSIVE GAS ATMOSPHERES A well-programmed maintenance of electric Motors designed for hazardous areas are fitted motors can be summed up as a periodical with additional safety features which are defined inspection of insulation levels, temperature rise in specific standards for each type of hazardous (winding bearings),...
  • Page 278 all unused space dust-free. For aggressive Motor noise should be measured at regular environment, IP(W)55 protection motors are intervals of one to four months. A well-tuned ear recommended. is perfect capable of distinguishing unusual noises, even with rudimentary tools such as a screw driver, etc.
  • Page 279 Table 1 MAXIMUM LUBRICATION INTERVAL FOR HORIZONTALLY MOUNTED MOTORS ROLLER BALL BEARINGS Amount Amount Lubrication Lubrication Bearings speed Bearings speed Interval Interval (hours) Grease limit (rpm) Grease limit (rpm) Bearings Poles (hours) Bearings Poles (grams) (grams) 60 Hz 50 Hz 100% 60 Hz 50 Hz 100%...
  • Page 280 Table 2 MAXIMUM LUBRICATION INTERVAL FOR HORIZONTALLY MOUNTED MOTORS LOCKED BALL BEARINGS Lubrication Bearing Amount Lubrication Bearing speed Limit Amount of speed Limit Interval Interval (hours) (rpm) Bearing Pole Bearing Pole Grease (hours) (rpm) Grease (grams) (grams) 100% 75% 60 Hz 50 Hz 60 Hz 50 Hz 100%...
  • Page 281 MAXIMUM LUBRICATION INTERVAL FOR HORIZONTALLY MOUNTED MOTORS SPHERICAL ROLLER BEARINGS LUBRICATION INTERVAL BEARING SPEED AMOUNT OF (HOURS) LIMIT (RPM) BEARING GREASE POLE (GRAMS) 60 Hz 50 Hz 100% 12 or + 2400 3000 1800 2400 23032 1700 1275 1300 1700 1100 12 or + 1800...
  • Page 282 4.2.1.2. QUALITY AND QUANTITY OF Standard grease used on WEG GREASE motors Polyurea-based POLIREX EM (Supplier: ESSO). Correct lubrication is important for proper The specification of this grease bearing operation. It means to say the grease as well as lubrication intervals must be applied correctly and in sufficient supplied on the bearing nameplate attached to motor frame.
  • Page 283 BEARING LUBRICATION STEPS 4.2.2. ASSEMBLY/DISASSEMBLY OF 1) Remove the grease relief cover. SLEEVE BEARINGS 2) Clean the area around the grease fitting with a clean cotton fabric. 4.2.2.1. GENERAL INSTRUCTIONS 3) With the motor running, add grease with a manual grease gun until the lubricant Sleeve bearing performance is dependent on commences to expelle from the grease relief, proper installation, lubrication and maintenance.
  • Page 284 4.11. MAINTENANCE SCHEDULE YEARLY EVERY 3 YEARS EVERY 3 COMPONENT DAILY WEEKLY (PARTIAL (COMPLETE MONTHS MAINTEN.) MAINTEN.) - Check - Drain noise and the - Retighten - Dismantle the motor. - Complete motor. condensed vibration bolts. Check spare parts. water (it any). levels.

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