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Sterling D48160s - page 1
1 B B P P 2 2 4 4 0 0 0 0 S S E E R R I I E E S S G G R R A A N N U U L L A A T T O O R R S S S S t t e e r r l l i i n n g g , , I I n n c c O O P P E E R R A A T T I I O O N N A A N N D D M M A A I I N N T T E E N N A A N N C C E E M M A A N N U U A A L L P P A A R R T T N N O O . . D D 4 4 8 8 1 1 6 6 0 0 s s B B u u l l l l e e t t i i n n N N ...
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Sterling D48160s - page 2
2 Sterling, Inc . 2900 South 160 th Street New Berlin, WI 53151 Tel: 1-262-641-8600 Fax: 1-262-641-8653 Parts and Service 1-800-229-2919 MACHINE DATA MODEL ________________ _______________ ________________ ____________ SERIAL NUMBER ______ ___________________________ ____________________ CUMBERLAND CUSTOMER ORDER NUMBER __________________ _________ ...
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Sterling D48160s - page 3
3 T T O O P P I I C C : : S S E E C C T T I I O O N N / / P P A A G G E E F F a a c c t t o o r r y y a a d d d d r r e e s s s s . . ……………………………………………… ……………….……… 2 I I N N T T R R O O D D U U C C T T I I O O N N W W h h a a t t i i s s a a g g r r a a n n u u l l a a t t o o r r ? ? … … . ...
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Sterling D48160s - page 4
4 TOPIC SECTION/PAGE SECTION 2 – MACHINE PARTS AND C ONTROLS …………………………………….…2-1 BP-Series gra nulators le ft front qua rter view BP-Series granulators, right front quarter vie w..………………………………………… ………….….2-2 BP-Series granulators, m achine open front view BP-Series granulator ...
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Sterling D48160s - page 5
5 T O P I C S E C T I O N / P A G E SECTION 4 – SETTINGS AND ADJUSTMENTS ( Continue d from previ ous page) Adjusting or replacing the bed knives (Continue d from previous page) Loosen the mounting screws ………………………………………… …………………………………..4-4 Remove the first knife clamp or shield Remove the ...
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Sterling D48160s - page 6
6 T O P I C S E C T I O N / P A G E SECTION 4 – SETTINGS AND ADJUSTMENTS (continue d from previous page) Adjusting or replacing the bed knives (Continue d from previous page) Set the down stroke knife s hield……………………………………… …………………………...4-15 Check the knife gap Tighten the scr ews to final t orque ...
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Sterling D48160s - page 7
7 T O P I C S E C T I O N / P A G E SECTION 4 – SETTING S AND ADJUSTMENTS (Cont inued from previous pa ge) Setting and adjusting the chamber jackscrew (Continued f rom the previ ous page ) The chamber st ops before it closes but th e motor continues to run……… ……………………..…..4-26 Set and test the mounting brack et limit switc ...
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Sterling D48160s - page 8
8 T O P I C S E C T I O N / P A G E SECTION 5 - (Continue d from previ ous page) Normal operation ……………………… ……………………………………………… ……………..5-4 Feed the machine Shut down the machine Discharge clea nout safety Cleaning the discharge transiti on Safely clearing the jam …………………? ...
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Sterling D48160s - page 9
9 T O P I C S E C T I O N / P A G E SECTION - 6 – MAINTENANCE (continued) Screen replacement (Continued from pre vious page) Close screen cradle interlock………… …………………………………… ……………………………6-8 Restart gran ulator Cutting chamber access …………………………………………………? ...
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Sterling D48160s - page 10
10 T T A A B B L L E E O O F F C C O O N N T T E E N N T T S S T O P I C S E C T I O N / P A G E SECTION – 8 PARTS LISTS AND DRAWINGS Recommended spare parts… ………………………………………… …………………………………… 8-1 Parts identification Sterling drawing no . A-48050 ………………… ……………… ...
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Sterling D48160s - page 11
11 THANK YOU FOR PURCHASING AN STERLING BP2400 SERIES GRANULATOR. READ THIS MAN UAL to learn how to operate and service your granulator safely. It covers t he family of granulators called the BP2400. This series of Sterling Granulators is designed for the big jobs in reclamation of larg e blow-m olded and thin walled, in jection molded plastic part ...
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Sterling D48160s - page 12
12 I I N N T T R R O O D D U U C C T T I I O O N N WHAT IS A GRANU LATOR? A GRANULATOR is a machine that is designed to size-reduce plastic materials to chips or granulate. The machine can be fed either by ha nd through a hopper opening in the front or automatically from a special hopper opening, which can be specially designed. THE GRANULATING OF ...
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Sterling D48160s - page 13
13 SAFETY SECTION 1-1 Safety Symbols and Plates LEARN MACHINE SAFETY Read this manual. Learn how to operate and how to use th e control. DO NOT ALLOW ANYONE TO OP ERATE THIS MAC HINE WITHOUT PROPER INSTRUCTIONS. THIS SAFETY alert sym bol MEANS ATTENT ION…BE ALERT! YOUR SAFET Y IS INVLOVED! This symbol appears frequently in this manual and on your ...
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Sterling D48160s - page 14
14 SAFETY SECTION 1-2 Safety Symbol s and Plates FOLLOW THE SAFETY INSTRUCTIONS : Read all safety messages in this manual and on your machine safety plates. Follow the recommended precautions and safe operating practices. Keep safety plates in good condition. Replace missing or damaged plates. ROTATING KNIVES SAFETY PLATE (Located below the infeed ...
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Sterling D48160s - page 15
15 SAFETY SECTION 1-3 Safety Symbol s and Plates ROTATING MACHINERY SAFETY PLATE (One located on the machine guard on the left side of the machine, one on the screen cradle on the front panel, to the right of the machine center.) Avoid personal injury by making sure that the rotor is stopped and the power is disconnected and locked out before remov ...
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Sterling D48160s - page 16
16 SAFETY SECTION 1-4 Safety Symbol s and Plates JACKSCREW REVERSING OPERATION (Located on the jackscrew operating console) This information plate reminds you of th e impor tant procedure for reversing the direction of jackscrew operation. Be sure to pause as advised . This allows the jackscrew drive the necessary time to coast to a stop before rev ...
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Sterling D48160s - page 17
17 SAFETY SECTION 1-5 Safety Symbol s and Plates SAFETY INSTRUCTION PLATE (Located on the front of the drive guard) The safety instruction plate summarizes the most important safety rules that you need to operate this machine safely. Read it care- fully and observe it always to promote safe machine operation. HAZARDOUS VOLTAGE SAFETY PLATE (Located ...
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Sterling D48160s - page 18
18 SAFETY SECTION 1-6 Safety Symbol s and Plates ROTATING KNIVES SAFETY PLATE (One located on the front of the cutting cham ber and one on the front of the cradle) The rotating knives are razor-sharp to the touch. Always verify that the rotor is not moving. Avoid personal injury by making sure that the rotor is stopped and the power is disconnected ...
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Sterling D48160s - page 19
19 SAFETY SECTION 1-7 Safety Cl othing & Practices (Located above the infeed opening at the front of the machine) Always wear proper eye protection when operating and/or servicing this equipment. Wear safety glasses with side shields or full-face safety shields. (Located above the infeed opening at the front of the machine) It is recommended th ...
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Sterling D48160s - page 20
20 SAFETY SECTION 1-8 Safety Clothi ng & Practices WEAR PROTECTIVE CLOTHING Never wear neckties, dangling jewelry, loose-fitting clothing, watches, bracelets, or rings. Tie back long hair or restrain it with a hair net to ensure your safety. KEEP YOUR WORK AREA SAFE Keep your work area clean and uncluttered. Store yo ur maintenance tools away f ...
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Sterling D48160s - page 21
21 SAFETY SECTION 1-9 Safety Clothi ng & Practices TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag-out of Energy Sources). If it is not possible to lock out the power, have an electrician remove the fuses. Make sure the rotor has come to a complete stop. The hydraulic cylinders or jackscrews, which open the mac ...
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Sterling D48160s - page 22
22 SAFETY SECTION 1-10 Safely Cleaning A Jam TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag-out of Energy Sources). If it is not possible to lock out the power, have an electrician remove the fuses. Make sure the rotor has come to a complete stop. The hydraulic cylinders or jackscrews, which open the machine, shou ...
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Sterling D48160s - page 23
23 SAFETY SECTION 1-11 Safely Cleaning A Jam CLEAR THE JAM A leather mallet and block of wood of sufficient length to keep hands away from the path of the knives can be used if required. Use the block of wood to exert force on the rotor, usu ally in the direction opposite normal rotation. Make sure you have secure footing on a clean floor and keep ...
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Sterling D48160s - page 24
24 MACHINE AND CONTROLS SECTION 2-1 BP 2400 Series Granulator -Left Fr ont Quarter View 1. Hold-down clamps - cutting cham ber 2. Screen cradle retainers 3. Interlock actuator screw - cutting chamber 4. Safety plates 5. Feed hopper 6. Rotor bearing housing 7. Discharge duct (pipe not shown-optiona l mount to either side) 8. Start/stop pushbuttons a ...
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Sterling D48160s - page 25
25 MACHINE AND CONTROLS SECTION 2-2 BP 2400 Series Granulator Right Front Quarter View 1. Drive guard 2. Drive guard cover 3. Inlet vent -discharge blower 4. Safety plates 5. Interlock actuator screw screen cradle 6. Infeed flap BP 2400 Series Granulator Machine Open Front View 1. Screen 2. Rotor Knife 3. Bed knife (down stroke) 4. Rotor locating p ...
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Sterling D48160s - page 26
26 MACHINE AND CONTROLS SECTION 2-3 BP 2400 Series Granulator Left Rear Quarter View I. Hydraulic cylinder/ jackscrew console 2. Hydraulic cylinder or jackscrew- cutting chamber 3. Cleanout- discharge transition 4. Discharge outlet (pipe not shown-optional mount to either side) 5. Rotor bearing housing 6. Rotor zero speed sensor 7. Upper chamber pi ...
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Sterling D48160s - page 27
27 INSTALLATION SECTION 3-1 OVERVIEW This section deals with the procedures required to place your BP 2400 Series Granulator into service after you receive it at your plant. The follo wing basic steps need to be accomplished. Uncrating the machine Accounting for all necessary parts Inspecting for damage and reporti ng any damage to the carrier Clea ...
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Sterling D48160s - page 28
28 INSTALLATION SECTION 3-2 MOVE THE GRANULATOR TO ITS WORK SITE If lifting the machine is necessary, use appropriately rated lifting equipment. Always lift the unit from beneath the base plate. The machine weights for the BP-Series Granulators are as follows : BP 2428-10000 pou nds BP 2439-13000 pounds BP 2456-16000 pounds ALLOW ADEQUATE WORK SPAC ...
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Sterling D48160s - page 29
29 INSTALLATION SECTION 3-3 The hydraulic cylinders or jackscrews, which open the machine should not operate until the rotor is completely stopped. If you discover that the hydraulic cylinders or jackscrews DO operate while the rotor is still turning, im mediately shut down the machine and call for maintenance to adjust it. Wear gloves to protect a ...
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Sterling D48160s - page 30
30 INSTALLATION SECTION 3-4 ELECTRICAL WIRING To wire the granulator, run power (of the proper voltage) from the plant source through a lockable, fusible disconnect to the machin e electrical control panel. To wire the jackscrew motor s, run power (of proper voltag e) from the plant sour ce through a fusible disconnect to the machine-mounted jack s ...
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Sterling D48160s - page 31
31 INSTALLATION SECTION 3-5 CHECK FOR MECHANICAL I NTERFERENCES TURN POWER OFF and LOCK IT OUT per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag-out of Energy Sources). Open the cutting chamber. Refer to the pr ocedures entitled Screen Replacement and Cutting Chamber Access in Section 6. Turn the rotor slowly with gloved hands, at least one full r ...
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Sterling D48160s - page 32
32 INSTALLATION SECTION 3-6 With all power to the electrical control panel disc onnected and locked out, reverse any two of the three power line conductors to the machine. If there is more than one motor on t he machine, and one is turning in the wrong direction, and one i sn't: reverse any two of the three line conductors at the overload rela ...
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Sterling D48160s - page 33
33 INSTALLATION SECTION 3-6 With all power to the electrical control panel disc onnected and locked out, reverse any two of the three power line conductors to the machine. If there is more than one motor on t he machine, and one is turning in the wrong direction, and one i sn't: reverse any two of the three line conductors at the overload rela ...
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Sterling D48160s - page 34
34 INSTALLATION SECTION 3-7 ALTERNATE TEST FOR THE INTERL OCK SWITCHES (Continued from previous page). After the test or repair, engage the screen cradle interlock actuator screw. If necessary, unlock and turn on the power. Push the start button to start the granulator. Retract the cutting chamber interlock actuator screw by turning it counterclock ...
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Sterling D48160s - page 35
35 INSTALLATION SECTION 3-8 LUBRICATION The machine is pre-lubricated excep t for the motor. For motor lubrication, check the tag supplied by the motor manufacturer. After the BP2400 Series Granulator has been in servi ce for some time, the jackscrews and the main bearings should be lubricated periodically. Refer to Section 6, Maintenance, for furt ...
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Sterling D48160s - page 36
36 SETTINGS AND ADJUSTMENTS SECTION 4-1 Adjusting or Replacing Bed Knives BASIC FACTS ABOUT THE KNIVES All of the rotor knives are ground in sets to e qual dimensions. M ount and servi ce them as sets. The rotor kniv es must be mount ed tightly agai nst the backs of the knife seats, in order to m ake it possible to achieve consistent knife clearanc ...
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Sterling D48160s - page 37
37 SETTINGS AND ADJUSTMENTS SECTION 4-2 Adjusting or Replacing Bed Knives (Continued from previous page) The hydraulic cylinders or jackscrews, which open the machine, should not operate until the rotor is completely stopped. If you discover that the hydraulic cylinders or jackscrews DO operate while the rotor is still turning, immediately shut dow ...
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Sterling D48160s - page 38
38 SETTINGS AND ADJUSTMENTS SECTION 4-3 Adjusting or Replacing Bed Knives The rotor knives and bed knives are very sh arp wear heavy gloves to avoid injury. Use the rotor-locating pin to lock the rotor in th e position that is least likely to cause injur y as you work. The pin keeps the rotor from turning. If the rotor knives and the bed knives are ...
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Sterling D48160s - page 39
39 SETTINGS AND ADJUSTMENTS SECTION 4-4 Adjusting or Replacing Bed Knives LOOSEN THE MOUNTING SCREWS Select either the upstroke knife or the down-stroke knife for first removal. Loosen the bed knife screws with a 30 mm socket mounted on a breaker bar. These screws are tightened to a torque of 472 ft Ibs (640 Nm ) so make sure you have the proper br ...
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Sterling D48160s - page 40
40 SETTINGS AND ADJUSTMENTS SECTION 4-5 Adjusting or Replacing Bed Knives CLEAN THE KNIFE MOUNTING SURFACES Clean the knife mounting surfaces with a stone or other non-marring tool and wipe them with a clean cloth. Make sure they are free of all material, dust, and dirt. DO NOT REPLACE THE MOUNTING SCREWS WITH ANY TYPE OF SCREW OTHER THAN THAT SPEC ...
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Sterling D48160s - page 41
41 SETTINGS AND ADJUSTMENTS SECTION 4-6 Adjusting or Replacing Bed Knives REPLACE THE DOWNST R OKE BED KNIFE Install the down-stroke bed knife (located on the near side of the rotor) making sure to install it with the knife- edge on the upper side. Engage the captive screws in th e slots on the near side of the knife bed and lower the knife onto th ...
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Sterling D48160s - page 42
42 SETTINGS AND ADJUSTMENTS SECTION 4-7 Adjusting or Replacing Bed Knives MEASURE THE KNIFE GAP If you are changing the rotor knives, do that now, otherwise, continue with this procedure. Use brass shim stock to set the knife gap to the cutting clearance of 0.006 in. to 0.008 i n. (0.15 mm to 0.20 mm). Remove the rotor-locating pin. Rotate the roto ...
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Sterling D48160s - page 43
43 SETTINGS AND ADJUSTMENTS SECTION 4-8 Adjusting or Replacing Bed Knives TIGHTEN THE SCREWS TO FINAL TORQUE When the knife gap is adjusted to the proper dimension, tighten the mounting screws to a torque o f 472 ft lbs (640 Nm). For safety, make sure that you have solid footing when you apply this final torque. Recheck the gap after tightening the ...
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Sterling D48160s - page 44
44 SETTINGS AND ADJUSTMENTS SECTION 4-9 Adjusting or Replacing Bed Knives FASTEN THE CUTTING CHAMBER Raise the hold-down clamps to their upright positions Turn the knobs clockwise until they are tight against the chamber housing. CLOSE THE CUTTING CHAMBER SAFETY INTERLOCK Engage the safety interlock by turning the actuator screw clockwise with a bo ...
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Sterling D48160s - page 45
45 SETTINGS AND ADJUSTMENTS SECTION 4-10 Adjusting or Replacing Rotor Knives BASIC FACTS ABOUT THE KNIVES All of th e rotor knives are ground in sets to e qual dimension s. Mount and s ervice them as sets . . The rotor kniv es must be mount ed tightly against the backs of kni fe seats in order to make it possi ble to achieve consistent knife cleara ...
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Sterling D48160s - page 46
46 SETTINGS AND ADJUSTMENTS SECTION 4-11 Adjusting or Replacing Rotor Knives RELEASE TH E CUTT ING CHAMBER FASTENERS Turn the hold-down clamps counterclockwise to loosen them. Swing the hold-down clamps toward you until the y are disengaged from the cutting chamber housing. SEE SECTION 6-10 PAGE 87 FOR CUTTING CHAMBER OPENING INSTRUCTIONS . ...
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Sterling D48160s - page 47
47 SETTINGS AND ADJUSTMENTS SECTION 4-12 Adjusting or Replacing Rotor Knives The rotor knives and bed knives are very sh arp wear heavy gloves to avoid injury. Use the rotor-locating pin to lock the rotor in the position that is least likely to cause injur y as you work. The pin keeps the rotor from turning. If the rotor knives and the bed knives a ...
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Sterling D48160s - page 48
48 SETTINGS AND ADJUSTMENTS SECTION 4-13 Adjusting or Replacing Rotor Knives CLEAN PARTS FOR REASSEM BLY Clean the rotor knife seats with a stone or other non-mar- ring tool. Make sure that the backs of the knife seats are clean so that the rotor knife can be placed squarely against them. Wipe the screws with lightly oiled cloth, do not leave an oi ...
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Sterling D48160s - page 49
49 SETTINGS AND ADJUSTMENTS SECTION 4-14 Adjusting or Replacing Rotor Knives TIGHTEN THE ROTOR KNIVES TO FINAL TORQUE Use a 30 mm socket wrench to tighten the mounting screws on each knife in small steps keeping them about even as you increase the torque on them. Use a torque wrench to apply the final torque of 472 ft lbs (640 Nm) to the mounting s ...
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Sterling D48160s - page 50
50 SETTINGS AND ADJUSTMENTS SECTION 4-15 Adjusting or Replacing Rotor Knives SET THE DOWNSTROKE KNIFE SHIELD Position the knife shield so that it sets back from the bed knife edge about 1/32 in. for film and 1/16 in. for thicker materials. Use a plastic or leather mallet, if necessary , to tap the shield or knife- The upstroke knife clamp does not ...
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Sterling D48160s - page 51
51 SETTINGS AND ADJUSTMENTS SECTION 4-16 Adjusting or Replacing Rotor Knives FASTEN THE CUTTING CHAMBE R Raise the hold-down clamps to their upright positions. Turn the knobs clockwise until they are tight against the chamber housing. RESTART TH E GRANULATOR If necessary to replace the fuses, ca ll an electrician to do it. UNLOCK AND TURN ON the ma ...
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Sterling D48160s - page 52
52 SETTINGS AND ADJUSTMENTS SECTION 4-17 Drive Belt Replacement Or Adjustment OVERVIEW Belt tension is important to the proper operation of the drive system of your granulator. Improper belt tension can lead to excessive belt wear and/or undue bearing wear on the rotor and motor bearings. This procedure shows you how to access the driv e belts and ...
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Sterling D48160s - page 53
53 SETTINGS AND ADJUSTMENTS SECTION 4-18 Drive Belt Replacement Or Adjustment INSPECT THE DRIVE BELTS Check the belts for cracks in the V-sections that ride in the pulley grooves as well as on the outside surface of the belts. Also look for signs of excessive wear. If replacement is necessary , conti nue with the steps that follow. If it is not nec ...
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Sterling D48160s - page 54
54 SETTINGS AND ADJUSTMENTS SECTION 4-19 Drive Belt Replacement Or Adjustment CHECK THE PULLEY ALIGNMENT Tug outward on the pulleys to verify that they are tight on their shafts. Check the pulley alignment by holding a straight edge against the edge of the large pulley and verifying that it is aligned with the edge of the small pulley. If the edges ...
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Sterling D48160s - page 55
55 SETTINGS AND ADJUSTMENTS SECTION 4-20 Drive Belt Replacement Or Adjustment COMPARE MEASURED FORCE TO RECOMMENDED FORCE Compare the deflection force measured, to the value shown in the table. For new belts the value for run-in should be used. For belts, which have been running two days or more, use the values for normal running. ADJUST THE BELT T ...
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Sterling D48160s - page 56
56 SETTINGS AND ADJUSTMENTS SECTION 4-21 Drive Belt Replacement Or Adjustment REPLACE THE DRIVE GUARD COVER Replace the guard cover. Use a socket wrench to replace the fasteners. RESTART THE GRANULATOR If necessary to replace the fuses, call an electrici an to do it. UNLOCK AND TURN ON the main power. Remove the OUT OF SERVICE tag. Start the granul ...
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Sterling D48160s - page 57
57 SETTINGS AND ADJUSTMENTS SECTION 4-22 Setting and Adjusting the Chamber Jackscrew OVERVIEW Proper adjustment of the two machine-mounted jack screws is important to performance and safety. Improper settings can result in premature failure of the jackscrews. To avoid severe damage to the jackscrews, BE PREPARED TO SHUT THEM DOWN IMMEDIATELY WHEN T ...
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Sterling D48160s - page 58
58 SETTINGS AND ADJUSTMENTS SECTION 4-23 Setting and Adjusting the Chamber Jackscrew RELEASE THE CU T TING CHAMBER FASTENERS Turn the hold-down clamps counterclockwise to loosen them. Swing the hold-down clamps toward you until they are disengaged from the cutting chamber housing When you REVERSE the jackscrew operating direction, always ALLOW THE ...
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Sterling D48160s - page 59
59 SETTINGS AND ADJUSTMENTS SECTION 4-24 Setting and Adjusting the Chamber Jackscrew The jackscrews, which open the machine, should not operate until the rotor is completely stopped. If you discover that the jack- screws DO operate while the rotor is still turning, immediately shut down the machine and call for maintenance to adjust it. Make sure n ...
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Sterling D48160s - page 60
60 SETTINGS AND ADJUSTMENTS SECTION 4-25 Setting and Adjusting the Chamber Jackscrew Make sure that no one is near the jackscrew or hopper. Clear the mating surfaces of the cutting chamber of any debris that might prevent tight closure. At the jackscrew console, turn the CC/Hopper (Cutting Chamber/Hopper) switch to the LOWER position. Hold the swit ...
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Sterling D48160s - page 61
61 SETTINGS AND ADJUSTMENTS SECTION 4-26 Setting and Adjusting the Chamber Jackscrew SET THE JACKSCREW CLOSED-POSITION LIMIT SWITCH (Continued from previous page) Rotate the CLOSED POSITION NUT (4) until the switch (5) trips. Then turn it an additional half turn toward the switch. Replace the keeper (1). Test the closed position and be prepared to ...
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Sterling D48160s - page 62
62 SETTINGS AND ADJUSTMENTS SECTION 4-27 Setting and Adjusting the Chamber Jackscrew SET & TEST THE MOUNTING BRACKET LIMIT SWITCH (Continued from previous page) Place a 4 in. x4 in.x12 in. (100 mm x l00 mm x 300 mm) wood block on its 4 in. (l00 mm) side between the mating surfaces of the cutting chamber, as shown. Carefully close the chamber un ...
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Sterling D48160s - page 63
63 SETTINGS AND ADJUSTMENTS SECTION 4-28 Setting and Adjusting the Chamber Jackscrew CLOSE THE CUTTING CHAMBER SAFETY INTERLOCK Engage the safety interlock by turning the actuator screw clockwise with a box wrench or a ratchet wrench. Make sure the screw is fully seated against the top surface of its housing. When engaged, the interlock closes the ...
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Sterling D48160s - page 64
64 SETTINGS AND ADJUSTMENTS SECTION 4-29 Setting and Adjusting the Cradle Jackscrew OVERVIEW Proper adjustment of the two machine-mounted jackscrews is important to performance and safety. Improper settings can result in premature failure of the jackscrews. To avoid severe damage to the screen cradle jackscrew, BE PREPARED TO SHUT IT DO WN IMMEDIAT ...
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Sterling D48160s - page 65
65 SETTINGS AND ADJUSTMENTS SECTION 4-30 Setting and Adjusting the Cradle Jackscrew When you REVERSE the jackscrew operating direction, always ALLOW THE JACKSCREW MOTOR TO COME TO A COMPLETE STOP. Re lease the control switch and allow a minimum of 5 seconds before switching to the opposite operating positi on. If you don't allow this pause, th ...
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Sterling D48160s - page 66
66 SETTINGS AND ADJUSTMENTS SECTION 4-31 Setting and Adjusting the Cradle Jackscrew (continued from previous page) Actuate the screen cradle jackscrew s by turning the selector switch to LOWER at the jackscrew console. Hold the switch in position until th e cradle approaches the open stop location described previously. TO AVIOD SERIOUS DAMAGE TO TH ...
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Sterling D48160s - page 67
67 SETTINGS AND ADJUSTMENTS SECTION 4-32 Setting and Adjusting the Cradle Jackscrew CHECK THE CRADLE CLOSED-POSITION SWITCH When the screen cradle is fully closed, the cradle front flange should be parallel with the down stroke knife block and the cradle wedges should engage the cradle freely. If this does not occur, or if the jackscrew motor conti ...
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Sterling D48160s - page 68
68 SETTINGS AND ADJUSTMENTS SECTION 4-33 Setting and Adjusting the Cradle Jackscrew ADJUST THE CRADLE CLOSED-POSITION LIMIT SWITCH Jog the cradle to close until it arrives at the stop position. Open the cradle jackscrew switch housing cover (1) and remove the keeper (2). Turn the CLOSED-POSITION NUT on the bottom (3) toward the switch until the swi ...
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Sterling D48160s - page 69
69 SETTINGS AND ADJUSTMENTS SECTION 4-34 Zero Speed Sensor ZERO SPEED SENSO R The zero speed sensor detects the motion of the rotor assembly. The sensor is interlocked to the control circuits of the two machine jackscrews. If th e rotor is turning, then the jackscrews should not operate. If you notice that the jackscrews are operational while the r ...
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Sterling D48160s - page 70
70 SETTINGS AND ADJUSTMENTS SECTION 4-35 Adjustable rotor knives ROTOR KNIFE PREPAR ATION Prepare the rotor knives for setting by installi ng the adjusting screws PHOTO and lock nuts int o the rear of the knife. Knife with screws Be sure that the screws are fully eng aged into the knif e. This will assure easy installati on into the kni fe setting ...
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Sterling D48160s - page 71
71 SETTINGS AND ADJUSTMENTS SECTION 4-35 Adjustable rotor knives KNIFE LENGTH SETTING-INSPECTIO N Check with a .0015 fe eler gauge to ensure that cutting ed ge of the knife PHOTO is snug ag ainst the front setting b lock. This should b e consistent along Knife in fixture the entire block length . If the fit is proper then the knife is at it’s pro ...
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Sterling D48160s - page 72
72 SETTINGS AND ADJUSTMENTS SECTION 4-36 Settings and Adjustments Hydraulic opening HYDRAULIC OPENING POSITION SWITCHES Both the Upper Cham ber/Hopper and the S creen Cradle have swi tches to assure proper closi ng positions. These switch locations are set a t the factory and shou ld not require adjustm ent. When operating properly, the hydraulic p ...
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Sterling D48160s - page 73
73 OPERATION SECTION 5-1 Initial Startup Before operating the granulator, make sure that a ll of the electrical, mechanical, and lubrication requirements have been completed in accordance wi th the installation instructions in Section 3. Proper adjustments and set- tings are made prior to shipment, however the machine may require readjustment. For ...
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Sterling D48160s - page 74
74 OPERATION SECTION 5-2 to 5-3 Initial Startup CHECK THE MOTOR ROTATION DIRECTION Unlock the power. Push the start-stop pushbutton in quick succession to start the machine, then, let it coast without power. While the machine is coasting to a st op, check the V-belt direction by looking through the slots in the driv e guard. The top of the V-belt s ...
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Sterling D48160s - page 75
75 OPERATION SECTION 5-4 Normal Operation Never reach beyond the hopper curtain while the machine is running. To clear a jam, refer to the procedure for clearing a jammed cutting chamber, which follows in this section. Avoid excessive feed rates. Feed the machine by placing the plastic pieces into the hopper at a rate approximating the rated capaci ...
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Sterling D48160s - page 76
76 OPERATION SECTION 5-5 Safely Clearing a Jam TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag out of Energy Sources). If it is not possible to lock out the power, have an electrician remove the fuses. Make sure the rotor has come to a complete stop. The hydraulic cylinders or jackscrews, which open the machine, sh ...
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Sterling D48160s - page 77
77 MAINTENANCE SECTION 5-6 Periodic Maintenance CLEAR THE JAM A leather mallet and block of wood of sufficient length to keep hands away from the path of the knives can be used if required. Use the block of wood to exert force on the rotor, usu ally in the direction opposite normal rotation. Make sure you have secure footing on a clean floor and ke ...
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Sterling D48160s - page 78
78 MAINTENANCE SECTION 6-1 Periodic Maintenance TABLE 1: PERIODIC MAINT ENANCE SCHEDULE CHECK DAILY WEEKLY MONTHLY Check tightness of upper chamber hold d own handles. Refer to Section 6, Cutting Chamber X Check tightness of screen chamber wedges. Refer to Section 6, Screen Replacement X Check infeed flap position/condition. Refer to Section 6 Peri ...
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Sterling D48160s - page 79
79 MAINTENANCE SECTION 6-2 Periodic Maintenance LUBRICATION Motor lubrication: check the tag from the motor manufacturer. Main rotor bearings are lubricated at the factory but need re-lubrication periodically. Grease fittings are pro- vided for re-lubrication and are located on the ri ght and left-ha nd bearing housings. Lubricate every month or 75 ...
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Sterling D48160s - page 80
80 MAINTENANCE SECTION 6-3 Periodic Maintenance INFEED FLAP CONDITION Daily, check the overall condition of the (3) infeed flaps, pictured in Section 2, Right Quarter View. Check for wear, or tears in the flap, or if pieces are missing. Replace them if you see damage. Check the rods that support the flaps: they should be in good condition and in pr ...
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Sterling D48160s - page 81
81 MAINTENANCE SECTION 6-4 Screen Replacement TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag out of Energy Sources). If it is not possible to lock out the powe r, have an electrician remove the fuses Make sure the rotor has come to a complete stop The hydraulic cylinders or jackscrews, which open the machine, shou ...
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Sterling D48160s - page 82
82 MAINTENANCE SECTION 6-5 Screen Replacement SEE SECTION 6-12 PAGE 90 FOR SCREEN CRADLE LOWERING INSTRUCTIONS Avoid contact with the rotor knives, which are just above the screen. The cutting edges are very sharp. Wear gloves to avoid injury when working in this area. ...
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Sterling D48160s - page 83
83 MAINTENANCE SECTION 6-6 Screen Replacement REMOVE THE SCREEN The screen is divided into segments. Remove one segment at-a-time. Grasp it on its near edge and raise the edge by allowing the screen to slide in the cradle. Pull it toward you slowly allowing it to slide over the edge of the screen cradle then, let it down onto the machine support ba ...
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Sterling D48160s - page 84
84 MAINTENANCE SECTION 6-7 Screen Replacement REPLACE THE SCREEN (Continued from previous page) Guide the screen carefully as yo u "roll" it into the cradle, then slide it down around the cradle until you can hang the front lip of the screen over the front edge of the cradle. Be careful not to hit the rotor knives with the far end of the ...
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Sterling D48160s - page 85
85 MAINTENANCE SECTION 6-8 Screen Replacement CLOSE THE SCREEN CRADLE INTERLOCK Engage the interlock screw by turning it clockwise with a box wrench or a ratchet wrench. Make sure the interlock actuator screw is fully seated against the top surface of its housing. When engaged, the interlock switch closes the electrical control circuit to the machi ...
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Sterling D48160s - page 86
86 MAINTENANCE SECTION 6-9 Cutting Chamber Access TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag out of Energy Sources). If it is not possible to lock out the power, have an electrician remove the fuses. Make sure the rotor has come to a complete stop. The hydraulic cylinders/jackscrews, which open the machine, sh ...
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Sterling D48160s - page 87
87 MAINTENANCE SECTION 6-10 Cutting Chamber Access When you REVERSE the jackscrew operating direction, always ALLOW THE JACKSCREW MOTOR TO COME TO A COMPLETE STOP. Release th e control switch and allow a minimum of 5 seconds before switching to the op posite operating position. If you don' t allow this pause, the JACKSCREW AND OTHER COMP ONENT ...
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Sterling D48160s - page 88
88 CLOSE THE CUTTING CHAM BER WITH JACKSCREWS MAINTENANCE SECTION 6-11 Cutting Chamber Access CLOSE THE CUTTING CHAMBER WITH H YDRAULICS After completing any m aintenance or a djustments inside the cutting ch amber, use the followin g procedure to close the cutting chamber and resum e use of the granulator. Make sure that no one is near the hydraul ...
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Sterling D48160s - page 89
89 RESTART THE GRANULATOR If necessary to replace the fuses, call an electrici an to do it. UNLOCK AND TURN ON the main power. Remove the OUT OF SERVICE tag. Start the granulator by depressing the start pushbutton on the electrical cabinet. MAINTENANCE SECTION 6-11 Cutting Chamber Access FASTEN THE CUTTING CHAMBER Raise the hold-down clamps to thei ...
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Sterling D48160s - page 90
90 MAINTENANCE SECTION 6-12 Cutting Chamber Access When you REVERSE the jackscrew operating direction, always ALLOW THE JACKSCREW MOTOR TO COME TO A COMPLETE STOP. Release the c ontrol switch and allow a minimum of 5 seconds before switching to the opposite operating position. If you don't allow this pause, the JACKSCREW AND OTHER COMPONENTS M ...
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Sterling D48160s - page 91
91 RAISING THE SCREEN CR ADLE WITH HYDRAULICS From the open/close co ntrol panel, ra ise the cradle approximat ely two-thirds of its fu ll travel by tur ning the Screen Cradle selector switc h to the “RAISE” position. Check the scr eens to make sure that they are seated pr operly in the cradle. Continue raising the cradle by turning the switc h ...
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Sterling D48160s - page 92
92 MAINTENANCE SECTION 6-14 Knife Sharpening ROTOR KNIFE SHARPENING The rotor knives must be sharpened to within 0.003" (0.076 mm) of each other. Greater dimensional variations prevent the proper setting of the knife gap and may create other serious complications. Grinding the cutting edge until it is free of nicks can be wasteful. It is not h ...
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Sterling D48160s - page 93
93 MAINTENANCE SECTION 6-15 Knife Sharpening BED KNIFE SHARPENING Each bed knife is provided with two cutting edges. When the exposed edges become blunt, the knives can be turned over and repositioned to present the new cutting edges. It is not necessary to grind bed knives to the closely matched tolerance of the rotor knives and as with the rotor ...
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Sterling D48160s - page 94
94 TROUBLESHOOTING SECTION 7-1 Overview OVERVIEW This section is intended to serve as a guide in ch ecking possible problems that may occur with the operation of your granulator. SAFETY The most important ingredient in any machinery operation is a constant a dherence to sound safety practices. The best way to assure safety in any ac tivity that inv ...
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Sterling D48160s - page 95
95 TROUBLESHOOTING SECTION 7-2 Processing Faults PROBLEM Processing Faults PROBABLE CAUSE REMEDY 1. Pneumatic discharge blower not running 1. Start the blower 2. Damper on discharge blower not open enough 2. Adjust the damper (on opposite side of machine from blower) A. Material building up below screen 3. Damper line is blocked 3. Open line and re ...
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Sterling D48160s - page 96
96 TROUBLESHOOTING SECTION 7-3 Mechanical Faults PROBLEM Mechanical Faults PROBABLE CAUSE REMEDY 1. Excessive wear on the V- Belt drive 1. Check belt tension and adjust as necessary 2. Inadequate lubrication 2. Check lubrication frequency and the recommended lubricants in motor and rotor bearings A. Bearing overheating 3. Dirt/Contamination in bear ...
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Sterling D48160s - page 97
97 TROUBLESHOOTING SECTION 7-4 Electrical Faults PROBLEM Electrical Faults PROBABLE CAUSE REMEDY 1. Power suppl y failure. 1. Check fuses. 2. Starter is inoperative. 2. Check supply mains. Also, check starter contacts for burning, replace if necessary. 3. Starter overloads cut out. 3. Check current re quirements on motor nameplate and adjust. A. Mo ...
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Sterling D48160s - page 98
98 PARTS LIST AND DRAWINGS SECTION 8-1 Recommended Spare Parts BP2400 SERIES PARTS LIST AND DRAWINGS SECTION 8-2 Parts Identification Drawing No. A-48050 (Sheet 1 of 4) PARTS LIST AND DRAWINGS SECTION 8-2 Parts Identification Drawing No. A-48050 (Sheet 2 of 4) PARTS LIST AND DRAWINGS SECTION 8-2 Parts Identification Drawing No. A-48050 (Sheet 2 of ...
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Sterling D48160s - page 99
99 PARTS LIST AND DRAWINGS SECTION 8-2 Parts Identification Drawing No. A-48050 (Sheet 1 of 4) ...
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Sterling D48160s - page 100
100 PARTS LIST AND DRAWINGS SECTION 8-2 Parts Identification Drawing No. A-48050 (Sheet 2 of 4) ...
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Sterling D48160s - page 101
101 PARTS LIST AND DRAWINGS SECTION 8-2 Parts Identification Drawing No. A-48050 (Sheet 3 of 4) ...
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Sterling D48160s - page 102
102 PARTS LIST AND DRAWINGS SECTION 8-2 Parts Identification Drawing No. A-48050 (Sheet 4 of 4) ...
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Sterling D48160s - page 103
103 PARTS LIST AND DRAWINGS SECTION 8-3 Parts Identification Drawing No. A-48150 (Sheet 1 of 1) ...
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Sterling D48160s - page 104
104 PARTS LISTS AND DRAWINGS SECTION 8-4 Part Identificatio n Drawing No.3 48070 (Sheet 1 of 1) ...
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Sterling D48160s - page 105
105 PARTS LISTS AND DRAWINGS SECTION 8-5 Parts Identification Drawing No. 348185 (Sheet 1 of 1) ...
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Sterling D48160s - page 106
106 PARTS LISTS AND DRAWINGS SECTION 8-6 Parts Identification Drawing No. 1554-460 (Sheet 1 of 1) ...
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Sterling D48160s - page 107
107 PARTS LIST AND DRAWINGS SECTION 8-7 Wiring Diagram Drawing No. A-399598 (Sheet 1 of 2) ...
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Sterling D48160s - page 108
108 ...
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Sterling D48160s - page 109
109 PARTS LIST AND DRAWINGS SECTION 8-8 Drawing No. 348078-1 (Sheet 1 of 1) ...
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Sterling D48160s - page 110
110 PARTS LIST AND DRAWINGS SECTION 8-9 Wiring Diagram for Hydraulics Drawing No. D-499061 (Sheet 1 of 1) ...
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Sterling D48160s - page 111
111 PARTS LIST AND DRAWINGS SECTION 8-10 Wiring Drawing No. D-499044 (Sheet 1 of 1) ...
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Sterling D48160s - page 112
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