Instruction/ maintenance manual of the product 1200 Sterling
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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 Number s H ere For Future Referen ce: _____.
BJ5-615 ii Shipping Info Unpacking and Inspection You should inspect your equipm ent for possible shipping damage. Thoroughly check the equipment for any dam age th at might have occurred in transit, such as broken or loose wiring and components, l oose hardware and mounting screws, etc.
BJ5-615 iii Storage, Disposal, Transportation Storage Clean the machine (see “Cleani ng the Machine”). Preserve all polished metal surfaces using a suitable rust preventing agent. Store the m achine in a dry, enclosed space. Cover the machine completely with a plastic sheet.
BJ5-615 iv Table of Contents CHAPTER 1: SAFETY ................................................................ 5 1-1 How to Use This Manual ............................................................................................. 5 Safety Symbols Used in this Manual .
EJ5-615 Chapter 1: Safety 5 of 85 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 a pplying efficient, proven techniques that enhance equipment productivity.
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.
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, fo llowing national and local safety codes.
EJ5-615 Chapter 1: Safety 8 of 85 ; ROTATION OF MOTO RS: The correct rotating direction for the machine motor is clearly marked on the machine. Always check for proper rotation of motors.
EJ5-615 Chapter 1: Safety 9 of 85 Type of Danger Activity Possible Consequences Preventative Measures Pulling in caused by running V-belts All activities Serious injury can result from hair, jewelry, etc. being pulled int o the machine. • Never dismount V-belt protection and window.
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.
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, 120 0, 1500 and 2000 Medium Duty Single Shaft Shredders.
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.
EJ5-615 Chapter 2: Functional Description 13 of 85 In-feed Hopper The material in-feed flows through an in-feed hopper to ensure the grinding m aterial is delivered safely and correctly. NOTE: An optional top-hinged cover to preve nt in-feed material fly-back during size reduction is available.
EJ5-615 Chapter 2: Functional Description 14 of 85 Drive The drive of the rotor runs using an electric motor via V-belts. The motor (m ounted on sliding rails or a motor plate) can be adjust ed for regulating the tension of the V-belts using tensioning screws.
EJ5-615 Chapter 2: Functional Description 15 of 85 The rotor is accessible after opening th e 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.
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 t ogether and fixed to the housing by screws in the standard execution.
EJ5-615 Chapter 2: Functional Description 17 of 85 Another optional feature is a screen support th at can be lowered by a hydraulic system. Discharge of Shredding Material Normally the shredded material will be di scharged onto a conveyor belt. (Options include a discharge with blower or with a screw conveyor.
EJ5-615 Chapter 2: Functional Description 18 of 85 Hydraulic Ram The hydraulic ram is fixed on two arms a rranged on flange bearings. Two heavy duty hydraulic cylinders move the ram back and forth. The ram m oves automatically after switching ON the hydraulic system and the sh redder when the machine is operated in automatic mode.
EJ5-615 Chapter 2: Functional Description 19 of 85 Pulse Push Function In normal process mode, the ram pushes forw ard 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 sw itch (1) is changed to “Pulse Push”.
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.
EJ5-615 Chapter 2: Functional Description 21 of 85 V-Belts and Ram Guards V-belt and ram guards are screwed to the machine. They can be dism ounted for installation and maintenance work only when a ll rotating parts have come to a com plete standstill and the machine is electronically locked out.
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 mounte d to t he control cabinet and another on the grinding ma terial in-feed.
BJ5-615 Chapter 3: Installation 23 of 85 Chapter 3: Inst allation 3-1 Uncrating the Equipment Requirements at Application Site Check the application site to make sure it conforms to the qualifications listed below.
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 su itable for the weight and the dimensions of the load. • Use suitable stopping equipment and pay attention to the gravity center location.
BJ5-615 Chapter 3: Installation 25 of 85 WARNING! Use caution when operating sp ecific equipm ent to prevent electrical shock. Installation, service, alterations, and/or modifica tions must only be done by qualified personnel and with high regar d for safety.
BJ5-615 Chapter 3: Installation 26 of 85 Checking the Rotational Direction Rotational direction of the motors must be checked before initial start-up. The following steps must be completed.
BJ5-615 Chapter 3: Installation 27 of 85 9 Switch ON machine for a short period of tim e and check rotational direction. The rotational direction can be seen at the disch arge air fan of the drive motor (observe running direction arrow). 9 Switch ON hydraulic unit for a short time and check rotational direction.
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 tightened with the specified torque.
BJ5-615 Chapter 4: Operation 29 of 85 • Throw the grinding material into t he 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.
BJ5-615 Chapter 4: Operation 30 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.
BJ5-615 Chapter 4: Operation 31 of 85 4-3 Shut-down Switch OFF Machine 1. Switch OFF the material in-feed device (accessories). 2. Wait until the remaining grinding m aterial has been shredded, and then switch OFF the shredder (main switch to 0). 3. Switch OFF the material discharge device.
BJ5-615 Chapter 5: Maintenance 32 of 85 Chapter 5: Maintenance 5-1 Preventative Maintenance Schedule Only trained and specialized personne l should carry out maintenance work . Maintenance Plan WARNING! • Danger caused by electrical voltage and starting the machine during maintenance work.
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 • S.
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 cases.
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.
BJ5-615 Chapter 5: Maintenance 36 of 85 5. Attach the bearing housing to the bearing seats using screws. 6. Push the distance sleev e 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.
BJ5-615 Chapter 5: Maintenance 37 of 85 Replacing or Refilling Lubricant • Fill the bearings uniformly with grease un til all operating surfaces are well-greased. • For the rotor bearings, a lubricant quantity of o ne third to a maximum of half of the bearing volume per bearing is required.
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”).
BJ5-615 Chapter 5: Maintenance 39 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 40 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.
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.
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.
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.
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.
BJ5-615 Chapter 5: Maintenance 45 of 85 WARNING! Danger of cutting caused by shar p 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.
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 ha nds and fingers can occur. Wear protective gloves! Mounting the Cutter Holders 1.
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 .
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 c utting cutters do not collide as the rotor turns. 9. Put back the cover plates and mount the m 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 to be adjusted.
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 m ode 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).
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 .
BJ5-615 Chapter 6: Troubleshooting 53 of 85 Chapter 6: T roubleshooting 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.
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 larg er screen perforation if necessary. V-belts slip. Check V-belt tension and condition.
BJ5-615 Chapter 6: Troubleshooting 55 of 85 Problem Possible Cause Possible Remedy View first 5 po ssible causes for “Machine blocks or switches itself off” View first 5 possible remedies of “Machine bloc ks or switches itself off” Screen perforation too small.
BJ5-615 Chapter 6: Troubleshooting 56 of 85 Problem Possible Cause Possible Remedy Cutter mounting screws not tight. Re-tighten using torque wrench following the instructions in this manual. Screw fatigue. Fit new screws. Washers def ormed. Insert new washers.
BJ5-615 0Appendix 57 of 85 Appendix A-1 Returned Material Policy Credit Returns Prior to the return of any material, authoriz ation 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.
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 corresp onding Spa re Parts lists in the following section. Cutter Mounting.
BJ5-615 0Appendix 60 of 85 Bed Knife Mounting.
BJ5-615 0Appendix 61 of 85 Rotor Assembly.
BJ5-615 0Appendix 62 of 85 Drive.
BJ5-615 0Appendix 63 of 85 Ram.
BJ5-615 0Appendix 64 of 85 Ram scraper.
BJ5-615 0Appendix 65 of 85 SMS 850 Hydraulic Diagram.
BJ5-615 0Appendix 66 of 85 SMS 850 Hydraulic Unit.
BJ5-615 0Appendix 67 of 85 SMS 850 Hydraulic Screen Diagram.
BJ5-615 0Appendix 68 of 85 SMS 850 Hydraulic Unit—Screen.
BJ5-615 0Appendix 69 of 85 SMS 1200-2000 Standard Hydraulic Diagram.
BJ5-615 0Appendix 70 of 85 SMS 1200-2000 Hydraulic Unit.
BJ5-615 0Appendix 71 of 85 SMS 1200-2000 Hydraulic Screen Diagram.
BJ5-615 0Appendix 72 of 85 SMS 1200-2000 Hydraulic Unit.
BJ5-615 0Appendix 73 of 85 A-4 Spare Parts List SMS 850 Pos. Pc Description/Standard 100 Machine complete 101 1 Standard hopper 102 2 PP-scraper side 103 1 PP-scraper top 104 1 Upper door 105 1 Lower .
BJ5-615 0Appendix 74 of 85 Gear pulley taper bushing T B 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 bushin.
BJ5-615 0Appendix 75 of 85 713 1 Cover plate for scraper 714 2 Upper cylinder screw 715 2 Lower screw for cylinder mounting 716 8 Mounting screw for cylinder scre w DIN912 – M16x25 – 12.9 717 4 Grease nipple GB1152/M10x1 800 Hydraulic 801 2 Cylinder for ram ø35xø7 0x420 802 Piping 803 Connectors 804 1 Hydraulic unit 3.
BJ5-615 0Appendix 76 of 85 300 2 Bearing 301 2 Bearing housing SN32 4 302 2 Bearing GB/T288-94-22324 303 2 Bearing Cover A 304 1 Bearing Cover B 305 1 Bearing housing cover pl ate 306 3 Sealing GB9877.1-86 J150 x1 80x15 307 2 Grease nipple GB1152-89/M8x1 308 2 Sleeve Ø150x16 24 Mounting screw cover plate DIN912-M10x40-8 .
BJ5-615 0Appendix 77 of 85 604 8 Upper bed knife adjustin g screw for pushing DIN912 – M16x45 – 12.9 605 16 Bed knife adjusting screw for pulling DIN912 – M16x60 – 12.9 2 Bed knife cover plate 1 Bed knife cover plate left 606 1 Bed knife cover plate right 607 16 Cover plate mounting screw DIN912 – M12x35 – 12.
BJ5-615 0Appendix 78 of 85 107 1 Safety grid back 108 1 Safety grid back 109 1 Ram residual chute 200 Screen complete (Standard) 201 1 Screen 12/16/20/25 202 6 Screen support screw DIN912–M12x35–8.8 203 6 Washer DIN125-B-13-140 HV 204 6 Spring washer DIN127-A-13 205 2 Clamp 206 2 Clamp mounting scre ws DIN933 – M20 – 8.
BJ5-615 0Appendix 79 of 85 416 1 Torque arm screw 417 1 Cover plate 418 1 Cover 75KW 419 6 Rubber bushing plate scre ws DIN933-M16x50-1 2.9 420 6 Washer DIN433-16 421 6 Spring washer DIN127-A-16 422 6.
BJ5-615 0Appendix 80 of 85 802 Piping 803 Connectors 804 1 Hydraulic unit 5.6kW 805 1 Set of sealing for cylinder 806 1 Oil filter 12AT-10-CR 900 Electrical parts 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 s witch EI0200 SMS 2000 Pos.
BJ5-615 0Appendix 81 of 85 Gear pulley taper bushing T B 3535-50 403 2 Gear pulley taper bushing T B 3535-55 404 2 Key C 25x210 V-Belt SPC 2430 405 8 V-Belt SPC 2550 Motor pulley SPC 250- 4 406 2 Moto.
BJ5-615 0Appendix 82 of 85 706 12 Mounting screws ram arm DIN912-M16 x90- 12.9 707 12 Nut DIN93 4-M16-10 708 12 Washer DIN 433-16-300HV 709 12 Sprin g washer DIN12 7-A-16 710 12 Mounting pin DI N94-2.
BJ5-615 0Appendix 83 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 s ystem).
BJ5-615 0Appendix 84 of 85 10 Pressure Gauge LA-250(inclu ding 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 va.
BJ5-615 0Appendix 85 of 85 Sterling, Inc. 2900 S. 160 th Street New Berlin, WI 53151 www.sterlco.com.
An important point after buying a device Sterling 1200 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Sterling 1200 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Sterling 1200 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Sterling 1200 you will learn all the available features of the product, as well as information on its operation. The information that you get Sterling 1200 will certainly help you make a decision on the purchase.
If you already are a holder of Sterling 1200, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Sterling 1200.
However, one of the most important roles played by the user manual is to help in solving problems with Sterling 1200. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Sterling 1200 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
