Model M103
Granulator
Part Number:
Bulletin Number: CO2-660
Effective: 3/31/04
Write Down Your Serial Numbers Here For Future Reference:
_________________________ _________________________
_________________________ _________________________
_________________________ _________________________
We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.
DCN No. CT000014
© Copyright 2005
All rights reserved.
4 Inch Granulator i
Shipping Info
Unpacking and Inspection
You should inspect your granulator for possible shipping damage.
Thoroughly check the equipment for any damage that might have occurred in transit, such as
broken or loose wiring and components, loose hardware and mounting screws, etc.
In the Event of Shipping Damage
According to the contract terms and conditions of the Carrier, the responsibility of the
Shipper ends at the time and place of shipment.
Notify the transportation company’s local agent if you discover damage.
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization.
File a claim with the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.
Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.
If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. You should have:
þ Granulator
þ Bill of lading
þ Packing list
þ Operating and Installation packet
þ Electrical schematic and panel layout drawings
þ Component instruction manuals
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.
If the Shipment is Not Correct
If the shipment is not what you ordered, contact the shipping department immediately. For
shipments in the United States and Canada, call 1 (800) 229-2919; for all other countries, call
our international desk at (508) 399-6400. Have the order number and item number available.
Hold the items until you receive shipping instructions.
Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.
4 Inch Granulator ii
Table of Contents
CHAPTER 1: SAFETY................................................................ 5
1-1 How to Use This Manual............................................................................................5
Safety Symbols Used in this Manual ..............................................................................................5
1-2 General Safety Regulations.......................................................................................6
1-3 Responsibility ............................................................................................................6
1-4 Warnings and Precautions.........................................................................................7
CHAPTER 2: FUNCTIONAL DESCRIPTION ............................. 9
2-1 Models Covered in This Manual.................................................................................9
2-2 General Description...................................................................................................9
2-3 Typical Features and Components ............................................................................9
Infeed Devices ................................................................................................................................ 9
Cutting Chamber............................................................................................................................. 9
Screen.............................................................................................................................................. 9
Discharge System............................................................................................................................ 9
Base................................................................................................................................................. 9
2-4 Safety Features .......................................................................................................10
Safety Switches............................................................................................................................. 10
Safety Tags.................................................................................................................................... 10
Level Sensor (optional)................................................................................................................. 10
CHAPTER 3: INSTALLATION.................................................. 11
3-1 Uncrating the Equipment .........................................................................................11
3-2 Making the Electrical Connections...........................................................................12
3-3 Accessing the Cutting Chamber...............................................................................13
3-4 Closing the Cutting Chamber...................................................................................13
3-5 Preparing for Initial Start-up.....................................................................................14
CHAPTER 4: OPERATION....................................................... 15
4-1 Starting the Granulator ............................................................................................15
4-2 Feeding the Granulator............................................................................................15
4-3 Clearing a Jammed Cutting Chamber......................................................................16
4-4 Making an Emergency Stop.....................................................................................17
4-5 Shutting Down the Granulator..................................................................................17
CHAPTER 5: MAINTENANCE ................................................. 18
5-1 Preventative Maintenance Schedule........................................................................18
5-2 Replacing the Screen ..............................................................................................18
5-3 Replacing and Adjusting the Knives.........................................................................19
Bed Knives.................................................................................................................................... 19
Rotor Knives ................................................................................................................................. 20
5-4 Sharpening the Knives.............................................................................................21
Bed Knives.................................................................................................................................... 21
Rotor Knives ................................................................................................................................. 21
4 Inch Granulator iii
Cleaning the Granulator...........................................................................................22
5-5
CHAPTER 6: TROUBLESHOOTING ....................................... 23
6-1 Introduction..............................................................................................................23
6-2 Electrical Faults .......................................................................................................23
6-3 Processing Faults ....................................................................................................24
6-4 Mechanical Faults....................................................................................................25
CHAPTER 7: APPENDIX.......................................................... 26
7-1 Customer Satisfaction Warranty Program................................................................26
7-2 Installing the Optional Level Sensor ........................................................................27
7-3 Spare Parts List.......................................................................................................28
7-4
T Models.............................................................................................................31
SW Models……………………………………………………………………………...32
7-5 Drawings and Diagrams…………………………………………………………………..33
T Models ............................................................................................................33
SW Models.........................................................................................................34
RT Models..........................................................................................................
Parts Department ...............................................................................................44
Service Department............................................................................................44
Sales Department………………………………………………………………………44
Technical Data.........................................................................................................31
35
Electrical Diagrams..................................................................................................40
7-6 Technical Assistance...............................................................................................44
4 Inch Granulator iv
Chapter 1: Safety
1-1 How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining your
granulator. The purpose is to assist you in applying efficient, proven techniques that enhance
equipment productivity.
This manual covers only light corrective maintenance. No other maintenance should be
undertaken without first contacting a service engineer.
The Functional Description section outlines models covered, standard features, and safety
features. Additional sections within the manual provide instructions for installation, preoperational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the granulator. We can also provide the assistance of a factory-trained technician to help
train your operator(s) for a nominal charge. This section includes instructions, checks, and
adjustments that should be followed before commencing with operation of the granulator.
These instructions are intended to supplement standard shop procedures performed at shift,
daily, and weekly intervals.
The Operation chapter includes a description of electrical and mechanical controls, in
addition to information for operating the granulator safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and
disassembly instructions for those areas of the equipment requiring service. Preventive
maintenance sections are included to ensure that your granulator provides excellent, long
service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, parts lists, and
available options. A spare parts list with part numbers specific to your machine is provided
with your shipping paperwork package. Refer to this section for a listing of spare parts for
purchase. Have your serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER! DANGER indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury.
WARNING! WARNING indicates a potentially hazardous situation or practice that, if
not avoided, could result in death or serious injury.
Caution! CAUTION indicates a potentially hazardous situation or practice that, if
not avoided, may result in minor or moderate injury or in property damage.
4 Inch Granulator Chapter 1: Safety 5 of 47
1-2 General Safety Regulations
This machine uses knives for the performance of its intended use. Consequently, it can be a
dangerous machine to operate and maintain unless these safety regulations are followed.
These regulations should be read, understood and periodically reviewed by all personnel
involved in any way with this machine.
Never operate or remove any machine components that are secured by wrench-type fasteners
unless the motor is electrically locked out and the rotor is motionless.
Never operate the machine or jog the rotor unless the cutting chamber covers, discharge
chute, or any guards or covers are in place and secure. Do not circumvent the safety
interlocks.
Prior to clearing a jam or performing any maintenance, the motor should be turned off and
electrically locked out. Be sure that the rotor has come to a stop. Hands must not be inserted
into the machine to clear the jam.
Do not extend any part of the body into feed roll openings or discharge area unless the motors
are electrically locked out and the rotor and feed rolls are motionless.
Never extend fingers through holes in screen.
Extreme care should be taken to see that all bolts are properly tightened at all times. During
the operation of the machine, rotor knife bolts may come loose. Although fine threads are
used on the rotor knife bolts because vibration does not easily loosen them, you should
inspect the tightness of the bolts frequently.
This machine is designed for the granulation of plastic materials. Do not feed any other
materials into the machine.
1-3 Responsibility
These machines are constructed for maximum operator safety when used under standard
operating conditions and when recommended instructions are followed in the maintenance
and operation of the machine.
All personnel engaged in the use of the machine should become familiar with its operation as
described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.
Becoming familiar with materials, inspection, speed limitations, screens, and guard
maintenance and total user responsibility will assist you in learning potential areas in need of
observation for danger.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All caution, warning and danger signs must be observed and obeyed. All actual or potential
danger areas must be reported to your immediate supervisor.
4 Inch Granulator Chapter 1: Safety 6 of 47
1-4 Warnings and Precautions
Our granulators are designed to provide safe and reliable operation when installed and
operated within design specifications, following national and local safety codes.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this granulator, use good judgment and follow these safe practices:
þ LEARN AND OBEY your company’s safety policy regarding granulating
equipment.
þ MOVING OR LIFTING THE GRANULATOR: Although our equipment is built
and engineered for great ruggedness in operation, care must be taken when moving
the machine along the floor or lifting it. Damage may occur to sheet metal covers,
electrical cabinets, or small brackets if pressure is applied to them when moving the
granulator. When lifting the granulator, be certain of total machine weight and the
capability of the lifting equipment. (See the Granulator Specification Sheets for
machine weights and dimensions.)
þ GRANULATOR LOCATION: Adequate area for routine maintenance should be
provided in order to open the machine for knife, screen, or cleanout service. Proper
service area clearances also should allow people who are working on the machine to
be clearly visible to others, thereby reducing the potential safety hazards.
þ SAFE HOUSEKEEPING: The work area must be kept clean and uncluttered during
periods of operation or maintenance. No hand tools or other metal objects should be
left on or around the machine. Any tools or other metal objects that mistakenly fall
into the hopper feed opening can cause severe damage to internal cutting chamber,
rotor and screen components.
þ SAFETY GLASSES OR A FACE SHIELD MUST ALWAYS BE WORN when
servicing or operating the machine. Although our machines are designed for the
maximum in flyback control, caution must be used when operating near the hopper
feed opening in order to guard against unexpected material flyback.
þ EAR PROTECTION may be required when operating the machine during
granulation of very hard or noisy materials. The Occupational Safety and Health Act
of 1970 has established guidelines for Permissible Noise Exposures (OSHA 1910.95)
that should be followed.
þ NEVER attempt to operate the granulator unless it is fully assembled with all guards
and interlocks in place and functional.
þ OBSERVE all danger, warning, caution and safety labels on the equipment.
þ Upon completion of any machine maintenance, be certain ALL SAFETY GUARDS
AND COVERS are securely and properly fastened prior to resuming machine
operation. All fasteners must be in place and properly tightened. ANY
SHORTCUTS MAY RESULT IN INJURY TO PERSONNEL OR DAMAGE
TO EQUIPMENT.
þ NEVER wear any loose fitting clothes, neckties, or dangling items such as earrings,
belts, or shoestrings. Jewelry, such as wristwatches, bracelets, or rings should
NEVER be worn. Long hair must be tied back or placed in a tight fitting hairnet.
NEVER lean against or rest hands or feet on the granulator when it is in operation or
open for maintenance. NEVER stand on the granulator when it is in operation.
4 Inch Granulator Chapter 1: Safety 7 of 47
þ ROTATION OF MOTORS: The correct rotating direction for the granulator motor
is clearly marked on the machine. Always check for proper rotation of motors.
Incorrect rotation direction can cause severe damage.
þ ELECTRICAL GROUNDING: All electrical equipment on the granulator must be
grounded in accordance to all local codes and Article 250 of the National Electric
Code.
þ ALWAYS DISCONNECT AND LOCKOUT the main electrical power to the
granulator before performing any service.
þ SAFETY INTERLOCKS MUST NOT BE BYPASSED. The mechanical and
electrical safety interlocks ensure the safety of personnel. They should never be
tampered with or removed for ANY reason. They should be checked frequently by a
qualified mechanic for proper operation.
þ NEVER modify the machine configuration or any individual component without
written notice from the factory.
For further information on granulator safety, installation, and operation, see the American
National Standard for Plastics Machinery¾Granulators, Pelletizers, and Dicers Used for
Size Reduction of Plastics¾Construction, Care, and Use. ANSI B151.11-1982.
We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide
by the foregoing recommendations in order to make operator safety a reality.
4 Inch Granulator Chapter 1: Safety 8 of 47
Chapter 2: Functional Description
2-1 Models Covered in This Manual
This manual covers M103 beside-the-press granulator. T models are for use with a sprue
removal device and feature a hopper so that material can be dropped directly from the sprue
removal device into the granulator. RT Models are fitted with an extended hopper. SW
models are for use underneath the discharge shaft of your processing machine. SW models
feature a steel auger feeder.
2-2 General Description
This granulator is specially designed for use next to or directly under the processing machine.
The low construction and noise level make this an ideal application. This granulator cuts at a
slow rotational speed, resulting in an extremely low noise level with minimal dust build-up.
All parts that come into contact with the material are easily accessible through large cleaning
openings.
Depending on the requirements, the granulated material can be re-introduced into the process
by a conveyor system with a two-components proportioning valve or a dosing and blending
unit.
2-3 Typical Features and Components
Infeed Devices
Hopper. The hopper is an upright enclosure bolted to the top of the cutting chamber. The
hopper is designed to facilitate feeding of material to the rotary knives and to prevent chips
thrown from the cutting chamber from reaching the operator.
Auger. The steel auger is meant for use underneath the processing machine.
Extended Hopper. If different types of tools are being used, it may be necessary to install an
additional collecting funnel on the opening of the hopper of the granulator. We recommend
that this sheet metal work be carried out on site.
Cutting Chamber
The rotor features 6 staggered horizontal HSS steel rotor blades that are designed for sprues,
and small molded parts.
Screen
The screen is positioned just below the rotor and acts as a separating barrier to the granulated
material, retaining the material in the cutting chamber until the particle size is such that it will
pass through the screen holes.
Discharge System
The granulated material that falls through the screen is collected by a discharge chute beneath
the cutting chamber and directed into a large capacity vacuum bin.
Base
The base is caster-mounted, with four swivel casters for easy positioning. The height of each
caster can be adjusted individually. As a result, the granulator can be positioned at an angle
without affecting its function.
4 Inch Granulator Chapter 2: Functional Description 9 of 47
2-4 Safety Features
Safety Switches
Safety switches at all access covers are wired into the starter control circuit. The machine
cannot be started when these parts are open. However, for safety purposes, the machine
should be disconnected from the power lines by a disconnect switch or by removing the plug
from its receptacle. Check all safety switches periodically for proper operation.
Safety Tags
A set of metal plates is attached to the machine to warn of potential danger.
Level Sensor (optional)
Level sensors monitor the level in the cutting chamber, automatically shutting off the
granulator in case of overfilling.
4 Inch Granulator Chapter 2: Functional Description 10 of 47
Chapter 3: Installation
3-1 Uncrating the Equipment
The granulator is delivered completely assembled and wired, except for the casters. Make
sure the casters are fitted to the baseframe underneath the motor. To lift and move the
granulator safely and correctly, cover any sharp corners or edges, and use the type of
equipment that has the most appropriate features and capacity. Use the designated lifting
points, and do NOT lift the machine by the hopper handles or guards. Refer to the Appendix
for detailed dimensional data and pertinent weights.
Prepare in advance the site you have selected for installation of the granulator. Be certain
that the area to be occupied by the machine is clean, level, and free of obstructions. The
machine should be set on a concrete floor, and care must be taken when moving the machine
across a hollow timber floor, so that the point loading of the casters does not cause damage.
The site you have selected must have a floor rating to adequately support the weight of the
machine. If necessary, use steel shims to level the machine.
Locate the machine so that access is given to electrical components, screen, and hopper.
Maintenance personnel should have unobstructed access to the units on which they will be
working.
To avoid squeezing people working near a machine, there should be adequate clearance
maintained between machines, walls, or partitions. Hinged doors and covers should have full
swing. Restrictions may force work in cramped quarters. An off-balance operator with an
awkward reach into a partially obscured area is unsafe.
Before lifting the granulator, remove the discharge box. Make sure that the limit switch and
the cable of the discharge box is not damaged.
4 Inch Granulator Chapter 3: Installation 11 of 47
3-2 Making the Electrical Connections
Check serial tag voltage/amperage requirements and make sure your electrical service
conforms before making any electrical connections. Make sure that all three phases are wired
correctly.
A separate fuse system is recommended but not absolutely necessary. Bring properly sized
power leads and grounds from a fused disconnect to the unit. If you use fuses, make sure that
they are dual-element, time-delay fuses, sized according to your electrical code. Refer to the
technical specifications in the Appendix for horsepower, voltage, phase, and frequency
requirements to determine the size and rating of the supply cable required.
Carefully check the diagrams packed with the machine. All internal wiring has been done at
the factory. All safety interlocks have been verified to be functional before shipment. The
only connection left to be made, is the electrical power source to the machine at the control
enclosure.
Use the following procedure to complete the electrical connections:
1. Check that the limit switches are closed.
2. Turn switch ON at main power supply.
3. Press the ON switch for at least 3 seconds.
4. With the electrical power ON, check that the motor rotates in a clockwise direction at
the viewing window. If the direction of rotation is incorrect interchange any two
power lines. Verify the direction of rotation for all available sockets.
Caution! Incorrect motor rotation reduces the quality of grinding considerable and
may damage the motor.
4 Inch Granulator Chapter 3: Installation 12 of 47
3-3 Accessing the Cutting Chamber
You will need to access the cutting chamber before initial startup and for various
maintenance procedures.
Use the following procedure to access the cutting chamber:
1. Turn the main power off, remove the line fuses, and tag the machine as out of
service.
2. Open the toggle fasteners.
3. Remove the discharge box.
4. Open the cutting chamber door.
5. Carefully remove the screen.
3-4 Closing the Cutting Chamber
After completing any maintenance or adjustments inside the cutting chamber, use the
following procedure to close the cutting chamber and resume use of the granulator:
1. Carefully install the screen.
2. Close the cutting chamber door.
3. Replace the discharge box.
4. Close the toggle fasteners.
5. Replace line fuses, turn power on, and remove the out of service tag from the
machine.
4 Inch Granulator Chapter 3: Installation 13 of 47
3-5 Preparing for Initial Start-up
This machine has been run under power and tested at the factory prior to shipment. The
necessary settings and adjustments have been made so that a minimum amount of setting up
or re-adjustment is required when starting up the machine in its new location.
With all electrical, mechanical connections and lubrication requirements having been
attended to, the following start-up steps should be carefully carried out before attempting to
place any material into the infeed hopper. Use the following procedure to prepare the
machine for initial start-up:
WARNING! Before operating the granulator, insure that the granulator has been
correctly assembled and wired.
1. Access the cutting chamber as describe in Section 3-3 on page 13.
2. Thoroughly clean the rust preventative materials or grease from the hopper, the inside
of the cutting chamber, knives, rotor, screen, discharge system, and exterior of the
machine. Do not use solvent on any of the painted areas, as solvent may damage the
paint.
3. Tighten down all the bolts of the rotor blades using a torque wrench (36 Nm).
4. Use a feeler gauge to check the clearance between the rotor and the bed knives by
turning the rotor backwards. Rotating the rotor backwards gives a better feel and does
not cut the gauge, should the knives be too close. Proper clearance is 0.004”-0.016”
(0.1mm-0.4mm), depending on material.
Note: Recheck knife clearance after the first 24 to 36 hours of operation.
5. To adjust the bed knives, the bed knife adjusting screws should be hand tightened to
hold the knife firmly against the knife seat while adjusting the knife forward using
push and pull screws. After the clearance is set, torque the screws to 36 Nm.
6. Manually turn the rotor for one complete rotation using an Allen key inserted in the
central bolt of the rotor.
7. Check that the cutting chamber does not contain any foreign objects or tools.
8. With the exposed parts of the machine thoroughly clean, and all knife clamping bolts
securely fastened, close the cutting chamber as described in Section 3-4 on page 13.
Note: After initial start-up, the rotor knife retaining screws should be checked after 8
hours running to be assured that the proper torque is maintained. Thereafter,
rotor knife retaining screws should be checked weekly.
Note: The rotor must be rotated at least two rotations every 30 days to prevent
brinnelling and corrosion of raceways.
4 Inch Granulator Chapter 3: Installation 14 of 47
Chapter 4: Operation
4-1 Starting the Granulator
Before starting the machine, check that the rotor rotates freely by rotating it by hand. Inspect
the cutting chamber carefully to insure that nothing has fallen into it. Make sure all screws
and bolts are properly secured. Check all electrical connections and motor rotations. See
Chapter 3 on pages 11-14 for detailed set-up instructions.
WARNING! The cutting chamber knives are extremely sharp. Always wear heavy gloves
and exercise care when working in the cutting chamber.
Use the following procedure to begin operation:
1. Check that the limit switches are closed.
2. Turn the main power supply switch to the “on” position. The yellow warning light
lights up.
3. Press the “On” switch for at least 3 seconds. The yellow warning light turns off and
the rotor starts to turn.
4. Allow all motors to run up to speed for at least 30 seconds.
4-2 Feeding the Granulator
Feed the granulator through the opening in the hopper. The method of feeding the granulator
depends on the physical form and nature of the material being processed.
For maximum efficiency, the granulator should be fed at a rate that is consistent with its
capacity; i.e., if the granulator is rated at 30 lbs./hr (15 kg/hr), then the general feed rate is 0.5
lbs./min. (0.25 kg/min). Under these operating conditions, the correct proportions of cut and
uncut particles will be present in the cutting chamber.
WARNING! Under no circumstances should the operator attempt to reach into the
hopper to dislodge any bridged or jammed material while the granulator is
in operation. To clear the hopper of bridged or jammed material, the
machine main power must be turned off and the machine isolated.
4 Inch Granulator Chapter 4: Operation 15 of 47
4-3 Clearing a Jammed Cutting Chamber
Never attempt to free a jammed machine by placing hands on the rotor, rotor knives, or inside
the cutting chamber. Hands must be kept clear of the rotational path of the rotor knives.
Good footing on a clean floor is essential and the body should be well braced to guard against
loss of balance should the jam suddenly come free. Use the following procedure to clear a
jammed cutting chamber:
1. Disconnect and lock out power.
2. Be certain that the rotor is motionless.
3. Access the cutting chamber as describe in Section 3-3 on page 13.
4. Use a pry bar to exert force on the rotor, usually in the direction opposite normal
rotation. A leather mallet and a block of wood of sufficient length to keep hands
away from path of knives can be used if necessary.
5. Use pliers to remove material from the cutting chamber, keeping in mind that the
removal of material may cause rotation of the rotor and rotor knives.
6. After clearing the jam, be certain that the screen and all guards and covers are
secured in place before connecting power and starting the machine.
4 Inch Granulator Chapter 4: Operation 16 of 47
4-4 Making an Emergency Stop
Use the following procedure shut down the machine in case of an emergency:
1. Press the “Stop” button. This shuts off the rotor drive motor.
2. For emergency machine stops, feedstock must be cleaned out of the hopper and
cutting chamber prior to restarting the machine.
4-5 Shutting Down the Granulator
Use the following procedure to properly and safely shut down the machine:
1. Stop all feeding of material.
2. Allow the granulator to run until the cutting chamber is completely empty.
3. Press the “Off” button. This shuts off the rotor drive motor. The yellow warning light
lights up, and the rotor stops turning.
4. Turn the main power switch to the “off” position. The yellow warning light turns off.
4 Inch Granulator Chapter 4: Operation 17 of 47
Chapter 5: Maintenance
5-1 Preventative Maintenance Schedule
Weekly: Retighten the bolts of the granulator blades (36 Nm) and check for wear.
Check the cutting edges of the granulator blades.
Clean the screen and check for wear.
5-2 Replacing the Screen
The screen must be replaced when abrasion marks are very prominent or when the screen
holes are oval. The standard screen holes are 5 mm. 4 mm, 6 mm, and 8 mm screen holes are
also available. Larger screen holes must be used if the amount of dust in the regrind is too
high. Smaller screen holes must be used if sprue pieces get stuck in the screen holes or are
pushed through the screen.
Use the following procedure to replace the screen:
1. Turn the main power off, remove the line fuses, and tag the machine as out of
service.
2. Open the toggle fasteners and remove the discharge box.
3. Open the front door and carefully remove the screen.
6. Carefully install the new screen, close the front door and fasten the toggle fastener.
7. Replace the discharge box and fasten the toggle fastener.
8. Replace line fuses, turn power on, and remove the out of service tag from the
machine.
4 Inch Granulator Chapter 5: Maintenance 18 of 47
5-3 Replacing and Adjusting the Knives
The rotor and bed knives are subjected to severe conditions, and you should inspect knives
periodically for sharpness. The sharper the knives are kept, the better the machine operates,
producing quality regrind. If the knives become severely rounded, chipped, or otherwise
damaged, the granulator experiences heavy shock loads during operation causing additional
and significant reduction in knife life.
WARNING! Exercise extreme care when rotating the rotor and handling knives.
Bed Knives
Install the bed knives first, but do not fully tighten the bolts until the rotor knives have been
installed and the knife gaps checked. Use the following procedure to replace or adjust the bed
knives:
1. Access the cutting chamber as directed in Section 3-3 on page 13.
2. Loosen the fasteners holding the bed knives, working from the knife edges inward to
the center. Note the relative position of each part before it is removed.
3. Thoroughly clean the knife seats with a stone or other non-marring tool, and wipe the
screws with a lightly oiled cloth. Do not leave an oil film on the screws, as
lubrication can adversely affect the stress on a screw installed to a fixed torque value.
4. Install the new or re-sharpened bed knives and adjustment screws. Make sure the
knives are fully back against the knife adjusting screws and loosen the adjustment
screws slightly. Do not torque the socket cap screws fully at this point.
Note: Make sure that the cutting edge of the left bed knife is facing upwards and the
cutting edge of the right bed knife is facing downwards.
4 Inch Granulator Chapter 5: Maintenance 19 of 47
Rotor Knives
We recommend that the rotor knife screws be replaced with new screws every time the knife
is changed to reduce the risk of screw failure due to abrasion. Screws must be replaced with
the type specified in the spare parts list.
Using the optional blade adjustment gauge, a second set of blades can be pre-adjusted outside
of the granulator for quick replacement. The blade adjustment gauge is available for the 6blade rotor models.
To replace or adjust the rotor knives using the optional gauge (6-blade rotors only):
1. Access the cutting chamber as directed in Section 3-3 on page 13.
2. Insert the rotor blades individually into the blade adjustment gauge.
3. Screw in the adjustment bolts by hand until the blade does not move.
4. When all the rotor blades have been pre-adjusted, insert them into the guides on the
rotor, pushing them up to the stopper and tightening them down (36 Nm).
5. Make sure that the longer end of the rotor blades makes contact with the rotor. The
cutting edges of slanted rotor blades must be inclined towards the center of the rotor.
6. Use the bed knife adjustment screws to set the knife gap to 0.004”-0.016” (0.1 mm-
0.4 mm).
7. Tighten the screws evenly (36 Nm)..
8. Rotate the rotor for one complete turn in order to make sure that the rotor blades spin
freely. The shaft is rotated by means of an Allen key inserted in the central bolt of the
rotor.
To replace or adjust the rotor knives without a gauge:
1. Access the cutting chamber as directed in Section 3-3 on page 13.
2. Set back the bed knives and carefully remove the rotor knives.
3. Position a bed knife parallel to the casing wall and tighten the bolts by hand.
4. Make sure that the cutting edge of the left bed knife blade is facing upwards and the
cutting edge of the right bed knife blade is facing downwards.
5. Push the first rotor blade right up to the stopper on the rotor and adjust the knife gap
to 0.004”-0.016” (0.1 mm-0.4 mm).
6. Tighten the screws evenly (36 Nm).
7. Install the second bed knife and tighten the bolts by hand.
8. Install the rest of the rotor knives, checking the knife gap between each rotor knife
and both bed knives, tightening all screws to 36 Nm.
9. Rotate the rotor for one complete turn in order to make sure that the rotor blades spin
freely. The shaft is rotated by means of an Allen key inserted in the central bolt of the
rotor.
4 Inch Granulator Chapter 5: Maintenance 20 of 47
5-4 Sharpening the Knives
Under normal operating use, the cutting edge of the knives will eventually become dulled,
resulting in reduced cutting efficiency. The blunt knives may either be re-ground to restore
the cutting edge, or replaced with new knives when regrinding is not possible.
Note: The minimum dimensions given for the rotor knife and bed knife cannot be
combined to produce a cutting combination. For example, a bed knife ground
to its minimum dimension cannot be combined with a rotor knife that is also
ground to its minimum dimension.
Bed Knives
Place the bed knife blades with the reverse side at right angles to the sharpening board of the
sharpening machine. The blunted blades are sharpened at a 15º angle until the cutting edge is
completely sharp. See Figure 1.
Note: If the cutting edge shows any change in color after the sharpening process, the
blades are useless and must be replaced with new ones.
Rotor Knives
Place the rotor blades with the reverse side at right angles to the sharpening board of the
sharpening machine. The blunted blades are sharpened at a 50º angle until the cutting edge is
completely sharp. See Figure 1.
Note: If the cutting edge shows any change in color after the sharpening process, the
blades are useless and must be replaced with new ones.
Figure 1: Knife Sharpening Specifications
Rotor Knives Bed Knives
4 Inch Granulator Chapter 5: Maintenance 21 of 47
5-5 Cleaning the Granulator
Use the following procedure to clean the granulator:
1. Access the cutting chamber as directed in Section 3-3 on page 13.
2. Loosen the central bolt of the rotor (M16) using an Allen key (SW 14).
3. Remove the rotor.
4. Make sure that the locking rings remain inside the rotor.
5. Clean the cutting chamber, housing, hopper, and discharge box using an industrial
vacuum cleaner. For SW models, clean the auger with compressed air.
6. Apply a small amount of oil to the shaft of the rotor to prevent the formation of rust.
7. Check that the rotor fits tightly when installing it.
8. Replace the screen and the discharge box, close the access door, and fasten the toggle
fasteners.
9. Replace line fuses, turn power on, and remove the out of service tag from the
machine.
4 Inch Granulator Chapter 5: Maintenance 22 of 47
Chapter 6: Troubleshooting
6-1 Introduction
The utmost in safety precautions should be observed at all times when working on or around
the machine and the electrical components. All normal trouble-shooting must be
accomplished with the power off, line fuses removed, and with the machine tagged as out of
service.
The use of good quality test equipment cannot be over-emphasized when troubleshooting is
indicated. Use a good ammeter that can measure at least twice the AC and DC current that
can be encountered for the machine. Be sure that the voltmeter has at least minimum
impedance of 5,000 OHMS-per-volt on AC and 20,000 OHMS-per-volt on DC scales.
Popular combination meters, VOM and VTVM can be selected to provide the necessary
functions.
Before making haphazard substitutions and repairs when defective electrical components are
malfunctioning, we recommend that you check the associated circuitry and assemblies for
other defective devices. It is common to replace the obviously damaged component without
actually locating the real cause of the trouble. Such hasty substitutions will only destroy the
new component. Refer to wiring diagrams and schematics.
Locating mechanical problems, should they occur, is relatively straightforward. When
necessary, refer to the parts catalog section.
6-2 Electrical Faults
Problem Possible Cause Possible Remedy
Motor Fails to Start
Motor starts but will not take
load
Motor will start when
disconnected from load but
not when connected
Supply failure Check fuses
Starter inoperative Check main supply
Starter overloads or cuts out Check motor requirements
and adjust accordingly
Safety switches inoperative Check and adjust as needed
Too much belt tension Check belt tension and adjust
as necessary
Incorrectly connected motor Check terminal connection
with manufacturer’s
connection diagram and
adjust as necessary
Defective starter winding Check current in each phase
with ammeter, if there is a
marked difference in current
in one phase, contact motor
manufacturer
Worn bearings Check and replace if
necessary according to
manufacturer’s literature
4 Inch Granulator Chapter 6: Troubleshooting 23 of 47
6-3 Processing Faults
Problem Possible Cause Possible Remedy
Stalling
Material overheating
Overfeeding Reduce feed rate
Partial or complete screen
blockage
Insufficient tension on v-belt
drive causing belt slip and
burning
Badly blunted or damaged
knives
Knife setting too wide Check clearances given and
Installation fault; motor
running in reverse direction
Safety switch cut out where
fitted
Check all possible causes
under “stalling”
Remove screen, clear and
inspect for damage
Check tension of the belt and
adjust as necessary
Check that the motor slide
base screws are secure
Fit re-sharpened or new
knives as required
adjust as required
Check with direction arrow
and re-fit electrical
connections to give the
correct direction
Tighten safety switch setting
screw
Remedy as shown above
Screen size too small Increase screen size
When granulating rubber,
insufficient talc causes
freshly cut surfaces to readhere
Blockage in aiveyor Check direction of fan
Increase talc percentage rate
of infeed
rotation, check venturi and
line or chute for blockage
4 Inch Granulator Chapter 6: Troubleshooting 24 of 47
6-4 Mechanical Faults
Problem Possible Cause Possible Remedy
Bearing overheating
Visible cracks in knife Incorrect grinding or
Knives moving on knife
seats
Knives breaking Cracks caused by incorrect
Excessive knife wear Open knife setting Re-set knives
Screen breakage Incorrectly seated screen Check that the screen is
Excessive tension on the belt
drive
Lubrication fault Check lubrication frequency
grinding procedure
Uneven knife seat surfaces Clean up to provide
Loose knife screws Knife screws should not be
grinding
Check tension of belt and
adjust as necessary
and recommended lubricant
Check method of grinding
and contact our technical
sales department
maximum bearing surface
used more than six times.
Replace if there is evidence
of stretch
Contact our technical sales
department
seated correctly and fully in
its cradle
4 Inch Granulator Chapter 6: Troubleshooting 25 of 47
Chapter 7: Appendix
7-1 Customer Satisfaction Warranty Program
The terms and conditions of the warranty set forth are for one (1) year from the original date
of purchase by the original purchaser.
The manufacturer warrants to the original purchaser the product and/or goods to which this
disclaimer is attached, and manufactured by us, to be free from defects in material and
workmanship under normal use and service. THIS WARRANTY IS EXPRESSLY IN LIEU
OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, INCLUDING
WARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, AND ALL OTHER OBLIGATIONS AND LIABILITIES ON OUR PART.
This warranty shall not apply to any goods or product manufactured by us which has been
subject to accident, negligence, alteration of any kind, abuse, or misuse. We further make no
warranty whatsoever in respect to accessories or parts not supplied by us. Any warranty of
any nature shall apply only to an “original purchaser” which shall be deemed to mean that
person or entity for whom the goods and/or product were originally ordered and installed.
We neither assume nor authorize any person to assume for us any liability in connection with
the sale or use of the products and goods sold hereunder, and shall not be responsible for
damages for which a purchaser may be liable to other persons, damages to property, or
injuries to any other persons.
Our sole obligation under this warranty shall be limited to replacing, repairing, or exchanging
any part or parts of goods and/or products sold which we determine are defective under
normal use and service within one (1) year of date of installation by the original purchaser.
We shall not be liable for any loss or damage resulting directly or indirectly from the use or
loss of the goods and/or products purchased. In no event shall we be liable for any general,
direct, consequential, incidental, or special damages of any kind.
We do not warrant any of our products that are installed in other machines or apparatus as
meeting requirements of any safety code of any nature. The purchaser assumes all risks and
liabilities resulting from the installation and use of product sold by us in combination with
other machines or apparatus.
We warrant our product to be of the kind and quality quoted, and no other warranty except of
title shall be implied. Our company shall repair or replace, at our discretion, any
manufactured item on your granulator without charge FOB factory, within one (1) year after
date of original purchase, which is proved to be defective when shipped. Claims for labor or
consequential damages are not allowed.
Excluded from the above are knives, screens, and belts. Purchased items, including electrical
components, motors, etc., shall carry the warranty of the supplier and no extension of that
warranty is allowed.
Refer to this manual for assistance in installing and maintaining a highly efficient machine.
Questions regarding areas that are not covered in the manual should be referred to the
customer service manager at the factory at (800) 229-2919.
4 Inch Granulator Chapter 7: Appendix 26 of 47
7-2 Installing the Optional Level Sensor
Rotary level sensing devices monitor the material level in the chamber, providing an
automatic cutout in case of over-filling.
Use the following procedure to install the optional level sensor:
5. Open the two toggle fasteners at the discharge box.
6. Remove the discharge box.
7. Remove the stopper at the rear of the discharge box.
8. Remove the cotter at the vane of the level indicator.
9. Pull out the vane.
10. Unscrew the lock nut.
11. Mount the level indicator in the discharge box.
12. Mount the lock nut and tighten.
13. Mount the vane at the level indicator.
14. Mount the cotter.
15. Replace the discharge box.
Close the two toggle fasteners at the discharge box.
4 Inch Granulator Chapter 7: Appendix 27 of 47
7-3 Spare parts list
Granulator Cutting Chamber
01 CTF00237 Chamber Housing
02 CTF0238 Front Door
03 CTF00236 Window
04 CTF00216 Pivot Pin
05 CTF00764 Disc Seal
06 124920051 Hook Clamp
07 150080182 M6 Socket Head Cap Screw
08 151340006 M6 Lock Washer
09 150070004 M5 Socket Head Cap Screw
10 151340005 M5 Lock Washer
11 20011-1122-00 Handle
12 150070076 M8 Socket Head Cap Screw
13 151340007 M8 Lock Washer
14 2120370001 Safety Switch
15 2120370002 Switch Actuator
16 150070003 M5 Socket Head Cap Screw
17 150740012 M5 Socket Head Cap Screw
18 20011-1123-00 M8 Hardened Washer
19 150080125 M8 Socket Head Cap Screw
20 150820025 M8 Socket Head Set Screw
21 151150011 M8 Hex Nut
22 150250003 M5 Socket Head Cap Screw
23 151410005 M5 Washer
25 150080194 M8 Socket Head Cap Screw
26 151410007 M8 Washer
28 CTF32013 Seal Ring
CTF220510064 Screen 1/4" diameter (Specify Size)
20010-0395-00 Gear Motor 1.5 KW
CT000015 Hopper
Rotor Assembly
01 CTF001430100 Rotor Segment
02 CTF001430500 Rotor Segment
03 CTF00504 Rotor End Cap
04 CTF00765 Rotor Shaft
05 CTF00000101 Rotor Key
06 CTF23106 Cover Plate
07 150036046 M8 Hex Head Screw (Rotor knife screw)
08 1500330173 M10 Hex Head Screw
09 151340009 M10 Lock Washer
CTF00207 Bed Knife
CTF12923 Rotor Knife
CTF12924 Rotor Knife
150550051 Sq Head Set Screw (Knife adjusting)
(Reference Drawing #CT000010)
4 Inch Granulator Chapter 7: Appendix 28 of 47
7-3 Spare parts list (Continued)
Base Assembly
01 CTF004470 Base Frame
02 ESL-Wheel Caster without brake
03 ESL-Wheel-1 Caster with brake
04 150420069 M10 Hex Head Cap Screw
05 151340009 M10 Lock washer
Discharge Assembly
01 CTF0052 Discharge Transition Chute
02 CA0701660100 Vacuum Tube
03 CT000004 Window
04 CTF00041 Latch Bracket
05 CTF01135 Safety Switch Bracket
06 3157160003 Hand Screw
07 124920053 Hook Clamp
08 2120370007 Safety Switch
09 20033-1115-00 Dome Plug
10 150070002 M4 Socket Head Cap Screw
11 CTF00090 Retainer Plate
12 150070035 M6 Hex Head Screw
13 150070001 M4 Socket Head Cap Screw
14 151410006 Washer
15 151150005 Hex Nut
16 150250092 M5 Socket Head Cap Screw
17 151340006 Lock Washer
18 121340003 #8 Lock Washer
19 151410005 M5 Lock Washer
20 20045-0105-00 Gasket 1/4" x1/4"
(Reference Drawing CT000025)
Auger/Coil Feed Option (Reference Drawing CTB32194)
01 CTF32195 Auger Trough
02 CT000036 Trough Bar
03 CTF00685 Auger/Coil
04 150730001 M5 Flat Head Socket Screw
05 150080097 M5 Socket Head Cap Screw
06 151410005 M5 Washer
07 CT300205 Motor Flange
08 151150011 M8Hex Nut\
09 151340007 M8 Lock Washer
10 150330153 M10 Socket Head Cap Screw
11 151340009 M10 Lock Washer
12 20010-0400-00 Gear Motor 0.12 KW
13 20025-0058-00 Key 5MM
14 2004-0001-00 Torque Clutch
15 124780034 Sensor
16 20005-0001-00 Pull Cord Switch Assembly
4 Inch Granulator Chapter 7: Appendix 29 of 47
7-3 Spare parts list (Continued)
17 151340005 M5 Lock Washer
18 150810042 Socket Head Set Screw
19 150080098 M5 Socket Head Cap Screw
20 CT000037 Clamp Washer
21 CTB321942000 Handle
22 151340006 M6 Lock Washer
23 1500800185 M6 Socket Head Cap Screw
Controls/Electrical (Reference Drawing #EG-3754
A70A0B460000 Control Panel Complete (USA Configuration)
00115-0158-00 Fuse 6FU; FNM1
00115-0448-00 Fuse 4-5FU; 460 & 575 volt only
00115-0422-00 Fuse 4-5FU; 208 & 230 volt only
00115-0432-00 Fuse 1-2-3FU, LPJ6
00115-0433-00 Fuse 1-2-3FU, LPJ10
00115-0434-00 Fuse 1-2-3FU, LPJ15
00125-0165-00 Overload Relay 1.6-5 Amp
00125-0166-00 Overload Relay 3.7-12 Amp
00130-0294-00 Pushbutton 2PB/4PB N.O.
00130-0295-00 Pushbutton 2PB/4PB N.C.
00130-0296-00 Pushbutton 2PB/4PB Red/Green
00130-0297-00 Pushbutton 2PB/4PB 120-volt light
00142-0448-00 Disconnect Handle 194RHS4E
00142-0373-00 Proximity Switch (Optional)
00149-0025-00 Beacon Light (Optional)
002120370001 Limit Switch
Controls/Electrical (Reference Drawing #EG-4007)
M103-2-150-LP Control Panel Complete (Euro CE Mark Configuration
00149-0030-00 Amber Column, 24V
00149-0031-00 Light
00149-0032-00 Lamp
00130-0317-00 Pushbutton N.O.
00130-0318-00 Pushbutton N.C.
00130-0321-00 Pushbutton
00147-0520-00 Transformer, 24 volt
00111-0136-00 Aux Contact 2N.O 2N.C.
00111-0128-00 Aux Contact 1N.O 1N.C.
00111-0130-00 Contactor
00125-0214-00 MSP Aux. Contact
00125-0210-00 Overload (M103 only)
00125-0211-00 Overload (M253 only
00105-0236-00 Circuit Breaker 05 A
00105-0240-00 Circuit Breaker 2.0 A
146-155-0 Timer
4 Inch Granulator Chapter 7: Appendix 30 of 47
7-4 Technical Data
T Models
Height: 36.9” max. (936 mm)
Width: 18.6” (472 mm)
Depth: 29.8” (757 mm)
Weight: appr. 264.6 lbs. (120 kg)
Throughput: appr. 33 lbs./hr (15 kg/h) with standard screen
Operation volt age: 3 x 400 V/50 Hz
Connected wattage: 2.2 kW
Speed of cutting rotor: 96 RPM
Options: level sensor
Special volt age on request
hopper (if the granulator is fed by means of a sprue removal
device)
6-blade-rotor for sprues (serial equipment)
3-blade-rotor for small hollow moldings
chamfered HSS blades for normal operation
straight HSS blades for small parts and rods
hardened sieves with 4, 5, 6 and 8 mm holes
Total sound intensity level:
without regrind: 70 dB(A)
with regrind: up to 90 dB(A) (dependency on material type)
Max. sizes of sprues: 3.9” (100) mm
Applicability: for feeding manually or by means of a sprue removal device or
separate conveyor belt
4 Inch Granulator Chapter 7: Appendix 31 of 47
SW Models
Height: 27.75” max. (705 mm)
Width: 18.6” (472 mm)
Depth: 48.2” (1225 mm)
Weight: appr. 308.7 lbs. (140 kg)
Throughput: appr. 33 lbs./hr (15 kg/h) with standard screen
Operation voltage: 3 x 400 V/50 Hz
Special voltage on request
Connected watt age: 2.2 kW
Speed of cutting rotor: 96 RPM
Options: level sensor
6-blade-rotor for sprues (serial equipment)
3-blade-rotor for small hollow moldings
chamfered HSS blades for normal operation
straight HSS blades for small parts and rods
hardened sieves with 4, 5, 6 and 8 mm holes
Total sound intensity level:
without regrind: 70 dB(A)
with regrind: up to 90 dB(A) (dependency on material type)
Max. sizes of sprues: 3.9” (100 mm)
Applicability: for feeding even long and bulky sprues
4 Inch Granulator Chapter 7: Appendix 32 of 47
7-5 Drawings and Diagrams
T Models
4 Inch Granulator Chapter 7: Appendix 33 of 47
SW Models
4 Inch Granulator Chapter 7: Appendix 34 of 47
RT Models
4 Inch Granulator Chapter 7: Appendix 35 of 47
4 Inch Granulator Chapter 7: Appendix 36 of 47
4 Inch Granulator Chapter 7: Appendix 37 of 47
4 Inch Granulator Chapter 7: Appendix 38 of 47
4 Inch Granulator Chapter 7: Appendix 39 of 47
4 Inch Granulator Chapter 7: Appendix 40 of 47
4 Inch Granulator Chapter 7: Appendix 41 of 47
4 Inch Granulator Chapter 7: Appendix 42 of 47
4 Inch Granulator Chapter 7: Appendix 43 of 47
7-6 Technical Assistance
Parts Department
Call Spare Parts Express toll-free 8am-8pm EST (800) 229-2919. OEM quality replacement
and spare parts ensure operation at design specifications. Please have the model and serial
number of your equipment when you call. Consult the Customer Parts List included in your
information packet for replacement part numbers.
Service Department
Call toll free (800) 966-8664 8am-8pm EST – Emergency service available 24 hours a day.
We have a qualified service department ready to help. Service contracts are available for most
of our products.
Sales Department
Call (508) 399-6400 Monday through Friday 8am-5pm EST. Our products are sold by a
worldwide network of independent sales representatives. Contact our sales department for the
name of the sales representative nearest you.
Auger Clutch Info (next page)
4 Inch Granulator Chapter 7: Appendix 44 of 47
4 Inch Granulator Chapter 7: Appendix 45 of 47
4 Inch Granulator Chapter 7: Appendix 46 of 47
4 Inch Granulator Chapter 7: Appendix 47 of 47
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