Cumberland U-Series User manual

U-Series Thermoforming Granulator
Models: 44U, 56U & 74U
Part Number: U-0040-C
Bulletin Number: CG6-625
Effective: May 6, 2009
Write Down Your Serial Numbers Here For Future Reference:
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We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.
DCN No. ____________
© Copyright 2009 All rights reserved.

U-Series Thermoforming Granulators ii
Shipping Info
Unpacking and Inspection
You should inspect your granulator for possible shipping damage.
Thoroughly check the equipment for any damage that might have occurred in transit, such as
broken or loose wiring and components, loose hardware and mounting screws, etc.
In the Event of Shipping Damage
According to the contract terms and conditions of the Carrier, the responsibility of the
Shipper ends at the time and place of shipment.
Notify the transportation company’s local agent if you discover damage.
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization.
File a claim with the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.
Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.
If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. You should have:
;Granulator
;Bill of lading
;Packing list
;Operating and Installation packet
;Electrical schematic and panel layout drawings
;Component instruction manuals
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.
If the Shipment is Not Correct
If the shipment is not what you ordered, contact the shipping department immediately. For
shipments in the United States and Canada, call 1 [phone]; for all other countries, call
our international desk at [phone]. Have the order number and item number available.
Hold the items until you receive shipping instructions.
Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.

U-Series Thermoforming Granulators iii
Table of Contents
CHAPTER 1: SAFETY ...............................................................5
1-1 How to Use This Manual.............................................................................................5
Safety Symbols Used in this Manual.....................................................................5
1-2 General Safety Regulations ........................................................................................6
1-3 Responsibility..............................................................................................................6
1-4 Warnings and Precautions..........................................................................................7
CHAPTER 2: FUNCTIONAL DESCRIPTION ............................9
2-1 Models Covered in This Manual..................................................................................9
2-2 General Description.....................................................................................................9
2-3 Typical Features and Components ...........................................................................10
Hopper.................................................................................................................10
Cutting Chamber .................................................................................................10
Drive System.......................................................................................................10
Discharge System...............................................................................................10
Base....................................................................................................................10
2-4 Safety Features.........................................................................................................11
Safety Switches...................................................................................................11
Safety Tags.........................................................................................................11
CHAPTER 3: INSTALLATION.................................................12
3-1 Uncrating the Equipment...........................................................................................12
3-2 Belt Tensioning..........................................................................................................12
3-3 Electrical Connections...............................................................................................13
3-4 Accessing the Cutting Chamber................................................................................14
3-5 Closing the Cutting Chamber....................................................................................14
3-6 Initial Start-up............................................................................................................15
CHAPTER 4: OPERATION......................................................16
4-1 Start-up......................................................................................................................16
4-2 Feeding the Granulator .............................................................................................16
4-3 Clearing a Jammed Cutting Chamber.......................................................................16
4-4 Shut-down.................................................................................................................17
CHAPTER 5: MAINTENANCE.................................................18
5-1 Preventative Maintenance Schedule.........................................................................18
5-2 Lubrication.................................................................................................................18
5-3 Replacing and Adjusting the Knives..........................................................................19
Rotor Knives........................................................................................................19
Bed Knives..........................................................................................................20
5-4 Sharpening the Knives..............................................................................................22
Rotor Knife Sharpening.......................................................................................22
Bed Knife Sharpening .........................................................................................22
5-5 Adjusting Belt Tension...............................................................................................23
5-6 Motor Drive Belt Replacement ..................................................................................24

U-Series Thermoforming Granulators iv
CHAPTER 6: TROUBLESHOOTING.......................................25
6-1 Introduction................................................................................................................25
6-2 Electrical Faults.........................................................................................................26
6-3 Processing Faults......................................................................................................27
6-4 Mechanical Faults .....................................................................................................28
CHAPTER 7: APPENDIX.........................................................29
7-1 Customer Satisfaction Warranty Program.................................................................29
7-2 Drawings and Specifications (including Options)......................................................30
Features..............................................................................................................30
Specifications ......................................................................................................30
Dimensions..........................................................................................................31
7-3 Illustrated Parts Breakdown ......................................................................................32
7-4 Spare Parts List.........................................................................................................34
7-5 Typical Wiring Diagram.............................................................................................35
7-6 Recommended Torque for Screws............................................................................36
7-7 Technical Assistance.................................................................................................37
Parts Department ................................................................................................37
Service Department.............................................................................................37
Sales Department................................................................................................37

U-Series Thermoforming Granulators Safety 5 of 37
Chapter 1: Safety
1-1 How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining your
granulator. The purpose is to assist you in applying efficient, proven techniques that enhance
equipment productivity.
This manual covers only light corrective maintenance. No other maintenance should be
undertaken without first contacting a service engineer.
The Functional Description section outlines models covered, standard features, and safety
features. Additional sections within the manual provide instructions for installation, pre-
operational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the granulator. We can also provide the assistance of a factory-trained technician to help
train your operator(s) for a nominal charge. This section includes instructions, checks, and
adjustments that should be followed before commencing with operation of the granulator.
These instructions are intended to supplement standard shop procedures performed at shift,
daily, and weekly intervals.
The Operation chapter includes a description of electrical and mechanical controls, in
addition to information for operating the granulator safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and
disassembly instructions for those areas of the equipment requiring service. Preventive
maintenance sections are included to ensure that your granulator provides excellent, long
service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, parts lists, and
available options. A spare parts list with part numbers specific to your machine is provided
with your shipping paperwork package. Refer to this section for a listing of spare parts for
purchase. Have your serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER! DANGER indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury.
WARNING! WARNING indicates a potentially hazardous situation or practice that, if
not avoided, could result in death or serious injury.
Caution! CAUTION indicates a potentially hazardous situation or practice that, if
not avoided, may result in minor or moderate injury or in property damage.

U-Series Thermoforming Granulators Safety 6 of 37
1-2 General Safety Regulations
This machine uses knives for the performance of its intended use. Consequently, it can be a
dangerous machine to operate and maintain unless these safety regulations are followed.
These regulations should be read, understood and periodically reviewed by all personnel
involved in any way with this machine.
Never operate or remove any machine components that are secured by wrench-type fasteners
unless the motor is electrically locked out and the rotor is motionless.
Never operate the machine or jog the rotor unless the cutting chamber covers, discharge
chute, or any guards or covers are in place and secure. Do not circumvent the safety
interlocks.
Prior to clearing a jam or performing any maintenance, the motor should be turned off and
electrically locked out. Be sure that the rotor has come to a stop. Hands must not be inserted
into the machine to clear the jam.
Do not extend any part of the body into feed roll openings or discharge area unless the motors
are electrically locked out and the rotor and feed rolls are motionless.
Never extend fingers through holes in screen.
Be sure that the v-belts are properly aligned and that tension is at its maximum.
Extreme care should be taken to see that all bolts are properly tightened at all times. During
the operation of the machine, rotor knife bolts may come loose. Although fine threads are
used on the rotor knife bolts because vibration does not easily loosen them, you should
inspect the tightness of the bolts frequently.
This machine is designed for the granulation of plastic materials. Do not feed any other
materials into the machine.
1-3 Responsibility
These machines are constructed for maximum operator safety when used under standard
operating conditions and when recommended instructions are followed in the maintenance
and operation of the machine.
All personnel engaged in the use of the machine should become familiar with its operation as
described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.
Becoming familiar with materials, inspection, speed limitations, screens, and guard
maintenance and total user responsibility will assist you in learning potential areas in need of
observation for danger.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All caution, warning and danger signs must be observed and obeyed. All actual or potential
danger areas must be reported to your immediate supervisor.

U-Series Thermoforming Granulators Safety 7 of 37
1-4 Warnings and Precautions
Our granulators are designed to provide safe and reliable operation when installed and
operated within design specifications, following national and local safety codes.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this granulator, use good judgment and follow these safe practices:
;LEARN AND OBEY your company’s safety policy regarding granulating
equipment.
;MOVING OR LIFTING THE GRANULATOR: Although our equipment is built
and engineered for great ruggedness in operation, care must be taken when moving
the machine along the floor or lifting it. Damage may occur to sheet metal covers,
electrical cabinets, or small brackets if pressure is applied to them when moving the
granulator. When lifting the granulator, be certain of total machine weight and the
capability of the lifting equipment. (See the Granulator Specification Sheets for
machine weights and dimensions.)
;GRANULATOR LOCATION: Adequate area for routine maintenance should be
provided in order to open the machine for knife, screen, or cleanout service. Proper
service area clearances also should allow people who are working on the machine to
be clearly visible to others, thereby reducing the potential safety hazards.
;SAFE HOUSEKEEPING: The work area must be kept clean and uncluttered during
periods of operation or maintenance. No hand tools or other metal objects should be
left on or around the machine. Any tools or other metal objects that mistakenly fall
into the hopper feed opening can cause severe damage to internal cutting chamber,
rotor and screen components.
;SAFETY GLASSES OR A FACE SHIELD MUST ALWAYS BE WORN when
servicing or operating the machine. Although our machines are designed for the
maximum in flyback control, caution must be used when operating near the hopper
feed opening in order to guard against unexpected material flyback.
;EAR PROTECTION may be required when operating the machine during
granulation of very hard or noisy materials. The Occupational Safety and Health Act
of 1970 has established guidelines for Permissible Noise Exposures (OSHA 1910.95)
that should be followed.
;NEVER attempt to operate the granulator unless it is fully assembled with all guards
and interlocks in place and functional.
;OBSERVE all danger, warning, caution and safety labels on the equipment.
;Upon completion of any machine maintenance, be certain ALL SAFETY GUARDS
AND COVERS are securely and properly fastened prior to resuming machine
operation. All fasteners must be in place and properly tightened. ANY
SHORTCUTS MAY RESULT IN INJURY TO PERSONNEL OR DAMAGE
TO EQUIPMENT.
;NEVER wear any loose fitting clothes, neckties, or dangling items such as earrings,
belts, or shoestrings. Jewelry, such as wristwatches, bracelets, or rings should
NEVER be worn. Long hair must be tied back or placed in a tight fitting hairnet.
NEVER lean against or rest hands or feet on the granulator when it is in operation or
open for maintenance. NEVER stand on the granulator when it is in operation.

U-Series Thermoforming Granulators Safety 8 of 37
;ROTATION OF MOTORS: The correct rotating direction for the granulator motor
is clearly marked on the machine. Always check for proper rotation of motors.
Incorrect rotation direction can cause severe damage.
;ELECTRICAL GROUNDING: All electrical equipment on the granulator must be
grounded in accordance to all local codes and Article 250 of the National Electric
Code.
;ALWAYS DISCONNECT AND LOCKOUT the main electrical power to the
granulator before performing any service.
;SAFETY INTERLOCKS MUST NOT BE BYPASSED. The mechanical and
electrical safety interlocks ensure the safety of personnel. They should never be
tampered with or removed for ANY reason. They should be checked frequently by a
qualified mechanic for proper operation.
;NEVER modify the machine configuration or any individual component without
written notice from the factory.
For further information on granulator safety, installation, and operation, see the American
National Standard for Plastics Machinery
⎯ Granulators, Pelletizers, and Dicers Used for
Size Reduction of Plastics
⎯ Construction, Care, and Use. ANSI B151.11-1982.
We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide
by the foregoing recommendations in order to make operator safety a reality.

U-Series Thermoforming Granulators Functional Description 9 of 37
Chapter 2: Functional Description
2-1 Models Covered in This Manual
This manual provides the necessary instructions for the installation, set-up, and maintenance
of our 44U (44”), 56U (56”) and 74U (74”) thermoforming granulators.
2-2 General Description
The thermoform granulator is a rugged, low-profile, rotary-cutting machine, designed to cut,
chip, and granulate the toughest thermoforming materials with a minimum expenditure of
horsepower.
A massively-built, high-inertia rotor with inclined knives gives more linear inches of cut,
greater capacity, and assures long, trouble-free service.
This extra capacity (not needed for normal operation) provides some surge capacity for
handling any incorrectly thermoformed material (as at initial start-up), which has not been
trimmed.
The access panel easily lifts off to fully expose the removable screen(s), the upstroke bed
knives, and rotor knives. Covers on the opposite side can be removed to expose the
downstroke bed knife shields and knives.
Reclamation of skeletal webs, sheet, and small parts for inclusion and application in any type
of thermoforming or extruding equipment is a specifically designed capability, and depending
on the screen size used, this machine will provide granulate or chips to meet most
requirements.
With no special enclosures, this granulator sets the industry standard for noise reduction with
95 dbA or less in most applications. Our traditional ruggedness includes heavy steel knife
blocks and a cutting chamber made of thick steel plate with oversize bearing housings.
Safety interlock switches prevent starting the machine with the in-feed chute or front access
door removed.

U-Series Thermoforming Granulators Functional Description 10 of 37
2-3 Typical Features and Components
Hopper
The V-shaped in-feed chute is an upright enclosure that is bolted to the top of the granulator
and is easily removed for unobstructed access to cutting chamber or the feed rolls where
applications require a feed roll assembly. It is designed to direct continuous reclamation of
skeletal web directly from the thermoform trim process.
Cutting Chamber
The cutting chamber is a rectangular enclosure comprising the main frame, with an access
panel that lifts off to fully expose the upstroke bed knives, a balanced rotor with split offset
rotor knives and removable screen. The covers on the opposite side can easily be removed to
expose the downstroke bed knife shields and knives.
Both the bed knives and bed knife shields are adjustable, and the bed knives have reversible
cutting edges for extended life.
The internal surfaces of the solid steel cutting chamber are machined to an exceptionally
smooth finish for ease of clean-out. The scissor-type cutting action of the angled rotor knives
gives optimum cutting efficiency with lower power consumption.
The screens are mounted in a swing-down cradle, positioned just below the rotor and act as a
classifier for the granulated material, retaining the material in the cutting chamber until the
particle size is such that it will pass through the screen holes.
The high-alloy steel rotor carries the rotor knives. High strength alloy steel screws are used
for attachment of all knives to the rotor.
Drive System
The drive system consists of a TEFC 1200 RPM motor set on an adjustable sliding base that
is mounted at the left end of the granulator. The motor drives the rotor directly and the feed
rolls are driven through a gearbox for assured RPM control. A belt guard shields the motor
drive sheave, feed roll reductor, rotor sheave and belts. Another guard at the opposite end
shields the feed roll sprockets and other mechanisms for complete safety.
Discharge System
The granulated material that falls through the screen is collected in a transitional section
located at the bottom of the granulator and directed through the base area to the right side of
the granulator for discharge with an airveyor system.
The transition section is connected to a blower (airveyor system), which conveys the
granulated material (through ducting) to the cyclone separator. The cyclone separator allows
the granulated material to drop out of the air stream into a bin or container.
Base
The base is caster-mounted, with four swivel (two locking) casters for easy positioning.

U-Series Thermoforming Granulators Functional Description 11 of 37
2-4 Safety Features
Safety Switches
Safety switches at all access covers are wired into the starter control circuit. The machine
cannot be started when these parts are open. However, for safety purposes, the machine
should be disconnected from the power lines by a disconnect switch or by removing the plug
from its receptacle. Check all safety switches periodically for proper operation.
Figure 1 shows some of the bolts, interlocks, and limit switches you may need to adjust
during maintenance. Refer to this diagram while performing the maintenance procedures.
Safety Tags
A set of metal plates is attached to the machine to warn of potential danger.
Figure 1: Safety Features, Interlocks, and Limit Switches
In-feed Chute
Swivel Caster
Safety SwitchActuator Arm Bolt
Bed Knife Cover Base Area
In-feed Chute Bolts
Floor Locks
Drive Belt Safety Cover
Drive Chain/Tensioner Arm
Safet
y
cover

U-Series Thermoforming Granulators Installation 12 of 37
Chapter 3: Installation
3-1 Uncrating the Equipment
The complete granulator, including accessory and auxiliary equipment, is packed in a special
wooden case for shipment. Refer to the Appendix for detailed dimensional data and pertinent
weights.
Prepare in advance the site you have selected for installation of the granulator. Be certain
that the area to be occupied by the machine is clean, level, and free of obstructions. The
machine should be set on a concrete floor, and care must be taken when moving the machine
across a hollow timber floor, so that the point loading of the casters does not cause damage.
The site you have selected must have a floor rating to adequately support the weight of the
machine. If necessary, use steel shims to level the machine.
Locate the machine so that access is given to electrical components, screen, and hopper.
Maintenance personnel should have unobstructed access to the units on which they will be
working.
To avoid squeezing people working near a machine, there should be adequate clearance
maintained between machines, walls, or partitions. Hinged doors and covers should have full
swing. Restrictions may force work in cramped quarters. An off-balance operator with an
awkward reach into a partially obscured area is unsafe.
If inspection after shipment has revealed no shipping damage, unpack the unit by removing
all hold-downs, tie-downs, bolts, nuts, etc. Remove the envelope with the electrical
schematics and instruction manual from the base evacuation area.
You can now have the machine lifted from the skid. To lift and move the granulator safely
and correctly, cover any sharp corners or edges, and use the type of equipment that has the
most appropriate features and capacity. Use the designated lifting points, and do NOT lift the
machine by the hopper handles or guards.
3-2 Belt Tensioning
Belt drives should initially be tensioned at the “run-in” recommended force. Check the
tension at least twice during the first two days of operation. After the belts have seated
themselves in the sheave grooves and the initial stretch is removed, re-tension the belts to
“normal running” and check periodically to maintain tension at the recommended value. See
Section 5-5 on page 23 for the belt tensioning procedure.

U-Series Thermoforming Granulators Installation 13 of 37
3-3 Electrical Connections
Granulator controls (if ordered) are shipped separately for mounting at a suitable location.
The safety interlock switches are connected to a common terminal box for ease of wiring.
The customer is required to provide a suitable fused supply with a disconnect switch and a
cable for the incoming line to the control (if ordered with the machine).
Refer to the technical specifications in the Appendix for horsepower, voltage, phase, and
frequency requirements to determine the size and rating of the supply cable required.
If optional controls are required, an electrical wiring diagram will be provided with the
machine in addition to the basic electrical diagram.
When the customer is providing either the motor or the control, the machine must be wired in
accordance with the basic electrical diagram and the starter manufacturer’s instructions.
Use the following steps to complete the electrical connections:
1. Check to be certain that the starter heater elements correspond with the motor
requirements. If controls are not supplied, the limit switches supplied on the machine
must be wired into the circuit at the common terminal box.
2. Check that the limit switches are closed.
3. Turn switch ON at main power supply.
4. Jog motor by pressing the START and then the OFF button. This starts and stops the
motor.
5. With the electrical power ON, check that the motor rotates in a clockwise direction at
the viewing port in the belt guard. If motor rotation is correct, continue to the next
step. If rotation is incorrect, complete the following procedure:
a. Shut power OFF and disconnect incoming power supply.
b. Reverse any two of the three power line connections to the machine.
c. Re-connect the incoming power supply line and turn ON the main power
switch to recheck motor drive rotation.
6. If Airveying system (optional) is fitted, press the Airveyor START button, and check
the blower motor rotation. The blower motor should rotate in a counterclockwise
direction. If blower motor rotation is correct, continue to step 7. If blower motor
rotation is incorrect, complete the following procedure:
a. Shut power OFF and disconnect incoming power supply line.
b. Reverse any two of the three power line connections to the blower motor.
c. Re-connect the incoming power supply line, and recheck the blower motor
rotation.
7. Allow all motors to run up to speed for at least 30 seconds.

U-Series Thermoforming Granulators Installation 14 of 37
3-4 Accessing the Cutting Chamber
You will need to access the cutting chamber before initial startup and for various
maintenance procedures. Use the following procedure to access the cutting chamber:
1. Turn the main power off, remove the line fuses, and tag the machine as out of
service.
2. Remove the access panel bolts. (This includes the safety switch actuator arm bolt),
and lift up and out to remove the access panel. The panel has a bottom internal skirt
that must be lifted clear of the base strip.
3. Remove the cradle arm bolts and swing the screen cradle arms down (See Figure 2).
4. Remove the screen.
Figure 2: Screen Cradle and Screens
3-5 Closing the Cutting Chamber
After completing any maintenance or adjustments inside the cutting chamber, use the
following procedure to close the cutting chamber and resume use of the granulator:
1. Replace the screen in the cradle arms, making sure that the far edges is trapped
beneath the downstroke bed knife block. Tighten the cradle arm bolts.
2. Replace the access panel and tighten in position, making sure that the interlock screw
sets the safety switch actuator arm into its correct operating position.
3. Replace line fuses, turn power on, and remove the out of service tag from the
machine.
Cradle Arm
Bolts
Cradle Arms
Screens

U-Series Thermoforming Granulators Installation 15 of 37
3-6 Initial Start-up
This machine has been run under power and tested at the factory prior to shipment. The
necessary settings and adjustments have been made so that a minimum amount of setting up
or re-adjustment is required when starting up the machine in its new location.
With all electrical, mechanical connections and lubrication requirements having been
attended to, the following start-up steps should be carefully carried out before attempting to
place any material into the in-feed hopper. Use the following procedure to prepare the
machine for initial start-up:
WARNING! Before operating the granulator, insure that the granulator has been
correctly assembled and wired.
1. Access the cutting chamber as described in Section 3-4 on page 14.
2. Thoroughly clean the rust preventative materials or grease from the hopper, the inside
of the cutting chamber, knives, rotor, screen, discharge system, and exterior of the
machine. Do not use solvent on any of the painted areas, as solvent may damage the
paint.
3. Check all rotor knives to make sure they are properly seated on the rotor and securely
fastened. Although they are ground as a set, one knife will probably be .001” to .002”
higher than the others. This should be marked and used when adjusting the bed
knives for proper clearance.
4. Use a feeler gauge to check the clearance between the rotor and the bed knives by
turning the rotor backwards. Rotating the rotor backwards gives a better feel and does
not cut the gauge, should the knives be too close. Check the knives on each end only.
Proper clearance is 0.15 mm (0.006”) to 0.20 mm (0.0008”). This clearance is
slightly greater at the center of the knives.
Note: Recheck knife clearance after the first 24 to 36 hours of operation.
5. To make the adjustment on the bed knives, the bed knife adjusting screws should be
hand tightened to hold the knife firmly against the knife seat while adjusting the knife
forward using push and pull screws. After the clearance is set, torque the 16 mm
screws to 271 Nm (200 lbs./ft.).
Note: All screw tightening torque figures are for un-lubricated thread conditions.
Screw threads should be wiped with an oil-dampened cloth before installation
to prevent galling.
6. With the exposed parts of the machine thoroughly clean, and all knife clamping bolts
securely fastened, close the cutting chamber as described in Section 0 on page 14.
Note: After initial start-up, the rotor knife retaining screws should be
checked after 8 hours running to be assured that 271 Nm (200 lbs./ft.)
of torque is maintained. Thereafter, rotor knife retaining screws should
be checked weekly.
Note: The rotor must be rotated at least two rotations every 30 days to prevent
brinnelling and corrosion of raceways.

U-Series Thermoforming Granulators Operation 16 of 37
Chapter 4: Operation
4-1 Start-up
Before starting the machine, check that the rotor rotates freely by rotating it by hand from
outside the machine using either the coupling or the sheave depending on the type of drive.
Inspect the cutting chamber carefully to insure that nothing has fallen into it, such as bolts or
tools. Make sure all screws and bolts are properly secured. Check all electrical connections
and motor rotations. See Chapter 3 on pages 12-15 for detailed set-up instructions. Allow all
motors to run up to speed for at least 30 seconds.
4-2 Feeding the Granulator
Feed the granulator through the V-chute opening in the hopper. The method of feeding the
granulator depends on the physical form and nature of the material being processed.
For maximum efficiency, the granulator should be fed at a rate that is consistent with its
capacity; i.e., if the granulator is rated at 60 kg./hr. (132 lbs./hr.), then the general feed rate is
1 kg./min. (2.2 lbs./min.). Under these operating conditions, the correct proportions of cut and
uncut particles will be present in the cutting chamber.
WARNING! Under no circumstances should the operator attempt to reach into the
hopper to dislodge any bridged or jammed material while the granulator is
in operation. To clear the hopper of bridged or jammed material, the
machine main power must be turned off and the machine isolated.
4-3 Clearing a Jammed Cutting Chamber
Never attempt to free a jammed machine by placing hands on the rotor, rotor knives, or inside
the cutting chamber. Hands must be kept clear of the rotational path of the rotor knives.
Good footing on a clean floor is essential and the body should be well braced to guard against
loss of balance should the jam suddenly come free.
Use the following procedure to clear a jammed cutting chamber:
1. Disconnect and lock out power.
2. Be certain that the rotor is motionless.
3. Open the machine as instructed in Section 3-4 on page 14.
4. Use a pry bar to exert force on the rotor, usually in the direction opposite normal
rotation. A leather mallet and a block of wood of sufficient length to keep hands
away from path of knives can be used if necessary.
5. Use pliers to remove material from the cutting chamber, keeping in mind that the
removal of material may cause rotation of the rotor and rotor knives.
6. After clearing the jam, be certain that the screen and all guards and covers are
secured in place before connecting power and starting the machine.

U-Series Thermoforming Granulators Operation 17 of 37
4-4 Shut-down
Use the following procedure to properly and safely shut down the machine:
1. Stop all feeding of material.
2. Allow the granulator to run until the cutting chamber is completely empty.
3. Press the drive motor “stop” button. This shuts off the rotor drive motor.
4. After the granulator has stopped, press the airveyor stop button (if applicable) located
at the blower motor.
5. Turn the main power switch to off.

U-Series Thermoforming Granulators Maintenance 18 of 37
Chapter 5: Maintenance
5-1 Preventative Maintenance Schedule
Check Frequency
Operation of safety interlock switches Daily
Knife clearance (0.15 mm – 0.20 mm; 0.006” – 0.008”) Weekly
Knife retaining screws for tightness (271 Nm; 200 lbs./ft.) Weekly
Knife exposure (1.0 mm; 0.040”) Weekly
Belt tension Monthly
5-2 Lubrication
The main drive motor, rotor bearings, feed roll reductor, tension idler sprocket, feed roll
cartridge bearings, and feed roll drive chain are all pre-lubricated at the factory. Check and
re-lubricate according to Figure 3.
Figure 3: Lubrication Requirements
Lubrication Point Lubricant Frequency
Drive motor Refer to instruction plate on
motor 4 months or 3000 hours
Feed roll reductor #90 Lube oil Refill as needed
Feed roll cartridge
bearings Chevron SRI #2 Exxon Andok C
Lidok EP1
2 months or 1500 hours. Grease
when machine is stopped until
small bead appears at bearing
seal, then wipe clean.
Feed roll tension arm
idler sprocket Chevron SRI #2 Exxon Andok C
Lidok EP1
2 Months or 1500 hours. Grease
when machine is stopped until
small bead appears at nut edge,
then wipe clean.
Feed roll drive chain Molykote Lubricant As required by visual inspection
Rotor bearings Chevron SRI #2
Exxon Andok C
Lidok EP1
2 Months or 1500 hours at 1
oz./bearing.

U-Series Thermoforming Granulators Maintenance 19 of 37
5-3 Replacing and Adjusting the Knives
During use, the clearance between the rotor knives and the bed knives will increase due to
wear. This is a normal condition that requires re-setting this clearance once or twice before it
is necessary to remove the knives for regrinding. Check the knives weekly for wear,
clearance, exposure, and screw tightness.
When new knives are fitted to the machine, adjustment after eight hours of running time may
be required.
Before assembling a new or reground set of knives, make sure the knife seats and mounting
holes are clean. Do not use grease or oil on screws or tapped holes when assembling the
knives.
Knives must be replaced in complete sets, otherwise it will not be possible to obtain even
clearance between the rotor knives and bed knives.
WARNING! Before applying a wrench to any knife bolt, be certain that the rotor is
blocked to prevent rotation. One such method is to use a block of wood at
least 1 1/2” thick between a knife and a fixed portion of the frame.
Rotor Knives
We recommend that the rotor knife screws be replaced with new screws every sixth knife
change to reduce the risk of screw failure due to overstretching. Screws must be replaced
with the type specified in the spare parts list. Use the following procedure to replace or adjust
the rotor knives:
Caution! Rotor knives should be changed one seat at a time to prevent rotor from
being rotated in an out-of-balance condition.
1. Access the cutting chamber as directed in Section 3-4 on page 14.
2. Remove the downstroke cover screws at the rear of the machine (this includes the
safety switch actuator arm screw), and carefully slide the covers out of the machine.
(See Figure 4 on page 21.)
3. Set back the bed knives to clear the rotor knives so that the rotor can revolve freely.
4. Remove the screws holding the knives to the rotor and remove the rotor knives.
5. Thoroughly clean the knife seats, and replace the knives.
6. Lightly tighten the screws and check that a 0.04 mm (0.0015”) feeler gauge will not
pass between the back of the knife and the knife seat. Tap the knife gently with a
rawhide hammer if necessary to close the gap.
7. Tighten the screws evenly and torque the high tensile 16 mm screws to 271 Nm (200
lbs./ft.)
Note: Bolt threads should not be oiled. Wipe thread with and oil-dampened cloth.
8. Re-check the gap between the back of the knife and the knife seat. If necessary,
readjust the knife.
9. Adjust the clearance between the bed knives and rotor knives. (See “Bed Knives” on
page 20.)

U-Series Thermoforming Granulators Maintenance 20 of 37
Bed Knives
We recommend that the same screws and washers be re-used only when the bed knives have
been repositioned or re-ground. When blunt knives are discarded and replaced with new
knives, use new screws and washers. This will reduce the risk of screw failure due to their
overstretching. Screws and washers must be replaced with the type specified in the Spare
Parts List. Use the following procedure to replace or adjust the bed knives:
1. Access the cutting chamber as directed in Section 3-4 on page 14.
2. Remove the downstroke cover screws at the rear of the machine (this includes the
safety switch acutator arm bolt), and carefully slide the covers out of the machine.
(See Figure 4 on page 21.)
3. Remove the bed knife shield screws and lift off the bed knife shield.
4. Remove the screws holding the bed knives, and remove the bed knives.
5. Before installing and adjusting the bed knives, check all rotor knives to make sure
they are properly seated on the rotor and securely fastened.
6. Thoroughly clean the knife seats.
7. Replace the bed knives on the bed knife seat and tighten the screws until they are
finger-tight.
8. Use the adjustment screws (See Figure 4 and Figure 5 on page 21) to set the knife
clearance to 0.15 mm – 0.20 mm (0.006” – 0.008”). The clearance should be
measured with a feeler gauge at the ends of the knife, by rotating the rotor sheave
backwards by hand. The clearance is slightly greater at the center of the knives.
9. Tighten the bed knife screws evenly and torque the 16 mm screws to 271 Nm (200
lbs./ft.).
10. Replace the bed knife shield and adjust the shield using its push and pull screws so
that its front edge is within 1.0 mm (0.040”) of the bed knife edges. If strip material
is to be cut, reduce the knife exposure to less than the strip thickness to prevent
material built-up on the bed knives.
11. Make sure all screws, bolts, and nuts are properly tightened.
12. Reset the downstroke cover in position and tighten in place with the downstroke
cover screws. Make sure the safety switch actuator arm screw sets the arm in the
correct switch operating position.