Technical Manual Rotary Size Grader: Revision G

Technical Manual
Rotary Size Grader

Revision G
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Notices
Proprietary Rights
This manual as well as the equipment described in this manual contains trade secrets,
copyrighted works of authorship, trademarks, and other proprietary intellectual
property of Key Technology, Inc. Unauthorized use, copying, modification, distribution,
or disclosure of that proprietary property is subject to civil and criminal penalties under
both United States and international law. © 2019 Key Technology, Inc. All Rights
Reserved.
License Grant
Key Technology grants to the original end user customer a nonexclusive,
nonassignable right to make a reasonable number of copies of this manual and to use
the Key Technology proprietary property embodied in the Key Technology equipment
described in this manual, but only in connection with its use of that equipment. Except
as described above, no one may copy or use Key Technology's proprietary property,
and in no event will anyone modify, disclose, distribute, sub- license, assign, or
reverse-engineer that property.
Safety
Customer will: (a) require each person who receives or uses the equipment described
in this manual to read and comply with all safety instructions in this manual and any
other safety notices that Key Technology makes available; (b) instruct its employees
and others who use the equipment in its proper use; and, (c) implement and enforce
the safety provisions of all product safety notices, warnings, instructions, or similar
documentation that Key Technology provides. Customer will not remove any shields,
guards, or other safety devices from this equipment.
Terms of Sale
By downloading and/or printing these materials, you agree to be bound by the Terms
and Conditions of Sale available on the Company's website at www.key.net.
Disclaimer
The information contained in this manual is representative of typical systems and may
not apply to specific applications or to equipment that has been customized to meet
your requirements. Performance of the equipment is dependent on many factors not
within the scope of this manual and should be considered with relation to the entire
processing line.
Rotary Size Grader Technical Manual | Revision G

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The information contained in this manual does not alter, expand, or supplement Key
Technology's warranty. The only warranty that applies is the warranty in Key
Technology's Terms and Conditions of Sale referenced above.
This manual is intended only as an installation and maintenance reference for typical
systems and is subject to change through revisions and additions without notification.
The English version of this manual is the original instructions. All other languages are
translations of the original instructions.
United States Trademarks

Key® is a trademark of Key Technology, Inc.
International Trademarks
Key® is a registered trademark of Key Technology, Inc. in China, the European Union,
India, and Mexico.

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1 Safety Awareness 7
CONTENTSSignal Word Definitions 7
Hazard-Alert Messages 8
General Safety Recommendations 9
Residual Risks 10
2 Introduction 12
Contact Information 12
Customer Service 12
Service Calls 12
Ordering Parts 13
System Overview 14
Primary Components 14
Common Options 15
Principles of Operation 15
3 Installation 16
Receiving the Shipment 16
Rotary Size Grader Technical Manual 16
Key Technology Equipment Drawings 16
Original Equipment Manufacturer (OEM) Literature 16
Handling Precautions 16
Damage Assessment 17
Installation Preparation 17
Safety Precautions 17
Selecting a Proper Location 17
Proximity, Space, and Clearance Requirements 18
Utility Requirements 18
Transporting the Rotary Size Grader 18
Installation Procedure 18
Rotary Size Grader Installation 18
Installation Adjustments 19
Modification 19
4 Operation 20
Daily Inspection 20
Start-up Procedure 20
Roller Spacing Adjustment 21
Adjusting the Roller Spacing 21

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Shutdown Procedure 22
5 Maintenance 23
Maintenance Schedule 23
Maintenance Procedures 24
Machine Lubrication 24
Lubrication 26
Worm Gear and Adjustment System 28
Motor and Gear Reducer 29
Drive Motor 29
Gear Reducer 29
Alignments and Adjustments 31
Drive Chain Adjustment 31
Sprocket Alignment 33
Mechanical Stop Adjustment 35
Roller Parallelism Inspection 37
Removal/Installation Procedures 39
Gear Box Replacement 39
Roller Replacement 42
Drive Chain Replacement 43
Worm Gear Replacement 45
Adjustment Block Assembly Replacement 51
Nubbin Roller Replacement 58
6 System Sanitation 62
Non-metallic Components 63
7 Sound Measurement Report 65
Measurement Parameters 65
Measurement Conditions 65
Results 65
8 Troubleshooting Guide 66
INDEX 68

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1 Safety Awareness
All installation and maintenance personnel must read this section before working on
the Rotary Size Grader (RSG). Employees who are unable to read English should
have it read to them in a language that is fully understood. If you need further
explanation, contact Key Technology, Inc. (Key) immediately. For telephone numbers,
see Customer Service on page 12.
Signal Word Definitions

Danger: Indicates a situation which, if not avoided, will result in death or
serious injury.
Warning: Indicates a situation which, if not avoided, could result in death or

serious injury.
Caution: Indicates a situation which, if not avoided, could result in minor or

moderate injury.
Important: Indicates an item affecting the installation, maintenance, or

operation of this equipment.
Note: Indicates a comment or explanation regarding this equipment.

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Hazard-Alert Messages
Table 1-1: : Safety Labels
Safety Labels
Pictogram Description and Locations
Description: Read the Technical Manual for

more information.
Refer to our website:
www.keytechnicalmanuals.com
Locations:
Left and right side of the RSG.
Description: Lock out switch. This switch

prevents the sorter from starting unexpectedly.
Locations:
Enclosure door of the main electric
and utility cabinet.
Left and right side of the RSG.
Description: Do not operate without all guards

in place.
Locations:
Left and right side of RSG.
Description: General caution.

Locations:

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Description: Moving parts, keep hands clear.

Locations:
Description: Keep hands clear.

Locations:
General Safety Recommendations

Ensure that all safety guards and shields are securely fastened in place
before starting the RSG.
Read the entire manual before attempting to install, operate, or maintain this
equipment.
Permit only authorized, properly trained personnel to operate, install, or
maintain the RSG.
Before removing any safety guards or covers, turn off and lock out power to
the RSG.
Keep the work area clean to prevent accidents and product contamination.
Use this equipment only for tasks that are designated or intended.
Follow all specifications for space, clearance, utilities, and environment,
which are provided in the RSG equipment drawings.
Keep the equipment in good working order at all times by performing regularly
scheduled maintenance and conducting periodic safety inspections. Correct
all unsafe conditions immediately.
Do not wear torn or loose clothing or jewelry around equipment with moving
parts. Always wear approved eye and ear protection.
Do not walk or stand on the RSG; it is not safe as a walkway, platform, or
ladder. Injuries or damage to equipment or parts may occur.
The combination of water and product can cause floors to become slippery
and hazardous. To avoid injury from slipping and falling, exercise extreme
care while working near the equipment.

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Residual Risks
Despite the safe design of this equipment, safeguarding, and adopted protective
measures, some residual risks may be present on this equipment. A hazard analysis
indicates the following potential hazards:
1. A pinch point exists between the rollers that may cause abrasions or lacerations
to the hands and/or fingers.
2. A entanglement point exists on the exposed discharge roller bearing that may
cause hair to be caught and pulled out.
3. A pinch point exists between the discharge shear and discharge roller that may
cause pinched fingers.
4. A pinch point exists between drive chain and sprockets that may cause severed
fingers.
Figure 1-1: Residual Risks - RSG

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Figure 1-2: Residual Risks - Exposed Roller Bearings (Both Sides)
Figure 1-3: Residual Risks - Drive Chain

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2 Introduction
Key Technology provides customer service through all of our offices. The corporate
headquarters and European office offers 24-hour customer support. The Australia and
Mexico offices offer customer support for their locations during normal business hours.
Support includes:
Telephone support for all Key equipment
Prompt delivery of parts orders
On-site service calls by our field service engineers
Contact Information
24-hour Phone Support
Europe, Middle East, India, Africa: +31 (0) 345 58 58 06
North America and all other locations: +1 877 878 4631
Online Service Desk Portal

https://service.key.net
Email Support
[email protected]
For all other locations, visit our website at www.key.net.
Customer Service
Service Calls
When calling for customer service, please have the following information at hand:
Company name and location of your plant
Equipment name, model, and serial number found on the equipment
drawings and the RSG nameplate - see Figure 2-1 and Figure 2-2
Complete description of problem including all details, equipment drawing
numbers, and measurements available
Name of the person at your plant requesting assistance
Your telephone and fax numbers

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Figure 2-1: RSG Nameplate
Figure 2-2: RSG CE Nameplate
Ordering Parts
When ordering parts, please provide the following information:
Company name and location of your plant
Equipment name, model, and serial number found on the equipment
drawings and the RSG nameplate (see Figure 2-1 and Figure 2-2 )
Name of the person at your plant requesting the parts
Your company purchase order number

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System Overview
Primary Components
The RSGs primary components are listed below, and illustrated in Figure 2- 3 and
Figure 2-4.
RSG primary components:
Adjustment system
Right-angle gear motor
Rollers
Figure 2-3: Rotary Size Grader—Discharge End

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Figure 2-4: Rotary Size Grader—Infeed End
Common Options
Auto-adjust system
Product deflectors
Spray bar
Principles of Operation
The RSG removes short pieces, nubbins, and snipped ends of vegetables. It then
conveys good product to the downstream equipment. The rotary bed consists of a
series of pocket rollers, each with a stainless steel shaft and specific combination of
rubber rollers and plastic disks that create the pockets. As the pocket rollers rotate, the
targeted size product settles in the pockets and passes through the bed and is
discharged under the RSG.

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3 Installation
Read through all of the information provided in this chapter before attempting the
installation.
Receiving the Shipment

Rotary Size Grader Technical Manual
This manual provides instruction on safety, installation, operation, maintenance, and
troubleshooting of the RSG. The information in this manual pertains to all RSGs.
Some mechanical points may vary on your equipment, depending on the specific
design.
Note: Some mechanical points may differ on your equipment, depending on

your specific design.
Key Technology Equipment Drawings

The equipment drawings provide information specific to your RSG.
Original Equipment Manufacturer (OEM) Literature

A packet of supplementary vendor literature is shipped with the equipment. These
documents pertain to non-Key Technology parts that are included in the assembled
equipment.
Handling Precautions
When unloading and moving the equipment from the truck to its permanent location,
use extreme care not to damage any part of the equipment.
Important: Use the appropriate lifting equipment when moving an RSG;

always lift the RSG by using the supplied lifting brackets (Figure 3-1). Failure
to do so may cause damage to the machine and may void your warranty.

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Figure 3-1: RSG Lifting Brackets
Damage Assessment
Before installing the RSG, carefully inspect all components for shipping damage and
loose fasteners.
Installation Preparation
Safety Precautions
Before beginning the installation, read and understand all safety precautions listed in
the Safety section of this manual, and give special consideration to all text headed with
DANGER, WARNING, CAUTION, IMPORTANT, and NOTE.
In addition, observe all safety precautions provided in the OEM literature included with
this equipment. If you do not fully understand these precautions, call Key Technology
Customer Service for further explanation.
Selecting a Proper Location

Consider the following when selecting a location for the RSG:
Plant layout requirements
Ability of the site to support the static and dynamic loads introduced by the
equipment
Cleaning and maintenance clearance

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Proximity, Space, and Clearance Requirements
For space and clearance requirements specific to your equipment, see the equipment
drawings sent with your equipment.
Utility Requirements
Refer to the cover sheet on the equipment drawings to find the utility requirements
specific to your RSG.
Transporting the Rotary Size Grader
Warning: Use extreme care when lifting, transporting, and lowering the
RSG. Always lift the RSG using the lifting brackets provided with the
equipment (Figure 3-1). Failure to do so may cause damage to the machine
and may void your warranty.
Installation Procedure
Warning: This equipment is not balanced or stable until it has been leveled
and mounted. Improperly installed equipment can be inefficient, costly, and
dangerous. Failure to do so may cause damage to the machine and may void
your warranty.
Important: The customer is responsible for providing an appropriate support

structure prior to beginning the installation.
Rotary Size Grader Installation

To install the RSG:
1. Mount the RSG to the support structure.
Important: Do not cut or weld on the RSG frame. Cutting or welding

can cause distortion and operational problems. If welding or cutting the
frame is necessary, contact Key Technology Customer Service.
Welding and cutting without proper approval may void your warranty.
2. Slide the handle onto the end of the crankshaft; insert and tighten the two set
screws.

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3. Make the electrical connection using at least 18" (457 mm) of flexible conduit at
the motor. The conduit connection should be flexible, allowing for at least 1" (25
mm) minimum of machine movement.
4. The electrical connection must be performed by a qualified electrician in
accordance with NEC and local codes. At minimum, the ability to physically lock
out the power to the unit must be supplied.
5. Verify that the frame has at least 1" (25 mm) of clearance from any adjacent
object, unless otherwise specified.
6. Wire the motor so that the rollers rotate counterclockwise, as shown in
RSG Roller Rotation below. “Bump” the power to the gear box and check the
rotation of the rollers. If it is incorrect, swap any two phases to reverse the
direction of rotation.
Warning: Running the motor without the chain guards in place can
result in injury due from the exposed chain and sprockets.
Figure 3-2: RSG Roller Rotation
7. Turn the adjusting handle to the fully open position, then to fully closed, to
ensure that no binding is occurring as a result of installation.
8. Verify that the infeed pan and discharge rollers do not interfere with the
hardware on either end of the RSG.
Installation Adjustments
It is sometimes necessary to make minor adjustments during installation. For further
information on adjustments, see Maintenance on page 23.
Modification
Never modify, alter, or change the design of any equipment manufactured by Key
Technology. Use only the spare parts recommended by Key.

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4 Operation
Daily Inspection
Check the RSG for signs of wear or damage. Damage can progress quickly; Key
recommends immediate repair of any problems discovered.
Caution: There are potential pinch points between rotating components

which can result in entanglement of clothing, hands, or fingers when the
system guards have been removed. Be sure that all energy sources have
been properly locked out prior to removing any guarding and use caution
when performing maintenance functions with the guarding removed.
To inspect the RSG:

1. Turn off and lock out power to the RSG.
2. Look for any signs of leakage near the gear box.
3. Check the rubber rollers for wear or damage.
4. Visually check the frame and support structure for any sign of breakage.
Start-up Procedure
To start-up the RSG:

1. Make all repairs noted in the daily inspection.
2. Restore power to the RSG.
3. Listen for any unusual noises. Notify maintenance personnel if you cannot
determine the cause and correct the problem.

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Roller Spacing Adjustment

The size of the product removed by the RSG is determined by the space between the
white disks that create the "pockets" along each roller shaft. Roller spacing is used to
fine-tune removal due to differences in product circumference.
Adjusting the Roller Spacing

Note: Perform this procedure while the RSG is operating.
To adjust the roller spacing:

1. In small increments, turn the adjustment handle clockwise to increase, or
counterclockwise to decrease the space between the rollers.
2. Check the size of the product removed. Repeat Step 1 until the removed
product is within the required specification.
3. Make note of the number on the indicator rod so that the product specification
can be repeated (Figure 4-1).
Important: The fully closed roller position is when the indicator is at “0”,
and fully open is at the point where the roller shafts touch the side
plates. Do not set the mechanical stops to allow adjustments to exceed
these points or damage to the adjustment system may result. See
Mechanical Stop Adjustment on page 35.

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Figure 4-1: Adjustment Indicator Rod
4. The mechanical stop system provided with the RSG comes factory-set to allow
the roller gaps adjustment through their full range of motion; a smaller
adjustment range can be set, if desired. See Mechanical Stop Adjustment on
page 35.
5. The RSG adjustment system has been designed so that the rollers remain
parallel throughout the full range of adjustment. If the roller parallelism is in
question, see Roller Parallelism Inspection on page 37.
6. The performance of the RSG is greatly dependent on the condition of the roller
surfaces. It is normal for the roller surfaces to wear over time, therefore a
decrease in machine performance can be expected over time. Periodic roller
reconditioning or replacement is needed. See Roller Replacement on page 42.
Shutdown Procedure
Turn off and lock out power before performing any maintenance on the RSG. For
specific details on how to lock out power to this equipment, contact your maintenance
personnel.

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5 Maintenance
Maintenance Schedule
The intervals given in the Maintenance section below are guidelines and should be
considered the minimum requirement for maintenance. Plant environment, product
type and condition, sanitation methods, sanitation schedule, and hours run per day or
week must be the determining factors in the set-up of a maintenance program.

Table 1: Maintenance Schedule
Component Action Duration¹
Weekly²
Check for damage, then lubricate with food
Chain 0.05 hours
grade silicone spray
Check for wear, grease bearings (see the
Bearings Lubrication/Bearings procedure later in this 0.1 hours
section)
Monthly
Check for damage, open and close fully,
Adjustment system then lubricate spindles with food grade 0.05 hours
silicone spray
Sprockets Check for damage 0.05 hours
Gear box Check for proper operation 0.1 hours
Worm gear Check for damage 0.1 hours
Rollers Check for wear and damage 0.1 hours
Bi-annually
Chain wear strip Check for damage 0.1 hours
Chain nose bar Check for damage 0.1 hours

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Component Action Duration¹
Annually
Bearing inserts Replace 4 hours
Conditional
Replace or recondition. This may be
required as frequently as once every year
in high-use applications. See the Roller
Rollers Replacement on page 42 and Nubbin 6 hours
Roller Replacement on page 58 for
guidelines to when this should be
completed
Inspect, clean, or replace as needed (when
Spray nozzles
installed)
¹ The listed times are an estimated duration for each action. Actual times may vary.
² These actions should never exceed a frequency of three weeks or premature failure
resulting in damage to the machine may occur.
Maintenance Procedures
Machine Lubrication
All greasable roller bearings on Key Technology machines are pre- packed with
aluminum complex or compatible H1 food grade grease. Premature bearing failure will
occur if an incompatible grease is used on these bearings. It is important to contact
your grease supplier if you are unsure that your grease is compatible.

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Figure 5-1: Example Greaseable Bearing
Key Technology does not recommend adding grease fittings to bearings that do not
come equipped that way from the Key Technology factory; these bearings are
lubricated for life and do not need to be greased.

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Figure 5-2: Grease Fitting Example
Important: Do not use aluminum complex compatible or H1 food grade

grease on components that require a different type of grease. Premature
failure may occur if an incompatible grease is used.
If you are unsure if a non-roller bearing component uses aluminum complex

aompatible or H1 food grade grease, please refer to your grease supplier
and/or the technical manual.
Lubrication
Tools / Supplies:
Clean shop cloth
Food grade grease
Manually operated grease gun
Lock out tag and padlock

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Warning: The proper bearing lubrication procedure requires maintenance

personnel to remove the safety guards. Extreme care should be taken during
this procedure to properly lock out the equipment to avoid injury due to
rotating shafts, sprockets, and other powered components.

To lubricate the bearings:

1. Lock out power to the RSG.
2. Remove/open the top covers from both sides of the machine to gain access to
the bearings and grease fittings.
3. Slowly add grease to the bearing. Grease should be added only until the first
signs of grease show past the seal. Generally one or two pumps should be
adequate, but this is dependent on many factors, including greasing interval,
equipment run time, and sanitation frequency (Figure 5-3).
Figure 5-3: Roller Bearing Lubrication
1.
Important: Lubricating the bearings with a pneumatic or electric style
grease gun is not recommended given the speed and quantity of
grease that these guns deliver. Use of these guns will damage the
seals, resulting in premature failure.

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4. Repeat Step 2 for all remaining bearings.

5. Clean the grease fittings with a clean shop cloth.
6. Replace covers and restore power to the RSG.
Worm Gear and Adjustment System
Tools / Supplies:
Clean shop cloth
Food grade grease

To lubricate the worm gear and adjustment system:

1. Turn on the RSG.
2. Referring to Adjustment System Lubrication— Infeed End on the facing page,
slowly add 1-2 pumps of lubricant to the grease fittings.

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Figure 5-4: Adjustment System Lubrication—Infeed End
3. Clean the grease fittings with a clean shop cloth.

4. Repeat Steps 2 and 3 for all remaining worm gear and adjustment systems.
5. Rotate the adjustment handle to fully open, then fully close the adjustment
system. Reset to the desired setting.
Motor and Gear Reducer
Drive Motor
The drive motor is designed with sealed bearings. The grease content is adequate for
the life of the bearing.
Gear Reducer
The gear reducer oil level and oil quality should be checked at regular intervals,
determined by usage and the environment. Oil changes are required at intervals of
10,000 operating hours or every two years, whichever comes first. In applications
where hostile operating conditions exist, such as high humidity, corrosive environment,
or large temperature changes, the lubricant should be changed at more frequent
intervals.
Note: See the the OEM literature for recommended lubricants.

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Tools / Supplies:
0.21 gallon (0.8 liter) lubricant
Basic mechanic’s tools, standard and metric
Drain bucket
Enclosure door key
Funnel

To change the gear reducer oil:

Note: Allow the gear reducer to reach room temperature.
2. Place a bucket beneath the gear reducer.

3. Remove the oil level plug and the oil drain plug. Drain the oil completely.
Caution: Oil may be hot; use extreme care when removing the drain
plug.
4. Insert and tighten the drain plug.

5. Insert a funnel into the oil fill hole. Pour oil into the gear reducer until it begins to
leak from the oil level check hole.
6. Insert and tighten the oil level check, and fill plugs.

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Alignments and Adjustments
Drive Chain Adjustment
Tools / Supplies:
Open-end wrench
Socket wrench

To adjust the drive chain:

2. Remove the securing fastener and lift the top cover and side plate from the drive
side.
3. Remove the drive side guard.
4. Loosen, but do not remove the two bolts on each side of the gear box.
5. Move the gear box so that the center of the drive chain is at its lowest sag point
(Figure 5-5).

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Figure 5-5: Drive Chain Lowest Sag Point
6. Move the gear box so the center of the drive chain is within 1/8" (3 mm) of the
lower wear strip.
Important: Donot overtighten the chain; this can cause premature
bearing, chain, and sprocket failure.
7. Tighten the gear box mounting bolts.

8. Replace the drive side guard.
9. Replace the top cover and side plate, and secure the fasteners.

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Sprocket Alignment
Tools / Supplies:
Food grade grease
Straight edge (minimum of 3' long)
Tape measure

To align the sprockets:

2. Ensure that the rollers are centered within the side plates.
side.
4. Remove the drive side guard.
5. Loosen all sprocket set screws.
6. Align the discharge roller sprocket and the motor sprocket to the chain guide
(Figure 5-6).

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Figure 5-6: Initial Sprocket Alignment
7. Place a straight edge against the motor sprocket and the discharge roller
sprocket and align all remaining sprockets (Figure 5-6).

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Figure 5-7: Sprocket Alignment Using a Straight Edge
8. Tighten all sprocket set screws.

10. Replace the top cover and side plate, then secure the fasteners.
Mechanical Stop Adjustment
Tools / Supplies:
Allen wrench set


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Important: Before beginning this procedure, inspect and verify that the
adjustment system and adjustment blocks are in good working order. Failure
to do so may cause damage to the adjustment system.
Important: Care should be taken when completing this procedure. Many of

the parts are plastic; over-tightening can break a part or strip threads.
To adjust the mechanical stop:

1. Loosen all set screws on both stop collars, located on both sides of the
mechanical stop block (Figure 5-8).
Figure 5-8: Mechanical Stop Mechanism
2. Turn the adjustment handle to the fully closed position, or to the smallest desired
roller gap position.
Note: If the adjustment stop locks the rotation of the adjustment handle
before the desired position is reached, rotate the appropriate stop
collar out of the way until the desired position can be reached.
3. Turn the stop collar to the left of the stop block until it is threaded tightly against
it. Tighten the one set screw in the stop collar.

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4. Turn the adjustment handle to the fully open position (where the roller shafts
touch the side plates), or to the largest desired roller gap position.
5. Turn the stop collar to the right of the stop block until it is threaded tightly against
the stop block. Tighten the one set screw in the stop collar.
6. To verify that the adjustment handle stops rotating at each position, turn the
adjustment handle to the fully closed position, then to the fully open position.
7. If needed, repeat steps 1 through 6 until the proper stop positions are
consistently repeated.
8. Tighten all set screws in the stop collars when adjustments are complete.
Roller Parallelism Inspection
Tools / Supplies:

To inspect roller parallelism:

2. Remove the securing fastener. Lift the top cover and side plates on both the
drive side and idle side of the machine.
3. Rotate the adjustment handle until the machine is fully closed.
4. Verify that all of the adjustment blocks are touching (Figure 5-9).
Note: If the machine adjustment range is set so that the fully closed
position does not allow the blocks to touch, measure the gap between
the blocks to verify that they are the same.

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Figure 5-9: Adjustment Blocks Touching
5. Verify that the indicator rods on both sides of the machine are in the same
location (Figure 5-9).
6. Rotate the adjustment handle to open the machine until the indicator rods read
3".
7. Verify that the indicator rods on both sides of the machine read the same and
have moved equally during Step 6.
8. If the indicator rods have moved equally, the machine rolls are parallel and the
machine adjustment system should be functioning properly. Proceed to step 11.
9. If the indicator rods did not move equally, further inspection of the adjustment
system is required to determine the issue. See Adjustment Block Assembly
Replacement on page 51 and Worm Gear Replacement on page 45.
10. Correct any issues found and repeat steps 3 through 7.
11. Install the top covers, side plates, and securing fasteners.

39
Removal/Installation Procedures
Gear Box Replacement
Tools / Supplies:

To replace the gear box:

side.
3. Remove the infeed and discharge end chain guards (Figure 5-10).
4. Remove the drive side guard (Figure 5-10).

40
Figure 5-10: Gear Box, Drive Side Guard, and Infeed End Chain Guard
5. Loosen, but do not remove the four bolts beneath the gear box (Figure 5-11).

41
Figure 5-11: Gear Box Mounting Bolts
6. Remove the chain. For instructions, see Drive Chain Replacement on page 43.
7. Remove the four gear box mounting bolts and remove the gear box.
8. Remove the drive sprocket and stub shaft from the used gear box and install into
the new gear box.
9. Install the new gear box.
10. Set the new gear box into place.
11. Attach the gear box guard from the used gear box to the new gear box.

42
12. Insert the four mounting bolts. Tighten the bolts enough to hold the motor in
place, while still allowing it to slide.
13. Replace and adjust the chain. For instructions, see Drive Chain Replacement
on the facing page.
14. Tighten the four gear box mounting bolts.
16. Replace the infeed and discharge chain end guards.
17. Replace the top cover and side plate and secure the fasteners.
Roller Replacement
Tools / Supplies:
Caution: Two people are required to perform this procedure safely.

To replace a roller:
2. Remove the securing fastener and lift the top cover and side plate from both
sides of the machine.
3. Remove the four flat head bolts (two on each side) that hold the bearing mount
plate to the adjustment block.
4. With one person on each end, lift the roller assemblies out of the RSG. Inspect
the sprockets and bearing; replace as necessary.
5. Slide the bearings and sprockets onto the new roller. Do not snug the bearings
at this time.
6. Set the new roller in place. Ensure that the chain sprokets fit correctly into the
drive chain before tightening the rollers.

43
Note: Each roller drive sprocket has a different number of teeth. Ensure
correct placement of the sprockets (Figure 5-12).
Figure 5-12: Sprocket Size Diagram—Top View
7. Install and tighten the flat head bolts through the bearing mount plate and the
adjustment block.
Important: The adjustment block threads are nylon and can be

stripped out. Do not overtighten.
8. Center the new roller between the side plates and snug the bearing locking
collars to the roller shafts.
9. Verify that the rollers do not touch each other when the RSG is in the fully closed
position.
10. Align and set the sprockets. For instructions, see Sprocket Alignment Using a
Straight Edge on page 35.
11. Replace all chain guards.
12. Replace the top cover and side plate, and secure the fasteners.
Drive Chain Replacement
Tools / Supplies:

44

To replace the drive chain:

2. Remove the securing fastener, then lift the top cover and side plate from the
drive side.
3. On the drive side, remove the drive chain guards from both the infeed and
discharge ends.
4. Loosen, but do not remove the two bolts on each side of the gear box.
5. Loosen the drive chain by sliding the gear box toward the discharge end.
6. Remove the drive chain master link.
7. On the discharge end, pulling one end of the chain, remove the chain from the
RSG.
8. Place the new chain at the discharge end, engaging it with the first sprocket.
9. Feed the chain toward the infeed end while rotating each sprocket in turn.
Ensure that the chain engages with each sprocket.
10. Wrap the end of the chain over the drive motor sprocket.
11. Bring both ends of the chain together and attach the master link as shown in
Figure 5-13.

45
Figure 5-13: Drive Chain Master Link
12. Adjust the chain. For instructions, see Drive Chain Adjustment on page 31.
13. Tighten the four gear box mounting bolts.
14. Replace the drive chain guards.
Worm Gear Replacement
Tools / Supplies:
FDA-approved food-grade grease


46
To replace the worm gear assembly:

2. Crank the adjustment handle until the rollers are completely closed.
3. Remove the four hex head bolts, lock washers, and flat washers, then remove
the worm block assembly (Figure 5-14).
Figure 5-14: Worm Gear Block Assembly
4. Lift off the worm shaft assembly, including the worms and retainers, then set
aside.
5. Remove the two flat head bolts from the worm gear cover then remove the
cover (Figure 5-14).
6. Remove the two set screws from the worm gear and slide the gear off of the
shaft.
7. Slide a new worm gear onto the shaft. Ensure the threaded holes are aligned
with the machined flats in the hex shaft. Insert and tighten the two set screws
(Figure 5-15).
Important: The top of the set screws must be flush with the worm gear
hub.

47
Figure 5-15: Worm Gear Installation
8. Using a grease gun, apply enough grease to cover all of the worm gear teeth.
9. Ensure the hex collar is flush against the frame (Figure 5-16).
Figure 5-16: Hex Collar

48
10. Replace the worm gear cover, then insert and tighten the two flat head bolts.
11. If you are also replacing the worm and retaining block, perform the following
steps. Otherwise, proceed to Step 12.
A. Carefully place the worm shaft assembly in a vice.
B. Install the following parts, in sequence, on the end of the shaft that has
only one keyway (the non-handle end):
Shaft collar
Flat washer
Key
Worm (set into retaining block, keyways aligned)
Flat washer
Shaft collar
Note: The recessed side of the worm retaining block faces the
frame of the machine.
C. Tighten the collar set screws, leaving 1/16" of the shaft end exposed.
D. Remove the grease fittings from the old worm retaining block and install
them in the new worm retaining block.
E. Install the parts described in Step 11B and Step 11D onto the other end of
the shaft but do not tighten the collar set screws.
F. On both sides of the RSG, turn the hex shafts with a wrench to move the
adjusting blocks together.
12. Place the worm shaft assembly into position under the worm gear.
13. Starting with the non-handle end, mesh the worm into the teeth of the worm
gear, tapping the underside of the block with a rubber mallet (Figure 5-17).
Note: You may have to rotate the shaft slightly to mesh the worm and
the worm gear.

49
Figure 5-17: Tap the Worm Into Place
14. Verify that all of the mounting holes are aligned, then place the worm cover over
the worm and finger-tighten the hex head bolts.
15. Remove the grease fitting from the old worm cover and install it in the new worm
cover.
16. Repeat Steps 13-15 for the other end of the worm shaft assembly.
17. Position the shaft collars against the sides of the worm blocks, then tighten the
set screws (Figure 5-18).

50
Figure 5-18: Tighten the Worm Shaft Set Screws
18. Tighten all four hex head bolts to securely mount the worm retaining blocks.
19. Pump the grease into the grease fitting at the end of the hex shafts until grease
can be seen emerging from between the brass shaft collar and the inside of the
frame plate (Figure 5-19).
Figure 5-19: Lubricating the Worm Gear

51
20. Pump the grease into the two outer grease fittings in each worm block until the
grease can be seen emerging from between the worm block and the flat washer
(Figure 5-20).
Figure 5-20: Lubricating the Worm Shaft
21. To properly set the mechanical stops, see Mechanical Stop Adjustment on
page 35.
Adjustment Block Assembly Replacement
Tools / Supplies:
6"-8" length 3/4" hex bar
Silicone spray lubricant

52

To replace the adjustment block assembly:

2. Crank the adjustment handle until the rollers are completely closed.
3. Remove the securing fastener, then lift the top cover and side plate from both
sides of the machine.
4. Unfasten the four flat head bolts (two on each side) that are holding the bearing
plates to the adjustment blocks.
5. With one person on each end, lift the roller assemblies out of the RSG. Remove
all rollers, leaving the bearings and sprockets attached.
6. Remove the long set screw from the collar. There are two punch marks on the
collar indicating the location of the long set screw (Figure 5-16).
7. Loosen but do not remove the short set screw. Slide the collar off of the hex
shaft.
8. Remove the worm block assembly and the worm gear. For instructions, see
Worm Gear Replacement on page 45.
9. Remove the two adjustment nuts on the discharge end (Figure 5-21).
Figure 5-21: Adjustment Nuts

53
10. Lift the adjustment block assembly from the RSG (Figure 5-22).
Figure 5-22: Lifting the Adjustment Block Assembly
11. Remove the hex shafts and clean them. New spindles and blocks are installed
onto the hex shafts from the end with the cut flats and hole. Retain the discharge
end spacer and the infeed end shaft collar.
12. Apply a light coating of silicone spray lubricant to a spindle. Thread the left-hand
threaded end of the spindle into an adjusting block. Use the end of the block
opposite of the end labeled “R.”
13. Slide the first adjustment block assembly onto the hex shaft from the end of the
shaft with the cut flats and hole (Figure 5-23).
Figure 5-23: First Adjustment Block Assembly on the Hex Shaft

54
14. Apply a light coating of silicone spray lubricant to a spindle. Thread the right-
hand threaded end of the spindle half way into the first adjusting block. The end
of the block should be labeled “R" (Figure 5-24).
Figure 5-24: Install the Second Spindle
15. Thread an adjustment block half way onto the spindle. Use the end of the block
opposite of the end labeled “R” (Figure 5-25).
Figure 5-25: Install the Second Adjustment Block
16. Insert a short piece of hex bar into the spindle and rotate it until the adjustment
blocks are aligned and touching (Figure 5-26).

55
Figure 5-26: Align the Adjustment Blocks
17. Apply a light coating of silicone spray lubricant to a spindle. Thread the right-
hand threaded end of the spindle halfway into the first adjusting block. The end
of the block should be labeled “R” (Figure 5-27).
Figure 5-27: Install the Subsequent Spindles
18. Repeat Steps 12 through 17 until all the blocks are installed.
Note: Use the short piece of hex bar to adjust each spindle alignment
so that they slide onto the hex shaft.
19. Apply a light coating of silicone spray lubricant to the stub spindle (half the length
of the other spindles). Thread the stub spindle all the way into the last alignment
block and slide the hex shaft completely through the entire assembly (Figure 5-
28).

56
Figure 5-28: Stub Spindle and Hex Shaft Installed
20. Slide the spacer onto the spindle of the first adjustment block (Figure 5-29).
Figure 5-29: Spacer in Place
21. Set the assembled adjustment block assembly in place on the RSG (Figure 5-
30).

57
Figure 5-30: Adjustment Block Assembly in Place
22. Retract the hex shaft from the discharge end of the machine, enough to slide the
collar onto the end of the hex shaft. Insert and tighten the long set screw
between the punch marks on the collar and over the indentation in the hex shaft.
Tighten the short set screw (Figure 5-31).
Note: Set screws must be flush with the outside diameter of the collar.

58
Figure 5-31: Hex Collar in Place
23. Replace and tighten the adjustment nuts and cover plates on the discharge end.
The spindle end should be slightly recessed in the adjustment nut.
24. Install the metal cover plate using two Allen bolts.
25. Replace the worm gear and worm adjustment block assembly.
26. Align the sprockets as necessary. For instructions, see Sprocket Alignment
Using a Straight Edge on page 35.
27. Replace the rollers. For instructions, see Roller Replacement on page 42.
28. Crank the adjustment handle until the rollers are completely open, and then
closed to ensure proper reassembly.
Nubbin Roller Replacement
Tools / Supplies:
Retaining ring pliers

59

To replace the nubbin rollers:

2. Unlatch and remove the top and side covers from both the drive and idle sides of
the RSG.
3. Remove the roller assemblies from the RSG. For instructions, see Roller
Replacement on page 42.
4. Remove the sprockets and bearings from the shafts.
5. Remove the end plates and retaining rings from both ends of the shaft.
6. Remove the nubbin rolls and spacers from the shaft.
Note: Save the spacers, as these can generally be re-used.
7. Clean the shaft, as needed.

8. On the idle shaft end, replace the end plate and retaining ring (Figure 5-32).
Figure 5-32: End Plate and Retaining Ring—Idle End

60
9. To ease replacement, soak the new nubbin rolls and spacers in a bucket of
warm water.
10. Position the nubbin roll on the shaft so that the fins point back in the opposite
direction of rotation (Figure 5-33).
Note: A 4" x 6" piece of wood with a 1 1/16" (26 mm) hole works well
for holding the shaft in position.
Figure 5-33: Nubbin Roll Rotation
11. Position the shaft vertically, with the sprocket end up.
12. Referring to Figure 5-32 through Figure 5-34 and the equipment drawings, slide
the new nubbin rolls and spacer disks onto the shaft.
13. The nubbin rolls must be compressed slightly to fit on the shaft. Lightly tap the
idle side end of the roll assembly on a wood or plastic pad (Figure 5-34).
Figure 5-34: Positioning of Nubbin Rolls and Spacers

61
14. When all of the nubbin rolls are on the shaft, put the other end plate and
retaining ring in place.
15. Measure the roll from each end plate to the roll center. Measure from each end
plate to the spacer, approximately halfway between the roller center and each
end plate. If the measurements from side to side are different, the rollers must
be shifted to correct the position of the rollers on the shaft.
Important: For optimum RSG performance the nubbin rollers must be

properly positioned on the shaft.
16. Depending on which end the rollers need to shift, lightly drop the appropriate
roller assembly end on the pad to shift the rollers so that their location matches
the equipment drawings. Repeat step 15 until the rollers are positioned
correctly.
17. Install the roller assemblies into the RSG. For instructions, see Roller
18. Replace the top covers and side plates, then secure the fasteners.

62
6 System Sanitation
Warning: Turn off and lock out power to the RSG prior to performing the
washdown procedure.
Clean the RSG regularly, in accordance with local health and safety guidelines and
requirements. Depending upon conditions, you may choose to use one or more of the
following:
Hot or cold, high- or low-pressure water
Compressed air
Appropriate scrapers, brushes, and scouring pads
Appropriate cleaning solutions
Important: Before using a cleaning solution, read the Safety Data Sheet
(SDS) to be sure it is appropriate for the materials to be cleaned.
Important: When using high-pressure water for cleaning the bearings, hold
the spray nozzle approximately 18" from the bearings. Holding the nozzle any
closer to the bearing will force water and contaminants into the bearing.
To prevent damage to the drive motor and gearbox, cover both tightly with well-
secured heavy plastic prior to the washdown.
After washdown, remove the plastic covering from the motor and gearbox. Check for
water that may have leaked through. Dry as required.
Important: After any high-pressure washdown or foam application, lubricate

the bearings. For instructions, see Lubrication on page 26.
Important: If a foaming cleaner is used, remove it as quickly as possible with

low-pressure water.

63
To clean the RSG:

2. At each scheduled cleaning, remove the access covers from the drive system
and the adjusting system. Adjust the rolls to the fully-open position.
3. Remove any residue that has accumulated in the adjusting system access area.
High pressure washdown is acceptable for cleaning the adjusting blocks and
spindles. Use a soft plastic brush to clean the threads of the adjusting spindles.
Avoid directing high pressure spray directly onto the bearings. Keep the spray
nozzle approximately 18" (500 mm) away from the bearings to prevent the
introduction of water into the bearings.
4. Clean the adjusting system thoroughly. Rotate the adjusting handle toward the
closed position to clean all surfaces of the adjusting spindles. Foam cleaning
agents should not be left on any longer than necessary, as they degrade the
polymer materials. Do not apply foaming agents to the external bearing seals.
Rinse the entire area completely to ensure all cleaning agents are removed.
Failure to rinse adequately may cause premature failure of the adjusting or drive
systems.
®
5. Apply a thin coating of food grade silicone lubricant, such as CRC Industrial
Food Grade Silicone, on the adjusting spindles. Adjust the rollers back and forth
to distribute the lubricant onto the adjusting blocks. The adjusting system should
move freely in both directions. Verify that there is no residue present after
exercising the adjusting system. Wipe off any excess lubricant.
6. Replace access covers and secure in place.
Non-metallic Components
Some Key Technology equipment has wear components incorporating polymers.
Most of the chemicals used for equipment cleaning and sanitizing also eventually
degrade the properties of polymers and may reduce the useful life of these
components. The effect on polyurethane of chemicals containing chlorine can be
particularly severe.
1. Maintaining equipment in proper sanitary condition is always the first priority in a
food plant. There are some measures that can be taken to maximize component
life.
2. Advise your sanitation chemical supplier about the presence of polymers, as
appropriate, when obtaining material, mixing, and application
recommendations.
3. Before applying chemicals, remove as much soil as possible with clear water.
Use water at the temperature specified by your sanitation and plant safety
departments, but not exceeding 140°F (60°C).

64
4. Ensure that sanitation chemicals are not mixed to concentrations higher than
what the chemical supplier and your sanitation department require.
5. Do not leave cleaning and sanitizing chemicals on longer than the required time.
Rinse thoroughly with clear water at the end of that time.
6. Do not allow strong acids such as hydrochloric, nitric, or sulfuric to come in
contact with polymer components.
7. Do not apply solvents such as benzene, gasoline, MEK, trichloroethylene, or
turpentine. Use a soap solution and a soft scrub brush to remove greasy stains.

65
7 Sound Measurement Report

Machine measured: Rotary Size Grader
Date: March 15, 2012
Measurement Parameters
Measurements were taken following the measurement guidelines in the Machinery
Safety Directive, 89/392/EEC, Annex 1, Part 1.7.4(u)2006/42/EC.
Measurement Conditions
The machine sound measurements were taken on a typical production- assembled
machine. The sound level meter was placed at a height of 1.6 meters above the floor,
with the machine resting on steel supports. Measurement points are listed in Table 7-1
below. Distance for the measurement was at 1m fro the sheet metal on each noted
side of the machine.
Results
Table 7-1: : Sound Measurement Reading Values
Reading Values
Discharge End Infeed End Drive Side Idle Side
Dba 67 67 68 66

66
8 Troubleshooting Guide
Table 8-1: : Troubleshooting Guide
General Performance
Symptom(s) Possible Cause Recommended Action
Adjust the RSG to fully-closed;
Adjustment block check to be sure that both sides are
assembly from drive completely closed.
side to idle side is If both sides do not close completely,
misaligned see Adjustment Block Assembly
RSG is difficult to adjust
Residue build-up on
Clean the spindles.
spindles
Infeed shear
Remove interference.
interference
Lubricate worm gear. For
Lack of lubrication in
instructions, see Lubrication on
worm gear
page 26.
Replace worm and/or worm gear. For
Worm and/or worm
instructions, see Worm Gear
gear are worn
Inspect the support structure and
Frame is not square
adjust so the frame is square.
Residue build-up on Clean the RSG. For instructions, see
Product is being retained on rollers or side plates System Sanitation on page 62.
the RSG
Add a spraybar to the RSG.
Machine is not Very that the RPM is running at
operating at the design speed. Refer to the equipment
designed RPM drawings for the correct RPM.

67
General Performance
Symptom(s) Possible Cause Recommended Action
Worm no longer Replace the worm gear and worm.
engaged in worm For instructions, refer to Worm Gear
gear Replacement on page 45.
Stripped adjusting Inspect adjustment system and
Losing too much good block and/or spindles replace parts as necessary.
product Adjust the RSG to fully-closed;
check to be sure that both sides are
Adjustment block completely closed. See Roller
assembly from drive Replacement on page 42 and Roller
side to idle side is Parallelism Inspection on page 37.
misaligned (rolls are
not parallel) If both sides do not close completely,
see Adjustment Block Assembly

68
A Drive Motor
Lubrication 29
Adjusting the Roller Spacing 21
Adjustment Block Assembly E
Replacement 51, 58
Equipment Drawings 16
Adjustment Issues 66
Equipment Modification 19
Adjustment System
Equipment Risk 10
INDEX
Lubrication 28
Alignments and Adjustments 31 G
Assesment, Damage 17
Gear Box
B Mounting Bolts 41
Gear Box Replacement 39
Bearings
Gear Reducer
Lubricating 26
Lubrication 29
C
H
Cleaning 62
Hazard Alert Messages 8
Clearance Requirements 18
Components I
Non-metallic 63
Inspection
Contact information 12
Daily 20
Customer Service 12
Roller Parallelism 37
D Installation 16, 18
Installation Adjustments 19
Daily Inspection 20
Installation Preparation 17
Damage 17
Installation Procedure 18
Difficult Adjustment 66
Installation Procedures 39
Drive Chain
Introduction 12
Master Link 45
Issues, Adjustment 66
Replacement 43
Drive Chain Adjustment 31

69
K O
Key Service 12 Operation 20
Operation Principles 15
L
Options 15
Literature, OEM 16 Original Equipment Manufacturer
Loss of Product 67 (OEM) Literature 16
Lubrication 26 Overview, System 14
Adjustment System 28
P
Drive Motor 29
Gear Reducer 29 Parts Ordering 13
Worm Gear 28, 50 Performance Troubleshooting 66
Worm Shaft 51 Phone numbers 12

Primary Components 14
M Product Retention 66
Machine Location 17
R
Machine Lubrication 24
Maintenance 23 Receiving the Shipment 16
Annually 24 Removal Procedures 39
Bi-annually 23 Residual Risks 10
Conditional 24 Risks
Monthly 23 Equipment 10
Weekly 23 Roller
Maintenance Procedures 24 Parallelism Inspection 37
Maintenance Schedule 23 Roller Replacement 42
Mechanical Stop Adjustment 35 Roller Spacing Adjustment 21
Modification, Equipment 19 S
Motor and Gear Reducer 29
Safety 7
N Safety Precautions 17
Nameplate 13 Safety Recommendations 9
Non-metallic Components 63 Sanitation 62
Notices 3 Selecting a Proper Location 17

70
Service
Key 12
Shutdown Procedure 22
Signal Word Definitions 7
Sound Measurement Report 65
Sprocket Alignment 33
SSR Components 14
SSR Options 15
Start-up Procedure 20
System Overview 14
T
Technical Manual 16
Trademarks 4
Transporting the SSR 18
Troubleshooting Guide 66
U
Unloading 16
Utility Requirements 18
W
Worm Gear
Block Assembly 46
Installation 47
Lubrication 28, 50
Replacement 45
Worm Shaft
Lubrication 51

Original English Version
Revision G
12/13/2019
Key Part No: 019983
© Key Technology - 2019

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Rotary Size Grader Technical Manual | Revision G

United States Trademarks

Rotary Size Grader Technical Manual | Revision G

Rotary Size Grader Technical Manual | Revision G

Rotary Size Grader Technical Manual | Revision G

Signal Word Definitions

Warning: Indicates a situation which, if not avoided, could result in death or

Caution: Indicates a situation which, if not avoided, could result in minor or

Important: Indicates an item affecting the installation, maintenance, or

Note: Indicates a comment or explanation regarding this equipment.

Rotary Size Grader Technical Manual | Revision G

Description: Read the Technical Manual for

Description: Lock out switch. This switch

Description: Do not operate without all guards

Description: General caution.

Rotary Size Grader Technical Manual | Revision G

Description: Moving parts, keep hands clear.

Description: Keep hands clear.

General Safety Recommendations

Rotary Size Grader Technical Manual | Revision G

Figure 1-1: Residual Risks - RSG

Rotary Size Grader Technical Manual | Revision G

Figure 1-2: Residual Risks - Exposed Roller Bearings (Both Sides)

Figure 1-3: Residual Risks - Drive Chain

Rotary Size Grader Technical Manual | Revision G

Online Service Desk Portal

For all other locations, visit our website at www.key.net.

Rotary Size Grader Technical Manual | Revision G

Figure 2-1: RSG Nameplate

Figure 2-2: RSG CE Nameplate

Rotary Size Grader Technical Manual | Revision G

Figure 2-3: Rotary Size Grader—Discharge End

Rotary Size Grader Technical Manual | Revision G

Figure 2-4: Rotary Size Grader—Infeed End

Rotary Size Grader Technical Manual | Revision G

Receiving the Shipment

Note: Some mechanical points may differ on your equipment, depending on

Key Technology Equipment Drawings

Original Equipment Manufacturer (OEM) Literature

Important: Use the appropriate lifting equipment when moving an RSG;

Rotary Size Grader Technical Manual | Revision G

Figure 3-1: RSG Lifting Brackets

Selecting a Proper Location

Rotary Size Grader Technical Manual | Revision G

Proximity, Space, and Clearance Requirements

Transporting the Rotary Size Grader

Important: The customer is responsible for providing an appropriate support

Rotary Size Grader Installation

Important: Do not cut or weld on the RSG frame. Cutting or welding

Rotary Size Grader Technical Manual | Revision G

Figure 3-2: RSG Roller Rotation

Rotary Size Grader Technical Manual | Revision G

Caution: There are potential pinch points between rotating components

To inspect the RSG:

To start-up the RSG:

Rotary Size Grader Technical Manual | Revision G