This material is supplied for use with the following Kelly Duplex machine: Machine: Model: Shipping Order

No.: Year Purchased:

DMMC Instruction Sheet 1183-1, Rev. 6/15/2005

Page 1 of 13

DMMC Instruction Sheet 1183-1, Rev. 6/15/2005

Page 2 of 13

Models KT, M, M10, K20 and S

PART NO.
100 101 102 103 104 105 106 107

PART DESCRIPTION
Sealing strip 180 deg. elbow Blower side (outside) Fan Feed pan Blower Housing w/protective cap Blower side (inside) Main shaft (short shaft for direct connected motor) (long shaft for belt drive) Cylinder discs Cylinder nuts Hammers: (complete set)
1/4, 3/8, Carbide Tipped

PART NO.
132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159

PART DESCRIPTION
Screen change panel Hinge rod for panel Feet Coupling seal Coupling bolts (set of 6) Coupling cover (two halves) Coupling mill side Coupling spring half Coupling spring half Coupling half-motor side Coupling gasket Coupling nuts Screen cradle eye bolt Finger guard Mill body Mill cover low top Mill cover high top Mill chute (plain)
Large adjustable mill chute

PART NO.
167 168 169 170 171 172 173 174 175 176 177 178 179

PART DESCRIPTION
Blower stack with protective cap Bolt, nut and washer Fan hub Fan Seal Ring Lock Washer Fan housing cover Bolt, nut and washer Bolt, nut and washer Fan liner Bolt Bolt Complete mill cylinder w/ bearings, pillow blocks and hammer rods. Assembled and balanced Inlet protective enclosure hood with segmented deflector curtain Totally enclosed coupling shield Protective interlocking limit switch (PLS) Padlockable protective interlocking electrical control switch (PCS) Operators Manual Case (OMC)

108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131

Hammer rods Spacers Pillow block Grease, 5 lb. can (special for high speed bearings) Seal ring (small) Lock Nut Lock washer Ball bearing Stabilizing ring Seal ring (large) Hammer rod pin Cradle hinge rod Chain cradle Cradle handle with nut Retarding screen clamp (top) Retarding screen Retarding screen clamp (bottom) Door lock handle Screen Vent slide gate Cradle hinge rod nut

180

160 161 162 163 164 165 166

Magnetic separator Chute arm Hand wheel Adjusting rod Spring Spring rod Hinge rod Hinge rod collar Motor sheave (Specify by outside dia. and number of grooves desired) Vent door Thumb Screw Air intake assembly with protective grate Feed pan Plate 180 deg. gooseneck elbow Blower housing

181 182 183 184

DMMC Instruction Sheet 1183-1, Rev. 6/15/2005

Page 3 of 13

DIMENSIONS
Approximate: Models KT, M, M10, K20 & S

DMMC Instruction Sheet 1183-1, Rev. 6/15/2005

Page 4 of 13

PART NO.
182

PART DESCRIPTION
Protective interlocking limit switch (PLS

PART NO. PART DESCRIPTION

416 417 418 419 420 Blower drive sheave Blower shaft Cap for bearing housing Ball bearing Bearing spacer Fan side (outside) Fan Fan housing w/protective cap Fan side (intake) Steel chute bottom Screen guide, lower Screen guide, upper Mill screen (complete set) Screen clamp band Screen clamp casting (inside) Screen clamp casting (outside) Adjusting screw for clamp Adjusting screw spring Nut Set screw Vent elbow with protective grate Mill top quarter section

PART NO. PART DESCRIPTION

438 439 440 441 442 443 Cap Screw Main body Lock washer Chute for Model LT Screen Puller Complete mill cylinder w/ bearings, pillow blocks and hammer rods. Assembled and balanced

183 184 401 402

PCS OMC 4 B sheave to blower Motor sheave (Specify by outside dia. and number of grooves) Main Shaft Pillow block (no bearing) Finger (small oil ring) Lock Nut Lock Washer Ball bearing Stabilizing ring Flinger (large oil ring) Cylinder arm Cylinder washer Cylinder arm spacer Hammer rod Hammers: (complete set)
1/4, 3/8, Carbide Tipped

403 404 405 406 407 408 409 410 411 412 413 414 415

421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437

444

Inlet protective enclosure hood with segmented deflector curtain Totally enclosed drive shields Totally enclosed drive shield for mill crusher drive

445 446

DMMC Instruction Sheet 1183-1, Rev. 6/15/2005

Page 5 of 13

DIMENSIONS

Approximate: Models L and LT

DMMC Instruction Sheet 1183-1, Rev. 6/15/2005

Page 6 of 13

DMMC Instruction Sheet 1183-1, Rev. 6/15/2005

Page 7 of 13

Models DS, D, FF and FFD

PART NO.
181 182 183 184 3100 3101 3102 3103 3104

PART DESCRIPTION
Totally Enclosed coupling shield Protective interlocking limit switch (PLS) PCS OMC Adjusting hinge rod Panel hinge rod Screen change and maintenance panel Adjusting plate Main shaft (short shaft for direct connected motor, long shaft for belt drive) Cradle handle Set screws for cradle handle Nut for cradle handle Washers for cradle handle(2) Eye bolt for cradle handle Back panel Adjusting screw Hammer rod Hammers: (complete set)
1/4, 3/8, Carbide Tipped

PART NO.
3135 3136 3137 3137a 3138 3139 3140 3141 3141a 3142 3143 3144 3145 3146 3147 3148 3149 3150 3151 3152 3153 3154 3155 3156 3157 3158 3159 3160 3161 3162 3163 3164 3165 3166 3167 3168 3169 3170 3171 3172 3173 3174 3175 3176 3177

PART DESCRIPTION
Angle iron ring Side seal Mill side for separate chute (left) Mill side with integral chute (left) (right side not shown) Feed pan Screen stop Top plate Bottom plate, mill only, for separate chute Bottom plate for integral mill and chute Coupling Cover Bolts Coupling gasket Coupling half-motor side Key Coupling cover nuts Coupling spring Coupling-mill side Coupling cover Coupling seal(not shown) Pillow block Hammer rod cover Nut Lock washer Tie rod Mill side for separate chute (right) Motor Motor key Chute sides Bottom chute pan Magnet frame Magnet Magnet fastener Mill frame Cap screw Cylinder discs Nut for cradle handle Washers for cradle handle Eye bolt for cradle handle Cradle handle Set screws Slide gate Mill transition Slide spacer Blower transition Back panel (FF) Long sweep elbow

PART NO.
3178 3179 3180 3181 3182 3183 3184 3185 3186 3187 3188 3189 3190 3191 3192 3193 3194 3195 3196 3197 3198 3199 3200 3201 3202 3203 3204 3205 3206 3207 3208 3209 3210 3211 3212 3213 3214 3215 3216 3217 3218 3219 3220 3221

PART DESCRIPTION
Dust collector Blower pipe (to dust collector) Dust collector ring Bolts for dust collector frame Legs for dust collector frame Conveyor outer tube U-trough cover with collector flange Nut Hanger rod Spiral Zerk Hanger bearing Bearing sleeve Coupling shaft Plain trough cover Motor Sheave set screw Motor key Sheave Belts Motor mounting plate Adjusting Nut Take-up stud Discharge screw endplate Motor mounting bracket Key Gear reducer Key Set screw Drive shaft Leveling screw nut Leveling screw Sheave Totally enclosed drive guard Standard discharge Set screw Rack and pinion wheel Shaft bearing Set screw Stabilizing collar Shaft Key Pinion gear Set screw

3105 3106 3107 3108 3109 3110 3111 3112 3113 3114 3115 3116 3117 3119 3120 3121 3122 3123 3124 3125 3126 3127 3127A 3128 3129 3130 3131 3132 3133 3134

Chain cradle Screen Cradle hinge rod Hammer Rod pin Large seal ring Lock washer Lock Nut Small seal ring Ball bearing Stabilizing ring Hinge rod cover Blower stack Blower housing Fan Liner Fan seal Fan hub Fan, hub type, 6 blades, 19 diameter Fan inspection panel Blower pipe 180 deg goose neck elbow Blower housing front cover

DMMC Instruction Sheet 1183-1, Rev. 6/15/2005

Page 8 of 13

PART NO.
3222 3223 3224 3225 3226 3227 3228 3229 3230 3231 3232 3233 3234 3235 3236 3237

PART DESCRIPTION
Flat head screw Rack holder Rack U-trough Rack and pinion discharge Slide Blower stack Bearing Seal Endplate Transition pipe Inspection door Blower front Fan, 6 blades, hub type, 14 diameter Fan hub Fan seal

PART NO.
3238 3238A 3239 3240 3241 3242 3243 3244 3245 3246 3247 3248 3249 3250 3251 3252 3253 3254

PART DESCRIPTION
Blower stack Fan liner Bearing Shaft Sprocket Screen Flapper Cotter key Rod Bearing bolts Bolts (4) Lock washers (4) Spacers (4) Nuts Reel Screen guide track Reel stand Adjusting Bolt

PART NO.
3255 3256 3257 3258 3259 3260 3261 3262 3263 3264 3265 3266 3267 3268 3269

PART DESCRIPTION
Screen change adjustment assembly Bolt Screen guide arm Washer Nut Screen door Bracket Mounting brackets for door Rod Rod Set screw Collar Cradle Arm Handle assembly Inlet protection enclosure hood with segmented deflector curtain

DMMC Instruction Sheet 1183-1, Rev. 6/15/2005

Page 9 of 13

DMMC Instruction Sheet 1183-1, Rev. 6/15/2005

Page 10 of 13

WARNING !

TO PREVENT DEATH, SERIOUS BODILY INJURY OR PROPERTY DAMAGE

Before you install your Kelly Duplex HAMMERMILL READ AND OBSERVE THIS INSRUCTION SHEET Do not attempt to assemble, connect power to, install, clean, service, maintain, adjust, repair or operate this HAMMERMILL until you read, understand and comply with this instruction sheet, and with DMMC Publication #369, KELLY DUPLEX PROCESSING MACHINERY HAZARD WARNINGS.

Remember ! Safety is everyones business!

STANDARD HAZARD CONTROL EQUIPMENT:

Depending on model, style, type and application your Kelly Duplex HAMMERMILL may be equipped with the following listed hazard control equipment. This equipment shall be kept in good repair and proper operational condition at all times. 1. Padlockable Protective Interlocking Electrical Control Switch (PCS): Install and wire as directed by DMMC publication #369. Note: if your machinery package is equipped with a factory supplied Motor Control Center, then a Lockable Emergency Stop Switch may be used in place of a separate PCS. 2. Operators Manual case (OMC): Supervisors are required to make use of the OMC as directed by DMMC publication #369. Each HAMMERMILL is furnished with a factory installed OMC. 3. Protective Interlocking Limit Switch (PLS): Install, wire and use as directed by DMMC publication #369. Machinery operators shall not attempt to override or by-pass the protective functions of the factory installed PLS. 4. Protective Covers, Hoods and Grates: Inlet and discharge openings may be provided with factory installed protective covers and/or grates. All inlet and discharge openings must be completely enclosed to prevent human access to pinch points when machine is running and remain enclosed until power is disconnected and locked out, and machine has come to a complete stop. Keep away from running machinery. Wear appropriate hearing and eye personal protective devices at all times when operating machinery. 5. Drive Shield: If your new HAMMERMILL is equipped with a factory-supplied drive, the drive will be covered with a totally enclosed drive shield. If your drive comes from some other source, operation is PROHIBITED until a proper drive shield has been manufactured and installed.

5021-79

5051-87

5050-86

5024-79

DMMC Instruction Sheet 1183-1, Rev. 6/15/2005

Page 11 of 13

ITEMS FOR SPECIAL ATTENTION:

WARNING!
TO PREVENT PROPERTY DAMAGE, DEATH or SERIOUS BODILY INJURY: DO NOT ATTEMPT TO UNCLAMP OR OPEN ANY MAINTENANCE PANEL UNTIL THE HAMMERMILL IS EMPTY, THE POWER HAS BEEN TURNED OFF AND LOCKED OUT, AND THE MACHINE HAS COME TO A COMPLETE STOP. OPERATORS MUST NOT attempt to clean or maintain the HAMMERMILL without supervisor permission, and without approved personal protective equipment. Maintenance panels and protective grates or shields are not to be opened or removed unless POWER IS TURNED OFF AND LOCKED OUT AND THE MACHINE HAS COME TO A COMPLETE STOP. Panels provided with a Protective Interlocking Limit Switch (PLS) must be wired BEFORE initial start-up so that MACHINE CANNOT RUN UNLESS INTERLOCKED PANEL IS CLOSED AND SECURED.

WARNING!

TO PREVENT PROPERTY DAMAGE, DEATH or SERIOUS BODILY INJURY: DO NOT attempt to install, connect power to, or operate this HAMMERMILL or other machine, until you read, understand and comply with this instruction sheet and with DMMC Hazard Warning Instruction Sheet #369. Keep hands and feet, and all human body parts out of machine and away from moving parts at all times. Use material level indicators, shaft motion sensors, current sensing relays, and hot-bearing sensors to protect mechanical components. DO NOT OVERLOAD HAMMERMILL DRIVE. Use ammeter to indicate load before establishing HAMMERMILL operating conditions. DO NOT TO PREVENT PROPERTY DAMAGE, DEATH or SERIOUS BODILY INJURY: Hammermill must NEVER be operated unless mill screen and drive shields are in place and properly secured. NEVER allow any kind of metal or other foreign objects to enter the machine. Operators must use proper ear and eye personal protective equipment when

stop HAMMERMILL until it has been emptied. DO NOT ATTEMPT TO START HAMMERMILL UNDER LOAD. The HAMMERMILL user is required to furnish and install adequate access to any service platform or work platform, and to provide necessary work area enclosures to provide for the protection of service and maintenance personnel when working in the area of the HAMMERMILL. ALL MACHINE INLET AND DISCHARGE OPENINGS MUST BE COMPLETELY ENCLOSED TO PREVENT HUMAN ACCESS WHEN MACHINE IS RUNNING AND REMAIN ENCLOSED UNTIL POWER IS TURNED OFF AND LOCKED OUT AND THE MACHINE HAS COME TO A COMPLETE STOP. operating the hammermill. Inspect and log hammers, hammer rods, hammer rod pins, fan, fan liner and other wear points, coupling, drive sheaves, protective interlocking limit switches (PLS), padlockable protective interlocking electrical control switch (PCS) and operators manual case (OMC) as appropriate for operating conditions.

WARNING!

DMMC Instruction Sheet 1183-1, Rev. 6/15/2005

Page 12 of 13

5028-79

5029-79

5036-79

Ordering Repair Parts:

When ordering parts for your KELLY DUPLEX HAMMERMILL, please furnish all of the following information: (1) The model number of the hammermill, (2) The serial number of the hammermill; (3) The part number of each individual piece you are ordering. You will find that the model number and the serial number are plainly marked on the metal tag attached to the hammermill. Part numbers of individual items can be found on the inside pages of this folder. For best results, use only genuine KELLY DUPLEX REPAIR PARTS.
THE DUPLEX MILL & MANUFACTURING CO. 415 Sigler St., P.O. Box 1266, Springfield, OH 45506 U.S.A. TEL: 937-325-5555 FAX: 937-325-0859

IMPORTANT: All illustrations and specifications are subject to change without notice and any drawing dimensions may not be to scale. Machines shown with protective covers, guards, grates, maintenance panels or interlocking limit switches removed are for illustrative purposes only. All protective devices must be in place before power is connected to machine and before operation. All sales are subject to our prevailing terms and General Conditions of Sale. See DMMC #1281-9. SAFETY IS EVERYONES BUSINESS! Safe operations are profitable operations. Write or phone today for your free copy of our publication #369: KELLY DUPLEX PROCESSING MACHINERY HAZARD WARNINGS. Instruction Sheet No.: 1183-1, Rev. 6/15/2005 KEEP HUMAN BODY PARTS OUT OF MACHINE AT ALL TIMES!

DMMC Instruction Sheet 1183-1, Rev. 6/15/2005

Page 13 of 13