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Thank you for allowing us to provide your company with this SIM grinder. The instruction manual provides you with fundamental data of the design and operation of the SIM grinder that is essential to its correct handling and operation. Correct care and handling are basic conditions for optimum performance by your SIM grinder in terms of function and economy. Therefore, read the manual carefully before taking the grinder into service. To get an operation free from interference and with a low degree of wear, the grinder should be handled according to our instructions. Changes to or conversions of the grinder and its equipment are not allowed without a written consent from Wahlquist. To avoid personal injuries and grinder break-downs the instructions should be followed regarding maintenance, installation and service of the equipment. WAHLQUIST is not liable for possible damages which may occur due to repairs made by non-professional persons. All service and operational measures are to be accomplished by trained and qualified staff. We recommend you to carefully study the safety regulations before the first start up of the grinder. WAHLQUIST is, of course, ready to answer any questions regarding the equipment. We congratulate you on your choice of a SIM grinder. The right to alternations is reserved.

The SIM grinder

Is used when there is a risk of personal injuries. Is used when there is a risk for a break-down in the equipment. Is used to make information clearer. Entering the grinder is prohibited. All safety equipment must be mounted before the grinder can be started up. Before start, make sure that nobody is within the grinder working area. Maintenance, cleaning and service must, by no means, be accomplished during operation. The main switch must be off and locked during service and adjustments. The grinder must be cleaned and maintained regularly. The grinder may be used only for such types of material for which it is designed. It may not be overloaded. Service and maintenance of the equipment must be accomplished by qualified staff only. The equipment can be started up without previous warning. When performing electric welding, follow the instructions. Incorrect earthing can damage sensitive electrical equipment. Only qualified staff is allowed to operate the grinder.

The manufacturer, the employer and the operational staff are in different ways responsible for issues regarding safety and security matters. The safety regulations must always be observed to avoid unnecessary accidents and to make the work with the machine as safe as possible. Inadequate knowledge must not be the cause of an accident. Therefore, we advise you to study the instruction manual very carefully, before the machine is started up. Neither may lack of training be the cause of accidents, and so staff operating the grinder must be trained in its control , function and regulations. Repairs within areas having direct bearing on safety may be done only by those with approved skills. Work on the heavy current section of the system may be done only by authorized staff. The safety instructions stated here apply to all working with the machine. However, it does not imply that legal or otherwise applicable regulations can be disregarded. Rules, directives and regulations applying to occupational safety and health must always be followed in the relevant areas and work situations, as must road traffic legislation during transports. In planning and designing the grinder, great efforts have been made to prevent risks of accidents which can be envisaged to occur during its use. This applies to operational time and to service and maintenance time. In those special cases where it is impossible to eliminate accident risks in the design, safety equipment has been installed. These devices must under no conditions be dismantled before the starting of the grinder has been disabled. A qualified person must remove the starter key from the control cabinet and also switch off the main power. The starter key and the main power switch must be retained by a responsible person in such a way that they cannot come into the possession of any unauthorized person. The same precaution naturally applies to all servicing and maintenance. In those special cases where it is impossible to eliminate accident risks in the design or through safety equipment, warning signs are fitted. Signs are fitted to draw both authorized staff's and unauthorized persons' attention. In addition, some signs are compulsory according to the regulations and for that reason they should be kept clean and readable. The warning signs must under no circumstances be rendered illegible. If a sign should fall off, it must be replaced immediately. In conjunction with the delivery of a grinder, the training of the operational staff also takes place, in respect of Safety issuesOperationCare and maintenance It is the responsibility of the owner to ensure that, in case of staff changes, the new staff gets information and training. Wahlqvist - as the the supplier - is always at your disposal, so always contact us! Should the grinder be operated by untrained staff, Wahlquist disclaims all responsibility on matters of warranty and safety.

It is important to check the operating site before the machine is started, and it is the responsibility of the operator to ensure that nobody is within the working area of the machine. The grinder can be controlled remotely and any other staff than the operator is prohibited from being within the working area of the grinder. Check the operating and warning systems on the machine in conjuction with starting. If any function fails to operate, the machine should be stopped and the fault remedied before restart. During operation material can be ejected from the grinder and therefore unauthorized persons are not allowed to be within the operating area of the machine. The safety radius is 10 m all round. Operating staff, who for various reasons must be next to the grinder while it is in operation, should be aware of the risks. Remember that material can fall over the edges during loading. Always wear a helmet and other safety equipment prescribed. Absolutely forbidden during operation to help out feeding in the infeed hopper to climb up unto the grinder or machine housing to stand close to the feeding hopper to load above the level of the hopper and to use the grinder for other materials than those for which it is intendend. Pay attention to the machine instruments and warning systems. In case of an alarm, the machine must be stopped immediately and the fault remedied before restart. Never leave the machine running unsupervised. The operating functions must be made inaccessible to unauthorized persons, when work is over. Lock the operating panel or machine room. Alternatively, the main power switch or possible safety switches can be locked. In case of diesel-powered machines the current should be cut and the keys removed.

The warranty period comes into force on the day of delivery stated in the warranty conditions. For constituent parts of the machine, components or systems supplied by subcontractors, the terms of the latter's warranty apply. Wahlquist is not responsible for any personal injury, property damage, expenses of various kinds or lost profit in conjunction with opertion of the warranty. The warranty only applies on the assumption that the machine has been operated normally, cared for and repaired in accordance with instructions issued and that service has been performed at the right time, and that only original spareparts have been used. Alternations to speed and hydraulic pressures may not be made in addition to those indicated by Wahlquist. The staff must have undergone Wahlquist's training programme and studied the contents of the instruction manual and the safety regulations to be entitled to operate the grinder. The warranty does not cover normal wear parts such as grinder and counter knives, wear plates, drive belts, conveyor belts, filters, grinder shaft rings, etc. WAHLQUIST VERKSTÄDER AB

The SIM type OC (Open Center) grinder shreds various types of organic matter such as wood, paper, plastics, tyres, building material, industrial and domestic waste and scrap timber waste. A rotating shaft crushes the waste into pieces. A rotating shaft grinds the waste, and the size of the pieces can be determined by a hydraulic and stepless change of the counter knife bracket also during operation. The crushed material is fed onto an integral conveyor for further transport out of the grinder. The conveyor has two operating positions. The grinder is dimensioned for handling elements of impurities that are hard to grind. To avoid damages on the grinder, always be careful when sorting out uncrushable material such as stone, iron, etc. The grinder can be fed in various ways, by crane, lorry or conveyor. The conveyor is connected to the grinder's longitudinal side so that the material will be distributed along the shaft of the grinder. The safety regulations shall always be followed. All ways of feeding require an even and continuous flow. Do not overfill the hopper; load in batches so that the shaft always has material to treat. Overfeeding the grinder may result in unwished reversions. The rotation speed of the prime mover is not allowed to exceed 1800 rpm. The quantity of batches fed must be tested from case to case, but if the grinder often reverses it is, in most cases, a result of overloading. Depending on the specific weight of the material it is not always necessary to have the pushers working. At such occasions the pushers are to be run to their resting position.

The SIM grinder is built around a massive beam framework where all units are mounted and mechanically connected. The construction enables different variations and complements, either mobile or stationary. The grinder has two types of drive sources, electric motors and diesel engines. The drive source in connected to the shaft by means of a flexible coupling and a patented reversible and overload protected gear. In the diesel version the engine is integral. By means of generously dimensioned doors and hatches it is easy to access for daily inspections and service. The fuel tank (diesel) is dimensioned for several shifts and is placed low for easy access and quick refilling. To minimize the quantity of dust and cooler/engine compartment soiling, all cooling air passes through fine, easily cleanable mesh screen sections. The long sides of the grinder and its specially designed ends form a infeed hopper made of hard-wearing shet metal. In addition to the counter knifes, a pusher is mounted along the counter knife bracket. This unit pushes the material against the shaft. The pusher works hydraulically. The counter knife bracket is resiliently suspended to minimize the risk of larger damages, if uncrushable material is fed into the grinder. The bracket can be hydraulically turned for easy access during service. The grinder shaft is mounted into the lower part of the grinder. Transverse, hardened teeth are helically mounted on the rotating shaft. Parallel to the crushing shaft, a counter knife shaft is mounted into the counter knife bracket. It is provided with teeth passing through the knives of the grinder shaft. The counter knife teeth have three wearing surfaces, which can be turned forward, if needed. The clearance between the grinder shaft and the counter knife shaft can be steplessly adjusted hydraulically, thus allowing the required size of the fraction on every occasion. The grinder is controlled from a control cabinet (alternatively remote controlled) where all contol units, warning functions and instruments are located.

The material is loaded into the hopper and falls down against the rotating grinder shaft. A hydraulically operating pusher pushes the material down against the grinder shaft. The teeth of the grinder shaft grab hold of the material and carry it against the counter knife shaft. The teeth of the grinder shaft and the counter knife shafts pass between each other, the material is crushed and falls down to be subsequently fed onto the conveyor belt. The size of the fraction is determined by the clearance between the grinder and counter knife shafts. By means of a manual hydraulic control the clearance against the grinder shaft is set, and can be adjusted continuously to the required fraction size. The setting of the fraction size can be adjusted during operation and allows the material to be mixed to its own formula for the optimum final use. A monitoring system protects the machine from overloads. The grinder shaft rpm are regularly checked and, if they fall below a certain level, due to blockages, the gear reverses the direction of rotation. The shaft reverses and disperses the blockage. After four attempts at reversing, the drive is disenganged, the engine rpm set to idling and warning lamps on both sides of the grinder flash. Before restarting, the operator must check the cause of blockage, for example that no uncrushable material has been loaded into the hopper. In order to minimize the risk of a tooth fracture the grinder is equipped with a mechanical safety coupling. If uncrushable material comes between a grinder tooth and a counter knife, the counter knife bracket is displace rearwards and downwards. An opening of 250-300 mm is formed along the entire length of the grinder shaft. The uncrushable material falls down on the conveyor belt and is removed from the grinder. The counter knife bracket automatically returns to its default position. The coupling is a safety measure that does not eliminate the need to remove uncrushable material when loading, as far as possible.

VOLVO TD 100 164 kW (223 hp) DIN. Type 1500 VOLVO TWD 1211 302 kW (410 hp) DIN. Type 2000 - 3500 Enclosure that protects the engine and gives a lower noise level. The cooling air of the engine passes over an easy to clean mesh filter. Fuel tank, volume approx. 700 litres. Power transmission Reversible spur gear with infinitely variable torque limitation, disengageable and overload protected. Flexible coupling between engine and gear.Automatic reversing unit for grinder shaft. Grinder shaft speed approx. 140 rpm Hydraulic system Circulation pumping systemAxial piston pump mounted directly on the engine, alternatively a gear wheel pump.Belt-driven gear wheel pumps.Thermostatically controlled hydraulic oil cooler. Hydraulic tank, volume approx. 160 litres. Electrical system Operating voltage 24 V, batteries: 2x105 Ah.Operating and monitoring functions mounted in an integral operating panel.Power socket for connection of work lamp.Electronic control system for grinder operation.Automatic or manual operation of grinder functions. Lubrication system Central lubrication supplemented with manual lubrication. Framework Framework of profiled tubes.Transport width 2400 mm.Transport height approx. 2350 mm. Hopper Manufactured from special wearing sheet.Load-detecting, automatic hydraulic load pusher which works inwards and downwards above the grinder shaft.Counter knife shaft and pusher are mounted in a pivoting craddle. Robust grinder shaft of toughened steel. Replacable grinder teeth, hardened for optimum wearing strength and toughness, weldable for re-use. Mounting rings of wearing steel. Counter knife teeth in the form of shaft mounted rotatable rings with three available wearing surfaces, weldable for re-use. The counter knife bracket is hydraulically adjustable for the required size of fraction beginning from approx. 50 mm. An infinitely adjustable safety coupling minimizes the risk of tooth fracture if uncrushable material enters the grinder. There is an integral hydraulically driven outfeed conveyor along the entire lenght of the grinder shaft. Rearwards extendable approx. 810 mm. There are four lifting eyelets for lifting the grinder. SCANIA or CATERPILLAR diesel engines. Remote control INFRALINK Extra hydraulic functions Lastväxlarlarm. Mechanical support legs for siting the grinder at a suitable working height.

Outputs: 160-315 kW Grinder type: 1500-3500Degree of protection: IP 54Separate prime movers for hydraulics, conveyors, etc. Power transmission Reversible gear provided with a infinitely adjustable moment delimiter, freewheel clutch and overload protection. Flexible coupling between motor and gear.Automatic reversing unit for the grinder shaft. Grinder shaft speed: approx. 140 rpm. Hydraulical system Circulation pumping systemSeparate electaric motor with direct mounted gear wheel pumps.Thermostatically operated hydraulic oil cooler.Hydraulic tank, volume approx. 160 litres. Electrical system Operating voltage 24 V (DC).Operating and monitoring functions are mounted in an integral control panel.Power socket for connection of work lamp.Electronic control system for grinder operation.Automatic or manual operation of grinder functions. Lubrication system Central lubrication, supplemented with manual lubrication. Framework Framework of profiled tubes: Conveying width 2400 mm.Transport width: approx. 2600 mm. Hopper Manufactured of wearing sheet.Automatic hydraulic load pusher which works inwards-downward above the grinder shaft.Counter knife shaft and pusher mounted in a pivoting cradle. Robust grinding shaft of toughened steel. Replacable grinder teeth, hardened for optimum wearing strength and toughness, weldable for reuse. Mounting rings of wearing steel. Hardened, weldable counter knife teeth in the form of shaft mounted rotatable rings with three available wearing surfaces, weldable for reuse. During operation the counter knife bracket is hydraulically adjustable for the required fraction size beginning from approx. 50 mm Infinitely adjustable safety couping minimizes the risk of tooth fracture if uncrushable material enters the grinder. An internal electrically operated outfeed conveyor along the entire length of the grinder shaft, rearwards extendable approx. 810 mm. There are four lifting eylets for lifting the grinder. Various motor manufactures and protections classes/degrees. Remote control INFRALINK Extra hydraulic functions. Mechanical support legs for siting the grinder at a suitable working level.

The grinder has a mechnical transmission signifying that the engine/motor is connected to a reversible gear by means of a flexible coupling. The grinder shaft is directly connected to the gear. Auxiliary units such as hydraulic pumps are operated from the motor by belt transmissions or by separate motors. The drive is monitored by a rpm-detecting system that electro-hydraulically controls functions such as reversing, stopping, etc. The operating conditions that apply to a grinder imply a number of requirements for the transmission, for which reason the machine is equipped with a special 2-stage reduction gear. The gear ensures a high degree of efficiency for the output supplies and is dimensioned for high impact resistance. It can be set to a neutral position, i.e. the grinder shaft is not entrained(no output is transmitted during engine/motor starting). In case of overload or blockage the gear reverses and reverts without unnecessary stopping times. The gear can be torque-limited, i.e. it is possible to use holding brakes to select a maximum permitted torque and thus avoid damage.

Transmission

The engine/motor in started, the gear break discs are unactuated and no drive force is transmitted to the grinder shaft (neutral position) See figure. The engine/motor rpm increases; in diesel operation 1700-1800 rpm and in electrical operation approx. 1500 rpm. The brake is activated and one of the brake discs is locked. The power is now transmitted to the grinder shaft wich reaches its working rpm. The pusher in the infeed hopper and the conveyor start working. In the event of blockage, the engine/motor gives its highest torque. Should it be insufficient, its speed will drop. In electric motor operation the rpm are lowered, when the brake disc begins to slip on the brake. The inductive sensor, which is mounted on the grinder shaft, detects the rpm and sends a signal via a time relay to the directional valve for the brake. The inductive sensor detects this drop and sends a signal that alters the position of the directional valve of the brake, the locked disc is released and the the free one locked. The grinder shaft reverses. The pusher valve (Diesel Pos 23, El Pos. 20 in the hydraulic diagram) is activated so that the pusher rises and remains in its upper position. If the reversing disperses the stoppage, the sensor will give an all-clear signal to the pusher and the gear brake to return to its normal position. If the stoppage cannot be remedied when the machine reverses, three more attempts will be made before the monitoring system raises an alarm and stops operation. Before a new attempt to restart, the causes of the operational stoppage are to be examined and remedied, the reasons may be uncrushed material or an overfilled infeed hopper.

On delivery the machine is set and adjusted according to the conditions applying to the stated area of application. Alternations to set pressures and flows may affect strength and service, so always contact Wahlquist before making any alternations. This work may be done only by skilled staff who have received SIM training. Wahlquist disclaims all responsibility for unapproved alternations. In all pressures and flow settings the hydraulic oil should be at operating temperature, with due consideration also given to its cleanliness. The figures stated for components in the descriptions of pressure settings are the same as on the hydraulic diagram. The letter D in front of a number indicates diesel powered machines.

Trottle non-return valve

Setting of brakes The adjustment in important for a gentle brake engagement. Idle the engine/motor. Loose the Allen screw in the knob on the trottle non-return valve. Shut the valve completely for the forwards operation position. Open the valve half a turn. Start the drive for grinder shaft forwards manually (do not use Auto) or press the slide on the electric valve manually (10-D11; the small button at the end of the valve). Measure the time from the activation of the contact cylinder until the break linings are pressed against the brake disc. This should take some 2 seconds from the maximum outer position. Adjust the trottle non-reverse valve if necessary, clockwise rotation increases the time, anti-clockwise decreases it. Tighten the Allen screw. An excessively long contact time may cause the grinder to reverse when starting. Check the time as the linings wear, since the stroke length of the cylinders thus increases. The machine shoud be operated at working rpm and in automatic mode. Connect a 250-bar manometer to the measuring outlet on the valve (10-D11).Start the machine, and read the manometer. Lock the nuts. If the pressure needs to be adjusted, loosen the locking nut of the pressure limiter (9-D10) and turn the setting screw carefully outwards in order to reduce the pressure and inwards in order to increase it. Stated pressures only serve as guidance; set values are given on the machine card. The machine should be run clear and empty before pressure settings.

The stated pressures are a guide. Set values are given on the machine card and should always be adapted to the material and the working conditions. Contact Wahlquist for information about the recommended pressures for materials and machine type. Do not exceed recommended pressures. Excessively high force downwards may damage the grinder shaft. Idle the engine/motor, connect a 250-bar manometer to the measuring outlet (17-D20).Remove the steel caps that cover the setting screws on the reversing valve (19D22) and screw in the setting screws in both sides.Run the machine in the automatic mode. Activate the pusher. The electric valve and the pressure limiter (16-D17) are engaged and the pusher descends.Set the pressure limiter to the required value.Alternatively, the reversing valve can be run manually, press the control button at the side of the valve that gives the down position.Contact Wahlquist for recommended pressures for materials and machine types. With the pusher in its lowest position the pressure of the reversing valve is set.Slowly screw out the adjuster screw on the side that gives the downward position until the pusher reverses, a sharp noise will be heard from the valve.The pusher now rises and stops in its uppermost position.Set the recommended pressure on the pressure limiter (16D17). Read the pressure on the manometer. Screw the adjuster screw for downwards position on the reverse valve. Screw until the pusher begins to descend.Lock the adjuster screw on both sides.Turn the pressure limiter (16-D17) setting screw 0,5-1 turn and lock it.In case of pressures excessing 160 bar the automatic mode may not be used during the settings. Do not exceed recommended pressures. Excessively high force may be harmful to the grinder shaft.

Plug the outlets (A-B-port) on the hydraulic motor directional valve (D18).Connect a 250 bar manometer to the measuring outlet. Idle the engine and activate the conveyor operation. Loosen the locking nut of the pressure limitation valve (D17). and turn the screw until the meter shows the pressure stated on the machine card. Lock the nut.The pressure set may under no circumstances exceed the value stated on the machine card.Conveyor pressure limiters apply only for diesel operated SIM grinders.

Alternation of set pressures may only be done when it is inevitable for some reasons. Normally there is no need to touch the valves. Dismount the valve (14-D15/24-D25) or remove the plastic plug from a new valve.Connect the valve to a pump or a porto-power, R½" connection and pump slowly until the valve opens.If an adjustment is needed, loosen the valve and slacken the locking screw. The valve is altered by approx. 80 bar per turn. Tighten the locking screw, reconnect the valve and check that the value is correct, if not - re-adjust.

It is important to check the operating site before the machine is started. It is the responisibilty of the operator to ensure that nobody is located within the operating area of the machine. The grinder can be controlled remotely and any person other than the operator is prohibited from being within the operating area of the grinder. Check the operating and warning systems of the machine in conjunction with starting. If any functions fail to operate, the machine should be stopped and the fault remedied before re-starting. During operation material can be ejected from the grinder and therefore no unauthorized person may be within the operating area of the machine. The safety radius is 10 M all around. Operating staff who, for various reasons, have to be next to the grinder should be aware of the risks. Remember that material can fall over the edges during loading. Always wear a helmet and other safety equipment prescribed. Absolutely forbidden during operation To help out feeding the hopper by poking with loose objects. To climb up onto the grinder or machine housing.To be located close to the infeed hopper.To load above the hopper edge level and to crush other material than such for which the grinder is designed. Pay attention to the machine instruments and warning systems. When an alarm is released the machine must be stopped immediately and the fault remedied. Never leave a running grinder unsupervised. When the work is over, the operating functions must be made inacessible for inauthorized persons. Lock the operating panel or the machine room. Alternatively, the main or safety switch can be locked. In case of diesel-powered machines the current should be cut and keys removed.

All operating functions, gauges and warning lamps are located in the panel. By pressing the ON button, a function will be started, which is disengaged by the OFF button.The conveyor is started and stopped by means of the same button (as in manul operation). Auto ON Automatic operation Manual forwards Grinder shaft in forward position, manual operation Pusher ON Manual pusher operation Reset 4-reverse attempts Alarm resetting after operation stop (cannot operate forwards) Working rpm ON Diesel engine working rpm Interlock preheating Start interlocking and engine pre-heating, keep depressed until starts. Reset alarm Manual reset. Warning lamps that light up for low hydraulic oil level, high temperature, alternator and engine fault. "3" on a button indicates that the function is extra/optional. The buttons are installed on customer's wish and are not available as standards. Extra hydraulics and remote control are activated and deactivated by "Remote control" button.

Perform daily service according to instructions in the chapter on Maintenance. The safelty regulations are always to be observed. Before work, check that: The battery disconnector is in OFF position.The emergency button is depressed.The key switch is in the 0 position and the key is removed.The regulations for the engine and other equipment enclosed should be followed.Before start, check that nobody is in the proximity of the grinder, motor and conveyor or is located within the risk area 10 m all around the grinder. Reset the emergency stop and close the battery disconnector. Press the interlocking button and keep it depressed.After 40-50 sec. turn the starter key to position S (start). Release the key as soon as the engine starts (spring loaded).Keep the interlocking button depressed until the engine indicator lamps go out. The engine pre-heating is engaged by the interlocking button. For cold weather starting, etc, refer to the motor instruction manual.Run at idling speed for a few minutes, until the gauge shows that the cooling water is beginning to get warm.Press the conveyor's start button to ON position and allow it to run meanwhile. Never increase directly to working rpm as long as the motor and hydraulic system are cold. Nor load the machine before it is warm. Press the button WORKING ON and when the engine rpm have increased, press the button AUTO ON. The pusher, the grinder conveyor (if not started previously), and the reversing and monitoring systems are now engaged automatically and the engine operates at 1700-1800 rpm. All function can be run manually. Press the relevant ON OFF button.The monitoring system is disengaged during manual operation.

Run the grinder clear of all material to avoid starting problems due to frozen materials, etc.Press AUTO OFF button Press the working rpm OFF button. Allow the engine to idle to cool down the engine and turbo.Turn the key switch to the 0-position. During longer stoppages, open battery disconnector, position OFF. When work is over for the day, the machine is to be left so that it cannot be started by an unauthorized person. Lock hatches and control cabins, remove the starter key and knob for the battery disconnector. After the drive motor has been stopped the grinder shaft will rotate a short while. It is the responsibility of the operator to check that nobody is within the working area of the grinder.

There are two emergency stop buttons and one engine stop button on the diesel-powered grinder. The emergency stop buttons are placed on boths sides of the grinder. One stop is pre-mounted, the other one is delivered unmounted and connected to a cable for appropriate mounting in terms of height and access. In an emergency situation, press the emergency stop button. The manual stop control, which is mounted next to the control box, should be pulled straight out to its end position to stop the diesel engine.

Control panel - electrical operation

All control functions, gauges and warning lamps are located on the panel. Pressing the ON-marked button starts a function, which is engaged with the OFF button. In manual operation the conveyor is started and stopped with the same button. Auto ON Automatic operation Manual forwards Grinder shaft in forward position, manual operation Pusher ON Manual operation of pusher Reset 4-reverse attempts Alarm resetting after operating stop (cannot operate forwards) Reset alarm Manual reset Warning lights are switched on for low hydraulic oil level and high hydraulic oil temperature. "3" on a button signifies that this function is for an item of extra of optional equipment. The buttons can be mounted according to the customer's wish and there are no standards. Extra hydraulics and remote control are activated and switched off by the Infralink button.

Perform daily service according to the instructions in the chapter on Maintenance. The safety regulations are always to be observed. Check the follwing items before starting the work: Operating safety switch is in the OFF position.The emergency stop button is depressed.The control cabinet is locked and the key is removed.The regulations enclosed for the motor and other equipment shall also be followed. Check before starting that nobody is in the proximity of the grinder, motor och conveyor or that nobody is within the risk area 10 m around the grinder. Reset the emergency stop and other switches. Turn-press the main switch and/or the operating switch, check that any indicator light is lit indicating that the current is on.Press the start button, then release it (spring-loaded). The motor will now start as do the hydraulics and conveyor motors. The indicator lamp should be lit. Allow the motor and hydraulics to run for a few minutes in order to warm up.Do not load the motor with a cold hydraulic system. Wait until it has been warmed up a little and then run one of the hydraulic functions for an instant. Press the AUTO ON button The pusher, grinder conveyor (if not started earlier), reversing and monitoring systems are engaged automatically. All functions can be run manually. Press the relevant ON-OFF button.The monitoring system is desengaged during manual operation.

Run the grinder clear of material to avoid starting problems due to frozen materials, etc. Press the AUTO OFF buttonPress the stop button for the motorTurn-press the main switch and/or operating switch. When work is over for the day, the machine is to be left so that it cannot be started by any unauthorized person. Lock switches, hatches and the control cabinet. After stopping the drive motor the grinder shaft will continue rotating for a while. It is the responsibility of the operator to check that nobody is within the working area of the grinder.

There are emergency stops on both sides of the electrically powered grinder. One is mounted into the electrical cabinet, the other one is on the pole next to the tank. Press the emergency stop button in an emergency situation.

Set the main or safety switch to the 0-position and lock it to avoid accidental starting. Remove the keys and keep them out of the reach of others than the repair staff. Works involving heavy current and other electrical equipment may only be performed by trained and authorized persons. The engine should be stopped and the battery disconnector shall be in the OFF position and the knob/starter key removed. During trouble shooting and testing when the machine is in operation the staff involved shall be notifiedthe work site shall be palced under special supervision with regard to the access of unauthorized persons. Before dismantling heavy components, use alxe stands or the like to eliminate risks for crushing. Use tools with the correct fit. Wear safety goggles when grinding and working with tools that can shed chips. Do not dismantle pressurized hydraulic systems as there is a risk for dangerous needle jets. The following rules are to be observed when welding: Switch off the main current.Pull out the connectors for electronic equipment.Earth as close as possible to the welding site for optimum result and to avoid damages on bearings, etc. To avoid sparking and risk for fire when jump-starting the diesel engine, ensure that one of the starter cables is connected to the positive poles of the battery, and that the other cable is first connected to the minus pole of the auxiliary battery and thereafter to the chassi of the grinder at a safe distance from the battery. Oils can cause allergies in certain individuals, especially in direct skin contact. Therefore we recommend you to carefully read the instructions on the product packages and follow them. Use the correct safety equipment and replace oily clothes and gloves. Always stop the machine before topping up with oil or fuel. Check after filling that plugs and caps have been correctly tightened. Never use damaged and incorrect plugs and caps. Oils are filled to the level marks or volumes indicated without any extra drops. The marks are calculated to allow sufficient space for the warm oil to expand. As there is a risk for slipping, spilled oil should always be wiped off handles and floors, etc. Check the ground under and around the machine after filling. Even small quantities of oil can contaminate wells and watercourses. Be aware of the fire risk when re-fuelling; do not smoke during such operations. Due to the explosion risk, do not mix petrol or alcohols with the oil. Do not overfill fuel - leave room for expansion. No maintenance may be performed before the motor has been stopped and the battery disconnector is disengaged. The emergency stop button is pressed down. The starter key is in the 0-position and the key is removed.

Some components or systems, such as motor and central lubrication, are delivered with their own instruction manuals. The service intervals and instructions given are always to be followed. Instructions enclosed for motor and other equipment shall also be followed. Each interval is dealing solely with those items that are relevant to it. A complete service also comprises the previous service items which are added. Example: A 400-hour service includes 8-hour + 50-hour + 200-hour + 400-hour service. The grinder is equipped with a central lubrication system which operates fully automatically. The system lubricates a.o. the cylinder lugs and pins. Only a few lubrication points require manual lubrication. Indicator lights for the system operation are fitted on the instrument panel. For their mode of operation and other information, refer to their manual. The quality should at least be equivalent to the recommended standards. Reversible gear ISO VG 320, synthetic gear oil. Also refer to the grade shown on the plate fitted on the gear. Hydraulic oil See SMR standard, Swedish Standard SS 155434SHS 46 down to -10°SHS 32 at lower temperatures long term. Alternatively, a multi grade oil can be used. Motor oil CD or MIL-L-21904C-D Refer to the engine manual Coolant Refer to the engine manual. Central lubrication Chassis grease (refer to enclosed manual). Bearings SKF bearing grease LGEP2 or equivalent. To maintain high operational reliability of the hydraulic system and avoid unnecessary costs, cleanliness is the most important factor in all handling of oil and components. Plug hose and cover the components during repairs. All topping up of oil shall be done across the filter. Cooling air intakeClean the intake when necessary. Diesel engine, oil and coolant levelRefer to engine instructionsFuel levelNever allow the tank to get empty.Refers only to diesel engines. Indicator for the engine air filterWhen the indicator shows red, replace the filter(s).Refer to the engine instructions. Diesel only.Oil leakageCheck that there are no oil leakages.RubbishClean the grinder from rubbish, etc. that can increase the risk of a fire. Oil coolerBlow the oil cooler clean approx. 20-30 sec.Press the switch, the cooling fan will then blow "backwards". Always keep the hydraulic oil cooler under careful supervision.

Brake linings

Hydraulic tank

Oil levelCheck the gear oil level The oil should be halfway up the level glass.Brake linings (see figure)Check the brake linings of the gear box.Se separate replacement instructions. Replace the lining when 4 mm remains. Counter knife and grinder shaftCheck counter knives and grinder shaft teeth.See replacement instructions. Hydraulic oil level (see figure) Check that the hydraulic oil level is visible in the tank sight glass.There is a warning lamp fitted on the instrument panel indicating an excessively low level.The engine connection cablesCheck the engine connection cables, and tighten if necessary.Pay special attention to fuel lines and turbo connections. Diesel only.BatteriesThe electrolyte level in the batteries should be 10 mm above the plates.Top up with destilled water.Only diesel engine.Hydraulic components and connectionsCheck that hydraulic components and connections are tight.Replace the return filter insert for the hydraulics after the first 50 hours of operation. Diesel only. Diesel enginesSee the engine instruction manual V-beltsCheck that the V-belts are correctly tensioned for the engine and hydraulic pump(s).

Reversible gear

Diesel engine Refer to engine instruction manualGear box Replace the gear box oil, clean the magnet plugs.Use synthetic ISO VG320 gear box oil. Alternatively, use the oil grade stated on the gear box type plate.Volume, see machine card enclosed. Only diesel engines Diesel enginesRefer to engine instruction manual.

Engine and hydraulic oil cooler

Diesel engineRefer to engine instruction manualMotor and hydraulic oil cooler (see figure)Clean the engine and hydraulic oil cooler.Keep the blades clean for an effective cooler operation. Wash with an oil-solvent agent and blow with compressed air. Return filter insertReplace the return filter insert for the hydraulic system.Ventilator Replace hydraulic oil tank ventilator.Electric motorsBlow the electric motors clean.

Grinder shaft

Annual maintenance: Diesel enginesRefer to engine instruction manual. Fuel systemCarefully check that the fuel system is tight, and the degree of wear on hoses and pipes. Diesel only. Electric systemCheck the electric system, suspensions and wear.Hydraulic systemReplace the oil in the hydraulic system.Use oil of the correct viscosity for the temperature range within which the grinder works.Refer to the section on oil grades.Grinder shaft (see figure)Replace the grease in the grinder shaft bearings.Loosen the bearings caps, remove the old grease and replace with fresh.Grease: SKF LGEP2 or equivalent.

Before this operation, check that nobody is within the risk area. If necessary, put up signs indicating "Maintenance in progress". Observe the safety regulations.Run the counter knife bracket to its end position; this is no necessary step, but it will increase the working space in the hopper. Position the shaft for easy access when replacing/grinding the grinder tooth.Stop the engine Diesel engine Open the battery disconnector.Remove the starter key.Press the emergency stops. Electric motor Open operating and safety switch.Press the emergency stops.Lock switches or control cabinets, remove the key. If the counter knife bracket has been run out, it should be mechanically locked in its extended position in such a way that no accident can occur. Loosen the two Allen screws (M24) and remove them. Knock the loose tooth if necessary and pull it straight out. Fit a new tooth. When fitting a new tooth, first check that the tooth seat in the shaft is clean. Drop some Loc-Tie 242 on the Allen screws and tighten them to 100 kpm (approx 1000 Nm oiled screw). Start the engine, and retract the counter knife bracket.

Counter knives

The shape of the counter knives allows three wearing surfaces, with the counter knife shaft being rotated one division to make use of a new wearing. Before this operation, check that nobody is in the risk area. If necessary, put up signs indicating "Maintenance in progress". Run the counter knife bracket to its end position.Switch off the engine/motor. See Alternation or grinding of grinder shaft teeth. Observe the safety regulations. The counter knife bracket should be mechanically locked in its extended position in such a way that no accidents can occur. Loosen the centre screws that retain the bracket, on at each end (Allen M36, torque approx. 200 kpm). Loosen the stop screw some turns Allen (M16) Apply the tool (2-13122) and screw the threaded rod in position in the end of the key. Turn the tool nut until the key lets go and can be retracted. Turn the counter knife shaft to a new position. Grease the key and knock it into position with a soft mallet. Use Loc-Tite 242 on the stop screw and apply it.Tighten the centre screws.Tightening torque 200 kpm (approx. 1960 Nm)Start the Engine/motor, and retract the counter knife bracket.Observe the safety regulations and rotate the grinder shaft manually, check that the teeth passes between each other without any noise.

Surfacing

Before this operation, check that nobody is in such a place where there may be a risk of an accident occuring. Grinder teeth are advisably welded at a workshop if several teeth are replaced regularly. The job can also be done at site in the grinder. For optimum economy the teeth should be allowed to wear a maximum of 4-5 mm before hard-facing. Heavily worn teeth whose profile must first be built up from a softer base and then hard-faced, generally have an impaired service life. Do not hard-face more than necessary to obtain the recommended final dimensions, unnecessary subsequent grinding is time-consuming. The above also applies to the counter knife teeth. Filarc 6154 for priming.Castolin 6710 or equivalent for hard-facing electrodes. Recommended pre-heating 100-150 C. Use only dry electrodes.Run the counter knife bracket to its end position.Swith off the engine/motor. For instructions, see "Alternation and grinding of grinder shaft teeth". Observe the safety regulations. The counter knife bracket should be mechanically locked in its extended position in such a way that no accidents occur. Brush the welding area clear of all loose material.Wipe off all moisture. Then lay a wear layer on top and when necessary, at the sides, with Castolin 6710. First prime with Filarc 6154.Grind to the finished dimensions and be careful with the width mesurements to avoid grinder and counter knife teeth knocking against each other.Rotate the grinder shaft manually and check that the teeth pass between each other without any noise.Do not weld in cold and damp weather, as there is a the risk of cracking under such conditions.

Brake linings

The linings are replaced when approx. 4 mm remains. Use only originals parts. Observe the safety regulations.Loosen the guide pins (4 pcs) and pull them out at least 30 mm. Lift off the brake linings, directly upwards. Clean the brake lining seats and check that the brake yoke is laterally mobile. Fit the linings and tighten the guide pins.Check that the guide pins move easily after tightening.

Diagram, central lubrication

Diagram, central lubrication 2

Hydraulic cylinder seals

The instructions apply to Stacke hydraulic cylinders. The work does not require special tools and can be done by means of normal workshop equipment. Always clean the hydraulic system carefully before installation and check that it is equipped with an oil cleaning filter. Replace oil and filter at recommended intervals. The positions indicate the following items: Wiper Piston rod sealSupport ring O-ring Support ringO-ring O-ringGuide ring Support ring Lock ring RI Piston rod seal When replacing packings, the following steps are to be taken: Drain the oil from the cylinder into a collecting vessel. Loosen the guide nut, alternatively the bolting washer. draw out the piston rod of the cylinder tube and remove the piston rod seal from the piston block.If the piston block is locked by a crosswise mounted bond, this is to be dismantled. Otherwise the piston is fitted by a thead locking fluid, which shall be slowly heated to approx. 200-250 C. Now the locking function of the fluid is eliminated and the piston block can be dismounted. Then dismantle the steering block and its seals. Clean all components carefully.Check the condition of the cylinder seals.Fit the new seal carefully. Do not use any hard objects.Oil the seals before re-fitting onto the piston rod and cylinder.Wash the piston threads and piston block clean of grease before applying new locking fluid.The locking fluid is applied onto the piston rod thread in its longitude direction with a thread. The curing time of the locking fluid is 4-12 hours.Refit the piston rod in the cylinder tube and fit the cylinder.The oil should preferably be replaced in conjunction with seal replacements.

Hydraulic oil is too hot Clean the cooler. Low hydraulic oil level Incorrect pressure settings. Top up with oil. Fuel shortage Venting and topping up with fuel. Water temperature too high Clean the cooler.Clean the air intake.Check the fan belts. Low oil pressure Check the oil level. The belt slips Check belt tension. Electrical fault Check current supply to the operating valve. Hydraulic fault Check the pressure.Component fault. Brake linings worn Minimum thickness 4 mm. Hydraulic fault Check the cylinder. Oil on the brake discs Check possible leakage Sticks Mechanical fault Hydraulic fault Check cylinders Hydraulic fault Electrical fault Fault on control unit.Adjust backtids-relay. Inductive sensor broken. Electrical fault Fault on control unit Engine/motor rpm drop dramatically, or engine/motor stops. Brake slipping, pressure check.Incorrectly adjusted torque.Check that AUTO ON is activated. Brakes Check that brakes apply