HAMMER MILL

HON YUNG DEVELOPMENT CO., LTD.

1F, NO.34, Alley 57, Lane 799, Wunsian RD.,North District,
Tainan City 704,Taiwan (R.O.C.)
TEL: +886 6 2594746 FAX: +886 6 3507600
E-MAIL : dyy.kuo@msa.hinet.net http://www.hon-yung.com.tw
 FOREWORD
This manual has been prepared to help you obtain the utmost in trouble-free performance from Hon
Yung. Receiving, handling, installation, operation and maintenance instructions for the system
components are included.
Failure to read and understand the information may result in injury to personnel or damage to the
equipment from improper unloading, storage, installation and/or initial startup.
Such mistreatment or damage may void the warranty of the equipment.

DO NOT FILE THIS MANUAL

See that it is placed in the hands of installation, operating service personnel.
Hon Yung is constantly making improvements in its machines to bring industry increased value for its
equipment investment.
Consequently, there may be minor variations between the equipment you receive and the details as
described in this manual.
If any problems arise which this manual does not cover adequately, contact your Hon Yung district
representative or the home office in Taiwan.

RECEIVING
Examine the equipment. Report any shortages, or damage, to the carrier within 48 hours for inspection.
Sometime damage cannot be detected until the equipment is placed in operation. (e.g. , a bent shaft)
Contact Hon Yung immediately when such defects are discovered.

HANDLING
Sling the hammermill from lifting lugs provided or place slings under the base of the unit. Never sling
from shaft. If a fork truck is used to move the mill, take care to prevent damage to underside of mill.

STORAGE
If stored, cover securely to protect from the elements and especially dust and dampness.
When removed from storage, open up the mill to check for foreign objects, water, corrosion, etc.
If storage is prolonged, pump bearings full of grease to prevent corrosion. Relieve pressure at startup.
See bearing maintenance section.
If storage is prolonged in a vibration area, shafts must be rotated weekly to prevent bearing peening.

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 INSTALLATION OF THE GRINDER
In order to obtain maximum efficiency from your grinder, it is important that it be properly and carefully
installed. Sufficient floor space and headroom should be available to permit proper operation and
maintenance. Refer to enclosed assembly drawing for dimensions.

FOUNDATION
The grinder should be mounted on a solid, level foundation, preferably concrete, with anchor bolts. If
a concrete foundation is used, anchor bolts must be set to correctly match the drilling of the grinder base
before the foundation is poured. Hook type bolts centered in metal sleeves at least twice the bolt
diameter are recommended. Use of the sleeves permits any bolt to be sprung sufficiently to correct for
small errors in setting or minor variations in drilling. The sleeves are then filled during the grouting
operation. Anchor bolts are not furnished as standard accessories.

LEVELING
After it has been set on the foundation, the grinder base should be shimmed wherever necessary to allow
the base to retain its natural configuration. This is important because the grinder and base have been
assembled on leveling blocks at the factory. Turn the anchor bolt nuts snug, but do not tighten.

ALIGNMENT
Alignment of the grinder shaft and motor shaft must receive careful attention. This not only assures
satisfactory coupling operation and normal life, but also prevents damage to the grinder or motor from
vibration or thrust forces. If Hon Yung has furnished and/or installed the motor, then the shaft
alignment will have been done at the factory. However, final rechecking and adjustment will be
required after installation. To recheck and adjust the coupling, refer to “Instructions for Coupling
Operation” in this manual. If the motor has not been installed at the factory, refer to “Instructions for
motor Installation” in this manual.

GROUTING
Grouting of the base follows completion of leveling and alignment. The concrete foundation must be
thoroughly cleaned and wet before grouting begins. Surfaces should be roughened by chipping to
remove any glaze or oily spots that would prevent proper bonding. Effective wetting may require as
much as 12 hours, assuming the foundation has been cured about three weeks. All metal surfaces that
will come into contact with the grout should also be thoroughly wetted just before the grouting operation
starts.
The grouting must flow into and fill all spaces and cavities before it sets, and must permanently retain its
original volume. A mix of one part cement and 1-1/2 parts clean sand has given good results, and will
have minimum shrinkage when water content by weight does not exceed 50 percent of the weight of the
cement. Wait at least 24 hours for the grout to set before tightening the anchor bolts.

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ELECTRICAL WIRING
Careful study should be made of all specifications for proper electrical wiring of the motor and controls.
In many locations an auto-transformer type of reduced voltage starter is required; however, in some
locations an across-the-line starter can be used. The decision concerning the type of starter is entirely
up to the owner, his insurance under-writers, and the local power company.
An ammeter of the proper size should be connected to the motor circuit. It should be located in a
position where it can be easily seen by the operator when adjusting the feeder for loading the mill to its
maximum capacity.
A wiring diagram has been included in this manual to show the necessary electrical connections.
Standard operating speed is 3000 RMP.

INSTRUCTIONS FOR INSTALLING MOTOR

Remove the motor mounting pads from the mounting area on the grinder base by grinding away the tack
welds. (The pads are tack welded to the base for shipping purposes.) Bolt the mounting pads to the
motor feet. Turn the bolts down snug, but do not tighten. The following steps should then be
followed in mounting, positioning, and securing the motor to the grinder base：

1. Position the coupling halves on the motor shaft and the mill shaft.
2. Set the motor into position on the base, bringing the end of the motor shaft to the end of the grinder
shaft and allowing 8.0 mm clearance between the two.
3. Following the “Instruction for Installing Dodge Couplings” in this manual, align the two coupling
halves. It may be necessary to place 1.0mm to 1.5mm thick shims between the motor feet and the
mounting pads to obtain the desired alignment.
4. After the coupling halves have been aligned, weld the mounting pads to the grinder base.
5. Recheck the coupling alignment to see if the welding operation has moved the coupling position.
If the coupling position has moved, repeat Step 3.
6. Securely tighten the bolts in the motor feet and assemble the coupling, again following the
“Instructions for Installing dodge Couplings.”
7. Drill and install roll pins (one on each side of motor) through the motor feet and into the mounting
pads. This guards against movement of the motor should the bolts become loose during
subsequent grinder operation.

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 INSTRUCTION FOR INSTALLING DODGE COUPLINGS
1. Check bores and keyways of coupling flanges against the diameters and keyways of the shafts
on which the flanges are to be mounted.
Flanges are ordered to fit shafts in even inch dimensions, each flange will be bored to the exact
fractional dimension given, to a tolerance of plus 0.03 or minus 0.0000mm.
2. Check the key itself to make sure it is the proper size to fit.
Keys should fit accurately. Loose-fitting keys may come loose and cause damage by working out
or letting flange wear around the keyway. Keys that are too tight are hard to drive in, and fracture
of the flange may result. If necessary, select an over-size key and file it down to the proper size.
3. Make sure that the bore of the flange and the end of the shaft on which it is to be mounted are
clean and free from defects.
Rusty shafts or small chips in the bore may cause trouble in mounting or even throw a flange out of
true. When mounted, the flange should be at exactly right angles to the shaft.
4. Lubricate the end of the shaft or the bore of the flange.
The best material for this purpose is white lead. If no lead is available, use any light oil.
5. Start the flange onto the shaft, making sure the keyways are aligned.
6. Drive or press the flange onto the shaft, place the coupling on the shaft so that a dimension of
( ) between flanges for ( )and ( ) for ( ) will be maintained. The shaft of the mil
and motor must be a min. of ( ).
Always use a wooden block to prevent damage to the flange or the end of the shaft.
7. Tighten set screws.
8. Before installing the flexible equipment, proceed with installation of machine as outlined in
following paragraphs.
9. After machine and motor have been installed and aligned, proceed with installation of flexible
element. The split flexible element is then placed so that each bead is held between its flange
and a clamping ring. The cap screws are then tightened into place.

After both flanges have been mounted, the remainder of the work has to do with the installation of the
machines themselves, and the coupling can be made a very useful tool. When the equipment being
assembled is not heavy, the machine and motor can be brought together endwise, and an approximate
operating position is already reached.
The next step is to check for misalignment, both parallel and angular. The flanges of each Dodge
coupling are round, square with the bore, concentric with the bored and to size. This means that a
simple straight edge can be laid across the faces of the two flanges and any parallel misalignment can be
detected immediately with the eye. Either the mill or motor should be shimmed up until the two shafts
lie in the same plane, both horizontally and vertically.

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After all parallel misalignment has been corrected, a further check should be made for angular
misalignment. This is easily done with a flat piece of steel the thickness of the distance between the
two flanges. If the space between the flanges at the top is the same as at the sides, little or no
alignment is present. Move either or both units at the end away from the coupling until all angular
misalignment, both horizontal and vertical, has apparently disappeared.
When the equipment being assembled is too heavy to handle easily, the machines should either be
moved into their places on rollers or let down from a hoist or crane. The two units should then be
lined up and securely fastened into place, as described above.
It is worthwile mentioning that a little care and time spent in properly aligning two shafts connected by a
flexible coupling returns the cost many times over.
No matter how carefully couplings are lined up, some misalignment will still be present. More may
develop as a result of wear, setting of foundation, uneven expansion of parts due to different conditions
of temperature, or from vibration. Barring accidents, a Dodge coupling, properly mounted and
carefully aligned when installed, can be expected to render trouble-free service for a god many years,
sometimes longer than the machine itself.
When equipment is carelessly put into operation with the shafts out of line more than is necessary, undue
wear must result, not only to the coupling itself, but to the shaft bearings as well. Power is wasted,
shutdowns for repairs follow, vibration may ensue, and a whole installation be somewhat unsatisfactory
all for the lack of a little time spent in getting the original installation as nearly right as possible.
Reasonable care and accuracy only are necessary.
After a Dodge coupling is installed and running, it should be inspected from time to time. If no wear,
vibration or misalignment is apparent, you can be reasonably sure that the whole installation is right.
The coupling is an excellent “barometer” that gives warning when some unforeseen development is
waiting to cause serious trouble unless located and corrected.

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 FIRST TIME STARUP
1. Open the grinding chamber. To do this, open the door clamps, lift door to vertical position and
slide toward motor.
2. Remove all construction debris.
3. Slide the desired screen through the opening into position. Screen should fit snugly against screen
guides. Close the door and close the door clamps.
4. Recheck level of unit and alignment of coupling if installation is not recent.
5. Check bearings to make sure that they have been lubricated. (See “Lubrication” Section for
lubrication procedure.)
6. Close the feeder gate, or, if so equipped, set the feeding device at the lowest setting. Do not start
yet.
7. Start the take-away system.
8. Start the hammermill motor. On initial startup, check for proper rotation. This model
hammermill is designed to rotate either direction; however, rotation must be according to location
of spout and wear plate. (See sketch)

9. After the hammermill has reached full speed, start the feeder motor and/or slowly open the feeder
gate until the ammeter shows that the mill is operating at 1/2 load. (Full load amperes are shown
on the motor mane-plate)
10. Check over the mill and all accessories for proper function, then bring it to full load.
11. The hammermill will provide maximum output with the motor at full load amperes. Draw a line
or place a colored tape on the ammeter to indicate this position to the operator. The capacity of
the hammermill will vary with the type of material being reduced and the screen perforation size.
Once an operator has become familiar with the mill, he will be able to adjust the feed to the proper
position for each grind.

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 HOW TO STOP MILL
1. Stop the feeder motor and/or close the feeder gate.
2. Continue running hammermill motor until all material is out of the grinding chamber. (Ammeter
reading falls to no-load indication.)
3. Stop the hammermill motor.
4. Stop the takeaway system.

DAILY STARTUP AND/OR PERIODIC CHECK

1. Check magnet in mill inlet. See magnet, Page 11.
2. Check for lubrication. See Lubrication, Page 12.
3. Look for piles of dust or material on floor or elsewhere indicating a leak, loose connection, etc.
4. When operating, observe setting of the feeder motor (or gate) and the ammeter. If the feed rate
must be reduced for the same ammeter setting then (when the mill is stopped) open the door and
check the hammers and the screen.
Do not allow the hammers to wear too much before turning. See Hammer Maintenance, Page 9.
See Screen changing, Page 11.

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HAMMER MAINTENANCE
WARNING：Before opening mill to perform maintenance or to otherwise do repair work on mill,
personnel should throw disconnect switch at electrical starter box. For duration of
maintenance or repair work, disconnect switch should be secured in off position with
padlock and key retained by man working on mill.
Hammers must be maintained properly for maximum production. To prevent vibration, they must be
distributed on the cylinder to provide equal weight and balance.
New sets of hammers supplied by Hon Yung are precision balanced and are of equal weight within 1/4
ounce in each set.

TURNING OR CHANGING HAMMERS

Hammers have four wearing corners as shown in fig. A. When Corner No.1 becomes worn and
rounded, turn the hammers around to put Corner No.2 in position for grinding.
After this corner has worm, turn the hammers end for two more wearing corners.

CAUTION：For maximum hammer life, do not allow a corner to become worn closer than 7mm from
the mid-point of the hammer. See Figure B.
To maintain cylinder balance and prevent vibration, it is important, when turning hammers, to replace
each hammer in the same position as before.
When putting in a new set of hammers, it is important to change the complete set to maintain cylinder
balance and prevent vibration. Maker sure opposite rows on the cylinder have equal numbers of
hammers and that the hammers swing freely on the hinge pins.

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To turn or change hammers： Y-Pin was change to end plate of the hinge pin
1. Lock-out instructions as outlined on Page 15 must be followed.
2. Open door clamps and open doors.
3. Remove pipe plug in coupling, both sides.
4. Rotate the cylinder until a hinge pin appears in the opening of coupling.
NOTE：Mark the position of each hammer with chalk or felt tip pen to help you replace each
hammer in the same position.
5. Loosen the set bolt in the hinge pin end, No.22, on the hinge pin, No.29.
6. Remove the hinge pin. As each hammer is released, arrange it so that on reassembly it will be
returned to the same position. If the hammers have worn grooves in a hinge pin more than 0.7mm
deep, replace the hinge pin.
They are specifically hardened steel and are part of the spare parts list.
7. Replace hinge pin No. 29. Do not turn it around-replace it the way it was removed. Replace
each hammer so the new corner is in position for grinding. Check direction of rotation.
8. replace the collar in the last row of retainer discs. See that the hinge pin projects equally through
each side of the retainer discs.
9. Tighten the set Y-PIN in the end side to lock the hinge pin in place and prevent possible slippage.
10. A final check：
Hammers are in correct position.
Hammers are facing correctly.
Hammers swing free on hinge pins.
Opposite rows have the same number of hammers.
Pairs of opposite hammers are between the same retainer discs.
11. Replace the screen. Close up the mill as per paragraph 3 in Section for First Time Startup.

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HAMMER HINGE PINS
After approximately 3000 tons of grinding, the hinge pins should be inspected. If upon inspection, you
fine that the hinge pins have been grooved by the hammers more than 0.7mm deep, turn each pin end for
end and return it to its respective hole. After an additional 3000 tons of grinding, inspect the pins again
and if grooved more than 0.7mm deep, rotate each pin 90 degrees from its present hole to the next
adjacent hole. Repeat this turning and rotating cycle until the pins are grooved to point where further
adjustments are useless, and then replace the pins with new ones. These pins are of special hardened
steel and should be obtained directly from Hon Yung.

SCREEN CHANGING
To change the screen or reverse it for longer wear, follow instructions Paragraphs 1 and 3 in section for
first Time Startup.

MAGNET
A lifetime magnet is located in the inlet throat of the hammermill to protect the mill from ferrous tramp
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metal.
The magnet is equipped with an easy-opening latch and a hinged mounting.
Check the magnet daily and remove accumulations of material.

BEARING MAINTENANCE
1. Keep them clean.
2. Keep protective covers on tight to prevent dirt from getting into the bearing causing excessive wear
and overheating.
3. The bearings in the equipment are ball bearing, anti-frication type.
4. LUBRICATION
Be sure the lubricant is CLEAN. Always clean grease fittings and pressure guns before using.
Use a highly developed premium grease possessing high stability with water resistant and
non-corrosive characteristics meeting the following specifications：
Base ：Soap type
Additives ：Lithium
Penetration ：270-300 (unworked at 77℃, per ASTM D217)
Viscosity ：283-450 SSU at 100℉
Moisture ：0.05﹪ maximum
Filler ：None
Drop Point ：350℉, minimum (Per ASTM D566)
Oxidation stability：5 PSI maximum drop (ASTM 0.942)
Anti-corrosion ：Must pass ASTM D 1261
Inhibitors to prevent corrosion
Contact the lubrication engineer of your preference to recommend a proper grease.
5. Relubricate the bearings while the mill is running. Pump grease in slowly until a bead form at the
seals. This bead, in addition to acting as an indicator of adequate lubrication, provides a barrier
for dirt.
NOTE：Bearing manufacturer suggests approximately 0.8 oz of grease per bearing.
Due to varying operating conditions, the bearings should be geased frequently at first until it is
determined how much grease it takes each time to make the bead appear around the seals. From
this, the proper lubricating interval can be established.

6. Pump the bearing full of grease once each month. Remove the grease fitting after greasing.
(Cover to keep dirt out). Run the unit at least one hour. Excess grease will relieve through the
fitting opening. Wipe clean. Replace fitting.
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7.
COUPLING MAINTENANCE
Dodge Para-Flex Couplings require no regular maintenance. When once properly installed and
running, and occasional inspection is all that is required, and, in fact, is all that can be done.
From time to time alignment should be checked. This is easy to do with a short straight edge and, if
extreme accuracy is desired, with a tapered feeler gauge. Dodge recommends 3mm between the two
shafts when the coupling is in the operating position. This is not a critical distance, and the point to be
checked is to make sure that the two flanges cannot actually come in contact with each other at any time
during normal operation.
Angular misalignment should not exceed four degrees and the parallel misalignment should not exceed
0.25mm to 0.4mm, depending on coupling size. No matter how carefully couplings are aligned, some
misalignment will still be present. More may develop as a result of wear, setting of foundations,
uneven expansion of parts due to different conditions of temperature, or from vibration. Therefore, it is
important when couplings are initially installed on shafts of driving and driven equipment that closer
alignment than those figures above be obtained. By so doing, longer coupling life can be realized. A
properly mounted Dodge Para-Flex Coupling that has been carefully aligned can be expected to render
trouble-free service for years, sometimes longer than the coupled equipment itself.

TROUBLE SHOOTING
Excessive vibration may be caused by：
1. Coupling misalignment
2. Bad bearings
3. Improper foundation
4. Improper balance of cylinder assembly
5. Bent shaft

Unsatisfactory finished product may be caused by：

1. Worn or ruptured screens
2. Excessive wear on hammers
3. Improper direction of rotation
4. Improper loading of hammers on cylinder
5. Improper venting of mill
6. Incorrect mill speed
7. Improper selection of screen perforations

Excessive heat in bearings may be caused by：

1. Improper lubrication procedures
2. Misalignment
3. Faulty bearings
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4. Exceeding rated loading

Excessive overheating of mill housing may be caused by：

1. Exceeding rated capacity of mill and screen perforations
2. Bearings-see above
3. Improper venting of mill
4. Building-up of material within housing

Excessive horsepower demand may be caused by：

1. Exceeding rated capacity of mill and screen perforations.
2. Faulty bearings
3. Improper lubrication
4. Improper venting of mill
5. Badly worn hammers
6. Screen openings blinded
7. Build-up of material within housing

Obviously low capacity may be caused by：

1. Improper direction of rotation
2. Badly worn hammers
3. Improper venting of mill
4. Take-away equipment not adequate
5. Bridging in hopper above mill

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 RECOMMENDED SPARE PARTS
The following list of spare parts should be kept on hand and in a clean and dry place：(See Page 18)
1. A set of hammers, No.21 per various cylinder arrangements.
2. A set of screens, No.46 for different grinds.
3. Hinge pins, No. 29, and set collars, No. 22, and set bolt plate, No. 30,31
4. Two bearing, No. 32

When ordering parts for the hammermill, please include the following：
1. Serial number of the mill. (Found on metal name-plate located on back mill housing.)
2. Part number. (See Page 18 and Drawing on Page 15, 16, 17)
3. Description of the part required.
4. Quantity required.
5. Drawing number, if given.
6. Shipping address.

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 ID NO. PART ARTICLE DESCRIPTION
PART1
1 HM1500B -01 HOUSING
2 HM1500B -24 SAFETY DOOR
3 HM1500B -01-1 HOLD DOWN STRIP
4 HM1500B -01-2 PLATE
5 BEARING HOUSING SNZ316
6 HM1500B -10 FEED DEFLECTOR
7 HM1500B -05 HING PINS COVER
8 HM1500B -26 CASE
9 CUPLING (RU250)
10 MOTOR
11 HM1500B -04 BEARING PLATE
11 LIMIT SWITCH 8112
12 DOOR CLAMPS GH-40341

PART2 ASSEMBLE DRAWING OFF SHAFT

21 HAMMERS
22 HM1500B–19 HAMMERS SPACE PLATE – 28 PCS*4
23 HM1500B -17 BUSH-INSIDE 26pcs 8T 1PC
24 HM1500B -18 BUSHING-END 2pcs
25 KEY 18*11*100
26 HM1500B -05 SHAFT
27 NUT OF ROLLER BEARING AN26
28 WASHER OF ROLLER BEARING AN26
29 HM1500B -20 HINGS PINS 8PCS
30 HM1500B -29 WEAR PLATE 8PCS
31 HM1500B -28 END PLATE HAMMER SHAFT 16PCS
32 BEARING 2316E
33 NUT OF ROLLER BEARING AN16
34 WASHER OF ROLLER BEARING AN16
35 HM1500B -12 ROTOR PLATE 12t 2PCS
ROTOR PLATE 6t 27PCS
36 KEY 25*14*1500

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 ID NO. PART ARTICLE DESCRIPTION
PART3 ASSEMBLE DRAWING OF SCREENS
41 HM1500B -03 IMPACT PLATE 8pcs
41a HM1500B -03a WEARING PLATE COUNTER-HAMMERS
3PCS
42 HM1500B -23 RETAINING CLAMP
43 HM1500B -25 HANDLE LOCKING
44 HM1500B -22 FULCRUM BAR
45 HM1500B -21 ROCK PIN
46 SCREEN FRAME
47 HM1500B -09 PERFORATED SHEET STEEL SCREEN
48 HM1500B -08 ABRASION RESISTANT BAR
49 HM1500B -27 CLAMP SHAFT

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