Model MTF3030 & MTF3045
Granulators
Operation & Instruction Manual
We thank you for your purchase of a Colortronic granulator. We feel certain that you will
have excellent results with this machine, along with trouble-free operation.
When the machine arrives at your plant, inspect it carefully for shipping damage before
uncrating and immediately report any damage to your transportation company. All shipments
are F.O.B. South Attleboro, Massachusetts.
Colortronic warrants that its products shall 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 which is proved to be defective when shipped without
charge F.O.B. factory, within one (1) year after date of shipment. Claims for labor or
consequential damages will not be allowed.
Excluded from the above are knives, screens, and V-belts. Purchased items, including
electrical components, motors and etc., shall carry the warranty of the supplier and no
extension of that warranty will be allowed.
This warranty shall be voided if the machinery is used for other than its intended purpose or if
the machine has not received recommended maintenance attention.
Refer to this Operation, Service, and Maintenance 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 factory for reply.
1
GRANULATOR SAFETY RULES 4
1.0 INTRODUCTION 6
1.1 Scope 6
1.2 General Description 6
2.0 INSTALLATION 8
2.1 Scope 8
2.2 General 8
2.3 Shipping 8
2.4 Unpacking 8
2.5 Set Up 9
2.6 Electrical Service Connections 10
3.0 PRE-OPERATIONAL PROCEDURES 11
3.1 Scope 11
3.2 Electrical Test 11
3.3 Pre-Operational Checklist 12
4.0 ELECTRICAL SYSTEM NOTES 13
4.1 Start-Up or Operation Problems 13
5.0 OPERATING INSTRUCTIONS 14
5.1 Operating Instructions 14
6.0 GRANULATOR TROUBLESHOOTING 15
6.1 Investigating Causes 15
6.2 Suggested Actions 15
7.0 MOTOR AND BELTS - SERVICE INSTRUCTIONS 17
2
7.1 Procedure 17
Figure 1 Belt Span and Deflection 18
Table 1 - Belt Deflection Force 18
8.0 KNIFE RECOMMENDATIONS AND ADJUSTMENTS 19
8.1 Knife Removal and Adjustment Procedure 19
8.2 Rotor Knife Removal 19
8.3 Rotor Knife Installation Procedure 20
8.4 Bed Knife Installation and Setting Procedure 20
9.0 RECOMMENDED TORQUE FOR KNIFE BOLTS 22
10.0 PROCEDURE TO OPEN/CLOSE THE SCREEN CHAMBER 23
10.1 Procedure to Open Screen Chamber 23
10.2 Procedure to Close the Screen Chamber 23
11.0 FANS/BLOWERS - PNEUMATIC EVACUATION 24
11.1 Description 24
11.2 Pre-Operational Checklist 24
11.3 Troubleshooting and Suggested Actions 24
11.4 Bearing Lubrication 25
11.5 Belt Adjustment Procedure 25
11.6 Spare Parts 25
12.0 RECOMMENDED SPARE PARTS 26
13.0 LUBRICATION SPECIFICATIONS 27
13.1 Description 27
13.2 Recommended Grease Product Names 27
14.0 PROCEDURE TO OPEN HOPPER DOOR, EXTENDED FEED UNITS 28
14.1 Procedure 28
3
Granulator Safety Rules
The Colortronic granulator has been designed and constructed to provide the highest possible
degree of safety for the operator and service personnel. However, the nature of the machine
demands strict attention to the following safety requirements.
ΗΗΗΗΗΗΗ DANGER ΗΗΗΗΗΗ
All operating and service personnel must comply
with the safety requirements contained in this
manual as well as your company’s safety policies
and procedures. Failure to do so can result in
serious bodily injury or death.
1. BEFORE OPERATING THE MACHINE, read and understand all company safety
and operating procedures, and all safety requirements and operating instructions contained
in this manual.
2. LEARN AND COMPLY WITH your company’s policies and procedures regarding the
processing of materials.
3. OBSERVE all DANGER, WARNING, CAUTION and SAFETY LABELS on the
equipment.
4. WEAR SAFETY GLASSES OR A FACE SHIELD AT ALL TIMES WHEN
OPERATING OR SERVICING THE GRANULATOR. The nature of material size
reduction causes extreme turbulence of the granulated material in the cutting chamber.
Flyback can propel particles at high velocity which can cause severe eye injury if not
protected. Although our machines are designed for the maximum in flyback control,
CAUTION must be used when operating near the area of the hopper feed opening in order
to guard against unexpected material flyback.
5. EAR PROTECTION MAY BE REQUIRED when granulating certain hard or noisy
materials. Follow the guidelines established in The Occupational Safety and Health Act
of 1970 contained in OSHA 1910.95, Permissible Noise Exposure.
6. WARNING - DO NOT
AREA WHILE THE MACHINE IS OPERATING. SEVERE INJURY OR DEATH CAN
RESULT FROM BEING CAUGHT BY THE KNIVES. In addition, flyback of material
being granulated can have sharp edges which can injure the face, hands and arms.
7. NEVER WEAR loose fitting clothes, neckties or jewelry when operating the granulator.
Operators with long hair must either tie the hair back or confine it with a hair net.
8. NEVER lean on or rest your hands or feet on the granulator when it is operating.
NEVER climb on the granulator when it is in operation or is open for service. NEVER
stand on the granulator when it is operating.
9. NEVER attempt to operate the granulator unless it is fully assembled with all guards and
interlocks in place and functional.
REACH INTO THE INFEED HOPPER OR DISCHARGE
4
10. KEEP THE WORK AREA AROUND THE UNIT CLEAN AND UNCLUTTERED at all
times. Never leave maintenance tools or other metal objects on the machine that could
fall into the cutting chamber. This could cause damage to the machine.
11. DISCONNECT AND LOCK OUT ELECTRICAL POWER BEFORE OPENING ANY
AREA OF THE MACHINE FOR CLEANING OR MAINTENANCE.
12. NEVER RELY SOLELY ON SAFETY LIMIT SWITCHES. (Limit switches are
provided to remove power from the machine if the unit is opened inadvertently.)
13. NEVER BYPASS SAFETY LIMIT SWITCHES. Mechanical and electrical interlocks
are provided for the safety of personnel and must never be tampered with for any reason.
14. FOLLOWING MAINTENANCE OPERATIONS, CHECK THAT ALL SAFETY
GUARDS AND COVERS ARE IN POSITION AND PROPERLY SECURED BEFORE
APPLYING POWER TO THE MACHINE. Check that all fasteners are in place and fully
tightened.
15. NEVER MODIFY THE MACHINE, its configuration or any of its components without
first consulting Cumberland Engineering
16. ROTATION OF MOTORS: All rotating items in the granulator are clearly marked on the
machine. Always check for correct rotation of the motor(s) before operating.
17. ELECTRICAL GROUNDING: All electrical equipment associated with the granulator
must be grounded in accordance with all local codes and Article 250 of the National
Electric Code.
18. SHORTCUTS CAN INJURE PEOPLE AND EQUIPMENT!
19. READ the following document for further information on granulator safety, installation
and operation: American National Standard for Plastic Machinery - Granulators,
Pelletizers and Dicers Used for Size Reduction of Plastics - Construction, Care and Use;
ANSI B151.11-1982.
Colortronic has long recognized the importance of safety and has designed and manufactured
it’s equipment with operator safety as a prime consideration. As a user, we expect you will
abide by the foregoing recommendations in order to make operator safety a reality.
SAFETY IS NO ACCIDENT
5
1.0 Introduction
1.1 Scope
This manual is intended to be used as a guide and reference for personnel who will be
installing, operating and maintaining the Colortronic MTF3000 Series Granulators. The
purpose is to aid these individuals in applying efficient, proven techniques which will
enhance equipment productivity.
This introduction includes a brief functional description, a physical description, and machine
specifications for these Granulators. Additional sections within the manual provide
instructions for installation, pre-operational procedures, operation, preventative maintenance,
and corrective maintenance.
Installation instructions include all required data for receiving, unpacking, inspecting, and
setup of the granulator. Also included are illustrations which will aid in utilizing techniques
to accomplish these tasks efficiently. We can provide the assistance of a factory trained
technician, for a nominal charge, who will help in training your operator(s).
Pre-operational instructions include procedures, checks, and adjustments which 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 Section includes a description of electrical and mechanical controls, in
addition to information for operating the granulator safely and efficiently.
The Maintenance Section is intended to serve both as a guide for identification and location of
most common problems and as a source of detailed assembly and disassembly instructions for
those areas of the equipment requiring service.
The Spare Parts Section contains a partial list of recommended parts which may require
replacement. Refer to the Spare Parts Manual for a comprehensive listing of spares which
can be purchased.
1.2 General Description
Colortronic granulators are designed to uniformly and consistently size reduce your scrap.
They have been engineered to consistently deliver clean granulate with a minimum of “fines”.
The rotor on which the cutting knives are mounted, is a fabricated, steel unit supported by
bearings mounted outside the cutting chamber. The rotor is driven by a motor which will
accept high torque loads, is equipped with a magnetic starter, and is protected by manually
resettable overload heaters.
Motors are individually fused for maximum protection in compliance with the National
Electric Code.
6
The control enclosure houses all of the necessary wiring, fuses, overload heaters, motor
starter coils, along with the 115V control transformer and granulator operating controls. The
control enclosure is built to meet NEC, JIC (M.T.), ANSI-B, and OSHA regulations.
7
2.0 Installation
2.1 Scope
This section contains all instructions required for experienced installation personnel to install
the Colortronic granulator and prepare it for production. It is essential to follow all
instructions carefully and in the sequence presented. Be sure to observe all DANGER,
WARNING, and CAUTION statements in order to prevent personal injury or machine
damage and to observe all NOTE statements which are designed to assist in the performance
of procedures.
2.2 General
The site selected for installation of the granulator should be prepared in advance. Be certain
that the area to be occupied by the machine is clean, level, and free of obstructions. The site
selected must have a floor rated to easily support the weight of the machine and a concrete
floor of 4” minimum in thickness is recommended.
2.3 Shipping
To prepare the granulator for shipment, it is mounted on wooden skids, then blocked and
banded to prevent movement. All non-painted items subject to corrosion are coated with a
quality rust preventative and the machine is then covered with heavy duty polyethylene to
protect it from moisture and dirt.
Colortronic granulators are normally shipped completely assembled unless the size of the
machine or an agreement for special shipping arrangements causes partial disassembly.
2.4 Unpacking
NOTE: When the machine arrives at your plant, inspect the crate carefully for
shipping damage BEFORE uncrating. Report any damage immediately to the
transporting company that delivered it. Sign the freight bill -- noting the damage.
If inspection revealed no shipping damage, unpack the unit by removing the outer crate and
then removing the banding and polyethylene protective covering. Attached to the machine
will be an envelope containing “Installation Instructions”. The usual contents of this
envelope are Floor Plan, Parts List, Motor Instruction Manuals, Assembly Drawings,
Electrical Diagrams, and a copy of this manual.
The machine may now be lifted from the skid. A fork lift is ideal for the purpose, but care
must be taken to properly position the forks between the base foot pads, from the front (door
side) of the machine.
DO NOT ATTEMPT TO LIFT THE GRANULATOR BY MEANS OF ANY SHAFT OR
PROTRUDING MEMBER, ESPECIALLY THE HOPPER.
Η Η Η Η Η CAUTION Η Η Η Η Η
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2.5 Set Up
Make certain the floor is clean, level, and free of obstructions before placing the machine into
position.
Visually inspect the hopper infeed opening to insure that no stray packing material or debris
is present.
Open the front doors and remove the fan transition on the front of the screen chamber by
releasing the clip fasteners at the top front edge of the chamber. Wipe out the inside of the
transition and then place it to one side.
Η Η Η Η Η CAUTION Η Η Η Η Η
The knives mounted on the rotor and also located at the edges of
the cutting chamber are extremely sharp. Always wear heavy gloves
and exercise care when working in the cutting chamber
Carefully inspect the interior of the cutting chamber for foreign material or debris. Slowly
turn the rotor by hand to verify that it rotates freely without obstruction or contact between
rotor and bed knives. Wipe the inside of the cutting chamber clean. Before closing the screen
chamber, check the chamber carefully to insure nothing has been left inside the machine.
Place the screen back into it’s original position and close the chamber securely. Insert all
bolts initially removed and tighten them fully.
Replace the fan transition, making sure that nothing has been left inside, and secure it to the
screen chamber with the clip fasteners.
Connect the fan transfer tube (optional) to the exhaust side of the transition by inserting it
through the transfer tube opening on the side cover of the machine. Fasten it securely with
clamps.
Position and connect any optional accessory equipment such as fans, conveyors, and
separators. Ensure all tubing joints are securely clamped and supported.
Make certain all electrical connections are properly made and supported between accessories
and the control enclosure (refer to the wiring diagram for wire and terminal connections).
Open the sheave guard (LH) by removing the bolts attaching the cover. Check the belts for
proper tension and alignment (refer to section 7). Upon completion, close the sheave guard
by placing the cover back into position by inserting all of the bolts originally removed and
tightening them fully.
Before closing the front doors, recheck all components to insure that they are properly
fastened.
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2.6 Electrical Service Connections
Carefully check the diagrams packed with the machine. All internal wiring has been done at
the factory. All safety interlocks have been verified for proper functioning before shipment.
It is only necessary to connect the electrical power source to the machine at the control
enclosure.
Η Η Η WARNING Η Η Η
All equipment must be grounded in compliance with Article 250
of the National Electric Code and all Local Codes. The customer’s
disconnecting means and branch circuit protection must also be in
compliance with the National Electric Code and all Local Codes.
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3.0 Pre-Operational Procedures
3.1 Scope
This section contains the information required to carry out pre-operational procedures, and a
checklist of items which should always be reviewed prior to a production run.
Before undertaking any machine repairs or maintenance, always
make certain that the machine disconnect switch is turned to the
OFF position or that the control enclosure is disconnected from
the main power source. When extensive work is anticipated, either
place a sign indicating that the main disconnect switch is to remain
off onto the switch or lock the switch to prevent accidental
activation by someone unaware of work in progress.
3.2 Electrical Test
Before applying power to the machine, check the incoming voltage from L1 to L2, L2 to L3,
and L1 to L3 (see wiring diagram packed with the machine). The voltage should be the same
as indicated on the silver tag in the control enclosure. If the voltage is not the same, contact
the Colortronic Service Department for voltage modification.
Once it has been determined the voltages are proper, it is necessary to start the motors and
check for the proper direction of rotation.
Turn the main disconnect switch to the ON position.
Press the Granulator START pushbutton to power the granulator motor. Visually compare
the direction of the motor shaft rotation to the rotation arrow label (counter-clockwise when
viewed from the shaft end). If the motor turns in the opposite direction, reverse any two
incoming power leads.
ΗΗΗΗΗΗΗ
DANGER ΗΗΗΗΗΗΗ
Once the rotation direction is correct, the remaining electrical controls need to be tested as
follows:
Press the Granulator STOP pushbutton and allow the machine to stop.
For granulators equipped with conveyors, fans, or etc., test their operation also by
pressing the appropriate pushbutton. Check fan outlets for proper airflow.
For granulators with Emergency Stop pushbuttons, test the buttons to insure all motion
stops.
Open the front doors to verify the safety interlock switch shuts the machine off.
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3.3 Pre-Operational Checklist
After all electrical and mechanical machine elements have been inspected and any defects
corrected, the machine can be put into production once the pre-operational checklist is
referred to.
Have all installation and preparation instructions been read and followed?
Have sufficient location clearances been allowed?
Has the equipment been grounded as required by local codes and/or Article 250 of the
National Electric Code?
Have all motors been checked for rotation?
Have all machine controls, pushbuttons, and limit switch safeties been checked for
proper functioning?
Have the cutting and screen chambers been checked for foreign matter?
Have the drive belts been checked for alignment and tension?
Is the machine properly closed with all visible fasteners tight?
Are all accessory components electrically and mechanically connected with proper
support and with all fasteners tight?
Are cyclonic air separator and filter bags empty? (optional equipment)
Has the fan (optional) been verified for proper rotation direction?
Are all electrical enclosure boxes tightly closed and clamped shut?
Are all personnel clear of the machine?
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4.0 Electrical System Notes
4.1 Start-Up or Operation Problems
Granulator will not start:
Check all fuses. If blown, try to locate grounds or other reasons. Replace fuses with the size
and type shown on the wiring diagram (located in the control enclosure).
Check granulator motor and fan overloads. If required, reset #1 MOL, #2MOL.
Check for an open safety limit switch at the machine front doors or at any limit switch
protected hopper cleanout door.
If not equipped with a fan, check the jumper on terminals #3 and #5.
Call the Colortronic Service Department for assistance if the machine still will not start.
Have the machine serial number and/or W/Q number at hand (located on the serial number
plate on the cutting chamber).
Fan motor will not start (optional):
Check fuses #1, #2, and #3. If blown, try to locate grounds or other reasons. Replace fuses
with the size and type shown on the wiring diagram (located in the control enclosure).
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5.0 Operating Instructions
5.1 Operating Instructions
Machine ready - all doors, covers, guards, and limit switches are in place, securely fastened,
and functional. All accessory components are properly connected.
Turn the main disconnect switch to the ON position.
Start the granulator and fan (optional) by pressing the appropriate pushbutton at the operator
station.
Load feedstock at a uniform rate that does not exceed the capacity of the machine.
For color and/or material changes, allow all existing material to clear the granulator and it’s
downstream equipment before stopping the machine in order to minimize cleaning
requirements.
Refer to Section 10 for instructions on how to open the screen chamber and obtain access to
other machine areas for clean out.
NOTE: If there is an access door on the hopper for inspection or clean-out purposes
that is limit switch protected, make certain the limit switch actuator bracket is
re-installed and is properly in contact with the limit switch or the machine
will not start.
Temporary machine stops: When temporarily stopping the machine, allow all material to
run out of the cutting chamber. NEVER try to re-start the machine with material remaining
inside the cutting chamber.
Final machine stops: When shutting the machine down, allow all material to pass through
the fan and into the cyclonic air separator before pressing the Stop Granulator pushbutton.
Emergency stops: The machine must be cleaned before restarting.
Η Η Η Η CAUTION Η Η Η Η
The Colortronic MTF3000 series granulators are not
designed for purgings, chucks of solid plastic, or other heavy
cross-sectional pieces.
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6.0 Granulator Troubleshooting
6.1 Investigating Causes
1. No granulate
2. Stringy granulate or fines
3. Fines
4. Excessive power required - blown fuses
5. Machine stalls
6. Bearings sound noisy or are hot
7. Belts slip of squeal
8. Motor will not start
9. Granulate builds up in the transition or tubing
10. Feedstock hangs up in the hopper or cutting chamber
6.2 Suggested Actions
1. No granulate
a) Feedstock may be hung up inside the hopper. Shut the machine down and
check.
b) Screens are plugged. Clean the screens.
c) Fan is too small. Replace with larger unit or fan wheel.
d) Fan line may be clogged. Clean as required.
2. Stringy granulate.
a) Knife gap is too large. Adjust knives to proper gap specification.
b) Knives are dull. Sharpen or replace knives and re-install.
c) Overloading of feedstock. Reduce the amount of feedstock put into the
machine per unit of time.
3. Fines.
a) Knives are dull. Sharpen knives and re-install.
b) Plastic is clogging the screens or transition preventing proper fan evacuation.
Shut the machine down and clean.
c) Rotor speed is too fast. Change pulley.
d) Screen size is too small. Change to a screen with larger holes.
4. Excessive power required - blown fuses.
a) Overloading of the machine. Reduce amount of feedstock put into the
machine per unit of time.
b) Knives are dull. Sharpen or replace knives and re-install.
c) Knife gap is too large. Adjust knives to proper gap specification.
15
d) Clearance between the rotor knives and screen is too small. Check that the
screen is properly seated in the screen chamber.
5. Machine stalls.
a) Overloading of the machine. Reduce amount of feedstock put into the
machine per unit of time.
b) Pieces of feedstock jammed in the rotor. Clear the jammed material then
visually inspect the rotor to ensure it is not damaged and that the knife gaps
are correct.
c) Machine has thrown belts. Inspect, and if acceptable for use, re-install and
tighten per maintenance instructions.
6. Bearings sound noisy or are hot:
a) Lack of lubrication. Lubricate per maintenance instructions.
b) Overloading of the machine. Reduce amount of feedstock put into the
machine per unit of time.
c) Bearings have exceeded their rated life. Consult with the Cumberland
Engineering Service Department for installation instructions.
7. Belts slip or squeal
a) Belts are too loose. Tighten per maintenance instructions.
b) Overloading of the machine. Reduce amount of feedstock put into the
machine per unit of time.
c) Machine has thrown belts. Inspect, and if acceptable for use, re-install and
tighten per maintenance instructions.
8. Motor will not start:
a) Fuses are blown. Replace fuses with the size and type shown on the wiring
diagram (located in the control enclosure).
b) A limit switch is open. Check the limit switches at the machine front doors
and any hopper cleanout door. Ensure proper actuation and replace if required.
c) Verify that the correct pushbuttons are being depressed and that the main
disconnect switch is in the ON position.
9. Granulate builds up in the transition or tubing:
a) Fan is too small. Replace with larger unit or fan wheel.
b) Transition or cyclonic air separator tubing is clogged. Clean as required.
c) Return air vents are covered or too small. Ensure the vents are open.
d) Fan is not evacuating properly. Check for loose fan wheel on shaft, worn fan
wheel, or loose fan drive belts.
10. Feedstock hangs up in the hopper or cutting chamber/
a) Material being placed into the machine for processing is too large for the
hopper, cutting chamber, or rotor diameter. Reduce the initial size of the
feedstock.
b) Knives are dull. Sharpen or replace and re-install.
c) Overloading of the machine. Reduce amount of feedstock put into the
machine per unit of time.
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7.0 Motor and Belts - Service Instructions
7.1 Procedure
Prior to startup of this machine, it is recommended that the drive belt tension be checked for
proper “RUN IN” deflection force as listed in column “A” next page.
After the equipment has run between 24 and 48 hours, drive belt tension must again be
checked for proper “RUNNING” deflection force as listed in column “B” next page.
A V-belt drive will successfully transmit its rated capacity if the belts are properly tensioned.
The method of tensioning is explained here in detail for your information.
1. Verify that the alignment of the pulleys is correct. Utilizing a straightedge of sufficient
length to span from one pulley to the other, place it along the sides of both pulleys. The
side of each pulley should contact the straightedge.
2. Measure the belt span (figure 1).
3. Using a spring scale, apply a perpendicular force to any ONE of the belts at the mid point
of the span.
4. Measure the force (lbs) required to deflect any one of the belts 1/64 of an inch for every
inch of span. For example: the deflection for a 32” span would be 1/64” x 32”, or 1/2”.
The force required to deflect the belt is listed in the Table below and it requires selecting
the correct belt section and corresponding smallest sheave diameter for the arrangement in
question.
5. The motor position should be adjusted until the actual deflection force matches the forces
listed in column “A” for new belt installations.
6. There will normally be a drop in belt tension during the first 24 to 48 hours of operation
due to belt stretch and the belts seating themselves in the sheave grooves.
7. After the initial “RUN IN” period the machine should be stopped and the belts should be
re-checked for tension. The motor position should be adjusted until the deflection force
matches the values in column “B”.
8. In no case should the belts be overtensioned as this can significantly reduce belt life
and/or bearing life.
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Figure 1 Belt Span and Deflection
BELT DEFLECTION FORCE (lbs)
SMALL SHEAVE A B
BELT DIAMETER (INCHES) RUN IN RUNNING
2.65 to 4.0 6.00 4.00
4.12 to 7.0 8.25 6.75
7.10 to 10.9 21.00 14.25
11.80 to 16.0 25.75 17.00
12.50 to 16.0 51.00 34.50
18.00 to 22.4 58.00 39.50
3.00 to 3.6 4.90 3.40
3.80 to 4.8 6.00 4.10
5.00 to 7.0 7.30 5.00
4.60 to 5.6 9.00 6.20
5.80 to 6.8 10.30 7.00
7.00 to 8.6 11.60 7.90
7.00 to 8.5 17.10 11.70
9.00 to 11.0 20.00 13.70
12.00 to 16.0 22.70 15.40
12.00 to 14.0 32.70 22.40
14.50 to 17.0 37.30 25.50
D* 18.00 to 22.0 42.30 28.80
E 20.00 to 32.0 51.80 34.50
3
5V*
8V*
A*
B*
C*
* For V-band belts, multiply the force shown in the table by the number of belts in the band.
Table 1 - Belt Deflection Force
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8.0 Knife Recommendations and Adjustments
NOTE: The rotor and bed knives are subjected to severe work and it is recommended that
they be inspected periodically for sharpness. The sharper the knives are kept, the better the
machine will operate and the better the quality of the granulate it will produce. Waiting until
the knives have been chipped or otherwise damaged will result in heavy stock removal during
operation causing a subsequent reduction in knife life.
8.1 Knife Removal and Adjustment Procedure
1. Shut OFF and lockout all power including the main disconnect switch.
2. Follow instructions in Section 10 on opening the machine and screen chamber.
NOTE: The shim knife, which is only under the primary bed knife, serves to protect the
primary knife from excessive abuse during granulation.
3. Remove the screen and stand it on end to avoid damage.
4. Loosen the socket cap screws holding the bed knives, clamps and shims, working from the
knife edges inward to the center. NOTE the relative position of each part before they are
removed.
5. As the last screw is backed out, the knife clamp, knife and shim will require support to
prevent them from falling.
Η Η Η Η Η Η ΗDANGER Η Η Η Η Η Η Η
Before undertaking any machine repairs or maintenance,
always make certain that the machine disconnect switch is
turned to the OFF position or that the control enclosure is
disconnected from the main power source. When extensive
is anticipated, either place a sign indicating that the main
disconnect switch is to remain off onto the switch, or lock
the switch to prevent accidental activation by someone
unaware of work in progress.
6. Clean the bed knife seats thoroughly with a scraper and/or emery paper to remove any
foreign material and rust.
7. Inspect the components and replace or resharpen as required.
8.2 Rotor Knife Removal
1. Carefully block the rotor with a piece of wood to prevent it from turning.
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2. Loosen the hex head rotor knife bolts and carefully remove all rotor knives.
3. Clean the rotor knife seats thoroughly with a scraper and/or emery paper to remove any
foreign material or rust.
4. Inspect the knives and replace or resharpen as required.
8.3 Rotor Knife Installation Procedure
1. Carefully block the rotor with a piece of wood to prevent it from turning.
2. Re-install the rotor knives onto the rotor. Do not torque the hex head rotor knife bolts
fully at this point - snug them down only.
Η Η Η Η Η CAUTION Η Η Η Η Η
New or resharpened knives should be handled with extreme
care. It is suggested that the sharp cutting edges be covered
with tape to prevent damage to the knives or injury to
personnel during installation.
3. Check that the heel of the rotor knife is tight up against the knife seat. Utilizing a .003”
feeler gauge, try to insert it between the heel of the knife and the knife seat at both ends
and across the rotor knife. If the feeler gauge will not go down between the heel of the
knife and the knife seat, the knife is installed correctly.
4. Torque down the rotor bolts. Start from the center of the knife and torque down the bolts
equally, working towards the ends of the knife. Refer to Section 10 for the correct torque
values based on the bolt size and thread pitch. After the bolts on each knife have been
fully torqued, re-check with a .003” feeler gauge between the knife and seat. Use the
same procedure on all remaining rotor knives.
8.4 Bed Knife Installation and Setting Procedure
1. Install the new or resharpened bed knives, shims, and clamps in the reverse of removal.
Make sure the knives are fully back against the knife adjusting screws and loosen the
adjusting screw checknuts slightly. Do not torque the socket cap screws fully at this point
- snug them down only.
Η Η Η Η Η CAUTION Η Η Η Η Η
New or resharpened knives should be handled with extreme
care. It is suggested that the sharp cutting edges be covered
with tape to prevent damage to the knives or injury to
personnel during installation.
2. Align the rotor knife with a secondary bed knife on the front of the granulator. With a
.006” feeler gauge between the rotor and bed knife, start to adjust the bed knife into the
rotor knife using the adjusting screw. During the movement of the bed knife, slowly
rotate the rotor back and forth checking the clearance. The proper clearance will be
established when a slight “drag” is felt on the feeler gauge as it is pulled between the
knives. Once this clearance is established across the length of a knife, partially tighten the
bed knife socket cap screws. Follow this procedure for all remaining bed knives.
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3. If you find a “high” rotor knife, mark it and re-adjust to this knife.
4. Once knife adjustments are completed, equally and fully torque the bed knife socket cap
screws, working from the center out toward the ends of the knife. Refer to Section 10 for
the correct torque values based upon bolt sizes and thread pitch.
5. Recheck the clearance once the bolts have been fully torqued and reset if necessary.
6. Turn the rotor so that the knives are aligned with a primary bed knife on the rear of the
granulator and continue with the same procedure used to setup the secondary bed knives.
7. After the clearance setting of both the secondary and primary bed knives is completed and
checked, turn the rotor by hand to ensure that none of the rotor knives hit the bed knives.
8. Re-install the screen into the screen chamber and close the machine (refer to section 10).
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9.0 Recommended Torque For Knife Bolts
NOTE: For Rotor knife applications, use SEC Grade 8 hex head cap screws.
For Bed knife applications, use Series 1960 Grade 8 socket head cap screws.
RECOMMENDED BOLT TORQUES
DIAMETER AND THREAD SIZE FT/LBS TORQUE
(DRY)
1/4-20 12
1/4-28 14
5/16-18 24
5/16-24 27
3/8-16 45
3/8-24 50
7/16-14 70
7/16-20 80
1/2-13 105
1/2-20 120
9/16-12 155
9/16-18 170
5/8-11 210
5/8-18 240
3/4-10 375
3/4-16 420
7/8-9 610
7/8-14 670
1-8 910
1-14 1015
The above listed torque values are standard specifications.
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10.0 Procedure to Open/Close the Screen Chamber
10.1 Procedure to Open Screen Chamber
Allow all material to run out of the cutting chamber.
Shut OFF and LOCKOUT all power including the main disconnect switch.
Open the front doors.
Disconnect the transfer tube (optional) from the exhaust side of the transition by unclamping
and then partially pulling through the transfer tube opening on the side cover of the machine.
Remove the transition on the front of the screen chamber by releasing the clip fasteners at the
top front edge of the chamber and then lifting it forward and out of the transition retaining lip.
Place the transition to the side, positioning it face down.
Open the screen chamber by removing the hex head cap screws and CAREFULLY lowering
it until fully open. The screen chamber is lowered by means of a hydraulic pump.
MTF3030, MTF3045 machines are lowered by hydraulic pump
Remove the screen and place it aside, always positioning it standing upright on its end.
New or resharpened knives should be handled with extreme
care. It is suggested that the sharp cutting edges be covered
with tape to prevent damage to the knives or injury to
10.2 Procedure to Close the Screen Chamber
Ensure all tools, screws, rags, and etc., are removed from the inside of the cutting chamber
and screen chamber.
Place the screen back into it’s original position, ensuring it is fully seated within the cradle
and then CAREFULLY raise the chamber to it’s closed position. Insert all of the hex head
cap screws initially removed and then tighten them fully, working from the center out towards
the ends.
Replace the transition, making sure that nothing has been left inside, by positioning it down
into the transition retaining lip and then securing it to the screen chamber with clip fasteners.
Re-connect the transfer tube (optional) to the exhaust side of the transition by inserting it fully
through the transfer tube opening on the side cover of the machine and then clamping it to the
transition.
Η Η Η Η Η CAUTION Η Η Η Η Η
personnel during installation.
Before closing and locking the front doors, recheck all components to insure that they are
properly fastened.
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11.0 Fans/Blowers - Pneumatic Evacuation
11.1 Description
Colortronic granulators can be supplied with an optional Fan (blower) system to provide
efficient, continuous evacuation of granulate from the machine. Colortronic offers a large
variety of Fan configurations. The following information is intended to be representative of
the basic functioning and design of a Fan, rather than being specific to one particular
configuration.
11.2 Pre-Operational Checklist
Have all installation and preparation instructions been read and followed?
Have sufficient location clearances been allowed?
Has the equipment been grounded as required by local codes and/or Article 250 of the
National Electric Code?
Have all fan motors been checked for rotation?
Have all fan controls, pushbuttons, and limit switch safeties been checked for
proper functioning?
Are all accessory components electrically and mechanically connected with proper
support and with all fasteners tight?
Are cyclonic air separator and filter bags empty? (optional equipment)
Are all electrical enclosure boxes tightly closed and clamped shut?
Are all personnel clear of the machine?
11.3 Troubleshooting and Suggested Actions
1. No granulate
a) Fan is too small. Replace with larger unit or fan wheel
b) Fan wheel is damaged or worn. Replace or repair as required.
c) Fan tubing is not connected properly. Connect as required.
2. Fan stalls
a) Fan has loose belts. Inspect, and if acceptable for use, install and tighten per
maintenance instructions.
b) Fan wheel is loose on shaft. Tighten set screws as required.
3. Bearings sound noisy or are excessively hot.
a) Lack of lubrication. Lubricate per maintenance instructions.
b) Bearing have exceeded their rated life. Call the Colortronic Service
Department for replacement instructions.
4. Belts slip or squeal
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a) Belts are too loose. Tighten per maintenance instructions.
b) Pulleys are not properly aligned. Loosen and align as required.
5. Fan motor will not start
a) Fuses are blown. Replace fuses with the size and type being removed.
b) A limit switch is open. Check all limit switches at the machine front doors,
hopper doors, or fan. Ensure proper actuation and replace if required.
c) Verify that the correct pushbuttons are being depressed and that the main
disconnect switch is in the ON position.
6. Granulate builds up in the transition or tubing.
a) Fan is too small. Replace with larger unit or fan wheel.
b) Transition or tubing is clogged due to overloading of the machine. Reduce
amount of feedstock put into the machine per unit of time.
c) Return air vents are covered or too small. Ensure vents are open.
d) Fan wheel is loose of shaft. Tighten setscrews as required.
11.4 Bearing Lubrication
Refer to Section 13.
11.5 Belt Adjustment Procedure
Refer to Section 7
11.6 Spare Parts
Consult with the Colortronic Parts / Service Department toll free at 1-800-229-2919 or by
fax at 1-508-399-6306 for detailed information on the specific fan used on your machine.
The serial number of the fan will be required when ordering parts from Cumberland
Engineering.
25
12.0 Recommended Spare Parts
(1) Set of rotor knives and screws
(1) Set of bed knives and screws
(1) Screen or set of screens
(1) Set of belts
(1) Set of fuses
(1) Set of motor starter heaters
(1) Cyclone filter bag (optional)
NOTE: Refer to part numbers in the spare parts catalog when ordering replacement parts.
Check the parts carefully as knives and screens generally have their numbers etched
or stamped on them. The serial number and/or Q/W number of the machine will also
be required when ordering parts from Cumberland Engineering. This listing of
recommended parts does not include all parts which are available for purchase. The
Colortronic Parts / Service Department can be reached via a toll free number (1-800229-2919 or by fax at 1-508-399-6306
26
13.0 Lubrication Specifications
13.1 Description
All MTF3000 Series granulators and accessories are supplied with pillow block bearing
which are pre-lubricated from the factory.
The external mounting of the bearings on the Colortronic MTF3000 Series granulators results
in trouble free, low maintenance, and long lived bearing design.
The pillow block bearings used require a high quality, lithium based, EP (extreme pressure)
type of grease which conforms to NGLI Grade 2 consistency. This grease has been chosen
due to its suitability for use in heavy duty applications under heavy shock loads. It also
contains rust inhibitors, has high temperature stability, and exhibits water resistance.
13.2 Recommended Grease Product Names
AMOCO Amolith EP 2
CASTROL EP 2
EXXON Ronex MP
GULF Crown #2
MOBIL Mobilith AW-2
SHELL Alvania EP LF #2
SUNOCO Sunaplex #2
TEXACO Multifak EP 2
The pillow block bearings should be lubricated with care. Too much grease applied to the
bearings at one time can rupture the bearing seals. Under normal operating conditions, a
moderate amount of grease applied every 2000 hours should be adequate to ensure long life.
Severe operating conditions will require more frequent lubrication intervals.
27
14.0 Procedure to Open Hopper Door, Extended Feed Units
14.1 Procedure
Shut OFF and lockout all power including the main disconnect switch.
Remove the bolt or nut holding the limit switch actuation bracket.
Remove all other bolts or nuts completely, but leave the top bolt partially attached.
On large hopper doors, two men may be required to lift off the door as the last bolt is
removed.
NOTE: When servicing the hopper area, use care to avoid sharp edges.
Close the hopper door in the reverse of opening it.
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