Sterling 1200 - Manual

EJ5-615 Chapter 1: Safety 6 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 perio...

EJ5-615 Chapter 1: Safety 7 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 installin...

EJ5-615 Chapter 1: Safety 8 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 gra...

EJ5-615 Chapter 1: Safety 10 of 85 Type of Danger Activity Possible Consequences Preventative Measures Crushing, cutting, amputation caused by manipulation of protective devices All activities Serious injury or death • Never make the protective devices ineffective. • Check the protective devices reg...

EJ5-615 Chapter 2: Functional Description 11 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 indust...

EJ5-615 Chapter 2: Functional Description 12 of 85 Machine (Standard Execution) 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 Material In-feed The material can be fed into th...

EJ5-615 Chapter 2: Functional Description 16 of 85 An optional feature is a water cooling system for the rotor used for special applications. 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 sl...

EJ5-615 Chapter 2: Functional Description 20 of 85 2-4 Safety Features 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 The shred...

EJ5-615 Chapter 2: Functional Description 22 of 85 The following protective gear must be worn when carrying out the following tasks: 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 a...

BJ5-615 Chapter 3: Installation 23 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 (Re...

BJ5-615 Chapter 3: Installation 24 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 ste...

BJ5-615 Chapter 4: Operation 28 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 tighten...

BJ5-615 Chapter 5: Maintenance 32 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 r...

BJ5-615 Chapter 5: Maintenance 33 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 ser...

BJ5-615 Chapter 5: Maintenance 34 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 case...

BJ5-615 Chapter 5: Maintenance 35 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. Dismount...

BJ5-615 Chapter 5: Maintenance 36 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 forc...

BJ5-615 Chapter 5: Maintenance 37 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 muc...

BJ5-615 Chapter 5: Maintenance 38 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...

BJ5-615 Chapter 5: Maintenance 41 of 85 Checking the tension force of 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...

BJ5-615 Chapter 5: Maintenance 42 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, replacin...

BJ5-615 Chapter 5: Maintenance 43 of 85 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...

BJ5-615 Chapter 5: Maintenance 44 of 85 Dismounting the Cutter Holders 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 c...

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! Dismounting the Bed Cutters 1. Switch OFF the shredder at the main switch. 2...

BJ5-615 Chapter 5: Maintenance 46 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! Mounting the Cutter Holders 1. Clean the cutter pocket and the cutter holder...

BJ5-615 Chapter 5: Maintenance 47 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 (D...

BJ5-615 Chapter 5: Maintenance 48 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....

BJ5-615 Chapter 5: Maintenance 49 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 t...

BJ5-615 Chapter 5: Maintenance 50 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....

BJ5-615 Chapter 5: Maintenance 51 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 o...

BJ5-615 Chapter 5: Maintenance 52 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 3...

BJ5-615 Chapter 6: Troubleshooting 53 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...

BJ5-615 Chapter 6: Troubleshooting 54 of 85 Problem Possible Cause Possible Remedy Too much feed material. Reduce grinding material in-feed. Screen blocked. Clean screen, check condition, select larger screen perforation if necessary. V-belts slip. Check V-belt tension and condition. Re-tighten or r...

BJ5-615 Chapter 6: Troubleshooting 55 of 85 Problem Possible Cause Possible Remedy View first 5 possible causes for “Machine blocks or switches itself off” View first 5 possible remedies of “Machine blocks or switches itself off” Screen perforation too small. Insert a screen with larger perforation....

BJ5-615 0Appendix 57 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...

BJ5-615 0Appendix 58 of 85 A-2 Technical Specifications

BJ5-615 0Appendix 59 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 85 of 85 Sterling, Inc. 2900 S. 160 th Street New Berlin, WI 53151 www.sterlco.com