Sterling D48160s manual Test Equipment, Locating Trouble, Troubleshooting Chart

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TROUBLESHOOTING

SECTION 7-1

Overview

OVERVIEW

This section is intended to serve as a guide in checking possible problems that may occur with the operation of your granulator. SAFETY

The most important ingredient in any machinery operation is a constant adherence to sound safety practices. The best way to assure safety in any activity that involves troubleshooting or repairing the granulator is to retain complete control of the machine.

TURN OFF AND LOCK OUT THE POWER per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag out of Energy Sources). If this is not possible, have an electrician remove the fuses.

TEST EQUIPMENT

The use of quality test equipment cannot be over-emphasized when troubleshooting is required. Secure a good ammeter, one with a capacity of at least twice the AC and DC current that can be encountered in the machine. Use a voltmeter that has a minimum impedance of 5,000 ohms per volt on the AC scale and 20,000 ohms per volt on the DC scale. Popular combination meters, YOM and YTM, can provide the necessary functions.

LOCATING TROUBLE

When you are correcting malfunctions, it is recommended that you check the associated circuitry, and assemblies to ensure that there are no other defective devices. This practice assures that a premature replacement of a pan does not result in a repeat of the malfunction and possible damage to the new pan. Refer to the wiring diagrams and schematics for information about these pans. Full size assembly drawings and wiring diagrams specific to your unit are usually included with the manual but under separate cover.

Locating mechanical problems, should they occur, is relatively straightforward. When necessary, refer to Section 8, Pans Lists and Drawings.

TROUBLESHOOTING CHART

Troubleshooting procedures are listed in the table that follows. The first column lists the apparent problem or symptom, the second column contains the probable cause, and the suggested remedy is listed in the third column.

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Contents Sterling,Inc Refer to this Sheet When Ordering Parts Sterling, IncTable of Contents Settings and Adjustments Topic SECTION/PAGE Table of Contents Adjustable Rotor Knives…………………………………………………………………4-35 OperationMaintenance From previousMaintenance TroubleshootingParts Lists and Drawings Page What is a GRANULATOR? IntroductionLearn Machine Safety SectionFollow the Safety Instructions Rotating Knives Safety PlateOpening Hopper Safety Plate Guards Safety Plate Jackscrew Reversing OperationSafety Instruction Plate Hazardous Voltage Safety PlateRotating Knives Safety Plate Motor Rotation Safety PlateSafety Clothing & Practices Keep Your Work Area Safe Wear Protective ClothingKeep CO-WORKERS OFF the Machine Machine Opening Devices Be Sure the Rotor is Motionless Before Opening MachineSection Open the Cutting ChamberClear the JAM Restart the GranulatorMachine and Controls BP 2400 Series Granulator Right Front Quarter View BP 2400 Series Granulator Left Rear Quarter View Section Overview Uncrate the GranulatorAllow Adequate Work Space Section Move the Granulator to ITS Work SiteLevel the Granulator Remove the Protective Coating Electrical Wiring Section Check for Mechanical Interferences SET UP the Machine FunctionsCheck Rotation of Motors Interlock Switch Test Procedure Alternate Test for the Interlock SwitchesInstallation Alternate Test for the Interlock Switches from previous Test the Zero Speed SensorLubrication Test the Zero Speed SensorSettings and Adjustments Release the Cutting Chamber Fasteners Open the Cutting Chamber InterlockSee -10 page 87 for Cutting Chamber Opening Instructions Install the Rotor Locating PIN Remove the BED Knives Loosen the Mounting ScrewsRemove the First Knife Clamp or Shield Replace the Upstroke BED Knife Replace the Upstroke Knife ClampReplace the Downstroke Knife Shields GAP Adjustment TipsReplace the Downstroke BED Knife Check the BED KnivesCheck the Knife GAP Measure the Knife GAPSET the Downstroke Knife Shield Tighten the Screws to Final Torque Finalize Installation of Upstroke BED KnifeSee -11 page 88 for Cutting Chamber Closing Instructions Close the Cutting Chamber Safety Interlock Fasten the Cutting ChamberBasic Facts about the Knives See -10 page 87 for Cutting Chamber Opening Instructions Remove the Mounting Screws Lock the RotorRemove the Rotor Knives Clean Parts for Reassembly PhotoGAP Adjustment Tips Measure the Knife GAPCheck the Knife GAP Tighten the Screws to Final TorqueFasten the Cutting Chamber Remove the Drive Guard Cover Remove the Belts Install the Matched BeltsInspect the Drive Belts Tighten the Belt TensionCalculate the Allowable Belt Deflection Check the Pulley AlignmentMeasure the Belt Span Measure the Deflection ForceCompare Measured Force to Recommended Force Adjust the Belt TensionTighten the Motor Base Bolts Replace the Drive Guard Cover Setting and Adjusting the Chamber Jackscrew Cutting Chamber Open Setpoint Adjust the Jackscrew OPEN-POSITION Limit Switch SET the Jackscrew CLOSED-POSITION Limit Switch If the Motor Stops Before the Cutting Chamber ClosesSET the Jackscrew CLOSED-POSITION Limit SET & Test the Mounting Bracket Limit SwitchChamber Stops Before IT Closes but Motor Continues to RUN From previous Close the Cutting Chamber Safety Interlock Retract the Screen Cradle Retainers Cradle Open Position Adjust the Cradle OPEN-POSITION Limit Switch Check the Cradle CLOSED-POSITION Switch Close the Screen Cradle Retainers Adjust the Cradle CLOSED-POSITION Limit SwitchClose the Screen Cradle Interlock Zero Speed Sensor Operation Adjust the Sensor PositionZero Speed Sensor Control CircuitKnife Length Setting Rotor Knife Installation Into FixtureRotor Knife Preparation Knife Length SETTING-INSPECTION Adjustable Rotor Knife InstallationHydraulic Opening Position Switches Hydraulic Pump OperationOperation Check the Motor Rotation Direction Discharge AIR AdjustmentRUN the Motor Cleaning the Discharge Transition Shut Down the MachineSafely Clearing a Jam Maintenance Periodic Maintenance Schedule Check Daily Weekly MonthlyBelt Tension Knife Screw TorqueScreen Condition Infeed Flap Condition Upper Chamber Pivot ARM-SCREWSOpen the Screen Cradle Interlock Retract the Screen Cradle RetainersSee -12 page 90 for Screen Cradle Lowering Instructions Remove the Screen Replace the ScreenMaintenance Close the Screen Cradle Interlock Cutting Chamber Access Open the Cutting Chamber with Jackscrews Open the Cutting Chamber with HydraulicsClose the Cutting Chamber with Jackscrews Fasten the Cutting Chamber Lower Raising the Screen Cradle with Jackscrews Rotor Knife Sharpening BED Knife Sharpening Test Equipment Troubleshooting ChartLocating Trouble Section Mechanical Faults Problem Probable Cause Remedy Electrical FaultsBP2400 Series Parts List and Drawings 100 Parts Identification Drawing No. A-48050 Sheet 3 Parts Identification Drawing No. A-48050 Sheet 4 Parts Identification Drawing No. A-48150 Sheet 1 Parts Lists and Drawings Parts Identification Drawing No Sheet 1 Parts Identification Drawing No -460 Sheet 1 Wiring Diagram Drawing No. A-399598 Sheet 1 108 Drawing No -1 Sheet 1 Wiring Diagram for Hydraulics Drawing No. D-499061 Sheet 1 Wiring Drawing No. D-499044 Sheet 1 112 113