SUNDANCE KID IIICOMPACT HORIZONTAL GRINDER

WITH PERKINS ENGINE& FLUID COUPLING

OPERATOR’S MANUAL

Sundance Equipment, LLCP.O. Box 485

Newton, KS 67114-0485(316) 283-5999

Rev A 01JUL10 SN 168183

TABLE OF CONTENTS

PageFORWARD 1

SAFETYSAFETY ALERT SYMBOL 2SAFETY 3KEYS TO SAFETY

-Before Starting the Machine 4- Avoid High Pressure Fluids 5-Safety During Operation 5-Safety for Maintenance & Storage 6

TOWING 7

GENERALBasic Explanation of Machine Operation 7

OPERATIONOperator Controls 9Before Starting the Engine 10Starting Engine 10Engine Shut-Down Procedure 11Grinder Controls 12Important Control Functions 13Grinder Operation 13Discharge Chute 14Feed Roll Travel Adjustments 15Spring Assist and Feed Roll Adjustments 15Feed Roll Operation in Raised Position 15Adjusting for Particle Size 16Concave Adjustment 16Hammer Inspection & Replacement 17Grinding Fingers 18Limit Switches 19Hydraulic Reservoir 19Fuel Tank 19Elastomeric Coupling 19Fluid Coupling 20Lubrication of Grinder 24Adjusting the Pressure Switches 24Trouble Shooting 26Manufacturer’s Warranty Policy 30

APPENDIXInstallation Instructions for Flexible Coupling A

FORWARD

The purpose of this manual is to better acquaint you with your new SUNDANCE KID III COMPACT HORIZONTAL GRINDER. The following pages will guide you in the proper operation and maintenance of your grinder.

The performance of the KID III depends upon proper operation and adjustment. Keep this manual available for future reference. It has been carefully prepared, organized and illustrated to make it as easy as possible to find needed information.

We are continually making improvements and developing new equipment. In doing so, we reserve the right to make changes or add improvements to our products without obligation for equipment previously sold.

Use of this machine for purposes other than those for which it was designed, or non-factory modifications made to this machine, may result in an unsafe operating condition or excessive stress, wear or damage to the machine for which SUNDANCE EQUIPMENT, LLC is not responsible.

IMPORTANT NOTICE:

In the interest of safety and accident avoidance, pay particular attention to the “Safety Alert Symbol”

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SAFETY ALERT SYMBOL MEANS

ATTENTION!BECOME ALERT!

YOUR SAFETY IS INVOLVED!

The Safety Alert Symbol identifies important safety messages on the equipment and in this manual. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message.

SIGNAL WORDS:Note the use of signal words: DANGER, WARNING and CAUTION with safety messages. The appropriate signal word for each message has been selected using the following guidelines:

DANGER An immediate and specific hazard which has a high probability of resulting in death or irreparable injury if proper precautions are not taken.

WARNING A specific hazard or unsafe practice that COULD result in severe personal injury or death if proper precautions are not taken.

CAUTION Unsafe practices which could result in personal injury or damage to the machine if proper practices are not followed, or as a reminder of good safety practices.

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SAFETY

You are responsible for the PROPER operation and maintenance of your KID III COMPACT HORIZONTAL GRINDER. You must ensure that you and anyone else who is going to operate, maintain or work around the KID III is familiar with the operating and maintenance procedures and related SAFETY information contained in this manual. This manual alerts you to good safety practices that should be adhered to while operating this equipment.

Remember, YOU are the key to safety. Good safety practices not only protect you, but also the people around you. Make these operating practices a working part of your safety program. Be certain that EVERYONE operating this equipment is familiar with the recommended operating and maintenance procedures and follows all the safety precautions. Accidents can be prevented. Do not risk injury or death by ignoring good safety practices. Think SAFETY! Work Safely!

Everyone must be given operating instructions before starting to operate the KID III and at least annually thereafter in accordance with OSHA regulation 1928.57. These instructions must be understood before operating this equipment.

Do not modify the equipment in any way. Unauthorized modifications may impair the function and/or safety of the equipment and could affect the life of the equipment and will void the machine warranty.

If you have any questions about the proper operating procedures, call your Sundance dealer or our main office at (800) 570-3551 or (316) 283-5999 before operating the machine. If you have any personnel who may be working with or near the machine who cannot read the warning decals in English, you MUST apply the appropriate translated versions of the warning decals before operating the machine.

ACCIDENTS COST!

ACCIDENTS CAN BE AVOIDED!

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KEYS TO SAFETY

**THIS IS IMPORTANT**

The “heart” of the KID III is a heavy rotating assembly called a ROTOR. The rotor is designed to rotate at a maximum speed of 2100 R.P.M. Because of its size and weight, extreme caution must be exercised at all times during operation of the KID III, especially when the rotor is coasting to a stop.

DANGER - Contact with rotating hammers inside the rotor housing will result in serious personal injury! The hammers rotate at high speed while the equipment is running, and they slow down gradually after the engine is shut off.

Keep hands and face out of the discharge chute while the rotor is spinning. Before doing any service or maintenance, shut off the engine, remove the start key and keep it in your possession, and allow all moving parts to come to a complete stop.

BEFORE STARTING THE MACHINE1. Do not attempt to operate your KID III Compact Horizontal Grinder until you are

familiar with this Owner’s/Operator’s Manual and understand the warnings and information given in this manual. IMPROPER OPERATION OF THIS MACHINE COULD RESULT IN SERIOUS OR FATAL INJURY!

2. Know where the engine shut down control is. Turning off the ignition key or pushing the red emergency stop button on either side of the machine shuts down the engine.

3. The heart of this equipment is a large rotor with a series of free-swinging hammers around the circumference. This results in material being thrown at high speed. This material is directed out the discharge chute, but some may be thrown back into the feed hopper. Always wear work gloves, hearing protection and safety glasses or other eye protection when working around this equipment. Do not wear loose fitting clothing, scarves, ties, etc. because they may become entangled in moving parts.

4. Make it a practice to visually inspect the equipment before starting the engine. Check to see that all nuts, bolts, and fasteners are properly secured. Check hydraulic hoses for signs of cracking or fraying (replace if necessary) and leaks. Check for proper hydraulic and engine oil levels.

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5. AVOID HIGH-PRESSURE FLUIDS. Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

6. Before starting the engine, make sure the discharge chute is directed where you want it, and the rotation clamp is secure. Adjust the top deflector and insure that no one is in the discharge area. Remember that material will be coming out the discharge chute at a high velocity and may ricochet and cause personal injury.

SAFETY DURING OPERATION

7. Keep your hands, face and clothing out of the feed hopper. You might become entangled in material moving into the rotor or particles may be thrown causing serious injury.

8. Keep your hands and face away from the discharge opening while the machine is running. Material is thrown out the discharge at high speed and can cause serious injury.

9. Never climb on any part of the machine while it is in operation. You might loose your footing and fall or become entangled in moving parts or material causing severe personal injury.

10. Never remove guards or protective shields for any reason UNLESS the machine is shut down and the rotor has come to a complete stop. After the maintenance or repair operation is complete, reinstall all covers before starting the machine.

11. Do not allow children or untrained persons to operate this equipment.

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12. Do not allow bystanders to be within 30 feet of this equipment while it is running.

13. Always stand clear of the discharge area. Direct the discharge chute in a direction that is clear. The discharged material can ricochet off hard surfaces and cause serious injury. Insure that the discharge area is clear for 60 feet.

14. Always be on the alert for unusual noises, clanging or vibrations. If this does occur, stop feeding material immediately and shut off the engine. Wait for the rotor to come to a complete stop and you have the engine start switch key in your possession before investigating the reason for the problem.

15. If material you are feeding becomes lodged, reverse the rotation of the feed roll to dislodge it, and try feeding again. If it still does not feed, try feeding the opposite end first. If that does not work, the material may be too large for the machine.

CAUTION - Do not force material into the rotor as the machine could become damaged causing serious person injury.16. If the discharge chute becomes plugged, shut off the engine and allow the rotor to

come to a complete stop before attempting to unclog the discharge. It may be necessary to open up the concave and clean out the inside of the rotor chamber as well.

WARNING - Never put your hands in the discharge chute while the rotor is running.17. When feeding the machine by hand, do not overreach into the feed hopper. Keep

proper footing and good balance at all times.

SAFETY FOR MAINTENANCE AND STORAGE

18. Before doing any service, maintenance, cleaning, inspection, changing of hammers or work of any kind on the machine, be sure the engine is stopped, all moving parts have come to a complete stop, and the start switch key is removed from the panel and in your possession.

19. Store this equipment where unauthorized persons will not have access to it.

CAUTION - It is the responsibility of the owner or employer to insure that the operator is trained and practices safe operation while using and servicing the machine. It is also the owner’s responsibility to provide and follow a regularly scheduled maintenance and repair program on the KID III using only factory approved replacement parts. Any unapproved repairs or modifications may not only damage the machine and its performance, but could result in severe personal injury.

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TOWING

Before towing the Sundance KID III, be sure that the following conditions are met:

1. The towing vehicle must have a rated towing capacity of at least 10,000 pounds.

2. The hitch and coupler on the towing vehicle must be rated for at least 10,000 pounds.

3. The hitch and coupler on the towing vehicle must be rated for at least 1250 pound tongue weight.

4. The towing vehicle must be equipped with the appropriate electric brake control.

5. The towing vehicle must be equipped with the appropriate and functional wiring connector.

6. Before towing, check to make sure that all lights and brakes are functioning and that the breakaway battery is sufficiently charged.

7. Make sure that the feeder ram is positioned all the way to the front of its stroke, concentrating its weight over the axles rather than at the rear of the machine.

GENERALBASIC EXPLANATION OF MACHINE OPERATIONYour KID III is designed to perform particle size reduction for various materials via impact shattering or “hammering” in conjunction with some shearing. Typical material includes yard waste (leaves, brush, grass clippings, tree limbs), wood waste (such as pallets and shipping crates, wood construction debris, etc.), hay, dried organic sludge, tree bark, paper, cardboard and manure.

The machine was not designed to process woody material over 8 inches in diameter. Introduction of heavy and/or abrasive materials such as mud/soil, sand, etc. will cause excessive wear to the hammers and other moving parts and should be kept out of the machine. Hard materials such as rocks, gravel, metals, etc. should not be run through the machine as personal injury or damage to the machine may result. Avoid mud and excessive amounts of soil when grinding material with the KID III. Mud separates and packs in the concave area and the discharge making it difficult or impossible to process the ground material. Excessive amounts of soil, especially mixed with sand and gravel, will wear the hammers prematurely.

Your grinder is equipped with a fluid coupling between the engine and the grinding rotor. By transmitting power through a fluid, rather than a mechanical clutch, overall performance is improved and both driving and driven components are protected. However since the mechanical connection is eliminated, the driving and driven components are always connected. Therefore, if the engine is running, it is turning or trying to turn the rotor. If the engine is running, always assume the rotor is turning.

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Once the machine is running at operating speed, load material directly into the hopper. Engaging the feed roll meters material into the grinding chamber. The speed of the feed roll is adjustable and can be reversed if required. The feeder assembly or pusher ram is used to move material to the feed roll. The feeder assembly reverses its direction of travel at the end of the forward travel and the same at the end of the reverse stroke. This is accomplished through the use of limit switches. The speed of the feeder or ram is also adjustable.

Loaders with bucket capacities up to one cubic yard can generally be used to properly load bulky material into the hopper. Do not overload the hopper because excessive material will jam at the feed roll and slow down production.

The feed roll meters material into the grinding chamber. The speed of rotation is adjustable and should be varied depending upon the material being processed. In case of plugging, the feed roll can be reversed to back material out.

The discharge chute is adjustable. It can rotate 360 degrees and can be locked into position. It has a deflector which can be adjusted up or down to direct the discharged product where desired. Care must be taken to insure that no one enters the discharge area. Material leaving the discharge chute is traveling at a very high speed and serious personal injury can result if it strikes you. If a higher discharge is required, add discharge extension sections (available from your dealer) until you reach the desired height. Heavy wet material cannot be exited through a high discharge. The high exit discharge is limited to dry type material. When grinding excessively wet and sticky material you will likely have to use the optional quick exit discharge.

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OPERATOR CONTROLS

(1)PowerView 101 Display(2)Feeder Start/Rev Button(3)Feed Roll Forward/Off/Reverse Switch(4)“Ramp” Throttle Rocker Switch(5)Emergency Stop Button(6)Feeder Stop/Start Button(7)Engine Start Switch

(10) Hydraulic System Pressure Gauge(11) Feeder Flow Control Valve(12) Feed Roll Flow Control Valve(13) Flow Control On/Off Valve (used only as an emergency shutoff)(14) Pressure Switch (style may vary)

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BEFORE STARTING THE ENGINEYour KID III is equipped with a Perkins 1104D Diesel Engine. Read your engine owner’s manual and become familiar with the features of your engine and the service requirements. Before starting the engine, make it a habit to visually inspect the machine. Check for loose or missing fasteners. Tighten and replace as necessary. Check all hydraulic hoses and fitting for leaks and fraying. Replace if necessary. Check the hydraulic oil level and replenish if necessary. The sight/temperature gauge should be at least 4/5 full of oil. Use a good grade of HD32 hydraulic oil. Also check the engine oil and replenish if necessary. Check the engine manual for oil recommendations. Check that the feed roll switch is in the OFF position. Make sure the rotor chamber is empty. If the rotor is not free of material, it must be cleared before proceeding. IF MATERIAL IS IN THE GRINDING CHAMBER AND YOU START THE ENGINE AND ATEMPT TO RAISE THE ENGINE RPM TO START THE ROTOR, THE FLUID COUPLING WILL SLIP, BUILINDG HEAT AND EVENTUALLY BLOW THE FUSIBLE PLUG, RELIEVING THE INTERNAL PRESSURE.

STARTING THE ENGINEBefore proceeding to start the engine, be sure you understand the engine control systems, operating procedure and shutdown procedure. Refer to the Perkins engine Operator’s Manual.

The control panel is located on the left side of the hopper opposite the loading side. Be sure the emergency stop buttons are pulled out. If the engine will not start it is often caused by one of the emergency stop buttons being pushed to the “in” or “stop” position. The emergency stop buttons are located on the loading side of the grinder in front of the hopper and in the control panel. If a problem with the grinder operation develops, you can stop both the engine and the hydraulic functions by pushing in one of the emergency stop buttons.

Make sure the grinding chamber (beneath the hammers) is free of material. If material has been left in the grinding chamber from previous operation or if it has fallen down during transportation, it may not allow the rotor to turn and the fluid coupling will slip, causing the fluid in the coupling to heat and possibly blow the fusible plug.

Be sure the Feed Roll Directional Control (3) is in the OFF position. Turn the start switch key (7) clockwise to the “R” or “run” position. In cold weather, continue to turn the switch key to the “H” or “heat” position. Pause in this position 5-10 seconds to allow the glow plugs to heat up. Then immediately turn the switch key clockwise to the “H/S” or “heat/start” position. When the engine starts, release the key. Listen for any unusual noises or clicking sounds. If such does occur, immediately shut off the engine and allow the rotor to come to a complete stop. Determine the cause of the noise and correct it before proceeding.

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WARNING – FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS DAMAGE BEING DONE TO THE GRINDER AND SEVERE PERSONAL INJURY COULD RESULT.Once the engine is running, check to make sure the rotor is turning freely. If the rotor is not turning, shut off the engine and determine the cause of the blockage before restarting. If the engine continues to run without turning the rotor, the fluid in the fluid coupling will eventually overheat and cause the fluid coupling temperature sensor to indicate an alarm or may blow the fusible plug, venting the fluid from the fluid coupling.

If material has been left in the grinding chamber from previous operation or if it has fallen down during transportation, it may not allow the rotor to turn. DO NOT TRY TO USE THE ENGINE TO CLEAR THE CHAMBER IF THE ROTOR DOES NOT TURN FREELY.

If the rotor is turning, allow the engine to come to operating temperature before proceeding. During this time, check to make sure the discharge chute is directed toward a clear area and is adjusted properly. Check to make sure the chute is locked in position.

With the engine idling smoothly and up to operating temperature, you are now ready to increase the rotor speed for grinding. Slowly increase the engine speed by pressing the fast (rabbit) position of the throttle rocker switch (4). The engine/rotor RPM should increase to about 2200 RPM. CAUTION! Do not operate the grinder at higher than 2200 RPM. Do not attempt to adjust for higher speed operation!

ENGINE SHUTDOWN PROCEDUREBefore stopping the engine of your KID III, be sure the rotor housing is free of all processed material. Let the rotor spin at full speed until all material has cleared the chamber.

To shut down the engine, push the appropriate throttle control button to decrease the engine speed to the idle speed. The momentum of the rotor will require some extra time to slow down. Let the engine idle for several minutes allowing it to cool down. Turn the start switch (7) to the “off” position. The engine will stop.

NOTE: BE SURE THE FEED ROLL FORWARD/OFF/REVERSE SWITCH (3) IS IN THE OFF POSITION WHEN SHUTTING DOWN THE ENGINE.

CAUTION – The rotor will continue to spin for several minutes after the engine has been shut off. Wait for the rotor to come to a complete stop before leaving the machine unattended or attempting and service or repair on the equipment.

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Before leaving the unit unattended, remove the start switch key and keep it in you possession.

There are trouble codes that will cause the engine control unit to shut down the engine, such as low oil pressure or high coolant temperature. If this occurs, TAKE CORRECTIVE ACTION BEFORE RESTARTING THE ENGINE

GRINDER CONTROLSConvenient buttons and switches assist in controlling the operation of the grinder hydraulic system. CAUTION! Only use the EMERGENCY STOP buttons when an emergency exists.

In normal operation, use the other controls to stop the hydraulic system. Push the Feed Stop (Yellow) Button (6) or place the Feed Roll Switch (3) in the center or “off” position.

NOTE: The engine RPM must exceed a preset limit (usually 1950 RPM) in order for the hydraulic system (feed roll and feeder) to function.The feed roll is controlled by a three-position switch (3). The center position is off, the clockwise position is forward, and the counter-clockwise position is reverse. The feed roll speed is controlled by the flow control valve (12). Turning the flow control valve clockwise reduces the speed and turning the flow control valve counter-clockwise increases the speed of the feed roll.

To start the feeder cycle, first the Feed Stop (Yellow) switch must be in the run or out position, and secondly the feed roll switch must be in the forward position . Pushing the feeder start/rev (green) button initially returns the feeder assembly (feeder) or pusher ram to the rear position. The feeder then moves forward until the front limit switch is activated, reversing the feeder again. The direction of travel of the feeder is again reversed when the rear limit switch, mounted on the feeder assembly, is activated Pressing the feeder start/rev button while the feeder is moving forward will reverse the direction of the feeder. This function may be helpful if the operator is at the control panel and sees a blockage beginning to develop. Pressing the Feed Stop (Yellow) button (6) will stop both the feed roll and the feeder. The speed of the feeder is controlled by the flow control valve (11). Turning the flow control valve clockwise reduces the speed and turning the flow control valve counter-clockwise increases the speed of the feeder.

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IMPORTANT CONTROL FUNCTIONS: Under Speed – When operating the grinder with material and the engine RPM drops below 1750 due to heavy load on the engine, the feeder and feed roll will pause until the engine RPM increases above 1950, then the feeder and feed roll will resume operation. If this happens repeatedly, you are probably overfeeding the grinder. In this case you should slow down the feed roll and/or the feeder.

High Pressure – When an overfeeding condition develops and the hydraulic system pressure reaches a preset level at either of the Pressure Switches (14), usually 2200-2300 psi, the feeder and feed roll will reverse. The feeder will continue rearward until it contacts the rear limit switch, at which time both the feeder and feed roll will again move in the forward direction. This action will attempt to clear the blockage and give the feeder and feed roll a fresh start.

GRINDER OPERATION

NOTE: Always run the feed roll faster than the feeder in order to help prevent material from building up or jamming in front of the feed roll.

NOTE: Always start the feed roll before starting the feeder. The feeder will not function unless the feed roll switch is in the forward position.a. With the engine running and at operating temperature, gradually increase the engine

RPM to approximately 2200 using the Throttle Rocker Switch (4)

b. Pull out the Feed Stop/Start Switch (6)

c. Turn the Feed Roll Switch (3) clockwise to “Forward” position. The feed roll will start rotating forward.

d. Adjust the Feed Roll Flow Control Valve (12) until the speed of the Feed Roll is approximately 15 RPM.

e. Push the Feeder Start/Rev (green) Button (2). The feeder will start reciprocating, starting in the reverse direction.

f. Adjust the Feeder Flow Control Valve (11) to the point it takes approximately 20 seconds to complete a cycle of the feeder. You are now ready to feed material into the grinder.

g. Adjust the speed of the Feed Roll and Feeder depending upon the material being ground, desired capacity or production.

Visual observation of the speed of the feed roll and feeder is necessary. Use good judgment in setting the feed rate. Hard material such as wood and paper must be fed slowly. Bulky material such as dry leaves can be fed at a much faster rate.

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CAUTION – The feed roll pulls material into the grinding chamber with considerable force. Always keep your hands and arms clear of the material as serious injury can result if you become entangled. If this happens, reach up and push in the EMERGENCY STOP BUTTON located on the feeding side of the grinder at the feed roll housing or on the control panel.

When grinding dense material such as wood, cardboard or paper, allow the feed roll to float through its full up and down travel. When grinding bulky material, the feed roll stop pin should be placed in the first or second hole which keeps the feed roll off the hopper floor and lets the feed roll pull material more readily in and feed it to the rotating hammers.

When grinding most bulky material, fill the hopper only to the bottom of the flared section. If too much material is placed in the hopper, plugging at the feed roll may occur. Best performance is obtained when the feed roll feeds material to the rotating hammers in an even flow.

The speed of the feeder should be set to obtain an even flow of material to the feed roll without overloading the feed roll. The material being ground and the desired particle size will determine the proper speed of the feeder.

NOTE: You may have to slow down the feeder to prevent a plugging problem at the feed roll.

CAUTION – The feeder retracts at a higher speed than it moves forward. Keep hands and arms away from the feeder when grinding.The movement of the feeder is maintained by the action of twin hydraulic cylinders which push and pull the feeder. Directional valves and limit switches control the direction of travel of the feeder. When the feeder gets to the end of its forward or rear stroke, a limit switch shifts the valve and the feeder then moves in the opposite direction.

DISCHARGE CHUTELoosen the clamp ring on the discharge chute, grip the discharge chute and turn it in the direction you want the material flow. Tighten the clamp ring on the discharge chute. Position the deflector so that the material is placed in the desired location. Additional optional height extensions may be added to gain a higher discharge if required.

DO NOT ATTEMPT TO ROTATE THE DISCHARGE CHUTE WHILE TH GRINDER IS OPERATING.

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FEED ROLL TRAVEL ADJUSTMENTS

The feed roll on your KID III has several features to help process a variety of materials. There is a Spring Assist feature to add down force to the feed roll. You can limit either the up or down travel of the Feed Roll Swing Arm by adjusting and locking the travel stops on both sides of the machine.

SPRING ASSIST AND FEED ROLL OPERATIONSAn important aspect of how well the feed roll pulls material into the processing rotor is the amount of down force on the roll. A double spring assist mechanism has been incorporated into the feed roll design.

When grinding dense material such as wood, paper or cardboard, the feed roll is left in its down position or the feed roll is positioned to operate just off the hopper floor. No positioning is required of the Travel Stop Bar.

In grinding dense material, the feed roll function is to help feed material to the rotor in the amount and at the speed the rotor can process the material without bogging down. Start with the feed roll variable speed control in a slow position and increase until you maximize your production and obtain the desired particle size. If the RPM of the engine drops excessively, slow down the speed of the feed roll.

FEED ROLL OPERATION IN RAISED POSITIONThe feed roll is mounted on a swing arm and can move up or down approximately 8 inches. When processing bulky material such as grass, leaves or straw, raising the feed roll off the floor of the hopper and locking it in a raised position improve feeding. This is accomplished by adjusting the travel stop screws on both sides of the machine to the desired position and locking them in place with the jam nuts. Testing performance in positions will determine the correct height for optimum feeding operation. The feed roll is free to move up as it assists feeding material to the rotor and hammers. The down travel of the feed roll is determined by the position of the adjustment screws.

In the event it is desired, you can also limit the upward travel of the feed roll by adjusting and locking the stop screws which limit the upper travel of the feed roll lift arm.

In grinding loose material, it is necessary to run the feed roll at a higher rate of speed than the feeder in order to help feed the loose material to the rotor and hammers. This will prevent a build-up of material in front of the feed roll. Adjust the speed of the feed roll until you obtain the desired feeding results and the desired particle size.

NOTE: The effective feed rate of the feed roll should always be higher than the speed of the feeder.

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ADJUSTING FOR PARTICLE SIZEThe following adjustments affect final particle size:

1. Concave – The closer the concave is to the hammers the finer the grind.2. Speed of Rotor – The slower the rotor operates the coarser the grind.3. Speed of Feed Roll and Feeder – Slowing down the rate of material moving to

the rotor and hammers will help provide a finer grind. This is accomplished by slowing down the forward motion of the feeder and slowing down the rotational speed of the feed roll.

NOTE: The effective feed rate of the feed roll should always be higher than the speed of the feeder.

CONCAVE ADJUSTMENT

To adjust the concave (A), first loosen the concave clamp bolts (B). Adjust the height of the concave by turning the concave adjusting nuts (C). If you are raising the concave to reduce the space between the concave and the hammers, loosen the bottom or lower adjusting nut approximately 1 inch. Tighten the top adjusting nut, alternating from side to side to keep the concave level. Reverse the procedure to lower the concave. When the concave is at the desired position, tighten the adjusting nuts on both sides and the concave clamp bolts.

For a finer grind, adjust the concave and fingers closer to the rotor and rotating hammers. For a coarser grind, adjust the concave and fingers farther away from the rotor and rotating hammers.

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HAMMER INSPECTION AND REPLACEMENTThe heart of your KID III grinder is a series of swinging hammers mounted on a heavy-duty rotor. When the hammers become worn, the quality of the grind is greatly reduced. For best results, keep a sharp point on your hammers. You can expect the point to last from 50 to 100 hours or more of grinding. This all depends on the type of material being processed. The more abrasive the material, the shorter the life of you hammers. A set of hammers should last from 150 to 200 hours or more of operation.

To inspect the hammers, remove the front hammer inspection plate by removing the attaching clamps. Also remove the two bolts and nuts holding the discharge, and then rotate the discharge to the rear for full exposure of the rotor and hammers.

DANGER – Coming in contact with the rotating hammers will result in serious personal injury. Be sure the engine is stopped, the start switch key is removed and in your possession, and the rotor has come to a complete stop before attempting any inspection.

Slowly rotate the rotor by reaching into the grinding chamber and pulling the hammers toward you. Inspect the hammers for wear and damage. If the hammer point has rounded by 3/8 inch or worn through the hard facing, the hammer should be rotated to the other point or replaced.

To change the hammers, remove the hammer air intake plates (A) on both sides of the grinding chamber. Turn the rotor to line up the hammer pins (B) with the air intake opening. The hammer pin is held in place with two flat countersunk socket head screws on the side opposite the engine. Remove the socket head screws. These screws may be difficult to remove. You may want to use a penetrating lubricant such as WD40 to help loosen the screws and/or strike the head of the screw or the socket wrench to help loosen the screw. The pin is now in a position to be tapped out. Take a 1-inch punch and tap the pin on the end opposite the pin retainer tab. Remove the hammers as they become free. Thoroughly inspect the hammer pin for wear or cracking.

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WARNING – If a hammer pin fails, it may cause hammers to be thrown from the rotor housing, which can cause serious personal injury. If a definite wear groove is noticeable in the hammer pin, it should be replaced.

To replace hammers, re-insert the hammer pin and hold a hammer between the first and second rotor plates. Push the pin through the rotor plate and hammer hole. Insert a hammer between the second and third rotor plate and push the pin through. Skip the space between the third and fourth plates. You should note a grinding finger mounted on the fingerplates filling the slot. Insert a hammer between the fourth and fifth plates and every other opening. You will have a total of eleven hammers on each hammer pin or a total of 44 hammers in the rotor.

When installing new hammers, they must be replaced in matched sets. When purchasing hammers from Sundance Equipment, LLC, they will come in color-coded sets of eleven. All hammers of the same color should be placed on the same pin. All sets have been matched to the same total weight to keep the rotor in balance. If you replace one complete row of hammers, the opposite row of hammers must also be replaced in order to keep the rotor in balance. We highly recommend that you replace all hammers at the same time.

You will note that the KID III hammers have two points. When the first point is worn down 3/8 inch or through the hard facing, you should rotate the hammer and use the other point. When the second point wears down, replace your hammers with a new set.

After all hammers have been re-installed, install the socket head screws in the hammer pin tabs and torque the screws to 44 ft-lb. We recommend using anti-seize compound on the screw threads to facilitate removal later.

GRINDING FINGERSYour KID III grinder is equipped with two rows of fingers, which project into the grinding chamber, between the hammers, and assist in reducing particle size and providing a uniform end product.

The grinding fingers are located in the front concave with two rows of nine fingers projecting into the grinding area. If conditions such as obvious foreign material in the product being ground exist, it may be necessary to reverse the position of the fingers and have them not project into the grinding chamber. Remove the fingerplates from the concave, turn them over and bolt the backside of the fingerplate to the concave, thereby plugging the holes in the concave. This removes the restriction of the fingers, which results in an increase in unrestricted clearance between the rotor plates and the concave. A piece of foreign material may now pass through without necessarily causing harmful damage to your grinder. Hammers will retract or swing when they encounter metal or other solid material and will also help carry the foreign material through the grinding chamber. For a finer grind you may also insert 36 hammers in the now open hammer slots for a total of 80 hammers.

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LIMIT SWITCHESLimit switches, which control the reversing action of the feeder, are located at the rear of the grinder beneath the rear cover. If the feeder does not readily reverse direction, the limit switch arm may be bent or loose or out of adjustment. Remove the rear cover and adjust the limit switch arms as necessary to provide positive reversing action.

The limit switches should be adjusted to reverse the direction of the feeder before it strikes the positive stops at either end of its stroke. If there is a “banging” sound at the end of either stroke, one or both limit switches are out of adjustment. Allowing the feeder to repeatedly hit the positive stops induces a shock load into the chassis that could damage sensitive electrical components.

HYDRAULIC RESERVOIRThe hydraulic reservoir holds 83 liters or 22 gallons of hydraulic fluid and is equipped with a sight gauge and temperature gauge. The hydraulic pump is a load sensing and flow sensing type with a capacity of 75 liters or 20 gallons of fluid per minute at 1900 RPM. Use a good quality of HD32 hydraulic oil when replacing or replenishing the hydraulic fluid. The hydraulic reservoir is also equipped with a shut-off valve and can be closed if a hydraulic problem develops in the system.

DO NOT OPERATE THE PUMP WITH THE SHUT-OFF VALVE IN THE OFF POSITION AS DAMAGE TO THE PUMP MAY OCCUR!

FUEL TANKThe diesel tank holds a total of 210 liters or 55.5 gallons, which should be sufficient for at least 10-12 hours of operation. The fuel tank is equipped with a visual level indicator located at the front of the fuel tank.

ELASTOMERIC COUPLINGThis coupling, which connects the engine PTO shaft and the grinding rotor shaft, accommodates the minor misalignment that is inherent in the drive. The assembly is made up of two hubs, a split ring insert and an outer holding ring.

For alignment or replacement, refer to the detailed instructions included in Appendix A.

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FLUID COUPLING

Your Sundance KID III is equipped with a Fluid Coupling from Transfluid Industrial Transmissions. Before operating the fluid coupling read all the safety and operating instructions in this manual.

Always follow all the instructions and assure that all the operators standing by the machinery are wearing all the protective equipment necessary for the job type and application being performed.

Do not use the machinery if you do not understand these instructions, and immediately refer to the manufacturer or the customer service desk for assistance.

The coupling must be protected by a convenient cover guard to avoid personal injury to people. Axial and radial ventilation openings should be incorporated in the guard for heat exchange.

If the coupling is fitted with fusible plugs, the said openings should not be directed towards operators or any hot or electrical installation.

Fluid Coupling Filling InstructionsYour Transfluid fluid coupling has been filled with ester phosphate hydraulic fluid at the factory. For refilling it is necessary to follow the following procedure.

Fig 1

1. With the coupling mounted (Fig 1) rotate it until the X cast into the housing is at the 12 o’clock position. This will put the fill plug (13) at the correct angle for the maximum fill level.

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2. Fill the coupling until oil drains from the filler hole. It is useful to gently rock the coupling back and forth to purge trapped air.

3. Reinstall the plug using a quality thread sealant. Torque to 21 lb-ft.

4. The fillings marked X-1-2-3-4 may be chosen to meet the best performance in terms of start-up and steady running operation. With the maximum fill X a condition of minimum slip and maximum performance is achieved: the starting torque/nominal torque ratio gets higher (value generally comprised between 1.8 and 2.0); decreasing the oil quantity inside the coupling (fill 1-2-3-4), the opposite result is obtained.

5. High slip causes overheating of oil contained in the working circuit, with a consequent decrease in overall performance.

6. For normal operating conditions, use only ISO HM 32 (or equivalent SAE 10W) oil types. At low ambient temperatures (near 0 oC), it is recommended to use ISO FD 10 (or equivalent SAE 5W) oil. For temperatures below –10 oC, ask Transfluid. For severe service, use ester phosphate hydraulic fluid. See your hydraulics supplier for sources.

Operation and Maintenance1. The normal operating procedures must be followed to keep balance and

temperature under control. To not damage the coupling seals, temperature must not exceed 195 oF values; all the coupling seals have to be made of a special material and the rotating ones in Viton. A high temperature value may be caused by the following conditions:

a. Insufficient oil fillb. Higher absorbed power than engine rated powerc. High ambient temperatured. High starting frequencye. Excessive starting timef. Too many consecutive start-upsg. Inadequate air ventilation due to cover guard

2. After the first 20 days of operation, check the oil fill (this operation to be carried out with cold oil) and the tightness of the screws.

3. Repeat the above checks every 6 months.

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4. Your fluid coupling is equipped with a thermostatic temperature switch. It is preset to give a visual alarm in the form of a red strobe light on top of the engine enclosure when the temperature reached approximately 107oC/225oF. The temperature probe is located in the flywheel housing and the adjustable temperature switch is located in an electrical box on the left rear of the engine enclosure. As a safety measure, the fluid coupling also contains a fusible plug at 198oC/390oF (122oC/250oF and 138oC/280oF settings are available upon request) as shown in Fig 2. If the temperature switch trips or the fusible plug blows at regular intervals, check for the causes of high temperature in paragraph 1.

Fig 2

5. Oil should be replaced after 4000 hours of operation.

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LUBRICATION OF GRINDERRefer to the engine manual for proper lubrication and maintenance instructions for the engine.

Bearing Location No. of Fittings PeriodRotor Shaft Bearings 2 100 hoursFeed Roll Shaft Bearings 2 25 hoursPTO Shaft Bearings 1 25 hours

ADJUSTING THE PRESSURE SWITCHES

The pressure switches are intended to improve the feeding of material by detecting a blockage and reversing the feeding mechanism to attempt to clear the material that is beginning to create the blockage. There is one pressure switch on the feed roll hydraulic circuit and one on the feeder hydraulic circuit. When either of the pressure switches, one of which is shown in the photo on the following page, is activated, both the feed roll and the feeder reverse until the feeder reaches its rearmost position, at which time both return to forward travel.

The hydraulic system relief valve at the pump should be set at 2500 psi. For a pressure switch to work, it must be set at some pressure less than the system relief pressure, otherwise the pressure switch will never see it’s activation pressure. We recommend setting the pressure switch at 2200-2300 psi.

To set the pressure switch, you need to force the system to the relief pressure. To do that for the feeder, remove the rear cover over the feeder cylinders, and raise the arm on the front limit, so that it will not be activated. That will allow the feeder to proceed to the positive stop at the front of it’s stroke, the hydraulic pressure will build and either the pressure switch will be activated, returning the feeder to the rear, or the feeder will stall, forcing the hydraulic system relief valve to open. That should occur at about 2500 psi.

The feeder pressure switch is located on the larger D05 valve located to the right of the control panel. On the pressure switch adjustment collar there is a locking screw. Loosen the screw to adjust the pressure switch. Turn the knurled adjustment collar counterclockwise very slightly to lower the activation pressure. Conversely, turn the knurled adjustment collar clockwise to raise the activation pressure. Adjust the switch so that it will always reverse the feeder before the system stalls by going over the relief pressure. That should be in the 2000-2200 psi range. Don’t forget to reset the front limit switch after completion of this adjustment. Make sure that, at operating speed, both limit switches reverse the travel of the feeder before the feeder contact the positive stop at either end of its travel.

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To get the feed roll to go the relief pressure is more difficult. You must insert a block under the feed roll that is too large to pass under it, causing the feed roll to stall. This is accomplished easier if you adjust the upper travel limit of the feed roll lift arm so that it does not rise very far. After that is accomplished, you can adjust the pressure switch in the same manner as the feeder pressure switch. The feed roll pressure switch is on the smaller D03 valve to the left of the control panel.

A simpler way to adjust the pressure switches is to observe the operation, and if one of the switches is activating too early, raise the pressure setting, or if one hydraulic circuit is stalling, lower the pressure setting.

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TROUBLE SHOOTING

Problem: No Hydraulic Functions

Possible Cause: The hydraulic system will only function when the engine RPM is above the under speed limit (see page 12). Insure that both Trip 1 & 2 lights on the Deep Sea speed switch is on. Trip 1 light should come on at approximately 1750 RPM and Trip 2 light should come on at approximately 1950 RPM. If necessary, adjust the Trip 1 and Trip 2 potentiometers for proper operation. If neither light comes on, the magnetic sensor on the flywheel may have failed.

Check the Hydraulic System Pressure Gauge, Item 10, page 9. With the engine running, even with both the feed roll and feeder ram off, the gauge should still read approximately 450 psi. If it does not, check the hydraulic pump. Is there any evidence of pump failure? If you manually shift the D03 or D05 valves, do you get movement?

Problem: Hydraulic System Stops For a Few Seconds, Then Starts Again

Possible Cause: This is normal operation of the grinder (see page 12). When the engine RPM drops below the under speed limit, the hydraulic system will go to neutral and pause until RPM exceeds the upper speed limit. If this happens frequently, you are feeding material to the grinder too rapidly or the material you are feeding is too large. Try slowing down the feed roll and/or the feeder. A good rule of thumb is that the feeder should not cycle in less than 20 seconds and the feed roll should not exceed 30 revolutions per minute. To count the revolutions of the feed roll, you can paint a stripe on the end of the feed roll through the travel slot on the drive end. Then you can count the number of times the stripe goes by the slot in a minute.

Problem: Feed Roll Does Not Rotate Either Way

1. With the engine (and hydraulic pump) running at any speed, manually shift the D03 valve both ways. The D03 valve is the smaller of the two directional control valves and is located to the left of the control panel. To manually shift the valve, insert a small tool through the hole in the end of the coil at each end of the D03 valve and push on the end of the spool, shifting the spool. Do this from both ends of the valve to check both directions of rotation. If this does not cause the feed roll to turn, go to steps 2-6. If this does cause the feed roll to turn, skip to step 7.

2. Insure that the flow control valve for the feed roll is not shut off. See item 12, page 9. Open the flow control valve sufficiently to insure that flow is permitted. Make sure the on/off valve, item 13 on page 9, is in the on position to the right.

3. Check the chain coupler between the hydraulic feed roll motor and the feed roll shaft. Are the double roller chain and both sprockets intact and in good shape?

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4. Check for a sheared key in the hydraulic feed roll motor shaft. If the hydraulic feed roll motor shaft is turning, but the chain coupler is not, you have sheared the key in the motor shaft.

5. Check for a sheared key in the feed roll shaft. If the chain coupler is turning, but the feed roll is not, you have sheared the key in the feed roll shaft.

6. You may have an obstruction in the hydraulic system. Disassemble the D03 valve and/or the hydraulic motor and check for contamination.

7. Swap relay 3 with one of the other identical relays (relay 2, 4 or 5) to see if that corrects the problem. If so, the original relay should be replaced.

8. With the engine at operating speed, make sure that both indicator lights on the Deep Sea speed switch module are illuminated, indicating that the engine is at operating speed and that voltage is being directed to control components. If it is not, raise the engine RPM until they come on or adjust the potentiometers until they come on. If the lights are still not illuminated, you probably have a faulty magnetic pickup on the engine flywheel.

9. With the start switch on, check for voltage at terminals 1, 8 and 11 on the Deep Sea speed switch.

10. At operating RPM, check for voltage at terminal 10 on the Deep Sea speed switch, at terminals B, 7 and 4 of relay 5 and at the common terminal of both contact blocks on the back of the 3 position Feed Roll selector switch.

11. At operating RPM and with the 3 position Feed Roll selector switch in the appropriate position, check for voltage at the normally open terminals of both contact blocks on the back of the Feed Roll selector switch.

12. At operating RPM and with the 3 position Feed Roll selector switch in the FWD position, check for voltage at common terminal 7 on relay 3, at terminal connector H, and that the LED on relay 9 is illuminated .

13. At operating RPM and with the 3 position Feed Roll selector switch in the FWD position, check for voltage at terminal 1 on relay 3 and terminal connector block O, and with the 3 position Feed Roll selector switch in the REV position, check for voltage at terminal 4 on relay 3 and terminal block N.

14. Check for a good ground at both coils on the D03 valve and at all terminals.

15. Check continuity of the cable to the coils of the D03 valve.

16. If you have adequate voltage to both coils of the D03 valve in step 13 and a good ground to both coils in step 14, the problem must be a failed coil (s).

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Problem: Feeder Assembly Will Not Cycle

1. Make sure the Feed Roll switch is in the FWD position. The Feeder Assembly will not cycle unless the Feed Roll switch is in the FWD position.

2. With the engine (and hydraulic pump) running at any speed, manually shift the D05 valve both ways. The D05 valve is the larger of the two directional control valves and is located to the right of the control panel. To manually shift the valve, insert a small tool through the hole in the end of the coil at each end of the D05 valve and push on the end of the spool, shifting the spool. Do this from both ends of the valve to check both directions of travel. If this causes the feeder ram to cycle, go to steps 6-13. If the feeder ram does not cycle, go to steps 3-5.

3. Insure that the flow control valve for the feeder ram is not shut off. Open the flow control valve sufficiently to insure that flow is permitted. See item 11, page 9. Open the flow control valve sufficiently to insure that flow is permitted. Make sure the on/off valve, item 13 on page 9, is in the on position to the right.

4. The feeder ram may be wedged between the feed floor and the retaining rails. If the feeder ram is jammed, the pressure gauge, item 10 on page 9, will be indicating a high pressure of 2000-2500 psi. Check with a feeler gauge to make sure there is clearance between the top of the feeder ram and the rails. If not, loosen the rails and adjust.

5. You may have an obstruction in the hydraulic system. Disassemble the D05 valve and/or the hydraulic cylinders and check for contamination.

6. With the engine at operating speed, make sure that both indicator lights on the Deep Sea speed switch module are illuminated, indicating that the engine is at operating speed and that voltage is being directed to control components. If it is not, raise the engine RPM until they come on or adjust the potentiometers until they come on. . If the lights are still not illuminated, you probably have a faulty magnetic pickup on the engine flywheel.

7. With the start switch on, check for voltage at terminals 1, 8 and 11 on the Deep Sea speed switch.

8. At operating RPM, check for voltage at terminals 9 & 10 on the Deep Sea speed switch, at terminals B, 7 and 4 of relay 5 and at the common terminals on both the Feeder Start (green) switch and the Feed Stop (yellow) switch.

9. At operating RPM, check for voltage at the normally open terminal of both the Feeder Start (green) and the Feed Stop (yellow) switches by pressing each switch to check voltage.

10. Swap relays 3 and 4. If the nature of the problem changes, one of the relays is bad and should be replaced.

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11. At operating RPM and with the Feeder Start (green) depressed, check for voltage at terminal B on relay 2 and terminal 8 on relay 4, and that the LED on relay 8 is illuminated.

12. At operating RPM and with the 3 position Feed Roll selector switch in the FWD position and the Feed Stop (yellow) switch pulled out, check for voltage at common terminal 7 on relay 2 and terminal 7 on relay 3.

13. Manually trip the rear (L1) and front (L2) feeder limit switches. The red LEDs on terminal blocks K and J respectively should be illuminated when the limit switches are maintained in the tripped position.

14. At operating speed and with the rear limit switch (L1) maintained in the tripped position, check for voltage at terminal B of relay 4, terminal 4 of relay 4 and the LED of terminal block L is illuminated.

15. At operating speed and with the front limit switch (L2) maintained in the tripped position, check for voltage at terminal 8 of relay 4, terminal 1 of relay 4 and that the LED of terminal block M is illuminated.

16. Check for a good ground at both coils on the D05 valve and at all terminals

17. Check continuity of the cable to the coils of the D05 valve.

18. If you have adequate voltage to both coils of the D05 valve in steps 14 and 15 and a good ground to both coils in step 16, the problem must be a failed coil (s).

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P.O. Box 485 Newton, KS 67114-0485(800) 570-3551 voice (316) 283-3063 fax

sundanceequipment@sbcglobal.net

STANDARD WARRANTY

Sundance Equipment, LLC, hereinafter Sundance, warrants to the original purchaser from the date of delivery, all parts, except hammers and hammer pins, of each new Sundance KID grinder purchased from Sundance or it’s authorized dealer, to be free from defects in material or workmanship for a period of six (6) months. Warranties on other components, such as rubber tires, supplied by original equipment suppliers (OEM’s) for the completion of the grinder are as stated in their warranty registrations.

Sundance agrees that it will replace free of charge, except for costs of installation and transportation, parts which are determined to be defective in material or workmanship and the warranty must be approved by an authorized representative of Sundance. This warranty does not apply to components supplied by other original equipment suppliers, as those would be covered by their warranty registrations.

Warranty does not apply to damage or malfunction resulting from accidents, damage in transit, abuse, modifications, alterations, improper servicing or using the product for functions it was not intended to perform. Warranty does not cover normal maintenance services such as adjustments, tune-ups, fuel system cleaning or the results of a natural calamity.

All warranty repairs must be performed by Sundance or by an authorized Sundance grinder dealer.

Sundance does not authorize any other party to make any representations or promises on behalf of Sundance or to modify the terms, conditions or limitations of the warranty, in any way. The date of delivery shall be recognized as the date shown on the Sales Order or delivery receipt.

Note: Using the grinder/chipper to process material for which it was not designed, i.e., material over 8” in diameter, mud, steel, large rocks etc., may be cause for not accepting warranty claims.

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