Single shaft shredder

Operation manual

Unit name: YL-2455 single shaft shredder unit

Equipment list ：
No. Item
1 YL-2455 single shaft shredder
2 YL-2455 belt conveyor
3 YL-PC500 crusher
4 YL-2455 blower storage system
5 YL-2455 electrical control cabinet
Form 1

Page 1 of 22
 Content
一、Brief introduction ..................................................................................................................... 4
二、Warnings .................................................................................................................................. 4
三、Machine introduction ............................................................................................................... 4
四、Basic parameters ...................................................................................................................... 5
五、Transportation and location ...................................................................................................... 5
5.1Crane moving ...................................................................................................................... 5
5.2 Folk truck transportation .................................................................................................... 6
5.3 Machine location ................................................................................................................ 6
六、Machine function ..................................................................................................................... 6
6.1 Description ......................................................................................................................... 6
6.2 Machine structure parameters ............................................................................................ 6
6.3 Overload protection ............................................................................................................ 7
七、Safety items .............................................................................................................................. 7
7.1 Dangerous items ................................................................................................................. 7
7.2 Warning .............................................................................................................................. 7
八、Assembling .............................................................................................................................. 8
8.1 Pre-inspection before running ............................................................................................ 8
8.2 Circuit connection .............................................................................................................. 8
九、Operation and daily maintenance ............................................................................................. 8
9.1 Operator train ..................................................................................................................... 8
9.2 Operation instruction .......................................................................................................... 8
9.3 Basic operation method .................................................................................................... 10
9.4 Warnings .......................................................................................................................... 11
9.5 Inspection ......................................................................................................................... 11
9.5.1 Daily inspection .................................................................................................... 12
9.5.2 Week inspection .................................................................................................... 12
9.5.3 Half-year inspection .............................................................................................. 12
9.5.4 One year inspection ............................................................................................... 12
9.5.6 Bearing lubrication： ............................................................................................ 12
9.6 Cleaning ........................................................................................................................... 13
十、Troubleshooting ..................................................................................................................... 13
十一、Maintenance ....................................................................................................................... 13
11.1 Changing blades ............................................................................................................. 13
11.1.1 Blade disassembly ............................................................................................... 13
11.1.2 Blade assembly .................................................................................................... 13
11.2 Pulley assembly .............................................................................................................. 14
11.3 Driving belt assembly..................................................................................................... 14
11.4 Belt tension ..................................................................................................................... 14
11.5 Bearings replacement ..................................................................................................... 15
十二、Reducer condition .............................................................................................................. 15
12.1 Running caution ............................................................................................................. 15
12.2 Repair and maintenance ................................................................................................. 16

Page 2 of 22
 12.3 Periodic table for maintenance ....................................................................................... 16
12.4 Common troubleshooting ............................................................................................... 17
十三、Hydraulic system ................................................................................................................ 17
13.1 Main technical parameter ............................................................................................... 17
13.2 Cautions for first time use .............................................................................................. 18
13.3 Repair and maintenance ................................................................................................. 19
13.3.1 Checking items for hydraulic system .................................................................. 19
13.3.2 Maintenance of hydraulic system ........................................................................ 20
13.3.3 Warning for hydraulic system maintenance ........................................................ 20
13.4 Common trouble shooting .............................................................................................. 21
13.4.1 Unusual system pressure ..................................................................................... 21
13.4.2 Abnormal movement ........................................................................................... 21
13.4.3 Oil temperature too high ..................................................................................... 22

Page 3 of 22
一、Brief introduction

Welcome to choose our shredder series products. Please carefully read the
operation manual before running the machine. Adept operation and skills will do a
lot of help to machine service life, running safety and improve working efficiency.
At the same time, this will largely decrease possibility of machine problem and
human safety threat. If you still get any confusion after understanding this
operation, please contact our after-sale service department immediately.

二、Warnings

Machine knives are very sharp and dangerous, please do take care during
maintenance. When checking machine, please do make sure the power supply is cut.
Any part of the body (hand, foot, hair etc.) should not get in touch with any part of
the running machine(Each machine has warning marks to remind).

三、Machine introduction

YL-2455 single-shaft shredder consists of a motor, a reducer with rigid gears, a

rotary shaft, imported rotary knife, fixed knife, frame, working platform, hydraulic
ram and an independent electrical control cabinet.
Fixed knives are installed on the frame behind the solid rotary shaft where the
moving knives are bolted. Moving knives are specially designed into four-angel
shape, when blunt customers could change the angel for recycling using. Moving
knives are installed by screws, which is convenient for future maintenance.
A hydraulic cylinder drove by hydraulic ram continually pushes the material
chamber moving back and forward to get the material multi-angel shredding. Two
travel switches are fitted near the side jampans to control the movement. A screen
mesh is needed sometimes to ensure materials shredded even further.
Single-shaft shredder is controlled by an independent electrical cabinet equipped
with PLC system. The machine features start, stop, reverse functions. Also it is fitted
with automatic overload return mechanism to prevent damage to working parts.

Page 4 of 22
四、Basic parameters

Machine Model YL-2455

Moving knife 24 pcs

Feeding mouth 780×550mm

Rotary shaft diameter 275

Shaft length 550mm
Rotary speed 87rpm
Main motor power 24KW
Hydraulic ram power 4KW
Machine weight 3600kg
Motor protection stage IP44
Decibel 95~110db
Discharge conveyor motor 1.5KW
Belt width 400mm
Crusher motor 15KW
Roller diameter 290mm
Moving knife qty. 15pcs
Fixed knife qty. 2pcs
Blower motor power 3KW
Silo volume 0.7CBM
Form 2

五、Transportation and location

5.1 Crane moving
Lock four slings into four corners of the travel jampan, then ensure the machine
will not be damaged during lifting. Before lifting, do make the four slings are tightly
locked up. Working method showed as below:

Page 5 of 22
 Image 1

5.2 Folk truck transportation

When the single shaft shredder is lifting through a folk truck, must pay attention
to supporting the machine's center of gravity, and with a strap tied to the machine
with the truck in the handling process in order to avoid dangerous eccentric.

5.3 Machine location

Equipment installation location must consider the space required for maintenance operations.
While ensuring a smooth display device, the best on rubber pads on each branch, four feet must
be pad level. Conveyor are movable member, customers can arrange the electrical control system
according to floor space.

六、Machine function
6.1 Description
After the materials are feed into the hopper, the hydraulic ram at the back of the
shredder will push and hopper move towards the rotating shaft, where the fixed
knives and moving knives are bolted. Material will drop down from space of shaft
and fixed knife, then transported by the downside belt conveyor.

6.2 Machine structure parameters

Details：
Shredder Model YL-2455
Exterior size 3400×1800×2500mm

Page 6 of 22
 Feeding mouth 780×550mm
Total weight 3600kg
Hopper design Hopper moving
Form 3

6.3 Overload protection

In order to prevent accidents and to ensure the normal use of the machine, the
machine is installed with overload protection system. The machine has sharp knife,
but when come across some very thick and solid materials, it may come into crash
condition. Therefore once the machine hopper overload halt, then back for a few
seconds, to ensure internal parts of the machine in good condition.
Warnings：<1> Press emergency button to stop machine under emergency condition.
<2> Ensure machine is shut down before cleaning and maintenance.
<3>Before running, check and confirm below items：
a) Confirm every part is tightly connected.
b) Clean the left materials between shaft and fixed knife.
c) Ensure stop button is good to use.

七、Safety items
7.1 Dangerous items
a) Rotary knife is very sharp and easy to cause into damage. Ensure power supply
is shut down when finishing work.
b) Feeding by man during the machine is running is dangerous. Do ensure machine
is shut down when feeding. Or choose belt conveyor automation feeding.
c) When opening the screen, do ensure machine is shut down.
d) Electrical cabinet is connected with high voltage, do be careful when opration.
e) High pressure oil pipe may have the risk of high pressure liquid erupting. Do
check the pipe is tight before running.

7.2 Warning
a) Electrical cabinet assembling and maintenance should be operated by
experienced engineers
b) When the machine maintenance must close the stop button, in order to prevent
misuse of the air circuit breaker can be disconnected and locked electrical boxes,
while hanging warning signs.
c) Make sure body is away from the machine before it totally stops.
d) Before unacknowledged machine stops running, do not open the screen bracket,
belt cover, cylinder cover.
e) If the motor is overloaded circuit caused the fire, you should first turn off the
power and use a fire extinguisher. As the use of reasonable basic cable this
situation does not occur.

Page 7 of 22
八、Assembling
(1) All parts must be correctly installed, to avoid personal injury or damage to the
machine.
(2) Blade is very sharp, when installed, should be very careful not to cut.
(3) Machine's power cord is connected by electrical workers.

8.1 Pre-inspection before running

 Before machine installation, you should carefully remove rust preventive oil on
parts.
 Check whether the joints connecting tightened.
 Check the hydraulic system oil level should not be less than the oil standard
midline, each part of the joint should be no oil leakage.
 Check the bearing, whether oiled gear reducer whether water cooling.

8.2 Circuit connection

 Machine circuit connections by professional electrical engineer.
 Machine power cord is connected to the power supply, refer to the circuit
diagram;
 Check the stop switch, reset confirmation;
 Press F1 automation start to running machine；
 Check the motor rotation direction is consistent with the direction of the arrow
on the housing, if the direction is not correct, alter the power cord;
 Check the fuel tank is accurate and smooth operation of the hydraulic system for
any leaks;
 Check Push hopper limit switch is reliable.

九、Operation and daily maintenance

9.1 Operator train
The machine should be equipped with a professional operator, the operator
before the induction, training should be professional operation. The operator should
be a basic quality: the professional operator should have some mechanical knowledge,
rapid response, quick action after determining the operation of candidates, should be
allowed to read the instructions, master the basic operation of the machine
performance, to understand the function of each control button and operating skills,
understand the working principle of the machine after the operation of the machine
before induction.

9.2 Operation instruction

(1) The machine should be grounded on stable place to ensure that there is sufficient
room for maneuver; ministries before turning to check for loose bolts, checking
Page 8 of 22
 the use of props, check whether there is debris inside the chassis; the start button
to be sensitive, the machine is no exception sound, non-startup phase;
non-metallic materials or materials containing metal parts thrown into the
discharge port; to keep the blade sharp edge; if the hydraulic oil reserves comply
with the requirements.
(2) The operator should be standing in front of the electrical control cabinet of the
machine, if broken thick or hard materials broken, the operator may not leave
their jobs in order to keep track of and control the machine's working condition.
(3) Start sequence is：connect power supply—start oil pump—start main motor—
hopper moves—feeding. Also we can choose auto start.
(4) Stop sequence is：stop feeding—hopper move to backward—stop motor.
(5) Due to higher crushing efficiency of the machine, when the material too much,
PLC set overcurrent protection, the hopper will automatically move back, and
also the shaft may revise to protect machine damage from hard force.

Page 9 of 22
 Form 4

9.3 Basic operation method

a) Connect the control wire and powers supply as the indication of circuit diagram.
b) Try starting single machine, and seeing if oil pump and main shaft rotary
direction are right as the arrow shows, and examine manual debugging is as the
direction of the electrical cabinet indicates. If one of those is not right, please
change the direction according to the circuit diagram, if all is right it can start to
work.
c) Normal working way: starting oil pump, starting rotary shaft, choosing the
automatic switch, and then pressing the automatic start and then shredder will
start to shred automatically. The feeding inlet can filled one time and can
continuous feeding in the work only don’t let the plastic drop out. If there is
overcurrent appears in the work, the work platform will automatically stop
feeding or back to protect the main motor.
d) In order to ensure the main motor starts under no-load, if need to stop or restart
after stop in the working process it has to make sure the hopper is at the end of
the machine.
e) The current setting have already setup completed before delivery, in order to
Page 10 of 22
 protect the life of motor, please don’t resetting it; but can adjust the oil pressure,
the higher the pressure is, the thicker the shredding thickness will be, but the
damage for the machine rises as well, the principle is not more than 90kg/m2 to
be the highest working pressure.
f) After powered on, press the direction key《▼》to enter the system, enter the
second page and the start the oil pump, check that if the motor rotating in the
right direction, and the check if the rotating direction of main shaft motor,
crusher motor and blower motor are right，after sure all is right, starting the main
shaft motor, after the motor is normal working, press F7 and then the shredder
hopper should move forward, and press F8 the shredder hopper should move
back; this operation can only done when the shredder hopper is empty, after
feeding can only operate the hopper move back.
g) Press the key《▼》to enter the automatic start page, press F1 to automatic start,
the blower starts(if have), and the crusher starts(if have) at the same time, after
the crusher working normally, the main shaft will automatic start a few seconds
later and no need to press other keys, the operation of start is over after the main
shaft reduction voltage starting normally. If the shaft is got stuck, please push the
hopper back to the limit switch and the restart the machine. Please don’t adjust
the adjusting valve on the oil cylinder at will, watching the current of the motor,
and when the crusher and main shaft motor are working normally the current on
the ammeter cannot use the rated current to measure, maybe the motor have
already got stuck when the ammeter shows large current. And the motor
protection in the electrical cabinet please don’t use the motor’s rated current to
measure and adjust, under the situation of normal working and inaction please
try to turn it smaller, please don’t just aimlessly focus on the output, and avoid to
damage the motor.
h) Stop: when ready to stop the machine, please let the hopper move back to the end,
and the press F2 to automatically stop, the main shaft and oil pump will stop，the
crusher and blower are still rotating, after the material in the crusher is crushed
done and then stop the motor, or when you try to restart the machine the motor
cannot start, if this is happened, please clean the material in the hopper of the
crusher, please don’t start it forcibly.

9.4 Warnings
1) Try to remove the fan before starting the indoor residual material.
2) Machine should be equipped with conveyor belt feeding machine, such as the
need to manually direct feed, you must set the necessary security measures to
ensure personal safety, please contact our company or dealer.

9.5 Inspection
Note: 1. Machine maintenance and repair should be carried out in strict accordance
with safety regulations, it must be cut off.
2. The following care and maintenance period is limited to 8 hours / day, if
more than 8 hours / day, maintenance and service intervals are reduced
Page 11 of 22
 accordingly.

9.5.1 Daily inspection

 Check the stop switch, power on, press the stop switch, if the machine is
immediately stopped, indicating that the stop switch is normal, and then press the
start button to restart.
 Check the fuel tank is accurate and smooth operation of the hydraulic system for
any leaks;
 Check travel switch is still reliable.
 Check the inner gear oil, with or without leakage;
 Check the moving knife and fixed knife, if any broken or blunt.

9.5.2 Week inspection

 Check the wire: Check wiring is damaged, in order to ensure production safety,
damage the wires must be replaced;
 Check the connection member is solid and reliable connection, bolts are loose;
 Check the belt tension situation;
 Check the safety switch: Check the safety switch according to the following
procedure must be very careful!
 Close the safety switch, then start the machine;
 Machine running normally, then shut it down.
 Close safety switch, the open the machine. If can not start it, meaning safety
switch is OK.
Warning: please do not open the screen when machine is running.

9.5.3 Half-year inspection

 Check the hydraulic oil usage, periodic replacement;
 Check the belt wear;
 Check the screen for wear;
 Check bearing usage.

9.5.4 One year inspection

 Conduct a comprehensive inspection of the machine, the need for replacement
parts to be replaced;
 Check the grounding line is good, if there is leakage, if there is please find
electrical engineer maintenance, to prevent accidents;
 Check reducer oil condition.

9.5.6 Bearing lubrication：

1) To keep machine and human safety, please choose good quality and right model
lubrication oil, name: 2 lithium grease. Filling amount of grease to the bearing
cavity space is generally 1/3 ~ 1/2. Single bearing oil adding quantity as below：

Shredder Model YL-2455

Oil amount 0.5~0.9L

Page 12 of 22
 表格 4
2) If you do not use the proper lubricating oil too much or not enough will cause
overheating and wear situation that we refuse to take responsibility.
3) When the grease dirty, dry or aging time, should be replaced. Under normal
circumstances, must be well-lubricated bearings must be re-added grease after 24
hours of operation, the grease from the fuel injection nozzle into the bearing.
9.6 Cleaning
Before cleaning the machine, be sure to first turn off the power switch and locked in the off
position and place the maintenance warning signs! When the machine cleanup should wear work
gloves to avoid injury, wear a mask to prevent inhalation of dust, if necessary; open sieve tray,
first brush cleaning, blow clean with compressed air; as long the machine does not work, should
guide the internal chassis Article knife roll, fixed knife clean up after the coated anti-rust oil.

十、Troubleshooting
a) If the machine can’t running, please firstly check the circuit according to
electrical diagram.
b) Check the hopper finding if there are materials stuck.
c) Then check whether hydraulic ram and travel switch is running good.
d) If still can’t solve the problem, please contact our company or agent.

十一、Maintenance

To avoid personal injury and damage to the machine, all repairs must be
performed by professional service personnel. Before servicing the machine, be sure
to first turn off the power switch and locked in the off position and place the
maintenance warning signs! Maintenance should strictly abide by safety rules.

11.1 Changing blades

Warning: blade sharp, do take care when handing.

11.1.1 Blade disassembly

(1) Open screen cover(if have), loosen screws, take down the fixed knife.
(2) Loosen screens in the shaft, take down the moving knife.

11.1.2 Blade assembly

 Rotate the bully by hand, change shaft face position, then change the blade.
 Adjust the distance between fixed knife and moving knife into1~3mm
 Use a hex socket wretch to tighten screws, torque number as below chat:
Screw size M14 M16 M18 M20 M22 M24 M27 M30 M36
Torque（Nm）8.8 137 206 284 402 539 686 1029 1225 1764
Torque（Nm）10.9 165 247 314 569 765 981 1472 1962 2453
Torque（Nm）12.9 225 363 480 676 911 1176 1764 2352 2940

Page 13 of 22
 Form 5
 All blades fixing screws, non-arbitrary replacement! Such as the need to
replace damaged and must be replaced with the same level of performance
screw element screws;

11.2 Pulley assembly

 Before assembling the transmission, check the pulley groove, should ensure that
no injuries or sharp edges, all dimensions are standard.
 Clear shaft sleeve, pulleys cooperating dirt surface of the sleeve, pulley set into
the shaft.
 There are leather on the wheel teeth half hole on the drogue toothless half hole
(the hole, said mounting hole); toothless hole on the pulley with teeth on the
cone sleeve hole (the orifice known as disassembly hole).
 Mobile sleeve in an ideal position, gently pull the pulley cone sleeve, is inserted
into the mounting hole in the hexagonal bolts.
 Use hex wrench to tighten the bolts gradually, until it reaches the torque in the
table below. (Note: To ensure tight fit, the bolts must be tightened evenly).
 To assemble the key, the key must first be placed on the keyway shaft, then in the
assembly sleeve.
 Pulley After installation, to ensure that the two pulleys parallel to the axis, the
position should be aligned.
 Running for some time under load, stop and tighten bolts of inspection.
 Tighten all screws, remove one or two bolt holes according to the number of
demolition, lubricating bolt patterns and bolt tip, the bolt insertion hole
disassembly.
 Tighten the bolts alternately until the sleeve and pulleys release.
 Remove the sleeve and pulleys from the shaft (such as holding the sleeve and the
shaft is too dead, available flat screwdriver to gently expand the drogue linear
grooves, cut excessive force to prevent the sleeve burst).

11.3 Driving belt assembly

Before you put the belt pulley Align the mounting, to avoid the belt flank wear.
Belts need to be installed before the center distance a little shorter, so that the belt can
be assembled effortlessly. In any case, it must not be allowed to pry into the belt
pulley shaft inside. Stretch belt with a sharp tool to make it into the round groove of
practice sets, easy to damage the belt and pulley groove.

11.4 Belt tension

Belts are wearing parts, will stretch when used, require frequent adjustment,
always check the belt tensioner situation so that they can ensure the normal operation
of the belt has a longer service life. Belt tension can be adjusted by the mounting
plate of the motor to achieve. You must always ensure that when adjusting the belt
pulley axis perpendicular.

Page 14 of 22
To determine the belt tension: Measuring two pulley center distance, according to
16mm / m calculated belt deflection.
Center distance (m) X16 = deflection (mm)
Force must be enough to make belt slanted
Compared the force on The force required to make belt deflection at 16mm
the belt with the number
Small block diameter（mm） Newton（N） （kg*h）
in the chat
Small pulley diameter（mm） Newton（N） （kg*h）

112~224 45~65 4.6~6.6

SPB
236~315 65~85 6.6~8.7
224~355 85~115 8.7~11.7
SPC
375~560 115~150 11.7~15.3
Form 6
If the force value is measured in the range of values given, the transmission
power should be considered satisfactory; if the force measured value is less than the
given value, indicating insufficient belt tension. Newly installed drive belt tensioner
to high tension value should be, but fortunately landed during normal tension test.
Belt drive should be checked after 30 minutes running belt tension and, if necessary,
re-adjust the belt tension to a higher value.

11.5 Bearings replacement

Replace the bearings by professionals should perform the following steps:
(1) Stop shredder；
(2) Take down belt cover；
(3) Take down driving belt；
(4) Take reducer；
(5) Open bearing base cover；
(6) Take down roller and round screw；
(7) Take down bearing base along with bearing；
(8) Clean bearing base and assemble same size bearing, assembly method is
opposite to disassembly.
(9) When assembly, do be careful to avoid damage to bearing.

十二、Reducer condition
12.1 Running caution
Before starting machine, ensure there is enough oil in reducer. First time oil
adding amount as below：

Machine model YL-2455

Gear box oil(kg) 50~60kg
Fuel cycle At least three months
Oil size 46# gear box oil
Page 15 of 22
 Form 7
(1) Oil is normally added before shipping；
(2) Reducer working temperature should be less than 40℃，Inside oil temperature
should be less than 80℃；
(3) When the ambient temperature is below 0 ℃, before the starting machine, the
oil must be heated to above 0 ℃ or choosing lubricating oil with low freezing
point, it is best to run a few minutes before the start without load；
(4) According to different operation condition, the temperature of reducer,
lubrication oil and small parts could be very high. Do not touch the area.
(5) Reducer is suitable for continuous running, also equipped with revise
mechanism.
(6) Before running, please get in cooling water, water flow direction is flexible, but
pressure should be less than 8bar. To avoid high pressure, water flow entrance
should have a pressure controller.
(7) Before running, please do check the oil amount in the reducer.
(8) If found anomalies (such as overheating or unusual noise, etc.) in the gearbox
during operation, should immediately stop and check.

12.2 Repair and maintenance

 For gearbox repair, maintenance , installation must be carried out when the
reducer does not work;
 Avoid hammering any parts during assembly and disassembly；
 After 400 hours running, please change the oil and clean the oil dirt (adding
amount according to Form 7).
 After first time oil changing, reducer oil should be replaced every 3000 hours.
 When changing lubrication oil, do be careful of the high oil temperature.
 When cleaning reducer inside, avoid using high pressure equipment.
 Alternate lubrication oil choice：
KUO-KUANG SHELL OIL MOBIL OIL ISO VG

HD-150 OMALA oil 220 MOBIL GEAR 630 EP220

Form 8

 Check oil level and add oil on time；

 Damaged screws during assembly or disassembly must be replaced with new
bolts back to the same level and type；
 It’s strictly avoided for welding work on reducer or serving as welding work
earth point, this will cause damage to reducer gear precision；
 When installed outdoors should avoid direct sunlight, be sure to avoid affecting
the normal performance of centralized heat reducer.

12.3 Periodic table for maintenance

Checking item Checking period Checking item Checking period
1.Oil temperature daily 7. Normal oil changing 3000 working hours
2.Unsual noise Daily 8.Clean breather cap Every three month
Page 16 of 22
3.Oil level Every month 9.Deposits in cooling tube 1 year, along with oil
changing
4.Oil leak Every month 10.Screw tightness Along with oil changing
5.Water percent in oil Once per year 11.All aspect checking 2 years, along with oil
changing
6.First time oil changing 400 working hours
Form 9

12.4 Common troubleshooting

Phenomenon Reason Solution
Big noise on tightening area Tightness screw flexible Tighten screws
1. Bad gear teeth inside Replace broken parts
Changes in reducer noise 2. Large bearing gap Adjust bearing gap smaller
3. Bearing broken Change new bearing, same size
1. Oil level too high or low Check level under normal
temperature, adding oil and
Bearing temperature too high decreasing
2. Oil too dirty Change new oil
3. Bearing broken Change new bearing
1. Oil level too high or low Check level under normal
temperature, adding oil and
decreasing
Working temperature too high
2. Oil too dirty Replace new oil
3. Oil is polluted Replace new oil
4. Cooling water flow too low Clean cooling tube
1. Bearing broken Change new one
Too high vibration at bearing
2. Gear teeth broken Change broken gear teeth
1. Body or connection part get bad seal Change and replace sealings
Reducer oil leakage
2. Shaft sealing broken Replace new one
Water in oil Cooling tube broken Change new cooling tube
Form 10

十三、Hydraulic system
13.1 Main technical parameter
Shredder Model YL-2455
Hydraulic ram power 4kw
Oil pump displacement 5.5L/min
Cooling method By cooling water
Pushing forward time Adjustable
Dragging backward time Adjustable
System rated pressure 7MPa

Page 17 of 22
 Form 11

13.2 Cautions for first time use

 Ensure oil tank get enough oil when first using, oil amount is as below chat：
Machine model YL-2455
Oil adding amount 40L

Form 12

Image 5

 Check oil level every three months, ensure oil level at 80% of total volume.
 Choose at least ISO VG32-46 anti-wear hydraulic oil
 Do not take out the screen mesh when adding oil.
 First time start, should pay attention to the hydraulic motor rotation direction and
the cooling air cooling blade rotation direction is correct;
 Ambient temperature range is used when the hydraulic station is 15 DEG -35
DEG, the ambient temperature is lower than 15 DEG C, should choose a heater
or depressant. In normal use, the temperature range of hydraulic oil should be
within 25 -50, and the highest should not be higher than 70. In use, such as in
case of high temperature and temperature mutation, should immediately stop
inspection, troubleshooting, and then use;
 The hydraulic system is equipped with rheumatism, cooler, air cooler should be
placed in ventilated open position, try to avoid in a closed space and near the
heat source.

Page 18 of 22
13.3 Repair and maintenance
13.3.1 Checking items for hydraulic system
Checked Checking Checking During Rated standard Maintenance Remark
item method period checking method
Run stop

Noise of Hearing or 1/season + Common When noise too Water, air

pump noise pressure: 7MPa; big, repair or mixed up
detector Noise≤75dB(A); change new one. with oil,
14MPa/noise screen
level≤90dB（A） blocked.
Pump body Temperature 1/year + 5~7 ℃ higher Stop and repair Oil
temperature indicator than oil when viscosity,
temperature temperature screen
increase largely block,
surrounding,
temperature.
Pressure of Pressure 1/season + Keep rated Stop and repair Pressure
pump gauge pressure when pressure is gauge
discharge changing largely co-vibration
mouth
Hydraulic Checking 1/season + Fault movement, Relief valve
ram movement bad sealing, etc. pressure
movement stability

Oil tank Seeing, 1/season + Piston rod is not Replace seal

leakage touching leaking
Dirt on Take out 1/season + No dirt on When screen
screen mesh screen surface, no gets too much
damage dirt, need to
wash or change
new one.
Pressure Standard 1/year + Error≤±1.5％ Big error or
gauge pressure damage, needs
display gauge to change new
one.
Temperature Standard 1/year + Error≤±1.5％ Big error or
valve test temperature damage, need to
valve change new one
Oil level Seeing 1/season + Keep in rated
range
Oil normal Seeing the 1/season + Meet standard oil If oil gets white
feature color, feature mark, needs to
smelling change new oil
Page 19 of 22
 Direction Check 1/season + Direction valve Replace new
valve movement outside without seal when oil
condition direction oil leakage leakage
when
changing
direction
Hydraulic Seeing and 1/season + No leakage Repair or change
device touching especially oil pipe new sealing
leakage joint
Rubber hose Seeing and 1/season + No damage Replace new one
outside touching when broken
damage
Form 13

13.3.2 Maintenance of hydraulic system

 In the process of the use of hydraulic system, should always keep the oil tank and
the oil tank around the clean, regular cleaning tank surface and hydraulic valve
parts on the dust, to prevent impurities or dust into the hydraulic system;
 Non-refueling or maintenance, the rest of the time is not open the gas port;
 It is strictly forbidden to take out the filter in the gas inlet to the system;
 Can shorten the inspection period of the "fuel tank level" project inspection, in
order to ensure that the hydraulic system has enough hydraulic oil to circulate
cooling;
 Check if any joint is loose, to prevent the air into the hydraulic system;
 To ensure the normal conditions in the system, the pressure relief valve should be
adjusted to a low point, in order to reduce energy consumption, reduce heat;
 The water cooling system, often need to check the cooling water supply, the
normal work of the system;
 The replacement cycle of hydraulic medium: (1) the hydraulic oil: 12~18 months;
(2) special hydraulic oil: more than 12 months; (5 days and 8 hours)

13.3.3 Warning for hydraulic system maintenance

 The maintenance requirements of the hydraulic system by the hydraulic
professional personnel responsible for maintenance;
 The system must be shut down, without pressure relief, not cut off the control
power, prohibited for maintenance of the system, to prevent the occurrence of
casualty accidents;
 The repair site must be kept clean, remove or loosen the pipe must be removed
before the component surface dirt, the repair process in a timely manner with
clean cover all exposed openings sealed to prevent contaminants from entering
the system. Do not allow the maintenance of the site to be polished, construction
and welding operations;
 To repair or replace the components must be kept clean, no dirt, sand, welding
slag, if can rinse, in installation;

Page 20 of 22
 To replace the seal, using a sharp tool does not allow the notice shall not damage
the seal or working surface;
 The removal or decomposition of hydraulic components should pay attention to
the direction and sequence of parts and properly preserved, not lost, not to hurt
the finish surface. When components are assembled, the parts must be cleaned;
 The hydraulic valve on the connecting screws does not allow arbitrary
replacement.

13.4 Common trouble shooting

13.4.1 Unusual system pressure
Fault phenomena and reasons Elimination method
1. Oil pressure pump does not absorb oil Oil adding, replace screen mesh
2. Oil spill over the tank Adjust overflow valve
No pressure 3..Oil pump broken Repair or replacement
4..Error position of pump’s direction control device Check control circuit
5..Pump’s driving device broken Repair or adjust coupling
1..Side valve of overflow valve broken Repair or replacement
2.. Rated date of overflow valve too low Reset
3..Big oil leakage of oil pump and oil tank Repair or replacement
Lack of pressure
4.. Rotation speed of oil pump too low Check hydraulic motor and
control
5..Oil level too low Adding to rated level
1.Air mixed into oil tank Adding oil and exhaust
2.Overflow valve broken, spring rigidity too high Repair or replacement
Unstable pressure
3.Oil pollution Washing and change oil
4.Pump and cylinder wearing Repair or replacement
Form 14

13.4.2 Abnormal movement

Fault phenomena and reasons Elimination method
1.Magnet broken in overflow valve Replacement
2.Mechnical problems Maintenance
Normal pressure but no
3.No indicator signal Check and repair
movement for actuator
4.Valve not work Adjust, repair, replace
5.Hydraulic tank broken Repair or replace
1.Pump input flow not enough or too much leakage Check, repair or replace
2.Oil viscosity too high or low Check, repair or replace
3.Valve control pressure not enough Wash, adjust
Actuator moves too slow
4.Too much external load Check, adjust
5.Valve center stuck Wash, filer, or change oil
6.Oil pump too much wear Repair or replace
1.Abnormal pressure Check and adjust
Irregular movement
2.Air mixed into oil Adding oil, exhaust air

Page 21 of 22
 3.Indicator signal not stable Check and repair
4.Sensor feedback failure Repair or replace
5.Valve center stuck Wash, clean oil
6.Oil pump too much wear Repair or replace
1.Air get in hydraulic pump or oil tank Exhaust air
2.Low or unstable pressure Repair or replace pressure valve
3.Sliding part too large resistance Repair, adding lubrication oil
Movement failure
4.Hydraulic cylinder and sliding parts of the Adjust and tighten
installation, such as the rigidity of the frame is not
enough, the fastening bolts loose, etc.
Form 15

13.4.3 Oil temperature too high

Fault phenomena and reasons
Oil temperature too high 1.System pressure too high
2. Low efficiency of oil cooling
a. No cooling water get in
b. Cooling tube stuck
c. Oil tank heat dissipation area too small
3.Pump, valve, tank or other parts get wear
4.Oil too dirty or less amount
5.Oil viscosity not in rated range
6.Near heat source, get radiation heat
Hydraulic pump too hot 1.Oil temperature too high
2.Overflow valve pressure too high
3.Oil viscosity too high or low
4.Pump wear or broken
5.Air in the oil
Form 16
Elimination method
Adjust lower pressure but need to meet normal running
requirement.
a. Check water cooling system, repair or replace
b. Wash, repair or replace cooling device；
c. Improve cooling system or enlarge oil volume；
Changed worn parts
Wash or replace screen mesh, add or change oil
Change oil with suitable viscosity
Use heat insulation material to launch plate or change
the layout place; set up the ventilation, cooling device
and so on, choose the right working fluid.
Enlarge cooling efficiency, change suitable oil
Adjust to rated number
Choose suitable oil
Repair or replace
Exhaust the air or change new oil

Page 22 of 22