Precrusher/Compactor Installation, Operation & Service Manual
Contents
1. D T E 13 Standard Industron 44 Exxon Nuto H 32 Electrical Connections Initial Cycling Container and Precrusher Compactor Alignment Hopper Doors Photo Electric amp Infrared Eye Systems Additional Safety Rules Oo J Vnde H The electrical controls must be connected to the correct power source 230 or 460 Power to the unit must be provided through a customer furnished fusible disconnect switch which shall be visible and accessible to the operator of the unit Local electrical codes should be consulted for proper installation specifica tions 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 Before the unit is coupled to the container it should be cycled several times first in compactor mode then in precrusher mode 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 connec tions 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 gaug2. filter 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 filter with a perforated support 4 Again wash the filter in a solvent and blow with shop air then inspect for damage Holes in the filter cloth will leak dirt into the pump and valve which may cause malfunctions in the hydraulic system See the chart below for recommended filter change frequency Usage Filter 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 first filter change and include the following 1 Check and tighten all electrical and hydraulic connections on the power unit control head and cylinders 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 Nylatron guide blocks located on the rear of the ram for loose ness and unreasonable wear Call a factory authorized representative if wear seems excessive or uneven 5 Check the gate cylind
3. 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 Installation Instructions Anchoring The Precrusher Compactor Hydraulic Connections Hydraulic Fluid If the installation drawing guide lines are followed enough clearance will be allowed for servicing internal parts through the rear and side access panels The precrusher 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 Thunderbolt 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 is the case do not pull the legs to the concrete the legs which do not touch must be shimmed then fastened se curely 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 and should be checked for tightness When connecting the hoses from the power unit to the cylinder s wrap thread sealant
4. of hazardous areas during operation Make sure all access covers are in place before starting the machine Keep the precrusher compactor working area clean uncluttered free of ice and snow and especially free of oil and grease 5 Locate the remote control head so the operator can clearly see the charg ing chamber although the controls should not be mounted where the operator has access to the charging chamber 6 Inspect the container binders and make sure they are securely fastened to the container as well as to the precrusher compactor 7 Secure the container door safety chain before attempting to elevate or transport the container Securely lock the container to the hoist frame before transporting DO NOT place or drop solid objects such as steel plate steel bar cast ings concrete etc into the chamber this type of material will seriously damage the precrusher compactor gate and gate track and or con tainer and will void warranty 10 DO NOT stand near the precrusher compactor when the ram is in motion material may be ejected from the charging chamber and cause serious injury Tools Required For Installation Of SP Industries Inc Precrusher Compactors 1 Fork Lift Truck To unload and position machine 2 Hilti Type Drill For drilling holes in concrete to mount concrete anchors through precrusher compactor mounting feet 3 Hand Tools Various electrical and mechanical tools for connecting hydr
5. ram back and forth Usually it is only used by the container hauler 5 After steps 1 4 are completed the electrical disconnect may be switched to the on position 6 PUSH THE START BUTTON In this mode the machine will continue to run until A 1TR has timed out stopping the ram in the retracted position 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 comes on Before the automatic mode will continue the Stop Button must be pushed to reset 2TR C The Stop Button is pushed ie Vd Te Do not allow personnel unfamiliar with this equipment to make adjustments and modifications to factory settings In order for the precrusher compactor to be used in the precrush mode the Pin Off Run Switch must be set in the run position the Keyed Off On Switch must be in the On position and the Precrush Compact Mode Switch must be in the precrush position The cycle will begin when the Start Button is pushed and held for approximately one second then released The precrusher will continue to run until 1TR has timed out the Stop Button is pushed the Keyed Off On Switch is turned off or the container is full 1 Set 4SS Precrush Compact Mode Switch in the Precrush position 2 Set 1TR Thirty Minute Cycle Timer as desired The machine can be set to cycle from one complete cycle to a 30 minute cycling time Set the timer for 8 seconds less t
6. tape around or apply liquid pipe sealant to all male threads that do not connect to a factory supplied swivel fitting Hydraulic lines over and above standard hose length usually ten feet must be hard piped All hard piping whether it s the standard length of six feet or above requires schedule 80 pipe and 2 000 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 The reservoir must be filled with a premium grade hydraulic fluid having a viscosity index of approximately 100 a viscosity of 150 SUS at 100 F and a Maximum viscosity of 4000 SUS in cold starting conditions Thermostatically controlled immersion oil heaters are recommended for extreme conditions Also the fluid must have antifoam antiwear and water separating additives Acceptable hydraulic fluids for all other conditions are as follows Union 76 Anax AW 150 Gulf Harmony 32 Shell Tellus 32 Texaco Rando HD 32 Mobil
7. A Replace the 1 4 plug in the tee entering the circuit control module with a pressure gauge if gauge has not been installed B If the pressure is 1800 PSI or higher the pressure switch may be sticking or malfunctioning a Turn the Compact Precrush Mode Switch to Compact mode Push the Start Button 1 If the gate goes up a Check Relay 6 Ram Extend Relay for proper operation b If Relay 6 is operating correctly the pressure switch may be malfunctioning See Item 2 on Photo Page 20 c Check for hydraulic obstructions in the pressure switch d Check the pressure switch s electrical mechanism for proper operation e Contact the factory for more information 2 If the gate does not go up a Check Gate Open Limit Switch for correct operation It may be stuck in the up position or the arm may be out of adjustment See Photo Page 21 b Check relay 7 Gate Open control Relay for proper operation c Contact the factory for more information 13 Gate Does Not Come Down During Precrush Stroke Gate Does Not Come All The Way Down After The Gate Closes The Ram Hesitates While Retracting 14 1 Check the Gate Open Limit Switch for correct operation 2 Check the Ram Retracts Past Gate Limit Switch for proper operation 3 Check relay 7 4 Contact the factory for more information Often during the first operation of the day or in cold weather the gate may not come all the way down Once t
8. Industries Inc Precrusher Compactor Installation Operation amp Service Manual SP Industries Inc e 2982 Jefferson Rd Hopkins MI 49328 Phone 800 592 5959 In MI 269 793 3232 Fax 269 793 7451 nop d X E m 2 dqugeje V orem EE 3 Tool Requirements for Installation ssss e 3 Power Lockout Procedute esee antenna ea epicurei ee eee Rees 4 Lifting Precrusher Compactor Properly sssss reide 4 Installation Instructions v0 0 eerie nnn 5 7 Anchoring the Precrusher Compactor sssssssss ens 5 Hydraulic Connections sssssssss mener 5 mi fe rz ilex giro E X 5 Electrical Collections ooo ao rectus dedee qon udpurQuee d etude p eic t EEUU DENN 6 INAS YSN Glas MT 6 Container and Precrusher Compactor Alignment ssssse 6 Hopper DGOOMS oT 6 Photo Electric amp Infrared Eye Systems sssssssssse 6 Additional Safety Rules ssssssssssssssssseeeeneenenee nennen nnne nennen 6 Remote Control Head rie creer cibis prs eerte ai 7 Funnels Hoppers Chutes and Security Chutes ssssssssesese 7 PUMP CIS cT 7 Loading ROTUSG 7 Precrusher Compactor Operation cccccccessseenceeeeseeeeeeeeeeeseeeeeeesesseneeeeeenseneeeeees 8 10 Compact Mode Operation irn Dor Erde E N 8 P
9. arts are provided with each starter Transformers Install a transformer with the same KVA rating Connect the wires in their correct positions Circuit Board If the wires are not numbered number them before removing to assure that all wires will be attached to the new board correctly Switches Install the same type of switch If one is not available use a switch which performs the same functions in the exact same manner 19 20 oco uoczomc c Motor 30 HP Shown Pressure Switch Circuit Control Module Gate Directional Valve Pressure Reducing Valve System Pressure Gauge Port Pressure Hoses 7a 7b 7c Manifold Nose Cone Pump System Relief Valve Gate Pressure Gauge Port Hi Lo Adjustment Filler Breather Dump Valve Pump Inlet Line Filter In Tank Precrusher Ram Directional Valve 3LS Gate Limit Switch 1 1LS Limit Switch for changing direction of ram travel 2 2LS Ram Retracts Past Gate Limit Switch 21 22 1TS 1FU 1MOL 1TR CR z 4E 4 9 eee n t up n ti Ls LI Terminal Strip 3 Each Fuse Overloads Cycle Timer Control Relays 1T 1M 1CTR 2TR Primary Fuses Transformer Motor Starter Counter Gate Down Timer Primary Fuses
10. aulic hoses and electrical connections 4 Welder For welding machine to cement embedded steel anchor pads if applicable 5 Cutting Torch To adjust or alter optional knock down chute if needed 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 perform ing 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 removed 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 lo
11. ckout 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 If it is 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 removed 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 informed 5 A machine connected to an electrical source by a plug in cord shall be considered in compliance if the plug is disconnected and tagged pro vided that the plug is a legal disconnecting means Plugs are acceptable as disconnecting means only for portable motors and 100V fixed equip ment 6 Any equipment component that needs blocking to prevent its movement by gravity or other means must be blocked Lifting the Precrusher Compactor Properly The precrusher compactor can be off loaded or moved from the side The fork lift must be large enough to handle the weight of the compactor If the fork lift will not lift the unit or if the unit teeters 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
12. cles have been completed pressure will be released from the ram and the gate will open 5b Once the gate is open the ram will resume its forward movement and compact the material into the container then begin to retract 6 After the ram has retracted approximately two feet past the gate the ram movement will stop and the gate will close 7 When the gate is closed the ram will continue to retract until the charge chamber is cleared As mentioned above the number of precrush cycles is controlled by counter 1CTR located inside the main control panel This counter will allow the ram to precrush the material within the charge chamber from one to nine times before the gate will open In addition the unit is controlled with an automatic multicycle system which operates as described above However when the unit is in the precrush mode additional time must be added to the timer to complete more than one cycle especially if counter 1CTR is set for more than one precrush cycle The operator must review the operation and adjust the counter and timer to best suite the waste handling system s needs tO Sa eggs Set 1TR for 8 seconds less than the time needed for the number of complete cycles desired Jogging Machine For Pinning Note Controls are normally mounted on the left front corner of the pre Operation And Manual crusher compactor Operation Of Precrush Gate 1 Use key to turn 2SS Pin Off Run Selector Switch to the Off posit
13. e If the sight gauge indicates that the reservoir is not full add an acceptable type of fluid until the gauge indicates the reservoir is full One inch all around clearance should be observed when the container is connected to the precrusher compactor charge opening the compactor mating surface of the container should fit flush with the mating surface of the pre crusher compactor If a gap is present on the top or bottom the front or rear legs of the precrusher compactor and or the wheels of the container must be shimmed until proper alignment is reached Do not over tighten the container hooks The container should only be drawn snug against the precrusher compactor If the precrusher 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 precrusher compactor With the interlock switch in a closed posi tion power will pass to the control system allowing the machine to operate If the precrusher compactor is equipped with a photo electric eye or infrared eye the reflector or receiver must be properly aligned opposite the eye to reflect the light beam and the light beam must be free of obstructions To comply with WASTEC Waste Equipment Technology Association guide lines for stationary compaction equipment along with current ANSI American National Standards Institute Safety Standards SP Industries Inc has made every reasonable effort t
14. er cavities for material or trash build up If material build up prevents the gate from opening completely the gate cylinder access cover must be removed and the cavity cleaned out 6 Check the ram hold down bars for wear If the gap is greater than 5 16 between the ram top and the hold down bars contact the factory 15 Hydraulic Fluid Changes Cold Weather Operation 16 Under normal conditions the fluid can be used for an indefinite time If you suspect 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 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 with kerosene or another suitable solvent then refilled with clean hydraulic fluid Recommended oil may be used for all but extremely cold temperatures An immersion oil heater is recommended for an area where temperatures are expected to frequently reach 0 F or below Instructions For Replacing Components AoA When calling SP Industries for information you must have the serial number of the precrusher compactor available Before attempting any repairs on the precrusher 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 n
15. han the time needed for the number of com plete precrush cycles desired Precrush Mode Operation Cont 3 Set 1CTR Precrush Counter to desired number of precrush strokes up to a maximum of nine To set the number of precrush cycles that the counter is factory set for turn 1TR to its maximum setting to record the time needed for the number of complete precrush cycles desired then reset 1TR for 8 seconds less than the recorded time Set 1SS Off On Selector Switch to the On position Set 288 Pin Off Run Selector Switch to the Run position After steps 1 5 are completed the electrical disconnect may be switched to the On position 7 Push the start button The precrusher cycle will run through the following steps 1 If the precrusher gate is open when the precrush cycle begins the ram will move forward into the container to clear any refuse remaining in the chamber The gate will close sealing the charge opening after the ram moves past the gate during its return stroke The first precrush cycle will start as soon as the ram reaches the retracted position 2 The ram moves forward crushing the material in the charge chamber against the gate 3 f the precrusher counter has been set for more than one precrush cycle the ram can no longer move forward and the system has reached its maximum pressure the ram will retract completely and step 2 will be repeated 4 When the predetermined number of precrush cy
16. he controls are set for the precrush or compactor mode The cycle will start automatically when the material in the compaction chamber builds up to a point where it blocks the beam of light between the photo electric eye and the reflector The precrusher compactor will continue to cycle until 1TR reaches its preset cycle time the container is full or the Stop Button is pushed 11 Trouble Shooting Motor Fails To Start Alogi When calling SP Industries for information you must have the serial Motor Starts But Ram Fails To Move 12 1 oN Oa A number of the precrusher compactor available Check that all switches are in their proper positions The Pin Off Run Selector Switch must be in the Run position The Off On Switch must be in the On position If applicable check to make sure all safety gates or doors are closed to energize interlock switches 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 10 Once the problem is resolved push the Stop Button to reset the system then start the compaction or precrush cycle Check the 4 amp fuse 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 o
17. he machine has warmed up it should operate normally However if the gate consistently fails to close all the way timer 2TR should be adjusted for more time It should normally take between 6 and 7 seconds for the gate to close completely When the precrusher compactor is started in the precrush mode after the system has been completely shut off the ram will pause during retraction for approximately eight seconds then continue to operate normally This is normal operation if the system is set for more than one precrush cycle LUESTTRL CS RES UM Ter Gate Cylinder Cavity Cleaning Filter Cleaning Initial Maintenance Check Before performing any maintenance on the precrusher compactor or power unit shut off the power at the disconnect switch and lock this switch in the off position Do not service the machine if it is possible for someone to start the machine The gate cylinder cavity must be checked monthly for material or trash buildup that may prevent the gate from opening completely If there is a buildup the gate cylinder access covers can be removed to clean the cylinder cavities SP Industries Inc power units use a permanent type oil filter which may be reused after each cleaning To keep down time at a minimum while cleaning the dirty filter replace it with a spare clean filter The dirty filter may then be cleaned as follows 1 Soak the filter in kerosene or other solvent to loosen the contaminant 2 Lightly scrub the
18. hed between the valve and manifold the fluid will leak 5 All valve mounting bolts must be torqued as indicated on the hydraulic schematic If a relief valve must be changed in whole or part the systems relief pressure must be reset 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 impressed on the outer layer of the hose If there are any ques tions 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 differently the electrical system will not perform correctly When setting the ram operating 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 4 to 1 2 inch before the end of either stroke The side guides should be adjusted to make firm contact with the compactor frame sides Top guides shou
19. ion Two operations may now be performed A Manually raise or lower the gate B Manually extend or retract the ram 2 Manually raising or lowering the gate A Turn 2SS to the Pin position and hold B While holding 2S8 turn and hold 5SS Precrusher Gate Up Down Switch in either the Up or Down position 3 Manually extending or retracting the ram A Turn 2SS to the Pin position and hold B While holding 2S8 turn and hold 3SS Retract Run Extend Selector Switch in either the Retract or Extend position Note To pin a load the gate must bi in the completely up position 10 Immersion Oil Heater Advance Warning Light Hydraulic Cart amp Container Dumper Low Oil Warning System Photo Electric amp Infrared Start System The heater is adapted to the one inch NPT half coupling at the end of the tank under 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 addi tional relay and a warning light which is mounted in the remote control panel The purpose of this system is to alert the operator when a pressure less than the maximum operating pressure is reached The press
20. ion for Replacing Components eeeeennnm nnn 17 19 IMQTOR cie cc N A dean aadinmeedeneneaeres 17 meme Tr 17 Directional Control Valve irierrtredpiei tete abd ee hd eee ERR I beati de rari pu Euh 18 ad2e T 18 Hydraulic HOSO as 18 Limit SWIN eg 18 Ran Guide BIOCKS E 18 Cylinder Piston Seals idet rie stb aE 19 mice HE REI 19 MN c Pn 19 Scc 19 Motor ea T in or To M E 19 CIRCUIT BONG e p ET 19 Terminal Stip kieren a i a ia aaa a 19 Swt Ne Shianan a a E a a E a ues 19 Photographs ertet ere n aana iaaea raen eRRexe aaan deae rea aaria 20 22 Power Unit Hydraulic Components ssssssss ee 20 Limit SWITCH OS oin repete te a a e ben piter ur e 21 Main Electrical Panel sssssee Hmmm 22 Congratulations On Your Precrusher Compactor Purchase 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 few safety tips 1 As per OSHA standards install safety rails and guards on walk ways decks and hopper openings 2 Erect suitable barriers around cart dumpers conveyors etc to keep personnel clear
21. lays must be properly set See Pages 8 9 The Directional Control Valve may be stuck in 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 running the ram should move forward or backward If the ram does not move the spool may be inoperative Motor Starts But Ram Fails To 7 Check whether or not the pump is building pressure If not it may be defective To check the pressure install a pressure gauge in the 1 tee provided on the pump side of the circuit control module Take the 1 4 plug out of the tee for pressure gauge installation See Photo Page 20 8 If 1 through 7 fail to resolve this problem a cylinder may be defective Contact the factory for further information Motor Starts Ram Operation 1 Is the Mode Switch 4SS in the Precrush position Normal Gate Fails To Move 2 Check the Ram Retracts Past Gate Limit Switch inside the compactor between the hydraulic cylinders See Photo Page 21 If the limit switch is loose stuck or the arm is held forward or backward by trash accumu lation it will not initiate the cycle for the gate to come down during the ram reverse stroke This will only allow the machine to function as a compactor Tighten free or replace the limit switch as needed 3 If the gate is down and the ram moves against the gate on the last precrush stroke but the gate doesn t open
22. ld be adjusted 1 2 turn clockwise after meeting the guide rail squarely Bottom guides should be adjusted with an 1 16 to 1 8 gap between the block and the guide rail Over tightening these blocks may result in excessive wear Cylinder Piston Seals 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 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 parts are in good condi tion 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 Relays Install the same type of relay with the hole locator in the right position Timers 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 Motor Overloads Install the correct size overload Overload ch
23. 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 precrusher compactor After the refuse has been loaded into the chamber stand at a safe distance during operation Precrusher Compactor Operation Compact Mode Operation Precrush Mode Operation The precrusher compactor has three modes of operation These are precrush compact and pinning boost override Before operating the precrusher compactor in any mode a compaction con tainer must be attached to the charge opening The controls other than the pinning boost override system controls are mounted in the main control panel or a remote control head Pinning boost override controls are mounted for convenience on the side of the compactor near the charge opening Yne B The Power supply to the controls MUST BE TURNED OFF while adjustments in the control panel are made 1 Set 4SS Precrush Compact Mode Switch in the compact position 2 Set 1TR Thirty Minute Cycle Timer as desired The machine can be set to cycle from one complete cycle to a thirty minute cycling time Set the timer for 10 15 seconds less than the time needed for the desired number of cycles 1SS Off On Selector Switch should be set in the on position 288 Pin Off Run Selector Switch should be set in the run position 28S should only be switched when manually jogging the
24. o adhere to this standard in the design of the machin ery controls and safety devices of its compaction equipment If SP Industries Inc does not install the equipment it is the responsibility of the owner to comply to the following safety rules Remote Control Head Funnels Hoppers Chutes Security Chutes The remote control head is supplied with a Keyed Off On Switch Start Button Stop Button with a Container Full Warning Light and a Compactor Precrusher Mode Switch 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 required If the funnel hopper etc is installed at the job site it is the responsi bility of the installer to provide an interlock system so that the precrusher 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 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 compactor with low hydrogen rod welds smaller units may be bolted securely
25. o one can start the machine while it is being serviced The following procedures should be used when replacement of any component is necessary 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 Support the pump to keep it fairly stable Then remove the 4 bolts holding the motor to the pump mounting bracket and move the bracket away from the motor slightly 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 warning 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 alignment with 005 inch tolerance Excessive misalignment will usually cause leaking 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 1 Remove the bolts from all 3 inlet port primary pressure port and seconda
26. recrush Mode Operaltlon eroe iii aent e retard ue E SR M Rasa M appear de 8 9 Jogging Machine for Pinning Operation and Manual Operation of Precrush Gate sisser iiia a 10 jo LIlM H 11 Immersion Oil FIealer itcr itecto a reu PPM EDU epe baEndEE 11 Advance Warning Light criteri rena dai SER de c sped haath 11 Hydraulic Cart amp Container Dumper sssss eme 11 Low Oil Warnirig Systelm cce terere sue erani Ebene de nome nix ER tae adum aed 11 Photo Electric Start amp Infrared Start System sssssssssssssssess 11 Trouble Shooting tienne ttt in ether scene casseecssnzsscnceradssesiestes 12 14 Motor Fals TO Salt c inrer Ree e mb P bere du etie rere ugue ens 12 Motor Starts But Ram Fails To Move ssssH ee 12 13 Motor Starts Ram Operation Normal Gate Fails To Move snee 13 Gate Does Not Come Down During The Precrush Stroke eere 14 Gate Does Not Come All The Way Down sssssem mee 14 After The Gate Closes The Ram Hesitates While Retracting 14 Maintenance cssscssssssseressecessseuessccensuscoeeuasareseeseseranenseususeeessanauaneeeuaveneuanceneneuenens 15 16 Gate Cylinder Cavity Cleaning escrin a eene 15 ilc gel nome 15 Initial Maintenance Check irrita ree rper aa 15 Hydraulic Fluid Changes siisii ienenge anin eere 16 Cold Weather Operations 2 itii kot eiecit ocho a ra R 16 Instruct
27. ry pressure port 4 bolt pump flanges 2 Remove the 2 bolts holding the pump to the pump mounting bracket then remove the pump 3 Remove the half coupling from the pump shaft 4 Install a new pump in reverse order If a C face motor is in use the following warning is automatically taken care of by the C face mounting nose cone Care must be taken when aligning the coupling between the pump and motor Pump manufacturers recommend an alignment with 005 inch tolerance Excessive misalignment will usually cause leaking 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 neces sary This warning is applicable only when a nose cone has not been used to couple the pump to the motor 1 Directional Control Valve Relief Valve Hydraulic Hoses Ram Guide Blocks 1 Remove the wiring plate wire nuts wiring conduit and conduit fitting 2 Remove the pressure switch mounted on the valve body To do this remove the two 1 4 bolts that hold the base to the main body of the pressure switch Caution must be taken not to drop the plunger out of the pressure switch when it is loose from its base 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 pinc
28. to the precrusher compactor 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 leading 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 on remote units are mounted in the remote control box with the precrusher compactor controls The controls consist of a mushroom type Start Stop Button similar to the Compactor Start Stop Button but tagged DUMPER PULL TO START PUSH TO STOP and an Up Down Selector Switch Pushing either the Dumper Start Stop Button or the Pre crusher Compactor Stop Button will stop the dumper in any position When the light is on in the Dumper Start Stop Button this indicates that the dumper motor is running Loading Refuse Ima oR ed enter the charging chamber PAM oN loji throw solid objects such as steel plate castings concrete blocks etc into the chamber this type of material may seriously damage the precrusher compactor and or container Note This Will Void The Warranty EE PLOW ON operate dumping devices unless area is clear of all personnel OSHA and the manufacturer require erection of suitable barriers when these devices are used P E lew eM stand near the precrusher compactor when the ram is in motion
29. ure is factory set at 400 PSI below maximum operating pressure This will allow the advance warning light to indicate when the container is approximately 75 full giving the opera tor 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 mechanism and a separate motor valve pump and operating controls A typical dumper will have its hydraulic components mounted on the same reservoir as the precrusher compactor s hydraulic components and the operating controls in the same control box as the precrusher compactor s operating controls The dumper may be started with or without operating the compactor as long as 2SS is in the Run position 1 SS is in the On position and the precrusher compactor stop button is in the closed up position The low oil warning system consists of a reservoir mounted low oil sensing device relay and a warning light The low oil sensing device sends a signal to the low oil warning light mounted in the main control panel when the oil level is dangerously low If this occurs the precrusher compactor shuts off and the low oil light comes on The reservoir hydraulic fluid must be checked and filled to the proper level as read on the oil sight gauge The photo electric or infrared start system consists of a photo electric or infrared eye assembly warning buzzer flashing strobe light and a reflector or receiver T
30. verloads on the motor starter Call the factory or an electrician if 1 through 7 check out but the motor 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 turning the pump coupling The ram operating limit switch located inside the machine between the hydraulic cylinders in the forward position See Photo Page 21 must be both in an operable condition and actuated by the ram Adjust the limit switch arm if necessary If the limit switch is inoperable when the ram moves forward the unit will shut off and the red full container light will illuminate If the limit switch is inoperable when the ram is retracted the ram will stop at the rear position and system pressure will read the same as container full pressure however the full container light will not illuminate and the motor will not shut off The cylinder may be seriously damaged if the limit switch is improperly 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 reaching the end of its stroke a loud banging noise will be heard when the ram changes direction 5 6 The Timing Re
Download Pdf Manuals
Related Search