DUAL-SHEAR M120E Operation manual

OPERATION AND
SERVICE MANUAL
Model: M120E(63)
Serial Number: S3243
Order Number: 422.1175
Job Number: 22.1098
Customer:
South Wake Scrap Tire Facility
This manual contains information that is the
property of SSI Shredding Systems, Inc. By
accepting this information, the borrower
agrees that it will not be used for any other
purpose than that for which it is loaned.
SSI Shredding Systems, Inc.
9760 SW Freeman Drive
Wilsonville, Oregon 97070, USA
[phone] phone
[phone] fax
www.ssiworld.com
Introduction
Installation
Operation
Preventive Maintenance
Service
Troubleshooting
---
---
---
Warranty
Specifications, Parts Lists,
and Drawings
Vendor Literature

INTRODUCTION TABLE OF CONTENTS
SECTION
1.0
PAGE
1
PURPOSE OF THIS MANUAL 1.1
CUSTOMER ASSISTANCE 1.2
SAFETY PRECAUTIONS 1.3.1
MACHINE LOCK OUT 1.3.2
DEFINITIONS AND ABBREVIATIONS 1.4
INTENDED USE AND LIMITATIONS 1.5
SSI Service Manual - 991285 Rev 1

PURPOSE OF THIS MANUAL
SECTION
1.1
PAGE
1
SSI Service Manual - 991267 Rev 0
PURPOSE OF THIS MANUAL
This manual contains guidelines for the set-up, safety, operation, maintenance, and service of equipment
provided by SSI.
A copy of this manual should be kept clean and near the machine at all times. Please read and
understand the applicable sections and their safety precautions prior to performing any procedures.
Serious injury or death could result from the improper use, repair or service of this
machine.
Repairs and/or service to this machine must only be done by properly trained
personnel.
It is very important that all personnel operating and maintaining this machine,
study the sections of this manual that pertain to their particular task before
beginning or damage to the equipment may occur.
This manual contains the following:
Section 1 Introduction
Section 2 Installation
Section 3 Operation
Section 4 Preventive Maintenance
Section 5 Service
Section 6 Troubleshooting
Section 7 Optional Equipment if Applicable (Section may be left blank)
Section 8 Optional Equipment if Applicable (Section may be left blank)
Section 9 Optional Equipment if Applicable (Section may be left blank)
Section 10 Warranty
Section 11 Specifications, Part Lists, Drawings and Program
Section 12 Vendor Literature
The information contained in the above sections was known to be accurate at the time of shipment. SSI
strives to keep customers informed of machine changes that may affect units already in the field. If you
have any questions regarding information in this manual or with your machine, please call SSI Customer
Service.

CUSTOMER ASSISTANCE
SECTION
1.2
PAGE
1
SSI Service Manual - 991268 Rev 1
SSI provides customer assistance with the operation, maintenance and service of this machine.
HOURS:
Office: Monday-Friday, 7:00 am to 5:00 pm PST
24-hour phone support available.
PHONE:
Voice: 503-682-3633
Fax: [phone]
EMAIL:
[email protected]m
[e-mail]
ADDRESS:
Shipping and correspondence should be sent to the following address:
SSI Shredding Systems, Inc.
9760 SW Freeman Drive
Wilsonville, OR 97070-9286
RETURNED MATERIAL:
Please call for a Returned Material Authorization (RMA) Number before shipping to SSI.
C.O.D. freight and packages will not be accepted.
SSI WARRANTY
For information regarding SSI’s warranty policy, please refer to Section 10 in this manual or contact SSI.

SAFETY PRECAUTIONS
SECTION
1.3.1
PAGE
1
SSI Service Manual - 991284 Rev 2
SAFETY PRECAUTIONS
Machine operators and maintenance personnel must always comply with the safety precautions given in
this manual and on the stickers and tags attached to the machine.
These safety precautions are provided for your safety. Review them carefully before operating the
machine and before performing general maintenance or repairs.
Supervising personnel should develop additional precautions relating to the specific work area and local
safety regulations.
The equipment manufactured by SSI will provide safe and dependable service if operated in accordance
with the instructions given in this manual. Read and understand this manual and any stickers and tags
attached to the machine. Failure to do so could result in personal injury or machine damage.
SAFETY SYMBOLS
Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and
repair actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or
damage to the machine.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
This safety alert and signal word indicate an imminently hazardous situation,
which, if not avoided WILL result in DEATH or SERIOUS INJURY.
This safety alert and signal word indicate a potentially hazardous situation, which,
if not avoided COULD result in DEATH or SERIOUS INJURY.
This safety alert and signal word indicate a potentially hazardous situation, which,
if not avoided MAY result in MINOR or MODERATE INJURY.
This signal word indicates a situation, which, if not avoided WILL result in
PROPERTY/EQUIPMENT DAMAGE.
This signal word indicates a situation, which, if not avoided MAY result in
PROPERTY/EQUIPMENT DAMAGE.

SAFETY PRECAUTIONS
SECTION
1.3.1
PAGE
2
SSI Service Manual - 991284 Rev 2
GENERAL SAFETY PRECAUTIONS
• Establish a training program for all operators to ensure safe operation.
• Do not operate the machine unless thoroughly trained or under the supervision of an instructor.
• Always wear safety equipment such as goggles, hearing protection, head protection and safety shoes
while operating or working around the machine.
• Do not inspect or clean the machine while it is running. Always ensure that power is locked out and
tagged out before performing maintenance. Accidental engagement of the machine can cause
serious injury or death.
• Do not operate a damaged or improperly adjusted machine.
• Never wear loose clothing that can become entangled in the working parts of the machine.
• Keep all parts of your body away from the working parts of the machine.
• Always keep critical markings, such as warning stickers legible.
• To avoid personal injury or machine damage, all maintenance, repair and service must only be
performed by properly trained personnel.
• NEVER load any flammable or explosive items into the shredder such as fuel tanks or
propane bottles.
• Use appropriate fall prevention techniques when working on machine platforms.
• Always have all shields and guards in place before operating machine.
• Do not process excessively long material that exceeds the top of the feed hopper.
• Never attempt to process materials for which the shredder was not designed.
• Do not put fingers in bolt holes or between other heavy parts.
• Always use extreme caution around electrical components.
• Do not stand above hopper/cutting chamber while in operation.
• Always allow the hydraulic system to cool before performing service work.
• Always release all pressure in air, fuel, oil and cooling systems before disconnecting lines and fittings.
• Always replace fasteners with SSI approved parts or equivalent.
• Keep the area around the equipment clean and clear. Clean up any spills promptly.

MACHINE LOCK OUT
SECTION
1.3.2
PAGE
1
SSI Service Manual – 991286 Rev 3
MACHINE LOCK OUT
Failure to lock out can result in severe personal injury or death.
To ensure safety when servicing or inspecting the equipment, all sources of energy must be switched
off, locked out and tagged at the source before beginning work. The following four general steps
should be followed. Locking out and tagging should be done in accordance with plant rules and OSHA
approved procedures.
1. Turn off all sources of energy and Isolate the machine from these sources of energy. This might
include, but is not limited to, turning off the main breakers, shutting down the diesel etc.
2. Lock out and tag all sources of energy with approved locks and tags. Everyone who will be
involved with the work must place their own lock on the disconnect device.
3. Remove or relieve all stored energy. This might include, but is not limited to, hydraulic pressure,
suspended objects, etc. Ensure all moving parts are in the safe position.
4. Verify that the energy has been turned off. Try starting the machine using all of the start buttons on
the control panel. Make absolutely sure that the machine cannot start unexpectedly. Unintended
machine startups can cause serious injury or death.

MACHINE LOCK OUT
SECTION
1.3.2
PAGE
2
SSI Service Manual – 991286 Rev 3
POSSIBLE SOURCES OF ENERGY
All possible sources of energy must be identified and locked out prior to working on the equipment. The
following is a list of common sources of energy. It is possible that other sources of energy exist that are
not identified here.
Electrical Energy
Control Voltage
The voltage on the control circuit is typically 24 VDC, but could be higher. Normally, locking out the main
disconnect switch isolates this voltage from any control wiring. In some situations, the control voltage can
be fed from external circuits and will have to be locked out at its source. In some case control power from
other equipment will be present in the SSI supplied panel. Lock out all of the sources of electrical energy
before working on the electrical system.
Main Power
The main incoming power will be significantly higher than the control voltage and present a lethal shock
hazard. In most cases, locking out the main breakers on the SSI supplied panels will eliminate this
voltage from all of the circuits except the incoming leads to the breakers themselves. In other cases, the
power will have to be locked out at facility breakers feeding the equipment. Carefully determine power
sources and lock out all of them prior to working on the equipment.
On units equipped with diesel engines there are electrical heaters in the hydraulic tank and engine block
that are powered from outside sources. Disconnect (unplug) these to eliminate hazards from this source.
Potential Energy (Gravity)
If the shredder is equipped with a ram hopper, the ram itself is a source of potential energy. Lower the
ram fully or block it up in the raised position prior to working around or under it.
If the shredder is equipped with hydraulically actuated access doors or maintenance points, always lock
them in the open position or actuate them until they are over center and cannot fall closed. Do not trust
the cylinder alone to keep them open.
Falling material is a source of potential energy. Make sure that material hanging in or around the hopper
or conveyors has been secured prior to working under it.
Hydraulic Energy
The hydraulic pressure decays from all the circuits within a few seconds after the electric motor shuts
down, with the exception of any hydraulic cylinders used in ram hoppers, access doors or other devices.
These cylinders have counterbalance valves that are designed to hold the pressure in the cylinders to
prevent unintended machine motion. Support the suspended load to minimize the pressure retained, and
then carefully crack a hose fitting between the cylinder and the counterbalance valve to bleed off any
pressure prior to working on these circuits.
Thermal Energy
In addition to the above forms of energy, there are two sources of potentially dangerous temperatures:
• Hot fluids: Hydraulic fluid and gearbox lubrication can reach temperatures capable of burning or
scalding flesh.
• Hot Surfaces: The surface temperatures of hydraulic components or gearbox housings reach
temperatures capable of causing burns.
The only way to eliminate these hazards is to wait until the unit has cooled.
Other Sources
There may be sources of pneumatic energy (compressed air), compressed springs or other suspended
loads depending on the equipment configuration.

DEFINITIONS AND ABBREVIATIONS
SECTION
1.4
PAGE
1
SSI Service Manual - 991173 Rev 4
CLEANING FINGER
A flat metal plate with a bar welded on one side and a semicircular notch cut out of the other. The
semicircular notch fits closely around the spacer to prevent material from building up between cutters.
CUTTER
A thick metal disk usually containing one or more hooks on the outer edge and a hole in the center.
The center hole may be keyed or hexed and allows the disk to be installed on a shaft.
CURRENT RELAY
(Also called instant-trip relay, used on some models) An electrical sensing device that monitors the
amperage used by the shredder motor. When the motor amperage exceeds the setting on the relay,
the signal to the PLC is removed, causing the shredder to start a reversal.

DEFINITIONS AND ABBREVIATIONS
SECTION
1.4
PAGE
2
SSI Service Manual – 991173 Rev 4
CUTTING CHAMBER
A rectangular area formed by the shredder gearbox, side walls, and end plate which contains the
cutters, spacers and cleaning fingers.
CUTTER TO CUTTER CLEARANCE
The effective shear gap between overlapping cutters in the cutting chamber.

DEFINITIONS AND ABBREVIATIONS
SECTION
1.4
PAGE
3
SSI Service Manual – 991173 Rev 4
CONTROLLED TORQUE COUPLING (SSP-SEVERE SHOCK PROTECTION)
(Used on some models) A device installed between the electric motor and gear reducer that protects
drive components by slipping instantaneously when excessive shredder loads are encountered.
GEARBOX
A rectangular box, part of the shredder frame, which contains the main cutter shaft bearings and on
some models large spur gears.
GEAR REDUCER
A cylindrical housing, located between the drive motor and shredder gearbox, which contains planetary
gears for reducing the input drive speed to the shredder.

DEFINITIONS AND ABBREVIATIONS
SECTION
1.4
PAGE
4
SSI Service Manual – 991173 Rev 4
HYDRAULIC POWER UNIT (HPU)
(Used on some models) A unit consisting of motors, pumps, and the hydraulic fluid reservoir to power
the shredder or equipment.
JAM REVERSAL
A reversing of the cutter shafts due to shredder overload or non-shreddable objects in the cutting
chamber. Its function is to protect shredder components.
JAM SHUTDOWN
A condition where the PLC has stopped the shredder due to repeated jam reversals within a specified
time period.
MASTER CONTROL RELAY (MCR)
The safety relay which, can be engaged only when all emergency stops are clear. When turned off, it
removes power to the PLC outputs and shuts off the shredder.
NON-SHREDDABLE
An object that the shredder does not have the power to shred due to its size, material, or hardness.
PROGRAMMABLE LOGIC CONTROLLER (PLC)
A solid-state electronic device typically located in the control panel. The PLC receives information from
sensors and push buttons, processes this information using stored, programmed logic and executes
commands to control the operation of machines or processes.
SCREEN
(If equipped.) A heavy duty metal sizing device typically mounted below the cutting chamber which
allows shredded material to pass if it is below the size of the screen’s openings. Oversized material is re-
circulated back to the cutting chamber for further size reduction.

DEFINITIONS AND ABBREVIATIONS
SECTION
1.4
PAGE
5
SSI Service Manual – 991173 Rev 4
SHREDDER HEAD
An assembly typically consisting of the shredder frame, endplate, shredder gearbox, planetary gear
reducer, cutting chamber, and all operating component parts contained therein.
SPACER
A small, non-hooked disk used to hold cutters a precise distance apart. The center hole may be keyed
or hexed and allows the spacer to be mounted on a shaft.
SPEED SENSOR
(Used on some models.) A speed-sensing device consisting of a proximity switch, target, and
associated wiring. Its purpose is to provide a pulsed signal to the PLC. The PLC will measure the time
between pulses and determine when the input shaft exceeds or falls below a pre-set speed.
UNIT
Refers to the shredder head, gear reducer, drive motor, and other components assembled for operation.

INTENDED USE AND LIMITS OF SHREDDER
SECTION
1.5
PAGE
1
SSI Service Manual – 991927 Rev 1
INTENDED USE AND LIMITS OF SHREDDER
• The Shredder is used for the size reduction of material for further processing or disposal. SSI must
approve all material prior to shredding.
• The shredder is to be operated and maintained only by trained, qualified personnel
• The Shredder is operated from the control panel. There is no requirement for direct contact with
shredder, except for maintenance and adjustment. All maintenance should be performed only when
equipment is shut down and locked out.
• Feeding material into the Shredder hopper should be done by mechanical means and not by direct
human action. All of the material must fit within hopper.
• Due to operational design requirements of a shredder, the infeed hopper is open to atmosphere and
thus will not contain any dust created when material is shredded. Also, solid objects can be ejected
from hopper in the process of shredding. The user must ensure that any discharge is contained and
all personnel are protected from hazards.
• The shredded material discharged from the shredder is to be removed by mechanical means. The
discharge area must be enclosed such that it prevents human access to the shredder while it is in
operation.

INSTALLATION TABLE OF CONTENTS
SECTION
2.0
PAGE
1
SSI Service Manual – 991186 Rev A
SET-UP CONSIDERATIONS 2.1
INSTALLATION 2.2
HYDRAULIC CONNECTIONS (IF SUPPLIED) 2.3
INITIAL START-UP 2.4

SET UP CONSIDERATIONS
SECTION
2.1
PAGE
1
SSI Service Manual – 991181 Rev 7
It is important to consider things like material flow and equipment placement when setting up the
shredder. The following setup considerations will help ensure:
• Safety
• Efficiency
• Ease of service
• Optimum performance
A hopper is required to direct material into the cutting chamber.
HOPPER FEED METHOD
Often the hopper is fed by a conveyor belt, so the rate of input is steady and about as fast as the
shredder can process (if a VFD Drive was purchased, the speed of the conveyor can be adjusted
according for shredder processing). Sometimes it is fed in batches by wheeled loaders, forklifts, or
cranes, but in general, a steady feed rate is preferable. The hopper infeed method depends on several
things:
• The type of material
• The size of the material
• The through-put rate
• The required particle size
INFEED HOPPER
The Infeed Hopper directs material into the cutting chamber. It can also hold material waiting to be
processed.
• If the machine needs mechanical help to push material to the cutters, SSI offers hoppers with a
hydraulic ram.
• If the material must be kept in the cutting chamber, SSI also offers enclosed hoppers.
DISCHARGE CHUTE
The discharge chute directs processed material from the cutting chamber to containers or conveyor belts.
It should not cause bridging or snagging.
• Depending upon particle size and throughput, adequate space is required below the cutting chamber.
• Generally, the chute walls are vertical, but occasionally are at a 15º to 30º angle.
• The chute design depends on the material’s size, the direction, access, and connections with
containers or conveyor belts.

SET UP CONSIDERATIONS
SECTION
2.1
PAGE
2
SSI Service Manual – 991181 Rev 7
DISCHARGE CONVEYOR
The Discharge Conveyor moves shredded material from the Discharge Chute to downstream equipment.
The type of conveyor recommended (rubber belt, steel pan, augers, etc.) depends on:
• Material type
• Material size
• Downstream requirements
A Conveyor Motion Switch should be installed to prevent discharge chute jams.
ELEVATION OF THE UNIT
The elevation of the unit depends on:
• The height of the infeed
• The clearance for the discharge chute
• The height of the discharge conveyor
When appropriate, walkways should be provided for easy access.
HEAD-ROOM OF THE UNIT
The head-room required for the unit depends on:
• Size and shape of the infeed hopper
• Size of the bulk material
• Clearance for other equipment handling the material (e.g. bale size, forklift mast height)
• Service (e.g. removal of the hopper or infeed conveyors)
PLACEMENT OF THE HYDRAULIC POWER UNIT (FOR HYDRAULIC
DRIVE SHREDDERS ONLY)
The skid-mounted Hydraulic Power Unit (HPU) is a self-contained unit that is connected to the hydraulic
motor with a minimum of two large high-pressure fluid lines and a smaller case drain line. The HPU
should be located close to the shredder hydraulic motors. Refer to Hydraulic Connections Section of this
manual for connection requirements.
Note: There are limitations on the maximum total length of connections and the height difference between
the HPU and the hydraulic motor. See Hydraulic Connections for additional information. If the HPU is
going to be located in a separate room, plan for sufficient airflow to dissipate generated heat.

SET UP CONSIDERATIONS
SECTION
2.1
PAGE
3
SSI Service Manual – 991181 Rev 7
Hydraulic oil must be filtered thru specific filter(s) when filling the reservoir.
See Hydraulic Connections and Lubrication Specification Section in the manual for
details
CLEARANCE AROUND THE SHREDDER AND HYDRAULIC POWER
UNIT (HPU)
For safety, ease of service and maintenance, clearance is needed for removal of the endplate, cutters,
and spacers. There should also be room for major repairs such as shaft, gear, bearing, or gear reducer
replacement. At least half the shredder head length is needed at both ends, plus room for lifting
equipment.
AMBIENT TEMPERATURE
The drive components are designed to operate in an ambient temperature range of 35ºF to 100ºF.
• If the unit is in an extremely warm area, a means of air circulation should be provided. The drive
system temperature should be monitored and additional cooling may be necessary.
• If the unit is in an extremely cold area, the lubricant should be changed to match the temperature (see
the Lubricant Specifications section). Also, the unit should be turned on for approximately 20 minutes
with no load to warm the oil prior to use.
EXCHANGERS
All heat exchangers should be stored in a covered, environmentally stable area between 70 and 105
degrees F. With relative humidity below 40%. Drain air cooled heat exchangers and reseal before
storage.
SPECIAL NOTE FOR WATER COOLED HEAT EXCHANGERS
• Make sure the water lines and the heat exchanger and completely sealed and blown dry with air
before storage to prevent corrosion. Water cooled heat exchangers should avoid freezing
temperatures at all times.

INSTALLATION
SECTION
2.2
PAGE
1
SSI Service Manual – 991196 Rev 6
Use appropriate fall protection when working on machine platforms.
The shredder contains components, which are too heavy for one person to lift.
When servicing, use approved lifting devices or equipment and get assistance
from other workers when needed.
Do not put fingers in bolt holes or between other heavy parts.
RECEIVING INSTRUCTIONS
Although this shredder was thoroughly inspected, it is possible for equipment to be lost or damaged
during shipping. When receiving a shipment, make sure to:
1. Check each item against the shipping manifest to make sure all items were received.
2. Check for evidence of damage to each item. Open the electrical panels and control boxes to check
for water seepage. If the shredder is equipped with a SmartDrive VFD, do NOT open the SmartDrive
itself.
3. If any damage is found, or if you have not received all the items listed, contact the carrier
immediately. Note damage on the Bill of Lading or other documents required by the carrier.
STORING THE UNIT ON SITE
Shredder components are protected from corrosion at the factory using a coating of light oil and rust
inhibitor. This is effective for a short time. If the unit is going to be stored outside or in a moist location, it
should be covered. If it will be in storage for three weeks or longer:
1. Cover any unpainted surfaces with protective grease or heavy oil.
2. Pump grease into bearing housings. Seal grease fitting with tape to prevent moisture getting in.
3. Fill the oil reservoirs to the top and tag them as “overfilled”
4. Seal any openings in electrical panels or control boxes, and move them under cover.
5. Protect against theft and vandalism.

INSTALLATION
SECTION
2.2
PAGE
2
SSI Service Manual – 991196 Rev 6
FOUNDATION / STRUCTURAL REQUIREMENTS
The foundation must support the weight of the shredder, support structure, peripheral equipment, and
material being shredded.
SSI cannot evaluate foundation stability and design.
If the shredder head is going to be mounted on a support structure, consider the following:
• Footing requirements for load distribution
• Load-carrying capacity of the soil
• Rigidity of the support structure
• Walkways around shredder to aid in servicing the unit
The support structure should be bolted to the foundation. If SSI is supplying the support structure, two,
three, or four mount holes will be provided in each pad. NOTE: Because of variations in fabrication,
mating foundation holes should be matched to the stand after it arrives at the site.
SSI can provide static foundation load information, as well as other data required for foundation strength
analysis in seismically active areas. It is highly recommended that the foundation design be reviewed by a
qualified structural engineer who is familiar with all appropriate codes and other requirements.
ASSEMBLY, INSTALLATION INSTRUCTIONS
When assembling Shredding Equipment, including but not limited to stand, shredder and hopper, the
following must be taken into consideration.
• Use appropriately rated lifting gear (slings, hooks, chains and lifting machinery) which must be used
by qualified personnel.
• Use appropriate lifting points provided on equipment .
• Refer to General Arrangement, Electrical Schematics and Assembly drawings provided in section 11
for assembly detail and dimensions.
• Torque bolts to specifications on Assembly drawings.
ELECTRICAL SYSTEM CONSIDERATIONS
Prevent electrical shock injuries and equipment damage. External wiring,
connections, and interlock devices must be installed in accordance with the latest
national electric codes, local codes, and local electric utility requirements. Only
competent, authorized electricians should attempt to install, modify, and maintain
the electrical system.