Installation, Operation & Service Manual
Contents
1. cccccccsceccceceseceeceeeeeeeceeeeeeseeeeceeseeeceeseeeeeeesegeeeesseeeeesaneees 7 Manual or Sustained Manual Pressure Mode Operation ccccccseececeeeeeeeeseeeeeeeeeeees 8 uisa ck ANNA NIE SUN 8 dogong WAC INN t an 8 elsi eet 9 Pinning Boost Override System cccccccccssseeeeeeeeseeeeeeeeeeseeeeeeeeeeaeeaeeeseessaeeeeeeesaanseeees 9 Immersion Oil Heater ERROR T 9 Advance Waning LIgN wrescscecnaicscentwseierensianetsguaciatrasancectnsant itusaneenseseranicleniviacemsastediiants 9 Hydraulic Cart amp Container DUMPpEr seessssssesssssseeeseneeenen eene nnne nnns 9 Low Hot Oil Warning System sssssssssssssseeeeeeeeene nennen nennen enn rns nnne nnn nnns 9 Programmable Cycling P 10 Photo Electric Start amp Infrared Start System sssssssssseeeeee 10 Remote Jog Cont Olssen sett sev i vem ata idet aft ah P HDI M deridet dpi ditur ee 10 Additional Remote Control Station cccccccccccseecceceeeeeeceeeeeeseeeeeeeseeeeeesseeeeeeeseneeeeeaes 10 Trouble SING OU Mtt 11 Motor FNS TO AIG oe srs tr 11 Motor Starts But Ram Fails To MOV cccccceecceceeeeeeceeeececeeeeeeeceeeeeesseeeeeeseneesessageees 11 IT ATAU RN sates eens earned E 12 Senece mele TTH 12 SU INET CISA ca Son ccsisis LU UU UU m 12 initial Maintenance CHECK vite le2. S A Industries Inc Waste Handling Compactors amp Dumpers for Wet or Dry Industrial and Commercial Applications ELECTRO MECHANICAL COMPACTOR SERVICE ADDENDUM Electro Mechanical EM compactors are SP s line of Oil Free equipment Installation and operational procedures are the same for both the EM amp hydraulic machines Preventative Maintenance on an EM machine is identical to that of a hydraulic unit minus any procedures intended to maintain a hydraulic power unit Necessary EM model preventative maintenance for direct drive units is as follows Ram Guide Blocks must be kept in alignment and changed if necessary For service procedure steps to adjust Ram Guide Blocks see Pg 14 High priority is placed on Compactor Clean Out Material waste build up behind the ram must not be allowed to make contact or contaminate the actuator shaft Product build up on the actuator shaft will cause abnormal wear and decrease the life span of the actuator Recommended Compactor Clean Out schedule USAGE Clean Out Frequency Heavy Over 6 Hrs Per Day Once every 2 months Medium 2 6 Hrs Per Day Once every 6 Months Light Up to 2 Hrs Per Day Once every 12 Months EM compactors are outfitted with an automatic lubrication system that applies grease directly into the actuators drive system and shaft housing The automatic lubrication system uses replaceable grease packets that can and will run out Replacement of the gr
3. Usage Strainer Change Or Clean Frequency Heavy 6 Hrs Per Day Initial change after 2 weeks Thereafter every 3 months Medium 2 6 Hrs Per Day Initial change after 3 weeks Thereafter every 6 months Light Up to 2 Hrs Per Day Initial change after 4 weeks Thereafter every 12 months The first maintenance check should take place with the strainer filter change and Initial Maintenance Check include the following 1 Check and tighten all electrical and hydraulic connections on the power unit control head and cylinder 2 Check and tighten all mechanical fasteners nuts bolts set screws etc 3 Drain some hydraulic fluid from the bottom of the reservoir by removing the 3 4 plug from the half coupling under the oil level gauge Inspect the fluid for the presence of water Drain all water 4 Check the wear guide shoes or Nylatron guide blocks located on the rear of the ram for looseness and unreasonable wear Call a factory authorized repre sentative if wear seems excessive or uneven Under normal conditions the fluid can be used for an indefinite time If you sus pect that the fluid has been contaminated or has otherwise lost its usefulness drain off some of the fluid take it to an oil distributor and have it analyzed Hydraulic Fluid Changes The bottom of the reservoir should be inspected every 12 to 18 months for sludge deposits If there is a detectable layer of sludge the reservoir should be drained flushed wit
4. 5959 Email info sp industries com Programmable Cycling Photo Electric Infrared amp Ultra Sonic Start Systems Remote Jog Control Additional Remote Control Station When a programmable cycling system is used special precautions must taken to make the compaction area off limits to all unauthorized personnel All safety devices such as warning lights etc must be working properly and all chute and hopper doors and gates must be closed and locked when not in use for dumping purposes The programmable cycling system consists of an additional timing device an additional relay extra starter mounted contacts and a warning strobe light and buzzer mounted on top of the electrical box Once the compactor has been started it cycles automatically until the stop button is pushed or the end of the preset cycle time is reached 1 TR allows the compactor to cycle for its preset amount of time 3 TR allows the compactor to maintain an off condition for its preset amount of time To operate the programmable system set the switches in the following positions 1 TR set for desired on time 3 TR set for desired off time 1 SS set to run position Turn the power to the electrical panel on Pull the start Stop Button To immediately stop the cycle at any time push the Start Stop Button In order to make the system inoperative remove 3 TR from the electrical box The photo electric infrared or ultra sonic star
5. and above standard hose length usually ten feet require y schedule 80 pipe and 3 000 Ib pipe fittings If the lines are more than 20 feet long pipe with a larger diameter must be used to prevent pressure losses Vibration can be lessened by using hydraulic hose between the cylinder connection and the pipe line and between the pipe line and the power unit During operation hydraulic hoses should not rub against an abrasive surface When the ram changes direction the pressure change will cause the hoses to move Rubbing could cause leakage usually starting in the form of a mist and eventually turning into a steady stream An explosion could occur if an open flame came in contact with the leaking oil Hydraulic Fluid The reservoir must be filled with a premium grade hydraulic fluid having a viscosity index of approximately 100 and a viscosity of 32 CST 400 C or an ISO VG32 Thermostatically controlled immersion oil heaters are recommended for extreme conditions Also the fluid must have antifoam antiwear and water seperating additives Acceptable hydraulic fluids for all other conditions are as follows Shell T S2M32 Gulf Harmony 32 Mobile D T E 24 Shevron Rando HD 32 Exxon Nuto H32 eA YU LOH The electrical controls must be connected to the correct power source 208 230 460 etc Electrical Connections Power to the unit must be provided through a customer furnished fusible dis connect switch which is visible and access
6. pressure is factory set at approximately 8096 of normal operating pressure This will allow the advance warning light to indicate when the container is approximately 80 full giving the operator time to contact the hauler to change containers for minimal compactor down time A hydraulic dumper consists of a side deck or remote mounted dumping mecha nism and a separate motor valve pump and operating controls A typical dumper will have its hydraulic components mounted on the same reservoir as the compac tor s hydraulic components and the operating controls in the same control panel as the compactor s operating controls The dumper may be started with or without operating the compactor as long as 2 SS is in the Run position 1 SS is in the On position and the compactor stop button is in the closed center position The low hot oil warning system consists of reservoir mounted low oil and hot oil sensing devices and a warning light The low sensing devices send a signal to the warning light mounted in the main control panel and shuts the motor pump off when the oil level is dangerously low or hot When the light comes on the reservoir hydraulic fluid must be checked and filled to the proper level as read on the oil sight gauge and or replaced if damaged from excessive heat The cause of the low or hot oil condition must be determined and repaired before the motor 1s started again JJ 9 IS www sp industries com Phone 800 592
7. with the mating surface of the compactor If a gap is present on the top or bottom the front or rear legs of the compactor and or the wheels of the con tainer must be shimmed until proper alignment is reached Do not over tighten the container hooks The container should only be drawn snug against the compactor Container and Compactor Alignment JJ 6 IS www sp industries com Phone 800 592 5959 Email info sp industries com If the compactor is equipped with a hopper security chute or safety gate which uses a safety interlock switch the gate or door must be closed to operate the compactor With the interlock switch in a closed position power will pass to the control system allowing the machine to operate Hopper Doors Adjustable decks and deck extensions must be installed so they are level The cen ter support arms of the deck must be welded to the compactor side frame Safety handrails must be installed on all decks as per OSHA standards If the compactor is equipped with a photo electric eye or infrared eye the reflector or receiver must be properly mounted opposite the eye to reflect the light beam also the light beam must be free of obstructions Photo Electric amp Infrared Eye Systems It is the owner s responsibility to provide suitable safety enclosures and or gates for all dumpers Safety interlock switches enabling the dumper to be operated only when gates are closed must be mounted on all gates leadi
8. Dumpers for Wet or Dry Industrial and Commercial Applications l
9. Electromechanical Stationary Compactors Installation Operation amp Service Manual Industrial Models EM 2101 EM 3101 HD EM 4101 HD EM 6001 HD iy MP Inc Waste Hanaling Compactors amp uan for Wet or Dry Industrial and Commercial Applications Commercial Models EM 1501 EM 2101 EM 3101 EM 4101 INDUSTRIAL COMMERCIAL M Built with Pride Stop Read the Following Safety Information Before Operating the Equipment SP Industries Inc has made every reasonable effort to produce a product that will perform successfully and safely during its expected life span for the owners and persons operating the equipment To increase the safety while operating this unit all persons should closely follow these safety tips as well as the safety guidelines in the ANSI Z245 2 Safety Standards for Stationary Compactors booklet included with the compactor and all OSHA guidelines l As per OSHA standards install safety rails and guards on walk ways decks and hopper openings Check your local OSHA regulations for additional requirements Erect suitable barriers around cart dumpers conveyors etc to keep personnel clear of hazardous areas during operation Make sure all access covers are in place before starting the machine Keep the compactor working area clean uncluttered free of ice and snow and especially free of oil and grease Locate the remote control head so the operator ca
10. R Ue REE 18 absrUem cw baiodene 19 MEINEM SN MS sene diu adig tussi uit ubp E oit ct Eu tup hes 20 Installation Inspection Report ucenieciinia Lora Coni pex ds a aiaia aAa 21 JJ 2 EA www sp industries com Phone 800 592 5959 Email info sp industries com Additional Safety Rules Remote Control Head Funnels Hoppers Chutes Security Chutes The remote control head is supplied with a Keyed Off On Switch and a Start Stop Button This remote control head must be permanently mounted within three feet of the point of operation All Access doors and or safety gates on factory built funnels hoppers chutes and security chutes are provided with factory installed interlock switches where re quired If the funnel hopper etc is installed at the job site it is the responsibility of the installer to provide an interlock system so that the compactor may only run when all safety gates and access doors are closed All factory built equipment is safety marked with applicable safety labels required by current ANSI Z245 2 Safety Standards It is the responsibility of the owner to obtain these labels and apply them to all chutes hoppers and funnels built by anyone at the site of the compactor or built elsewhere and brought to the site for installation All funnels hoppers chutes and security chutes should be mounted to the com pactor with low hydrogen rod welds
11. S Stop Extend or Stop Retract Toggle Switch to the desired ram stop position at the end of the timed cycle 3 2 SS Retract Run Extend Selector Switch is spring loaded to center in the run position This is an option on some models See photo on page 18 4 1SS Jog Run Selector Switch should be set in the run position 1 SS should only be switched when manually jogging the ram back and forth This is an option on some models 5 3SS On Off Selector Switch should be set in the on position See photo on page 18 6 After steps 1 5 are completed the electrical disconnect may be switched to the on position 7 PULL AND HOLD THE START STOP BUTTON the machine will continue to run until A The Start Stop Button is released B The ram is unable to reach the limit switch because of a full load or an obstruction This will be indicated when the full container light located in the Start Stop Button lights Before the automatic mode will continue the Start Stop Button must be pushed to reset 2 TR If the forward movement of the ram is impeded the full jam indicator located inside the Start Stop Button will light This indicates that either the container is full or an object such as an oversized skid or a 4 x 4 1s wedged in the charging chamber If the unit is jammed but the container is not full and the compactor is equipped with jog controls operate the jog controls as described below If the Machine Jamming ma
12. aeeessuaneeesaaaeeeesaanes 3 Funnels Hoppers Chutes and Security Chutes ccccccccecsescceceeeeceeseeeeeeseeeeeeeseeeees 3 LO AGING CI LI TEE m o 3 Tool Requirements for Installation eeeeee lesse ecce esee e nennen nennen nnn nnns 3 Power Lockout PrOCOeQUEF6G u aiii ansia eios Yid ind func a Gud a us ues sa pad aud ew icu2 da ass aadi 4 Lifting The Compactor Prop erly sisosuavuzaotuesae yendo i a a 4 Installati n InstrucliOris uui ere uou co o poti vOr d Fa a c vut uu tu ix Vx dau LG UN UU dua v aa sd d Du 5 Leveling The Compactor eessssessessseseeeeeee nennen nennen nnne nnn nna nn nnns nna nnn nns 5 Anchoring TSC OMI ACUON 5 FIYOrauliG CONNECTIONS P R 5 ho e210 Tes ilU o ee T 6 Electrical CODnecllOriS aiccinaoer cesses tui te ute te Esto eut qas esti sab Roni Eaa c aa REEL UE Ma Eran ln eco 6 falis IE CII e A A A A T E AAEN AA A 6 Container and Compactor Alignment cccccsseeeeeeeeeeaeeeeeeeeeeaaeeeeeeeeesaeeeseeeeeasaeneeeeeeaas 6 PHO SU DOO S m 7 Photo Electric amp Infrared Eye Systems cccccsssssseeeeeceeesseeeeeseaueeseeeesesuaseeeessanassseeess 7 PVA GS C 7 Compactor o 1 fe 9 REED TRO trea omm 7 Automatic Mode Operation
13. arts are in good condition and a power loss is still experienced the piston seals will most likely have to be replaced If the internal cylinder walls are found to be scored with deep scratches and grooves new seals will not eliminate the leakage the entire cylinder must be replaced New piston seals must be of the same make and model Extreme care must be taken not to score tear or otherwise damage the seals during installation Install the same type of relay with the hole locater in the right position Install the same type of timer adjusted to the proper setting Install the same size starter with a 120 volt coil All wires must be installed in the correct positions Install the correct size and make overload Overload charts are provided with each starter Install a transformer with the same KVA rating Connect the wires in their correct positions If the wires are not numbered number them before removing to assure that all wires will be attached to the new board correctly Install the same type of switch If one 1s not available use a switch which performs the same functions in the exact same manner JJ 15 IS www sp industries com Phone 800 592 5959 Email info sp industries com Lifting a compactor from the side V Ls 16 EAS www sp industries com Phone 800 592 5959 Email info sp industries com Nylatron ram guide blocks for a CP 2101 amp CP 2101 HD Ram guide system for all indus
14. chine is not jammed but the container is full the container must be emptied If the ram jams on the reverse stroke there 1s probably an object wedged between the ram floor and compactor floor or refuse buildup possibly caused from an improperly working top scraper jamming the ram from the back In any case the jamming object has to be freed before the automatic cycling can continue eV LOH ATI power must be turned off and locked out before entering the ma chine to remove the object causing the jam ALOAN H Jog controls are an option on commercial compactor models 1 Set 1 SS Jog Run Selector Switch in the Jog position 2 Hold 2 SS Retract Run Extend Selector Switch in either the extend position for forward ram movement or retract for rearward ram move ment See photo on page 18 Jogging Machine JJ 8 EA www sp industries com Phone 800 592 5959 Email info sp industries com Pinning Boost Override System Immersion Oil Heater Advance Warning Light Hydraulic Cart amp Container Dumper Low Hot Oil Warning System ALOAN H The Pinning Boost Override System is standard on the CP 6002 CP 6002 D CP 7002 CP 7002 D CP 8002 be CP 13001 and all precrusher com pactors It is on option when available on all other compactor models This system adds 300 PSI Approximately 9 000 Ibs force per 6 cylinder boost pressure over the regular operation pressure of the machine Th
15. ctor If the fork lift will not lift the unit or if the unit is unbalanced when lifted the compactor must be lifted with a larger fork lift or two fork lifts on opposite sides To balance the compactor when lifting from the side the forks must be positioned off center closer to the chamber end to compensate for the greater weight at this end Once the compactor is in its approximate position its position can be adjusted without lifting it completely off the concrete Lift one end of the compactor and shift it into position with the fork lift JJ 4 IS www sp industries com Phone 800 592 5959 Email info sp industries com Installation Instructions Leveling The Compactor Anchoring The Compactor Hydraulic Connections 1 Set the compactor on the concrete pad 2 Place a jack under the front of the compaction floor or floor support Be sure that the jack is in the center of the floor as shown 3 Raise the compactor until both front legs are off the ground 4 If both legs leave the floor at the same time the concrete is level Lower the compactor and proceed to anchor the compactor to the concrete 5 Ifoneleg is higher than the other the concrete is not level Lower the com pactor until one leg touches the concrete then shim the leg which is still raised 6 Once the leg is shimmed anchor the compactor to the concrete If the installation drawing guide lines are followed enough clearance will be allowed f
16. d to perform that work per the requirements of NFPA 70E 2012 Those safe work practices shall include at a minimum the identification of a Electrical shock and arc flash boundaries b Personal protective equipment to be worn c Need for electrically insulated measuring equipment amp other tools Energized electrical work shall only be performed by under supervision of a Qualified Person as defined by OSHA amp NFPA Qualified Persons shall be trained as defined by OSHA and NFPA All other workers performing energized electrical work shall be trained at a minimum to a Understand the specific hazards associated with electrical energy b Understanding the safety related work practices and procedural require ments necessary to provide protection from the electrical hazards associ ated with their respective job or task assignments c Identify and understand the relationship between electrical hazards and possible injury d Other specialized work practices to be followed to perform work safely e Requirements for the use of an Electrical Hot Work Permit 1 e Phone 800 592 5959 Email info sp industries com Safety INTONMAllON mer li MOCI eei 2 Additional Safety Rules 56 xiu ona paco Susu pw cura ne EE e wi anaa aaan a CERE aaa NEUE EE ein dE Ea 3 Remote Control HOad cc ccccccccsseccceeeeceeeeeseeeeseeeceeeaeeeceeseeeceeeseaeesseu
17. e system includes right or left side machine mounted boost controls a dual solenoid spring centered directional valve and a pressure actuated switch The pinning boost override system operates similar to the jogging mode of operation 1 Set 1 SS Pin Off Run Selector Switch to the pin position and hold this switch will return to the off position when released 2 Hold 2 SS Ram Extend Retract Selector Switch in either the extend position for forward ram movement or retract position for rearward ram movement This system overrides the auto or sustained pressure operation of the unit and delivers an extra 300 PSI to the cylinder The boost pressure has been preset at the factory any unauthorized adjustments of this pressure will void the warranty The heater is adapted to the one inch NPT half coupling at the end of the tank un der the electrical box and necessitates the use of a larger transformer The heater is thermostatically controlled to maintain oil temperature at the desired setting during cold weather The heater will maintain the temperature only while the disconnect supplying power to the electrical box is in the on position The advance warning light consists of a pressure regulated switch an additional relay and a warning light which is mounted in the remote control panel The pur pose of this system is to alert the operator when a pressure less than the maximum operating pressure is reached The
18. ease packets must be completed to maintain actuator operation SP recommends checking the grease pack levels each time the attached container is serviced Replacement grease packs can be purchased from SP Industries or your local industrial supplier P 1 800 592 5959 2982 Jefferson Road F 1 269 793 7451 Hopkins MI 49323 Info sp industries com 1 269 793 3232 Power Lockout Procedure The following are the General Industry Safety Division s minimum requirements for establishment of a Power Lockout Procedure A written power lockout procedure shall be provided All necessary employees shall be instructed on this procedure Employees shall be instructed in and conform to the following procedures 1 Alert the operator s that power is being disconnected 2 Before starting repair service or setup work on engine motor or power driven equipment person s performing work shall make sure power is disconnected and any hazardous residual pressure shall be relieved prior to and during such work A padlock s shall be placed at the point of power disconnect where lockout is required by each person s performing work Individual locks shall be used or an authorized employee of each crew shall be responsible for placing the lock and determining that each crew member is clear before removing the lock or a supervisor may place a lock for which he has the only key and assure that all crews are clear before removing the lock Keys shall be re
19. erently the electri cal system will not perform correctly When setting the limit switch actuator the switch must be actuated before the cylinder bottoms out in either direction A loud banging noise at the end of the stroke will indicate that the cylinder is bottoming out This will shorten the life of the cylinder bushings seals and packings The limit switch should be actuated between 1 2 to 1 inch before the end of either stroke The side guides should be adjusted to make firm contact with the compactor frame sides Top guides should be adjusted 1 2 turn clockwise after meeting the guide rail squarely Bottom guides should be adjusted with a 1 32 gap between the block and the guide rail Over tightening these blocks may result in excessive wear JJ 14 EA www sp industries com Phone 800 592 5959 Email info sp industries com Cylinder Piston Seals Timers Motor Overloads Transformers Terminal Strip Loss of power in the hydraulic system may be caused by any one or more of the following 1 Defective relief valve broken spring scored ball etc 2 Defective pump pump seals defective vanes or gears etc 3 Defective directional valve scored spool etc 4 Leakage through rod end of the cylinder rod seals scored rod 5 Internal cylinder leakage through the piston seals SP Industries Inc recommends that before making an attempt to replace the piston seals check items one through three If these p
20. g is automatically taken care of by the C face flange When installing a motor the coupling alignment between the pump and the motor must be very accurate Pump manufacturers recommend an align ment with 005 inch tolerance Excessive misalignment will usually cause leak ing pump shaft seals short bearing life in the pump and motor and or short total pump life Shim the pump or motor with banding material small washers etc if necessary This warning is applicable only when a nose cone has not been used to couple the pump to the motor Pump 1 Loosen the union between the pump and the suction line 2 Remove the nipple and half union from the pump 3 Loosen the hose from the manifold then remove the check valve from the pump 4 Remove the two bolts holding the pump to the pump mounting bracket then remove the pump 5 Install anew pump in reverse order using thread sealant compound or tape on the check valve threads and thread sealing compound on the nipple and union being fastened to the pump Care must be taken when aligning the coupling between the pump and motor Pump manufacturers recommend an alignment with 005 inch tol erance Excessive misalignment will usually cause leaking pump shaft seals short bearing life in the pump and motor and or short total pump life JJ 13 IS www sp industries com Phone 800 592 5959 Email info sp industries com Directional Control Valve Relief Valve Hydraulic Ho
21. h kerosene or another suitable solvent then refilled with clean hydrau lic fluid JJ 12 EA www sp industries com Phone 800 592 5959 Email info sp industries com Recommended oil may be used for all but extremely cold temperatures An im Cold Weather Operation mersion oil heater is recommended for an area where temperatures are expected to frequently reach 0 F or below Instructions For Replacing Components Before attempting any repairs on the compactor or power unit shut off all electrical power at the disconnect switch and lock this switch in the off position See power lockout procedure on page 4 Make sure that no one can start the machine while it is being serviced The following procedures should be used when replacement of any component is necessary Motor 1 Remove the wiring plate from the side of the motor 2 Loosen and remove the 4 or 6 wire nuts fastening the power wires and the motor leads 3 Take the electrical lock nut off the fitting where the conduit enters the motor then drop the conduit out of the hole 4 Remove the 2 bolts holding the pump to the C face mounting falnge Pull the pump and coupling away from the motor and nosecone 5 Remove the four bolts which hold the motor to the hydraulic tank 6 Making sure the new motor is of proper size and voltage use the removal steps above in reverse order to install the new motor If a C face motor is in use the following warnin
22. ible to the operator of the unit Local electrical codes should be consulted for proper installation specifications The voltage that the unit is factory wired for is listed on the decal attached to the main electrical box door If the incoming line voltage differs from the power unit factory wired voltage the motor connections transformer connections motor starter overloads and the size of power line wires if they are not rated for higher line current must be changed The wiring diagram will show the correct wire and overload size In some cases on motors over 10 HP the motor and starter may also have to be changed Before the unit is coupled to the container it should be cycled several times During this cycling observe all pipe and hose connections for leakage If the pump makes loud or crackling noises and or the ram jerks stop the machine and tighten all intake connections to the pump from the tank After smooth cycling is observed stop the ram in the RETRACTED POSITION and check the fluid level on the sight gauge If the sight gauge indicates that the reservoir is not full add an acceptable type of hydraulic fluid until the gauge indicates that the reservoir is full Full is at a point between the top of the thermometer and the black line Initial Cycling One inch all around clearance should be observed when the container is connected to the compactor charge opening the compactor mating surface of the container should fit flush
23. iecssecasusvensilesdimoseeashetiewsxlasbeunanineesievesdesheiiieeaneiselardl lt eeieinsetde 12 Hydraulic Fluid Changes decease size etic cine nita ong sa nbn Cede eremita Dated e ua Ste URINE HU RUN BURN 12 Cold Weather Operatorii x 13 Instruction for Replacing Components 1 eeeeeeeeeeseeeee nennen nnn nnn nn nnn nn nns 13 lU e fo MN EEUU mmm 13 PRN s E cc neaeeneeeas 13 Dire tonal Control BUE m UT 14 RIBUS 14 PY ON AMEN HOSO S RENE E E T LO T D UL 14 Mouse ea ste ates E E T cm 14 Ram Guide BIOGNS iiti teint tet rebns sectae sa Rae Bex dndeKebua re ed Ea bens meisa mein EA 14 Cylinder Piston Seals cen erepti etta ee edt ani tati er ira csatbin b aca CR asse kun urba deu UR EM diu 15 icc m 15 lur c 15 elg ET C 15 ferreo COGS TT 15 Er pNe MI E E A A A T E P T A TT 15 Terminal Strip MR TT 15 VTEC PENNE EDEN TERN 15 aco d 9 16 LUPUS The Compactor mm 16 Ram Guide Pe RE T TE OS 17 Quoque MA HP 18 Main Electrical Panels 2ii rtt are EEERe SERERE IRRRU REEL ee EUE E HERUARI EVA EON ERIS A FREI RE D
24. ing loaded to center in the run position It is only used in the other positions for jogging an option on commercial models See photo on page 18 5 1 SS Jog Run Selector Switch should be set in the run position 1 SS should only be switched when manually jogging the ram back and forth Usu ally it is only used by the container hauler This is an option on commercial models 6 3 SS On Off Selector Switch should be set in the on position See photo on page 18 7 After steps 1 6 are completed the electrical disconnect may be switched to the on position 8 PULL THE START STOP BUTTON In the automatic mode the machine will continue to run until JJ 7 EA www sp industries com Phone 800 592 5959 Email info sp industries com Automatic Mode Operation A TR has timed out stopping the ram in the desired position Cont B The ram is unable to reach the limit switch because of a full load or an ob struction This will be indicated when the full container light located in the Start Stop Button lights Before the automatic mode will continue the Start Stop Button must be pushed to reset 2 TR C The Start Stop Button is pushed to the stop position Manual or Sustained Manual The Power supply to the controls MUST BE TURNED OFF while Pressure Mode Operation adjustments in the control panel are made 1 Set TGS Auto Manual Toggle Switch in the manual position See photo on page 18 2 Set2 TG
25. moved at the time of lockout Before work is started equipment shall be tested to insure power is off 3 No one other than person s placing padlock s on power lockout shall remove padlock s and restore power Exception Supervisor may remove padlock s and restore power after a thorough check to make sure that no person will be exposed to danger 4 fitis necessary to work on a machine or installation to be continued by the next shift personnel the padlock s of the original employees shall be re moved by those employees in the presence of the oncoming shift who will immediately insert their own padlock s into the disconnect All concerned personnel operators repairmen and supervision shall be thoroughly in formed 5 Amachine connected to an electrical source by a plug in cord shall be consid ered in compliance if the plug is disconnected and tagged provided that the plug is a legal disconnecting means Plugs are acceptable as disconnecting means only for portable motors and 100V fixed equipment 6 Any equipment component that needs blocking to prevent its movement by gravity or other means must be blocked Lifting The Compactor Properly The compactor can be off loaded or moved from either the side or small compac tors can be lifted from the chamber end by securing it to the fork lift truck with a chain around the breaker bar See photos page 16 The fork lift must be large enough to handle the weight of the compa
26. n clearly see the charging chamber although the controls should not be mounted where the operator has access to the charging chamber Inspect the container binders and make sure they are securely fastened to the container as well as to the compactor Secure the container door safety chain before attempting to elevate or trans port the container Securely lock the container to the hoist frame before transporting LOR EOM drop solid objects such as steel plate steel bar castings concrete etc into the chamber this type of material will seriously damage the compac tor compaction chamber and or container and will void warranty 10 PORNOA stand near the compactor when the ram is in motion material may IST www sp industries com be ejected from the charging chamber and cause serious injury e Phone 800 592 5959 Email info sp industries com Procedures for Electrical Arc Flash and Shock Safety References OSHA 29 CFR 1910 Subpart S OSHA 29 CFR 1926 Subpart K NFPA 70 E 2012 WARNING ARC FLASH BLAST AND SHOCK HAZARD USE PROPER ELECTRICAL SAFE WORK PRACTICES Installers and Operators h IST www sp industries com Prior to intentionally coming into contact with energized electrical conductors or circuit parts of 50 volts or greater with the hands feet or other body parts with tools probes energized electrical work a shock amp hazard analysis shall be performed to determine the safe work practices require
27. ng to the dumping area SP Industries Inc can provide safety decals to post on or near safety enclosures and gates constructed on the job site The dumper controls except when remote controls are ordered are mounted in the main control panel or on the remote control head with the compactor controls The controls consist of a mushroom type Start Stop Button tagged DUMPER PULL TO START PUSH TO STOP and an Up Down Selector Switch Pushing either the Dumper Start Stop Button or the Compactor Stop Button will stop the dumper in any position When the light is on in the Dumper Start Stop Button this indi cates that the dumper motor is running Compactor Operation Automatic Mode Operation OTOU LONH The Power supply to the controls MUST BE TURNED OFF while adjustments in the control panel are made 1 Set 1 TGS Auto Manual Toggle Switch in the auto position See photo on page 18 2 Set2 TGS Stop Extend or Stop Retract Toggle Switch to the desired ram stop position at the end of the timed cycle 3 Set 1 TR Five Minute Cycle Timer as desired The machine can be set to cycle from one complete cycle to a five minute cycling time 2 TR One Min ute Container Full Timer has been preset and marked at the factory Do not tamper with this timer If 2 TR is set wrong the unit will not function proper ly The proper setting is 8 seconds above the forward stroke time 4 2 SS Retract Run Extend Selector Switch is spr
28. or servicing internal parts through the rear or optional side access panels Some units are equipped with top access panels only The compactor must be bolted securely to a concrete slab and located as illustrated on the installation drawing SP Industries recommends using anchorable mounting pads embedded in the concrete if new concrete is poured or anchors such as Thun derbolt Concrete Anchors if existing concrete is used The installation drawing shows the mounting hole pattern and anchor pad layout If the concrete is not level all four compactor mounting pads will not be touching the cement If this 1s the case do not pull the legs to the concrete the legs which do not touch must be shimmed then fastened securely If the raised leg is pulled down the frame could be twisted causing a gap between the ram and floor surface resulting in undue jamming and premature floor wear The hydraulic connections may have loosened during shipment therefore they should be checked for tightness When connecting the hoses from the power unit to the cylinder s apply thread sealant around or apply liquid pipe sealant to all male threads that do not connect to a factory supplied swivel fitting eA YU LOS When using liquid pipe sealant do not allow sealant to seep into the pump or valve severe damage may result V Ly 5 EAS www sp industries com Phone 800 592 5959 Email info sp industries com Hydraulic Connections Cont Hydraulic lines over
29. oting Motor Fails To Start b 2 3 4 5 6 T Motor Starts But Ram Fails To Move 2 3 4 Check that all switches are in their proper positions The Jog Run Selector Switch must be in the Run position The Retract Run Selector Switch must be in the Run position The Manual Auto Toggle Switch must be in the Auto position for automatic cycling The Off On Switch must be in the on position Check the container full warning light If the light is on the container may be full or the ram may be jammed by an object in the charging chamber If the container is full change containers if the compactor is jammed clear the jam see page 8 Once the problem is resolved push the Start Stop Button to reset the system then start the compaction cycle Check all fuses located in the main control box Check for proper line voltage entering the control box Check for proper line voltages going into and out of the transformer Check for kicked out overloads on the motor starter Call the dealer factory or an electrician if 1 through 6 check out but the mo tor still fails to start Check the level of hydraulic fluid in the reservoir If it is low add hydraulic fluid until it reaches the proper operating level Check the rotation of the motor The shaft must rotate in the direction of the arrow decal on the motor housing Check the motor and pump coupling The motor coupling must be in contact with and tu
30. problem a cylinder may be defective Con tact the factory for further information 11 e Phone 800 592 5959 Email info sp industries com Maintenance Before performing any maintenance on the compactor or power unit shut off the power at the disconnect switch and lock this switch in the Off posi tion See Power Lockout Procedure on page 4 Do not service the machine if it is possible for someone to start the machine while it 1s being serviced Use the strainer cleaning schedule as a time period to clean out any build up of material behind the ram Compactor Clean Out SP Industries Inc power units use a permanent type oil strainer which may be reused after each cleaning To keep down time at a minimum while cleaning the dirty strainer replace it with a spare clean strainer The dirty strainer may then be cleaned as follows Strainer Cleaning 1 Soak the strainer in kerosene or other solvent to loosen the contaminant 2 Lightly scrub the strainer with a soft bristle paint brush DO NOT USE A WIRE BRUSH 3 Remove embedded contaminants with clean dry shop air Direct the flow of air against the inside of the strainer with a perforated support 4 Again wash the strainer in a solvent and blow with shop air then inspect for damage Holes in the strainer cloth will leak dirt into the pump and valve which may cause malfunctions in the hydraulic system See the chart below for recommended strainer change frequency
31. rning the pump coupling The limit switch must be both in an operable condition and actuated by the ram Adjust the limit switch arm if necessary The cylinder may be seriously damaged if the limit switch is improp erly adjusted The limit switch must be actuated 1 2 before the cylinder reaches the end of its stroke If the arm is not correctly adjusted and the cylinder is reach ing the end of its stroke a loud banging noise will be heard when the ram changes direction P 6 10 IST www sp industries com The Timing Relays must be properly set The Manual Auto Toggle Switch must be in manual position for manual or sustained pressure operation The Directional Control Valve may be stuck in the neutral position or the valve solenoid may be defective To dislodge the control valve insert a small rod into the end of the solenoid housing and push in while the motor is run ning the ram should move forward If the ram does not move the spool may be inoperative Check whether or not the pump is building pressure If not it may be defec tive To check the pressure block A and B ports going to the cylinder install a pressure gauge in B port and start the motor If there is no pressure in B port the Pump may be defective or the Relief Valve Spring may be broken To check the spring unscrew the pressure setting screw until the spring is exposed If the spring is broken replace it If 1 through 8 fail to resolve this
32. ses Limit Switch Ram Guide Blocks 1 Remove the wiring plate wire nuts wiring conduit and conduit fitting 2 Ifthe unit has a pressure switch mounted on the valve body remove it at this time 3 Remove the 4 or 6 mounting bolts holding the valve to the manifold block Remove the valve 4 Replace with a new valve in reverse order making sure all O rings are installed and properly placed If an O ring is left out or pinched between the valve and manifold the fluid will leak 5 All valve mounting bolts must be torqued as indicated on the hydraulic sche matic If a relief valve must be changed in whole or part the systems relief pressure must be reset A pressure gauge must be mounted on the B side of the valve to set pres sure while the ram is fully extended If the correct factory pressure setting is not known call the factory for information SP Industries Inc compacting units are equipped with SAE rated hose All hoses must be replaced with hoses of the same type The SAE number is stamped or im pressed on the outer layer of the hose If there are any questions call the factory Make sure that no part of the hose rubs against an abrasive surface during machine operation This rubbing could eventually cause a leak creating a low oil level in the reservoir and a fire hazard When removing a limit switch the replacement must have the same sequence of normally open and closed contacts If the switch is wired diff
33. smaller units may be bolted securely to the compactor Loading Refuse 1 EORNOAN enter the charging chamber 2 ORNO throw solid objects such as steel plate castings concrete blocks etc into the chamber this type of material may seriously damage the compac tor and or container ACA OA ACM NE EAA 3 POR esy operate dumping devices unless area is clear of all personnel OSHA and the manufacturer require erection of suitable barriers when these devices are used 4 BIS stand near the compactor when the ram is in motion material may be ejected from the charging chamber and cause serious injury To avoid falling into the compaction chamber stay at a safe distance when loading refuse into the compactor After the refuse has been loaded into the chamber stand at a safe distance during operation Tools Required For Installation Of The Compactor 1 Fork Lift Truck To unload and position the machine 2 Hilti Type Drill For drilling holes in concrete to mount concrete anchors through the compactor mounting feet 3 Hand Tools Various electrical and mechanical tools for connecting hydraulic hoses and electrical wiring 4 Welder For welding machine to cement embedded steel anchor pads if appli cable or attaching loading hoppers enclosures etc 5 Cutting Torch To adjust or alter optional knock down chute if needed JJ 3 EA www sp industries com Phone 800 592 5959 Email info sp industries com
34. t systems consists of a photo elec tric infrared or ultra sonic eye assembly a reflector or receiver and a warning strobe light and buzzer The controls are set the same as the controls for the auto matic mode The cycle will start automatically after the material in the compaction chamber builds up to a point where it blocks the signal between the eye and the reflector and the warning light and buzzer have been activated for 15 seconds The compactor will continue to cycle until 1 TR reaches its preset cycle time the container is full or the Stop Button is pushed ALOAN H Jog controls are an option on all commercial compactor units The jog run controls are typically mounted on the front of the electrical box how ever if required they can be mounted on the side of the compactor These controls are used for manually jogging the ram as outlined on page 10 The jogging func tion operates on normal operating pressures it does not apply additional pressure like a boost system If the compactor is to be operated from more than one location additional remote control stations are available All stations will have Keyed Start Switches and Start Stop Buttons In order for the machine to operate properly ALL Keyed Start Switches must be in the On position All stop buttons MUST be wired in series and be in the closed center position JJ 10 IS www sp industries com Phone 800 592 5959 Email info sp industries com Trouble Sho
35. trial and transfer station stationary compactors IN www sp industries com Phone 800 592 5959 Email info sp industries com MTM Automatic Cycle with Advance Pinning Boost Override Standard Automatic Warning Light and Dumper System Controls Mount Cycle Remote Remote Control Station ed on the side of the Control Station compactor 750 VA Transformer Standard Automatic Cycle Control Panel for Stationary Compactors Precrusher Control Panel V Ly E amp www sp industries com Phone 800 592 5959 Email info sp industries com ID Plate Valve for Double Cylinder Dumper Standard Valve for APT 331 CP 331 with 6 or 10 GPM Pump System CP 711 CP 1001 CP 2002 CP 2101 and all self contained models Directional Valves A Standard 3 4 valve for CP 2101 HD CP 2102 CP 3101 CP 3101 HD CP 4101 CP 4101 HD CP 6101 CP 2202 CP 3002 and CP 4002 B Standard Valve for CP 6002 CP 6002 D CP 7002 and CP 7002 D and Valve for pinning Boost Override System on 7 5 GPM or greater pump systems Manual Override on Spool Coil Main Spool ID Plate a a vp E www sp industries com Phone 800 592 5959 Email info sp industries com One Circuit Pressure Switch Standard Limit Switch for all SP Industries compactors All Automatic Cycle 802T NPTE LS WE LS WE X 2 X 3 8 4 12 35 8 6 10 7 58 8 1l 802T NPTE and 2 are closed at extend only 3 and 4 are open at extend onl
36. y 5 and 6 are open at retract only 7 and 8 are closed at retract only ISP il A www sp industries com Phone 800 592 5959 Email info sp industries com SP Industries Products amp Service Nationwide Click on the map to connect to SP Industries to find the products and services for your area F Let Your Index Finger do the Walking SP Industries products and services are available nationwide from our sales and service staff and our network of authorized factory trained dealerships For more information or to discuss your specific application requirements click the map above or call our home office 8am 5pm EST SP Industries designs and manufactures a comprehensive standard line of industrial and commercial grade compactors with precrushers transfer station equipment and cart dumpers to meet small to large capacity operations Our new EM Series electromechanical systems eliminate hydraulic fluid and system complexity save workspace provide easier safer cleaner operation and an environmentally improved approach to compacting We also offer a wide variety of specialized systems to handle wet waste food products metal scrap collection fluid recovery newsprint recycling and other difficult and or voluminous materials 2982 Jefferson Rd Hopkins MI 49328 800 592 5959 269 793 3232 Click amp Go d ITICU SU IGCS ITIC Fax 269 793 7451 Waste Handling Compactors amp
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