Sterling 1200, 1500, SMS 850, 2000 User Manual

SMS Medium Duty Single Shaft Shredder

SMS 850, 1200, 1500, 2000

Part Number: ESS-0039-S

Bulletin Number: BJ5-615

Effective: 9.30.2008

Write Down Your Serial Numbers Here For Future Reference:
_________________________ _________________________

_________________________ _________________________
_________________________ _________________________

We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.

DCN No. ____________
© Copyright 2008
All rights reserved.

Shipping Info

Unpacking and Inspection

You should inspect your equipment for possible shipping damage.
Thoroughly check the equipment for any damage that might have occurred in transit, such as

broken or loose wiring and components, loose hardware and mounting screws, etc.

In the Event of Shipping Damage

According to the contract terms and conditions of the Carrier, the responsibility of the
Shipper ends at the time and place of shipment.

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:

; Bill of lading
; Packing list
; Operating and Installation packet
; Electrical schematic and panel layout drawings
; 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 parts and service department
immediately at [262] 641-6410. 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.

BJ5-615 ii

Storage, Disposal, Transportation

Storage

Clean the machine (see “Cleaning the Machine”). Preserve all polished metal surfaces using
a suitable rust preventing agent. Store the machine in a dry, enclosed space. Cover the
machine completely with a plastic sheet.

Disposal

The disposal of machines, machine components, and process materials is partially subject to
legal controls. More detailed information is given at the relevant administrative authority
(i.e. regional and national Water Conservation Bureau and Environmental Protection
Agencies). Only deposit the material to be disposed of at authorized drop-off points.

Transportation

WARNING! Suspended load!

• Falling loads can cause serious injury or death. Only use a crane or

forklift that can withstand the weight and dimension of the load!

• Use suitable stopping means and pay attention to gravity center

location!

• Do NOT step under the suspended load!

• Wear protective helmet in addition to basic protective gear!

BJ5-615 iii

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...........................11

2-1 Models Covered in This Manual................................................................................11

2-2 General Description...................................................................................................11

2-3 Typical Features and Components ...........................................................................12

2-4 Safety Features.........................................................................................................20

CHAPTER 3: INSTALLATION..................................................23

3-1 Uncrating the Equipment...........................................................................................23

3-2 Electrical Connections...............................................................................................24

3-3 Initial Start-up............................................................................................................26

CHAPTER 4: OPERATION.......................................................28

4-1 Start-up......................................................................................................................28

4-2 Operation Procedures...............................................................................................28

4-3 Shut-down.................................................................................................................31

CHAPTER 5: MAINTENANCE .................................................32

5-1 Preventative Maintenance Schedule.........................................................................32

5-2 Preventative and Corrective Maintenance ................................................................33

CHAPTER 6: TROUBLESHOOTING .......................................53

6-1 Introduction................................................................................................................53

APPENDIX ............................................................................57

A-1 Returned Material Policy...........................................................................................57

A-2 Technical Specifications............................................................................................58

A-3 Drawings and Diagrams............................................................................................59

A-4 Spare Parts List.........................................................................................................63

A-5 Technical Assistance.................................................................................................84

Parts Department ................................................................................................84

Service Department.............................................................................................84

Sales Department................................................................................................84

Contract Department...........................................................................................84

BJ5-615 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
equipment. The purpose is to assist you in applying efficient, proven techniques that enhance
equipment productivity.

This manual covers only light corrective maintenance. No other maintenance should be
undertaken without first contacting a service engineer.

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 equipment. 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 equipment.
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 equipment 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 equipment 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.

EJ5-615 Chapter 1: Safety 5 of 85

1-2 General Safety Regulations

This machine uses cutters 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.
Be sure that the v-belts are properly aligned and that tension is at its maximum.
Extreme care should be taken to see that all screws are properly tightened at all times. During

the operation of the machine, rotor cutter screws may come loose. Although fine threads are
used on the rotor cutter screws because vibration does not easily loosen them, you should
inspect the tightness of the screws 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.

EJ5-615 Chapter 1: Safety 6 of 85

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:

; LEARN AND OBEY your company’s safety policy regarding granulating

equipment.

; 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.)

; SHREDDER LOCATION: Adequate area for routine maintenance should be

provided in order to open the machine for cutter, 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.

; 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.

; 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.

; 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.

; NEVER attempt to operate the machine unless it is fully assembled with all guards

and interlocks in place and functional.

; OBSERVE all danger, warning, caution and safety labels on the equipment.
; 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.

; 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.

EJ5-615 Chapter 1: Safety 7 of 85

; ROTATION OF MOTORS: The correct rotating direction for the machine motor is

clearly marked on the machine. Always check for proper rotation of motors. Incorrect
rotation direction can cause severe damage.

; ELECTRICAL GROUNDING: All electrical equipment on the granulator must be

grounded in accordance to all local codes and Article 250 of the National Electric
Code.

; ALWAYS DISCONNECT AND LOCKOUT the main electrical power to the

granulator before performing any service.

; 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.

; NEVER modify the machine configuration or any individual component without

written notice from the factory.

Remaining Risks
The machine is constructed so that you are able to operate it safely. Structurally non-

avoidable dangers are prevented as well as possible by the protective devices. Certain risks
still remain. It is imperative to be aware of these risks in order to avoid accidents. To avoid
danger, please observe all safety advice provided.

Type of Danger Activity Possible

Consequences

Danger of crushing by
heavy parts falling
down/over

Cutting caused by
sharp cutters—even
when rotor is
stationary

Crushing when
opening/closing
maintenance doors on
front side of machine

Tripping over cables
and other objects

Crushing, cutting,
amputation caused by
run down of the rotor

Unloading and
transporting the
machine and/or
components

Cutter replacement,
cutter setting, cutter
sharpening and other
maintenance work

Maintenance work Serious injury

All activities Serious injury

Maintenance work Serious injury or death

Serious injury

Serious injury
particularly to hands
and fingers

Preventative Measures

• Wear personal protective gear

• Follow safety instructions in

manual

• Wear personal protective gear

• Follow safety instructions in

manual

• Make sure no persons are in the
danger area while closing the door

• Lay cables in accordance with
regulations.

• Keep work station clean and tidy.

• Maintenance doors must always

be tightly locked during operation.

• DO NOT make the run down
safety devices ineffective by using
technical aids or other
manipulations.

• NEVER use hands to check if the
rotor has stopped.

EJ5-615 Chapter 1: Safety 8 of 85

Type of Danger Activity Possible

Consequences

Preventative Measures

Pulling in caused by
running V-belts

Direct/indirect contact
with live parts in
terminal box.

Failure of Emergency
Stop function

Fire/explosion caused
by throwing
dangerous objects
(i.e. spray cans) into
the shredder

Damage to hearing All activities Diminished hearing,

Instability of machine
caused by vibration

Loosening of the
cutting cutter
mountings caused by
vibration

Inhalation of grinding
dust

All activities Serious injury can result

from hair, jewelry, etc.
being pulled into the
machine.

Maintenance work,
start up

All activities Serious injury or death

Grinding Serious injury or death

All activities Serious injury

All activities Serious injury

All activities Diseases of the

Serious injury or death

headaches, impaired
balance, deterioration of
concentration

respiratory tract, etc.

• Never dismount V-belt protection
and window.

• Only trained electricians may carry
out all work on the electrical
equipment. If work is necessary
on parts that conduct dangerous
voltage, a second person should
be present to break the power
supply in case of emergency.

• The yellow-marked lines conduct
voltage at all times—even when
the machine is switched off.

• Only use original safety fuses with
stipulated intensity of current.

• Faulty electrical components must
be replaced immediately.

• If faults occur in the electrical
energy supply, switch machine off
immediately.

• The terminal box must be locked
during operation. Before opening
the terminal box switch too off
(“O”).

• It must be guaranteed that failure
of an Emergency Stop button is
displayed and leads to an
immediate stop.

• Only grind material which
corresponds to the agreed
customer-specific specifications in
all points.

• Reduce noise emissions by taking
suitable measures.

• Wear ear protection.

• Install the machine according to

the instructions in the manual.

• Check the cutting cutter mountings
regularly according to the
instructions in the manual.

• Mount a suitable air suction device
and wear breathing equipment if
necessary.

• When cleaning the machine, use
suction; do not blow out grinding
dust.

EJ5-615 Chapter 1: Safety 9 of 85

Type of Danger Activity Possible

Consequences

Preventative Measures

Crushing, cutting,
amputation caused by
manipulation of
protective devices

For further information on granulator safety, installation, and operation, see the American
National Standard for Plastics Machinery
Size Reduction of Plastics

We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide
by the foregoing recommendations in order to make operator safety a reality.

All activities Serious injury or death

⎯

Granulators, Pelletizers, and Dicers Used for

⎯

Construction, Care, and Use. ANSI B151.11-1982.

• Never make the protective devices
ineffective.

• Check the protective devices
regularly for proper function
according to the manual’s
specifications.

EJ5-615 Chapter 1: Safety 10 of 85

Chapter 2: Functional Description

2-1 Models Covered in This Manual

The models included in this manual are the Sterling SMS 850, 1200, 1500 and 2000
Medium Duty Single Shaft Shredders. The SMS Series is designed for processing scrap
from wood industries—miscellaneous trim and panel scraps, furniture, injection and
extrusion mold start-up purge, heavy wall parts, paper and cardboard, and film (baled and
loose).

2-2 General Description

Mechanical Section

After the machine has been switched ON, a hydraulically controlled “swing-style” ram
pushes a quantity of material onto the slow-running profiled rotor. The in-feed is
controlled according to load.

The material can be placed (unsorted) in the hopper mounted on top of the machine. Pay
attention to this material; it cannot contain any other metal parts except for staples and
nails. (The guarantee does not cover any damage to the machine as a result of metal parts
being fed into the machine.) The material in the hopper is shredded by the cutters on the
rotor. This shredding process is repeated as often as required until the whole diameter of
the screen below the rotor has been reached.

The shredder can also be switched off with material still in the hopper.

Control

The machine is fitted with an automatic shut-down; i.e. when set to automatic, the
machine switches off after a pre-set period in the time relay.

The ram feeds the shredding unit (rotor) with as much material as it is able to process.
Upon reaching 70 to 90 % of rated current, the feeding of the ram will be stopped and
automatically started again after the power consumption has fallen by 20% in comparison
with rated current. If the high current is applied longer than 0.7 - 1.5 seconds, the main
drive motor switches off and runs back after about 3 seconds standstill time. The ram
plate also runs back while the rotor runs back. The drive motor then stops for another 3
seconds before starting again.

Duration of pauses and return and current settings can be adjusted.

NOTE: Any alterations should only be carried out after consulting the manufacturer.

EJ5-615 Chapter 2: Functional Description 11 of 85

Machine (Standard Execution)

(1) Base Frame
(2) Machine door
(3) Hopper door
(4) Gear Box
(5) Drive motor
(6) V-belt guards
(7) Ram hydraulic guards
(8) Discharge area

The machine housing, drive motor, gear box, hydraulic system and terminal box are
mounted on the base frame for electrical connections.

2-3 Typical Features and Components

3

7

4

2

6

5

8

1

Material In-feed

The material can be fed into the shredder in the following ways:

• Manual in-feed of the material directly into the in-feed hopper.

• Manual in-feed of the material with the help of an additional in-feed device

(e.g. hydraulic feeding unit).

• Automatic in-feed of the grinding material via an additional in-feed device

(i.e. conveyor belt).

EJ5-615 Chapter 2: Functional Description 12 of 85

Special hopper
with hydraulic
cover

In-feed Hopper

The material in-feed flows through an in-feed hopper to ensure the grinding material is
delivered safely and correctly.

NOTE: An optional top-hinged cover to prevent in-feed material fly-back during size
reduction is available.

Additional In-feed Device

If the machine has an optional in-feed device such as a conveyor belt, please refer to the
additional information about the accessory in the manufacturer’s manual that
accompanied the accessory. A special hopper for an in-feed with conveyor arrangement
can be supplied as an option to the standard hopper.

Hopper for conveyor
belt in-feed

EJ5-615 Chapter 2: Functional Description 13 of 85

Drive

The drive of the rotor runs using an electric motor via V-belts. The motor (mounted on
sliding rails or a motor plate) can be adjusted for regulating the tension of the V-belts
using tensioning screws. The V-belt pulley is attached to the motor shaft with a special
tensioning element.

Drive motor

NOTE: Please observe the operation manual from the manufacturer!

Rotor, Cutters, Bed Cutters

Rotor, cutters, bed cutters

• The material is shredded between the cutters assembled on the rotor and the bed

cutters; they are mounted in a fixed position in the machine lower section.

• All rotors are equipped with square cutters. These cutters make light work of the

heaviest pieces.

NOTE: The cutters have four corners so they can be easily turned once a corner has

worn out.

• The design of the rotor has a significant influence on the quality of the shredding

process and the results. The rotor construction, the type of cutter mounting and
the number of cutters have been matched to the application.

EJ5-615 Chapter 2: Functional Description 14 of 85

(1) Rotor cutter
(2) Screen support

(hydraulic)

(3) Bed cutter

1

3

2

(1) Rotor cutter
(2) Screen support

1

2

The rotor is accessible after opening the machine door and removing the screen.

The rotor is arranged on roller bearings that situated outside the housing. The V-belt
pulley is attached to the rotor axis with a taper brush. The rotor is dynamically counter­balanced and has vibration-free concentricity.

EJ5-615 Chapter 2: Functional Description 15 of 85

An optional feature is a water cooling system for the rotor used for special applications.

Bearing with water plug
for rotor cooling

Screen and screen support

The screen and the screen support are welded together and fixed to the housing by screws
in the standard execution.

The screen is slightly larger in radius than the cutting circle of the rotor cutters. The
screen perforation is selected according to the desired grain size of the grinding material.
All shredding material parts which are smaller than the screen perforation fall through the
screen. The screen is replaceable and can be taken out after opening the machine door.

Standard screen

EJ5-615 Chapter 2: Functional Description 16 of 85

(1) Hydraulic cylinder
(2) Screen support
(3) Screen

Another optional feature is a screen support that can be lowered by a hydraulic system.

Discharge with
conveyor

3

1

Discharge of Shredding Material

Normally the shredded material will be discharged onto a conveyor belt. (Options
include a discharge with blower or with a screw conveyor.)

EJ5-615 Chapter 2: Functional Description 17 of 85

Hydraulic Ram

The hydraulic ram is fixed on two arms arranged on flange bearings. Two heavy duty
hydraulic cylinders move the ram back and forth. The ram moves automatically after
switching ON the hydraulic system and the shredder when the machine is operated in
automatic mode.

NOTE: The ram can be moved by hand on the control panel when run in manual

(1) Hydraulic cylinder
(2) Flange bearing
(3) Ram arm
(4) Ram
(5) Hydraulic unit

2

4

3

mode.

(1) Serrated ram front

plate

(2) Rotor

2

1

1

5

EJ5-615 Chapter 2: Functional Description 18 of 85

Pulse Push Function

In normal process mode, the ram pushes forward continuously until the ram arm reaches
the proximity switch, reverses the function, and the ram moves backwards.

The ram moves forward in steps when the switch (1) is changed to “Pulse Push”. This
means that after each step, the ram remains in position for a couple of seconds before it
moves forward again.

This function should be used for very heavy applications and when overloading the
system is a concern.

(1) Pulse push switch

1

EJ5-615 Chapter 2: Functional Description 19 of 85

2-4 Safety Features

Safety device:
machine door

Protective Devices

CAUTION: The Machine may under no circumstances be operated without these

protective devices. The use of faulty or manipulated protective devices
is strongly prohibited.

Safety Device for Housing Flap

Safety device:
hopper door

The shredder can only be operated if the doors are closed—deactivating the safety switch.
The safety contact is broken when the machine or hopper door is open, thus switching off
the machine.

EJ5-615 Chapter 2: Functional Description 20 of 85

V-Belts and Ram Guards

V-belt and ram guards are screwed to the machine. They can be dismounted for
installation and maintenance work only when all rotating parts have come to a complete
standstill and the machine is electronically locked out.

(1) Ram guarding
(2) V-belt guarding

NOTE: The operator must fit and mount the protective devices delivered with the

machine according to current legal safety regulations if a machine is delivered
without drive motors per request of the customer.

Safety Markings

Safety markings are attached to the machine. Should one of these markings
becomes detached or is no longer recognizable, it must be replaced. New safety
markings can be ordered through safety signage provides or from the
manufacturer.

Personal Protective Gear

Wear close-fitting clothing. Hair must be pulled back, and loose jewerly is
prohibited.

1

2

EJ5-615 Chapter 2: Functional Description 21 of 85

The following protective gear must be worn when carrying out the following tasks:

Unloading machine. x x x
Connecting machine. x
Operation. x x x x

Cleaning. x x x
Maintenance of bearings. x
Screen replacement. x x
Maintenance of V-belts. x
Maintenance of cutting

cutters.
Cutter sharpening. x x x x

Safety
helmet

Emergency Stop Button

The machine may only be operated with the installed Emergency Stop buttons.
An Emergency Stop Button must be mounted to the control cabinet and another
on the grinding material in-feed.

Immediately press one of the Emergency Stop buttons in case of an emergency.

CAUTION! The Emergency Stop must be activated in all situations where injury or

damage could result!

Re-operation:

Safety
boots

Safety
gloves

x x

Safety
goggles

Ear
muffs

1. Eliminate cause of Emergency Stop.

2. Unlock Emergency Stop button

3. Acknowledge fault.

4. The machine is now ready for operation.

EJ5-615 Chapter 2: Functional Description 22 of 85

Chapter 3: Installation

3-1 Uncrating the Equipment

Requirements at Application Site

Check the application site to make sure it conforms to the qualifications listed below.

• The site is an enclosed space.

• The ground has sufficient load-bearing capacity (Refer to “Technical

Specifications” in the Appendix for machine weight). The unevenness of the
ground surface may not exceed 5 mm.

• The machine must be freely accessible from all sides.

• There must be sufficient room available for operating and service personnel.

• Spatial requirements: Refer to “Drawing and Diagrams” in the Appendix for

machine dimensions . All hinged parts must be able to be opened
completely.

• Vibration-free environment.

• The site has sufficient lighting.

• The machine may not be exposed to direct radiation caused by radiators or

the sun.

• Room temperature: +41 to 104 °F (+5° to +40°C)

• Relative atmospheric humidity according to DIN 40040:

15 to 70 % (indoor)

NOTE: By humidity levels higher than 70 %, apply anticorrosive agent

to the metallic-finished machine parts. Insulation for the
tropics is also necessary.

• The machine may not be operated within range of static discharges or strong

magnetic fields as this could lead to faults in the machine control system.

Unloading and Installing the Machine

The machine and components are packed so they arrive safely. Use a suitable crane or
forklift for unloading the packaged machine and/or components.

1. Remove the packaging material and all transportation safety devices after

unloading the machine.

2. In the case that the shredder and its accessory components have been

delivered as individual items, mount them at the site of application in
accordance with the Assembly Drawing. This is the only way to
guarantee there are sufficient piping parts, tubing, and cable connections,
and that the linking places match.

BJ5-615 Chapter 3: Installation 23 of 85

WARNING! SUSPENDED LOAD!

• Falling loads can cause serious injury or death.

• Only use a crane or forklift suitable for the weight and the

dimensions of the load.

• Use suitable stopping equipment and pay attention to the gravity

center location.

• DO NOT step under the suspended load.

• Wear a safety helmet in addition to basic protective gear.

WARNING! OVERTURNING OR FALLING MACHINE!

• Serious injury or death can result.

• If erecting the granulator over a pit, on a frame, or on a platform,

you MUST secure the machine by putting mounting screws through
the holes on the mounting pads (see Assembly Drawing). If
assembling the machine on solid ground, this safety device is not
always necessary.

3. Align the machine horizontally with the help of a suitable spirit level.

4. Do not use blocks to place underneath the machine; use metal strips to

prevent buckling of the base frame. Make sure that an even distribution
of weight is achieved on all the points of support.

3-2 Electrical Connections

CAUTION! Electrical connections should only be made by a qualified electrician.

WARNING! DANGEROUS VOLTAGE! Touching live parts can lead to serious
injury or death. All work relating to the electricity of the machine may only be
carried out by trained electricians. Observe the currently effective EMC regulations.

Voltage, current, frequency, and protection are marked on the type plate. The voltage
tolerance is +/- 10%.

The electrical connection is to be carried out in accordance with the wiring diagram in the
terminal box for machines not pre-wired by the manufacturer.

NOTE: When making electrical connections, the regulations of the local electricity

authority must be followed. The required cable cross section required is
determined according to the rated capacity of the units.

BJ5-615 Chapter 3: Installation 24 of 85

WARNING! Use caution when operating specific equipment to prevent electrical
shock. Installation, service, alterations, and/or modifications must only be done by
qualified personnel and with high regard for safety. Not conforming to the
requirements could result in bodily harm, death, or costly damage.

NOTE: Alterations to the wiring diagrams require approval. Failure to do this will

exclude all guarantee claims.

The wiring schematics are located in the control panel.

Connection of Emergency Stop Button

The machine may only be operated with installed Emergency Stop buttons. An
Emergency Stop button must be installed at the control cabinet and at the grinding
material in-feed if no Emergency Stop buttons have been installed at the factory.

NOTE: The control panel with the switches and Emergency Stop button must be installed

near the machine. The distance should not exceed 5 m.
The distance between the floor and the lower edge of the control panel should be

at least 1 m.

The connecting cables between the control panel and the machine must be protected
against damage (cable tray, protective sleeve).

An additional Emergency Stop button has to be installed on the machine if the control
box cannot be installed according to these rules.

BJ5-615 Chapter 3: Installation 25 of 85

Checking the Rotational Direction

Rotational direction of the motors must be checked before initial start-up. The following
steps must be completed.

1. Switch the machine ON and then immediately OFF again.

2. Observe whether the discharge air fan in the drive motor is rotating in the

direction of the direction arrow.

NOTE: If running in the wrong direction, reconnect the motor connection
immediately. Damage to the machine will result from operation in the wrong direction.

3-3 Initial Start-up

General Advice

• All work related to start-up may only be carried out by trained and specialized

personnel.

• Check the machine for possible transportation damage or other damage. If any

damage exists, confirm it with the freight company and report it to the manufacturer.

• After setting up for service and before starting up for the first time, necessary checks

must be completed.

• Check the oil level of the gear box before operating the machine.

• Fill oil into the hydraulic tank.

• Please observe the operation manual from the manufacturer

!

Machine Check Prior to Start-up

9 Use a torque wrench to check the cutter mounting screws when lower housing flap is

open.

9 Search the grinding chamber for foreign matter.
9 Open the lower housing flap and make sure the screen has been inserted in

accordance with the regulations.

9 Close upper housing flap and fasten screws tightly.
9 Check oil level of the gear box.
9 Fill oil into the hydraulic unit.
9 Examine in-feed device (accessories) for foreign matter.
9 Check that the Emergency Stop buttons are unlocked.
9 Check all safety devices for proper functioning.

BJ5-615 Chapter 3: Installation 26 of 85

9 Switch ON machine for a short period of time and check rotational direction. The

rotational direction can be seen at the discharge air fan of the drive motor (observe
running direction arrow).

9 Switch ON hydraulic unit for a short time and check rotational direction.
9 Allow machine to run for approximately 10 minutes without shredding material.
9 Connect material discharge device and in-feed device; check rotational direction

drives.

9 Feed grinding material uniformly. Too much grinding material can lead to overload

of the machine.

9 Check the temperature of the shredded material if necessary.
9 Monitor the ammeter. This displays the present current consumption and gives

information on the load of the machine.

BJ5-615 Chapter 3: Installation 27 of 85

Chapter 4: Operation

4-1 Start-up

WARNING! No persons should operate the machine until they have read and
understand all parts of the operation manual.

Machine Check—Before Switching Machine ON

9 Cutters and bed knives are properly set and the screws are tightened with the

specified torque.

9 Screen is inserted into the screen support according to the instructions, and the screen

support is fixed at the end position with tightened mounting screws.

9 The cutting chamber is free of foreign matter.
9 The machine and hopper doors are closed.
9 All safety devices, including those of the installed grinding material in-feed and

discharge devices, are checked and operative.

Switch ON Machine

1. Switch ON the material discharge device.

2. Switch ON the shredder (main switch to 1). Wait until the rotor has reached

its full speed and switched from star to delta.

3. Switch ON the hydraulic system.

4. Switch ON the material in-feed device (accessories).

4-2 Operation Procedures

Manual In-feed of Material

DANGER! Rotating Cutters!

Can cause serious cutting and crushing injuries that could result in
death.

Do NOT reach into the in-feed hopper or lean in while the rotor is
running. (Pay attention to the run down time). Only use approved
grinding material.

BJ5-615 Chapter 4: Operation 28 of 85

• Throw the grinding material into the in-feed hopper.

• The machine should be fed from the front.

• If your machine has an additional in-feed device installed, please observe the

additional information for working with the in-feed device.

DANGER! Do not climb into the in-feed hopper while operating the
machine. Death will result.

Emptying the Screen (standard screen)

1. Switch OFF the shredder at the main switch

2. Safeguard main switch using a padlock.

3. Open the machine door.

4. Safeguard the machine door.

5. Hold the screen with a forklift.

2

3

(1) Screen
(2) Screen mounting screws
(3) Cutter adjusting screws
(4) Forklift

4

6. Remove the screen.

7. Empty the screen.

8. Put the screen back using a forklift.

9. Fasten the mounting screws.

10. Close the machine door.

11. Shredder can be started again.

1

BJ5-615 Chapter 4: Operation 29 of 85

Emptying the Screen (hydraulic screen)

1. Switch OFF the shredder at the main switch.

2. Safeguard main switch using a padlock.

3. Open the lower machine door.

4. Safeguard the machine door.

5. Pivot the screen support downwards by pushing the button screen open on the control

box.

6. Remove the screen.

7. Empty the screen.

8. Put the screen back into the screen support.

9. Pivot the screen support into the working position and fasten using the mounting

screws.

10. Close the machine door.

11. Shredder can be started again.

(1) Hydraulic cylinder
(2) Screen support
(3) Screen
(4) Rotor

4

3

1

BJ5-615 Chapter 4: Operation 30 of 85

4-3 Shut-down

Switch OFF Machine

1. Switch OFF the material in-feed device (accessories).

2. Wait until the remaining grinding material has been shredded, and then switch OFF

the shredder (main switch to 0).

3. Switch OFF the material discharge device.

BJ5-615 Chapter 4: Operation 31 of 85

Chapter 5: Maintenance

5-1 Preventative Maintenance Schedule

Only trained and specialized personnel should carry out maintenance work

Maintenance Plan

WARNING!

• Danger caused by electrical voltage and

starting the machine during maintenance
work. Death can result!

• ALWAYS turn main switch to 0, safeguard using a padlock, and attach

a warning sign while carrying out maintenance work.

The tasks for maintenance work are described below.

Perform the following after every 8 operation hours:

• Check protective devices.

• Check cutting cutter mountings.

• Check condition of cutting cutters.

Perform the following after every 40 operation hours:

.

• Check V-belt tension force and V-belt condition.

• Check all screws of the machine for a tight fit.

• Check wearing parts.

Check hydraulic oil level and consistence.

•

Per form the following after every 2000 operation hours:

• Change hydraulic oil

•

Check gearbox oil level

Yearly maintenance:

• The purpose of yearly maintenance is primarily to check the general condition of

the machine and to arrange for the supply of any necessary replacement parts. A
service engineer can carry out this request.

BJ5-615 Chapter 5: Maintenance 32 of 85

5-2 Preventative and Corrective Maintenance

Checking the Protective Devices

Check the safety devices for:

• Stipulated condition

• Stipulated location

• Safe mounting

• Stipulated function

WARNING! Danger due to non-functioning protective devices can cause serious injury

or death!

• Eliminate all defects before operating the machine!

• If defects occur during operation, stop the machine

immediately and eliminate the defects!

• Do NOT change or remove any protective devices. Do NOT put any

protective devices out of action by modifying them.

Cleaning the Machine

WARNING! Danger of cutting caused by sharp cutting cutters—even when the rotor is not

operating! Serious injury, especially to the hands and fingers, can result.
Wear protective gloves!

Proceed as follows:

1. Switch OFF the shredder at the main switch.

2. Safeguard main switch using a padlock.

3. Open the machine and hopper doors.

4. Safeguard the machine and hopper doors.

5. Remove the screen.

6. Empty the screen.

WARNING! Inhalation of process dust is hazardous to your health! Never blow out the

shredded material residue—always use suction instead! Wear breathing
protection if necessary!

7. Pre-clean the cutting chamber using a hand brush.

8. Vacuum the remaining shredded material residue using a suitable device.

9. Remove clinging grinding material residue using a suitable wooden scraper.

BJ5-615 Chapter 5: Maintenance 33 of 85

10. Place the screen back into its working position and fasten with the mounting

screws.

11. Close the machine and hopper doors.

12. Machine can be started again.

Replacing the Gear Box

The gearbox is made so a replacement is only necessary in exceptional cases.
Dismounting and mounting the gear box requires specialist knowledge and a careful
working method. Please observe the instructions given in the installation manual of the
gear box manufacturer or ask the service department for help.

Replacing the Rotor

The rotor’s design is heavy duty, so a replacement is only necessary after a crash, (i.e. a
hammer fall inside). Dismounting and mounting of the rotor requires specialist
knowledge and a careful working method. Call the Service Department for assistance.

Dismounting the Rotor

1. Dismount the V-belt cover.

2. Dismount the V-belts.

3. Dismount the gearbox.

4. Remove the screen.

5. Remove the rotor mounting slot cover plates from the housing.

6. Screw in hooks on both shaft ends.

7. Remove the bearing housing mounting screw.

8. Carefully lift out the complete rotor using suitable lifting and stopping equipment.

9. Lay the rotor down in a safe location using appropriately sized timber beams.

Mounting the Rotor

1. Before starting, clean the bearing seat surfaces and check the key.

2. Lift the rotor using suitable lifting and stopping equipment and place carefully into

the bearing seats.

3. Attach the bearing housing (Pos.) to the bearing seats using screws.

4. Put the gear onto the rotor axis.

5. Put back the rotor mounting slot cover plates.

6. Put in the screen.

7. Pull on V-belts and adjust the V-belt tension force.

8. Attach the V-belt.

BJ5-615 Chapter 5: Maintenance 34 of 85

9. Carry out a test run.

NOTE: If the spare rotor is delivered without bearings, the bearings MUST be

mounted first.

Replacing the Main Bearings

The main bearings of the machine are made so a bearing replacement is only necessary in
exceptional cases. Dismounting and mounting of the bearings requires specialist knowledge
and a careful working method. In addition to the following advice, please observe the
instructions given in the installation manual of the bearing manufacturer or ask the service
department for help.

The bearings mounted in this machine are indicated in the spare parts list. A suitable pulling­off device is a required for dismounting and mounting the bearings

Dismounting the Main Bearings

1. Dismount the V-belt cover.

2. Dismount the V-belts.

3. Dismount the gearbox.

.

4. Pull the distance sleeve off the rotor axis.

5. Remove the screen

6. Remove the rotor cover plates from the machine housing.

7. Screw in hooks on both shaft ends.

8. Hang on rotor on both shaft ends.

9. Remove the bearing housing mounting screw.

10. Carefully lift out the complete rotor using suitable lifting and stopping equipment.

11. Lay the rotor down in a safe location using timber beams of appropriate size.

12. Loosen the mounting screws on the bearings cover.

13. Pull the bearing housing off with a pulling-off device.

14. Pull the bearing off the rotor axis using a pulling-off device.

Mounting the Main Bearings

1. Before mounting, clean the bearing surfaces and the shaft surfaces thoroughly and

grease lightly.

2. Mount bearing in bearing housing.

3. Attach the bearing with the bearing housing to the rotor axis.

4. Lift the rotor using suitable lifting and stopping equipment and place carefully into

the bearing seats

BJ5-615 Chapter 5: Maintenance 35 of 85

5. Attach the bearing housing to the bearing seats using screws.

6. Push the distance sleeve onto the rotor axis.

7. Put the gear onto the rotor axis

8. Put back the rotor cover plates

9. Put in the screen

10. Pull on V-belts and adjust the V-belt tension force.

11. Attach the V-belt cover.

12. Carry out a test run.

NOTE:

• The roller bodies will be damaged unless the mounting forces engaged into inner

ring.

• The hardened bearing rings are sensitive to impact stress; never hit the rings with

the hammer. Use a brass arbor or a striking bushing (piping piece) made from a
soft material. The inner diameter of the striking bushing should be only slightly
larger than the diameter of the bearing base.

• The bearing is then pushed onto the shaft using light blows. The force of pressure

must be evenly distributed on the circumference of the bearing ring.

Lubricating the Main Bearings

An important requirement for high operational safety and long service life of the arrangement
of bearings is the correct lubricant supply. Every machine is greased and checked in test runs
before delivery.

NOTE: Unsuitable lubricant, lubricant deficiency, excessive lubricant, or impurities in the
lubricant lead to overheating and extreme wear of the bearings.

Lubrication Intervals

Shift Operation Replace Lubricant Check

One shift operation Every 18 months Monthly
Two shift operation Every 9 months Monthly

Three shift operation Every 6 months Monthly

Check lubricant quality

You can judge whether the lubricant needs to be replaced by checking for the
following features:

• Change in consistency

• Discoloration

• Degree of soiling

BJ5-615 Chapter 5: Maintenance 36 of 85

Replacing or Refilling Lubricant

• Fill the bearings uniformly with grease until all operating surfaces are well-greased.

• For the rotor bearings, a lubricant quantity of one third to a maximum of half of the

bearing volume per bearing is required. If too much grease is used, the lubricant will
become unusable due to excessive temperature.

• Only one type of grease may be used, mixing different types of grease is prohibited.

The bearings have been filled at the factory with lithium base saponification roller
bearing grease F3.

• Refer to the “List of Lubricants” in this section for recommended bearing grease.

Refilling lubricant

The grease reaches through the circulating grooves and bores via lubrication nipples into the
interior of the bearing.

The greasing quantity is .13 to .22 lbs (60 to 100 g) roller bearing grease F3 per bearing.

Grease Nipple

Replacing Lubricant

Renewing the lubricant between intervals is only necessary when there unusual noises or
overheating. Mounting and dismounting of the bearings must be carried out in
accordance with the instructions in this operation manual (see replacing the bearings).

1. Open the bearing.

2. Remove the bearing housing and the bearing cover.

3. Clean the bearing carefully using petroleum ether.

NOTE: Petroleum ether, petroleum, spirit, aqueous neutral or alkaline

cleaning agents may be used to clean the bearings. After washing

BJ5-615 Chapter 5: Maintenance 37 of 85

out, the bearing must immediately be preserved using lubricant, in
order to avoid corrosion.

4. Fill bearing with approved lubricant (refer to “List of Lubricants”).

List of Recommended Lubricants

Country of Manufacturer/Manufacturer Roller Bearing Grease

ARAL ARL Grease HL 3
BP BP ENERGREASE LS 3
CASTROL CASTROL SPHEEROL AP 3
ESSO Beacon 3
FUCHS FUCHS Grease 1200

FUCHS Grease FWA 220
SHELL SHELL Alvania Grease 3
MOBIL-OIL MOBILUX 3
WISURA WISURA Liba L 3
Zeller $ Gmelin ZET GE Grease M 50
FAG FAG L 71
ANTAR ROLEXA
Holland, Beverol Beverol Multi Purpose Grease
Italy, Agip AGIP Grease 33 FD
Swede, NYNAS Nynas FI 3-42

BJ5-615 Chapter 5: Maintenance 38 of 85

Mounting and Dismounting TAPER-LOCK Tensioning Element

The motor and the gear V-belt pulleys are attached to the shaft using a TAPER-LOCK
tensioning element. The disks must be dismounted for certain maintenance processes.

BJ5-615 Chapter 5: Maintenance 39 of 85

Tightening Torque of the Screws

Refer to the table below.

Tensioning Screws- Screw details
element (Type) Tightening torque in Nm Number Size (BSW)

1008 5,6 2 1/4"
1108 5,6 2 1/4"
1310 20 2 3/8"
1315 20 2 3/8"
1210 20 2 3/8"
1215 20 2 3/8"
1610 20 2 3/8"
1615 20 2 3/8"
2012 31 2 7/16"
2017 31 2 7/16"
2517 48 2 1/16"
2525 48 2 1/16"
3020 90 2 5/8"
3030 90 2 5/8"
3535 60 3 1/2"
4040 102 3 5/8"
4545 155 3 3/4"
5050 185 3 7/8"

Replacing the Screen

V-Belts

The condition of the screen must be checked regularly in order to keep the throughput of
the shredder and the quality of the shredded material constant.

The screen may be damaged, dirty or not suitable for shredding material when:

• Screen holes are too fine—overheating of the shredded material can occur.

• Screen holes are too course—shredded material can have larger pieces that

are unacceptable.

Standard Screen and Hydraulic Screen
Please refer to the section “Emptying the Screen” in Chapter 4.

V-belts are wearing parts that stretch and must be re-tensioned. Regular checks on the
tension force of the V-belts and the condition of the V-belts are necessary in order to
guarantee a long service life.

BJ5-615 Chapter 5: Maintenance 40 of 85

Checking the tension force of the V-belt

Profile section Efficiency of x in

SPA 100 - 132 20 - 27 4,4 - 5,9
SPA 140 - 200 27 - 35 5,9 - 7,7
SPB 160 - 224 35 - 50 7,7 - 11
SPB 236 - 315 50 -65 11 - 14,3
SPC 224 - 355 60 - 90 13,2 - 19,8
SPC 375 - 560 90 - 120 19,8 - 26,4
XPB 224 - 250 25 - 35 5,5 - 7,7

a: Distance between
roller centers.

b: Sag
F: Force (direction)

Re-tensioning and relaxing the V-belt

1. Remove the V-belt cover.

2. Measure the distance between the roller centers.

3. Determine the belt sag force F for each belt at 16 mm sag if sag "b" is

equal to 1 m distance between roller centers. Do this by measuring the
distance between roller centers at a right angle to the V-belt.

Force required for 1m distance between
roller centres and 16mm sag

P in Newton P in lbs

mm

4. Compare determined value with the value in the above table. If the value

lies below the lowest tolerance limit, the V-belt must be re-tensioned. If
the value lies above the highest tolerance limit, the V-belt must be relaxed.

Enlarging or decreasing the centre distance “A” tensions or relaxes the V-belt.

1. Loosen the tensioning screw.

2. Shift the drive motor as required onto the sliding rails.

BJ5-615 Chapter 5: Maintenance 41 of 85

3. Lock the drive motor into new position using tensioning screws so the motor

shaft is parallel to the rotor axis and aligned.

4. Check the tension force of the V-belt (refer to previous section).

5. Mount the V-belt cover.

Checking V-belt condition, replacing V-belt

CAUTION! Running V-belts can pull objects into the machine! Hair, jewelry

etc. can be pulled into machine without proper precaution
resulting in serious injury. NEVER dismount the V-belt cover
and window during operation.

If a V belt is porous or ripped, it must be replaced as follows:

1. Remove the V-belt cover.

2. Loosen the front and rear tensioning screw.

3. Relax the V-belt by shifting the drive motor.

4. Put new V-belt in.

5. Tension the V-belt (refer to previous section).

6. Mount the V-belt cover.

Working on the Cutting Cutters

Correctly setting and mounting the cutting cutters is important when working with
shredders to ensure efficient and economic function.

Replacing and Checking the Cutting Cutter Mountings

Certain machine parts are subject to stress during operation as a result of vibrations that
can lead to loosening of the screw connections. Therefore, it is absolutely necessary to
check the cutter and bed knife mounting screws in accordance with the Maintenance
Plan.

1. Tighten the mounting screws on the cutters and bed knives using a torque wrench.

(Check required torque for the screw size.) The required torque for the cutter
mounting screws is 120 Nm.

NOTE: You can find out the required torque from the following table. Tightening

capacity decreases for screw when loosened and tightened again several times.

New screws of the same material quality must replace the cutting cutter
mounting screws after they have been loosened and tightened several times.

BJ5-615 Chapter 5: Maintenance 42 of 85

Screw type Grade 8.8 Grade 10.9 Grade 12.9

M8 25 18.4 35 25.8 41 30.2
M10 49 36.1 69 50.9 83 61.2
M12 86 63.4 120 88.5 145 106
M16 210 154 295 217 355 261
M20 410 302 580 428 690 508
M24 710 523 1000 737 1200 885

Nm lbf ft Nm lbf ft Nm lbf ft

Torque

Checking the Condition of the Cutters

WARNING! Danger of cutting caused by sharp cutters at all times—even when rotor

is at standstill. Serious Injury especially to the hands and fingers can occur. Wear
protective gloves!

The cutting cutters become blunt after a certain number of operation hours; they should be
checked regularly. Using blunt cutters can affect the efficiency and performance of the
machine in the following ways:

• Decreased shredding capacity.

• Increased current consumption of the drive motor.

• Inexact cut.

• Overheating of the shredded material.

Dismounting the Cutters (see drawing below)

1. Switch OFF the shredder at the main switch.

2. Safeguard main switch using a padlock.

3. Open the machine door.

4. Safeguard the machine door.

5. Remove screen.

NOTE: Although it is possible to reach the cutting shaft by climbing into the

feeding chamber, it is recommended to access the cutters through the
machine door located at the front of the machine. The shaft can be
rotated manually by turning the motor v-belt pulley.

6. Clean the hexagon head socket of the cutter mounting screw (2).

7. Loosen the screw using a high quality Allen key (10 mm). Knock the Allen key

lightly with a hammer to loosen it if necessary.

8. Take out the cutter mounting screw, the washer, and the cutter.

BJ5-615 Chapter 5: Maintenance 43 of 85

(1) Cutter
(2) Cutter mounting screw
(3) Cutter holder
(4) Cutter holder mounting

screws

1

Dismounting the Cutter Holders

2

3

1. Switch OFF the shredder at the main switch

2. Safeguard main switch using a padlock.

3. Open the lower machine door.

4. Safeguard the machine door.

5. Remove screen

NOTE: Although it is possible to reach the cutting shaft by climbing into the
feeding chamber, it is recommended to access the cutters through the
machine door located at the front of the machine. The shaft can be rotated
manually by turning the motor v-belt pulley.

6. Clean the hexagon head socket of the cutter mounting screw (2).

7. Loose the screw using a high quality Allen key (10 mm). If necessary knock the

Allen key lightly with a hammer to loose it.

8. Take out the cutter mounting screw, the washer and the cutter.

9. Clean the hexagon head socket of the cutter holder mounting screws (4).

10. Loose the screw using a high quality Allen key (6 mm). Knock the Allen key

lightly with a hammer to loose it if necessary.

11. Take out the cutter holder mounting screws.

12. Remove the cutter holder with the delivered Extractor.

NOTE: See previous drawing.

BJ5-615 Chapter 5: Maintenance 44 of 85

WARNING! Danger of cutting caused by sharp cutters at all times—even when rotor is
at standstill. Serious Injury especially to the hands and fingers can occur. Wear
protective gloves!

Dismounting the Bed Cutters

1. Switch OFF the shredder at the main switch.

2. Safeguard main switch using a padlock.

3. Open the upper hopper door.

4. Safeguard the hopper door.

NOTE: Although it is possible to reach the cutters by climbing into the feeding
chamber, it is recommended to access the cutters through the front side door.

5. Clean the hexagon head socket of the cutter mounting screws (2) and the cover plates

mounting screws.

6. Loosen the cover plate mounting screws using a high quality Allen key (10 mm). Knock

the Allen key lightly with a hammer to loosen if necessary.

7. Take out the screws and cover plates.

8. Loosen the cutter adjusting screws for pulling and take them out.

9. Loosen the cutter mounting screws with Allen key (10 mm). Use a hammer to lightly

knock key if necessary.

10. Take out the cutter mounting screw and cutter.

BJ5-615 Chapter 5: Maintenance 45 of 85

WARNING! Danger of cutting caused by sharp cutters at all times—even when rotor is at
standstill. Serious Injury especially to the hands and fingers can occur. Wear protective
gloves!

(1) Bed knife
(2) Knife mounting screws
(3) Knife holder
(4) Cover plates
(5) Knife adjusting screw for

pushing

(6) Cutter adjusting screw for

pulling

(7) Cover plate mounting

screws

Mounting the Cutter Holders

2

6

5

3

4

7

1. Clean the cutter pocket and the cutter holder.

2. Insert cutter holder into the pocket.

NOTE: Cutter holder must slide in easily. Do not damage the cutter holder

surfaces with a hammer.

3. Put in the cutter holder mounting screws (DIN912 – M8x25 – 12.9) and put some

Loctite on them.

4. Make sure that the cutter holder fits properly.

5. Tighten the cutter mounting screws using a torque wrench.

NOTE: The required torque for the cutter holder mounting screws is 39 Nm

(also see the table under “Working on Cutting Cutters”).

WARNING! Danger of cutting caused by sharp cutters at all times—even when rotor is at
standstill. Serious Injury especially to the hands and fingers can occur. Wear protective
gloves!

BJ5-615 Chapter 5: Maintenance 46 of 85

Mounting the Cutters

1. Clean the cutter supporting surface and the hole on the cutter holder.

2. Insert sharp cutter or turn old cutter, and push against the cutter holder surface.

3. Put in the cutter mounting screw (DIN912 – M12x40 – 12.9) and the washer

(DIN433 – 13 – 300HV).

4. Screw in the mounting screws and tighten lightly first.

5. Make sure the cutter fits planar in the seat.

6. Tighten the cutter mounting screws using a torque wrench.

NOTE: The required torque for all cutter mounting screws is 120 Nm (also see

the table under “Working on Cutting Cutters”).

7. Check if the cutting gap is correct and make sure the cutters do not collide

as the rotor turns.

8. Remove tools and other objects from the cutting chamber.

9. Put back screen and fix it.

10. Switch on the shredder for a short time without material, and listen for noises. If

there are unusual noises, determine the cause and eliminate it.

NOTE: The cutting knives, in particular the cutters, should only be sharpened

Mounting the Bed Cutters

1. Clean the cutter supporting surface and the holes on the cutter holder

2. Insert sharp cutter or turn old cutter.

3. Put in the cutter adjusting screws and adjust them roughly

4. Put in the cutter mounting screws (DIN912 – M12x55 – 12.9) and tighten lightly

first

5. Adjust the gap between cutter and bed knife to 0.8-1.0 mm

6. Tighten the cutter mounting screws using a torque wrench.

or replaced in sets. There is a danger of balance error if a combination
of rotor cutters from different cutter sets is used.

Cutters are reversible and have four symmetrical cutting edges. This
makes it possible to turn the cutters and only to sharpen after every
fourth cutter change.

NOTE: The required torque for all cutter mounting screws is 120 Nm (also see the

table under “Working on Cutting Cutters”).

BJ5-615 Chapter 5: Maintenance 47 of 85

7. Turn the rotor by hand

8. Check whether the cutting gap is correct and make sure the cutting cutters

do not collide as the rotor turns.

9. Put back the cover plates and mount them with the screws.

10. Remove tools and other objects from the cutting chamber.

11. Put screen back and mount it.

12. Switch ON the shredder for a short time without grinding material and listen for

noises. If there are unusual noises, determine the cause and eliminate it.

NOTE: Cutters are reversible and have four symmetrical cutting edges. This makes

it possible to turn the cutters and only to sharpen after every fourth cutter
change.

WARNING! Danger of cutting caused by sharp cutters at all times—even when rotor is at
standstill. Serious Injury especially to the hands and fingers can occur. Wear protective
gloves!

Sharpening Cutters and Bed Knives

Shredder cutters have 4 cutting edges. This means they can be turned 3 times. The
cutters should be replaced after the third use. Bed knives can be turned 2 times and can
be re-sharpened as long as you can mount them with the long hole.

1. Dismount the cutting cutters (see “dismounting the rotor cutters”).

2. Sharpen the cutters and bed knives.

NOTE: A specialist in accordance with the sharpening plan using particular care

should uniformly sharpen the cutting cutters mechanically. It is important to

make sure that sharpening takes place with small grinding allowance and

sufficient coolant supply. The sharpening process is finished when the cutting

edge is sharply cut. Not all indentations must be ground out; otherwise the

number of possibilities for sharpening is unnecessarily reduced. For the

sharpening process, use soft grinding wheels (Quality 40 H or 46 K). Cutters,

which have grinding cracks, are not to be reused due to danger of breakage

during operation.

3. Whet the cutting edges of the cutting cutters using a whetstone.

NOTE: the service life of the cutting cutters can be increased by taking these

measures.

4. Set the cutters and bed knives (refer to “Setting the cutters”).

5. Mount the cutters and bed knives (see “Mounting the cutters and bed knives”).

NOTE: The cutting cutters, in particular the cutters, should only be sharpened or
replaced in sets. There is a danger of balance error if a combination of cutters from
different cutter sets is used.

BJ5-615 Chapter 5: Maintenance 48 of 85

WARNING! Danger of cutting caused by sharp cutters at all times—even when rotor is at
standstill. Serious Injury especially to the hands and fingers can occur. Wear protective gloves!

Setting the Cutting Knives

Cutters for the SMS series shredder do not have to be adjusted. All adjustments have to
be done with the bed cutters. To simplify cutter setting and shorten standstill periods
when replacing cutters, bed cutters have 4 adjusting screws, 2 each for pushing and
pulling the cutter. Having several cutter sets helps to avoid standstill periods. Correct
and careful setting of the gap between the cutters and bed knives (cutting gap) is
important for productive capacity of the shredder. Factors for the size of the cutter gap
are the size of the rotor, the design of the rotor, and the material to be ground.

(1) Bed knife
(2) Knife mounting screws
(3) Knife holder
(4) Cover plates
(5) Knife adjusting screw for

(6) Knife adjusting screw for
(7) Cover plate mounting

pushing
pulling
screws

6

5

2

3

4

1

7

1. Remove old knives (see “dismounting the bed knives”).

2. Insert sharp cutter or turn old cutter.

3. Put in the cutter adjusting screws and adjust them roughly

4. Put in the cutter mounting screws (DIN912 – M12x55 – 12.9) and tighten

lightly first

5. Adjust the gap between cutters and bed knife to 0.8-1.0 mm using a

calibre gauge.

6. Tighten the cutter mounting screws using a torque wrench.

BJ5-615 Chapter 5: Maintenance 49 of 85

NOTE: The required torque for all cutter mounting screws is 120 Nm
(see the table under “Working on the Cutters”).

7. Turn the rotor by hand

8. Check whether the cutting gap is correct and make sure the cutters

and bed knives do not collide as the rotor turns.

NOTE: Recommended cutter gap: 0.8 mm – 1 mm

9. Mount the cutter cover plates.

Transporting and Storing the Cutting Cutters

WARNING!

• Danger of cutting caused by sharp cutting cutters.

• Serious injury, in particular to hands and fingers, can result.

• Wear protective gloves.

• Only transport and store the cutting cutters packaged.

• Grease the cutting cutters well, so that they do not rust. Protect the

cutting edges with doubled cardboard and use adhesive tape to
safeguard the cutters against slipping out of the sides of the sheath.

• After unpacking, you must degrease the cutting cutters so that they

can be gripped safely.

Hydraulic Maintenance

Hydraulic oil has to be filled into the tank before start-up of the machine. The type of oil
that should be used depends on location. Recommend oils include type DIN 51524 HLP 32
for areas with temperatures below 32°F (0°C) in the winter and HLP 46 for temperatures of
around 86°F (30°C) in the summer. For extremely hot tropical areas (i.e. Thailand,
Malaysia, Nigeria etc.) it is recommended to use HLP 68. The first oil replacement should
be done after 1,000 operating hours and then after every 2,000 operating hours. The oil filter
must be replaced too.

NOTE: Overheating of the oil and dirt in the oil will cause damage to the hydraulic

system if the oil is not replaced in the specified amount of time. This can lead to
complete standstill of the machine.

The same type of oil must be used when adding hydraulic oil. If the same type of oil is
unavailable or if it is unknown, then the oil in the tank and the entire hydraulic system has to
be removed and carefully and completely flushed. The system may only be filled with new
oil after this procedure has been done because it is necessary in preventing the valves from
gumming.

BJ5-615 Chapter 5: Maintenance 50 of 85

Checking and Adjusting of the Hydraulic System (see figure below)

1. Start the machine in automatic running mode and wait for approximately 20

minutes.

2. When the ram moves forward the pressure gauge (1) should indicate 0 – 30 bars

depends on the adjustment of the throttle check valves (2). (Also adjust the

speed of the ram with this valve.)

3. When the ram moves backwards the pressure gauge (1) should indicate 0 – 30

bars depends on the adjustment of the throttle check valves (2).

4. The pressure gauge (1) should indicate 50 – 70 bar at the change over point of the

hydraulic cylinders other wise the spill over hand wheel (3) should be adjusted.

5. The pressure gauge (4) should indicate a maximum of 2.5 MPa other wise the

screw of the sequence valve (5) has to be adjusted.

6. The ram should run upwards in less than 10 seconds, otherwise the throttle check

valve (2) has to be adjusted.

7. When pressure gauge at the oil filter (6) indicates >5 bar, the filter should be

replaced.

Figure: Checking and adjusting the hydraulic system

4 6

5

1

3

2

BJ5-615 Chapter 5: Maintenance 51 of 85

Hydraulic liquid recommendation

Designation to DIN 51 524 HLP 32

Ambient temperature: -7 to +70°C

Supplier Name of the oil

ARAL Aral Vitam GF 32

Aral Vitam HF 32

BP BP Energol HLP-D 32

BP Energol HLP 32
BP Energol SHF 32

ELF Elfolna 32

Hydrelf 32

ESSO Nuto H 32

HLPD-Oel 32
FINA Fina Hydran 32
FUCHS Renolin MR 10

Renolin B 10
MOBIL Mobil DTE 24

Mobil DTE 17

Drucköl HLP 32 - C

Hydrauliköl HLPD 32
TEXACO Rando Oil HD A - 32

Rando Oil HD AZ - 32

Alcor Oil DD 32

BJ5-615 Chapter 5: Maintenance 52 of 85

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 troubleshooting must be accomplished
with the power off, line fuses removed, and with the machine tagged as out of service.

The use of good quality test equipment cannot be over-emphasized when troubleshooting is
indicated. 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.

BJ5-615 Chapter 6: Troubleshooting 53 of 85

Problem Possible Cause Possible Remedy

Machine blocks or switches
itself off

Too much feed material.

Screen blocked.

V-belts slip.

Cutter condition.

Cutting gap.

Discharge blocked.

Current failure.

Reduce grinding material in­feed.

Clean screen, check
condition, select larger
screen perforation if
necessary.

Check V-belt tension and
condition. Re-tighten or
replace if necessary.

Check cutters and re­sharpen or replace if
necessary.

Check cutting gap and set
following the instructions in
this manual.

Check if discharge conveyor
belt is running.

• Check limit switch for
defective contact.

• Check electrical
connection.

Rotor does not grip bulky
material.

Fuse too small.

Rotational direction of rotor.

Rotor speed.

Cutter condition.

Protruding bed cutter.

Cutters not aggressive
enough.

• Tighten limit switch if
necessary.

Fit larger fuse only after

consulting the service
department.

Check motor and reverse
polarity if necessary.

Change rotor speed only

after consulting the
service department.

Check and sharpen if
needed following the
instructions provided in this
manual.

Consult the service
department.

Fit underlay plates below
cutter holders.

BJ5-615 Chapter 6: Troubleshooting 54 of 85

Problem Possible Cause Possible Remedy

Overheating of the shredded
material.

Unusual vibrations.

Extreme cutter wear.

View first 5 possible causes
for “Machine blocks or
switches itself off”

Screen perforation too small.

Cutters wrongly sharpened.

Material rubs against the
housing wall.

Insufficient cooling. Fit rotor cooling.
Rotor out of balance.

Bearing damage.

Anti-vibration pads defective.

Bearing damage.

Cutter finish.

Wrong cutting gap.

View first 5 possible
remedies of “Machine blocks
or switches itself off”

Insert a screen with larger
perforation.

Modify cutter finish only

after consulting the
service department.

Fit anti-winding device.

Weight cutters, balance
rotor.

Check bearings and replace
if necessary.

Check mounting pads and
replace if necessary.

Check bearings and replace
if necessary.

Check cutter and sharpen or
replace if necessary.

Check cutting gap and set
following the instructions in
this manual.

Bearings too hot.

Too many fines in shredded
material.

Foreign matter.
Too much grease in bearing. Reduce amount of grease.

V-belts too tight. Reduce tension.
Rubbing on housing sealing

ring.
Bearing damage.
No grease in bearing. Lubricate bearing.
Screen worn.

Unsuitable screen
perforation.

Fit feed device with metal
detector.

Check sealing ring and oil or
replace.

Check bearings and replace
if necessary.

Renew screen (possibly
using manganese steel).

Replace screen after

consulting the service
department.

BJ5-615 Chapter 6: Troubleshooting 55 of 85

Problem Possible Cause Possible Remedy

Cutting gap alters during
operation.

Screen damage.

Shredder does not start.

Cutter mounting screws not
tight.

Screw fatigue. Fit new screws.
Washers deformed. Insert new washers.
Cutter holder surface

deformed.
Supporting surfaces not

clean.
Threads in housing worn.
Screen wrongly inserted. Fit screen correctly.

Screen support buckled. Replace screen support.
Wrong screen radius. Correct it.

Limit switches not activated.
Main and control fuses. Replace fuse.

Feed device not connected. Switch on in sequence.
Material jam.

Re-tighten using torque
wrench following the
instructions in this manual.

Insert new cutter holders.
Clean and re-dust supporting

surfaces.
Fit new bushinges in

housing.

Check position of limit switch
and correct.

Empty shredder before
switching ON.

Shredder blocks when under
load.

Frequent switching off of
material in-feed device.

Star delta connection. Correct wiring on motor.
Motor protection switches

off.
Star delta time relay. Correct time.
Feed starts too early.
Limit switch loose or wrongly

set.

Fuse defective.

Motor fuse switches off – red
indicator.

Current relay switches off Correct setting.

Check motor relay for correct
setting and increase if
necessary.

Start feed only after switch
over from star to delta.

Re-position and tighten limit
switch.

• Replace fuse.

• Fit larger fuse only after

consulting the service
department.

• Reduce feed quantity of
the grinding material.

• Correct setting.

• Replace fuse.

BJ5-615 Chapter 6: Troubleshooting 56 of 85

Appendix

A-1 Returned Material Policy

Credit Returns

Prior

to the return of any material, authorization must be given by the manufacturer. A

RMA number will be assigned for the equipment to be returned.
Reason for requesting the return must be given.
All returned material purchased from the manufacturer is subject to 15% (75.00 minimum)

restocking charge.

returns are to be shipped prepaid.

All
The invoice number and date or purchase order number and date must supplied.
No credit will be issued for material that is not within the manufacture’s warranty period

and/or in new and unused condition, suitable for resale.

Warranty Returns

Prior

to the return of any material, authorization must be given by the manufacturer. A

RMA number will be assigned for the equipment to be returned.
Reason for requesting the return must be given.

returns are to be shipped prepaid.

All
The invoice number and date or purchase order number and date must supplied.
After inspecting the material, a replacement or credit will be given, at the manufacturer’s

discretion, if the item is found to be defective in materials or workmanship. Purchased
components are covered under their specified warranty terms.

BJ5-615 0Appendix 57 of 85

A-2 Technical Specifications

BJ5-615 0Appendix 58 of 85

A-3 Drawings and Diagrams

NOTE: Please refer to the corresponding Spare Parts lists in the following section.

Cutter Mounting

BJ5-615 0Appendix 59 of 85

Bed Knife Mounting

BJ5-615 0Appendix 60 of 85

Rotor Assembly

BJ5-615 0Appendix 61 of 85

Drive

BJ5-615 0Appendix 62 of 85

Ram

BJ5-615 0Appendix 63 of 85

Ram scraper

BJ5-615 0Appendix 64 of 85

SMS 850 Hydraulic Diagram

BJ5-615 0Appendix 65 of 85

SMS 850 Hydraulic Unit

BJ5-615 0Appendix 66 of 85

SMS 850 Hydraulic Screen Diagram

BJ5-615 0Appendix 67 of 85

SMS 850 Hydraulic Unit—Screen

BJ5-615 0Appendix 68 of 85

SMS 1200-2000 Standard Hydraulic Diagram

BJ5-615 0Appendix 69 of 85

SMS 1200-2000 Hydraulic Unit

BJ5-615 0Appendix 70 of 85

SMS 1200-2000 Hydraulic Screen Diagram

BJ5-615 0Appendix 71 of 85

SMS 1200-2000 Hydraulic Unit

BJ5-615 0Appendix 72 of 85

A-4 Spare Parts List

SMS 850

Pos. Pc Description/Standard

100
101 1 Standard hopper
102 2 PP-scraper side
103 1 PP-scraper top
104 1 Upper door
105 1 Lower door
106 2 Safety grid side
107 1 Safety grid back
108 1 Safety grid back
109 1 Ram residual chute

200
201 1 Screen
202 5 Screen support screws DIN912-M12x35-8.8
203 5 Washer DIN125-B-13-140HV
204 5 Spring washer DIN127-A -13
205 2 Clamp
206 2 Clamp mounting screws DIN933-M20x40-8.8
207 2 Washer DIN125-A 20-140HV
208 2 Spring washer DIN127-A20

200
201 1 Screen
202 5 Screen support screws DIN912-M12x35-8.8
203 5 Washer DIN125-B-13-140HV
204 5 Spring washer DIN127-A-13
205 1 Screen support
206 2 Cylinder for screen support opening

300 2
301 2 Bearing housing SN320/16Mn
302 2 Bearing GB/T288-94/22320
303 2 Bearing Cover A
304 1 Bearing Cover B
305 1 Bearing housing cover plate
306 3 Sealing GB9877.1-86 J115x140x12
307 2 Grease nipple GB1152-89/M8x1
308 1 Sleeve Ø150x16

24 Mounting screw cover plate DIN912-M10x40-8.8 309

8 Mounting screw cover plate DIN912-M10x45-8.8
310 1 Bearing mounting plate
311 2 Mounting plate screw DIN912 – M24x50 – 8.8
312 2 Washer DIN 125 – A 24

400

403 1 Gear pulley taper bushing TB 3020-48

Machine complete

Screen complete (Standard)

Screen complete (Hydraulic)

Ø50xØ25x145

Bearing

Drive

Motor 37 kW/460V/60Hz 401 1
Motor 55 kW/460V/60HZ
Gear pulley SPB280-4 402 1
Gear pulley SPC300-4

BJ5-615 0Appendix 73 of 85

Gear pulley taper bushing TB 3535-50

404 1 Key C 28x250

V-Belt SPB 2150 405 4
V-Belt SPC 2430
Motor pulley SPB 224-4 406 1
Motor pulley SPC 250-4
Motor pulley taper bushing TB 3020-60 407 1

Motor pulley taper bushing TB 3535-65
408 1 Key Motor shaft
409 1 Pulley cover
410 1 Motor plate
411 1 Gear box SEW MC2PLHT02 i=20
412 1 Torque arm plate
413 1 Rubber bushing plate
414 1 Rubber bushing
415 1 Copper bushing
416 1 Torque arm screw
417 1 Cover plate

500 1
501 60 Rotor knife 34x34x20
502 60 Rotor knife mounting Screw

503 60 Washer GB/T1230-13
504 60 Rotor knife holder
505 120 Knife holder mounting screw DIN912 – M8x25–

600 2
601 6 Bed knife 279x80x30
602 12 Mounting Screw DIN912 – M12x55 – 12.9
603 6 Lower bed knife adjusting screw for pushing

604 6 Upper bed knife adjusting screw for pushing
605 12 Bed knife adjusting screw for pulling
606

607 12 Cover plate mounting screw DIN912–M12x35–

700 1
701 2 Arm for ram
702 2 Bearing for arm UCFC212
703 8 Mounting screw for bearing DIN912-M16x50-

704 2 Screw for arm
705 1 Ram
706 12 Mounting screws ram arm DIN912-M16x80-12.9
707 12 Nut DIN982 – M16 – 10
708 12 Washer DIN 433-16-300HV
709 12 Spring washer DIN127-A-16
710 12 Mounting pin DIN94-2.5x32
711 1 Scraper
712 4 Spring for scraper YI GB1356-78

E-knife rotor ø387x850

DIN912 – M12x40 – 12.9

12.9

Bed knife complete

DIN912 – M16x35 – 12.9

DIN912 – M16x45 – 12.9

DIN912 – M16x50 – 12.9

1 Bed knife cover plate
1 Bed knife cover plate left
1 Bed knife cover plate right

12.9

Ram complete

12.9

n=12/d=2/D=12/H=60

BJ5-615 0Appendix 74 of 85

SMS 1200

713 1 Cover plate for scraper
714 2 Upper cylinder screw
715 2 Lower screw for cylinder mounting
716 8 Mounting screw for cylinder screw

DIN912 – M16x25 – 12.9
717 4 Grease nipple GB1152/M10x1

800
801 2 Cylinder for ram ø35xø70x420
802 Piping
803 Connectors
804 1 Hydraulic unit 3.75kW
805 1 Set of sealing for cylinders
806 1 Oil filter 12AT-10-CR

900
901 2 Safety switch AZ15ZVRK-1476-1
902 1 Small control box
903 1 Control panel
904 2 Proximity switch II0297
905 2 Cable for proximity switch EI0200

Pos. Pc Description/Standard

101 1 Standard hopper
102 2 PP-scraper side
103 1 PP-scraper top
104 1 Upper door
105 1 Lower door
106 2 Safety grid side
107 1 Safet y grid b ack
108 1 Safet y grid b ack
109 1 Ram residua l chute

200
201 1 Screen
202 5 Screen supp ort screw DIN912–M12x35–

203 5 Washer DIN125-B-13-140HV
204 5 Spring washer DIN127-A-13
205 2 Clamp
206 2 Clamp mounting screws DIN933 – M20 –

207 2 Washer DIN125-A – 20 – 140HV
208 2 Spring washer DIN127-A-20

200 1
201 1 Screen
202 5 Screen supp ort screws DIN912-M12x35-

203 5 Washer DIN125-B-13-140HV
204 5 Spring washer DIN127-A-13
205 1 Screen support
206 2 Cylinder for screen support opening

Hydraulic

Electrical parts

Screen complete (Standard)

8.8

8.8

Screen complete (Hydraulic)

8.8

Ø50xØ25x145

BJ5-615 0Appendix 75 of 85

300 2
301 2 Bearing housing SN324

302 2 Bearing GB/T288-94-22324
303 2 Bearing Cover A
304 1 Bearing Cover B
305 1 Bearing housing cover plate
306 3 Sealing GB9877.1-86 J150x180x15
307 2 Grease nipple GB1152-89/M8x1
308 2 Sleeve Ø150x16
309

310 1 Bearing mounting plate
311 1 Mounting plate screw DIN912 – M24x50 –

312 1 Washer DIN125 - A - 24

400

404 1 Key C28x 250

408 1 Key Motor shaf t
409 1 Pulley cover
410 1 Motor plate
411 1 Gear box SEW MC2PLHT03 i=20
412 1 T orque arm plate 55KW
413 1 Rubber bushing plate
414 1 Rubber bushing 116x68x100
415 1 Copper bushing 68x63x100
416 1 T orque arm screw
417 1 Cover plate

500 1
501 81 Rotor knife 34x34x20
502 81 Rotor knife mounting Screw

503 81 Washer GB/T1230-13
504 81 Rotor knife holder
505 162 Knife holder mounting screw

600 2
601 8 Bed knife 2 79x80x30
602 16 Mounting Screw DIN912 – M12x55 – 12.9
603 8 Lower bed knife adjusting screw for

24 Mounting screw cover plate
8 Mounting screw cover plate

Bearing

DIN912-M10x40-8.8
DIN912-M10x45-8.8

8.8

Drive

Motor 55 kW 460V/60Hz 401 1
Motor 75KW 460V/60Hz
Gear pulley SPC300-4 402 1
Gear pulley SPC375-4
Gear pulley taper bushing TB 3535-50 403 1
Gear pulley taper bushing TB 3535-55

V-Belt SPC 2430 405 5
V-Belt SPC 2550
Motor pulley SPC 250-4 406 1
Motor pulley SPC 300-4
Motor pulley taper bushing TB 3535-65 407 1
Motor pulley taper bushing TB 3535-75

E-knife rotor ø457x1130

DIN912 – M12x40 – 12.9

DIN912 – M8x25 – 12.9

Bed knife complete

pushing DIN912 – M16x35 – 12.9

BJ5-615 0Appendix 76 of 85

604 8 Upp er bed knife adjusting screw for

pushing DIN912 – M16x45 – 12.9

605 16 Bed knife adjusting screw for pulling

DIN912 – M16x60 – 12.9

606

607 16 Cover plate mounting screw

700 1
701 2 Arm for ram
702 2 Beari ng for arm UCFC212
703 8 Mounti ng screw for bearing DIN912-

704 2 Screw for arm
705 1 Ram
706 12 Mounting screws ram arm DIN912-

707 12 Nut DIN934-M16-10
708 12 Washer DIN 433-16-300HV
709 12 Spring washer DIN127-A-16
710 12 Mounting pin DIN94-2.5x32
711 1 Scraper
712 4 Sprin g for scraper YI GB1356 -78

713 1 Cover p late for scraper
714 2 Upper cylinder screw
715 2 Lower screw for cylinder mounting
716 8 Mounti ng screw for cylinder screw

717 4 Grease nipple GB1152-M10x1

800
801 2 C ylinder for ram ø40xø80x470
802 Piping
803 Connectors
804 1 H ydraulic u nit 5.6kW
805 1 Set of sealin g for cylinders
806 1 Oil filter 12AT-10-CR

900
901 2 Safety switch AZ15ZVRK-1476-1
902 1 Small co ntrol box
903 1 Control panel
904 2 Proximity switch II0297
905 2 Cabl e for proximity switch EI0200

2 Bed knife cover plate
1 Bed knife cover plate left
1 Bed knife cover plate right

DIN912 – M12x35 – 12.9

Ram complete

M16x70-12.9

M16x90-12.9

n=14/d=2/D=12/H=50

DIN912 – M16x25 – 12.9

Hydraulic

Electrical parts

SMS 1500

Pos. Pc Description/Standard

100
101 1 Standard hopper
102 2 PP-scraper side
103 1 PP-scraper top
104 1 Upper door
105 1 Lower door
106 2 Safety grid side

Machine complete

BJ5-615 0Appendix 77 of 85

107 1 Safety grid back
108 1 Safety grid back
109 1 Ram residual chute

200
201 1 Screen 12/16/20/25
202 6 Screen support screw DIN912–M12x35–8.8
203 6 Washer DIN125-B-13-140HV
204 6 Spring washer DIN127-A-13
205 2 Clamp
206 2 Clamp mounting screws DIN933 – M20 –

207 2 Washer DIN125-A – 20 – 140HV
208 2 Spring washer DIN127-A-20

200
201 1 Screen
202 6 Screen support screws DIN912-M12x35-8.8
203 6 Washer DIN125-B-13-140HV
203 6 Spring washer DIN127-A-13
204 1 Screen support
205 2 Cylinder for screen support opening

300
301 2 Bearing housing SN324/16Mn
302 2 Bearing GB/T288-94/22324
303 2 Bearing Cover A
304 1 Bearing Cover B
305 1 Bearing housing cover plate
306 3 Sealing GB9877.1-86 J150x180x15
307 2 Grease nipple GB1152-89/M8x1
308 2 Sleeve Ø150x16
309

310 1 Bearing mounting plate
311 1 Mounting plate screw DIN912 – M24x50 –

312 1 Washer DIN125 - A – 24

400
401 1 Motor 75 kW 460V 60HZ
402 1 Gear pulley SPC375-4
403 1 Gear pulley taper bushing TB 3535-55
404 1 Key C28x250
405 4 V-Belt SPC2550
406 1 Motor pulley SPC 300-4
407 1 Motor pulley taper bushing TB 3535-75
408 1 Key Motor shaft
409 1 Pulley cover
410 1 Motor plate
411 1 Gear box SEW MC2PLHT04 i=20
412 1 Torque arm plate 75 KW
413 1 Rubber bushing plate
414 1 Rubber bushing 116x68x100
415 1 Copper bushing 68x63x100

24 Mounting screw cover plate
8 Mounting screw cover plate

Screen complete (Standard)

8.8

Screen complete (Hydraulic)

Ø50xØ25x145

Bearing

DIN912-M10x40-8.8
DIN912-M10x45-8.8

8.8

Drive

BJ5-615 0Appendix 78 of 85

416 1 Torque arm screw
417 1 Cover plate
418 1 Cover 75KW
419 6 Rubber bushing plate screws

DIN933-M16x50-12.9
420 6 Washer DIN433-16
421 6 Spring washer DIN127-A-16
422 6 Nut DIN934-M16-10
423 1 Torque arm complete 75KW

500 1
501 102 Rotor knife 34x34x20
502 102 Rotor knife mounting Screw

503 102 Washer GB/T1230-13
504 102 Rotor knife holder
505 204 Knife holder mounting screw

600 2
601 10 Bed knife 279x80x30/Cr12Mo1V1
602 20 Mounting Screw DIN912 – M12x55 – 12.9
603 10 Lower bed knife adjusting screw for pushing

604 10 Upper bed knife adjusting screw for pushing
605 20 Bed knife adjusting screw for pulling
606

607 20 Cover plate mounting screw

700 1
701 2 Arm for ram
702 2 Bearing for arm UCF212-1
703 8 Mounting screw for bearing DIN912-

704 2 Screw for arm
705 1 Ram
706 12 Mounting screws ram arm DIN912-M16x90-

707 12 Nut DIN934-M16-10
708 12 Washer DIN 433-16-300HV
709 12 Spring washer DIN127-A-16
710 12 Mounting pin DIN94-2.5x32
711 1 Scraper
712 4 Spring for scraper YI GB1356-78

713 1 Cover plate for scraper
714 2 Upper cylinder screw
715 2 Lower screw for cylinder mounting
716 8 Mounting screw for cylinder screw

717 4 Grease nipple GB1152-M10x1

800
801 2 Cylinder for ram ø50xø100x470

1 Bed knife cover plate (right)
1 Bed knife cover plate(left)
3 Bed knife cover plate

E-knife rotor ø457x1410

DIN912 – M12x40 – 12.9

DIN912 – M8x25 – 12.9

Bed knife complete

DIN912 – M16x35 – 12.9

DIN912 – M16x45 – 12.9

DIN912 – M16x60 – 12.9

DIN912 – M12x35 – 12.9

Ram complete

M16x70-12.9

12.9

n=14/d=2/D=12/H=50

DIN912 – M16x25 – 12.9

Hydraulic

BJ5-615 0Appendix 79 of 85

SMS 2000

802 Piping
803 Connectors
804 1 Hydraulic unit 5.6kW
805 1 Set of sealing for cylinder
806 1 Oil filter 12AT-10-CR

900
901 2 Safety switch AZ15ZVRK-1476-1
902 1 Small control box
903 1 Control panel
904 2 Proximity switch II0297
905 2 Cable for proximity switch EI0200

Pos. Pc Description/Standard

100
101 1 Standard hopper
102 2 PP-scraper side
103 1 PP-scraper top
104 1 Upper door
105 1 Lower door
106 2 Safety grid side
107 1 Safety grid back
108 1 Safety grid back
109 1 Ram residual chute

200
201 1 Screen 12/16/20/25
202 8 Screen support screws DIN912-M12x35-8.8
203 8 Washer DIN125-B-13-140HV
204 8 Spring washer DIN127-A-13
205 1 Screen support
206 2 Cylinder for screen support opening

300
301 2 Bearing housing SN324/16Mn
302 2 Bearing GB/T288-94/22324
303 1 Bearing Cover A
304 3 Bearing Cover B
305 0
306 4 Sealing GB9877.1-86 J150x180x15
307 2 Grease nipple GB1152-89/M8x1
308 2 Sleeve Ø150x16
309 32 Mounting screw cover plate

310 2 Bearing mounting plate
311 4 Mounting plate screw DIN912 – M12x70 –

400
401

1
1 Motor 75 kW 460V/60HZ (right)
1 Motor 75 kW 460V/60HZ (left)

402 2 Gear pulley SP C300-4

Electrical parts

Machine complete

Screen complete (Hydraulic)

Ø50xØ25x145

Bearing

DIN912-M10x40-8.8

12.9

Drive

Motor 55 kW 460V/60HZ (right) 1
Motor 55 kW 460V/60HZ (left)

BJ5-615 0Appendix 80 of 85

Gear pulley taper bushing TB 3535-50 403 2
Gear pulley taper bushing TB 3535-55

404 2 Key C25x210

V-Belt SPC 2430 405 8
V-Belt SPC 2550
Motor pulley SPC 250-4 406 2
Motor pulley SPC 300-4
Motor pulley taper bushing 3535-65 407 2

Motor pulley taper bushing 3535-75
408 2 Key Motor shaft
409 2 Pulley cover
410 2 Motor plate
411 2 Gear box MC2PLHT03 i=20
412 2 Torque arm plat e 55KW
413 2 Rubber bushi ng plate
414 2 Rubber bushi ng 116x68x100
415 2 Copper bushi ng 68x63x100
416 2 Torque arm scre w
417 2 Cover plate
418 2 Cover 55KW
419 12 Rubber bushing plate screws

DIN933-M16x50-12.9
420 12 Washer DIN433-16
421 12 Spring washer DIN127-A-16
422 12 Nut DIN934-M16-10
423 2 Torque arm complete SEW

500 1
501 144 Rotor knife 34x34x20
502 144 Rotor knife mounting Screw

144

504
505 288 Knife holder mounting screw

600 2
601 14 Bed knife 279x80x30 /Cr12Mo1V1
602 28 Mounting Screw DIN912 – M12x55 – 12.9
603 14 Lower bed knife adjusting screw for pushing

604 14 Upper bed knife adjusting screw for pushing
605 28 Bed knife adjusting screw for pulling
606

607 28 Cover plate mounting screw

700 1
701 2 Arm for ram
702 2 Bearing for arm UCFC212
703 8 Mounting screw for bearing D IN912-M16x70-

704 2 Screw for arm
705 1 Ram

144

1 Bed knife cover plate (right)
1 Bed knife cover plate(left)
5 Bed knife cover plate

E-knife rotor ø457x1950

DIN912 – M12x40 – 12.9

Washer GB/T1230-13 503

Rotor knife holder

DIN912 – M8x25 – 12.9

Bed knife complete

DIN912 – M16x35 – 12.9

DIN912 – M16x45 – 12.9

DIN912 – M16x60 – 12.9

DIN912 – M12x35 – 12.9

Ram complete

12.9

BJ5-615 0Appendix 81 of 85

706 12 Mounting screws ram arm DIN912-M16x90-

12.9
707 12 Nut DIN934-M16-10
708 12 Washer DIN 433-16-300HV
709 12 Spring washer DIN127-A-16
710 12 Mounting pin DIN94-2.5x32
711 1 Scraper
712 4 Spring for scraper YI GB1356-78

n=14/d=2/D=12/H=50
713 1 Cover plate for scraper
714 2 Upper cylinder screw
715 2 Lower screw for cylinder mounting
716 8 Mounting screw for cylinder screw

DIN912 – M16x25 – 12.9
717 4 Grease nipple GB1152-M10x1

800
801 2 Cylinder for ram ø50xø100x470
802 Piping
803 Connectors
804 1 Hydraulic unit 5.6kW
805 1 Set of sealing for cylinder
806 1 Oil filter 12AT-10-CR

900
901 2 Safety switch AZ15ZVRK-1476-1
902 1 Small control box
903 1 Control panel
904 2 Proximity switch II0297
905 2 Cable for proximity switch EI0200

Hydraulic

Electrical parts

SMS 850 Hydraulic Unit Spare Parts

Pos Description Standard Pc Supplier

1 Oil filter net MF-06 1 CLC
2 Oil filter net MF-08 1 CLC
3 Electric motor 5HPX4P(straight system)380V 1 Qunce
4 Wheel pump HGP-2A-F6R 1 Xinhong
5 Vane pump 50T-19 1
6 Check valve CIT-03, CIT-04 2 CLC
7 Check valve CRG-03 1 7Ocean
8 Spillover valve BG-03 1 7Ocean
9 Sequence valve HG-03 1 7Ocean
10 Pressure Gauge LA-150(including connector) 1 FTB
11 Solenoid valve DSD-G03-0C-DC24 1 7Ocean
12 Pilot operated check valve MPD-03-W-5 1 7Ocean
13 Throttle check valve PT-04 2 7Ocean
14 Pressure relay PS-02-2-10 1 7Ocean
15 Oil gauge LS-3 1 CLC
16 Oil lubricator AB-1162 1 CLC
17 Scavenge oil filter 70134-10C-R 1
18 Oil box 100L 1 7Ocean

BJ5-615 0Appendix 82 of 85

SMS 850 Hydraulic Screen Spare Parts

Pos Description Standard Pc Supplier

1 Oil filter net MF-06 1 CLC
2 Oil filter net MF-08 1 CLC
3 Electric motor 5HPX4P(straight system) 380V 1 Qunce
4 Wheel pump HGP-2A-F6R 1 Xinhong
5 Vane pump 50T-19 1
6 Check valve CIT-03, CIT-04 2 CLC
7 Check valve CRG-03 1 7Ocean
8 Spillover valve BSG-03-INP-2 1 7Ocean
9 Sequence valve HG-03-B 1 7Ocean
10 Pressure Gauge LA-250(including connector) 1 FTB
11 Solenoid valve DSD-GO3-6C-DC24 1 7Ocean
12 Pilot operated check valve MPD-03-W-2 1 7Ocean
13 Throttle check valve PT-04 2 7Ocean
14 Pressure relay PS-02-2-10 1 7Ocean
15 Oil gauge LS-3 1 CLC
16 Oil lubricator AB-1162 1 CLC
17 Scavenge oil filter 70134-10C-R 1
18 Oil box 100L 1 7Ocean
19 Solenoid valve DSD-G02-2C-DC24 1 7Ocean
20 Throttle check valve PT-03 2 7Ocean

SMS 1200-2000 Hydraulic Unit Spare Parts

Pos Description Standard Pc Supplier

1 Oil filter net MF-06 1 CLC
2 Oil filter net MF-08 1 CLC
3 Electric motor 7.5HPX4P(straight system) 1 Qunce
4 Wheel pump HGP-2A-F9R 1 Xinhong
5 Vane pump 50T-26 1 Kaijia
6 Check valve CIT-03, CIT-04 2 CLC
7 Check valve CRG-03-1-10 1 7Ocean
8 Spillover valve BG-03-3-10 1 7Ocean
9 Sequence valve HG-03-1-10(70kgf) 1 7Ocean
10 Pressure Gauge LA-250kgf(including connector) 1 FTB
11 Solenoid valve DSD-G03-8C-DC24-31 1 7Ocean
12 Pilot operated check valve MPC-03-W-1-1 0 1 7Ocean
13 Throttle check valve PT-04 2 7Ocean
14 Pressure relay PS-02-3-10 1 7Ocean
15 Oil gauge LS-3 1 CLC
16 Oil lubricator AB-1162 1 CLC
17 Scavenge oil filter 12AT-10-CR 1
18 Oil box 75L 1 7Ocean

SMS 1200-2000 Hydraulic Screen Spare Parts

Pos Description Standard Pc Supplier

1 Oil filter net MF-06 1 CLC
2 Oil filter net MF-08 1 CLC
3 Electric motor 7.5HPX4P(straight system) 1 Qunce
4 Wheel pump HGP-2A-F9R 1 Xinhong
5 Vane pump 50T-26 1 Kaijia
6 Check valve CIT-03 1 Huatian
7 Check valve CRG-03-1-10 1 7Ocean
8 Magnetic Spillover valve BSG-03-INP-3-30 1 7Ocean
9 Sequence valve HG-03-B-4(70kg) 1 7Ocean

BJ5-615 0Appendix 83 of 85

10 Pressure Gauge LA-250(inc luding connector) 1 FTB
11 Solenoid valve DSD-G03-6C-***-31 1 7Ocean
11-1 Solenoid valve DSD-G02-6C-***-31 1 7Ocean
12 Pilot operated check valve MPD-03-W-1-10 1 7Ocean
12-1 Pilot operated check valve MPD-02-W-1-10 1 7Ocean
13 Throttle check valve PT-04 2 7Ocean
14 Pressure relay PS-02-3-10 1 7Ocean
15 Oil gauge LS-3 1 Huatian
16 Oil lubricator AB-1162 1 Huatian
17 Scavenge oil filter 701 34-10C-R 1 7Ocean
18 Oil box 90L 1 7Ocean
19 Check valve CIT-04 1 CLC
20 Throttle check valve PT-03 2 7Ocean
21 Pressure gauge switch GCT-02 2 Huatian
22 Pressure Gauge LA-100(inc luding connector) 1 FTB

A-5 Technical Assistance

Parts Department

Call toll-free 7am–5pm CST [800] 423-3183 or call [262] 641-8610, Fax [262] 641-8653
The ACS Customer Service Group will provide your company with genui ne OEM quality parts
manufactured to engineering design specifications, which will maximize your equipment’s
performance and efficiency. To assist in expediting your phone or fax order, please have the
model and serial number of your unit when you c ontact us. A customer replacement p arts list
is included in this manual for your conveni ence. ACS welcomes inquiries on all your parts
needs and is dedicated to providing excellent customer service.

Service Department

Call toll-free 8am–5pm CST [800] 423-3183 or call [262] 641-8610
Emergencies after 5pm CST, call [847] 439-5655
We have a qualified service department ready to help. Service contracts are available for most

of our products.

Sales Department

Call [262] 641-8610 Monday–Friday, 8am–5pm CST
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.

Contract Department

Call [262] 641-8610 Monday–Friday, 8am–5pm CST
Let us install your system. The Contract Department offers any or all of these services: project
planning; system packages including drawings; equipment, labor, and construction materials;
and union or non-union installations.

BJ5-615 0Appendix 84 of 85

Sterling, Inc.

2900 S. 160

th

Street

New Berlin, WI 53151

www.sterlco.com

BJ5-615 0Appendix 85 of 85